BROAD TECHNICAL SPECIFICATIONS

OF
BOILER TURBINE GENERATOR (BTG)
FOR
2X300 MW COAL BASED THERMAL POWER PROJECT
AT
BOTSWANA


1. INTENT OF SPECIFICATIONS:
This specifications in intended to cover supply and installation of 2X300 MW Boiler
island including ESP, Turbine Generator sets and respective auxiliaries associated
integral and power cycle piping . Scope shall include design, engineering,
manufacture, procurement, inspection and testing at manufacturers works,
packing and shipment and delivery at site.
In addition the bidders scope shall also include erection/installation including
loading & unloading , storage and handling at site, site testing, commissioning,
trial run, performance and guarantee tests and other services including supply co-
ordination, engineering and project management related to equipments/systems,
liquidation/attending to punch points.
Bidder shall be responsible for provising all material, equipment and services,
required to complete the scope and fulfill the intent of ensuring efficiency,
operatibility, maintainability and reliability of the complete work.
2. DESCRIPTION OF SITE:
Site Mmamabula, Botswana
Nearest Town Gaborone (180 km)
Mahalapye (70 km)
Francistown (250 km)
Nearest Railway
Station
Mookane (25 km)
Mahalapye (70 km)
Nearest Airport Gaborone (180 km)
Nearest Seaport Botswana doesnt have a seaport
Walvis Bay (Namibia) 1600 km
Maputo (Mozambique) 1100 km
National Highway A1 connecting Gaborone to Francistown passing through
Mahalapye
Site is off 23 km from A1 at the Tropic of Capricorn line

3. CODES AND STANDARDS

3.1. Except where otherwise specified, all items under Contractor's scope shall
comply with the appropriate Indian codes & standards or agreed
internationally accepted codes & standards as listed below, each
incorporating the latest revisions at the time of Contract.

3.2. Where the Contractor proposes alternative codes or standards he shall
include in his bid one copy (in English) of each Standard to which materials
offered shall comply. In such case, the adopted alternative standard shall be
equivalent or superior to the standards mentioned in the specification.

3.3. The Plant shall conform to various statutory regulations prevailing in
Botswana such as Boiler Regulations, Electricity Rules, Explosives Act,
Factories Act, Environment (Protection) Act etc. Wherever required,
approval from statutory authorities for the Plant supplied under the
specification shall be the responsibility of the Contractor.

3.4. In the event of any conflict between the codes and standards referred
above, and the requirements of this specification, the requirements that are
in this specification shall govern.

3.5. In case of any change of code, standards and regulations between the date
of award of Contract and the date the Contractor proceeds with
manufacturing, the Owner shall have the option to incorporate the changed
requirements. It shall be the responsibility of the Contractor to advise Owner
of the resulting effect.

3.6. List of Codes & Standards for Reference :

a) Boiler Regulations Codes & standards prevailing in Botswana (IBR).
b) Electricity, Explosives, factories Rules prevailing in Botswana.
c) Pollution Control regulations of Botswana.
d) Any other statutory Codes/ Standards/ Regulations prevailing in
Botswana.
e) Environment (Protection) Act, USA.
f) International Standards Organization (ISO).
g) International Electro-technical Commission (IEC).
h) American Society of Mechanical Engineers (ASME).
i) American National Standards Institute (ANSI).
j) American Society for Testing and Materials (ASTM).
k) American Institute of Steel Construction (AISC).
l) American Welding Society (AWS).
m) National Fire Protection Association (NFPA), USA.
n) National Electrical Manufacturer's Association (NEMA), USA.
o) Japanese Electro-technical Committee (JEC).
p) Institute of Electrical and Electronics Engineers (IEEE), USA.
q) Federal Occupational Safety and Health Regulations (OSHA), USA.
r) Instrument Society of America (ISA).
s) National Electric Code (NEC), USA.
t) Heat Exchanger Institute (HEI ), USA.
u) Tubular Exchanger Manufacturer's Association (TEMA), USA.
v) Hydraulic Institute Standards (HIS), USA.
w) International Electro-Technical Commission Publications.
x) Power Test Code for Steam Turbines (PTC), USA.
y) Applicable German Standards (DIN).
z) Applicable British Standards (BS).
aa) Applicable Russian Standards (GOST)
bb) Electric Power Research Institute (EPRI), USA.
cc) Standards of Manufacturer's Standardization Society (MSS), USA.
dd) American Petroleum Institute (API).
ee) ICAO.

4. SCOPE OF WORK:
Scope covers design, engineering, manufacturing, procurement, inspection &
testing at manufacturers works, supply, insurance, receipt at site, storage and
preservation at site, intra site transportation, construction, erection, trial run,
commissioning, performance guarantee testing, handing over to owner, along with
commissioning & recommended spares for two years operation, catalogues,
drawings, documents and services including lubricants, transformer oil,
consumables for the proposed 2X300 MW Thermal power plant.
Division of work shall be as per attached Annexure A.
Terminal points shall be as per attached Annexure B
Analysis of Coal to be utilized is as per attached Annexure - C
5. BRIEF TECHNICAL REQUIREMENTS:
STEAM GENERATOR & AUXILIARIES
Two nos steam generator of 300 MW capacity with an indicative boiler outlet
pressure 175 Kg/cmsteam temperature of SH and RH 540/540 Deg C to match
turbine inlet steam parameters including all related auxiliary equipments, control
& instrumentation. Steam generator shall be sub-critical type, natural circulation,
double pass/ tower type, single radiant furnace, dry bottom, balanced draft,
pulverized coal fired with all auxiliaries, corner fire, ESP, integral piping,
elevators, coal bunkers and structures, SCAPH,etc.
Boiler maximum continuous rating (BMCR) shall correspond to at least 103% of
steam flow at turbine inlet under VWO condition plus continuous steam
requirement of auxiliary steam systems of the unit.
Design criteria:
a) Excess air at economizer outlet at TMCR load: 20% (minimum)
b) Flue gas temperature at air-heater outlet at TMCR load: 125 Deg C
c) Loss due to unburnt carbon in ash at all loads: 3%
Following minimum values of anticipated parameters with respect to ESPs shall be
considered in steam generator design:
i) Air infiltration in ESP: 1% of ESP inlet gas flow
ii) Pressure drop in ESP: 20mm WC
iii) Temperature drop in ESP: 2 Deg C
The design of steam generator shall be such that it does not call for any oil
support for flame stabilization beyond 40% BMCR load.
Steam generator shall be designed for continuous operation with all HP heaters out
of operation. Under above condition the super heater and reheater outlet steam
temperature shall be maintained at rated values within the whole control range of
steam generator load.
When unit trips on full load, HP-LP bypass system will come into operation.
Design life of the steam generator sets shall be 30 years minimum. However unit
shall also be capable of operation for two shifting cycle. The design duty for 30
years shall be as follows (as per IEC 45-1):
Very hot: 300
Hot start: 6000
Warm start: 1000
Cold start: 300
Design conditions:
Main steam line pressure drop, maximum: 7 to 8 bar
Super heater pressure drop, maximum: 15 bar
Pressure drop across economizer: 4 bar
Pressure drop through steam generator from economizer inlet to superheter
outlet: 20 bar
Reheater pressure drop maximum: 2 bar
Fans including drives and controls
Induced draft system including two nos ID fans, combustion air system including
two nos. FD fans and two nos PA fans with 2 X 60 % capacity.
Air preheaters
Rotary regenerative trisector type.
Soot Blower system
Wall Blower, LRSB and associated complete system required for soot blowing
system
Coal feeding Equipment sizing: Steam generator shall be furnished with
pulverized and raw coal feeder to attain BMCR of steam generator. The pulverizes
shall be of sufficient capacity to attain BMCR when firing specified range of coal
and one pulverizer and feeder out of service.(N+1+1 mills).
Coal feeding system
Crushed coal from the crusher will be fed to raw coal bunkers/silos. The capacity
of series of bunkers/silos per unit would be to provide 12 hrs requirements at
maximum mill capacity of the unit.
Power cycle piping: piping with hangers & supports.
Ducting, damper and expansion joints:
Thermal insulation: All equipments/pipes/ ducts whose surface temperature is
higher than 60 Deg C shall be provided with thermal insulation along with
aluminum cladding for personnel protection and heat conservation.
PG test: as per ASME PTC-4
Electro Static Precipitators:
For collection of dust (fly ash), adequately sized outdoor type ESP and fabric bag
filter shall be installed on the cold end side of regenerative air preheater for each
unit. The flue gas shall be drawn from air pre heater outlet and guided through
adequately sized duct work.
The basic idea of the ESP+FF hybrid filter is to remove the large amount of dust
(80-90%) by the ESP first to reduce the dust concentration of flue gas, then collect
the residual particulate dust ( 10-20%) from the flue gas by the filter and ensure
dust emission standard.
The ESP+Filter will remove particulate from flue gas of the steam generators to
achieve guaranteed outlet emission of less than 50 mg/Nm.
Scope of supply for ESP shall include but not limited to followings:
a) Casing and hoppers with required accessories such as heaters, vibrators, level
detectors, and their controls.
b) Structural steel and access stairs, platforms and ladders.
c) Gas distribution system
d) Collecting electrodes
e) Discharge electrodes
f) Rapping system with microprocessor based control system
g) Dust hoppers
h) Casing
i) Opacity monitors
STEAM TURBINE AND AUXILIARY:
a) Steam turbine shall be reaction type comprised of tandem compound, single
reheat, regenerative, condensing type, single/ multi cylinder type, with
separate HP, separate IP and separate LP casing OR combined HP-IP as per
standard design of manufacturer directly coupled with generator suitable for
indoor installation.
Turbine capability/systems
a) Net power output at generator terminals at TMCR: 300 MW each
b) VWO rating: 105 % of TMCR
c) Limitation of variation from rated steam pressure/temp: as per IEC-45
d) Number of extractions: 6 or more
e) Make up : 0%
f) Speed: 3000 RPM
g) operating frequency range: 47.5Hz to 51.5 Hz
h) type of governing: Throttle
i) type of governor: electronic
j) turbine oil pumps: MOP (1X100% shaft driven), AOP(2X100% one AC+ one
DC), EOP(1X100%DC),JOP(2X100% -one AC+ one DC)
k) control oil pumps: 2X100% AC
l) oil purification equipment/ oil tank
m) turning gear: with hand barring facility
n) bearing cap vibration: ISO-10816
o) shaft vibration: ISO-7919
p) HP/LP Bypass system
q) Integral piping with hangers & supports
r) Drains & valves
s) Noise level: 85 dBA at 1.5 Mtr from outline of Equipment
t) Feed water HP /LP heaters/Dearator for 10 minutes capacity
u) Power cycle pumps ( MDBFP,TDBFP, CEP)
v) Butter fly valves
w) Air extraction system Vacuum pumps ( 3x50%)
x) RE Joints
y) Condenser: Air cooled
z) emergency stop and control valves, reheat stop and control valve
aa) Turbine automation system (ATRS)
bb) Turbine supervisory system
TURBOGENERATOR
300 MW Three phase, horizontal mounted, indoor installed, hydrogen cooled, two
pole, class F winding insulation with temperature rise limited to class B.
For design opf equipment/systems, ambient temp of 50 Deg C and relative humidity
of 95% shall be considered.
Equipment shall be suitable for rated frequency of 50 Hz with a variation of +3% & -
5%, terminal voltage of +/- 10% and 5% combined variation of voltage & frequency.
All the equipments shall confirm to latest edition of relevant International codes and
standards. Generator shall conform to IEC-34.
Rated parameters:
Power factor: 0.85(lag) to 0.95(lead)
Terminal voltage: 20 to 22KV
Frequency: 50 Hz
Speed: 3000 RPM
Short circuit ratio: not less than 0.5 (without negative tolerance)
System of cooling:
Stator winding: Hydrogen cooled
Rotor winding; directly hydrogen cooled
Systems: gas system/ seal oil system/stator water cooling system (if
applicable)/excitation System (brushless/static)