Clause No. 1.00.00 1.00.

01

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) EXHAUST GAS SYSTEM Each exhaust gas system shall comprise of ducting, exhaust silencers turning vanes (if applicable), thermal insulation, lightning arrestors, expansion joints, supports etc., so as to make the system complete. The exhaust gases from each gas turbine shall be led to its HRSG through an exhaust duct. Material of construction a) Externally Insulated System i) All metallic components coming in contact with hot gas shall be of stainless steel construction. The material of construction of exhaust gas duct plate/liner, silencer stiffeners and structures in hot gas path shall be stainless steel. Outer shell for ductwork, transition piece/turning vanes (if applicable) and exhaust silencer shall be at least 6.0 mm thick stainless steel plate. Cold external stiffeners and flanges shall be made up of structural quality steel as per ASTM A-36. Material for external stiffners which are at the same temperature as the duct plate shall be stainless steel while suitable material shall be selected for stiffners at intermediate temperatures. For the thermal insulation the contractor shall provide first layer of ceramic wool of density minimum 128 Kg/m3 and minimum thickness 40.0 mm and subsequent layers shall be of ceramic wool or of resin bonded rock wool of minimum density 100 Kg/m3 followed by aluminium cladding of 18 SWG thick corrugated sheet.

1.00.02

1.01.00

(ii)

(iii)

b)

Internally Insulated System (i) For outer shell provide 6.0 mm thick steel plates as per ASTM A285 Grade-C. The outer shell shall not come into the contact of hot gases. Internal liners wherever provided shall be of ASTM A-176 Grade 409 stainless steel of thickness 12 SWG. For thermal insulation self stitched ceramic wool shall be used. The minimum density of insulation shall be 128 kg/m3. Mattresses of minimum thickness of 40 mm shall be used.

(ii)

(iii)

1.02.00

Design Basis/Sizing Criteria (a) The structural design of the exhaust gas system shall take into account very rapid startups and shut down rates common to gas turbines.
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KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. (b)

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) The complete exhaust gas duct shall be sized so that maximum gas velocity shall not exceed 40.0 m/s under base load operation and design ambient temperature for the project. Sizing of insulation shall conform to the criteria given at cl. no. 2.11.03 of this section for the HRSGs. Expansion joints shall be designed to achieve the required skin temperature at outer surface of 60 deg.C without considering the thermal insulation bags/ bolster temp. drop. The silencer unit shall be sized so that the maximum gas velocity shall not exceed 60m/second under base load operation and design ambient conditions for the project.

(c)

(d)

(e)

1.02.01

Exhaust Plenum The GT exhaust plenum shall be designed for proper gas velocity and temperature distribution and effective pressure recovery. The plenum may be provided with flow turning vanes (if necessary), constructed of stainless steel.

1.02.02

Exhaust Silencer a) The silencer(s) in the exhaust gas system must comply with the specified criteria for the combined cycle operation. The silencer shall be located after the diverter damper at the inlet of the bypass stack. Parallel baffle type silencer employing sound absorbing soft packing material shall be used in construction of exhaust silencer. Ceramic wool shall be used for acoustic insulation. The material of construction shall be stainless steel. Acoustic baffle liners shall be of perforated stainless steel sheet as per ASTM A-176 Grade 409 of thickness 12SWG. To take care of differential thermal expansion the acoustic baffles shall be freely supported on structural cleats attached to the silencer shell. The leading and trailing edge of the baffles shall be aerodynamically shaped, so that there is homogeneous flow across the silencer. The flow velocities shall be so selected that the pressure losses and the self generated noise due to flow turbulence is kept to a minimum. The rigidity of silencer shell shall be provided by internal stainless steel tie members. The silencer unit shall be connected to the inlet and outlet duct by means of expansion joints so that, if required, the silencer unit can be removed with ease. Diverter Damper The T-connection for bypass stack, in each GT exhaust duct to HRSG inlet shall have one diverter type damper for gas tight closure of HRSG inlet

b)

c)

d)

e)

1.02.03

i)

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

PAGE 2 of 19

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) when operating in open cycle mode and for gas tight closure of bypass stack when operating in combined cycle mode. The design and arrangement of the diverter damper shall be proven one. Sizing of the diverter damper shall be done so that the maximum gas velocity does not exceed 30 m/ sec at base load of the GT. Diverter damper shall be hydraulically operated with percentage opening clearly marked on each damper. Hydraulic actuator of proven make shall be provided for the diverter damper. Make and sizing of the actuator and the margin considered in the sizing will be to owner's approval. In this regard, shaft driving torque calculation shall be submitted. The hydraulic power pack unit shall consist of 2X100% oil pumps and all other accessories for safe and fast operation of the damper. In addition, the damper shall have the facility to be remote/manually operated and shall be able to provide the desired relationship between percentage opening and flow under all operating conditions. There shall not be any back lash with actuators and final control elements. It will be ensured that during operation the flap is not stopped in the first 150 from the closed to bypass stack position to avoid vibration/tearing of sealing strips due to high gas velocities. The sealing assemblies shall be of twin seal type, both on bypass side and HRSG side. Diverter damper shall ensure a sealing efficiency of 99.92% based on volume of gas at its operating pressure and temperature, both in open cycle and combined cycle modes, without the seal air fans working. 2X100% seal air fans shall be provided for each damper, located sufficiently away from the high temperature zone and ground level, to attain a sealing efficiency of 100%. Cold seal leakage test shall be done on each diverter damper at the shop before dispatch. Seal leakage test shall be repeated on each diverter damper after the units have operated on combined cycle mode for more than 2000 hrs. Seal leakage test at site, shall be performed under hot conditions while the GT is running at base load. Seal leakage for the above tests shall be measured by running the seal air fans and pressurizing the seal cavity at various pressure levels as per leakage test procedure. Seal air flow shall be measured by means of pitot tube and measurement will be made over a grid to attain accuracy. Leakage air flow measured from the above test will be corrected for actual gas density at operating pressure and temperature to compute gas leakage from seals. Seal cavity pressure levels, calculation procedure and test procedure details will be finalized before the award of contract based on the concept as outlined above. The diverter will be put to a functional test at shop before dispatch to site with diverter in completely assembled state and the actuator in position. Details of the functional test will be finalized before the award of contract. The damper arrangement shall be designed in such a way that shut down and isolation of HRSG from a combined cycle mode to open cycle mode is carried out without affecting the GT operation.

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) The damper shall be of heavy duty construction. All components for the damper shall be rigidly constructed to prevent bending, vibration and distortion. They shall be balanced about the bearing shaft axis and shall be designed to withstand operating gas temperature without distortion. The design of structural components shall be based on 60% of the yield strength of the material at the design temperature. Bidder shall elaborate design features provided by him to reduce vibration of seals and resulting material fatigue caused by the flowing gas. Damper shall be capable of withstanding the maximum operating temperature and thermal expansion of the GT exhaust system, continuously as well as suddenly from cold condition without distortion or any loss in tightness efficiency. Care shall be taken in the design that the thermal expansion of ducting does not affect damper operation. When operating in combined cycle mode, the design of the diverter damper shall ensure minimum radiation loss and shall be totally leak proof using seal air. The material for insulation of dampers shall be ceramic wool of density not less than 128 kg/m3. The construction shall be the shaft bearings are mounted outside the damper box channel and arranged for convenient inspection. The flap frame will be connected to the pivot shaft by extending the frame members itself and not by welding short arms to the frame. The flap of the damper shall be provided with two independently expanding blades fixed to the frame of the flap in a manner so that the frame and the two blades expand independently of each other. The flap shall be insulated from both sides. Sealing strips shall be attached to the flap while the diverter cubicle will have seal landing bars. Sealing strips as well as landing bars will be segmented to allow free expansion and avoid warping. Basis for selection of liner thickness, insulation/liner holding pin diameter and spacing, liners layout, pin welding method etc. shall be finalized before award to the satisfaction of the owner. The diverter dispatch able units will be dispatched to site complete with insulation and cladding. Number of dispatch able fragments of the diverter for transportation shall be finalized jointly with the owner. ii) Guillotine Gate When in open cycle, complete isolation of the HRSG shall be provided using a motor operated Guillotine gate in order to ensure complete gas tightness when in closed position, to ensure safety of maintenance personnel working on downstream side with GT in operation at full load. Bidder shall indicate the total time required for closing the gate. The guillotine gate will have bulb seals at the top edge of the duct and a gas tight bonnet which will enclose the complete bade in open condition ensuring zero atmospheric leakage. The blade assembly (coming in contact

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

PAGE 4 of 19

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) with hot gas) shall be suitable to withstand the maximum operating temperature of the GT exhaust gas. The guillotine gate will be put to functional test at shop before dispatch to site and at site after installation. Guillotine damper shall ensure a sealing efficiency of 99.92% in terms of flow of diverter damper without the use of seal air. 2 X 100% seal air fans shall be provided for each damper to attain a sealing efficiency of 100%. The same shall be demonstrated during shop test.

1.03.00

Expansion Joints (a) Differential thermal expansion of the complete system, starting from the discharge flange of gas turbine exhaust outwards shall be accommodated by expansion joints, fixed anchor and sliding support system. Expansion joints of suitable design shall be provided in between gas turbine exhaust flange and the exhaust duct to HRSG side and any other location where the contractor considers it necessary to take care of differential thermal movements and to isolate vibration and load transfer. Fabric expansion joint of suitable type shall be provided. The expansion joint frame will have a elongated neck of minimum depth of 125 mm. The fabric shall be mounted on the flange of this neck. The frame in turn shall be fastened to the duct flange. Fabric expansion joints shall be provided with rain canopy to avoid rain water entry into fabric of expansion joint. Stainless steel (type 304) liner-plates shall be provided to shield the fabric from direct contact with hot gas. For protection, thermal insulation bags shall be inserted between the liner plates and the fabric ply. The expansion joint fabric, frame, liners, insulation, fasteners, etc. shall be designed/manufactured, conforming to proven design and transported to site as composite assembly. Rust proof fasteners of suitable material shall be used and the life of complete expansion joint shall not be less than 20000 hours of operation.

(b)

(c)

(d)

(e)

1.04.00

Bypass Stack The height of the bypass stack shall not be less than "H" meters (as specified in Part-A, Section-VI of Technical Specification), above the grade level. The bypass stack shall be of stainless steel construction. The bypass stack shall be insulated at least upto the height of which clears the HRSG as well as that facilitating personnel safety and movement. The type of insulation offered (external or internal) shall be as per the standard practice of the bidder. Bider shall ensure that there are no oscillations in the bypass stack under any condition of operation. The velocity of exhaust gases through the bypass stack shall be proven practice of the bidder for similar stack heights and bidder shall furnish sufficient details to substantiate

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

PAGE 5 of 19

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) this. However, in no case the maximum velocity of the gases should exceed 40 m/ sec. Other requirements for the stack as specified under Volume-IV of Part-B shall be complied.

2.00.00 2.01.00 2.01.01

HEAT RECOVERY STEAM GENERATOR (HRSG) & AUXILIARIES Type of HRSG The Heat Recovery Steam Generator (HRSG) shall be unfired, forced/natural circulation type with dual or triple pressure stages with or without Reheat. The capacity and parameters of HRSG shall be decided by the contractor based on selected turbine cycle. The HRSG shall be suitable for outdoor installation. The entire HRSG shall be constructed to form a gas tight envelope to prevent gas leakage. The design shall be based on finned tube heat transfer banks of superheaters, evaporators, economisers, etc. Adequately sized drum(s) shall be provided. The sizing, sectionizing and positioning of heat transfer banks in the gas path will be decided by the contractor based on his turbine cycle optimization. A condensate preheater at the tail end of HRSG shall be provided to preheat condensate from gland steam cooler before its entry into deareator. Design Criteria for HRSG The design of HRSG shall be suitable for direct on line starting alongwith the gas turbine, during a startup after a sixteen (16) hours shut down. The design of offered HRSG shall take into account running of HRSG with LNG/ natural gas firing in the associated gas turbine on a long term continuous basis. The HRSG will also be suitable for running with high speed diesel (HSD) firing in the associated GT which may occur during the life of the plant, on a long term continuous basis. The HRSG shall be designed to operate on sliding pressure mode. In the event of loss of feed, it shall be permissible to continue HRSG operation at a constant heat output and without any feed whatsoever, until, the gas turbine is tripped and coasted down. The HRSG shall be based on package concept to ensure that maximum amount of manufacturing is carried under carefully controlled shop conditions and the need for site preassembly / fabrication is minimized. All tube to header weld joints will be carried out at shop. The HRSG should be capable of operating on base load and should be capable of two shift operation and cyclic load variations. The HRSG should be capable of rapid load charges and hot restarts without any restrictions.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 6 of 19

2.01.02

2.01.03

2.02.00 2.02.01

2.02.02

2.02.03 2.02.04

2.02.05

2.02.06

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.03.00 2.03.01

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Thermal Design of HRSG The gas temperature at HRSG exit and condensate temperature at condensate preheater inlet shall take into account protection of condensate preheater from dew point corrosion under all conditions of operation and with gas & HSD firing and water/steam injection in the gas turbine. Minimum metal temperature of condensate preheater tubes/fins shall be atleast 10 deg. C above acid dew point temperature of the flue gases. The required condensate temperature shall be achieved by suitable design of condensate cycle. CPH recirculation pump may be used to recirculate the condensate. Pressure levels, number of pressure stages, steam mass flows, pinch points, approach temperatures, etc. shall be based on proven design & standard practice of the contractor and turbine cycle optimization. However at no section of the HRSG, temperature differential between gas and steam/water for heat transfer between them shall be less than 6 (six) deg. C. Selection of tube pitching, tube diameter, fin thickness/density, gas mass velocity, etc. will be based on field proven design and shall take into account liquid fuel firing on long term continuous basis. Fin density shall be as low as possible commensurate with the contractors experience with liquid fuels. However, in no case the fin density shall be higher than 5 fins/inch. The gas velocity through the HRSG shall be limited to a maximum value of 20 m/sec. The evaporators shall be designed for multi-pass operation with high circulation ratio to ensure that the circuit remains wetted under any transient conditions. The evaporator section shall be fully drainable. The economiser shall be of non steaming type and the economizer surfaces shall be arranged for up flow of water. Down flow as well as up and down flow type economiser with proven design and proper sizing to avoid steaming at all loads can also be provided if the contractor establishes the same in the bid. Maximum design fluid velocities through tubes/pipes shall take into account water hammer, erosion and pressure drops in the line. The velocity of steam in the superheaters shall be selected for optimum pressure drop, however, it shall not exceed 40 m/s. The feed regulating station may be located either upstream or downstream of the economisers. However, in either of the above system it shall be ensured that there is no possibility of steaming in the economiser at any load condition. If the feed water regulating station is located upstream, a minimum approach temperature of 9.4 deg.C is to be provided at the design point. The superheater steam temperature control system shall utilize feed water spray attemperator, the feed water being tapped off from a suitable source. An arrangement with superheater attemperator located after final superheater shall not be acceptable.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 7 of 19

2.03.02

2.03.03

2.03.04

2.03.05

2.03.06

2.03.07

2.03.08

2.03.09

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.03.10

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) The boiler drum(s) shall be sized to have a minimum storage capacity (time) of 3.0 minutes between normal water level(NWL) and low-low trip level (LLT) at rated steam mass flow for the HRSG. LLT level shall be decided so that with total loss of feed the water level shall not reach drum dry level before Gas Turbine is coasted down. NWL for the drum shall be selected based on the proven practice of the contractor and to meet the specified steam quality requirements. Constructional Features of Pressure Parts The arrangement of heat exchanger tubes and their supporting system shall be so designed that the operation of HRSG meets the specified noise criterion. All headers shall be located outside the gas path. Type of fins adopted will be of proven design. Solid fins will be used for the first two leading rows of HRSG, if these tubes are envisaged to be finned. Only solid fins (unsegmented) will be used for the condensate preheater tubes. Sufficiently large clear spaces shall be left between the individual tube bank of all the heating surfaces to provide easy personnel access to the heating surfaces. In no case the space between two banks shall be less than 1000 mm. Maximum tube bank depth should not be higher than the depth which can be effectively cleaned using soot blowers. In any case the bank depth shall not exceed ten numbers of tube rows. The headers shall be provided with drains and suitable openings with forged weld on caps for internal inspection and chemical cleaning. Superheater spray system consisting of valves, drains and pipeline and accessories shall be adequately sized to cater to the maximum requirements. Drum * The drums shall be of fusion welded construction designed as per applicable regulations of IBR. The design pressure shall be at least 1.05 times the maximum operating pressure. The longitudinal weld seams shall be suitably staggered, if possible. The welds shall be properly heat treated and 100% radio graphed during manufacture. The drum location shall be such that it is not exposed to hot gases. * The interior of the drum shall be cleaned to remove mill scale, rust, corrosion products, dirt, grease, moisture or other loose foreign materials after fabrication at works either by shot blasting or non-silica bearing grit or as per the manufacturers standard cleaning process subject to Employers approval. The fixing of internal fittings to the drum shall prevent their displacement during operation. Unless and otherwise specifically approved they shall not
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 8 of 19

2.04.00 2.04.01

2.04.02

2.04.03

2.04.04

2.04.05

2.04.06

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) be welded directly to the internal surfaces of the drum. Bolts and studs inside the drum shall be fitted with cap nuts, wherever removability may be required during the life of the plant. The arrangement and fabrication of drum internals shall permit easy removal and replacement through drum manholes.

2.05.00 2.05.01

Constructional Features of HRSG enclosure The bottom of the enclosure shall be sloped suitably and shall be provided with drain connections to ensure unrestricted draining of water. At the HRSG entrance and wherever enclosure interior is exposed to hot gases of 550 deg. C or higher, a stainless steel / casing / liner shall be provided. The construction shall be weather proof, water tight and shall withstand monsoon winds. The HRSG shall be provided with a roof canopy. All platforms/walkways/stairways/critical equipments/valves etc. shall be provided with rain covering/sunshade. All necessary arrangement for drainage of rain water such as gutters, drain pipes, etc. shall be provided. The enclosures shall be adequately stiffened to withstand 1.5 times the actual pressure drop in the HRSG at the maximum GT output. Suitable turning vanes and baffles shall be provided wherever required to ensure vibration free operation and satisfactory gas distribution under all operating conditions. The structural design of HRSG shall conform to the requirements specified in Civil Volume, Volume-IV, Part-B, Section-VI. Metallic expansion bellows provided shall be of proven design. Operation and Maintenance Requirements The drum shall be equipped with suitable moisture eliminators, screens and other necessary internals to ensure that the amount of dissolved solids carried over with the saturated steam leaving the HRSG drums does not exceed one (1) ppm. It shall be ensured that in no superheater than 0.02 times the average flow. header the unbalance of flow is more

2.05.02

2.05.03

2.05.04

2.05.05

2.05.06 2.06.00 2.06.01

2.06.02

2.06.03

The temperature of superheated steam at superheater outlet shall be maintained within 5 deg. C of the rated temperature at all loads from 60% load to the peaking load of the gas turbine unit. During startup it should be possible to moderate steam to metal temperature differential with the help of the attemperator. The superheater sections shall be fully drainable for easy washing of internal deposits. To safely perform maintenance on any one HRSG during normal operation of the other HRSG, suitable isolation system shall be provided in line with the relevant Boiler codes applicable to multi Boiler installation. Isolators at the evaporators inlet to be provided for each HRSG, in case of common feed system.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 9 of 19

2.06.04

2.06.05

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.06.06

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) For steam drums all necessary nozzles and connections including steam outlets, safety valves, feed water inlet, downcomers, blow down vessels, drum level indicators, chemical feed, pressure gauges, vents and drains, sampling connections, saturated steam connections, acid washing connections etc. shall be provided. Thermocouples on the drum for monitoring the drum metal temperature shall be incorporated. Test pressure gauges shall be provided on the superheater outlet pipes to facilitate adjustment of the setting of safety valves. Adequate thermocouples shall be provided and fixed to the superheater tubes surface for measuring and recording metal temperature during pre-commissioning trial operation and normal operation. For instrumentation and control requirements for the HRSG refer Section-VI, Part-B, Volume-III. Any special instrument required, like the optical fiber viewing system to detect the leaking tubes and to view headers from inside shall also be provided by the contractor. Forced Circulation System (if applicable) The circulation system shall ensure adequate circulation ratio during rapid startup and load changes. This shall be controlled by water circulation pumps if forced circulation system is offered. There shall be 2x100% capacity pumps for each HP, IP (if applicable) and LP steam generation systems of each HRSG. Each circulation pump shall be complete with drive motor, coupling guard, lubrication, sealing and cooling arrangements. The design shall be such that in the event of a failure the complete unit (pump and motor) can be removed and replaced quickly. The design shall be such that in case the circulation ratio changes due to circulation pumps going out of operation suddenly or by any other maloperation, it shall not jeopardize the safety of the tubes or the HRSG. HRSG integral piping, valves, fittings and mountings All integral piping, valves, fittings and mountings shall meet the Employers approval regarding their location, type, quantity, make and size. All heat transfer banks shall be provided with necessary mountings, fittings, drains, vents and instrument connections. The materials, design and detail construction of all the types of valves shall be subject to the approval of the Employer. Valves which are to be operated during chemical cleaning shall be of the type which are resistant to the chemicals proposed to be used during chemical cleaning.

2.06.07

2.06.08

2.06.09

2.06.10

2.06.11

2.07.00 2.07.01

2.07.02

2.08.00 2.08.01

2.08.02

2.08.03

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

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Clause No. 2.08.04

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Drain pipes shall be designed to withstand the maximum operating pressure of process line. The number, size, location and setting of safety valves on drums and superheater shall be as per Indian Boiler Regulations. The escape pipes shall lead to the nearest convenient point on the HRSG house roof. Separate silencers for the lowest set pressure safety valves on the drum and superheater shall be provided in order to minimise the noise nuisance when the valves lift. The safety valves on drum and superheater together shall be capable of discharging atleast 105% of the maximum steam generating capacity of the HRSG. The main feed control valves shall be designed for operation under a constant pressure differential across the valves. Feed control valves shall be provided with spare trims for initial operation. Scheme of water and steam system Feed regulating station shall have three parallel flow paths, one for startup and low load operations, capable of regulating for a load range 0-30% of BMCR and one for higher loads from 25-100% BMCR and the third as regulating standby for 25-100% BMCR. Above three control valves shall regulate accurately the rate of feed water flow to the HRSG. A bypass line to the condensate preheater with motorised inching type valve shall be provided. For each HRSG separate condensate recirculation control station shall be provided so that different condensate temperature for each HRSG can be maintained if required. Recirculation line for CPH recirculation pumps shall be provided, if considered necessary. If considered necessary, an economiser recirculation line with valves shall be provided to prevent steaming under all conditions of operation. All control valves shall be provided with 100% capacity bypass control valves which shall be remote operated and motorised inching type respectively. Both main as well as bypass control valves shall be provided with remote operated, motorised isolating valves, upstream of control valves. The control valves shall also be provided with manual isolating valves on the downstream. Pressure gauges shall also be provided at the inlet as well as outlet of all control valves. Drains shall be provided on the upstream and the downstream of control valves. Drain and vent valves which are required to be operated during startup and shut down of the HRSG shall be motor operated. It shall be ensured that none of the valves are in an inaccessible position. However if for some constraint a valve is located in an inaccessible position it shall be provided with a motorised actuator The HP, IP & LP main steam line for each HRSG will be provided with an isolator in addition to the motor operated isolating valve for positive isolation during hydro test of the HRSG HP/LP circuit. All drains and vent pipes shall be so routed and terminated that it meets the Employers approval. All drain lines and vents shall be provided with two valves in series. Drain and vent lines shall be of minimum 50 mm size.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 11 of 19

2.08.05

2.08.06

2.09.00 2.09.01

2.09.02

2.09.03

2.09.04

2.09.05

2.09.06

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.09.07

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Drain from steam drums, heaters, gauge glasses and integral piping of HRSG shall be terminated into one or more drain collection headers which shall be connected to the blow down tank. For HRSG water circulation pumps (if applicable), all instruments, warm up drains and other connections on the circulating system shall have two isolating valves in series on both suction and discharge of HRSG circulation pump. Suitable connection for acid washing the HRSG shall be provided. All startup vent lines shall be provided with one motorised isolating valves and one motorised regulating valve of low noise, erosion resistant type. Air release valves and drain valves wherever necessary shall be provided. All drain valves shall be capable of draining the pressure parts within one hour. Independent sampling points with necessary probes, impulse pipping, valves, fittings and accessories, terminated at the sampling table shall be provided. The sampling probes shall be provided as per relevant section of the latest ASME Power Test Code. For laboratory samples necessary sample coolers with valves and cooling water piping shall be provided. Impulse pipes and root valves shall be of stainless steel. Flow nozzle/orifice plate assemblies complete with branch pipes and all other accessories shall be furnished for the flow measurements/controls. CPH Recirculation Pumps (if applicable) 3x50% motor driven CPH recirculation pumps (if applicable) shall be provided for of each module. One or two pumps shall be in service while one pump shall be on auto standby. The pumps shall be sized for atleast 10% margin on the flow and 20% on the head when the unit is operating on maximum capability point. Each pump shall also be capable of sustaining the maximum unit load when the frequency drops to 47.5 Hz. Insulation, Outer Casing and Lagging The materials for thermal insulation of the equipment covered under HRSG, ducts and stack shall conform to the relevant Indian Standards unless otherwise specified. For insulation of piping, valves and fitting, contractors shall meet the requirements specified in chapter titled, 'Piping and Insulation' of this Volume. The insulation system offered i.e, internal or external, shall be the standard proven practice of the contractor. Design of insulation, lagging and outer casing shall be suitable for the exposure of an outdoor type HRSG design for tropical climatic conditions. All insulation must be adequately fastened in place so as to prevent shifting during service. Mechanical integrity shall not be affected by vibrations of the equipment on which it is applied.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 12 of 19

2.09.08

2.09.09 2.09.10

2.09.11

2.09.12

2.09.13

2.10.00 2.10.01

2.10.02

2.11.00 2.11.01

2.11.02

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.11.03

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) The thickness of the insulation shall be so chosen that the temperature of the cold cladding/casing surface does not exceed 60 deg. C with an ambient temperature of 45 deg. C, surface air velocity of 0.25m/sec, emissivity of aluminum cladding being 0.2 and thermal conductivity not less than the maximum value as per IS:8183. In case internal insulation is offered by the contractor, the total thickness of the insulation shall be of self stitched ceramic wool of density not less than 128 Kg/ m3. For external insulation the contractor shall provide first layer of ceramic wool of density minimum. 128 Kg/m3 and minimum thickness 40 mm and subsequent layers shall be of resin bonded rock wool of minimum. density 100 Kg/m3 followed by aluminium cladding of 18 (SWG) thick sheet. Insulation thickness calculation shall be done as per ASME code. Access to HRSG: Stairways, Platforms, etc. All parts of HRSG shall be accessible for inspection and suitable maintenance access doors shall be provided with sealing arrangement to ensure gas tightness. All such openings shall have suitable approach platforms and ladders extended from the nearest platform level. In critical location it shall be possible to inspect the unit in operation and pressurised inspection doors shall be provided for this purpose. Stairways and platforms shall afford easy and safe access to the following as a minimum : all access, inspection and test/cleaning ports components requiring regular inspection or maintenance equipment which under normal or emergency conditions is to be operated by hand. Aviation lighting on the top of HRSG main stack. safety valves floor shall have access by regular staircase. Gas monitoring and sampling ports on the main stack.

2.11.04

2.11.05 2.12.00 2.12.01

2.12.02

2.12.03

In the arrangement of stairways and platforms the contractor shall take into account all types of damage and malfunctions that to his knowledge and experience are possible in the HRSG and shall reduce danger to the operating personnel to the lowest possible level in particular by providing escape facilities. All platforms and main walkways shall have a minimum clear width of 1200mm. Access walkways for maintenance shall be not less than 1000 mm in clear width.

St ai r s shal l be not l ess t han 1000mm i n cl ear wi dt h. St ai r ways wi l l have a r am p angl e of 40 deg.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 13 of 19

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.12.04

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) The drum dished ends shall be provided with properly sized manholes and hinged manhole covers of forged steel secured by forged steel yokes and bolts. Materials of construction Materials used in piping, associated equipments and be equal to or better than the following: heat exchanger tubes shall

2.13.00 2.13.01

For design metal temperature upto and including 400 deg. C, carbon steel to ASTM A-106 Gr. B/C, SA 178 A or approved equivalent. For design metal temperature above 400 Deg. C but below 550 deg. C alloy steel to ASTM-A-335-P22/P11, T22/T11 or approved equivalent. For design metal temperature above 550 Deg. C, T91 (upto 590 deg.C) or approved stainless steel.

2.13.02 2.13.03

Only seamless tubes shall be used for the heat exchangers. The fins/tubes/headers/etc of the condensate preheater will be of suitable grade of corrosion resistant ferritic stainless steel. The maximum skin temperature to which the tubes will be subjected shall not exceed the oxidation limit as applicable to the material. Alloys containing Molybdenum only will not be accepted. Unless otherwise specified supporting steel design, materials, fabrications and erection shall conform to the latest version of IS:800 for use of structural steel or other approved equivalent codes. Soot Blowing System The location of steam source shall be decided by the contractor to suit his requirement. Necessary valves to reduce the steam pressure to the pressure required for blowers shall be provided. The entire soot blower piping system with valves, fittings and hangers shall be furnished. All the soot blowers shall be of approved make, type and proven design. Platforms/galleries shall be provided at and around all the soot blowers to facilitate maintenance. The soot blowers shall be accessible from location operating platforms. All soot blowers shall be suitable for local and remote automatic sequential operation. If the contractor does not foresee a requirement of steam soot blowers, provision shall be made for installation of steam soot blowers at a later date, after the unit is commissioned, without any commercial implication, if operating experience warrants the same. For this purpose the HRSG enclosure shall be provided with wall box openings for future installation of soot blowers. Approach platforms for future roof blowers to be provided. However, for all the condensate preheater banks soot blowers shall be provided.
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 14 of 19

2.13.04

2.13.05

2.14.00 2.14.01

2.14.02

2.14.03

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No. 2.15.00 2.15.01

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Water Washing System Provision shall be made for off load water washing of HRSG. To this effect wash water connections on every boiler platform, piping around the HRSG, suitable number of manholes to carry out cleaning activity, suitable provision inside the HRSG for locating and maneuvering wash water nozzles, suitable pumps, buffer tank, drainage scheme, etc. shall be provided. Provision for mixing of chemicals to washing water, will be provided.

2.15.02

The contractor shall indicate the performance parameters along with their values based on which the need for water washing could be established. The interval between two water washings shall be such that it matches with GT inspection so that no separate unit shut down is required for HRSG water washing alone. However, in no case this shall be less than 6000 hours of operation. Time required for cleaning the HRSG shall also match the GT inspection period. Blow Down System The blow down and drain system for each HRSG shall be provided with one blow down tank to which all blow downs and drains from HRSG shall be led. No separate tank for continuous blowdown is envisaged. The blow down vessel shall receive blowdowns and drains from the drum, drain header, attemperator header, etc. The blow down tanks shall be designed and fabricated as per the latest applicable requirements of IS:2825 or approved equivalent. All the inlet connections to the above tanks shall be tangential and wear plates shall be provided to take care of erosion. Stub connections, where required, shall be welded to the tank. Necessary pressure tapping with isolating valves, safety valves, if necessary, shall be provided on the tanks. The tanks shall be provided with local indicators. The blow down tanks shall be provided with local instruments like gauge glass, pressure and temperature indicators etc. Drain valves and drain piping system of the blow down tank shall be provided at the bottom of the vessel. Steam vent pipe from the tank shall be terminated at an elevation atleast 3 m higher than the highest operating platforms. All blow down, drain and air release point of HRSG shall have two valves in series one being an isolating valve and other a regulating valve. The blow down tank shall be sized for 5% maximum blow down from both HP, IP and LP drums (if applicable) and starting drains. It shall not discharge free water from the vent. The drain from the blowdown tank shall be cooled to 50 Deg C using water injection before being thrown into the drain channel. High Pressure Chemical Dosing System The complete high pressure chemical dosing system shall be separate for each
TECHNICAL SPECIFICATION SECTION-VI, PART-B VOLUME-I CHAPTER-M2 PAGE 15 of 19

2.16.00 2.16.01

2.16.02

2.16.03

2.16.04

2.16.05

2.16.06

2.17.00 2.17.01

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

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Clause No.

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) HRSG. The pumping system will be independent for each drum while the solution tanks will be common for the HRSG. This will comprise of one solution preparation tank, one metering tank, 2x100% dosing pumps with motors separate for each drum of HRSG, necessary suction filters, valves, relief valves, connecting pipes, discharge pressure gauges/switches, fittings and flushing lines for cleaning the complete system. Discharge from dosing pumps shall be routed to each drum of the HRSGs through permanent piping.

2.17.02

A solution of tri-sodium phosphate having a concentration of 2% shall be dosed in the drum. The solution preparation tank shall have capacity to hold about one days dosing requirements and shall be of stainless steel construction. The metering tank shall be identical in capacity to the preparation tank and shall be provided with necessary accessories and connections. The tank shall be provided with necessary hinged cover, mixer supports, removable dissolving basket, gauge glasses with isolating valves, vent, overflow and drain connection, inlet connections for admitting demineralised water or condensate, connections to the metering tank, motorised stainless steel stirrer, level switch for low level alarm, support legs with foundation bolts and breather valves. The flow to the metering tank from preparation tank shall be by gravity. The pumps shall be of horizontal positive displacement reciprocating and variable stroke type. The pumps shall be capable of varying the discharge over the entire range of operation. The pump stroke shall be capable of remote manual adjustment from 0% to 100%. The stroke adjustment and locking shall be possible while the pumps are in operation. Main Stack Discharge of hot waste gases from HRSG to be done at "H" meters from the grade level as stipulated in Volume-IV, Part-A, Section-IV of Technical Specification. For the above, bidder shall provide a steel self supporting stack of required height suitable to the type of HRSG offered. The stack shall be such as to accomodate the stack closure damper. The velocity of exhaust through stack shall not exceed 25m/second. The steel stack shall be completely insulated over the complete length of the stack and should be of self supporting type. The contractor shall also provide a stack closure damper suitably located at the inlet of the HRSG exhaust stack which may be closed during shutdown to retain heat in the HRSG. The damper shall have self opening feature to avoid pressure build up in HRSG casing beyond allowable limit, in case due to some reason damper fails to open before HRSG startup. Drain shall be provided so that rain water does not collect at the bottom of the HRSG exhaust stack in case of HRSG with horizontal layout. A hood to avoid rain water entry to the HRSG shall also be included for HRSG design where heat exchangers are located directly below HRSG stack. Provision for access to the various platforms on the stack and for taking gas samples shall be provided.

2.17.03

2.17.04

2.18.00 2.18.01

2.18.02

2.18.03

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

PAGE 16 of 19

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Clause No. 2.18.04

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Non-metallic expansion joint at HRSG outlet a) Reinforced fabric-type expansion joints suitable for the service conditions shall be provided. Fabric compensator shall be suitable for most adverse operating conditions of the ductwork. Expansion joints shall not support the ductwork. Complete installation of expansion joint shall be under supervision of the expansion joint manufacturer. The fabrics shall be tested as per suitable, IS/ASTM/DIN or other International standards. Composite fabrics shall be tested for 'temperature withstandability & permeability'. The corrosion resistant barrier shall be free from pinholes. Needle glass mats of 9mm thickness with mechanical bonding shall be used for temperature below 600 degree Celsius. The minimum trouble free operational life of expansion joint shall be not be less than 20000 hours of operation from the date of commissioning. Where ever bolsters are used, the design of the expansion joint should be such that is does not take into account the temperature drop in the bolster.

b) c)

d)

e)

f)

g)

2.19.00 2.19.01

Chemical Cleaning and Steam Blowing The HRSG heater and quirements 'Piping and circuit upto steam drum shall be chemically cleaned. Further the superassociated integral piping shall be cleaned by steam blowing. The reas brought out under the clause No. 8.00.00 and 9.00.00 of chapter Insulation' of this volume shall be complied with for these systems also.

2. 20. 00

Handling Facilities All components requiring regular maintenance/inspection, critical equipments/valves/ safety valves, etc. shall be provided with permanent handling facility for lowering equipment to the grade level. The handling facility shall also be suitable for movement of equipment required for carrying out maintenance. Provision for locating the chain pulley block above these equipments shall also be provided at each equipment location. Details in this regard will be finalised during the contract finalisation stage.

2.21.00

Boiler Fill Pumps 2x100% Boiler Fill Pumps complete with necessary piping, valves, fittings, etc. The fill up pumps will be used to fill the empty pressure parts of the HRSG. The sizing of the pumps will be done to fill the evaporator(s)/drum(s), Superheater(s), economiser(s) and CPH completely of one HRSG in two hours time. All required piping will also be supplied. The piping will be suitably lined to avoid corrosion from DM water.

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

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Clause No. 2.22.00 2.22.01

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Codes and Standards HRSG shall completely meet or exceed all the regulations of the Indian Boiler Regulations (IBR). Any other standard acceptable to IBR can also be considered, provided the requirements of that standard are equivalent to or exceed the IBR requirements. Wherever specification stipulates requirements in addition to those specified in IBR, the same shall also be complied with by the contractors. In all such cases specific approval of the Central Boiler Board shall also be obtained by the contractor. In all other cases where IBR does not govern, German, American, British or other National Standards established to be equivalent or superior to the Codes and standards specified, are also acceptable. In the event of any conflict between the requirements of the equivalent codes and standards and the requirements of the Indian standards/Regulations, the latter shall govern, unless, specified otherwise in the specifications. It shall be the responsibility of the contractor to obtain the necessary approval of the concerned Inspection Authority, Chief Inspector of Boilers for the design and design calculations, manufacturing, erection procedure as called for under the Indian Boiler Regulations. The contractor shall be required to submit all the manufacturing drawings and particulars of materials, design and construction of the Boiler for approval to the Chief Inspector of Boiler of the state concerned before the commencement of the manufacture. All such documentation shall also be furnished to the Employer for his review. It shall also be the responsibility of the Contractor as required by the Employer for getting the HRSG registered under IBR. Design not meeting the above stipulations of the Codes and Standards will not be considered acceptable. Auxiliary Boiler In case the startup requirement of the module offered by the bidder requires availability of auxiliary steam, the bidder's proposal shall include provision of auxiliary boiler to supply such auxiliary steam at the desired parameters. In such case, bidders offer shall include one (1) no. Auxiliary boiler adequate capacity with a 5% margin on flow (total steam requirement for cold start up of steam turbines) with required steam parameters at Superheater outlet complete with piping, valves, fittings, draft plant, fuel firing system (RLNG/Natural gas/HSD), chemical dosing system, ducting, dampers, chimney, approach platforms, complete electrical, C&I and all associated structural and civil works. The scope shall also include one (1) no. of feed water storage tank for half hour storage capacity of auxiliary boiler. The auxiliary boiler should cater to steam requirement of all units of Stage-II. Interconnecting piping with isolating valves (motorized) etc. to feed auxiliary steam to each unit shall be provided. Bidder shall furnish the calculations in support of the auxiliary boiler sizing supplied by him.

2.22.02

2.22.03

2.22.04

2.23.00

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

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Clause No. 2.24.00

EXHAUST GAS SYSTEM, HRSG AND AUXILIARIES (M2) Painting The contractor's scope of work includes supply and painting of all equipments and structures of exhaust gas system and HRSG upto chimney inlet as per Employer's standard color coding scheme. The quality and finish of paints shall be as per standards of BIS or equivalent. a) The surfaces (with or without insulation) shall be painted with at least two coats of red oxide zinc phosphate primer as per IS:12744 and three coats of enamel paint with total DFT not less than 100 microns. Gas swept surfaces shall be applied with min two coats of red oxide zinc phosphate primer as per IS:12744 with min DFT of 50 microns. Heat resistant aluminium paint on high temperature surfaces on case to case basis with min. DFT of 40 microns.

b)

c)

KAWAS CCPP, STAGE - II BIDDING DOC NO. CS-2630-001-2

TECHNICAL SPECIFICATION SECTION-VI, PART-B

VOLUME-I CHAPTER-M2

PAGE 19 of 19

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