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1 0

Rev.

Purchase Order For bid request


Description/Objeto de la edicin

12/02/10 03/11/09
Date/Fecha

FFF PBS
Prep./ Realiza

MFG MFG
Verif./Co mpr.

NA NA
Construct

LGC LGC
Appr./J.Proy.

CLIENT/CLIENTE:

CONSORTIUM/CONSORCIO

Energa
JOB DESCRIPTION/PROYECTO:

NAVOI C.C.P.P. (477,75 MW)


TITLE/TITULO:

MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

Disc/Disciplina

Scale/ Escala

Job Number

Documento

Unit/ Unidad

System/ Sistema

Doc.Orig/ Ent.Emisora Type/Tipo

Doc nr.

Sheet Number/ n pgina

Free

NA

91151
Project/ Proyecto

001
Num of Sheets/ n pginas Rev.

Energa

Size/ Formato

A4

N A V

1 0

PAB

M I

I E M

4 6 5

30

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(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

INDEX

1. 2.

OBJECT .............................................................................................................................................. 3 GENERAL ........................................................................................................................................... 4 2.1. SERVICE REQUIREMENTS .................................................................................................... 4 2.2. QUALITY ASSURANCE ........................................................................................................... 4 2.3. CODES AND STANDARD........................................................................................................ 5 SCOPE OF SUPPLY .......................................................................................................................... 9 3.1. EQUIPMENT AND SERVICES................................................................................................. 9 3.2. OTHER CONDITIONS ............................................................................................................. 9 3.3. TERMINAL POINTS / BATTERY LIMITS............................................................................... 10 DELIVERY DATE.............................................................................................................................. 11 DESIGN AND MANUFACTURING ................................................................................................... 12 5.1. DESIGN .................................................................................................................................. 12 5.2. MANUFACTURE .................................................................................................................... 16 INSPECTIONS AND TESTING ........................................................................................................ 23 6.1. GENERAL............................................................................................................................... 23 6.2. INSPECTION.......................................................................................................................... 23 6.3. SHOP TEST ........................................................................................................................... 24 6.4. FIELD TEST ........................................................................................................................... 25 GUARANTEES ................................................................................................................................. 28 7.1. GENERAL............................................................................................................................... 28 7.2. PARTICULAR ......................................................................................................................... 28 ANNEX AND COMPLEMENTARY DOCUMENTS ........................................................................... 30 8.1. ANNEXES............................................................................................................................... 30 8.2. COMPLEMENTARY DOCUMENTS....................................................................................... 30

3.

4. 5.

6.

7.

8.

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Doc. Code/ Cd. de Documento:

(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

1.

OBJECT

This Technical Specification establishes the basic standards and criteria for the complete design, procurement of material and equipment, manufacturing, inspection and testing in shop, cleaning, coating, packing protection for shipment, concrete/GRP work supervision, erection supervision, commissioning supervision, training of end clients operating and maintenance personnel, and site testing supervision of one (1) Mechanical Draft Cooling Tower with all the required accessories and equipment for the CC Power Station of Navoi (1 x 477,75 MW gross power) in Uzbekistan Republic.

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Doc. Code/ Cd. de Documento:

(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

2.

GENERAL

1x477, 75 MW gross power NAVOI TPP Project will consist on a Power Generation complex made up by one (1) Gas Turbine, one (1) Steam Turbine (with multi shaft disposition), one (1) Heat Recovery Steam Generator, two (2) main transformers and corresponding mechanical and electrical auxiliaries, and associated instrumentation and control systems. All information and documents listed in the section 8 Annexes of this specification shall be considered part of the same. 2.1. SERVICE REQUIREMENTS

Plant location and environmental conditions are described in the document Project General Data NAV-10-VD-IR-IEM-001. 2.2. QUALITY ASSURANCE

The Supplier shall comply with the requirements detailed in this specification, according to the codes and standards as specified herein and in the annexes listed in chapter 8. The supplier shall have a Quality Assurance System according to ISO 9001:2008. The Supplier shall also apply similar quality control requirements to his Sub-suppliers and suppliers. The Quality Assurance Manual shall be available to the Purchaser and his authorised representative upon request. The Purchaser may perform factory quality assurance inspections at the Supplier's facility during fabrication to ensure equipment is being built to the specification in a timely manner. As a part of, or prior to that inspection, the Purchaser shall review the Supplier's Quality Assurance and Quality Control System and manuals to assure their adequacy for equipment being supplied. Quality Assurance audit may be performed by the Purchaser during the inspection or at any other time prior notice, to verify that the Supplier's Quality Assurance System is being adhered to. The Supplier shall submit for Purchaser approval the disposition of nonconforming material discovered during final inspection and test or at any time within the warranty period. The Supplier shall be the responsible to make a disposition of materials identified as nonconforming with this specification satisfactory to the Purchaser. The Supplier shall at its own expense repair or replace defective or unsatisfactory materials at the Supplier's shop or project site depending upon where the defect is noted.

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NAV-10-PAB-MI-IEM-465

Rev.: 1

2.3.

CODES AND STANDARD

2.3.1.

Material and equipment selection, and therefore design, engineering, procurement and maintenance, of the scope of supply included in this technical specification will be according to the latest editions of the below mentioned codes and standards current at the date of signing of the Contract, unless otherwise specified. For those points that are not defined explicitly in the foregoing standards or in the text of this Specification, The Supplier can employ other standards, in accordance with good engineering practice and provided they have been submitted for prior acceptance by INITEC Energa.

2.3.2.

INTERNATIONAL CODES AND STANDARDS

The general criteria, codes and standards governing the design and manufacture of the equipment object of this Specification, will be those indicated hereunder and those indicated in the listed document Project General Data NAV-10-VD-IR-IEM-001. American Cooling Tower Institute (CTI): ATC-105, Acceptance Test Procedure (modified for ambient wet bulb). ATC-105S, Acceptance Test Procedure for Closed Circuit Cooling Towers. PTB-110, Recirculation. STD-111, Gear Speed Reducers. PTG-116, Recommended Recirculation Allowances. ATC-128, Code for Measurement of Sound from Water Cooling Towers. STD-131, Fiberglass-Reinforced Plastic Panels. ATC-133, Acceptance Test Code for Spray Cooling Systems. STD-136, Polyvinyl Chloride Materials used for Film Fill, Splash Fill, Louvers and Drift Eliminators. STD-137, Fiberglass Pultruded Structural Products for Use in Cooling Towers. ATC-140, Isokinetic Drift Measurement Test Code for Water Cooling Tower. PFM-143, Recommended Practice for Airflow Testing of Cooling Towers. STD-146, Standard for Water Flow Measurement. ATC-150, Acceptance Test Procedure for Wet-Dry Plume Abatement (for wet and dry cooling towers). STD-154, Cooling Tower Filament Wound Fiberglass Piping Systems. STD-203, Industrial Cooling Tower Standard.
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(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

American Society of Mechanical Engineers (ASME): ASME II Material specifications. ASME V Non-Destructive examinations. ASME IX Welding and Brazing Qualification.

American Institute of Steel Construction (AISC) 9th edition: M016, Manual of Steel Construction Allowable Stress Design. S334L, Specification for the Design, Fabrication and Erection of Structural Steel for Buildings.

ASME Power Test Code (PTC): PTC 23, Atmospheric Water Cooling Equipment. PTC 36, Measurement of Industrial Sound. PTC 19.3, Temperature Measurements

American Society for Testing Materials (ASTM): ASTM A-123, Standard Specification for Zinc (Hot-Dip Galvanised) Coatings on Iron and Steel Products. ASTM A-153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. ASTM A-167, Standard Specification for Stainless and Heat-Resisting Chromium Nickel Steel Plate, Shell and Strip. ASTM A-525, General requirements for Steel Sheet, Zinc-coated (Galvanized) by the Hot-Dip Process. ASTM B-97, Copper Silicon Allow Plate, Sheet, Strip and Rolled Bar for General purposes. ASTM B-98, Copper-Silicon Alloy, Rod, Bar and Shapes. ASTM B-99, Copper-Silicon Alloy Wire for General Purposes. ASTM 3841, Standard Specification for Glass-Fibre Reinforced Polyester Plastic Panels. ASTM E-84, Standard Test Method for Surface Burning Characteristics of Building Materials.

ISO 10816 Mechanical vibrations, Evaluation of machine vibrations by measurement of non rotating parts. American Welding Society. American Gear Manufacturer Association (AGMA):

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NAV-10-PAB-MI-IEM-465

Rev.: 1

STD 6010-E88, Spur, Helical, Herringbone and Bevel Enclosed Drives.

Expansion Joint Manufacturers Association of America (EJMA). Steel Structures Painting Council (SSPC): International Electrotechnical Commission (IEC). Institute of Electrical and Electronic Engineers (IEEE). National Electrical Manufacturers Association (NEMA). National Fire Protection Association (NFPA): NFPA 70, National Electrical Code (NEC). NFPA 78, Lighting Protection Code. NFPA 214, Water Cooling Towers.

Uniform Building Code (UBC). Uniform Mechanical Code (UMC). American Water Works Association (AWWA) AWWA C950 Standars for fiberglass pressure pipe. AWWA M45 Fiberglass pipe design manual. AWWA C207 Class D: AWWA standards for steel pipe flanges for waterworks services.

American National Standards Institute (ANSI): ANSI B1.1 - Unified Screw Threads. ANSI B2.1 - Pipe Threads. ANSI B16.5 - Pipe flanges and flanged fittings. ANSI B16.9 Standards of piping and fitting. ANSI B.16.11 - Forged steel fittings, socket-welding and threaded. ANSI B16.25 - Butt-welding ends. ANSI B16.34 - Valves flanges, threaded and welding end. ANSI 762 IEEE - Definition of Electrical generation unit reliability, availability and productivity.

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Rev.: 1

ANSI A58.1, Design Loads for Buildings and Other Structures. ANSI S1.4 Specification for sound level meters. ANSI S1.11 Specification for octave, half octave and third octave band filter sets. ANSI S1.2 Method of Physical Measurements of sound. ANSI/ASME B31.1-1, Power piping.

American Petroleum Institute: SE605 - Large Diameter Carbon Steel Flanges.

American Society for Non-Destructive Testing. Instrument Society of America (ISA). American Society of Civil Engineers (ASCE): ASCE-7, Minimum design loads for buildings and other structures. INTERNATIONAL STANDARD ISO 2314, Amendment 1997-12-01. Properties of Water and Steam, the Industrial Standard IAPWS-IF97 for the Thermodynamic Properties and Supplementary Equations for Other Properties. ISO 3740 Series, DIN45635 and ISO 9614-2 applicable for general noise test requirements.

2.3.3.

In the event of contradiction between the different standards of application, the wording of the Specification, the parameters of the Data Sheets or any other document related with the design and manufacture of the equipment the priority regarding applicable criteria shall be the following: Purchase Order Technical Specification. Purchase Order Technical Data Sheets. International codes and standards here listed. Manufacturer standards.

In all instances of conflict between the applicable codes, standards, specifications, regulations, tests and procedures of organizations listed above, the Supplier shall follow the most stringent and conservative requirements. International codes equivalent to above codes listed may be acceptable subject to Purchasers approval.

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NAV-10-PAB-MI-IEM-465

Rev.: 1

3.

SCOPE OF SUPPLY

3.1.

EQUIPMENT AND SERVICES

The Scope of Supply is indicated in Annex 1 of this Technical Specification. The Supplier understands to supply, all equipments, materials and deliverables essential for the safe and reliable operation of the Cooling Tower and auxiliaries although not expressly specified in this invitation to tender or its annexes. 3.1.1. PERSONNEL TRAINING

The Supplier shall provide on site the necessary training to ensure safe operation of the equipment by Purchaser's operation and maintenance staff. This training will be scheduled for 25 persons and shall include: Four (4) days of classroom training (Theoretical part) at the end of erection/start of commissioning stage and Two (2) days of hand-on training (Practical part) during commissioning.

The detailed program of staff training will be defined four months before the beginning of the training. The Supplier is responsible for the training expenses of their own personnel. Training aids and training will be provided in English accompanied with a Russian translator. 3.2. OTHER CONDITIONS

The Supplier shall fulfil and issue the documents list included in Annex 2 Required Documents List including delivery dates. The language for the documents shall be English except for as built documents and Operation and Maintenance Manuals that shall be in both Russian and English. Stainless steel nameplates shall be installed on a clearly visible area of the equipments. Nameplates or visible marks shall also be employed to indicate the characteristics of main components such as flanges, filters, tubes, etc. Equipment nameplates or visible marks shall be in both English and Russian languages. Shall the Supplier, wish to subcontract any of the work covered by this specification, it is his responsibility to ensure that his sub-suppliers are made fully aware of the relevant requirements if this specification. The Purchaser has the right of approval of proposed sub-suppliers.

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Rev.: 1

The Supplier is responsible for the total supply and for the supplies of his Sub-suppliers. If Supplier consider that additional items or accessories are required to complete the scope of supply, they shall be quoted as optional. Any optional shall be previously written accepted by the Customer before manufacture begins. Under NO circumstances, the approval of the documents and drawings will release the Supplier of his responsibility over all the supplied equipment. The Supplier will include in the Proposal the number of units into which the Cooling Tower shall be split for transport and erection. 3.3. TERMINAL POINTS / BATTERY LIMITS

The battery limits of the Cooling Tower shall be: One Inlet water flanged connection per riser shall be located at 5 feet from the finished ground (exact location to be confirmed). Supplier shall include all necessary gaskets, nuts and bolts. A Power Junction box at each fan motor ( for motor power and space heaters terminal connections). All Instrumentation wiring ( including wires, conduits and hardware ) from instrument located at the fan gear boxes and motor up to the local Junction Boxes. Supplier will give all the instruments, mounting accessories and instrumentation boxes needed for a correct monitoring and control of the Cooling Tower. Supplier will carry out the wiring supply, connection and routing of all instruments and control signals of the Colling Tower untill the terminal junction boxes. Wiring from terminal junction boxes to DCS will be done by others.

The following services and supplies shall be provided by others: All civil works, including required foundations, basin and support steel. All Instrumentaion wiring ( including wires, conduits and hardware ) from the local Junction Boxes to plant DCS. All Power wiring ( including wires, conduits and hardware ) from motors terminal boxes to MCC. All power supply as per document NAV-10-VD-IR-IEM-001 Project General Data.

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(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

4.

DELIVERY DATE

the Supplier shall send within 15 days after purchase order, the detailed design, engineering, manufacturing, test and delivery program. The Supplier shall send within the next 30 days enough information for the civil works. Maximum acceptable delivery dates are indicated in the commercial documents. Final acceptance of the Cooling Tower will be done after succeed the field test and the guarantees according CTI.

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Rev.: 1

5.

DESIGN AND MANUFACTURING

5.1.

DESIGN

5.1.1.

General

The equipment shall be designed and installed to facilitate inspection, cleaning and maintenance and operation where the continuity of service and reliable operation is the first consideration. The plant and equipment shall be designed with adequate design margins and stand-by capability. Supplier shall consider the requirements indicated in the document Mechanical Design Criteria NAV10-V-BR-IEM-001. 5.1.2. Cooling Tower Type

The Cooling Tower shall be a mechanical induced draft tower of counter flow type and shall consist of the number of independent cells as specified in the Cooling Tower Data Sheets NAV-10-PAB-MH-IEM465. 5.1.3. Main design parameters

The design of the cooling tower shall take into account not only normal operating conditions, but also the possible pressure and temperature gradients and operating transients which may occur in the course of start ups or shutdowns, as well as the loading conditions occurring in special operating cases. The design of all elements and components shall cover the following items: Thermodynamic design. Hydraulic design of the Water Distribution System. Noise mitigation design. Overall Civil engineering design.

The cooling tower shall be designed for operation under all operating conditions in accordance to the ambient conditions as specified in Project General Data NAV-10-VD-IR-IEM-001, and Cooling tower Data Sheets NAV-10-PAB-MH-465, taking into consideration the thermal stresses, rubbing, misalignment and other adverse effects. Supplier shall provide a Cooling Tower Maintenance Procedure for long duration shutdowns.

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Supplier shall include, according to its experience, an operation philosophy as protection for the system on the basis of the minimum ambient temperature values in order to prevent ice formation into the air inlets, the fill or any other element of the Cooling Tower. The cooling tower shall be designed, as far as possible, to use Supplier standard production models and for maximum interchangeability of parts between cells. The system performance shall be based on the start up and shut down of the fans, depending on the thermal load of the condenser. Fans will be stopped if meteorological conditions and temperature allow it, so cells must be designed to let water pass through with their fan stopped for a long period of time. All components of the cooling tower will be easily accessible, foreseeing the disassembly of any independent component to be repaired. Each cell shall be able to be isolated for maintenance or partial load operation. Partition walls shall be provided to assure that there will be no loss of performance due to fan-to-fan recirculation in the adjacent operating cell, particularly in the event of fan shutdown, failure or maintenance. Windscreens shall be provided to avoid water drift due to wind crossing the cooling tower in the air inlet area. The cooling internals shall consist of layers of plastic material packs arranged crosswise one on top of the other. The internals shall be of low fouling characteristic, low pressure drop and high heat transfer values. The internals shall be adequately reinforced to assure mechanical stability and no deformation during the design life. The water distribution system shall be such that it ensure that the arrangement of the piping and the use of special sprayers ensure that the hot water is evenly spread in fine droplets of over the cooling fill. The distribution system shall be designed to be self cleaning during operation. Fan stacks shall be provided. The stacks shall have the necessary provision to allow the incorporation of noise abatement devices if required in the future to reduce the motor power requirements and to minimize recirculation. 5.1.4. Water requirements

Cooling tower make-up water quality and circulating water and the number of concentration cycles as defined in the Cooling Tower Data Sheets NAV-10-PAB-MH-IEM-465. Supplier shall indicate the water treatment and chemical dosing needed to maintain the required quality throughout the circuit. Blow down acceptable limits as indicated in the attached data sheets NAV-10PAB-MH-IEM-465. Maximum allowed blow down flow is indicated in the Cooling Tower Data Sheet NAV-10-PAB-MHIEM-465. On the basis of the available water analysis and the characteristics of the Cooling Water System, Supplier shall make a proposal of the best practises on the following points, which must be compatible with the guarantee of the proposed materials:
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Maximum and normal allowed concentration of solids in the circulating water or number of times they exceed the concentration in make up water. Circulating water concentration cycles. pH limits permitted in the circuit. Minimum, normal and maximum total blow down flow. Minimum, normal and maximum make up flow.

The cooling tower basin capacity shall be as indicated in the Cooling Tower Data Sheets NAV-10PAB-MH-IEM-465. 5.1.5. Electric Power Supply

Apart from the design conditions included in this section, all applicable requirements to the Purchase Order shall be fulfilled including Technical Specification for Electrical Equipment for Package Plants NAV-10-B-EI-IEM-325. The motors of the tower fans up to 250 kW can be powered from LV power centres (400 V, threephase, 50 Hz) as indicated in Low Voltage Induction Motor Specification NAV-10-VGM-EI-IEM-332. 5.1.6. Performance Curves

Performance curves on the proposed tower shall be furnished, showing expected and guaranteed performance with circulating water flows, temperature ranges, and wet bulb temperature different from the design conditions. Separate sets of curves shall be furnished for 90%, 100% and 110% of the design condition circulating water flow. Each set shall show wet bulb temperature plotted as abscissas, and cold circulating water temperatures from the tower plotted as ordinates. A curve shall be shown for the design conditions water temperature range and additional curves for 90% and 110% of the design condition range. The curves shall indicate the guaranteed performance operating ranger limitation established by the ASME Power Test Code PTC 23. Curves shall be drawn to a scale adequate to permit reading to an accuracy of plus or minus 0.05 C (0.1 F).These performance curves will be used in the analysis of field tests for determining whether the tower has met the guaranteed performance and shall be based on fans operating at high speed. The Supplier shall provide curves relating wet bulb temperature, approach and L/G over the operating spectrum The Supplier shall provide curves relating KAV/L versus L/G for the complete spectrum of performance.

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5.1.7.

Cooling tower structural design

The methods used by the Supplier for structural calculation shall be in accordance with applicable codes and standards. The thickness required to meet the stress limits shall be increased by the corrosion allowance. The stresses resulting from the various loading cases shall be calculated and superimposed as and where required, taking the following into account as a minimum requirement. Stresses due to dead and live weights Stresses due to reaction forces of the distribution system under steady state and transient conditions. Stresses due to wind loads. Stresses due to seismic loads. Stress due to thermal and humidity gradients during all modes of tower operation. Thermal stresses due to the use of materials with unequal coefficients of thermal expansion. Stresses due to internal or external pressure. Stresses due to external forces and moments, e.g. by connecting piping. Design pressure and temperature of pressure-retaining parts shall be as a minimum:

The connecting nozzles defined as the cooling tower suppliers provision limits shall be capable of safely with standing the forces and moments transmitted by any Purchasers piping connection to the Suppliers nozzle at the interface of pipe. The Supplier shall indicate the actual permitted loads during the kick-off meeting. Additionally, the fan blade clamps that fasten the cooling tower axial flow fans shall be designed to prevent broken parts from the blades or other rotating components from being projected out of the cooling tower. Additional passive fastening devices or grips shall be provided to avoid such projections. 5.1.8. Cooling tower noise

The cooling tower shall be designed in such a way that 85 dBA is not exceeded during standard operating conditions, measured at one meter (1 meter) from all accessible elevation of the whole cooling tower structure. The cooling tower supplier will be required to submit calculating justifying all noise guarantees in the design report for approval.

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Rev.: 1

Noise measurement testing procedures and guarantees shall be in accordance with ASME PTC-36 and ISO standards. Special attention shall be paid to the noise created by water splashing over the fill packs and water dropping on the cooling basin surface. Preventive measures aimed at noise reduction shall be taken. 5.2. MANUFACTURE

5.2.1.

Materials

Materials shall be selected in accordance with water analysis included in the data sheets attached to this Specification. All materials used in the construction of the Cooling Tower and its associated equipment shall be of first class quality and suitable for the severity of the service intended. Compatibility of the materials with the fluids handled in the unit and accessories is the responsibility of the Supplier. Provide materials suitable for the specified service and conditions stated herein, subject to acceptance by the Purchaser. The materials included in the Data Sheets attached are recommended by the Purchaser. The Supplier may suggest alternative materials, according to his experience and practice. Corrosion allowance for materials in contact with water shall be indicated by the Supplier for Purchaser approval. Construction materials and structures will be set in such a way to avoid damages due to potential difference through the water working as electrolyte. Isolation shall be used where and as needed.

5.2.2.

Structure, Enclosure, Partition Walls and Basin

Structural calculation, dimensional design and constructive drawings of the reinforced concrete CT structure shall be done by CT supplier. Calculation shall include design of ladders, stairs, anchor bolts for motors, gear boxes and fan stacks, handrails, clips for power/control conduits or pads, maintenance areas and emergency evacuation runs. The structure of the cooling tower shall be in reinforcing concrete resistant to sulphates and to cooling water of the characteristics mentioned in this specification under the environmental conditions of the selected location. All concrete structures shall be completely watertight, preventing water leakage throughout anchor bolts holes

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NAV-10-PAB-MI-IEM-465

Rev.: 1

The cooling tower foundations and basin shall consist of the basin slab and walls made of reinforced concrete which serves as a foundation for the cooling tower structure. The basin extends slightly beyond the width of the cooling tower on both sides and is used for collecting cold water. The cooling tower structure and housing shall be a cubic structure consisting of walls, columns, decks and support beams that divides the cooling tower into individual cells. The cooling internal, water distribution and drift eliminators are housed by walls and supported by columns that also support the fan foundation. The structural frame shall be anchored to the structure by means of heavy fabricated steel plates. The cooling tower casing protects the internals against weathering effects. Special deflectors shall direct the water to the inside of the cooling tower and thus minimizing water splashing outside the cooling tower. The cooling tower enclosure shall be designed considering operating conditions during start-up, shutdown and transient conditions. They will be designed considering ambient and cooling water temperatures at Site. Railing columns shall be an integral part of the tower structure. Wherever motors are located, fan decks shall allow the installation of two or three power and control cable racks of 600 mm wide. Mechanical equipments must be supported in a one-piece frame designed to effectively resist weight and operating loads of motor, gearbox and fan. Loads at the supports must be directly transmitted to the tower foundation. Full height longitudinal partitions shall also be provided to prevent air bypassing from one fan cell to the other, especially when one fan is shutdown. Multi-cell towers shall be equipped with minimum 20minute fire-rated cell partitions, per NFPA 214. Unless otherwise specified, fan deck design live load shall be 300 kg/m2 and a concentrated load of 200 kg. Fan deck shall be reinforced as needed in the areas where mechanical equipment and electric motors are to be handled during maintenance. 5.2.3. Packing / Fill

The Packing shall be of the film flow and antifouling type designed. Packing modules shall be designed to enable an easy handling during their assembly and maintenance. Packing shall be made of a material suitable to the characteristics of the cooling water and temperatures existing at Site. Supplier shall state, according to the type of offered Packing, the assembly procedure and the characteristics of the supports to be used. Packing supports shall consist on stainless steal mesh and designed to allow their disassembly. All transitions, corners, etc. shall be designed to avoid solid deposits.

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(477,75 MW) MECHANICAL DRAFT COOLING TOWER TECHNICAL SPECIFICATION

NAV-10-PAB-MI-IEM-465

Rev.: 1

In order to avoid sagging or any other kind of distortion which could cause preferential channels for air or water, the Supplier shall consider the proper number and location of internals supports. Supplier shall indicate the method used to design the support. All packing materials shall be self-extinguishing (NFPA). Supplier shall state the maximum allowable water temperature for the Packing withstands during continuous operation. 5.2.4. Drift eliminators

Drift eliminators shall be formed by removable panels. Drift eliminators shall be of three-pass sinusoidal wave type ensure a maximum drift losses indicated as a percentage of the cooling water inlet flow as indicated in the Cooling Water data Sheets NAV-10-PAB-MH-IEM-465. All fastening accessories will be stainless steel. The drift eliminators shall be lightweight, easily removable and arranged above the water distribution pipes. 5.2.5. Water distribution system

Water distribution system shall have a pressure drop as low as possible. Water shall be fed to nozzles by a closed piping system. Connections between main water distribution piping/risers and headers shall be plug in type and designed to prevent impurities accumulation in its interior. Connections between risers and each distribution header shall be arranged as evenly-spaced as possible from each nozzle. Supplier shall provide an expansion joint for each riser to reduce stress in the terminal point. Hot water shall be distributed by a FRP pipe header in accordance with the manufacturer standard. The minimum piping diameter shall not be less than 2" in order to avoid maintenance problems when inserting the nozzles. Piping slope shall guarantee headers will empty when a shutdown occurs thus preventing mud and sediments accumulation. Each cell header shall be provided with a transparent plastic tubing to control the water column related to the distribution losses and to allow flow balance between cells. Water injection nozzles shall allow the pass of the condenser tube cleaning system rubber balls, which could not have been retained by the strainer. Nozzles shall be of high performance (twin-plate).

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Rev.: 1

Supplier shall design an optimised water distribution system with the minimum pressure loss and TDH and shall guarantee losses of the distribution system. 5.2.6. Platforms, Access Doors, Handrails and Ladders

All those areas where maintenance tasks shall be carried out shall be easily accessible. Two (2) galvanized cage ladders ( one per each side ) and one concrete stairways at one end of the CT shall be considered to allow access and emergency run-ways to the fan deck. Each cell shall be accessed by a manhole. Ladder access shall be considered to the water distribution system and fan gear unit. An access door or a hatch with a ladder shall be provided in each cell on the deck floor for entering to the drift eliminator plenum. Each cell shall include stairways and walkways to allow internals, drift eliminators and water distribution system inspection. A protection handrail shall surround the fan deck, including fan platforms and hot water areas. The fan platform shall have a walkway along its entire length designed to allow free passage. Fan platform shall be designed such that there is full walk access around the motors. Provisions for equipment removal from fan platform shall be provided for. The fan platform and other walkways shall have a non-slip surface on top, in order to ensure safe walking. There must be a walkway along inside the tower, equipped with tilting gates which must be lockable from the outside roofs and in each cell division. This walkway will have at least two accesses with ladders for climbing down to the bottom of the cold water pool, located in the end modules, All ladders, walkways and platforms shall be fitted with handrails and skirting boards. All platforms, ladders and handrails shall be made of galvanized steel and shall be painted in order to withstand wet conditions of the area. 5.2.7. Fans

Fans shall be vertical propeller type, specially designed to work in cooling towers in continuous operation. They will be located into a stack with diffuser. The shaft shall be galvanized as a corrosion protection measure. Impellers shall be individually balanced in order to reduce vibrations to the minimum. Impellers shall be designed to rotate in the opposite sense to normal operation when required (ice formation, etc). Shafts shall be balanced in Suppliers shop to reduce vibrations to the minimum. The maximum allowed vibration velocities shall be 2.5 mm/s radially and 5 mm/s axially.

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Rev.: 1

Each fan will be driven by a high-efficiency, single or double speed (as indicated in Cooling tower Data Sheets NAV-10-PAB-MH-IEM-465) electric motor mounted externally to the fan stack. The blades shall have a manually adjusted pitch to suit different operating requirements and nominally adjusted for tip clearance to assure maximum operating efficiency. Each fan shall be statically balanced before installation. 5.2.8. Gearboxes

Each fan shall be driven via reduction gearboxes specially designed for cooling towers service. Each gearbox shall consist of thermally treated helicoidal gears and heavy-duty roller bearings. A minimum continuous service factor of greater than 2.0 is required when measured against the motor rated power, in accordance with AGMA Standards. Gearboxes shall comply with CTI-STD-111 Standard except that gears and bearings life shall be 100.000 hours minimum. Gearboxes shall be designed considering the installation of position shock vibration control devices. Digital signals for rotor high vibrations indication and protection shall be provided. Each gearbox shall be equipped with a lube oil system. Supplier shall indicate the usual cleaning procedures for these pipes. Each gearbox shall be provided with adequate means for external access to lube oil filling, including level indicator, drainage and sampling. Adequate vent to be used during lube oil filling shall be provided if necessary. Flexible connections between gearboxes and lube oil piping shall be provided. These flexible connections shall be designed so that their natural frequency is above natural frequency produced by the air discharge. Each gearbox shall include a magnetic plug to provide protection against particles that may be found in the lube oil. A thermocouple for high temperature alarm remote indication shall also be provided. Labyrinth seals shall be provided where pressurized oil is used. Threaded connections shall be secured to avoid loosening bolts. Gearboxes shall be provided with a low oil level, or flow, or pressure switch. Anti-reverse ratches shall be provided in order to avoid reverse-rotation movement of the drive unit. 5.2.9. Drive Shafts and Couplings

Drive shafts and couplings shall be dynamically balanced together to reduce vibrations to the minimum. Balance shall be carried out at the work shop.

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Rev.: 1

Motor couplings shall be flexible and the design will not allow transmitting undesired axial loads to the motor or the gearbox bearings due to thermal expansion. Each coupling shall be dynamically balanced and will avoid misalignment of motor-gearbox shaft. Shaft protector shall cover the shaft in the entire length including the motor coupling. Drive shafts shall be made of stainless steal and couplings shall be flexible. Motor-drive shaft-fan assembly shall be supported by a steel structure firmly tight to the cooling tower structure. This structure shall be galvanized to protect it against corrosion. Should vibration levels of the assembly be over satisfactory limits as per ISO after site erection, the whole assembly shall be balanced. 5.2.10. Stacks

Stacks shall be high enough to prevent vapour recirculation Fan stack shall be in the form of a flared diffuser that provides a gradual increase in cross-sectional area beyond the fan with a resultant decrease in leaving air velocity. Supplier shall state guaranteed vibration level for stacks. Fan tip clearance shall be determined by the Supplier but not exceed 0.5% of the fan diameter. 5.2.11. Air Inlets Openings

Each cell shall be provided with 2 air inlets openings (one at each side). An adequate width/tall ratio of the inlet openings shall be considered to avoid recirculation. If required, the air inlet openings shall include any devices to avoid inlet of undesired elements. The material of the inlet louvers shall be compatible with the rest of the Cooling Tower. 5.2.12. Electric Motors

Electric Motors shall be designed according specification Low Voltage Induction Electric Motors. An extra 15% power margin at constant speed shall be required over the operating power point. 5.2.13. Instrumentation

Supplier shall consider all the signals and instrumentation required for a reliable operation.

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All instrumentation and mounting will be according to document NAV-10-C-YR-IEM-711 I&C Design Criteria for equipments and package plants. Motors will include all the corresponding instrumentation to guaranty a good working, control and monitoring of the system. The instrumentation for secondary circuits, like oil circuit, will be included in the same way. The package plant will be controlled and monitored form the plant DCS. For this reason, supplier will give all the information required to implement this control in the DCS. The list of documents required as minimum is located in annex 2. 5.2.14. Fire Fighting

No provisions for fire fighting system are foreseen. The supplier shall comply with NFPA 214 requirements. The selected materials shall be selfextinguishing. 5.2.15. Cleaning and coating

The cleaning, surface preparation and coating procedures for the equipment covered by the scope of this specification will comply with the document attached NAV-10-VDJ-MI-IEM-465 Painting Specification Painting material for touch up paint at site should be supplied by the Supplier. Equipment and parts that do not require painting shall be suitably protected with preservatives where necessary. The Purchaser shall be fully responsible for providing the packing or protection required to maintain the quality of all items during shipping, storage and handling. All tubes, nozzles and connections shall be protected and sealed. The cooling tower components shall be thoroughly cleaned and prepared in the shop. Scale, oxides, weld flux, etc, as applicable, shall be removed. Burrs, casting scars, and sharp edges shall be ground smooth prior to galvanizing of components, or prior to shipment if these are made of synthetic or noncorroding materials.

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Rev.: 1

6.

INSPECTIONS AND TESTING

6.1.

GENERAL

Inspections related to the reception of materials, equipment and auxiliary items, their manufacturing and erection, testing, as well as the final activities of labelling, painting and packing for shipment, shall be carried out by the Suppliers Quality Service to the satisfaction of the Purchaser or his representatives, who shall witness, supervise or decline to witness the inspections at their discretion. The Supplier shall consider as reference the Purchasers Inspection and Test Plan (ITP) attached to this specification (see Annex 4). This Inspection Point Program will explicitly and correlatively detail each of the stages of procurement, manufacturing, pre-assembly and testing, packing for shipment and site assembly, documents submittal on which the inspections points to be carried out by the Supplier will be indicated. The applicable internal procedure for each point will be indicated, showing whether a report or protocol will be generated for said point or if there is another document associated with it (quality certificates, reception reports, etc). The Purchaser shall select the points that he or his representatives have the right to witness in these programs. This Inspection Points Programme shall be in accordance with the applicable codes and standards. During the inspection visits, the Purchaser reserves the right to review the applicable documentation that has not been submitted to the Purchaser for approval (reception and manufacturing procedures, etc.). Performance of any tests and inspection shall not relieve the Supplier of his overall responsibility for his equipment guarantees required en section 7 of this specification. 6.2. INSPECTION

In the document Manufacturing Schedule and Inspection Points the Supplier shall include the Inspection Point Programme. This program shall consider as a minimum the following: Casting shall be tested by drie penetrant. Accessible areas of the nozzles and necks shall be inspected by drie penetrant after machining and before the final mounting. Defective areas shall be repaired and re-tested. Minor superficial defects (depth less than 1/32 inches) shall be repaired but avoiding to weak the final thickness under the minimum acceptable.
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Rev.: 1

Welding shall be tested and inspected as per ASME Code section VIII. Verification before the manufacturing process will include as a minimum.

Review of material and semi-finished products certificates and dimensions. Certification of Supplier qualification certificates as required. Procedures and examinations of preparation for manufacturing: welding of pressure retaining parts, preparations of weld edges. Verification during manufacturing will include as a minimum: Checking of welding procedure plan examinations and records. Checking that non-destructive examinations and production test meets Requirements. Checking of heat treatment charts as required.

6.3.

SHOP TEST

Cooling Tower shall be manufactured in shop in the most extend parts that can be handled for transportation and field erection. During the pre-assembly Supplier shall perform all the inspections that may be possible. At least following test shall be performed: Pressure test examination of cooling tower tube bundles, if required. Leak test examination of tube bundles, if required. Dimensional examination during cooling tower shop pre-assembly test. Examination of cleaning before coating, coating materials and after Coating. Checking preparation for transportation.

Shop Tests can be witnessed by the Customer Inspector. All fans, motors, gear reducers, shafts on shop shall be tested and the reports shall be submitted to Purchasers for approval.

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6.4.

FIELD TEST

6.4.1.

Site assembly examinations and tests

The Supplier is responsible for the verification of requirements during the erection ad testing of the cooling tower and auxiliaries which is to be performed by others. The Supplier shall establish adequate supervision and review of the erection and site testing. In addition, the Purchaser has the right to carry out verification whenever considered convenient. The following verification defined by the Purchaser is to be applied to the mechanical draft cooling tower and auxiliaries during this project phase: 6.4.2. Erection procedures, including handling and assembly of parts. Applicable examination and testing concerning manufacture process performed on site. Final cleaning and coating. Site hydrostatic test and leak test as required.

Acceptance test

The Cooling Tower shall be tested according the requirements indicated in the Acceptance Test Code for Water Cooling Tower (CTI ATC-105) and the "ASME" PTC-23 latest edition. To obtain the values of weather wet and dry bulb temperatures, internal wet bulb temperature and to calculate the circulating water flow, supplier shall apply the calculus method indicated in A.4.1, A.4.2 and A.4.3. of Annex PTC-23 (Atmospheric Water Cooling Equipment). Supplier shall provide a test procedure according with the CTI to be approved by the Customer. During testing the Cooling Tower shall perform the cooling capacity as indicated in the performance curves included in the proposal. Any modification required to match this performance shall be carry by the Supplier at NO charge for the Customer. Supplier shall provide the required equipments (except for the water flow measurement) for the testing in accordance with the above mentioned Standards. Supplier shall include the supervision personnel that may require during testing. Provisional acceptance of the Cooling Tower will be related to the test result. The Purchaser may decide that an acceptance test shall be conducted using the Performance Curve Method in accordance with CTI Code ATC-105 for the cooling performance to determine compliance with the performance guarantee. The ISO Kinetic Drift Rate test shall also be performed. Should any of the tests prove the tower performance deficient, the Supplier shall make all necessary changes at the Suppliers own expense to meet the require performance.

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The acceptance test will be performed under the conditions prevailing at the time the unit is commissioned, with every parameter to be measured, adjusted within the operating condition limits mentioned in ATC-105. The tested performance will be corrected, using correction curves as described previously to determine the performance under guarantee conditions. Immediately prior to the acceptance test, fan blades shall be adjusted to the Suppliers quoted design power consumption if not achievable under guaranteed operating conditions; then, correction from tested power consumption to guaranteed power consumption will not be allowed. Wet bulb measurements shall be taken away from the cooling tower air inlet so as to minimize the effect of recirculation. The location selected shall be agreed upon at the time of the test to a mutually agreed upon location that minimizes the effect of surrounding equipment and cooling tower recirculation. The test should normally be conducted within 12 months after final mechanical acceptance, but may be tested during the second summer after this mechanical acceptance, if necessary, to permit testing with a full thermal load. Should the test show the tower performance to be deficient, the Supplier shall be required to make any necessary alternations and improvements, at no extra cost to the Purchaser, to ensure the tower meets the required level of performance with no increase in fan design horsepower or pump head requirements. Noise guarantee acceptance tests shall be conducted by the Supplier in accordance with CTI ATC 128. The most stringent requirement will apply. A noise test procedure will be prepared by the Supplier and commented on by the Purchaser before the test is performed. Vibration test shall be performed in accordance with the requirements defined in this Technical Specification. The cooling tower will be accepted once all above conditions and guarantee values are achieved. The Supplier shall be responsible for the performance of each component supplied regardless of their manufacturer. Should the cooling tower fail to meet the guaranteed conditions in accordance with the above procedure, the Supplier shall carry out a formal cooling tower test, in full compliance with CTI code ATC-105 ATC and noise test procedure. All costs related to this test shall be borne by the Supplier. If a repeat test is necessary, it shall be conducted within 12 months of final mechanical acceptance of any modifications effected to make the tower meet the specified performance. The Purchaser shall have the opportunity to witness the performance test at the cost of the Supplier.

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The Supplier shall be responsible for equipment protection and for the correction of any defect encountered during testing, as well as for repetition of the tests until compliance with design conditions achieved. The Supplier shall provide the Purchaser with formal test results for review and final approval by the Purchaser. The Supplier may at his own expense provide personnel to review instrument installation and supply especial instruments and to witness the actual tests, in accordance with the test procedures approved by the Purchaser, and to ensure that proper test data are obtained.

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Rev.: 1

7.

GUARANTEES

7.1.

GENERAL

The Supplier shall warrant that the equipment furnished is entirely suitable for the service described herein and is in complete accordance with this Specification, except where modified by specific exceptions authorized in writing by the Purchaser. Supplier shall submit a certificate of conformance to the Purchaser. The equipment to be supplied shall undergo tests on Site and inspections to verify that and the associated systems meet the specified performance guarantees. The Supplier shall guarantee the continuous performance of the tower with the conditions stated in this Specification under Guarantee Design Conditions. Other cases indicated in the datasheets in Annex 1a are off-design performance cases and are used for equipment sizing only. The Supplier guarantees the professional design and engineering, the proper selection of materials, first class workmanship and accurate completion of the works in accordance with prudent and recognized international practices. The warranty period shall begin from the Provisional Acceptance of the Power Station. 7.2. PARTICULAR

The instructions given in the following standards will be used to establish the fulfilment of the guarantees, unless otherwise agreed upon. If deficiency of the performance is verified by the performance test, the Supplier is obliged to repair or modify the equipment by his own expense within the period agreed separately. After the repair or modification of the equipment, the Supplier again fails to attain the guaranteed performance; the Supplier shall be subjected to Liquidated Damages according to the relevant clause of this technical specification and in the Contract. Supplier should guarantee the following items under the operating conditions stated in the Cooling Tower Data Sheet NAV-10-PAB-MH-IEM-465 as Guarantee Case. All performance guarantees shall be valid simultaneously at each guarantee point. In case that operating condition deviates from those stated herein on the performance test, correction of the results shall be made according to correction curves submitted by the Supplier and approved by the Purchaser. The following parameters will be held to Liquidates as specified in chapter 5 of the document General Purchase Conditions attached to the Purchase order:

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Rev.: 1

Parameter

Unit

Values

Liquidated Damages (LD ) or Rejection (R)

Code/Standard

Water outlet temperature Noise Vibration Drift Loses Electrical consumption Pumping Static Head Guaranteed Total Weight Availability

C dBA

17,81 (Design Case) 85 2.5 mm/s radially 5.0 mm/s axially

LD R R R LD LD R R

CTI-ATC 105 CTI / ISO ISO CTI/Certificate

% kW m t %

<0.01 250 per motor 8,00 According to shipping list 98

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Rev.: 1

8.

ANNEX AND COMPLEMENTARY DOCUMENTS

8.1.

ANNEXES

Annex 1 Annex 2 Annex 3 Annex 4

NAV-10-PAB-MI-IEM-465-A1 NAV-10-PAB-MI-IEM-465-A2 NAV-10-PAB-MI-IEM-465-A3 NAV-10-PAB-MI-IEM-465-A4

Scope of Supply Required documents list Deviation /clarification list Inspection and Test Plan

8.2.

COMPLEMENTARY DOCUMENTS

NAV-10-VD-IR-IEM-001 NAV-10-C-YR-IEM-711 NAV-10-B-EI-IEM-325 NAV-10-V-BR-IEM-001 NAV-10-VDJ-MI-IEM-526 NAV-10-PAB-MH-IEM-465 NAV-10-VGM-EI-IEM-332 NAV-10-U-CI-IEM-610 NAV-10-U-TDF-IEM-850

Project General Data I&C Design Criteria for Equipments and Package Plants Technical Specification for Electrical Equipment for Package Plants Mechanical General Criteria Painting Specification Cooling Tower Technical Data Sheets Low Voltage Induction Motor Specification Requirements for Equipment Foundation Design General Plot plan

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SCOPE OF SUPPLY

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ANNEX 1 SCOPE OF SUPPLY

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SCOPE OF SUPPLY

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1.

SCOPE OF SUPPLY
SP = COOLING TOWER SUPPLIER BO = BY OTHERS NA = NOT APPLICABLE OP = OPTIONAL

1 - ENGINEERING, LAYOUT, CRITERIA AND INPUT DATA 2 - ENGINEERING, BASIC DESIGN 3 - ENGINEERING, DETAILED DESIGN 4 - SUPPLY 5 - ERECTION AND CONSTRUCTION SUPERVISION 6 - ERECTION AND CONSTRUCTION LABOURS 7 - COMMISIONING AND START UP SUPERVISION 8 - COMMISIONING AND START UP LABOURS

Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

General
Complete Cooling Tower Assembly Performance guarantees Design requirements Operation performance Structural Calculation and Construction Drawing SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP SP BO BO BO BO BO BO (3) NA NA NA NA BO BO BO BO BO BO NA NA NA NA

1 3 3 4 5

II

Cooling Tower Internal Components


Fill / Packing supporting frames accessories with and

SP

SP

SP

SP

BO

BO

2 3 4

Drift Eliminator with supports and accessories Anti-freeze protection Windscreen and deflection boards Full-width cooling air doors at wet sections FRP External Cladding with supporting frames Water Spray Nozzles with supporting frames and accessories

SP NA SP

SP NA SP

SP NA SP

SP NA SP

BO BO BO

BO BO BO

SP

SP

SP

SP

BO BO

BO

OP

OP

OP

OP

BO

BO SP SP SP SP BO

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Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

Inlet FRP hot manifold headers.

water

SP

SP

SP

SP

BO

BO

Steel Structural Supports for Spray Nozzles and Pipes. Steel Decks for Nozzle Inspection, with handrails and access doors. Concrete Partition Walls between Cells Plenum located static air baffles and air deflecting system

SP

SP

SP

SP

BO

BO

10

SP

SP

SP

SP

BO

BO

11

SP

SP

SP

BO

BO

BO

12

SP

SP

SP

SP

BO

BO

If required

III
1

Fans
Fans with manual adjustable blades pitch Static recovery Fan Stacks Fan Structural Supporting Frame Steel SP SP SP SP SP SP SP SP SP SP SP SP BO BO BO BO BO BO

2 3

IV
1 2

Motive Assembly ( Motor, Shaft and Gearbox )


Gearboxes Shaft between and Motors Gearbox SP SP SP SP SP SP SP SP BO BO BO BO

Complete Lubrication system for Gearbox Complete Lubrication Piping system, oil sight, reservoir and filling connections. One-piece Shaft non-lubricating

SP

SP

SP

SP

BO

BO

SP

SP

SP

SP

BO

BO

SP SP

SP SP

SP SP

SP SP

BO BO

BO BO

6 7

Shaft Covers Couplings with Covers between Gearbox and Motors Complete Motors Motors Supporting Frames Motor Terminal Gland Conectors. Cables

SP

SP

SP

SP

BO

BO

SP SP SP

SP SP SP

SP SP SP

SP SP SP

BO BO BO

BO BO BO

9 10

This Document is property of Consortium INITEC-ALIK. Reproduction is Prohibited

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Rev.: 1

Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

11

Motor Cable trays and conduits

SP

SP

SP

BO

BO

BO

V
1

Acoustic
Expansion Acoustical Shroud Joint NA NA NA NA BO BO If required

Noise abatement devices for water splash, motor, casing, fans.

NA

NA

NA

NA

BO

BO

If required

VI
1

Platforms, Stairs, Ladders and Handrails


External Stairs Structure on the SP SP SP BO BO BO

Ladders for Access Access Doors Platform for Operating Area

to

SP

SP

SP

OP

BO

BO

Main

SP

SP

SP

BO

BO

BO

Platform for Maintenance Access to the Stack and Spray Nozzles Ladders for Access Internal Fill / Packing to

SP

SP

SP

SP

BO

BO

SP

SP

SP

OP

BO

BO

Doors, Galvanized Platforms, Handrails, Ladders, and Stair Treads

SP

SP

SP

OP

BO

BO

VII
1 2 3

Water Pipes
Water Spray Nozzles Internal Manifold Pipes Internal Piping Supports Water distribution system including all necessary piping, expansion joint, diffuser and accessories Hot Water Inlet Pipe Riser for each cell Water distribution system support Inlet Pipe Riser Support Circulation Inlet Piping ( at ground level ) SP SP SP SP SP SP SP SP SP SP SP SP BO BO BO BO BO BO

SP

SP

SP

SP

BO

BO

SP

SP

SP

SP

BO

BO

Including expansion joint

6 7 8

SP SP BO

SP SP BO

SP SP BO

SP SP BO

BO BO BO

BO BO BO

This Document is property of Consortium INITEC-ALIK. Reproduction is Prohibited

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Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

9 10

Make-up Piping, Blowdown Piping

Water

Inlet

BO

BO

BO

BO

BO

BO

Water

Outlet

BO

BO

BO

BO

BO

BO

11 12 13

Risies Drain connection and pipe to pool Drain Piping Chemical Feed Injection piping dosing

SP BO BO

SP BO BO

SP BO BO

SP BO BO BO

BO BO BO BO

BO BO BO

14

Water Sampling System Piping

BO

BO

BO

BO

BO

BO

BO

BO

VIII

Fire fighting system


Design, Enginnering, Bill of Materials, Material Requisition. Purchase of Fire Fighting equipments and accesories. Installation, Commissioning and field Test.

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

IX
1 2 3

Silencer for Fans ( If required )


Silencer Silencer Installation Silencer Supports NA NA NA NA NA NA NA NA NA NA NA NA BO BO BO BO BO BO If required If required If required

X
1

Instrumentation
Motors Temperature Sensors and Transmitters Gearboxes Temperature Sensors and Transmitters Fans Vibration Transmitters Gearboxes Vibration Transmitters Oil Level Transmitters Fire detectors (firing system) Pressure Gauges SP SP SP SP BO BO

SP

SP

SP

SP

BO

BO

SP

SP

SP

SP

BO

BO

4 5 6 7

SP SP NA NA

SP SP NA NA

SP SP NA NA

SP SP NA NA NA NA

BO BO NA NA NA NA

BO BO NA NA

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Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

Local Temperature Indicators Heating Surface Thermocouples Test Thermowells Water Level Indicators Flow elements Pressure, flow, level. etc transmitters and switches Sample Nozzles Instrument valves Cabling, conduits and wiring from instrument cable terminals to local junction boxes Cable trays and conduits for instrument wiring to local junction boxes

BO

BO

BO

BO

BO

BO

BO

BO

9 10 11 12 13 14 15

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

BO BO BO BO BO BO BO

16

SP

SP

SP

SP

BO

BO

BO

BO

17

SP

SP

SP

SP

BO

BO

BO

BO

XI
1

Control and Control Elements


Control philosophy (DCS) Instruments Wiring Diagrams from instruments to terminal junction box Field wiring from terminal junction box to DCS Binary control loops Analog and binary signal acquisition Analog control loops SP SP SP SP SP BO SP BO

SP

SP

SP

SP

BO

BO

BO

BO

3 4 5 6

SP BO BO BO

SP BO BO BO

SP BO BO BO

BO BO BO BO

BO BO BO BO

BO BO BO BO

BO BO BO BO

BO BO BO BO

XII
1 2

Insulation and electric Heat tracing


External insulation and cladding materials Electric Motors heat tracing Heat tracing Protection of Instruments and Instrument Tubing NA SP NA SP NA SP NA SP NA SP NA BO SP BO

SP

SP

SP

BO

BO

BO

XIII

Miscellaneous

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Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

Complete Sampling System (including all necessary valves and connections as required and control) Complete Chemical dosing system (including all necessary tanks and connections as required and control) Complete make-uo and blow-down system Power cabling from Motor terminals to Motor Control Centre Cable trays and conduit for powering Motor Control Centre for Motors and Motor Operators within scope Plant general area lighting Plant emergency lighting Gaskets, Bolt & Nuts Spare Parts for commissioning and startup Special Tools to commissioing and start up Frames for Shipping and Erection

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

BO

6 7 8

BO BO SP

BO BO SP

BO BO SP

BO BO SP

BO BO

BO BO BO BO

SP

SP

SP

SP

BO

BO

10

SP

SP

SP

SP

BO

BO

11

SP

SP

SP

SP

NA

NA

NA

NA (*)To be supplied if special lifting devices are reauired

12

Lifting beam for site unloading

BO

BO

BO

BO

BO

NA

13 14 15 16 17 18

Training Manuals (Eng/Rus) O&M Manuals (Eng/Rus) Special tools por erection Surface preparation Primer coating and shop coating Final coating

SP SP SP SP SP SP

SP SP SP SP SP SP

SP SP SP SP SP SP

SP SP SP SP SP SP

NA NA

NA NA BO

NA NA

NA NA BO

NA NA

NA NA BO

NA NA NA

NA NA NA

As per painting spec. As per painting spec As per painting spec

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Engineering No. Description 1 SP SP SP 2 SP SP SP 3 SP SP SP

Supply 4 SP BO SP

Erection and Construction 5 6 BO BO NA BO NA

Commisioning and startup Remarks 7 8 BO NA NA NA NA

19 20 21

Field Touch up painting Cooling Tower lighting rod Complete shop tests and inspections

XIV

Commissioning and Start-up


Assembly, Setting, Alignment, and Grouting of Equipment Foundations Labour Civil Work Foundation Design Foundation Base Plates Foundation Anchor Bolts and embeddments Field Erection & Commissioning Utilities Erection Technical Field Assistance (TA) Commissioning Advisor Start-up Assistance Operator Training Personnel training and courses for operation and maintenance end clients personnel Pipes Shop Hydrostatic Test Field Labours Cleaning Performance Test Permanent and temporary instruments performance test Hoists for C.T. equipment Site Office and Facility including furniture Field Office facilities (copy equipment, telephone, fax, etc)

SP

SP

SP

BO

BO

NA

NA

2 3 4 5 6

BO BO BO SP SP

BO BO BO SP SP

BO BO BO SP SP

BO BO BO SP SP

BO BO BO

BO BO BO BO BO

BO BO BO

BO BO BO BO BO

SP

SP

SP

BO

BO

BO

9 10 11 12

NA NA NA SP

NA NA NA SP

NA NA NA SP

OP OP OP SP

OP NA NA SP

BO NA NA BO

OP OP OP SP

BO BO BO BO

13

SP

SP

SP

SP

SP

BO

SP

BO

14 15 16

SP BO SP

SP BO SP

SP BO SP

SP BO SP

BO BO BO

NA

NA BO

OP

BO

[1]

17

SP

SP

SP

SP

OP

OP

BO

[1]

18 19

SP BO

SP BO

SP BO

BO BO BO

NA BO BO

NA

20

BO

BO

BO

BO

BO

BO

BO

This Document is property of Consortium INITEC-ALIK. Reproduction is Prohibited

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Engineering No. Description 1 2 3

Supply 4

Erection and Construction 5 6

Commisioning and startup Remarks 7 8

21 22

Site storage, warehouse, control and handling Instrument Calibration All requirement Indoor/Outdoor Storage of Equip & Material Transport of Damaged/Defective Material for Repair

BO SP

BO SP

BO SP

BO SP

BO NA

23

SP

SP

SP

BO

BO

BO

BO

24

NA

NA

NA

SP

SP

BO

SP

BO

XV
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Erection and Construction


Mobile cranes Fixed crane Jacks, winches, tackles Hydraulic jacks Hand tools Welding machines Welding gases Welding material Scaffolding work Greases and lubricants Lube-oil initial fill Safety equipment / personal Lighting Rent of elephant legs SP SP SP SP SP SP SP SP SP SP SP SP SP NA SP SP SP SP SP SP SP SP SP SP SP SP SP NA SP SP SP SP SP SP SP SP SP SP SP SP SP NA BO BO BO BO BO BO BO BO BO SP SP BO BO NA BO BO BO BO BO BO BO BO BO BO BO BO BO NA BO BO BO BO BO BO BO BO BO BO BO BO BO NA

REMARKS:

(1)

Performance and functional tests procedures to be provided by supplier. Supply of temporary instrumentation or devices for performance test to be quoted as optional. Permanent instrumentation to be supplied by Cooling Tower Manufacturer. Engineering for anchor bolts, slide plates, embedment and any other anchorage material. Supplier shall submit to purchaser as minimum a specification for cooling tower assembly and erection.

(2) (3)

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SUPPLIERS DOCUMENT LIST SUPPLIER: ESINDUS


DOCUMENT: NAV-10-PAB-MI-IEM-465-A2 SUPPLIERS DOCUMENT CODE *(to be used only with the permit of the Project Manager) ESTIMATED ISSUING DATE TO INITEC (WEEKS) ANNEX A2 OBJECT (APPROVAL /INFORMATION)

Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


1.1 1.2 1.3 1.4

DOCUMENT NAME (DESCRIPTION)

Equipment detailed description and performance Completed technical data sheets of the equipment Process and Instrumentation Diagram P&IDs General Cooling Tower and Circulating System layout drawings including outer dimensions, plan view and vertical sections with dismantle areas and weights General Equipment layout drawings (plan view, vertical sections and piping, instrument, and auxiliary equipment connection details with dismantle areas and weights Piping layout drawings General and detailed drawings of internals, internals support and insulation requirements Detail drawings indicating field welds Fan, gearbox, drive shaft and couplings drawings. Complete cooling tower parts list including identification codes of parts Noise analysis study and data Anti-freeze protection description and details (if applicable) Material list and drawings including auxiliary piping, valves and fittings Chemical dosing requirements Valves list (acc. INITEC format) Piping list (acc. INITEC format) Equipment list (acc. INITEC format) Terminal point list (large bore and small bore) Blow down system data Clearing procedure of lubrication piping Thermal expansion and allowable forces and moments for every piping terminal points Characteristic curves KV/L vs L/G and cold water vs. Wet bulb temp at 90-100-110% circulating flow

2 2 2 4

X X

1.5

4 4

1.6. 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22

4 2

X X

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Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


1.23 1.24 1.25 1.26 1.27 2.1. 2.2. 2.3. 2.4. 2.5. 3.1. 3.1.b 3.2. 3.3. 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 4.1. 4.2

DOCUMENT NAME (DESCRIPTION)

Drift Loss curve as a function of air speed Calculations ( civil works + water balance ) Performance curves inc. Air flow, pressure, efficiency, and horsepower vs. Fan speed and blade pitch Fill specification and data Arrangement of fan, fan data, performance curve and critical speed Electrical diagrams of control and terminal box wiring Completed electric motor data sheets Motor Dimensional drawing and Terminal box arrangement. Motor performance curves Electrical load list Functional description and operation Control Diagrams of the tower ) Operation and functional description List of alarms and set points with actuation points. List of i/o signals for the control system. Instrument List Instrument Data Sheets Instrument field mounting typical (hook-up). Junction Boxes Wiring Schematic and Signal grouping. Instruments Calibration sheets Location and layout plan of instruments and junction boxes. Heat tracing specification and material data sheets to purchase order by other Instrumentation heat tracing details Heat tracing layout Instruments and control cable list General arrangement drawing Drawing of all structures and trenchs (NOT Logic and Analogical

4 8

X X

4 8 10 10 4 4 4 4 4 4 6 8 6 8 8 NA NA NA 4 4 NA A X X X X X X X

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Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


4.3 4.4 4.5 4.6 5.1. 5.2 5.3 5.4 5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11. 5.12 5.13 6.1 6.2 6.3 6.4 6.5 6.6 6.7. 6.8

DOCUMENT NAME (DESCRIPTION)

Platform, stairs & ladder arrangement drawing Drawing Layout of concrete structures indicating dimension of all elements Loads Drawing Foundation Bolts layout Erection drawings Filed assembly program, commissioning and Start-up, indicating time schedule, manworkship and category. Supervisory program, indicating number of supervisors and category ( in case that no field assembly is in contract ) Erection Procedure Insulation and electric tracing installation procedures Lifting procedures and requirements for erection and maintenance Field weld list & Field Bolt List Erection Utility list Packing List Preservation and storage instruction Packing Shipping Weights & dimensions List of special tools for installation and maintenance. Field Cleaning and Painting Procedures Detailed description of the equipment and operation, including auxiliary systems. Accurate description of the scope of supply Exception and Acceptance Conformance to Specification List of codes and standards used during design, manufacture and testing. Utility list Lubrication list. Nameplate drawing Shop Surface preparation and painting specification and procedure.

8 10 8 12

I I A A X X X

10

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Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


6.9 7.1 7.2 7.3 7.4 7.5. 7.6. 7.7. 7.8. 7.9. 7.10. 7.11. 7.12. 7.13. 7.14. 7.15. 7.16. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.1

DOCUMENT NAME (DESCRIPTION)

Assembly and Erection manual Material certificates Test and inspection certificates calibrations and reports Packing-list and instructions for transport and field warehousing Reference List Quality Plan Inspection and test point program Procedure Qualification specifications (WPS) Quality analysis report Shop test documentation Material and equipment certifications NDT procedures Test procedure at site Certificates of conformance Painting report Supplier's certifications Quality and technical final report Project organization manual Project schedule Fabrication Plan Project Monthly Progress Reports Unpriced Subcontractor Orders Subcontractor list List of project documents with expected schedule Spares parts List for erection, commissioning, start-up and agreed operation period Bill of material Installation Manual reports (PQR) & welded procedure

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DOCUMENT: NAV-10-PAB-MI-IEM-465-A2 SUPPLIERS DOCUMENT CODE *(to be used only with the permit of the Project Manager) ESTIMATED ISSUING DATE TO INITEC (WEEKS) ANNEX A2 OBJECT (APPROVAL /INFORMATION)

Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


9.2. 9.3 10.1 10.2 10.3 10.4 10.5 11.1 11.2 11.3 11.4 11.5 11.6 12.1 12,2 12.3 12.4 12.5 13.1 13,2 13.3 13.4 14.1 15.1 15.2 15.3 16.1 16,2 16.3

DOCUMENT NAME (DESCRIPTION)

Training manuals Operation & maintenance manuals Installation Manual Training manuals Operation & maintenance manuals Motor Certificates and Test Procedures Motor Conection and instruments GEARBOX DATA SHEET. GEARBOX DRAWING . GEARBOX FINAL CONTROL PROCEDURE GEARBOX STANDARD PAINTING PROCEDURE. GEARBOX CERTIFICATES AND TEST REPORTS . GEARBOX INSTRUMENTS . FAN DATA SHEETS . FAN DIMENSIONAL CONTROL PROCEDURE . FAN BALANCE PROCEDURE . FAN MATERIAL CERTIFICATE . FAN TEST CERTIFICATES . COUPLING DATA SHEETS . COUPLING DRAWING. COUPLING MATERIAL CERTIFICATE . COUPLING BALANCE PROCEDURE FAN STACK MATERIAL CERTIFICATE . HEADER MATERIAL CERTIFICATES FILLING MATERIAL CERTIFICATES PIPES MATERIAL CERTIFICATES . FILLING PACKAGES MANUFACTURING PROCEDURE SPRAYERS AND PLASTIC ACCESSORIES MANUFACTURING PROCEDURE DELIVERY PROCEDURES

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Rev.: 01 Date: 18/03/10 CRITICAL DOCUMENTATION

INITEC DOCUMENT CODE


16.4 17.1 17.2 18.1 18.2 18.3 18.4 18.5 18.6 18.7

DOCUMENT NAME (DESCRIPTION)

COUPLING BANLANCE PROCEDURE . COOLING TOWER OPERATION AND MAINTENANCE MANUAL .. EQUIPMENT INSTALLATION AND MAINTENANCE GEARBOX, COPLING MANUAL, FAN MANUAL) . BASIN FORMS AND LOADS DELETE DELETE GEARBOX ACCESS WALKWAY HDGS STAIRWAY HDGS LADDER DELETE DELETE MANUALS (MOTOR,

NOTE:

DOCUMENTS MARKED WITH "X" ARE SUBJET TO "LIQUID DAMGAES" AS PER PURCHASE ORDER

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NAV-10-PAB-MI-IEM-465.A3

Rev.: 0

ANNEX 3

DEVIATIONS /CLARIFICATIONS LIST

INITEC Energa
Item Party

Deviations / Clarifications List


Deviation/ Required Clarification

PROJECT: C.T.C.C. NAVOI (477.75 MW) SUPPLY: COOLING TOWER Bid No: Doc No. Section

BIDDER: DATE: 05-11-2009 PAGE: 1 of 1 SIGNATURE: Comments / Resolutions Status opened

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(477,75 MW) INSPECTION AND TEST PLAN

NAV-10-PAB-MI-IEM-465.A4

Rev.: 0

ANNEX 4

INSPECTION AND TEST PLAN

INITEC Energa

INPECTION AND TEST PLAN

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 1 of 6

The table below lists the minimum inspections and tests to be carried out on the equipment: No. Item 1. Material Inspection Inspection / Test Performed by M Report X Purchaser R Owner Remarks

2. Static Balanced

3. Blades Dynamic Balanced 1. FUNS 4. Final Inspection /release for shipment Marking and tagging Shipping preparation Quality verification documentation

5. Verify approval and authorization to ship

2.

GEAR BOX

1. Material Inspection

2. Shop Tests Reduction factor Heating Vibrations Noise Tightness Loads

INITEC Energa
No.

INPECTION AND TEST PLAN


Item

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 2 of 6 Performed by M Report X Purchaser Owner Remarks

Inspection / Test 3. Visual and dimensional inspection (Control of defects)

4. Final Inspection /release for shipment Marking and tagging Painting Shipping preparation Quality verification documentation

5. Verify approval and authorization to ship

1. Material Inspection

2. Dynamic balanced

3. Visual and dimensional inspection (Control of defects) 3. DRIVE SHAFTS 4. Final Inspection /release for shipment Marking and tagging Shipping preparation Quality verification documentation

5. Verify approval and authorization to ship

INITEC Energa
No.

INPECTION AND TEST PLAN


Item

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 3 of 6 Performed by M Report X Purchaser R Owner Remarks

Inspection / Test 1. Raw materials reception

2. Visual and dimensional inspection (Control of defects)

3. Tests Routine test Measuring resistance Measuring of insulation resistance Testing by locked rotor No load test Check of motor running Direction of rotation High voltage test 4. MOTOR

4. Final Inspection Marking and tagging Shipping preparation Quality verification documentation Material certificate Test Reports

5. Verify approval and authorization to ship

INITEC Energa
No.

INPECTION AND TEST PLAN


Item 1. Material Inspection

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 4 of 6 Performed by M Report X Purchaser R Owner Remarks

Inspection / Test

2.Visual and dimensional inspection (Control of defects)

5.

FILLS

3. Visual inspection Marking and tagging Shipping preparation Quality verification documentation M X W

4. Verify approval and authorization to ship

6.

WATER INJECTION NOZZLES

1. Material Inspection

2.Visual and dimensional inspection (Control of defects)

3. Visual inspection Marking and tagging Shipping preparation Quality verification documentation M X

INITEC Energa
No.

INPECTION AND TEST PLAN


Item

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 5 of 6 Performed by M Report X Purchaser H Owner Remarks

Inspection / Test 4. Verify approval and authorization to ship

1. Material Inspection

2. Visual and dimensional inspection (Control of defects) 3. Visual inspection 7. WATER DISTRIBUTION PIPING/RISERS Verify approval and authorization to ship Marking and tagging Shipping preparation Quality verification documentation

4. Verify approval and authorization to ship

INITEC Energa
Symbols:

INPECTION AND TEST PLAN

PROJECT: C.C. NAVOI (477,75 MW) SUPPLY: COOLING TOWER No: NAV-10-PAB-MI-IEM-465.REV0_annex4 PAGE: 6 of 6

M: Manufacturer /supplier or Sub-supplier X: Required R: Review P: Purchaser O: Owner W (Witness point): A critical step in the manufacturing process at which contractor is to notify owners representative within the time defined in the commercial so that it may be witnessed by Owners representative. Contractor may proceed past the witness point only if by owners representative is not available at the appointed time. Contractor is obligated to notify owners representative of each occurrence of that operation. The contractor shall submit pre-notice and notice of inspection to be witnessed. It shall include the information, such as equipment name, inspection method, place, etc. In the event that a schedule date is changed, the contractor shall advise to purchaser expeditiously. H (Hold point): a critical step in the manufacturing process at which contractor is to notify owners representative within the time defined in the commercial so that it may be witnessed by Owners representative. Contractor may not proceed with work beyond the Hold point without witness by owners representative except by written authorization from owner. Contractor should not proceed to next stage until inspection to be witnessed by purchaser is finished satisfactory. If Purchaser exempts the witness, contractor shall submit the inspection record as soon as inspection is completed. Inspection and test record shall be bound item by item as they shipped and submitted to Purchaser per each shipping. Also, compilation of all inspection and test record shall be submitted within 2 weeks after completion of the shop work of each unit. Inspection record shall include cover sheet contractors logo, signature of QA/QC section, contents, and page number. Notes:

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