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Title: Medupi P.S. Scope of Work for Outstanding Construction of Dust handling Plant
Unique Identifier: 348-9913941
Alternative Reference Number: N/A
Area of Applicability: Medupi P.S.
Documentation Type: Scope of Work
Revision: 2
Total Pages: 77
Next Review Date: N/A
Disclosure Classification: CONTROLLED DISCLOSURE
Scope of Work Medupi P.S.
1 INTRODUCTION ............................................................................................................... 4
2 SUPPORTING CLAUSES ................................................................................................. 5
2.1 SCOPE ....................................................................................................................................5 2.1.1 Purpose ................................................................................................. 5 2.1.2 Applicability ............................................................................................ 5
2.2 NORMATIVE/INFORMATIVE REFERENCES ...............................................................................5 2.2.1 Normative .............................................................................................. 5 2.2.2 Informative ............................................................................................. 5
2.3 DEFINITIONS ..........................................................................................................................7 2.3.1 Disclosure Classification ........................................................................ 7
2.4 ABBREVIATIONS .....................................................................................................................8 2.5 ROLES AND RESPONSIBILITIES ...............................................................................................9
3 SCOPE OF WORK .......................................................................................................... 10
3.1 THE WORKS ......................................................................................................................... 10 3.1.1 Labelling ,KKS and Painting ................................................................. 10 3.1.2 Mechanical Works ................................................................................ 11
3.2 DETAILED SCOPE OF WORK ................................................................................................. 15 3.2.1 Pulse Jet Fabric Filter Plant (PJFFP) Hoppers. .................................... 16 3.2.2 Dust Conveying Plant (DCP) ................................................................ 16 3.2.3 Ash Conditioning Plant (ACP) .............................................................. 17
3.2.3.1 FLY ASH STORAGE SILOS (REFER TO DRAWINGS 084/618, 084/765, 084/806)17 3.2.3.2 SILO AERATION SYSTEM (REFER TO DRAWINGS 084/766) ........................... 18 3.2.3.3 BLOWER HOUSES IN ASH CONDITIONING COMPLEX (REFER TO DRAWINGS 084/764) 18 3.2.3.4 ASH CONDITIONING PLANT (REFER TO DRAWINGS 084/499) ....................... 18 3.2.3.5 CRAWL BEAMS, CRANES AND HOISTS ............................................................ 19 3.2.3.6 AUXILIARY SERVICES ......................................................................................... 19 3.2.3.7 GENERAL ............................................................................................................. 19 3.2.3.8 PIPE RACKS/GANTRIES ...................................................................................... 20 3.2.3.9 HAZOP STUDY ..................................................................................................... 20 3.2.3.10 EXTENT OF WORK .............................................................................................. 20
4 SYSTEM DESCRIPTION ................................................................................................ 21
4.1 OVERVIEW ........................................................................................................................... 21 4.2 MAJOR COMPONENTS .......................................................................................................... 21 4.3 DESIGN INFORMATION ......................................................................................................... 22
4.3.1 General ................................................................................................ 22 4.3.2 Design Parameters .............................................................................. 23
4.3.2.1 PULSE JET FABRIC FILTER PLANT (PJFFP) ..................................................... 23 4.3.2.2 DUST CONVEYING PLANT (DCP) ....................................................................... 24 4.3.2.3 CONVEYING – AND INSTRUMENT AIR SUPPLY ............................................... 25 4.3.2.4 FLY ASH STORAGE SILOS .................................................................................. 25 4.3.2.5 AIR ACTIVATED GRAVITY CONVEYORS (AAGC).............................................. 26 4.3.2.6 CONDITIONING SYSTEM .................................................................................... 26
4.3.3 Ash Properties ..................................................................................... 26 4.3.3.1 ELEMENTAL ANALYSIS ....................................................................................... 26 4.3.3.2 SIZE DISTRIBUTION ............................................................................................ 27 4.3.3.3 OTHER PROPERTIES .......................................................................................... 27 4.3.3.4 WATER QUALITIES .............................................................................................. 27
4.3.4 Areas Identified for Modification ........................................................... 28 4.3.4.1 CONVEYING PIPELINE LEAKS ........................................................................... 28 4.3.4.2 INLET DOME VALVE SEALS ................................................................................ 28 4.3.4.3 EXPANSION BELLOWS ....................................................................................... 28 4.3.4.4 NON RETURN VALVES (NRVS) .......................................................................... 28 4.3.4.5 SPARE LINE SELECTION VALVE ........................................................................ 28
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4.3.4.6 FLEXIBLE HOSING AND CLAMPING MECHANISM ............................................ 28 4.3.4.7 CONTINUOUS LEVEL INDICATORS ................................................................... 29 4.3.4.8 AERATION SYSTEM............................................................................................. 29 4.3.4.9 FLY ASH STORAGE SILO EXTRACTION SYSTEM ............................................ 29 4.3.4.10 IMPACT WEIGHERS............................................................................................. 29 4.3.4.11 SHUT-OFF VALVES.............................................................................................. 29 4.3.4.12 INLET AND OUTLET DOME VALVES MAINTENANCE ....................................... 29 4.3.4.13 CONVEYING PIPELINES MAINTENANCE ........................................................... 29 4.3.4.14 OTHER AREAS FOR IMPROVEMENT ................................................................. 29
4.3.5 29 4.4 OPERATING AND CONTROL PHILOSOPHY ............................................................................. 30
4.4.1.1 DUST CONVEYING PLANT (DCP) ....................................................................... 30 4.4.2 Ash Conditioning Plant (ACP) .............................................................. 30 4.4.3 Mode Of Operation .............................................................................. 31
4.4.3.1 REMOTE AUTO MODE ......................................................................................... 31 4.4.3.2 REMOTE MANUAL MODE .................................................................................... 31 4.4.3.3 MAINTENANCE MODE ......................................................................................... 31
4.4.4 Protection And Alarms ......................................................................... 32 4.4.5 Control Functions To The Control Room Operator ............................... 32 4.4.6 Control functions .................................................................................. 32
4.4.6.1 INDICATIONS TO THE OPERATOR .................................................................... 32
5 PLANT REQUIREMENTS ............................................................................................... 33
5.1 TECHNICAL SPECIFICATIONS ................................................................................................ 33 5.1.1 Continuous level indication .................................................................. 34 5.1.2 Valves .................................................................................................. 34
5.1.2.1 CLEAN AIR/WATER VALVES ............................................................................... 34 5.1.2.2 ASH VALVES ........................................................................................................ 34 5.1.2.3 DIVERTER VALVES.............................................................................................. 35
5.1.3 Pipelines .............................................................................................. 35 5.1.4 PJFFP Hopper Aeration ....................................................................... 35
5.1.4.1 HOUSING .............................................................................................................. 35 5.1.4.2 AERATION BLOWERS ......................................................................................... 36 5.1.4.3 HEATERS .............................................................................................................. 36 5.1.4.4 PJFFP HOPPER AERATION PADS...................................................................... 37
5.1.5 Ash Conditioning Complex (ACC) (Refer to drawing 084/806) ............. 37 5.1.5.1 GENERAL ............................................................................................................. 37 5.1.5.2 FLY ASH STORAGE SILOS .................................................................................. 38 5.1.5.3 ASH FLOW CONTROL ......................................................................................... 41 5.1.5.4 AIR ACTIVATED GRAVITY CONVEYORS (AAGC) – AIRSLIDES ....................... 42 5.1.5.5 CONDITIONER ..................................................................................................... 42 5.1.5.6 WATER SUPPLY .................................................................................................. 45 5.1.5.7 ASH SCRUBBER UNITS ....................................................................................... 46 5.1.5.8 BLOWER HOUSE ................................................................................................. 46 5.1.5.9 FANS ..................................................................................................................... 47 5.1.5.10 BLOWERS ............................................................................................................. 47 5.1.5.11 FILTERS ................................................................................................................ 48 5.1.5.12 HEATERS (IF REQUIRED) ................................................................................... 48
5.1.6 Access ................................................................................................. 48 5.1.7 Compensators/Expansion Fittings ........................................................ 48 5.1.8 Noise Levels ........................................................................................ 49 5.1.9 Dust Levels .......................................................................................... 49 5.1.10 Insulation ............................................................................................. 50 5.1.11 Crawl Beams, Cranes And Hoists ........................................................ 50 5.1.12 Specification Of Open Grid Flooring, Stairways And Hand railing ........ 51 5.1.13 Corrosion Protection ............................................................................ 51 5.1.14 Pipe Racks/Gantries ............................................................................ 52 5.1.15 Reliability, Availability and Maintainability ............................................ 52 5.1.16 Technical Risk Assessments................................................................ 53
5.1.16.1 HAZOP (HAZARD AND OPERABILITY) STUDIES ............................................... 53 5.1.16.2 FMECA (FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS) ................. 53
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6 SAFETY REQUIREMENTS............................................................................................. 54
7 ELECTRICAL REQUIREMENTS .................................................................................... 55
8 PROCESS CONTROL AND INSTRUMENTATION REQUIREMENTS .......................... 56
8.1 GENERAL ............................................................................................................................. 56 8.2 DESIGN STANDARDS, GUIDELINES AND CODES .................................................................... 56 8.3 REQUIREMENTS RELATED TO SAFETY .................................................................................. 57 8.4 REQUIREMENTS RELATED TO AVAILABILITY AND RELIABILITY .......................................... 57 8.5 EARTHING, LIGHTNING AND ELECTRICAL PROTECTION ....................................................... 58 8.6 REQUIREMENTS RELATED TO MAINTAINABILITY ................................................................. 58 8.7 INTEGRATION AND CONSISTENCY OF DESIGN ...................................................................... 58 8.8 EXPANDABILITY ................................................................................................................... 59 8.9 LIFE EXPECTANCY ............................................................................................................... 59 8.10 STANDARDIZATION .............................................................................................................. 59 8.11 REQUIREMENTS RELATED TO TECHNICAL DOCUMENTATION .............................................. 60 8.12 DESCRIPTION OF SOME OF THE C&I TEMPLATES AND DOCUMENTS ..................................... 60
8.12.1 Limits of Supply and Services (LOSS) ................................................. 60 8.12.2 Function IO Block Diagrams ................................................................ 60 8.12.3 Instrument Schedule ............................................................................ 61 8.12.4 Panel Interface List .............................................................................. 61 8.12.5 Virtual Signal List ................................................................................. 61 8.12.6 Drive & Actuator Schedule ................................................................... 61
9 CIVIL WORKS ................................................................................................................. 62
10 FIRE PROTECTION AND DETECTION ......................................................................... 63
11 TESTING REQUIREMENTS AND PROCEDURES ........................................................ 64
11.1 TESTING ............................................................................................................................... 64 11.2 MECHANICAL TESTING (FACTORY TESTING) ....................................................................... 64
11.2.1 DRIVE UNITS ...................................................................................... 64 11.2.2 NON-DESTRUCTIVE TESTING .......................................................... 64 11.2.3 Tests On Completion (Mechanical Works) ........................................... 64 11.2.4 TESTS AFTER COMPLETION (MECHANICAL WORKS) ................... 65
11.3 ELECTRICAL TESTING ................................................................................................... 66 11.3.1 Factory Testing (Electrical Works) ....................................................... 67 11.3.2 Electrically operated actuators inspection and testing .......................... 67
11.3.2.1 ROUTINE TESTS OF MOTORS ........................................................................... 67
12 SPARES .......................................................................................................................... 68
13 TRAINING REQUIREMENTS ......................................................................................... 69
14 APPENDIX....................................................................................................................... 70
14.1 LIST OF APPLICABLE DRAWINGS AND DOCUMENTS .......................................................... 70 14.2 SCHEDULES ......................................................................................................................... 76 14.3 DOCUMENT SUBMITTAL SCHEDULE .................................................................................... 76 14.4 COMMON REQUIREMENTS .................................................................................................. 76
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1 INTRODUCTION
Medupi Power Station is at an advanced stage in terms of construction, with unit 6, 5, 4 and 3 fully constructed and earlier units in commercial operation (Unit 6, 5 & 4). This scope of work is for construction and design completion of the Dust Handling Plant (DHP) for unit 2 and unit 1 with the associated systems such as Silo 2 and Silo 3 as well as any auxiliary system linked to these systems.
The Dust Handling Plant is a part of the operating Unit that conveys fly ash pneumatically from the Pulse Jet Fabric Filter Plant (PJFFP) to the ash silo complex. The design, supply and construction contract of the entire DHP at Medupi was placed under one package with the construction unitised, starting from Unit 6, and was not completed by the appointed Contractor at Unit 1 and Unit 2 with the associated systems. Commissioning was also not completed for Unit 2. The client also does not have all the necessary design documentation for Unit 2 and Unit 1, as some of this documentation is end of construction documentation.
This requires a new Contractor to complete all the outstanding works including design, procurement, construction/installation and commissioning, testing and handover to the client of the dust handling plant.
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2 SUPPORTING CLAUSES
2.1 SCOPE
2.1.1 Purpose
This Scope of Work provides the requirements and information to enable complete design and construction of the Dust Handling Plant outstanding works at Medupi P.S.
2.1.2 Applicability
This document shall apply throughout Eskom Holdings Limited Divisions and in particular Medupi P.S.
2.2 NORMATIVE/INFORMATIVE REFERENCES
Parties using this document shall apply the most recent edition of the documents listed in the following paragraphs.
2.2.1 Normative
[1] 4600011479, Medupi P.S., Dust Handling and Conditioning Systems Contract
2.2.2 Informative
[2] 240-91297106 Pneumatic Conveying Systems Design Standard
[3] Occupational Health and Safety Act (Act 85 of 1993)
[4] ISO 9001: Quality Management System Requirements
[5] Occupational Health and Safety Management Systems Requirements (OHSAS 18001)
[6] 348-670608 Medupi Occupational Health, Safety and Management Policy
[7] The Environmental Conservation Act (Act No 73 of 1989).
[8] 32-245 Eskom Waste Management Standard
[9] 32-421 Eskom Life Saving Rules
[10] 36-681 Eskom Plant Safety Regulations
[11] 240-60490979 OHS Operational Plan
[12] 200-1679 Project Quality Plan
[13] 200-1689 Medupi Quality Specifications
[14] 200-45965 Manufacturing Inspection and Testing
[15] 348-860843 Storage and Preservation Work Instruction
[16] 348-883808 Document and Record Management Procedure
[17] 348-621432 Documentation Handover List
[18] 240-86973501 Engineering Drawing Standards
[19] 240-61227631 Piping and Instrumentation Diagram (P&ID) Standard
[20] 348-644789MDL Management Procedure
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[21] 348-883760 Control of Drawings Procedure
[22] 348-883860 Documentation Format and Layout Specification
[23] ISO 10007 Guidelines for Configuration Management
[24] 348-694071KKS Key Part – Fossil power station
[25] 348-882024 Application for KKS Coding
[26] 348-80410 Issuing of KKS Certificate Work Instruction Rev 07
[27] 348-630398 KKS CODING AND LABELLING STANDARD REV 4
[28] 348-885912 MEDUPI POWER STATION LIST OF ABBREVIATIONS REV 9348-885429 Medupi ECM Procedure rev 05
[29] 240-53113685 Eskom Design Review procedure
[30] 348-860840 Commissioning and Completion of Medupi Power Station Rev 07
[31] 348-702600 Issuing of the Taking Over Certificate 2
[32] SANS 10108 The Classification of Hazardous Locations and Selection of Equipment for Use in Such Locations
[33] 240-56536505 Hazardous Location Standard
[34] 240-106628253 Standard for Welding Requirement on Eskom plant
[35] 240-56356396 Earthing and lighting protection standard
[36] 240-55714363 Coal-Fired Power Stations Lighting and Small Power Installation Standard
[37] 240-57617975 Procurement of Power Station Low Voltage Motors Specification
[38] 240-56227443 Requirements for Control and Power Cables for Power Station Standard
[39] 348-686832 Identification and Assessment of Health and Safety Hazards and Risks
[40] 240-49230030 Reliability Engineering Analysis Guideline
[41] 240-49230046 Failure Mode and Effect Analysis (FMEA) Guideline
[42] 240-49230067 Life Data Analysis Guideline
[43] 240-49230100 Safety Engineering Analysis Guideline
[44] 240-49230111 Hazard and Operability Analysis (HAZOP) Guideline
[45] 240-49910508 Environmental Analysis Guideline
[46] 240-50056004 Constructability Analysis Guideline
[47] 240-56364545 Structural Design and Engineering Standard
[48] 240-57127955 Standard for Design of Drainage and Sewerage Infrastructure
[49] 240-57127955 Geotechnical and Foundation Engineering Standard
[50] SANS 10144 Detailing of reinforcement for concrete
[51] SANS 1024 Welded steel fabric for reinforcement of concrete
[52] SANS 10400 All Parts National Building regulations
[53] SANS 10400 The application of the National Building Regulations
[54] SANS 1115 Cast iron gratings for gullies and stormwater drains
[55] SANS 1123 Pipe flanges
[56] SANS 1200A Standardized specification for civil engineering construction Section A: General
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[57] SANS 2001 CC1 - Construction works Part CC1: Concrete works (structural)
[58] SANS 2001 CS1 Construction works
[59] SANS 282 Bending dimensions and scheduling of steel reinforcement for concrete
[60] SANS 5863 Concrete tests - Compressive strength of hardened concrete
[61] SANS 10021 The waterproofing of buildings (including damp-proofing and vapour barrier installation)
[62] SANS 62 Steel pipes Part
[63] SANS 100 Part 1 Structural use of concrete (Design) [64] SANS 920 Steel bars for concrete reinforcement
[65] SANS 10160 General Procedures and Loadings [66] SANS 10162-1 The structural use of steel Part 1: Limit-states design of hot-rolled steelwork
[67] SANS 1700-16-2 Fasteners Part 16: Washers Section 2
[68] SANS 1700-16-3 Fasteners Part 16: Washers Section 3: Plain washers chamfered
[69] SANS 121 Hot dip galvanized coatings on fabricated iron and steel articles
[70] SANS 50197-1 Cement Part 1: Composition, specifications and conformity criteria for common cements
[71] SANS 1058 Concrete paving blocks
[72] 200-3583 Specification for the Identification of the Contents of Pipelines and Vessels
[73] 348-133183 Medupi Power Station Corrosion Protection Specification
[74] 84CIVL053 Medupi Power Station Specification for Structural Concrete Rev03
[75] 200-7117 BOILER SEISMIC DESIGN [76] SANS 100 Part 1 Structural use of concrete (Design)
2.3 DEFINITIONS
Definition Description
System An integrated set of constituent pieces that are combined in an operational or support environment to accomplish a defined objective. These pieces include people, hardware, software, firmware, information, procedures, facilities, services and other support facets.
Pipework Pipes and fittings used for the conveyance of fluids.
Piping Pipes, tubes or flexible pressure hose elements intended for the transport or distribution of any fluid.
Pump A pump is a device that moves a fluid by mechanical action.
Valve A device for shutting-off or controlling the flow of a fluid through a pipe or duct.
2.3.1 Disclosure Classification
Controlled disclosure: controlled disclosure to external parties (either enforced by law, or discretionary).
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2.4 ABBREVIATIONS
Abbreviation Description
AC Alternating Current
AAGC Air Activated Gravity Conveyor
ABD Availability Block Diagram
ACC Ash Conditioning Complex
ACP Ash Conditioning Plant
ACP Ash Conveying Plant
BMCR Boiler Maximum Continuous Rating
BS British Standard
C&I Control and Instrumentation
C&I Control and Instrumentation
CD Compact Disc
CEMA Conveyor Equipment Manufacturers Association
CFA Conditioned Fly Ash
DC Direct Current
DCP Dry Chemical Powder
DCP Dust Conveying Plant
DCP Dust Conditioning Plant
DCS Distributed Control System
EMC Electromagnetic Compatibility
FM Federal Mutual
HAZOP Hazard and Operability
HDG Hot Dip Galvanised
HDPE High Density Polyethylene
HL High Level
HMI Human Machine Interface
I/O Input/Output
IPR Independent Pipe Rack
KKS Kraftwerk Kennzeichen-System
LCS Local Control Station
LCS Local Control Station
LED Light Emitting Diode
LL Low Level
LLL Low-Low Level
LOSS Limits Of Supply and Services
LPS Low Pressure Services
LPS Low Pressure Systems
MCR Maximum Continuous Rating
9
MDT Mean Down Time
MS Mild Steel
MTBF Mean Time Before Failure
MTTF Mean Time To Failure
MTTR Mean Time To Repair
NB Nominal Bore
NFPA National Fire Protection Association
NPS Negative Phase Sequence
OD Outside Diameter
OHSA Occupational Health and Safety Act
OPCR Outside Plant Control Room
OPCR Outside Plant Control Room
P&ID Piping and Instrumentation Diagram
PDS Plant Data System
PJFFP Pulse Jet Fabric Filter Plant
PLC Programmable Logic Controller
PPS Positive Phase Sequence
PVC-M Modified poly(vinyl chloride)
RMS Root Mean Square
SABS South African Bureau of Standards
SANS South African National Standards
THD Total Harmonic Distortion
TIR Total Indicator Run-out
TLF Torque Limiting Factor
TP Terminal Point
UHMWPE Ultra-High Molecular Weight Polyethylene
UPS Uninterruptible Power Supplies
VSD Variable Speed Drive
WTP Water Treatment Plant
2.5 ROLES AND RESPONSIBILITIES
The following sections may contain specifics functions within each of the following roles and responsibilities related to the execution of the works
The Contractor constructs the plant as per the documentation provided.
The Employer provides the necessary requirements and documents to construct the plant.
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3 SCOPE OF WORK
3.1 THE WORKS
The Works comprise the design completion, supply, complete construction and commissioning of the Dust Handling and Conditioning System for units 1 and 2 and Ash Silo 2 and 3 of Medupi Power Station. The Contractor shall be responsible for the Works, that includes, engineering support, manufacture, supply, shipment to South Africa, transport from ship or local works to Site, unloading from road or rail, transport at Site, erection, quality assurance, on and off Site testing, painting, finishing, complete in working order and commissioning of the Dust Handling and Conditioning System. The Works include all matters which, although not expressly provided for, can be reasonably inferred from the Contract, the only exclusion being items or services expressly excluded or specifically stated to be free issued or otherwise to be provided by the Employer or by others.
The high level Scope of work for the remaining scope is as follows and a bill of quantity is attached:
3.1.1 Labelling ,KKS and Painting
a. Unit 2
Blower Room
- Touch up painting on compressed air piping.
Hopper Aeration
- KKS labeling
Silo 2
- KKS labeling
b. Unit 1
PJFFP
- Touch up painting on conveying pipes, compressed air piping.
- KKS labeling.
Blower Room
- Touch up painting on compressed air piping.
- KKS labeling.
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Silo 3
- Touch up painting on conveying pipes, compressed air piping.
- KKS labeling.
3.1.2 Mechanical Works
a. Installation and commissioning of silo passenger lift.
b. IPR additional plinths and supports to be completed.
c. Silo 6
Installation and testing of crawler beam and Hoist
d. Silo 5
Installation and testing of crawler beam and Hoist.
e. Silo 4
Installation and testing of crawler beam and Hoist.
f. Silo 3
Installation and testing of crawler beam and Hoist.
g. Unit 2
Safety clearance and commissioning of the DHP is required.
PJFFP - Blower Room
- Installation and testing of crawler beam and Hoist.
- Installation of insulation on Aeration piping.
TAC
- Erection/Construction of plinths and access service platform for switch valves.
Silo 2
- Install instruments on the air slide.
- Installation and testing of crawler beam and Hoist.
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h. Unit 1
Safety clearance and commissioning of the DHP is required.
PJFFP - DHP
- Assembly and installation of 4 switch valve & manifold control panels.
- Assembly and installation of 4 master control panels.
- Assembly and installation of 20 slave control panels.
- Installation of walkways, gratings and handrails on banks 1-4 (top level & 2nd level).
- Installation of MD pumps guards and Cat ladders on banks 1-4.
- Installation of A frame pipe gantry end supports on banks 1- 4.
- Installation of master, slave and outlet pumps on banks 1- 4.
- Installation of 300NB 28 * inlet dome valves and 4 * outlet dome valves on banks 1- 4.
- Installation of 28 * 80NB vent dome valves on banks 1 – 4.
- Installation of 4 * 300NB outlet air bend spools on banks 1 – 4.
- Installation of vent piping, compensators and square to round transitions on banks 1- 4.
- Installation of 300NB inlet compensators and 250NB expansion joints (klamflex) on banks 1- 4.
- Installation of conveying pipes between MD pumps on banks 1- 4.
- Installation of compressed air and instrument air piping from TAC to banks 1 – 4.
- MD pumps support legs modification to be done.
- Aeration system installation and Insulation.
- Complete grouting work.
- ELECTRICAL / C&I
o The contractors scope include:
o The installation of racking and control panels. Pulling, dressing, terminating and testing of cables.
o Installation of earthing of all equipment that requires an earth connection as well as providing continuity test results of the earthed equipment.
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o All site installation testing and commissioning of installed electrical equipment including cables and motors.
o All equipment should be chosen such that it will integrate with the existing electrical and control infrastructure installed on site.
o Construction lighting shall be provided by the contractor.
o All as built settable electrical parameters should be recorded and handed over.
Blower House
- Installation of air piping to PJFFP
- Installation and testing of crawler beam and Hoist.
- Installation air heaters and Fans with ducting and instruments.
- Installation and insulation of aeration piping to banks 1-4.
- Installation and terminations of control equipment.
TAC
- Erection/Construction of plinths and access service platform for switch valves.
- Installation of support beams
- Installation of 300NB conveying piping.
Silo 3
- Installation of steel structure on top of silo, bottom silo and side of silo and internals.
- Installation of bag filters system.
- Installation of in let plate and fan.
- Installation of manhole, cathedral vent pipes, blanks and over under pressure relief valves.
- Installation of cone, aeration pads and aeration pads manhole.
- Installation of air slide system bottom of silo :
o air slides
o air slide piping
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o air slide cathedral
o cone vents piping
o ring header and supply
o 4 off valve stations
- Installation of conditioner chutes, nozzles, scrubber, impact weigher, fan and ducting on conditioner 1 &2.
- Installation of greasing system on both conditioners.
- Installation of piping on the following systems:
o Conditioner water
o Instrument air inside silo
o Portable water train
o Instrument piping (IPR to TOS)
o Compressed air piping
o Conveying piping
- Installation and testing of crawler beam and Hoist.
- Erection/Construction of plinths for the access to the pressure vessels
- Grouting of remaining plinths ( design and installation)
- Installation of platforms and staircase to the pressure vessels
- Record books production of all works upon completion to enable the certification
- of works
- Additional tests for durability and strength of concrete
- ELECTRICAL / C&I
o The contractors scope include:
o The installation of racking and control panels. Pulling, dressing, terminating and testing of cables.
o Installation of earthing of all equipment that requires an earth connection as well as providing continuity test results of the earthed equipment.
o All site installation testing and commissioning of installed electrical equipment including cables and motors.
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o All equipment should be chosen such that it will integrate with the existing electrical and control infrastructure installed on site.
o Construction lighting shall be provided by the contractor.
o All as built settable electrical parameters should be recorded and handed over.
3.2 DETAILED SCOPE OF WORK
The scope of work is from the Pulse Jet Fabric Filter Plant (PJFFP) hopper outlets, after manual knife gate isolation valve, to the discharge of the conditioners onto the overland link ash conveyor systems. This will include erecting of the pipe work (ash conveying and compressed air), installation of valves (Dome valves, NRVs, switch over valves and slides gates at the silos outlets), installation of instruments (pressure gauges, pressure switches) and plant auxiliaries. The aeration pads to be installed in the PJFFP hoppers and air supply to them are included. The detail design and construction of the civil works of the Fly ash storage silos shall be undertaken by the Employer, the Contractor shall utilise the exiting design of the silo storage.. Cast-in items already installed by the Employer, the Contractor shall utilise those Cast-in on the constructed silos. Also refer to drawing no. 084/753 available in Section 3.2.1. All other civil work related to the Plant to be erected by the contractor is included in the Scope of work.
Deliverables against this Contract includes and shall not be limited to the following:
a. Design review of all the documents, drawings and procedures available and new design for any outstanding design information necessary for the completion of the Medupi Dust Handling Plant.
b. Stock taking of what is already available on the lay down area, Complete construction, procurement of outstanding items, fabrication, workshop assembly, corrosion protection, testing, inspection, quality control, labelling, packing, delivery to site, erection, thermal insulation, project management, cold – and hot commissioning of the entire engineering works to ensure a fully functional Dust Handling and Conditioning System, here after referred to as the Works.
c. The Contractor shall review the current operating and control philosophy describing the proposed controls to achieve the performance requirements of this Contract, during all operating conditions including start-up, normal operating, shutdown, total emptying and emergency shutdown. The contractor is to propose additional changes to the operating philosophy after review of the current available operating and control philosophy.
d. Installation of all Plant according to the Employer’s KKS configuration system.
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e. Review and proposed updates if necessary on the current Reliability, Availability and Maintainability (RAM) study.
f. Technical Risk Assessments.
Important Notes:
1. All designs shall be submitted to the Engineer for acceptance.
2. Layout sketches to enable design of the systems are included in Section 14.1.
The scope of work to accomplish a fully functional Dust Handling and Conditioning Plant shall include, but shall not be limited to the following
3.2.1 Pulse Jet Fabric Filter Plant (PJFFP) Hoppers.
a. Stock taking and Supply an intermediate level indication in addition to the high – and low level indication already supplied by the Employer. This must be supplied as a take-out option.
b. Stock taking and supply and installation of hopper aeration and continuous level indication. The High Performance Guided Wave Radar instrument by Rosemount/Alpret, model no. 5303HA1S1V6BM00600RANAM1Q4 shall be supplied. The Contractor is expected to propose alternative instruments as the guide wave radar is unreliable.
c. The hopper aeration system and air requirements for the hopper aeration shall be provided for by the Contractor.
d. A fully functional complete blower house including but not limited to pressurized blower house(s), blowers, driers, pipe work, intake filtration, ventilation Plant, auxiliary cooling, air receivers, safety devices, etc. shall be supplied.
e. Monitoring and control system shall be supplied and installed by the Employer [C&I Contractor].
3.2.2 Dust Conveying Plant (DCP)
a. Complete erection of the multi pressure vessel, positive pressure pneumatic fly ash conveying system with one vessel per PJFFP hopper outlet, relevant measuring instruments, aeration Plant, ash valves, conveying pipe work, conveying air supply pipe work, aeration air pipe work, supports, vents, outlet Plant, etc.
b. Pressure vessels are already installed, stock taking and supply of their auxiliaries, valves, supports, vents, inlet – and outlet Plant, etc. Pneumatic conveying pipelines support structures and elevated gantries from the transverse ash concrete support structure to the fly ash storage silos. Conveying – and control air supply pipelines, support structures and elevated gantries from the compressor houses to the points of usage.
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c. Pressure vessel supports for Unit 1 will require a detailed proposal as there is a misalignment issue however the Employer will provide a proposal that the contractor can review and use if it is deemed sufficient.
d. All bulk conveying – and control air requirements for the Dust Handling and Conditioning Plant shall be provided for by the Employer.
e. All flanges at interface points, gaskets, nuts, bolts, pipe and Plant supports, and fixing arrangements necessary, plus any removal and replacement of insulation/cladding on existing structures and retouching of paintwork/galvanizing are included in this scope. The Contractor shall be responsible for the proper sealing of the Pulse Jet Fabric Filter Plant flanges, irrespective of the condition of these flanges.
f. Access stairs, platforms, walkways, handrails and ladders necessary to provide complete, convenient and safe access for operation, inspection, testing and maintenance of the Plant supplied under this enquiry, (inclusive of hopper level probes and aeration pads).
g. Ash valve per vessel for isolation during operation.
h. Plant support structures from ground (basement) level, in the case of equipment to be supported below the PJFFP. No support from PJFFP hoppers or structure will be allowed.
i. Crawl beams necessary for maintenance of all Plant. (Crawl beams to be supplied with crawler).
j. Piping, valving, etc. and routing of service air and control and instrumentation air from the bulk supply at each Fabric Filter Plant to all Plant and service points as required.
k. Any attachment at Contract interfaces is/forms part of this Contract.
3.2.3 Ash Conditioning Plant (ACP)
The Ash Conditioning Plant (ACP) consists of the following:
- Fly ash storage silos
- Silo aeration system
- Blower houses
- Ash Conditioners
3.2.3.1 Fly ash storage silos (Refer to drawings 084/618, 084/765, 084/806)
a. Ash discharging Plant to the silos. Supports for all dust conveying
pipelines on the silo roofs. Expansion joints/compensators shall be fitted to the silo filling Plant i.e. pipelines, valves, etc. Additional manual
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isolating damper valve for each silo dust filling valve (automatic) shall be provided.
b. Silo filling and venting Plant, including valves, filters, fans, access walkways, crawl beams and hoists, piping, structural steelwork, pipe supports and expansion couplings for the two remaining silos. A filter air quality monitoring device shall be fitted to the discharge of each silo's venting Plant.
c. Provision shall be made in the silo roof layout for 1 (one) silo maximum (high-high) level transmitter per silo.
d. Complete erection of silo floor aeration system including blowers, fans, filters, piping lagging, valving, and aeration pads to ensure a complete workable system. The complete inside surface of the silo conical floor shall be aerated and continuous aeration shall be provided to the discharge outlets.
e. Ash silo outlet cone. It should be noted the cone currently installed on Silo 3 is without documentation and it is necessary to qualify its use before safety clearance.
f. Silo vacuum measurement.
g. One silo over/under pressure valve shall be provided per silo.
h. All access stairs, platforms, walkways, handrails and ladders necessary to provide easy and safe access to Plant for operation and maintenance. Crawl beams and crawlers necessary for maintenance of all Plant.
i. Complete design, construction and commission passenger lift and associated Plant with the controls and power required (power rating) must be stated on the design.
3.2.3.2 Silo Aeration System (Refer to drawings 084/766)
Stock taking, complete design, erection of pipe work and commission of Aeration system to silo 2 & 3.
3.2.3.3 Blower houses in ash conditioning complex (Refer to drawings 084/764)
a. Stock taking of the blowers, fans, filters, piping, lagging and valving and where there is a shortage, shall be supplied by the Contractor.
b. Pressurisation and filtration Plant shall be supplied by the Contractor.
3.2.3.4 Ash Conditioning Plant (Refer to drawings 084/499)
a. Stock taking, complete design and construction of ash conveying system including all fans, heaters, lagging, isolation valves, product flow control valve, airslides, ash flow metering and venting Plant to ensure a fully functional system.
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b. The complete ash conditioner including all interfaces, scrubbers, isolation valves, liners, water supply and drives to ensure a fully functional system. Conditioners are already in place.
c. Bulk water supply for the conditioners shall be supplied by the Employer at a point adjacent to the silo complex, on ground level.
d. Each ash conditioner shall be equipped with a fully automated ash vapour scrubbing unit.
e. Bulk water supply for the scrubbers shall be supplied by the Employer at a point adjacent to the silo complex, on ground level.
3.2.3.5 Crawl beams, cranes and hoists
The Contractor shall perform stock taking, provide and install all the necessary crawl beams, cranes and hoist for the successful operation and the maintenance of the Plant.
The conditioning Plant shall be equipped with an overhead crane capable of handling the heaviest Plant unit of Plant, filled with ash if applicable, for maintenance purposes.
3.2.3.6 Auxiliary services
The Contractor shall provide all pipe work, valves, pumps, mounting devices etc. associated with the water supply up to the termination points (i.e. conditioner water supply, fire water, auxiliary cooling water and scrubber water supply).
3.2.3.7 General
The Contractor shall provide all access stairs, walkways, handrails, ladders,
crawl beams and hoist necessary to provide complete, convenient and safe access to the Plant for operation, inspection, testing and maintenance.
Piping, valving, routing, etc. of water supplies from bulk supplies (provided by Employer) to all Plant and service points within the Contractor’s scope to be supplied by the Contractor.
All flanges, gaskets, nuts, bolts, washers, pipe and Plant supports and fixing arrangements necessary shall be supplied by the Contractor.
Drawings
Operating and Maintenance Manuals
Training and training manuals.
Testing and Commissioning
Special tools
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Recommended spares lists
3.2.3.8 Pipe Racks/Gantries
3.2.3.9 HAZOP Study
Review and update the HAZOP study on the entire Dust Handling and Conditioning Plant and submit a report to the Engineer.
3.2.3.10 Extent Of Work
The Works entails design, execution and completion of a fully functional Dust Handling and Conditioning Plant.
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4 SYSTEM DESCRIPTION
4.1 OVERVIEW
The station consists of six boiler units and the dust handling and conditioning Plant shall therefore be designed for six (6) unit operation.
Dust (fly ash) shall be removed continuously from the Pulse Jet Fabric Filter Plant (PJFFP) hoppers and conveyed pneumatically to a conditioning complex comprising six (6) fly ash storage silos, situated on the Unit 6 (southern side) of the station. The pneumatic fly ash conveying system shall be based upon a multi pressure vessel system with one vessel per PJFFP hopper. Seven vessels shall be linked into a common conveying pipe to ensure continuous conveying for an optimised system. Each vessel comprises the fluidising system that supports conveying cycle. There shall be the pressure transmittal prior the vessel that intakes main conveying air and another one after the last vessel that shall be able to take a reading on ash conveying line.
The fly ash in the fly ash storage silos shall be fluidised by an aerated silo floor prior to the outlet and transferred in a controlled manner to the conditioner by means of a product control valve and air activated gravity conveyor system. Conditioned ash is then discharged onto the overland link ash conveyors. High component reliability shall be designed into the Plant to enable overall Plant availability to be equal or greater than 99.994% achieved throughout its design life. This means that any unplanned outage to perform maintenance work shall not exceed eight (8) hours, which is the storage time available in the fabric filter hoppers. Planned maintenance work shall be conducted on the Plant according to and to coincide with the unit maintenance outage philosophy. The ability of the fly ash handling and conditioning system to handle the required quantity of ash and to meet the availability requirement shall be evaluated and demonstrated by a Reliability, Availability and Maintainability (RAM) study.
4.2 MAJOR COMPONENTS
The Dust Handling and Conditioning System shall consist of:
Dust Conveying Pipes
Conveying – and Instrument air supply pipes.
Pressure Vessels
Fly Ash Storage Silos
Silo venting system
Silo Aeration System
Blower Houses and blowers
Ash Conditioning Plant
Silo 6 lift
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All of the above shall include relevant measuring Plant, ash valves, pipe-work, instrumentation, driers, air receivers, intake filtration, safety devices, etc., required for the intended operation of the systems.
4.3 DESIGN INFORMATION
4.3.1 General
a. All maintenance parts subject to abrasion and/or in contact with the fly ash shall be designed to minimize wear in order to achieve a service life of at least five years continuous operation.
b. The Plant shall be of weatherproof construction, suitable for outdoors operation in climatic conditions prevailing at Site, without undue maintenance, and deterioration. Emphasis is placed on the selection of primary devices, control panels, etc. to ensure that unnecessary/spurious trips are eliminated.
c. The entire Plant i.e. mechanical, electrical, control and instrumentation, etc. shall be designed to be cleaned by water washing at a pressure of up to 10 bar, without impairing the performance of any component. All components shall be designed for operation in a dusty environment.
d. The nature of the ash handled is extremely abrasive and utmost consideration shall be given to the design of sealing arrangements, selection of materials, bearings, etc. throughout the Plant.
e. Full accessibility shall be provided for maintenance and replacement of component parts on all Plant. Jacking points shall be provided to facilitate replacement of components, if necessary.
f. The system (including all components) shall be of proven design.
g. Care shall be taken to ensure that air or dust shall not leak out of the system or that cold air and moisture shall not infiltrate into the system or hoppers, causing dust removal difficulties due to choking or bridging of the dust.
h. All filtration systems shall be capable of meeting the heavy dust loading of air under extremely dusty (fly ash) ambient conditions.
i. All Plant requiring frequent lubrication shall be fitted with an automatic lubrication system equipped with alarms indicating lubrication system failure.
j. Each item of the Plant shall be guaranteed for 130 weeks operation from taking over.
k. All components, requiring future removal for maintenance purposes, whose mass exceeds 50 kg shall be fitted with lifting lugs (or similar).
l. Standardisation of specifications of Plant utilized throughout the system shall be attempted as far as practically possible.
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4.3.2 Design Parameters
The Plant shall operate with each quality of coal, i.e. design - and worst coal for extended periods of time. Fly ash production rates are given on a per unit basis. Fly ash production is based on the max. fraction of 91.9% of the total ash production being fly ash (8.1% coarse ash fraction measured at Matimba P.S.).
Capacity: Normal = 135 Tph - based on 40% daily avg. ash content (dry basis) in
coal.
Backlog recovery = 170 Tph (125%).
4.3.2.1 Pulse Jet Fabric Filter Plant (PJFFP)
a. The hopper configuration per unit is two (2) casings with 7x2 hopper configuration (Refer to drawing B114103-98-52-IC17-00003-00, B114103-98-52-IC02-00055-00 and 210-01692-01-001). One cell per hopper.
b. Hopper flange detail is depicted in drawing no. 210-01692-01-002.
c. The PJFFP hoppers provide for the storage of up to eight (8) hours of fly ash production.
d. Occasional puffs due to boiler operation may occur, at which time the PJFFP can be subjected to short term pressurisation to 1 kPa.
e. One cell out (routine maintenance) – 4 to 6 hrs
f. Simultaneous pulsing of both casings – front to back
g. A complete on-load re-bag shall take approximately one month every 4 years. The philosophy for routine maintenance and a re-bag shall be to isolate one (1) cell at a time to conduct these activities.
h. Bag replacement with a single draught group in operation is considered abnormal but can be done with one (1) cell taken out at a time.
i. Single draught group operation at 60% BMCR with all cells in service on the applicable gas pass.
j. The following requirement was included in the Contract between the Employer and the PJFFP Supplier: ”The fly ash Plant shall discharge air at the rate of 1 312 m3/hr instantaneously into each hoper or 375 m³/hr over an hour vent operation. This air is generated by the aeration system at the hoper outlet that enhances the ash flow from the hopper into the fly ash Plant as well as from venting of the pneumatic dust handling system that shall be installed at the later stage”.
k. Included in Section 3.2.1 : Drawings, is the following information received from the supplier of the PJFFP:
System Pressure Characteristics – B114116-06-99-IB06-00001-00
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Ash distribution in hoppers – B114103-13-02-IB02-00001.
Inquiry data sheet - B114103-13-02-ID98-00001
Fly ash particle size distribution - B114103-13-02-ID23-00101
Knife gate details - B114116-13-02-ID04-00004 -00
4.3.2.2 Dust Conveying Plant (DCP)
a. The pneumatic conveying system shall be a multi pressure vessel based pneumatic conveying system of the positive pressure type conveying simultaneously into a common conveying pipe. The following Plant may not be included and shall not be acceptable to the Employer:
Low pressure, “dilute-type” systems which operate at high pipeline velocities with high air volume requirements.
Vacuum type systems
Screw feeders, chain conveyors and pneumatic pump type systems.
Systems with sensitive air flow distribution and/or pressure regulation requirements.
Air Activated Gravity Conveyors (AAGC) - (airslides), horizontal airslides (aeroslides) or Air Activated Gravity Conveyors.
A conveying pipe system with a membrane type aeration chamber.
b. The design capacity of the pneumatic fly ash handling Plant shall be based on a minimum of 125% of the maximum dust collection rate at each hopper to allow for each one hour backlog build up to be removed in four hours together with the maximum ash production rate to the hopper. All six (6) units can be operated on backlog recovery rate at a time.
c. Small quantities of air from the pneumatic conveying Plant below the PJFFP hoppers may be vented back into the hoppers if so required.
d. Six (6) meters of head height is available for installation of pneumatic conveying Plant below the PJFFP hoppers.
e. The Contractor shall provide for a single stage transportation system with which the fly ash shall be transported directly from the PJFFP hoppers to the silos in a single operation.
f. No below ground level installations shall be acceptable.
g. The design of the dust handling Plant shall make provision for the successful removal of “coarse” ash (flakes) and “oil-ash”, which are associated with each start-up of the boilers. It is foreseen that a total quantity of approximately 2 m3 of “coarse” and “oil” ash per precipitator hopper are produced on each occasion and shall therefore be handled via the Dust Handling Plant.
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h. The dust from each of three (3) units can be conveyed to the top of three (3) silos on site. The Plant shall be designed to convey dust to the silos in a reliable and efficient manner. Plant sizing and material velocities shall be selected to minimize material wear and turbulence in the conveying system.
i. Pick-up velocity shall be approximately 7 m/s and discharge velocity approximately 20 m/s.
j. The system shall be able to start conveying, with full conveying pipelines, after a loaded system trip.
k. The Contractor shall provide a description of an anti pipe blockage system as well as a philosophy to the Engineer for approval.
l. The Contractor shall provide a description and philosophy of an automatic pipe un-blockage system to the Engineer for approval.
m. A method of removing excessive quantities of “coarse” ash (flakes) and “oil-ash”, which are associated with each start-up of the boilers, during initial boiler commissioning, if required, shall be provided. This functionality shall also be utilised to facilitate removal of foreign objects after General Overhauls (GO’s) of the PJFFP, if required.
4.3.2.3 Conveying – and instrument air supply
Bulk conveying – and instrument air supply shall be provided by the Employer at the compressor houses.
Distribution of the conveying – and instrument air to the point of use shall be by the Contractor.
Conveying air supply capacities shall be based upon the air requirements during backlog recovery.
Conveying – and instrument air supply requirements shall be supplied to the Employer as per VDSS.
4.3.2.4 Fly ash storage silos
The system consists of six (6) fly ash storage silos, each with a storage capacity of twenty four (24) hours of maximum boiler dust production. The ash contained below the Low-Low Level (LLL), which shall be the minimum level required to maintain a fully aerated bed of fly ash, shall not be included when the required storage capacity is determined.
During normal operation, all silos shall be in service, one for each of the associated boiler units. During lower boiler loads two (2) or even three (3) units may be discharged into one silo to limit conditioner tripping due to the level in silo reaching the Low-Low Level (LLL). During emergency conditions up to three (3) units on backlog recovery mode can be discharged into one (1) silo.
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Each silo shall have two (2) ash conditioning systems (one duty the other standby). Each conditioning system per silo shall have a dedicated discharge to one of the two (2) overland link ash conveyor systems.
An inverted, metal, discharge cone shall be installed centrally; over the silos’ bottom dust outlets.
To ensure a steady state ash discharge rate from the silos, silo aeration system shall be installed in each silo complex.
4.3.2.5 Air Activated Gravity Conveyors (AAGC)
The minimum airslide angle shall be 70.
4.3.2.6 Conditioning system
The final conditioned product moisture content shall be limited to a 10 to 16% range. Ideal set point shall be at 13% moisture.
Capacity: Normal = 108 to 132 Tph at 13% moisture by mass.
Backlog recovery = 200 Tph at 20% moisture by mass.
4.3.3 Ash Properties
4.3.3.1 Elemental analysis
For information the values of the chemical constituents of Matimba Power Station. ash reflected in the following table are from 18 samples taken from Boiler 1, precipitator hoppers 1, 2 and 3 in 1995.
Ash quality element Unit Min. Max.
SiO2 % 59.6 63.9
Al2O3 % 21.7 25.9
Fe2O3 % 6.7 7.6
Mn2O3 % 0.1 0.1
TiO2 % 1.2 1.4
CaO % 2.1 2.6
MgO % 0.8 1.0
P2O5 % 0.1 0.4
SO2 % 0.1 0.4
Cl % 0 0
K2O % 1.0 1.3
Na2O % 0.1 0.1
F.CaO % <0.1 0.3 Table 2
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Previous investigations undertaken by the Employer has shown that the shape of the ash particles have the dominant influence on the extent of the abrasiveness of ash. The shape of the ash particles are determined by the combustion process, milling process and coal quality. Thus the shape of the ash particles that shall be produced by the Medupi process cannot be predicted. The supplier of Plant shall thus design for typical Eskom power station ash. Ash samples from Eskom power stations can be supplied if required, for analysis purposes.
4.3.3.2 Size distribution
A chart depicting measured values of typical fly ash size distributions for Eskom Power Stations are included in Section 3.2.1: Drawings.
4.3.3.3 Other properties
Temperature: Fly ash: maximum of 160°C
maximum 80°C in silos
Flue gas: maximum of 165°C
Densities
Bulk density of fly ash (dry) : 700 – 1 200 kg/m³ - depending on the degree of
aeration.
Bulk density of fly ash (20% moisture) : 1 200 kg/m³
Relative density of dust : 2 200 kg/m³
Design parameter for storage : 940 kg/m³
Other properties
Surcharge angle of fly ash : 0º
Surcharge angle of conditioned fly ash : 5º
Angle of repose of aerated fly ash : 0º
4.3.3.4 Water qualities
4.3.3.4.1 Conditioning supply water
Conditioning water shall be normally supplied from the Dirty Water Tank no. 2, which has the following sources:
- Clean – and Dirty dams - Coal stockyard pollution control dam - Effluent from Water Treatment Plant (WTP) - Raw water (back-up)
Effluent from Water Treatment Plant typical composition is included in Section 3.2.1 Drawings.
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Alternatively conditioning water can also be supplied from the Dirty Water Tank no. 1, which has the following sources:
- Raw water (back-up) - Clean – and Dirty dams
Emergency conditioning water supply shall be from the fire water mains, which is potable water.
4.3.3.4.2 Scrubber supply water (Potable water/Fire mains)
Refer to GGSS 0517 Rev. 4, “Chemistry Standard for Potable Water”, included in Section 3.2.4 Employer standards.
4.3.4 Areas Identified for Modification
Due to the failures and dust leaks experienced on the operating plant, there are a number of areas which require additional work to enable the plant to perform as intended. The Contractor shall look at the following areas and provide workable solutions to the Employer for acceptance and implementation. A schedule must be agreed up front for these deliverables.
Any modifications to the plant shall follow the Project Engineering Change Management Procedure (240-53114026)
4.3.4.1 Conveying Pipeline Leaks
The Contractor to conduct pressure testing of the system as per PER requirements.
4.3.4.2 Inlet Dome Valve Seals
The inlet dome valve seals installed in the DHP system need to be changed as being capable of handling product temperatures of 200 °C (maximum).
4.3.4.3 Expansion Bellows
The expansion bellows installed in the DHP system need to be changed as being capable of handling product temperatures of 200 °C (maximum).
4.3.4.4 Non Return Valves (NRVs)
The non-return valves installed in the DHP system need to be changed as being capable of handling product temperatures of 200 °C (maximum) and the operating environment.
4.3.4.5 Spare Line Selection Valve
The spare line selection valves need to be changed with suitable automated control valves for the operating environment (fly ash). These valves should be equipped with valve position indication.
4.3.4.6 Flexible Hosing and Clamping Mechanism
- The suitable flexible hose and clamping arrangement needs to be changed to one that will be fit for purpose.
- The Contractor to conduct pressure testing of the entire system as per PER requirements.
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- The hosing installed must satisfy the operating temperature (200 °C) of the DHP and the operating environment.
4.3.4.7 Continuous Level Indicators
The Contractor to conduct a root cause analysis the cause of failure of the continuous level indicators and propose a more suitable instrument than the specified instrument in section 3.2.1+
4.3.4.8 Aeration System
Proposal on installation of manual isolation valves per hopper.
4.3.4.9 Fly Ash Storage Silo Extraction System
The Contractor to conduct a design analysis of the system to determine if it is capable of handling three (3) unit’s ash being discharged in a single silo as per the performance requirements of the system. The Contractor shall identify and propose modifications if necessary.
4.3.4.10 Impact Weighers
The Contractor to propose an effective sealing arrangement for the control box on the impact weighers.
4.3.4.11 Shut-Off Valves
The Contractor to propose an alternative valve which will be fit for the operating environment – fly ash at 80 °C.
4.3.4.12 Inlet and Outlet Dome Valves Maintenance
The Contractor to provide an effective means to ensure that maintenance of the dome valves can be conducted in a safe and reliable manner and a proposed strategy pertaining to lifting of the dome valves to be provided by the Contractor.
4.3.4.13 Conveying Pipelines Maintenance
An effective maintenance method is required in these areas to ensure that the conveying pipelines can be maintained easily and in a safe manner. The Contractor needs to ensure that the maintainability issues of the conveying pipelines are addressed and this includes the lack of anchoring structures for rigging.
4.3.4.14 Other Areas for Improvement
The Contractor, over and above the preceding issues, shall identify and provide solutions to any other problematic areas on the plant.
4.3.5
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4.4 OPERATING AND CONTROL PHILOSOPHY
4.4.1.1 Dust Conveying Plant (DCP)
a. Dust shall be removed on a continuous basis from the PJFFP hoppers. Boiler unit 1, 2 and 3 to either of the first three ash silos. Boiler units 4, 5 and 6 shall feed silos 4, 5 and 6. No ash conveying crossover exists between Silos 1 – 3 and Silos 4 - 6.
b. Anyone of three (3) units’ fly ash can be diverted into any one of three (3) silos and three (3) units can be fed into a single silo. The selection of discharge points are determined by the Common Plant Control System dependant on fly ash storage silo level signals.
c. A maximum of three (3) out of three boiler units’ fly ash pneumatic conveying systems can be operated on backlog recovery mode at any time.
d. Transportation and discharge of ash into a silo shall be terminated once a High High Level (HHL), which equates to 24 hours storage is reached. The operator shall then have to select the next available silo to discharge dust into.
4.4.2 Ash Conditioning Plant (ACP)
a. Six ash silos shall be provided; three silos either side of the transverse conveyor.
During normal operation, all silos shall be in service, one for each of the associated boiler units. During lower boiler loads two (2) or even three (3) units may be discharged into one silo to limit conditioner tripping due to the level in silo reaching the Low Low Level (LLL).
b. Each silo shall be fitted with two ash conditioning systems. Normally one conditioner shall be on duty and one on standby. Each conditioner feeds a dedicated transverse ash conveyor.
c. During normal operation, both conveyors shall be running, with three (3) conditioners discharging onto one conveyor and the other three (3) onto the other transverse conveyor.
d. The level in the silo shall be operated in a normal operating range, between the Low Level (LL) and High Level (HL), by automatically switching the conditioner between normal and backlog recovery mode. This is to limit conditioner shut downs to an absolute minimum and to maximise available storage capacity in case of the downstream transportation system not being available. This shall be achieved by setting the normal conditioning capacity lower than the normal dust conveying capacity.
e. A conditioner shall only be tripped whenever it’s dedicated transverse conveyor trips or when a Low-Low Level (LLL) is reached in the silo. Stopping or tripping of conditioners shall not automatically trip the transverse ash conveyors. Under normal operating conditions the working level inside the silo shall not be allowed to decrease below the Low-Low Level (LLL). The LLL level shall be the minimum level required to maintain an effectively aerated bed of material. The operator shall have the facility to override this level to facilitate emptying the silo completely for maintenance purposes.
f. The silo venting system shall operate whenever the pneumatic fly ash conveying or silo aeration systems are operating.
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4.4.3 Mode Of Operation
The entire dust handling and conditioning Plant shall be operated from the Outside Plant Control Room (OPCR). Plant operations shall be fully automated with no direct operator involvement required when operating in the automatic mode. Remote auto, remote manual and maintenance operating modes shall be available.
The modes of operation shall be defined as follows:
4.4.3.1 Remote auto mode
In this mode, the Plant shall be controlled from the Outside Plant Operating Control Room.
Start-up sequence:
After the conveying route has been selected and all local control stations have been set to remote auto mode, the system shall start automatically in a logical sequence with all protections and interlocks activated. The PLC shall control all sequences. In the event of Plant failing to start or tripping during the run up, the PLC shall automatically trip the faulty Plant and inhibit any further sequential starting of Plant. The PLC shall not perform an automatic shutdown sequence of the running Plant until requested to do so by the operator, unless such auto shut-down/closure is essential to the process control. The PLC shall at all times signal the status of all drives and generate alarms for any Plant or primary device which is in a fault or abnormal state.
Shut-down sequence:
Should a fault condition occur in the system whilst the Plant is in a fully operational/running state, all Plant shall stop in the required sequence to ensure a safe shut-down. The controlled shut-down of the system shall be in sequence to completely clear the system of any ash and leave the system in a “ready” to start condition.
4.4.3.2 Remote manual mode
The operator shall sequentially start Plant in sequence to put the Plant in a fully operational state. The PLC shall, however, control all sequence interlocking and protection. As for remote auto mode, the PLC shall continuously signal the status of the Plant and generate all alarms. In the event of midstream Plant failing to start or tripping due to a fault condition the PLC shall inhibit any further starting of subsequent Plant until the fault is cleared. No auto trip sequences shall be initiated.
4.4.3.3 Maintenance mode
The purpose of this selection is to run individual items of the Plant out of sequence. The control room operator shall direct the PLC via the keyboard to release the Plant (to be maintained) from any sequence interlocks with adjacent Plant, i.e. the Plant in question may be started and run up without interfacing with the upstream or downstream Plant. All Plant and personnel safety protection systems shall be fully operational in the maintenance mode.
For the duty and standby units where the standby unit cuts-in automatically on a trip function, there shall be a facility to rotate the selection of standby and duty units. Where the standby units are available, a system automatically recording running hours of each system, shall be available.
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4.4.4 Protection And Alarms
Modes of operation (remote auto, remote manual, and maintenance) with no local control station (LCS) shall have normally enabled sequence interlocks with an option of disabling them. The following shall be covered by the protection philosophy:
4.4.5 Control Functions To The Control Room Operator
The Dust Handling and Conditioning Plant shall be a fully automated system. Plant shall have three modes of operation, i.e. remote auto, remote manual and maintenance modes. Operation shall be from only one location at a time.
4.4.6 Control functions
The levels of fly ash in both the PJFFP hoppers and the fly ash storage silos shall be utilized to determine whether the Plant shall be run on normal or backlog modes.
4.4.6.1 Indications To The Operator
The display information in the Outside Plant Operating Control Room shall be a pictorial layout of the entire Plant indicating the status of all Plant.
SY3
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5 PLANT REQUIREMENTS
5.1 TECHNICAL SPECIFICATIONS
In the event of a conflict between Employer’s Requirements, the Engineer shall decide which shall apply. Any deviation from these Employer’s Requirements shall be clearly stated in writing.
GENERAL
a. The entire Plant i.e. mechanical -, electrical -, control and instrumentation - , etc.
Plant shall be designed to be cleaned by water washing at a pressure of up to 10 bar, without impairing the performance of any component.
b. Particular attention shall be given to the overall layout of aeration, water and service air pipe work, valves etc. in order to obtain a neat arrangement which shall facilitate ease of maintenance and operation of the Plant supplied under this Contract (i.e. to be routed below airslide landing).
c. All oil level indicators or glasses on oil tanks, oil baths, gearboxes etc. shall be volumetrically calibrated i.e. not by percentage or depth. Furthermore, these indicators shall show the maximum, minimum and normal oil working level.
d. The Contractor shall bring to the Employer’s attention all special maintenance features.
e. All automatically operated valves shall fail-safe closed.
f. Airborne dust emission (leaks) from the system shall not be permitted.
g. The Contractor shall supply any items, components or services to render the Plant complete and serviceable on the starting date of cold commissioning.
h. The Contractor shall supply all base plates, holding bolts, packers, grouting etc. for mechanical Plant supplied under this Contract and fixing to civil works.
i. The Contractor shall submit a list indicating all items that require high maintenance, cleaning, inspection etc. The frequency of maintenance and/or inspection and/or cleaning and a description of the work involved shall be included with the Contract.
j. The Contractor shall submit Lists indicating expected life of all components subject to direct or indirect abrasion by the fly ash, as well as precautionary and preventative measures which should be taken to prolong the life of the Plant.
k. The Contractor shall supply sealing arrangements around each opening in the concrete floors, for example, the opening where the conditioner chutes discharge ash down to the conveyors below. The arrangement shall prevent wash down water from either passing through the openings and entering the conveyor loading chutes, or from simply flowing down onto the level below. No restrictions to the installation or removal of the conditioner casings shall occur due to these sealing arrangements.
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l. All civil works not supplied by the Employer shall be supplied under this Contract by the Contractor.
5.1.1 Continuous level indication
a. Shall be situated inside of the PJFFP hopper.
b. Shall be of the radar probe type. Alternatives can be submitted to the Engineer for consideration and approval.
c. Shall enable functional level indication over the full height of the hopper.
d. Shall have a self-diagnostic ability.
e. Shall possess the ability to identify and process faulty signals.
5.1.2 Valves
a. All valves shall be of proven design for the duty (i.e. pressure, temperature, operating environment, operating fluid, application, etc.) and in accordance with the relevant specifications.
b. The Contractor shall take care in the position/orientation of all valves on the Plant to prevent actuators, spindles, etc. being positioned below possible pollution/contamination sources.
c. All valve actuator arms/spindles/shafts, located in a dusty environment and/or used on valves in ash applications shall be covered/protected from the dust to extend the life of actuator seals, valve spindles, etc.
d. If diverter valves are used in the system, flap type diverters shall not be acceptable in pressure applications.
e. For flap valves, all wearing parts shall be easily exchanged and the contact areas of the flaps shall be hard-faced.
Valves are classified into four (4) general categories below:
5.1.2.1 Clean air/water valves
According Low Pressure Services (LPS) specification, Section 7.
5.1.2.2 Ash Valves
a. This category of valves include all types of valves which operate (open or close) while in direct contact with the fly ash, excluding slide gate valves mentioned above.
b. Valves which operate in systems handling dust with a pressure differential across the valve shall be designed so that there is no metal to metal contact between the casing and the opening/sealing components.
c. The valve shall repeatedly render an air tight seal even with dust resting on the valve, when in the closed position.
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d. The valve seal and sealing surfaces shall not be subjected to rubbing by metallic parts during operation.
e. Air supply to valve seal shall be monitored to enable detection of air leakage due to a ruptured seal.
f. Valves not subject to abrasion between surfaces, which do not require critical sealing surfaces – 20 cycles per hour maximum.
g. Valves subject to abrasion between surfaces, which do require critical sealing surfaces – 5 cycles per hour maximum. Life expectancy (MTBF), maintenance costs, maintenance time (MTTR) of the abovementioned valves shall be supplied by the Contractor.
h. Fitment space allocation for “Dome” valves shall be such as to accommodate all similar valves currently available from other suppliers. Employer shall provide dimensional details of such valves to the Contractor.
5.1.2.3 Diverter valves
a. Flap type diverter valves are not acceptable in a pressure application.
b. All wearing parts of flap valves shall be easily exchanged and the contact areas of the flaps shall be hard-faced.
5.1.3 Pipelines
a. Bends, tail pieces and high wear points shall be of a high wear resistant material to meet or exceed the expected Plant life. The life expectancy shall be based upon design ash quantities and normal operation. . An adequate distance on the exit of a bend shall also be lined. Lining material to be utilised shall be submitted to the Engineer for approval.
b. All air supply piping shall be corrosion protected internally and externally in
accordance with the relevant specifications.
c. Pipelines conveying dust shall have a minimum wall thickness of 8 mm.
d. A positive alignment system (such as a stepped flange), at pipe connections, shall be utilised and approved by the Employer.
5.1.4 PJFFP Hopper Aeration
5.1.4.1 Housing
a. An area, on ground level, adjacent to each unit’s PJFFP, has been proposed for the purpose of erecting a building to enclose the PJFFP hopper aeration air supply blowers. See drawing no. 0.84/1737 Sheet 1 Rev. 11.
b. The building shall be pressurized to ensure that the building’s internal remains dust free, even if access doors are accidentally left open.
c. A crawl beam and chain block hoist for maintenance shall be provided.
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d. This building will be located in a dusty environment and shall therefore be designed for adequate sealing of the building and filtration of pressurizing air. For this purpose a single self-cleaning filter shall be provided. The filter’s suction inlet shall be routed from a clean environment. To facilitate maintenance of this filter with the filter’s fans in service, a bypass facility on the filter shall be provided, with sufficient isolation facilities to bypass the filter unit.
e. The floor level within the fan building shall be at least 200 mm above the surrounding ground level.
f. It is envisaged that the air supply filter units and pressurizing fans shall be located on this building’s roof. This roof shall therefore comprise a screeded concrete slab with perimeter bund walls and 300 NB drainage down pipes to floor level.
g. The building shall be of sufficient dimensions to provide ample access to all housed Plant, local panels, maintenance activities, etc.
h. The blower buildings shall be orientated such that vehicular access for loading/off-loading of Plant can be easily achieved from the roadways/ramps provided on the Power Station.
5.1.4.2 Aeration blowers
a. The blower’s suction shall be from inside the building.
b. The blower intakes shall be provided with dedicated inlet filters, over and above the self-cleaning filtration of the building pressurising air, suitable for a dusty environment.
c. Blower discharge pipe work shall incorporate automated isolation valves, in addition to manual isolation valves (where required), for the purpose of starting/stopping/isolating standby Plant as well as to facilitate maintenance of the fans while the Dust Handling Plant is in service.
d. The number and layout of blowers and Plant in the blower house shall be to the Engineer’s approval. At least one standby blower and secondary filter unit shall be supplied and installed for each type of blower used.
e. Should an air manifold be used, the Contractor shall state the method of volume and pressure regulations from the manifold to each distributed point.
5.1.4.3 Heaters
a. The Contractor shall provide aeration air heaters to maintain the aeration air temperature above dew point.
b. Temperature sensors, shall be provided by the Employer [C&I Contractor], and an air flow transmitter shall be provided to monitor and control the temperature of the air passing through the heater.
c. An air bypass, with manual valves, shall be provided for heater maintenance.
d. The design of the heater system shall ensure that the heater box is distanced from the heater control panel and located in a clean environment, e.g. control panel incorporated into the blowers’ control panel.
e. The heaters should be preferably located outside the blower room.
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f. A junction box shall be located between the heaters and the control panel. Silicon covered wires shall be used to cable the heaters to the junction boxes and normal cabling may be used between the junction boxes and the control panel. Furthermore the silicon covered wiring shall be protected by a sheath (steel pipe or similar) which can be sealed on both ends once installed.
g. The heaters boxes shall have IP65 enclosures. Insulation and cladding of the heaters shall conform to the requirements of this document. The heaters shall be mounted above the floor level, on plinths.
h. The design of the heaters and the insulation shall take cognisance of all maintenance activities which shall be carried out on this Plant. General arrangement drawings of the heaters, insulation, maintenance facilities, etc. shall be provided.
5.1.4.4 PJFFP Hopper Aeration pads
a. To ensure a reliable and steady ash discharge rate from the PJFFP hoppers, the dust in the hoppers is agitated and aerated by aeration pads installed in the hoppers.
b. The air supplied to the aeration pads shall be clean, moisture - and oil free to avoid blockage of the membrane material.
c. The aeration membranes shall be supported and protected from the top and bottom by means of a grating to minimise movement, wear, and extend the life of the membrane.
5.1.5 Ash Conditioning Complex (ACC) (Refer to drawing 084/806)
5.1.5.1 General
a. All access points shall be so designed to allow two access ports to the highest
elevation for safety reasons.
b. All floors shall be designed to specifically carry the loads of Plant items placed on them for purposes of transferring loads to the hoists and/or cranes.
c. Maintenance access platforms with cat ladders (back braced for elevated points exceeding 2 m) in galvanized metal grating shall be provided for all crawl beams/manual and electric hoists and these shall be capable of supporting the mass of the hoist units for transfer and maintenance purposes.
d. At least 1.5 m, or enough floor area to lay down removed guards, free unobstructed floor area shall be allowed for around major Plant for maintenance purposes.
e. The buildings shall be designed and provided with anchor points for temporary rope attachments for draw cables for rigging Plant items and similar maintenance functions.
f. Access doors/openings to the complex shall have enough space to allow mobile Plant to enter. They shall also be equipped with grating covered drains, wide enough, to avoid contamination of surrounding area with wash water.
g. Personnel doors and large sliding doors shall be provided.
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h. The buildings shall generally be provided with at least all of the features and facilities as specified and/or indicated on the enquiry drawings.
i. Bund walls (double brick wall, 0.5 m high) shall be provided around the perimeter of the floor slab of the complex to prevent contamination of the surrounding area. They shall contain any wash water and direct it into a drainage system that directs it to the wash down water collection sump adjacent to the complex. These bund walls shall however not limit or restrict access to the complex by small mobile Plant. Wash water from elevated concrete floors shall be directed to the ground level drainage system in a controlled manner. Thus not be allowed to cascade uncontrollably down to ground level through openings in concrete slab.
j. Storm water shall be prevented from entering the floor wash down water drainage system.
k. The complex shall incorporate an automatic centralised greasing system to service all greasing points in the area. A low level grease reservoir alarm signal shall be provided, to be displayed in the central control room (by others).
l. The Employer’s Requirements in section 3.1.11 shall govern all work on open flooring, stairways and hand railing that is within the transfer house.
m. Lighting in the complex shall be supplied by the Employer.
n. In the area of the maintenance bay, the overland link ash conveyor shall be protected from accidental damage from falling objects.
5.1.5.2 Fly ash storage silos
5.1.5.2.1 Design parameters
a. Fly ash silos (by others) shall be of conventional cylindrical concrete construction. They are raised and supported on a reinforced concrete ring/plinth and have a semi-conical sloping base and concrete roof.
b. The semi-conical shaped floor shall taper towards a centralised round drop box which houses the floor square outlets.
c. The silo shall be equipped with an inverted discharge cone installed centrally above the outlets. This cone shall be raised and supported from the silo base and has dedicated aeration pads that serve to aerate the material inside the cone.
d. Silo vacuum measurement is required to ensure that a vacuum has been established in the silo prior to discharging ash into selected silos.
e. The internal pressures in the silos shall be limited by an under/over – pressure valve. The pressure ranges from + 1 kPa to – 4 kPa.
5.1.5.2.2 Filling
a. Each silo dust filling valve (automatic) is provided with an additional manual isolating damper valve, situated between the silo roof and the dust conveying pipelines. The dust conveying pipelines are raised sufficiently above the silo roofs to provide access to each of the isolating valves.
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b. The silo filling Plant i.e. pipelines, valves, etc are fitted with expansion joints/compensators to allow for the relative movement between the silos and to cater for thermal etc. requirements.
c. All dust conveying pipelines on the silo roofs are adequately supported to enable the silo filling valves to be removed (maintenance) without unnecessarily dismantling adjoining pipe work etc.
5.1.5.2.3 Aeration (Refer to drawing no. 084/765, 084/766)
a. To ensure steady ash discharge rate from the silos, the dust in the silos is agitated and aerated by aeration pads installed on the silo bottom/floor. The aeration surface is divided into eight (8) ‘segments’ of equal area. The aeration philosophy calls for serial pulsing of opposite segments.
b. The complete inside surface area below the central silo discharge cone, around the discharges shall be aerated by similar aeration pads which are connected from a ninth (9th) aeration segment. This segment is controlled and vented separately from the rest of the silo. Continuous aeration shall be provided to the discharge outlets.
c. The aeration air for the six (6) silos shall be supplied by six (6) blowers plus two (2) standby blowers installed in a blower house/s on ground level below the silos.
d. The air supplied to the aeration pads shall be clean, water and oil free to avoid blockage of the membrane material. One of the considerations in achieving these requirements shall be the selection of the position of intake for the blowers i.e. in addition to filters, etc.
e. Consistent ash discharge from each silo is imperative, irrespective of the number of silos in operation or level of ash in any silo, at any time.
f. Valves for purging all the airlines shall be supplied under this Contract. To facilitate ash removal from aeration piping flexible housing shall be supplied along with quick release couplings.
g. The air supply to each silo shall be from a dedicated aeration blower.
h. Membranes
The layout for aeration membranes shall allow for the inclusion of the inverted cone.
The shape and size of membrane shall be selected for maximum interchange ability. (Modular construction)
The silo aeration module shall be serviced/ removed from inside the silo, for this reason, size of modules shall enable removal through the silo manways and manholes provided.
The aeration membranes shall be supported and protected from the top (membranes not underneath the inverted cone) and bottom by means of a grating to minimise movement, wear, and extend the life of the membrane.
Details of the membrane protection, support and tensioning arrangements shall be to the Engineers approval.
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Each aeration module shall be designed to self protect against foreign objects which may pass through the silo which could damage the membrane.
The membrane shall have a minimum life of 5 years. A high temperature membrane fabric (up to a maximum of 250 0C) shall be used. Asbestos fabric is not allowed.
Each module shall be attached to a permanent fixture in the silo floor. The attachment is shall allow for easy removal of aeration modules.
Should the weight of each module exceed 35 kg then the Contractor shall provide a means of lifting and moving these modules.
i. Aeration pressure
The Contractor shall be responsible for the air quality from the blower; the air supply shall not damage or reduce the efficiency of the aeration system.
The aeration pressure at entry to the silo shall be adjustable to allow for optimisation during commissioning, the air supply control system shall prevent the pressure from exceeding the set point to allow constant membranes aeration pressure into all the aeration membranes.
The system shall be designed to facilitate rotation of supply air to each of the aeration sections.
5.1.5.2.4 Venting
a. Conveying – and aeration air entering the silos shall be vented by silo mounted filters installed on the silo roof.
b. The filters shall be modular type bag filters with reverse pulse cleaning. The dust dislodged by the cleaning pulse shall fall directly back into the silo.
c. Compressed air cleaning shall be controlled by the differential pressure across the filter unit.
d. An emission detector shall be provided on the discharge stack of each filter fan to signal if dust emission exceeds a set point, indicating a fault or damaged filter bag.
e. The silos shall be interconnected by cathedral vents fitted with isolation dampers.
f. The maximum quantity of air which shall be vented is when three boiler unit's dust production is simultaneously discharged into one silo. The criteria for the filter’s design assume that all three of the three boiler units are operating on backlog recovery mode. All units are assumed to be burning worst quality coal and are operating at MCR. In addition to the above mentioned quantity of air to be vented, the amount of air, originating from the silo aeration system, shall also be vented through the silo venting Plant. The filter inlet from the silo and dust return to the silo shall be positioned far enough apart to minimize any dust re-entrainment.
g. The filter design shall be for high dust concentration with an operating philosophy which prevents recirculation of fine dust particles.
h. Conditions when the conveying air fully expands, under normal as well as backlog recovery capacity, shall be taken into consideration in the design of the vent filters.
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5.1.5.2.5 Level measurement
a. Two (2) silo level transmitters shall be installed for indication and control.
b. Other level probes at different levels of the silo shall be installed as required.
5.1.5.3 Ash flow control
a. The control system (provided by others) shall be compatible with the silo aeration and feed systems to ensure a uniform, consistent controllable ash feed to the conditioner machines.
b. If a V-Notch type gate valve (ash flow control valve) is used the Contractor shall specify and guarantee the working life of the gate, body, spindle and actuator, which shall be in excess of 5 years. It shall not be used for isolation purposes.
c. Ash flow control systems, (supplied by others), operating in conjunction with flow measurement systems, shall have an appropriate response time in order to meet the requirements of this specification.
d. The Contractors shall take cognisance of the range of bulk densities of dry fly ash, which can vary between 700 kg/m3 and 1200 kg/m3 depending on the degree of aeration.
e. Below all silo discharge outlets a manual operating isolation gate shall be supplied. The silo outlets not in service shall be flanged/ blanked off.
f. Silo outlets feeding the ash conditioners shall be fitted with additional automated quick-acting cut-off valves. (Closing times from fully open to fully closed to be <5 seconds and visa-versa). These valves shall be electrically operated and shall close in the case of a power failure in the conditioning Plant.
g. No moisture or air shall enter the silos via the ash feed systems. Any system which permits reverse-flow of moist air into the silos shall not be considered. (Same applies to the airslide feeding the ash conditioner).
h. The actual flow of dust into the conditioner shall be monitored to control dry ash throughput and moisture content of the product to the permutations specified.
i. The system shall be designed to prevent flooding of the conditioner machine. Notwithstanding this requirement, the Contractor shall take the necessary precautions to ensure that in the event of flooding, no damage is caused to Plant e.g. ash into shaft seals, damage to the mass measuring meter etc.
j. Where necessary, Plant shall be adequately lagged to ensure that the dust is maintained above dew point temperature.
k. Provision shall be made for ash sampling on the feed systems.
l. Access shall be provided for cleaning the neck of the chute at the conditioner inlet and above the product flow valve.
m. A manually operated knife-gate shall be installed where each ash feed system joins the conditioner. When closed, this valve shall isolate the feed arrangement from the machine, preventing any vapour from re-entering the ash feed Plant. Care shall be taken when designing this valve to ensure that the runners do not block with ash.
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n. Gravity assisted flap valves shall be installed between the ash flow control device and the ash conditioner, to prevent dust and water vapour from the conditioner from entering the ‘dry’ airslide system.
o. Suitable access platforms shall be provided to all ash feed Plant.
p. Where air slides are used these shall conform to the airslide specification.
5.1.5.4 Air Activated Gravity Conveyors (AAGC) – airslides
a. The conveyor fabric shall be protected top (impact zones) and bottom by means of grating so as to prevent abrasion of the fabric and to support the fabric.
b. The conveyor fabric used shall be able to withstand peak temperatures occurring in the system. A high temperature (higher than 250°) fabric is not permitted. The Contractors shall state the maximum temperature that the fabric can withstand for prolonged operation. Asbestos containing fabric shall not be permitted.
c. Casings shall be manufactured in interchangeable sections, each casing having handles to manipulate/ align the sections during maintenance. Lifting lugs shall be provided.
d. Casings shall be fitted with hinged inspection hatches.
e. Casings shall be fitted with one pair of inspection windows on each AAGC. The location and detail of these windows shall be indicated on drawings submitted.
f. The top, sides and base of the casings shall have a minimum wall thickness of 4 mm.
g. Notwithstanding the guarantee requirements of this document, provision shall be made to detect dust and to facilitate cleaning of the area beneath the fabric membranes in case of ash passing through the fabric due to a damaged or worn membrane.
h. The Contractor shall identify the high wear areas in the system and shall explain what precautions have been taken to minimise wear in these areas.
i. The system design shall ensure that under no circumstances shall fly ash be allowed to remain in the AAGC casings after a Plant trip, where the dust can cool down.
j. The material flow into the airslide shall be controlled.
k. The material shall be fed into the airslide at an angle.
l. Airslide aeration air shall be supplied via fans installed in the common blower house/s. This is distributed to the aeroslide segments by a series of manual (lockable) throttle valves; these valves shall be set on commissioning.
m. Airslide aeration air and air vented from underneath the silo discharge cone shall be vented by large bore de-dusting pipes to the top of the silos and via the silo filter/fans.
5.1.5.5 Conditioner
a. Two conditioners, each with a dedicated discharge to an overland link ash conveyor system, shall be available to condition dry fly ash from each silo.
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b. The machines shall be required to produce a consistent (in time and across the machine width) and homogeneous mix of dry fly ash and water, for all ash quantities and moisture settings. For this reason Contractors shall check that their design ensures adequate conditioner length, blade pitch, speed of rotation and ash retention time. The machines shall be the contra-rotational type.
c. A deflector plate, suspended from the cover, shall direct the flow of ash downward into the first, worm-agitated, zone in the trough.
d. Conditioning water shall be distributed evenly over the ash, throughout the conditioner, as it is agitated, transported along the central portion of the trough. This shall be done by a series of water spray nozzles fitted to two spray header pipes attached centrally (axial) and two fitted across the conditioner cover.
e. Short lengths of continuous norm-type blades shall be fitted to the shafts at the ash feed end. These shall provide positive conveying of the ash into the first agitated zone where most of the conditioning water is added.
f. A deflector plate shall be is fitted at the discharge end of the conditioner trough to prevent material being compressed into, and wearing, the end plate.
g. The ash conditioners and associated Plant shall be designed to facilitate quick removal and replacement (1 hour).
h. The conditioner system shall be designed as a module with quick release couplings, compensators and mounted on a common base plate.
i. Airborne dust emission from the machines and the machine outlets shall not be permitted. Ash scrubber units shall be supplied.
j. The conditioner machines shall discharge conditioned fly ash onto belt conveyors situated on the floor below, via loading chutes.
k. Hinged inspection doors shall be provided on the top of each conditioner to facilitate inspections, maintenance, cleaning etc. In addition smaller inspection hatches shall be provided to prevent injury and system trips.
l. Drive arrangements: Each gearbox shall be shaft (flange) mounted and, together with the motor, fixed to a common base frame. The drive arrangements shall be sized to enable a fully loaded machine to be started up after a 30 minute standing time, for example after a power failure.
m. Each conditioner machine shall have its drive, reducer, and timing gears mounted on the conditioner discharge end unless the timing gear can be handled with ease (i.e. using light tackle). Sufficient provision shall be made to facilitate maintenance (i.e. crawl beams, access for overhead crane etc.) when designing and laying out the conditioning Plant.
n. All shaft to shaft connections shall be easily removable, no hollow shaft connections shall be allowed.
o. Removable wear liners shall be fitted to each conditioner machine. Care shall be taken to prevent corrosion occurring between the liners and the conditioner outer walls. The Contractor shall state how he shall prevent such corrosion. The liners shall be a minimum of 12 mm thick throughout (including the exit/discharge chute areas).
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UHMWPE liners are preferred. The method of attachment to be to the Engineer’s approval.
p. Shaft rotation shall be monitored to provide a ‘running’ signal to the control system additional to that obtained from the drive motor.
q. Conditioner shaft blades:
The blades shall be attached to the shafts in the simplest way possible. Bolt threads and nuts, which can be damaged (caked in ash) and are therefore difficult to remove, are to be avoided. The Contractor shall submit proposed fixing details. Blades shall be easily replaceable with the shafts in situ. The materials of construction of the blades shall be selected with care to ensure a long working life. The Contractor shall include UHMWPE lined blades; however the Contractor may include an alternative option. In each case, the Contractor shall state and guarantee the life expectancy of the blades.
The Contractor shall specify the method of attachment of the wear resistant material to the blades, and shall guarantee the method of attachment for the duration of the wear life of the liner.
One or more blades with reverse pitch shall be located at the discharge end of the shafts to prevent the ash mixture from building up on the end plate.
Alternative liner and blade materials may be supplied however the Contractor shall be responsible for satisfying the requirements of these Employee’s Requirements, irrespective of the option selected.
r. Timing Gears (if applicable):
If timing gears are used to synchronise the paddle shafts, these gears shall be oil bath lubricated and completely closed. The oil baths shall have oil level indicators/site glasses clearly showing the oil levels.
s. Shaft Seals:
Where the shafts pass through the conditioner casing, adequate seals shall be provided to prevent all ash and grease leakage from the machine. The preferred shaft seal is of either horizontal or vertical split labyrinth design. The shaft seal design shall be to the Engineer’s approval.
Deflector plates shall be installed inside the conditioners to deflect ash away from the seals.
t. Bearings:
The main bearings supporting the shafts shall be of the split roller bearing type. The machine shall be so designed that the shafts, complete with blades, can be lifted out of the machine for refurbishing. All bearings shall be designed for an L10 Life of 50 000 hrs. The Contractor shall submit calculations to the Engineer for approval.
Plummer blocks shall be protected against an ash environment. The distance between shaft seals and plummer blocks shall be maximised to minimise possibility of contamination entering plummer blocks when shaft seals are leaking
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or fails catastrophically. The installation of a physical barrier between the shaft seals and plummer blocks shall also be considered.
Grease shall be fed continuously to the shaft seals and bearing plummer blocks by an automatic centralised grease distributor.
u. Isolation of vibration:
The Contractor shall take every care to reduce vibration to a minimum. Vibration amplitudes and frequencies are to be stated in the Contract. Anti- vibration mountings and isolators/compensators are to be provided to prevent any vibrations being transmitted to the silo complex and all ducting etc. serving the conditioner machines.
The layout and connections of all piping, ducting etc. serving the conditioners shall be neatly and simply arranged so as to facilitate easy removal of the complete conditioner machine, viz. minimal disturbance to or removal of associated Plant.
v. Water spray system:
The sizing of the nozzles shall be based on the related water quality.
For poor water qualities nozzles shall be sized accordingly as they shall either be blocked by particles carried in water supply or they shall scale up due to calcium deposits etc.
Damp ash tends to cake up on the non-working nozzles and this ash sets hard and hence impedes the water flow upon return to normal operation. For this reason the installation of nozzles shall be for ease to be removed and replaced when cleaning or inspection is required. Nozzle selection and positioning shall be to the Engineer’s approval.
w. Hollow conditioner shafts can be considered.
5.1.5.6 Water supply
a. The water to be provided for conditioning with the dust shall be supplied from two (2) header tanks installed on top of the fly ash storage silos.
b. Due to the possible aggressive nature of the water handled, special care shall be taken when selecting the piping.
c. Flushing points shall be provided along the water supply line to the conditioners. All flushing water shall be routed to the floor washing drains in the silo and ACC complexes.
d. Subsequent to an auto shut down, no water leakage into the conditioner machines shall occur. Manual isolation is not acceptable to achieve this condition.
e. The water control and isolation valves, operating in conjunction with the ash flow control system, shall have an appropriate response time in order to meet the requirements of this specification.
f. A water flow meter shall provide a signal for both indication and for feedback to the water control valve.
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g. Resilient seal gate valves with rising spindles shall be used for manual isolation.
h. All water piping shall be in accordance with the piping requirements.
i. All mounted isolating valves shall be of the quick acting type i.e. closing times from fully open to fully closed to be <3 seconds, and visa-versa).
j. Flexible rubber or HDPE hosing with quick release couplings can be used to link the conditioning water supply to the ash conditioner.
5.1.5.7 Ash scrubber units
a. Each ash conditioner shall be equipped with a dedicated ash vapour scrubbing facility, which continuously extracts the dust and water vapour arising from the conditioning process.
b. The scrubber units shall be fully automated.
c. The ‘clean’ air discharged from the scrubber shall be discharged to atmosphere (outside the confines of the silo complex) via a short stack.
d. ‘Dirty’ water draining from the scrubber unit shall be gravitated back to the conditioner to form part of the conditioning water addition.
e. Potable water supply shall be available for the scrubber unit.
5.1.5.8 Blower house
a. Areas have been reserved for a blower house/s on ground level below the silos that shall house blowers for silo aeration and fans for airslide aeration.
b. The blower house shall be constructed from brick.
c. The blower house/s shall each be pressurized by two (2) fans/filter units that draw air ducted from outside the silo complex to ensure that the building internals remain dust free, even if access doors are accidentally left open. The design shall include an over and under pressure relief system. The design shall include a double door design.
d. The blower house shall be designed for adequate sealing of the building and filtration of pressurising air.
e. Fans shall be located outside the blower house.
f. The Contractor shall prepare the blower house floor, cast a plinth for each blower to be mounted on. The Contractor shall screed the entire floor.
g. Where fans are to be mounted on concrete the same procedure shall apply. In both cases a single robust plinth shall be used to mount either a blower or a fan to the gearbox and drive unit. (i.e. No separate plinths shall be acceptable).
h. The blowers, fans, heaters, piping, cabling etc. shall be laid out to facilitate removal of all mechanical Plant for maintenance. The layout shall be to the Engineer’s approval.
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5.1.5.9 Fans
a. Two (2) 100% capacity airslide aeration air supply fans shall be provided per silo and shall be housed in the blower house. Non-return isolation - and crossover valves shall be provided so that the two fans serving one silo may be interchanged automatically as required.
b. Lockable manual flow control valves shall be installed in the fan discharges so that the fan’s delivered volume may be set.
c. All fans shall take suction through pleated cartridge type inlet filter assemblies.
d. Each fan’ discharge pressure shall be monitored by a pressure indicator transmitter at the discharge.
5.1.5.10 Blowers
a. Each ash silo shall have a dedicated blower supplying aeration air at a constant pressure. A fourth (4th) blower per three (3) silos shall be installed as a standby and shall be provided with a cross-over facility to any of the three (3) silo aeration air feed systems.
b. Each blower (where applicable) shall be furnished complete with drive motors, inlet and outlet silencers (if required), filters, air dryers, acoustic hoods and heaters, safety relief valves and safety components, protection and instruments, and other accessories necessary for the required duty.
c. The blower suction shall be taken from inside the (blower house) building. The blower intake shall be provided with dedicated inlet filters, over and above the self- cleaning filtration of the building pressurising air (mentioned elsewhere), suitable for a dusty environment. The condition of the blower inlet filter shall be monitored by a differential pressure transmitter that signals the control system when the filter is blocked.
d. Each blower unit shall be enclosed in an acoustic enclosure. The enclosure shall be designed and constructed to ensure a rigid structure. Sufficient access shall be provided for inspection of the Plant and for normal services, without removal of the enclosure and without obstruction. Heat build-up in the acoustic hood shall be prevented by a small axial fan, in the hood wall. The hood shall be easily removable without interrupting the operation of the system. Details are to be provided for the Engineer’s approval.
e. Each blower’s discharge air pressure shall be monitored by a local pressure indicator.
f. A full capacity blow-off vent silencer shall be furnished on each blower. Silencers shall reduce the noise level (sound pressure level) measured at the outlet of the blow- off silencer during blower unloading to a level not exceeding that specified in the Occupational, Health and Safety Act.
g. Each blower shall be of the package type, with the unit and all accessories mounted on a common base frame for easy removal for maintenance.
h. Each silo shall have a dedicated blower and pressure control system (control system supplied by the Employer [C&I Contractor]). Each blower shall exhaust to atmosphere separately.
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i. Sufficient airflow and pressure with adequate standby capacity/requirement shall be available for aeration under worst conditions, all three units feeding simultaneously, full silo standing for 48 hrs (i.e. partly consolidated).
5.1.5.11 Filters
a. The blower house shall be located in a dusty environment and shall therefore be designed for adequate sealing of the building and filtration of pressurisation air. For this purpose a self-cleaning filter shall be provided.
b. The filter suction inlet shall be routed from a clean environment. The filter shall be self-cleaning (i.e. reverse pulse).
c. Pressure transmitters shall be installed on the filter units signal when filter element cleaning or replacement is necessary.
5.1.5.12 Heaters (if required)
a. Heaters shall be used to maintain an AAGC aeration air and silo aeration air temperature of at least 700C, measured at the AAGC casings, and at silo aeration pad inlet respectively, during the various operating conditions. The Contractors shall specify the method of air temperature monitoring, control and regulation, in their bids.
b. The design of the heater system shall ensure that the heater box is distanced from the heater control panel and located in a clean environment e.g. control panel incorporated into the air supply fans’ control panel, which are located locally.
c. A junction box shall be located between the heaters and the control panel. Silicon covered wires are to be used to cable the heaters to the junction boxes and normal cabling may be used between the junction boxes and the control panel. Furthermore the silicon covered wiring is to be protected by a sheath (steel pipe or similar) which can be sealed on both ends once installed.
d. The heater boxes shall have IP65 enclosures Insulation and cladding of the heaters shall conform to the requirements of this document. The heaters shall be mounted above the floor level, on plinths. The design of the heaters and the insulation shall take cognizance of all maintenance activities which shall need to be carried out on this Plant. General arrangement drawings of the heaters, insulation, maintenance facilities etc. shall be provided by the Contractor.
5.1.6 Access
a. The positions of access platforms shown on drawings provided are indicative only. All access platforms, stairways and walkways shall be the responsibility of the Contractor and shall be submitted to the Engineer for the approval.
b. The locations of all the above means of access shall ensure that the Plant can be safely operated and maintained.
5.1.7 Compensators/Expansion Fittings
a. No undue force due to the movement of the Dust Handling Plant shall be transmitted
onto the PJFFP.
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b. Compensators and expansion joints shall be of a standard “off the shelf” type, normally used in high pressure applications. The selection shall ensure that there is no risk of dust leaks from the compensators.
c. Movement (expansion) in the dust conveying pipelines and for example the silo filling valves shall be accommodated by suitably selected compensators and expansion fittings.
5.1.8 Noise Levels
a. Noise levels (sound pressure levels) of every item of the Plant, measured according to SANS 10083/2004 at a distance of 3 m from the item in it’s permanent location at site, shall not exceed 85 dB(A). In cases where the noise levels are exceeded acoustic treatment (cladding, silencers, screens) necessary to reduce noise level to 85 dB(A) shall be employed. This applies to normal operating conditions at site, for items of Plant operating periodically; this shall apply for the time they are operating.
b. In the case of portable or movable Plant (e.g. compressors, travelling cranes, etc.) the sound pressure level, measured in the free field over a reflecting plane, shall not exceed 85 dB (A) at a distance of 3 m from the surface of the item, when working at full load.
5.1.9 Dust Levels
Inhalable and respirable dust levels shall be according to “Occupational Health and Safety Act,-1993, Hazardous Chemical Substances Regulations, 1995, Annexure 1, Applying Occupational Exposure Limits:
“36. The general approach necessary to control occupational exposure to dusts is as follows: not all dusts have been assigned occupational exposure limits but the lack of such limits should not be taken to imply an absence of hazard. In the absence of a specific exposure limit for a particular dust, exposure should be adequately controlled. Where there is no indication of the need for a lower value, personal exposure should be kept below both 10 mg/m³ 8-hour time-weighted average total inhalable dust and 5 mg/m³ time-weighted average respirable dust. Such, or greater, dust concentrations should be taken as the substantial concentrations. A substantial concentration of dust should be taken as a concentration of 10 mg/m³, 8-hour time-weighted average, of respirable dust, where there is no indication of the need for a lower value, and as such they are referred to as substances hazardous to health.
TOTAL INHALABLE DUST AND RESPIRABLE DUST
37. Total inhalable dust approximates to the fraction of airborne material that enters the nose and mouth during breathing and is therefore available for deposition in the respiratory tract. Respirable dust approximates to the fraction which penetrates to the gas exchange region of the lung. A fuller definition is given at the end of Table 2 of Annexure 1 (Abbreviations). (reproduced below)
The concentration of respirable dust shall be determined from the fraction passing a size selector with an efficiency that shall allow:
i. 100% of particles of 1 mm aerodynamic diameter
ii. 50% of particles of 5 mm aerodynamic diameter
iii. 20% of particles of 6 mm aerodynamic diameter
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iv. 0% of particles of 7 mm aerodynamic diameter and larger to pass through the size selector.”
5.1.10 Insulation
a. Removable insulation panels shall be interchangeable, easily removable/reassembled and designed to last the life of the Power Station.
b. Removable panels shall be robust, of reinforced construction to prevent damage during removal and re-installation and during activities associated with the manual operation and maintenance of the Plant.
c. The insulation panels shall be waterproofed to prevent the ingress of water which is directed at the insulation from the floor washing hose, at a pressure of up to 10 bar. Notwithstanding the waterproof design of the insulation cladding, the lower (base) panels shall have 5 mm diameter drain ports drilled into the cladding, to drain any water which may have entered the insulation.
d. Where vertical sections of pipe work/ductwork are insulated, the insulation shall be supported from the pipe work/ductwork by frequently spaced fixed anchor points, to prevent sagging and or deformation of the insulation with time.
e. Inspection doors and clean-out doors shall be insulated with hinged insulation doors whose cladding material thickness shall be not less than 1.6 mm.
f. Notwithstanding the Plant guarantee requirements as stated elsewhere, the removable panels shall be designed to be removed and re-installed once every 18 months for the remaining life of the power station, without degradation of the insulating characteristics/requirements.
g. The fixing/attaching devices used to secure removable insulating panels to the Plant shall be simple, robust, quick release devices.
h. Air Activated Gravity Conveyors (AAGC) insulation panels shall be designed to facilitate maintenance of the membrane material, without unnecessarily removing portions of the insulation.
i. The insulation requirement is to maintain an internal AAGC wall surface temperature of not less than 90 0C, when heated air only is passing through the conveyors and in a worst case ambient temperature at site.
j. Cladding of all AAGC insulation shall be galvanised to a minimum thickness of 0.8 mm and each panel is double folded for rigidity.
k. The insulation panels shall be supported from the AAGC casings/structures at frequent intervals to prevent deformation of the insulation and panels, over the life of the station.
5.1.11 Crawl Beams, Cranes And Hoists
a. Crawl beams, all fitted with a trolley, shall be provided where maintenance of Plant cannot be undertaken by a mobile crane. The Contractor shall remain responsible to ensure that all Plant remains serviceable for maintenance and operation.
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b. All crawl beams shall be positioned so that components can be lowered or raised to/from ground level.
c. Provision, i.e. stairways and platforms, shall be provided for fitting/hanging hoists, onto crawl beams at all points needed.
d. Lifting lugs shall be installed above all maintenance components, from which lifting apparatus can be suspended in order to hoist components into position. The final location and number of these lifting lugs shall be to the Engineer’s approval.
e. The Contractor shall provide and install all crawl beams required for the Plant as part of the structural steelwork.
f. The crawl beam capacity shall be clearly marked on the crawl beam every 20 meters.
g. Where the hoist unit operates over a well, the pendant controller shall be mounted on a swing arm.
5.1.12 Specification Of Open Grid Flooring, Stairways And Hand railing
a. Flooring shall be of open grid type and shall be of welded or dimpled construction and capable of carrying a minimum of 5 kPa of distributed load with a maximum deflection of 1 in 200 of the span or 10mm whichever is less. The maximum distance between supports of the open grid flooring shall be 2 m.
b. Flooring panels shall be positively located on supporting steelwork by means of suitable clamps and self fixing studs or shall be tack welded to supporting steelwork.
c. Angles and kick flats of 5 mm minimum thickness and 75 mm height shall be provided around all openings in open grid flooring and at edges of galleries/walkways except at entrances to staircases.
d. Stairways shall be designed for a minimum load of 5 kPa and shall be not less than 750 mm wide. They shall be placed at an angle not greater than 45º to the horizontal. Treads shall be open grid flooring without risers and shall be fitted with galvanised friction nosings.
e. Ladders shall only be installed with the approval of the Engineer.
f. Hand railing shall be provided to the peripheries of permanent openings and to the edges of floors. Stairways shall have hand railing on both sides.
g. Handrails shall be secured to stanchions to prevent drawing out. Stanchions shall be fabricated of forged steel. Joints in railings shall be made using a minimum 150 mm ferrule smoothly pinned through both parts.
h. Handrails shall have radius curves or bends at each change of direction.
i. Internal hand railing shall be painted and external hand railing shall be galvanized.
5.1.13 Corrosion Protection
a. Corrosion protection of the works shall comply with the Employer’s specification, “Corrosion Protection Specification of Project Alpha, March 2006” (see Section 3.2.4.4 [Eskom Standards]).
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b. Plant shall be adequately protected against physical damage and corrosion during transport and storage.
c. All unprotected finished surfaces of ferrous metals, including screw threads that shall be exposed while awaiting installation, shall be thoroughly cleaned and given a heavy uniform coating of an approved petroleum soluble rust preventive compound.
5.1.14 Pipe Racks/Gantries
a. A pipe rack shall be provided to route and support the conveying pipes from the transverse ash conveyor structure to the fly ash storage silos as indicated in drawing no. 084/4785 (see Section 3.2.1 Drawings).
b. All other pipe gantries required to route the conveying – and instrument air supply from the compressor houses to the points of use is included in this scope.
c. The layout of pipes in these racks/gantries shall allow sufficient maintenance access..
5.1.15 Reliability, Availability and Maintainability
The Contractor shall perform RAM (Reliability, Availability and Maintainability) studies on all major areas of Plant in the works. The objectives of these studies are to achieve the following:
Predicting the availability of various areas of Plant.
Performing redundancy studies.
Using the study to optimize the LP Services Plant spares holding. Essential to the above process is the construction of an ABD (Availability Block Diagram) of the system and shall form part of the RAM study. The ABD shall show the interconnections between equipment for each of the subsystems making up the Plant. All redundancies shall also be shown. The VisualSPAR version 2.2 reliability simulation software package shall be used in performing the RAM analysis. The Contractor shall supply the following:
RAM Reports as per the objectives listed above.
The availability calculations for each subsystem and the complete system. The operating logic of the LP Services Plant shall be modeled in VisualSPAR.
The complete ABD models and software logic – the actual ABD VisualSPAR version 2.2 software models. The ABD models and software logic provided by the Contractor, as part of the Works, is supplied in its entirety and is sufficient in itself for the Employer to replicate or re-create all the ABD calculations using only the VisualSPAR version 2.2 software.
Capital, maintenance, operating and unavailability cost estimates for those systems in their supply, for inclusion in the ABD.
MTTF (Mean Time to Failure) for each type of equipment and the type of failure distribution i.e. Exponential or Weibull.
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MTTR (Mean Time to Repair) or MDT (Mean Down Time) and Availability estimates for those systems in their supply, for inclusion in the ABD.
Subsystem level ABD’s indicating degree of redundancy if any and estimates as given above.
5.1.16 Technical Risk Assessments
5.1.16.1 HAZOP (Hazard and Operability) Studies
The Contractor shall carry out formal Hazard and Operability (HAZOP) Studies on all systems in their supply. These studies shall be done in accordance with the requirements as
laid down in the Eskom HAZOP Guideline: 240-49230111.
5.1.16.2 FMECA (Failure Mode Effects and Criticality Analysis)
The Contractor shall carry out formal Failure Mode Effects and Criticality Analysis (FMECA) Studies on all systems in their supply. These studies shall be done in accordance with the requirements as laid down in the Eskom FMECA Guideline: PGZ 45-25.
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6 SAFETY REQUIREMENTS
All Plant shall be designed to fail-safe. Sudden power losses shall not have an adverse effect on Plant and shall not unduly delay return to operation after power is restored.
The machine shall be designed and built to ensure maximum reasonable safety and comfort of the operator, maintenance personnel and people in the area of the machine.
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7 ELECTRICAL REQUIREMENTS
Unless otherwise specified all electrical Plant necessary for the safe and efficient working of this Plant shall be provided in terms of the electrical Employer’s Requirements attached in Section 4.3.
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8 PROCESS CONTROL AND INSTRUMENTATION REQUIREMENTS
8.1 GENERAL
a. The systems and design shall ensure a consistent and integrated platform for the Power Station’s
C&I system across and within all plant areas. b. The Power Station’s C&I systems shall be configured as fully operational systems and are
workable in all respects and are implemented in a consistent and integrated manner. c. The Power Station’s C&I system provided shall be configured, designed, engineered, installed and
commissioned using this Specification, OEM best practices and industry best practices.
8.2 DESIGN STANDARDS, GUIDELINES AND CODES
The Control and Instrumentation (C&I) system shall comply to the following standards and guidelines as a minimum:
Table 1: C&I Specific Minimum Standards and Guidelines
Type Number Name
Eskom 240-56227443 Requirements for control and power cables for power stations
Eskom 240-56355466 Alarm Management System Standard
Eskom 240-56355729 Plant Control Modes Guideline
Eskom 240-52844017 System Reliability, Availability and Maintainability Analysis Guideline
Eskom 240-56355754 Field Instrument Installation Standard
Eskom 240-56355815 Junction Boxes and Cable Termination Standard
Eskom 240-56355843 Pressure Measurement Systems Installation Standard
Eskom 240-56355888 Temperature Measurement Systems Installation Standard
Eskom 240-55410927 Cyber Security Standard for Operational Technology
Eskom 240-49230046 Failure Mode and Effects Analysis Guideline
Eskom 240-49230111 HAZOP Analysis Guideline (Rev 1)
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Type Number Name
IEC IEC 62381 Automation systems in the process industry - Factory acceptance test (FAT), site acceptance test (SAT), and site integration test (SIT)
Eskom 240-56355728 Human Machine Interface Design Requirements Standard
Eskom 240-56355535 Process Calibration Equipment Standard
a. The Contractor shall obtain his own copies of International and National standards. b. The Contractor shall report any conflict within this Specification, with any referenced standards,
specifications or technical guideline. c. This Specification shall take precedence over differences existing between this Specification and
any document except for statutory requirements. d. Substitutions of any standard shall be approved by the Engineer. Additional standards proposed by
the Contractor shall be submitted to the Engineer for approval. e. Only the most recent versions of the relevant standards, guidelines, or codes shall be used with this
Works.
8.3 REQUIREMENTS RELATED TO SAFETY
a. No individual C&I fault shall endanger the safety of the people or plant or jeopardise the integrity of major plant.
b. The earthing concept applied by the Contractor shall be based on recognised best engineering practices and shall ensure the safe and reliable operation of the C&I systems and the protection of the electronic equipment against damaging transients.
8.4 REQUIREMENTS RELATED TO AVAILABILITY AND RELIABILITY
a. No individual C&I fault or two concurrent faults shall instantaneously cause a multi- Unit trip. b. The availability of the complete Unit C&I system over its life in percentage of time shall be 99.99% or
greater measured annually. c. No individual C&I fault shall cause the loss of an operator workstation. d. Failure of any operating screen shall not inhibit plant operation. e. No individual C&I fault shall cause the loss of control or operator information. f. The equipment shall have a failure rate of less than 0.6% of the installed base over a calendar year
for I/O modules and a failure rate of less than 1% of the installed base over a calendar year for field equipment.
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8.5 EARTHING, LIGHTNING AND ELECTRICAL PROTECTION
a. All C&I system equipment shall be earthed to the station earth point. b. All metal instrument casings shall be properly earthed (grounded) to the earth mat to avoid any
electromagnetic interference which may arise from portable RF transmitters, cell phones and other equipment used on the plant.
c. All earthing required to eliminate any interference shall be provided. d. All field cables and network cables shall be earthed (grounded). The cables shall be earthed at one
end or both ends depending on the interference signal and shall comply with an overall recognized earthing arrangement.
e. Lightning and Surge protection shall be included in all the circuits where there is exposure to potential lightning.
f. All earthing and surge protection shall as a minimum be in accordance with the following standards and specifications:
SANS 10142-Part 1 - The Wiring of Premises Part 1: Low-voltage installations.
240-55714363 - Coal Fired Power Stations Lighting and Small Power Installation Standard.
240-56356396 – Earthing and Lightning Standard
8.6 REQUIREMENTS RELATED TO MAINTAINABILITY
a. The components installed shall be protected from the harsh or hazardous power plant environment. b. The Contractor shall ensure that the installation of the transmitters:
Allow for safe and easy access for maintenance and calibration.
Allow for the environmental conditions.
Allow for the removal of equipment for maintenance in the vicinity of the transducer. c. Emergency plans shall be provided for system failures and faults such that appropriate measures
can be taken immediately without having to first analyse the cause of the failure.
8.7 INTEGRATION AND CONSISTENCY OF DESIGN
a. The HMI shall present an integrated and standardised set of displays and facilities which are designed to conform to ergonomic principles and modern power plant practice.
b. The design approach of the HMI, and the underlying functionality of the C&I systems behind the interface shall be consistent across all C&I systems and functional areas covered by the Medupi C&I system.
c. Uniformed signal descriptions and abbreviations shall be used throughout the Power Station C&I system.
d. The control system software and database(s) are fully integrated and seamless.
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8.8 EXPANDABILITY
a. The C&I system design shall provide for later expansion of the control and instrumentation system such that future changes and enhancements can be readily incorporated.
b. The following shall be provided at basic design freeze:
10% of all installed IO used per AU kept spare i.e. 10% of each type of IO installed (binary and analogue IO).
20% spare installed terminals in all junction boxes for field cables, i.e. 20% unused terminals in the field terminal block.
20% unused and terminated cores in all trunk cabling. The unused cores shall be terminated at both ends.
10% spare installed terminals in the field terminal block in the automation units.
20% reserve physical space for IO modules per AU, i.e. 20% uninstalled space.
20% reserve physical space for field terminal blocks per AU.
10% reserve physical space (rounded up) on all trunk cabling infrastructure.
20% reserve power availability per power supply system (power distribution, cabinet power supplies).
Space for 10% additional network cables (rounded up) in every network cabinet.
10% spare cores in all multi-core fibre optic cables (rounded up) terminated at both ends.
10% unused network ports per network switch (rounded up).
10% spare 1U rack space in all network cabinets (rounded up).
8.9 LIFE EXPECTANCY
a. All equipment, protection systems and control components will be supported and maintained until the end of 2032.
b. The Contractor shall provide his latest power plant proven technology for the Works.
8.10 STANDARDIZATION
a. The purpose of standardisation of the control and instrumentation plant and equipment is as follows:
Reduced life cycle cost/cost of ownership cost.
Interchangeability of equipment.
Reduced number of different types of equipment used on site, thereby also reduced spares holding requirements.
Reduced training requirements of different systems. b. The Contractor shall develop a standardisation strategy for approval by the Engineer. c. The Contractor shall standardise on all similar plant and equipment provided for the complete
control and instrumentation system forming part of the Works. d. The standardisation shall include for as a minimum the following aspects for all plant and equipment
forming part of the Works, and shall include but not be limited to:
HMI (make, model, and size): i. Screens. ii. Input Devices. iii. Computer. iv. Desks.
Computers and servers (make, model, and 19” rack mounting).
Network equipment (make and model): i. Switches and hubs. ii. Fibre optic cable (type of cable and terminations).
Cubicles and enclosures (make, size, construction and colour).
Control system controllers (make and model).
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Control system input/output units (model, series, specifications and form factor).
Automation systems/PLC’s used (make, model, and series).
Field instrumentation: i. Instrumentation for each measurement type (make, model, series, accuracies, ranges,
process connections, mountings and terminations). ii. Actuators (make, model, series, mountings and terminations). iii. Impulse piping (size, material, connections and arrangements). iv. Transmitters (make, model, series, accuracies, mountings, housings and
terminations). v. Transmitter racks (arrangement and mountings). vi. Junction boxes (size, colour, arrangement and mounting). vii. Splitter boxes (size, colour, arrangement and mounting). viii. Instrument isolation valves and manifold (size, make, model, arrangement and
connections). ix. Condensate pots (make, size, arrangement and connections).
Cabling (routing, make, size, type, number of conductors, terminations).
Racking, trunking and conduits (routing, make, size, type and mountings). e. Standardisation shall not compromise the plant and/or the control and instrumentation system
performance.
8.11 REQUIREMENTS RELATED TO TECHNICAL DOCUMENTATION
The Contractor shall supply all documented as specified in the Vendor Document Submittal Schedule (VDSS – Document Number 240-85521112).
The following Templates are provided to the Contractor and the Contractor shall complete the templates as per below and as specified in the VDSS.
a. 240-72349423 Instrument Schedule b. 240-61379755 Drive and Actuator Schedule c. 240-72344339 Virtual Signal List d. 240-72346360 Load Schedules for UPS Supply e. 240-72346591 C&I Defects Checksheet f. 240-72350241 Panel Interface List
8.12 DESCRIPTION OF SOME OF THE C&I TEMPLATES AND DOCUMENTS
8.12.1 Limits of Supply and Services (LOSS)
The scope of supply and services of the Contractor is given in graphical format in the LOSS diagrams. The LOSS diagrams indicate the scope of supply and services for individual Control and Instrumentation (C&I) items such as instrumentation and the supply and interfaces to systems.
The Contractor shall be responsible to identify scope of supply and services that are not indicated on the LOSS diagrams and identify systems and or equipment that are not covered by the LOSS diagrams and red-line the supplied LOSS diagrams.
8.12.2 Function IO Block Diagrams
The Functional IO Block Diagrams details the type and quantity of the inputs and outputs from control and instrumentation equipment and systems. In the case of a bus interface, the Functional IO Block
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Diagrams reference a Virtual Signal List. The Virtual Signal List gives a detail description of the information that shall be transmitted over the bus.
The Contractor shall be responsible to identify systems and equipment not covered by the supplied Functional IO Block Diagrams.
8.12.3 Instrument Schedule
The Contractor shall list all the field instrumentation that shall be required for the complete process forming part of the Works in the Instrument Schedule.
The instrumentation shall include all instruments forming part of the design whether the supply thereof is included in the Works or not. The Contractor shall ensure to complete the reference to the LOSS diagrams in the Instruments Schedule indicating the scope of supply.
8.12.4 Panel Interface List
The Panel Interface List indicates the stand alone control systems supplied by the Contractor. The detail of the bus and/or hard wired interface is given in the Functional IO Block Diagrams referenced in the Panel Interface List.
Instrumentation that forms part of a skid, that is where it is agreed by the Engineer that the instrumentation only (excluding the control equipment) will be supplied by the Contractor on a factory fitted system, shall be indicated in the Instrument Schedule and not the Panel Interface List.
8.12.5 Virtual Signal List
The Virtual Signal List referenced in the Functional IO Block Diagrams gives the detail information on the quantity and signal descriptions of the information that is transmitted over the bus.
8.12.6 Drive & Actuator Schedule
The Contractor shall list all actuators including electrical, pneumatic and solenoids and motor drives and feeders for the complete process forming part of the Works in the Drive and Actuator Schedule.
The drives and actuators shall include all forming part of the design whether the supply thereof is included in the Works or not.
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9 CIVIL WORKS
Unless otherwise specified all Civil Works necessary for the safe and efficient working of this Plant shall be provided in terms of the Civil Employer’s Requirements attached in Section 4.3.
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10 FIRE PROTECTION AND DETECTION
Unless otherwise specified all Fire Protection and Detection Plant necessary for the safe and efficient working of this Plant shall be provided in terms of the Fire Protection and Detection Employer’s Requirements section 4.3.
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11 TESTING REQUIREMENTS AND PROCEDURES
11.1 TESTING
General
Unless otherwise stated in these Employer’s Requirements, the Works shall be tested in accordance with the requirements and procedures approved by the Engineer. To this end the Contractor shall submit his proposed requirements and procedures for all tests (including for the Tests on Completion and the Tests after Completion) to the Engineer, for approval, within 84 days of the Contract Date. These requirements and procedures shall be developed so as to suitably and properly demonstrate that the Works meet the Employer’s Requirements and shall:
a. be in accordance with the details (if any) stated in the Contract; and b. be further developed or amended and re-submitted at the expense of the Contractor until
they are approved by the Engineer.
11.2 MECHANICAL TESTING (FACTORY TESTING)
11.2.1 DRIVE UNITS
The drive unit shall be completely assembled, aligned and run under light load before delivery to Site. After the run under light load, the speed reducer shall be drained of all oils/fluids and refilled with the correct working oil. Oils and greases shall be in strict accordance with the individual suppliers’ recommendations. Gearbox housings shall be subject to paraffin tests for oil tightness, prior to being painted on the inside.
11.2.2 NON-DESTRUCTIVE TESTING
Digital X-ray or magnetic scan (only on steel chord) shall be conducted on all conveyor belting as being rolled. Both scans shall also incorporate a visual inspection by means of a video camera and digital footage of the damaged areas (i.e. repairs, blemishes, patches, etc.). The Contractor shall submit the test results to the Engineer for approval prior to dispatch from place of manufacturing.
11.2.3 Tests On Completion (Mechanical Works)
After manufacture and erection, the Contractor shall satisfy himself that the Plant is complete in all respects and shall carry out the necessary tests of the Plant, (supplied by the Contractor). During this period the Engineer shall carry out visual inspection on the Plant and witness the tests.
The Contractor shall provide personnel and all Equipment and Plant necessary for the tests.
The Contractor shall submit, for approval by the Engineer, a complete and detailed test and inspection procedure for test before Taking Over. This test and inspection procedure shall include all tests and inspections required in terms of the respective specifications and other tests and inspections deemed necessary by the Contractor to prove to the Engineer’s satisfaction that the Plant has been delivered according to this specification and shall include stability tests, operational
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tests under simulated conditions, functional tests, tests to prove the integrity of the safety and limit systems and inspections for final quality, including paint quality.
After approval of the test and inspection procedure by the Engineer, the Contractor shall fully test the Plant supplied by him in the presence of the Engineer and according to the approved procedure.
Training and certification of the Employer’s Personnel shall be done during this period to render them competent to operate and maintain the Plant after TO.
Preliminary Operating and Maintenance manuals shall be handed over 90 days prior to commencement of tests. Five hard copies and one electronic copy of the final manuals and preliminary as-built drawings shall be handed over before TO.
The Plant shall be tested in empty running condition to confirm that the complete Plant performs according to the specification. It shall be confirmed that the control system performs according to the design with reference to control and sequence starting and stopping and that all protection devices, limits and the communication links operate correctly.
Before the commencement of any tests the Contractor shall provide the initial fill of oil for all gearboxes and grease for components which require grease lubrication.
All simulation devices, test weights and instruments required shall be provided by the Contractor.
A dedicated air flow meter to measure air supply specific to Dust handling plant Unit 1. This air flow meter configuration and pipe network should allow for ease of installation and relocation to can be used anywhere in the Dust Handling Plant, .i.e., not limited to Unit 1.
11.2.4 TESTS AFTER COMPLETION (MECHANICAL WORKS)
The Contractor shall apply formally to the Engineer for each test / test phases to start. The test shall only start when the Plant is in a fully operational state. Plant commissioning and optimization shall not be allowed during testing.
The Contractor shall submit, for approval by the Engineer, a complete and detailed test and inspection procedure for tests after TO. This test and inspection procedure shall include all tests and inspections required in terms of the respective specifications and other tests and inspections deemed necessary by the Contractor to prove to the Employer’s satisfaction that the Plant is performing according to this specification and shall include reliability - and capacity tests.
All simulation devices, test weights and instruments required shall be provided by the Contractor. These devices will be permanently installed in accessible locations.
Reliability tests shall constitute at least 30 days of continuous unassisted operation of the Plant of which the last 7 days shall be completely trouble free. The reliability test shall be regarded as successful when the stoppages as a result of this relevant system is limited to a maximum of 0.5 incidents per day and that the downtime as result of the combined stoppages is less than 15 minutes per day on average measured over the period of 30 days continuous operation in the fully automatic mode with no control simulations in place.
During capacity tests the following two tests shall be conducted:
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The system shall operate at normal capacity for a continuous period of more than 24 hrs. The Plant shall operate satisfactorily with no indication of constraints at this load.
The system shall operate at backlog recovery capacity for a continuous period of at least 24 hrs on all available Plant. The Plant shall operate satisfactorily with no indication of constraints in the functional performance for extended operation at this maximum load.
The following shall be tested and confirmed, as a minimum:
Confirmation that the control system performs according to the design with reference to control and sequence starting and stopping and that all protection devices, limits and the communication links operates correctly.
No spillages
No water and air leakages.
No blockages or build ups that may result in blockages
Acceptable levels of dust in the environment. The levels of dust shall comply with statutory requirements and no nuisance dust in the general working areas for operators and maintainers shall be present.
The ability of the system to start conveying, with full conveying pipelines, after a loaded system trip.
All the functional operations of the Plant under load.
Air – and power consumption and conditioned ash moisture content
In case of failure of any of the test phases, the functional tests for the relevant Plant area and all other effected Plant shall be repeated. The capacity and reliability test shall be re-done in total on the relevant system.
During the tests period, the Employer’s Personnel shall operate the Plant, under the supervision of the Contractor. The Contractor shall not be allowed to operate the Plant directly.
The backlog and nominal (design) capacities shall be proven during the test period.
The Employer shall reserve the right to carry out further tests on the installation.
On completion of the tests the Contractor shall supply in triplicate complete test certificates as necessary, and such prescribed statutory documents as are required certifying that the Plant is in complete working order and that all working parts are effectively lubricated.
11.3 ELECTRICAL TESTING
General
For standard Plant and Materials, the Contractor shall submit type test certificates before commencing with manufacturing. Type tests shall be performed at least once for each type of component, or system. Any component or system offered by the supplier as part of the Works shall also be subject to pre-delivery tests. It is important to note that where not specified, the routine testing requirements shall be as per the relevant national and/or international standards. These tests shall include performance tests, insulation tests, Plant checks with regards to the drawings and any other tests or checks necessary to confirm conformance of the Works.
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11.3.1 Factory Testing (Electrical Works)
The Contractor shall submit full details of the testing and optimisation procedures for the approval of the Engineer before the tests are to be performed.
11.3.2 Electrically operated actuators inspection and testing
Each actuator shall be factory tested. Tests shall be performed in accordance with the IEC standards as and where applicable. A final inspection record shall be supplied with each actuator. This shall include the following information:
General actuator data;
Nominal current (continuous);
Nominal current (short time over load);
No load current;
Starting current;
Power factor at rated torque;
Output speed;
Torque switch setting;
Limit switch setting (turns/stroke);
High voltage test;
Functional test (including all options);
Visual test.
11.3.2.1 Routine tests of motors
Insulation resistance: Stator and rotor winding insulation resistances for the motor shall be measured and recorded together with the temperature at the time.
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12 SPARES
The Contractor shall submit a schedule of, and include in the offer, all spares that are considered necessary for the long tem operation and maintenance of the Plant, taking into account the life expectancy and lead time of the components. The Contractor shall identify, and include in the offer, all special tools required for ongoing operation and maintenance
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13 Training Requirements
Training for Employer’s Personnel
In-factory and on-Site training for the Employer’s Personnel (for a minimum of 21 days and conducted by at least 2 people) in the operation and maintenance of the Plant shall be carried out by the Contractor before the completion of the first unit. The Contractor shall provide training in the use of the instruction manuals, drawings, diagnostic features and Plant for operation and maintenance of the Works.
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14 APPENDIX
14.1 LIST OF APPLICABLE DRAWINGS AND DOCUMENTS
Table 2: Applicable Drawings and Documents
SPO Number Document No. Description
348-136385
0.84/46166 UNIT 1 PJFFP BLOWER HOUSE PLINTH REINF. LAYOUT
348-132834 0.84/46167 UNIT 1 PLINTH P1A REINF. LAYOUT
348-136499 0.84/46168 UNIT 1 PLINTH P1B REINF. LAYOUT
348-134380 0.84/46174 UNIT 1 BLOWER ROOM CONCRETE LAYOUT
348-128988 0.84/38895 PJFFP AERATION AIR HEATER UNIT 1 - 1 OETP23 AC001
348-129843 0.84/11336 Unit 1-6 PJFFP Aeration Blower Room Layout
348-133961
0.84/11419 Sheet 1
PJFFP Unit 1-6 Hopper Aeration Piping - General Arrangement
348-136548 0.84/11419 Sheet 2
PJFFP Unit 1-6 Hopper Aeration Piping - General Arrangement
348-129320
0.84/30257 Sheet 1
Compressed Air Distribution Manifold Unit 1-6
348-129875 0.84/30257 Sheet 2
Compressed Air Distribution Manifold Unit 1-6
348-128968
0.84/30258 Sheet 1
Instrument Air Distribution Manifold Unit 1-6
348-128832 0.84/30258 Sheet 2
Instrument Air Distribution Manifold Unit 1-6
348-130956 0.84/33133 Sheet 1
UNIT 1-6 PJFFP C & I LOCATION GA
348-134171 0.84/33133 Sheet 2
UNIT 1-6 PJFFP C & I LOCATION GA
348-134168 0.84/33133 Sheet 3
UNIT 1-6 PJFFP C & I LOCATION GA
348-135529 0.84/33133 Sheet 4
UNIT 1-6 PJFFP C & I LOCATION GA
348-130326 0.84/33133 Sheet 5
UNIT 1-6 PJFFP C & I LOCATION GA
348-135138 0.84/33133 Sheet 6
UNIT 1-6 PJFFP C & I LOCATION GA
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348-136048 0.84/33133 Sheet 7
UNIT 1-6 PJFFP C & I LOCATION GA
348-136047 0.84/33133 Sheet 8
UNIT 1-6 PJFFP C & I LOCATION GA
348-132550 0.84/33133 Sheet 9
UNIT 1-6 PJFFP C & I LOCATION GA
348-132549 0.84/33133 Sheet 10
UNIT 1-6 PJFFP C & I LOCATION GA
348-129185 0.84/25841 Unit 1 - Fly Ash Dense phase Instrumentation Air Distribution P & ID
348-129750 0.84/32412 UNIT 1-6 PJFFP AERATION BLOWER ROOM LAYOUT
348-912577 SERVICES PIPE SUPPORTS AT PJFFP UNIT 1-3
348-912581
SERVICES PIPE SUPPORTS AT PJFFP UNIT 1-3
348-128824 0.84/11311 Unit 1 - PJFFP Hopper Aeration P & ID
348-128978
0.84/11317 Sheet 1
Unit 1 - Fly Ash Dense phase Pneumatic Conveying P & ID
348-128689 0.84/11317 Sheet 2
Unit 1 - Fly Ash Dense phase Pneumatic Conveying P & ID
348-134384
0.84/30259 Sheet 1
Pneumatic Conveying Piping 300NB Unit 1
348-135238 0.84/30259 Sheet 2
Pneumatic Conveying Piping 300NB Unit 1
348-136277
0.84/30259 Sheet 3
Pneumatic Conveying Piping 300NB Unit 1
348-135239 0.84/30259 Sheet 4
Pneumatic Conveying Piping 300NB Unit 1
348-135238 0.84/30259 Sheet 1
Pneumatic Conveying Piping 300NB Unit 1
348-135238 0.84/30259 Sheet 2
Pneumatic Conveying Piping 300NB Unit 1
348-136277 0.84/30259 Sheet 3
Pneumatic Conveying Piping 300NB Unit 1
348-909599 UNIT 1 MASTER VESSEL CONTROL PANEL - GA
348-909601 UNIT 1 SLAVE 1-5 VESSEL CONTROL PANEL - GA
348-909609 UNIT 1 OUTLET VESSEL 0ETG07 CONTROL PANEL - GA
348-909612 UNIT 1 OUTLET VESSEL 0ETG14 CONTROL PANEL - GA
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348-909614 UNIT 1 OUTLET VESSEL 0ETG27 CONTROL PANEL - GA
348-909620 UNIT 1 OUTLET VESSEL 0ETG34 CONTROL PANEL - GA
348-129038 0.84/36102 DOME SWITCH VALVE CP SILO 2&5 UNIT 1-6 CONV LINES
348-128508 0.84/42462 SILO 2 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - GA
348-128737 0.84/42464 SILO 1 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - GA
348-909715 UNIT 1 MASTER VESSEL CONTROL PANEL - PNEUMATIC DIAGRAM
348-909725 UNIT 1 SLAVE 1-5 VESSEL CONTROL PANEL - PNEUMATIC DIAGRAM
348-909727 UNIT 1 OUTLET VESSEL 0ETG07 CONTROL PANEL - PNEUMATIC DIAGRAM
348-909732 UNIT 1 OUTLET VESSEL 0ETG14 CONTROL PANEL - PNEUMATIC DIAGRAM
348-909735 UNIT 1 OUTLET VESSEL 0ETG27 CONTROL PANEL - PNEUMATIC DIAGRAM
348-909739 UNIT 1 OUTLET VESSEL 0ETG34 CONTROL PANEL - PNEUMATIC DIAGRAM
348-129590 0.84/36104 DOME SWITCH VALVE CP PD SILO 2&5 - UNIT 1-6 CONV LINES
348-128738 0.84/42466 SILO 2 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - PNEUMATIC DIAGRAM
348-129806 0.84/42468 SILO 1 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - PNEUMATIC DIAGRAM
348-909765 UNIT 1 MASTER VESSEL CONTROL PANEL - WIRING DIAGRAM
348-909793 UNIT 1 SLAVE 1-5 VESSEL CONTROL PANEL - WIRING DIAGRAM
348-909789 UNIT 1 OUTLET VESSEL 0ETG07 CONTROL PANEL - WIRING DIAGRAM
348-909800 UNIT 1 OUTLET VESSEL 0ETG14 CONTROL PANEL - WIRING DIAGRAM
348-909806 UNIT 1 OUTLET VESSEL 0ETG27 CONTROL PANEL - WIRING DIAGRAM
348-909811 UNIT 1 OUTLET VESSEL 0ETG34 CONTROL PANEL - WIRING DIAGRAM
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348-128527 0.84/36106 DOME SWITCH VALVE CP WD SILO 2&5 - UNIT 1-6 CONV LINES
348-128739 0.84/42470 SILO 2 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - WIRING DIAGRAM
348-129808 0.84/42472 SILO 1 UNIT 1-3 - SWITCH VALVE CONTROL PANEL - WIRING DIAGRAM
348-128788 200-115738 UNIT 1-3 PJFFP WALKWAYS
348-129499 0.84/27677 Boiler 1 PJFFP Aeration Plinths Type 01 Reinforcement
0.84/22064 Boiler 1 Switch Valve Access Platform
348-129191 0.84/22065 Boiler 1 End Pipe Supports
348-128580 0.84/11350 General Arrangement Blower House Civil Outline
348-136200 200-27440 Electrical Consumer List
200-30275 Electrical Motor Catalogues
200-30276 Electrical Actuator Catalogues
200-30277 Electrical Motor Technical Information
348-135137 348-134190 348-134085 348-136818 348-136820 348-130082 348-135143 348-135040 348-132369 348-136178 348-134311 348-132442 348-136176 348-135282 348-135931 348-134405 348-133170 348-132427 348-131782
0.84/12205 SHEET 1-19
Electrical Hook-Up Diagrams THE NUMBERS STARTING WITH 348-1… ARE ARRANGED IN AN ASCENDIING ORDER FROM SHEET 1 TO 19
348-128882 0.84/31946 Proposed Termination Points
348-128757 0.84/23564 LPS Water System – Termination points
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348-130683 200-46811 Termination Diagrams
Operating and Control Philosophy
348-132884 200-27374 Operating & Control Philosophy for the Dust Conveying Plant & Hopper Aeration
348-130368 200-27375 Operating & Control Philosophy for the Silo and Conditioning Plant
Commissioning Procedure
348-129268 200-84172 Commissioning Procedure: Dust Handling Plant
348-133744 200-01702 COMMISSIONING PROCEDURE FIRE SYSTEM ASH COND BLDG
348-135833 200-98582 COMMISSIONING PROCEDURE SILO 5 BLOWER ROOM EQUIPMENT
348-131833 200-35366 COMMISSIONING PROCEDURE - MD-PUMP CONVEYING SYSTEM
348-131930 200-36123 COMMISSIONING PROCEDURE: PJFFP AERATION
348-132593 200-34843 COMMISSIONING PROCEDURE - POTABLE WATER SILO 1,2,3,4,5,6
348-130901 200-34844 COMMISSIONING PROCEDURE - CONDITIONING WATER
348-132328 200-36591 COMMISSIONING PROCEDURE - SILO AIRSLIDES & IMPACT WEIGHERS
348-133481 COMMISSIONING PROCEDURE - MD-PUMP CONVEYING SYSTEM
348-44250 Commissioning Procedure: PJFFP Aeration
348-44251 Commissioning Procedure: Conditioning Water for Silos
348-130135 COMMISSIONING PROCEDURE - SILO AIRSLIDES & IMPACT WEIGHERS
348-130134 COMMISSIONING PROCEDURE - CONDITIONERS FOR SILO 1, 2, 3, 5, 6
348-130069 200-39131 COMMISSIONING PROCEDURE - ASH CONDITIONER GREASING SYSTEM
348-134371 200-36121 COMMISSIONING PROCEDURE - TOP OF SILO INSTRUMENTS & VALVES
348-44249 Commissioning Procedure - Top of Silo Instruments & Valves
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348-130070 200-34842 COMMISSIONING PROCEDURE - SILO 1,2,3,4,5 6 BAGFILTERS
348-133893 200-31254 COMMISSIONING PROCEDURE - COMPRESSED AIR SUPPLY (PROCESS AIR AND INSTRUMENT
348-134289 200-36122 COMMISSIONING PROCEDURE - ASH CONDITIONER SCRUBBERS
348-130133 200-33268 COMMISSIONING PROCEDURE - SILO AERATION EQUIPMENT
348-132641 COMMISSIONING PROCEDURE - ASH CONDITIONER GREASING SYSTEM
348-131774 COMMISSIONING PROCEDURE - ASH SILO BAGFILTERS EQUIPMENT
348-130136 COMMISSIONING PROCEDURE - ASH CONDITIONER SCRUBBERS
348-131362 200-38940 ITP FOR COMMISSIONING OF SILO 5 BLOWER ROOM 0 5UEW11
348-131103 200-34950 METHOD STATEMENT FOE SAFETY CLEARANCE AND COMMISSIONING OF THE OVERHEAD
348-133089 200-39656 METHOD STATEMENT FOR COMMISSIONING OF SILO 5 BLOWER ROOM
348-133890 200-39658 METHOD STATEMENT FOR COMMISSIONING OF THE ASH SILO AERATION SYSTEM
348-132709 200-34951 RISK ASSESSMENT FOR SAFETY CLEARANCE AND COMMISSIONING OF THE OVERHEAD
348-135738 200-39657 RISK ASSESSMENT FOR COMMISSIONING OF SILO 5 BLOWER ROOM
348-135745 200-39659 RISK ASSESSMENT FOR COMMISSIONING OF THE AERATION SYSTEM
Equipment List
MP066-MDL-121
EQUIPMENT AND LABEL LIST – UNIT 1 FLY ASH DENSE PHASE INSTRUMENTATION AIR DISTRIBUTION
MP066-MDL-127
EQUIPMENT AND LABEL LIST- UNIT 1 PJFFP HOPPER AERATION
MP066-MDL-128
EQUIPMENT AND LABEL LIST – UNIT 1 FLY ASH DENSE PHASE PNEUMATIC CONVEYING
200-135088 EQUIPMENT AND LABEL LIST - SILO 2 FEED AERATION & CONDITIONING
200-135087 EQUIPMENT AND LABEL LIST - SILO 3 FEED AERATION & CONDITIONING
200-43304 LIMIT OF SUPPLY AND SERVICE – MEDUPI POWER STATION CIVIL INTERFACES
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*In red: Eskom Engineering created the document as the P32 Contractor never submitted this document at the compilation of the scope of work.
14.2 SCHEDULES
14.3 DOCUMENT SUBMITTAL SCHEDULE
14.4 COMMON REQUIREMENTS
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