ABB Switzerland Ltd.

Business Unit Minerals

Thai Nguyen
Issued by department Date Lang. Revision Page

Heat Recovery Unit 2010-10-19 d A 1 (23)

Division of Supply

Project: Heat Recovery Unit DG Khan ABB ORC Power

Plant for Thai Nguyen Cement Plant

between: ABB Schweiz AG and Thai Nguien

Segelhofstrasse 9P Vietnam
CH-4505 Daden-Dättwil

Revision
Rev. Who Function / Company Date Dep./Init.
1 Hagen Head of sales 19.10.2010/HH

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Content

1 PROCESS EQUIPMENT.............................................................................................................3

2 ELECTRICAL EQUIPMENT.....................................................................................................5

3 ENGINEERING & PROJECT MANAGEMENT....................................................................5

4 TRANSPORTATION...................................................................................................................5

5 SERVICES ON SITE....................................................................................................................6

6 GENERAL OBLIGATIONS OF THE CUSTOMER / LOCAL SUPPLY.............................8

7 APPENDIX..................................................................................................................................10

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No.:

Engineering and/or Planning

Responsible Party for detail
Description Remarks

eng, supply,, quality and

Item
Customer / Others =
LOCAL = On Shore

claims, etc.

Material
ABB = Off Shore

1 Process Equipment
No.: HEAT SOURCE R M E Remarks
HEAT EXCHANGER PREHEATER
1 ABB ABB ABB
(PH) & CLINKER COOLER (CC)
1.1 Heat Exchanger ABB ABB ABB
1.2 Adaptor / Connection to HEX LOCAL LOCAL ABB Refer to Appendix 7
2 HEAT EXCHANGER CC BYPASS ABB ABB ABB
2.1 Piping LOCAL LOCAL ABB Refer to Appendix 7
3 HEAT EXCHANGER ABB ABB ABB
3.1 Adaptor / Connection to HEX LOCAL LOCAL ABB Refer to Appendix 7
4 HEAT EXCHANGER PH BYPASS LOCAL LOCAL ABB Refer to
4.1 Piping LOCAL LOCAL ABB Refer to Appendix
PRESSURE COMPENSATION
5 ABB ABB ABB
VENTILATOR
6 SEWER PORT ABB ABB ABB
7 SCREW CONVEYOR LOCAL LOCAL ABB Refer to Appendix 7
7.1 Conveyor Screw LOCAL LOCAL ABB Refer to Appendix 7
7.2 Motor LOCAL LOCAL ABB Refer to Appendix 7
7.3 Compensator LOCAL LOCAL ABB Refer to Appendix 7
8 DUCTING LOCAL LOCAL ABB Refer to Appendix 7
8.1 Extraction LOCAL LOCAL ABB Refer to Appendix 7
8.2 Feedback LOCAL LOCAL ABB Refer to Appendix 7
8.3 Bypass LOCAL LOCAL ABB Refer to Appendix 7
8.4 Engineering LOCAL LOCAL ABB Refer to Appendix 7
9 COMPENSATORS LOCAL LOCAL ABB Refer to Appendix 7
9.1 Heat Exchanger Bypass LOCAL LOCAL ABB Refer to Appendix 7
10 DAMPERS ABB ABB ABB
No.: WATER CIRCUIT R M E Remarks
11 WATER CIRCUIT PUMP ABB ABB ABB
12 EXPANSION TANK LOCAL LOCAL ABB Refer to Appendix 7
12.1 Surge Tank LOCAL LOCAL ABB Refer to Appendix 7
12.2 Heating LOCAL LOCAL ABB Refer to Appendix 7
13 PIPING LOCAL LOCAL ABB Refer to Appendix 7
13.1 Straight Pipes LOCAL LOCAL ABB Refer to Appendix 7
13.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
13.3 Compensator LOCAL LOCAL ABB Refer to Appendix 7
13.4 Fittings LOCAL LOCAL ABB Refer to Appendix 7
13.5 Vent/Drain LOCAL LOCAL ABB Refer to Appendix 7

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No.: FLUID CIRCUIT R M E Remarks

14 FLUID CIRCUIT PUMP ABB ABB ABB
15 HEAT EXCHANGERS PROCESS ABB ABB ABB
16 POWER TRAIN ABB ABB ABB
17 CONDENSER ABB ABB ABB
18 PIPING LOCAL LOCAL ABB Refer to Appendix 7
18.1 Straight Pipes LOCAL LOCAL ABB Refer to Appendix 7
18.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
18.3 Compensators LOCAL LOCAL ABB Refer to Appendix 7
18.4 Fittings LOCAL LOCAL ABB Refer to Appendix 7
18.5 Vent/Drain LOCAL LOCAL ABB Refer to Appendix 7
No.: SUPPORTING CIRCUITS R M E Remarks
19 LEACKAGE GAS RECOVERY ABB ABB ABB
21 COMPRESSED AIR LOCAL LOCAL ABB Refer to Appendix 7
21.1 Compressor LOCAL LOCAL ABB Refer to Appendix 7
21.2 Dehumidifier LOCAL LOCAL ABB Refer to Appendix 7
21.3 Air vessel LOCAL LOCAL ABB Refer to Appendix 7
21.4 Piping LOCAL LOCAL ABB Refer to Appendix 7
21.5 Fitting LOCAL LOCAL ABB Refer to Appendix 7
22 NITROGEN LOCAL LOCAL ABB Refer to Appendix 7
22.1 Bottle set LOCAL LOCAL ABB Refer to Appendix 7
22.2 Piping LOCAL LOCAL ABB Refer to Appendix 7
22.3 Fitting LOCAL LOCAL ABB Refer to Appendix 7
23 OPERATING FLUIDS LOCAL LOCAL ABB Refer to Appendix 7
23.1 Water fully desalinated LOCAL LOCAL ABB Amount spec. pending.
23.2 Organic Fluid LOCAL LOCAL ABB Refer to Appendix 7
23.3 Nitrogen LOCAL LOCAL ABB Refer to Appendix 7
23.4 Lubrication Oil LOCAL LOCAL ABB Refer to Appendix 7
No.: ISOLATION R M E Remarks
24 WASTE GAS CIRCUIT LOCAL LOCAL ABB Refer to Appendix 7
24.1 Heat Exchanger PH LOCAL LOCAL ABB Refer to Appendix 7
24.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
24.3 Heat Exchanger CC LOCAL LOCAL ABB Refer to Appendix 7
24.4 Piping LOCAL LOCAL ABB Refer to Appendix 7
25 ORC POWER PLANT LOCAL LOCAL ABB Refer to Appendix
25.1 Expansion Tank LOCAL LOCAL ABB Refer to Appendix
25.2 Heat Exchangers Process LOCAL LOCAL ABB Refer to Appendix
25.3 Piping LOCAL LOCAL ABB Refer to Appendix
No.: STEELWORKS R M E Remarks
26 WASTE GAS CIRCUIT LOCAL LOCAL ABB Refer to Appendix 7
26.1 Fundament gussets/strengthening LOCAL LOCAL ABB Refer to Appendix 7
Water Treatment-Tower
26.2 LOCAL LOCAL ABB Refer to Appendix 7
gussets/strengthening
26.3 Heat Exchanger PH Sub Frame LOCAL LOCAL ABB Refer to Appendix 7
26.4 Heat Exchanger CC Sub Frame LOCAL LOCAL ABB Refer to Appendix 7
26.5 Heat Exchanger PH Platform LOCAL LOCAL ABB Refer to Appendix 7
26.6 Heat Exchanger CC Platform LOCAL LOCAL ABB Refer to Appendix 7
26.5 Piping LOCAL LOCAL ABB Refer to Appendix 7
27 ORC POWER PLANT LOCAL LOCAL ABB Refer to Appendix 7
27.1 Module LOCAL LOCAL ABB Refer to Appendix 7
27.2 Condenser LOCAL LOCAL ABB Refer to Appendix 7

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27.3 Piping LOCAL LOCAL ABB Refer to Appendix 7

27.4 Base Structure for E-Container LOCAL LOCAL ABB Refer to Appendix 7

2 Electrical Equipment
No.: CONTAINER & EQUIPMENT R M E Remarks
29 E-CONTAINER ABB ABB ABB Refer to Appendix 7
30 CONTROLLER ABB ABB ABB
40 POWER DISTRIBUTION ABB ABB ABB Refer to Appendix 7
50 CABLES LOCAL LOCAL ABB
60 MOTORS ABB ABB ABB
70 VARIABLE SPEED DRIVES ABB ABB ABB
No.: MEASUREMENTS R M E Remarks
80 HEAT SOURCES ABB ABB ABB
90 WATER CIRCUIT ABB ABB ABB
100 FLUID CIRCUIT ABB ABB ABB

3 Engineering & Project Management

102 PROJECT MANAGEMENT R M E Remarks
102.1 Overall project management ABB ABB
102.2 Training Overseas ABB ABB
103 ENGINEERING R M E Remarks
103.1 Customer process plant analysis ABB ABB
103.2 Customer’s electrical architecture ABB ABB
103.3 Lead eng. for technical Coordination ABB ABB
103.4 Basic Engineering (Guidelines) ABB ABB
Civil Engineering and Adjustment to
103.5 LOCAL LOCAL
existing plant
103.6 Detail Plant Engineering ABB ABB
104 DOCUMENTATION R M E Remarks
104.1 Specifications ABB ABB ABB
Of ABB Scope &
104.2 As built drawings ABB ABB ABB
Responsibilities
104.3 Instruction Manuals ABB ABB ABB
104.4 Service Manual and Instructions ABB ABB ABB
104.5 Training Material ABB ABB ABB
105 APPROVALS R M E Remarks
105.1 Construction authorities LOCAL LOCAL LOCAL
105.2 Environmental authorities LOCAL LOCAL LOCAL
105.3 Safety Conformity LOCAL LOCAL LOCAL
Delivery by ABB to
105.4 Shipping and custom paperwork LOCAL LOCAL LOCAL Seaport EU (ref. 4.
Transportation)

4 Transportation
No.: SHIPPING & HANDLING Remarks
All material within the scope of ABB
106 will be delivered FOB to European ABB ABB ABB
Seaport according Incoterms 2000
All material within the scope of
107 Customer will be available at plant LOCAL LOCAL LOCAL
site according contractual schedule

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5 Services on Site
No.:

Responsible Party for

No.: CIVIL WORKS
Description R M E Remarks
Remarks

detail work, quality

Item

and claims, etc.

120 ABANDONMENT LOCAL LOCAL ABB Specification
Customer / Others =

Supervision
pending…

Material
LOCAL = On Shore
120.1 Steelwork LOCAL LOCAL ABB Refer to Appendix 7
120.2 Tower LOCAL LOCAL ABB ABB
Specification
= Supervision
pending…
130 CONSTRUCTION (Civil& LOCAL LOCAL LOCAL Refer to Appendix 7
Steelwork)
130.1 Building Gussets/Strengthening LOCAL LOCAL LOCAL Specification
pending…
Specification
130.2 Tower Gussets/Strengthening LOCAL LOCAL LOCAL
pending…
Specification
130.3 Ground Plate / Fundation LOCAL LOCAL LOCAL
pending…
INSTALLATION &
No.: R M E Remarks
COMMISSIONNING
140 SITE PREPARATIONS LOCAL LOCAL LOCAL Refer to Appendix 7
Supplied, installed and
140.1 Office Container LOCAL LOCAL LOCAL
operated by LOCAL
Supplied, installed and
140.2 Material Storage LOCAL LOCAL LOCAL
operated by LOCAL
Supplied, installed and
140.3 Fixed Crane LOCAL LOCAL LOCAL
operated by LOCAL
Supplied, installed and
140.4 Mobile Crane LOCAL LOCAL LOCAL
operated by LOCAL
Supplied, installed and
140.5 Installation Platforms LOCAL LOCAL LOCAL
operated by LOCAL
Supplied, and
140.6 Forklift LOCAL LOCAL LOCAL
operated by LOCAL
Refer to Appendix
INSTALLATION OF WASTE GAS
150 LOCAL LOCAL ABB Error: Reference
CIRCUIT
source not found
150.1 Heat Exchanger PH LOCAL LOCAL ABB Supervised by ABB
150.2 Heat Exchanger CC LOCAL LOCAL ABB Supervised by ABB
150.3 Ventilator LOCAL LOCAL ABB Supervised by ABB
150.4 Sewer Port LOCAL LOCAL ABB Supervised by ABB
150.5 Screw Conveyor LOCAL LOCAL ABB Supervised by ABB
150.6 Piping LOCAL LOCAL ABB Supervised by ABB
150.7 Steelwork LOCAL LOCAL ABB Supervised by ABB
Refer to Appendix
INSTALLATION OF ORC POWER
160 LOCAL LOCAL ABB Error: Reference
PLANT
source not found
160.1 Fluid Circuit Pump LOCAL LOCAL ABB Supervised by ABB
160.2 Extension Tank LOCAL LOCAL ABB Supervised by ABB
160.3 Process Heat Exchangers LOCAL LOCAL ABB Supervised by ABB
160.4 Power Train ABB ABB ABB
160.5 Condenser LOCAL LOCAL ABB Supervised by ABB
160.6 Piping LOCAL LOCAL ABB Supervised by ABB
160.7 Steelwork LOCAL LOCAL ABB Supervised by ABB
160.8 E-Container LOCAL LOCAL ABB Supervised by ABB
170 CABLING & WIRING LOCAL LOCAL ABB Supervised by ABB

180 COMMISSIONNING ABB ABB ABB

180.1 Preparations ABB ABB ABB

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180.2 Signal Testing ABB ABB ABB

180.3 Cold Start-up ABB ABB ABB
180.4 Warm Start-up ABB ABB ABB
180.5 Basic Test Run ABB ABB ABB
180.6 Load Test Run ABB ABB ABB

No.: HANDOVER & AFTERSALES R M E Remarks

190 HANDOVER ABB ABB ABB
190.1 Documentation ABB ABB ABB
190.2 Training (on-/ off site) ABB ABB ABB
200 AFTERSALES SERVICES ABB ABB ABB
According separate contract to be
200.1 ABB ABB ABB
agreed upon

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6 General Obligations of the Customer / Local Supply

1. The Customer shall ensure that the necessary entry and exit, residence and work
permits and all other permits for the Supplier's personnel and the permits for the
import and export of tools, equipment, measuring and testing equipment and
materials are granted in good time and remain valid.
2. The Customer shall carry out all construction and other preparatory work
professionally and, if applicable, in accordance with any documentation supplied by
the Supplier. The Customer shall undertake all that is necessary in order that
Services can be commenced on time and carried out without hindrance or
interruption.
3. The Customer shall ensure that the transport access routes to the installation site
are usable, that access to the installation site is guaranteed, all necessary rights of
way are secured and that the installation site itself is in a condition allowing
installation work to commence.
4. The Customer shall take all accident prevention measures required. If the Customer
fails to take such measures and if the safety of personnel is not guaranteed, the
Supplier may at any time refuse or stop the provision of Services and order the
return of its personnel. The Supplier may also refuse or stop the provision of
services or order its personnel to return if the safety or health of personnel is not
guaranteed for any other reasons. The Customer shall provide any necessary
assistance should any of the Supplier's personnel suffer an accident or become ill.
5. The Customer shall arrange for the provision of heated or air-conditioned, lockable,
working, living and changing rooms for the Supplier's personnel, including suitable
sanitary facilities throughout the period of provision of the Services. In addition, the
Customer shall provide lockable, dry rooms for the storage of tools, equipment and
material. All these rooms shall be located, if possible, in the immediate vicinity of the
installation site.
6. The materials and spare parts to be used for the Services shall be stored in
accordance with the Supplier's instructions in such a manner that they are protected
from any damaging influences. Before the provision of the Services commences,
the materials and spare parts shall be checked by the Customer for completeness
and damage in the presence of a Supplier's representative. Should any material or
spare parts be lost or damaged, they shall be re-supplied or repaired by the
Customer or, upon the Customer’s request, by the Supplier, at the Customer's
expense.
7. The Customer shall provide the following in accordance with the Supplier's ins-
tructions:
 Qualified skilled and unskilled workers with the necessary tools and
equipment. These workers shall comply with the working instructions of the
Supplier personnel. In no event shall any employment or other legal
relationship to the Supplier be established by the giving of such instructions;
 Cranes (must be capable to lift high loads (∼ 40t) and other lifting devices, in
good working order, with attendant personnel, appropriate scaffolding and
means of transport for personnel and materials, appropriate workshop
equipment and measuring equipment;

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 All necessary consumable and installation materials (incl. energy for

installation) , cleaning materials, lubricants and miscellaneous sundry items;
 Electricity and lighting (including the necessary connections to the
installation site), heating, compressed air, water, steam and fuel;
 Sufficient means of communication, at least telephone and fax connections
and a PC modem;
8. The tools made available to the Supplier by the Customer shall be returned to the
Customer after completion of the services. Unless instructions to the contrary are
given, these tools shall be kept available on the installation site, at the Customer’s
risk.
9. The Customer shall use the future operating personnel to assist during the
installation of the Plant so that they become familiar with the Plant.
10. The Customer is liable for losses and damages caused by its personnel irrespective
of whether the Supplier's personnel manage and supervise the works unless the
losses and damages can be proved to have been caused through grossly negligent
instructions or supervision by the Supplier personnel.
11. The Customer is liable for losses and damages caused by material, spare parts,
tools and equipment provided by the Customer irrespective of the fact that the
Supplier's personnel may have used them without complaint.
12. The Customer shall fulfill its obligations in time and correctly and without cost to the
Supplier. If the Customer does not fulfill its obligations, in whole or in part, the
Supplier may, in particular, fulfill such obligations itself at the Customer’s risk or
have them fulfilled by a third party. The costs shall be borne by the Customer in any
event. The Customer shall release the Supplier from any liability for claims of third
parties and indemnify the Supplier for any loss suffered there from.

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7 Appendix
a. WASTE GAS
Integration of Heat Exchanger PH
After the preheater, the waste gas is currently led to the GCT.
For the installation of the ABB ORC power plant the waste gas has to be taken out.
For that purpose a take out is installed in the downcomer, which leads the waste gas
to the heat exchanger (HEX). There the gas is cooled to the temperature, which is
required by the raw mill. After cooling, the gas is led into the duct after GCT (inlet of
fan) and then to the raw mill.
The yellow ducts and blue dampers (flaps) in the sketch (see attachment) are to be
built for the ORC plant.
The diameter of the new ducts is identical to the existing ducts. The isolation
(thickness, material, installation) is the same as with the existing ducts.
For more details and typical drawing, refer to Document Annex T5 GA Drawings
enclosed
• Pre heater HEX Inlet and Outlet Ducts

Heat Exchanger Clinker Cooler

The clinker cooler air is taken after the cooler and led into a dust precipitator (cyclone)
and then to the heat exchanger.
For more details and typical drawing, refer to Document Annex T5 GA Drawings
enclosed
• AQC Boiler Inlet and Outlet Ducts
Screw Conveyor
Screw conveyor or band-conveyor for the backfeed of the segregated raw meal and
clinker shall be done by the screw conveyors. (Amount of raw meal & clinker
segregated not yet determined)

Compensator
Compensators for the compensation of thermal expansion of piping material must be
introduced after PH in accordance to local standards and requirements.
→ Specification pending – will be delivered at a later stage.

b. WATER CIRCUIT
Expansion Tank
design prone -
medium water -
max. operating temperature water 130 °C
max. operating pressure 25 barg

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density of water 959.9 kg/m3

volume 3000 l
temperature range -5/130 °C
pressure range 1/25 barg

Piping
The pipes are designed for a nominal operating pressure of 25 barg.
Diameter 250 mm
Approximate total length 250 m
→ Detailed specification of piping pending – will be delivered at a later stage.
Rough estimate Tubes between the HEX and ORC Plant
The estimation of distance and bends as well as supports has to be made
at actual plant situation!

c. FLUID CIRCUIT
Piping

Diameter* 150 mm
Approximate total length 41 m

Diameter 250 mm
Approximate total length 60 m

Diameter 350 mm
Approximate total length 31 m

Diameter 450 mm
Approximate total length 12 m

Diameter 500 mm
Approximate total length 23 m

Diameter* 1000 mm
Approximate total length 44 m

The pies marked with * are to be designed for a nominal operating pressure of 16
barg, all other pipes for 40 barg.
→ Detailed specification of piping pending – will be delivered at a later stage.

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d. SUPPORTING CIRCUITS
Compressed Air
Support of compressed air from the local system including all fittings, mountings,
pipings valves and accessories.
volumetric flow 0.3 l/min
operating pressure 6 barg
compressed air reservoir 350 l
pressure condensation point at -25 °C
volume flow 0.3 l/min
max. pressure 11 barg

Rough estimate Tubes within the ORC Power Plant

Tubes nominal specs

Temperature during operation: max 185 °C
flanges technically tight, i.e. flanges with tongue and groove

diameter pressure length 90° bows

mm bar m #
600 8 24 6
350 40 10 2
250 40 14 6
250 8 24 3
200 8 30 10
80 8 15 10

Material Specs.
Insulation Specs

Nitrogen
Support of nitrogen for the operation of the ORC Power Plant from a bottle set
including all fittings, mountings, pipings valves and accessories.

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Operating Fluids
Acquisition, ordering/purchasing and handling of the organic operation fluid
(Isobutane).
Acquisition, ordering/purchasing and handling of the lubrication fluids.
→ Specification of fluid and lubrication pending – will be delivered at a later stage.

e. ISOLATION
Waste Gas Circuit
The dimensions to connect the new ducts with the existing ducts and piping,
shall be in principle, the same material and dimensions as already used and
accepted at the existing process installation. In addition, the material has to be
not flameable, stable up to 320°C. Stone wool or equal, Thickness of insulation
approx. 15 cm. Density approx. 30 kg/m3. Thermal conductivity 0.04 W/mK.
Protection Alumina cover or equal.
For the execution, ABB will submit the detail specification.

cold - and condensation insulation

• In areas where condensation can
be expected, a condensation insulation has to be provided. Material PUR
(flexible polyurethane)
• If liquids may freeze or crystallize at ambient temperature the
necessary components have to be provided with a trace heating. The
media temperature must at all times at least 5 ° C above the
crystallization temperature.
• If gases or gas components can vapour or condense at the lowest
ambient temperature the system components have to be insulated to cool
down and if necessary to provide a trace heating. This is particularly
important to avoid corrosion.
• cold spots are avoided by appropriate design of the insulation.

Sound Emissions
If there are no plant / country specific emission values given, the design
of the system components consider at a distance of 1 meter a sound
pressure level of LPA max. 85 dB (A) (DIN 45641 & DIN 45645) .This
does not include units in separate installation spaces with sound-
absorbing surrounding walls or in sound-proof canopies.
Material
Mineral fiber insulation in particular the following requirements shall comply
with:
• Asbestos Free
• Non-flammable
• bulk density 80-180 kg/m3
• thermal conductivity λ of 0.04 W / (m K) at 100 ° C mean temperature

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• Structure, rot and vermin fixed

• Dimensionally stable at operating conditions and short-term moisture
• Must not have adverse impact on the material cause or the coating of the
system part
• binder must withstand the expected stresses during operations and may not
release toxic substances.
For a good quality of installation fibrous mineral or rock wool mats, with one
side quilted on wire mesh have to be used in thicknesses of 30 to 100 mm.
Wire mesh of galvanized steel wire with a mesh width of max. 20 mm and a
wire diameter of 0.7 mm. Alternatively, even aluminum alloy or stainless steel
wire are used (<400 ° C optional stainless steel with a minimum of 0.5 mm
diameter)
•Use of loose mineral wool is only permitted if the use of mats or fittings shall
be excluded for technical reasons.
The mats should have according to VDI 2055 its nominal thickness at a
surface load of 100 kg/m2.

Insulating layer thickness (s)

s <100 mm: one layer

100 mm <s <200 mm: two layers
> 200 mm: three or more layers

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f. STEELWORKS
Waste Gas Circuit
For preliminary specification refer to: “Integration of Heat Exchanger PH 7”

ORC Power Plant

A) Main base frame for the installation of the process technical equipment and
one part of the condenser array.

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Bill of Qty for Steel strucutres and Piping for Preheater and Clinker Cooler HEX
Connection

Please refer to Excel File enclosed

I:\01_Projects\
_Offers\HRU\291199 Thai Nguyen\COMMERCIAL\07 Proposal to Client\Revised quote Oktober 2010\Annex T3 - Bill of Quan

CONTAINER & ELECTRICAL EQUIPMENT

There is one E-Container according to the specifications in the picture below considered.
Not included, and therefore needed to be supplied by the Customer, is the base construction
of height 1500mm for the E-Containers.

Power Distribution
1 2 3 4 5 6 7 8

Electric Room 6kV

A A
... Auxiliaries Feeder

...
B B
We reserve all rights for this document and the information
contained therein. Reproduction, use or disclosure to third

E-Container
parties without express authority is strictly forbidden.

ABB
© ASEA BROWN BOVERI 1993

C
6 / 0.4kV C
2000kVA GCB
6kV
Customer

D D
Fuer dieses Dokument und den darin dargestellten Gegenstaend behalten
wir uns alle Rechte vor. Verfielfaeltigung, Bekanntgabe an den Dritte oder
Ververtung seines Inhalts sind ohne unsere ausdrueckliche Zustimmung

MCC
ACS800
Multidrive
400V
verboten. © ASEA BROWN BOVERI 1993

E E

M M M
G
PCoolers= 384 kW

F PAuxiliaryConsumers= 200kW PH Pump CC Pump Fluid P1 6kV F

91kW 14kW 461kW 4.8MVA

0 2010-09-27, ROHA Drawn 2010 -09-27, ROHA Dept.resp. Title =
Power System Integration Concept Alesd Rev .0.vsd
Change

Change

Checked NIL Project XY ATB Power System +

Sh.No. No.Sh .
Norm NIL Integration
Released NIL Dervd.from: Supersedes: Superseded by: Doc. Format A4 Lang. 1 1

Power Factor Compensation 1 2 3 4 5 6 7 8

The correction of the Power Factor (PF) is not included in the ABB scope

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g. ERECTION, ERECTION SUPERVISION & COMMISSIONING

General
ABB is ready to delegate qualified technical personnel for installation, supervision of
installation, start-up, commissioning and support of the customer’s performance tests
of the equipment as per the scope of supply.

Working Time
Normal working hours are 8 hours, 5 days per week.

Estimated Personnel and Duration

The supplier (ABB) will delegate qualified technical personnel for installation,
supervision of installation, start-up, commissioning and performance guarantee tests
of the ABB equipment.
The number of personnel needed in Man*Months (mm) has to be defined in
coordination with the Customer / Local Supplier.
Installation (Customer / Local Supply)
The installation work basically begins with Mobilization on site, unloading of the
equipment at the site and ends - with the exception of the remedial work on
installation deficiencies - with the Certificate of Taking Over issued by the End user
and De-Mobilization on site. It includes, however, disposal of existing equipment, the
dismantling and restoration work of the lay down area as well as the cleaning work
after completion of the erection.
The work includes all material (tools, cranes, etc.) and services that are necessary for
the due fulfilment of the complete installation, erection and handing over of the
project such as:

Site Preparation and temporary Facilities

Our offer is based on the assumption that the following services are provided free
issue for ABB by the customer or a third party.
Site preparation:
 Land and places suitable and sufficient for the installation of the temporary
facilities provided by Supplier and located at site;
 Site access road;
 Preparation of site, including levelling and compacting, sufficiently be advanced
and be suitable for commencement of the work.

The Customer or a third party will provide the temporary facilities necessary
for execution of the installation works, such as:
 Accommodation for delegated personnel;

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 All Security and Healt and Safety Services necessary according

international Standards to protect our delegates
 Furnished office;
 Access to the internet
 Local transportation for personnel;
 Canteen;
 First aid station;
 Storage area with fencing and guard post;
 Warehouse and workshop;
 Site security services
 Car parking area;
 Electrical power distribution system including temporary lighting;
 Water distribution system
 Compressed air system;
 Sanitary and sewage system;
 Fire fighting system;
 Communication system and services;
 The grouting of frames, supports, steel structures, machines, etc... on the
civil works constructions are effected by the construction company;
 PVC pipes casted in concrete for electrical routing, if any;
 The necessary equipment for fire proof (e.g. fire proof doors in tunnel,
sealing material for cables opening);
 Doors with emergency and safety locks for all rooms (E-Rooms, Control
Rooms, offices, etc.).

Installation Work steps

 Transportation of the equipment from the port (EU) which port?
 Unloading, unpacking, storage, and custody, at the site, of the equipment
and materials, according ABB storage instructions.
 Visual inspection of the equipment for completeness and damages.
 Assembling and installation of the equipment and materials, after
checking the levels, dimensions, etc. of foundation and buildings.
 Touch-up painting works for the equipment and materials erected and
installed at the site.
 Installation and preparation of all cable ways by supervision of ABB.
 Pulling of cables according routing information given by ABB.
 Insulation and continuity testing of cables.
 Insulation testing motors, panels, distr. boards etc.
 Earthing checks.

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 Battery preparations for UPS and DC Power supplies.

 Lighting and socket outlet measurements.
 Inspection of the equipment and materials erected and installed at the
site.
 Loop test, this is a signal/wiring check from the field terminations up to I/O
channels of the process control system. Test results are to be recorded on
appropriate test sheets.
 Rotation tests of uncoupled LV-motors
 Assistance for the Commissioning-Team.
 Adjustment and rectification, if any, and finishing of the equipment and
materials.
 Cleaning-up of the site and removal of the temporary facilities and waste
materials from the site.
 An “end of installation certificate” shall be filled out after all work above is
completed and signed by the customer, the installation company and the
installation supervisory company.
Responsibilities of Installation Supervisors (ABB Supply)
The installation supervisors are responsible for the professional implementation of the
Installation work of ABB’s scope of delivery and include the following:
 Checking of all ABB equipment when opening the boxes at site and issuing of
certificates about the conformity of the box contents with the packing lists,
checking of damages and losses and issuing of respective reports, which are to
be signed by ABB and the customer.
 Instruction and supporting of the personnel of the customer, contractors /
sub-contractors or third parties, in the technically correct execution of the
installation in accordance with the ABB-Standards and the contractually
stipulated International technical standards.
 Administration of installation documents such as diagrams, drawings,
instructions necessary for the Supervision, their proper storage, for updating
them with changes, and for the maintenance of a document register.
 Modification of the installation documents according change orders in
cooperation with the ABB back offices resp. their technical department.
 Advising and supporting of customer, contractor, sub-contractors, sub-
suppliers etc. in handling and all aspects towards industrial safety-technical
interests in accordance with OHSAS 18001.
 Continuous monitoring if the Installation Standard fits the ABB
requirements and drawings.
 Support of the Customer, Contractors / Sub-contractors or third parties in
clarifying interface problems.
 Continuous monitoring of the installation progress vs. the master
installation time schedule; immediate reporting of all recognised delays and
unusual occurrences towards the site manager.
 Forecasting of necessary resources and ordering of commissioning
personnel in due time in accordance with the actual planning and the customers
approval.

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 Monitoring and administrating deficiency lists in cooperation with

Customer, Contractors / Sub-contractors or third parties.
 Supervision of the working time of all assigned ABB Personnel on site.
 Signing of “end of installation certificate” section-wise when the
installation is concluded according ABB requirement.

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Commissionning (ABB Supply)

Tools for Commissioning
The necessary special tools needed for commissioning are included in our proposal.
These tools remain in the property of the Supplier.

Process Equipment Test

Commissioning of the plant is done object by object and carried out by ABB. An
object can be a fan, a pump, a belt conveyor etc. The object test is carried out after
related electrical auxiliaries are commissioned and the process control system is up
and running. The object test includes:
 Check of all signals belonging to the object. Signals are actuated or
injected in the field and verified on the screen of the process control system.
 Check of all interlocks and verify it on operator screen.
 Verification correct protection relays setting if applicable (e.g. compare
rated current, which is indicated on the motor plate with the relays setting in
MCC)
 Shortly energizing of the equipment and check for correct action e.g.
correct rotation of a motor. Whether electrical drives need to be disengaged
from the mechanical equipment for the fist run has to be decided case by case.
 The object is now released for local operation. The object is operated
from the field and proper functioning of the equipment is checked and recorded.
Necessary adjustments, tunings, calibrations, run-in-tests, etc. are carried out as
per instruction manuals for tested object.

Electrical Equipment Test

Electrical equipment test consists mainly of a verification of finalization of
construction and the energizing of the equipment, with the result, that the complete
electrical supply system is ready for distribution of all necessary main and auxiliary
power to the plant. Suggested test procedures for the various devices will be
provided during project execution.

Group Sequence No Load Test

After all objects of a group have passed the object test, a group sequence test
without material is carried out. Correct start up / shut down / flying change-over (if
applicable) are checked. Interlocks with the material stream are verified.

Group Sequence Load Test

If all groups of a department have passed the no load test, the department is ready
for production. The groups are started up with material. Remaining adjustments,
tunings, calibrations that couldn’t be done earlier without material are carried out in
this last phase of commissioning. The plant will be finally tuned to its rated capacity.

System Optimisation
 Providing conformity between screen indications and analogue values.
 Calibration of the instruments.

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 Adjustment and optimisation of control loops.

Performance Tests
Until the end of the performance tests the electrical commissioning staff should
secure a technical assistance, with personnel on site in view to avoid that their
deliveries do not disturb the tests in the best possible time.
A “Preliminary Acceptance Certificate” (PAC) shall be filled out after all
commissioning work above has been completed. The PAC shall be signed by ABB,
the machinery supplier and the customer.

Other Commissioning Work

As per written change orders, the following additional work may be required:
 Adjustment of operation method, if requested.
 Programming modifications required by the process specialists.
 On the job training for the plant maintenance team.
 Removal of deficiencies.

As Built Documents
Normally 3 months after PAC, ABB will provide a complete set of as built and
installation drawings under CD-ROM form (Autocad, Excel, Word, Acrobat reader).

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