Purchase Order Specification

A MAR.24,08 INITIAL ISSUE M.H.LEE E.S.YOON H.S.YUM REV. DATE DESCRIPTION PREPD CHKD APPD

OWNER :

PROJECT TITLE : RAS LAFFAN C IWPP PROJECT CONTRACT NO :

CONTRACTOR : SUBCONTRACTOR :

DESIGNED BY DATE TITLE : M.H.LEE MAR.21,08

CHECKED BY DATE CONDENSATE EXTRACTION PUMP E.S.YOON MAR.21,08 FOR APPROVED BY DATE DUMP CONDENSER H.S.YUM MAR.21,08 SCALE DOCUMENT NUMBER CEP for Dump RAS LAFFAN C IWPP Technical Specification for Condensate Extraction Pump

CONTENTS

1. GENERAL...... 1

2. SCOPE OF SUPPLY...... 1

3. CODES AND STANDARDS...... 3

4. DESIGN AND OPERATING CONDITIONS...... 3

5. DESIGN AND CONSTRUCTION REQUIREMENTS...... 4

6. ELECTRICAL...... 8

7. INSTRUMENTATION & CONTROL...... 8

8 TEST AND INSPECTION...... 8

9 DELIVERY REQUIREMENT...... 10

10. PERFORMANCE AND GUARANTEE...... 10

11. DRAWING AND DOCUMENT REQUIREMENTS...... 11

ATTACHMENT 1. GENERAL TECHNICAL REQUIREMENTS - GENERAL 2. GENERAL TECHNICAL REQUIREMENTS - MECANICAL 3. GENERAL TECHNICAL REQUIREMENTS - ELECTRICAL 4. GENERAL TECHNICAL REQUIREMENTS – INSTRUMENTATION & CONTROL 5. BID FORM 6. TECHNICAL DATA SHEET 7. P & I DIAGRAM – CONDENSTE SYSTEM 8. OWNER’S REQUIREMENT FOR CONDENSATE EXTRACTION PUMPS 9. VENDOR DATA REQUIREMENT (VDR)

0df734debe39e23ffc1acc22cf462bc0.doc i RAS LAFFAN C IWPP Technical Specification for Condensate Extraction Pump

1. GENERAL

1.1 This Specification covers the technical and associated requirements for design and furnishing of Condensate Extraction Pump complete with all accessories.

It is not the Purchaser's intent to specify all technical requirements nor to set forth those requirements adequately covered by applicable codes and standards. The Supplier shall furnish high quality equipment meeting the requirements of this Specification and industry standards.

All intrinsic equipment necessary for the proper and safe operation of the equipment and auxiliaries furnished under this Specification shall be provided by the Supplier.

All data, specification, drawings and documents shall be written in English. All documentation which is specifically produced for the project shall be supplied in SI (system International) units except that temperatures shall be given in degrees Celsius and pressures in bara.

Any conflict between this Specification and its references shall be brought to the attention of the Purchaser for written resolution prior to any further action by the Supplier.

1.2 The Equipment No. of the items to be supplied by the Supplier are as follows:

Equipment No. Description Q ’t y Location Later Condensate Extraction Pump for Dump condenser 2 × 100% outdoors

2. SCOPE OF SUPPLY

2.1 EQUIPMENT AND SERVICES BY SUPPLIER

In addition to the Supplier's scope of supply specified in other section of this Specification, the Supplier shall furnish the services and equipment including all necessary features, components, accessories and appurtenances for the safe, efficient and reliable erection, operation and maintenance whether mentioned in this Specification or not. These shall include, but not be limited to, the following :

2.1.1 All necessary supervision, labor, tools, materials and equipment required to design, furnish materials for fabrication, test, clean, paint, prepare for shipment and deliver the equipment complete with appurtenances as specified herein.

2.1.2 All tests and inspections of the equipment in the Supplier's shop.

2.1.3 All necessary supervision for handling, erection, installation, start-up, commissioning and performance test of the equipment, as required.

2.1.4 The pumps shall be complete with all auxiliaries and accessories necessary for the safe, efficient and reliable operation including, but not be limited to, the following :

1) Two(2) sets of pumps with electric motor, including coupling, guards, anchorage, etc.

2) All noise prevention measures to meet the noise limit, if necessary.

3) Permanent suction strainers and temporary strainers for commissioning use

4) Mechanical seals RAS LAFFAN C IWPP Technical Specification for Condensate Extraction Pump

5) Lifting lugs, assembly clips or other attachments as required to facilitate erection, assembly and maintenance.

6) Common base plate with anchor bolts, nuts, washers, shims, etc

7) All integral pipe works, necessary internal piping, nozzles, connections, root valves within the Supplier's terminal points, if any.

8) Companion flanges, gaskets, bolts, nuts and washers

9) Insulation and lagging materials, where necessary

10) All internal wiring within the Supplier’s terminal points

11) Dual temperature instruments (RTD or T/C) with transmitters (1 out of 2 voting) and instrument rack for the control and monitoring of the pump’s and motor’s bearing and winding temperature. Signal cable shall be connected from sensors to transmitter

12) Vibration probes and transmitters with instrument racks which will be connected to the plant DCS. Instrument location and quantity shall be provided by the Supplier. Signal cable shall be connected from probe to transmitter.

13) Local pressure gauges with accessories on suction and discharge side with block valves.

15) A complete water sealing system to seal the stuffing boxes and all parts subjected to vacuum at start-up, during standby operation and/or during normal operation. The sealing water shall be taken from the pump delivery

16) All safety devices necessary for protecting the equipment

17) Lubricants and/or grease for initial filling

18) All Lubricants and consumables including chemicals for erection, start-up, commissioning and performance test

19) Spare parts (Refer to “Description of Spare Parts” attached to Bid Forms)

- Spare parts for erection, start-up, commissioning and performance test

- Two (2) years spare parts for Routine Maintenance.

20) One (1) set of all special tools and special lifting tackles required for erection, operation and maintenance

21) Surface preparation and shop painting for corrosion prevention and protection

22) Field touch-up paints

23) Marking, packing and shipping

24) Performance corrections, if necessary

25) All the required Drawings and documents

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26) Grounding terminal lug, special cables if required and power cable terminal lug or compression type terminal.

2.2 Terminal points

1) Piping : Suction and discharge flange of condensate extraction pump. Companion flanges, gaskets, bolts, nuts and washers are within the Supplier’s scope of supply.

2) Electric power supply : Each feeder will be provided and connected by the Purchaser at motor terminal box.

3) Control cables : Supplier’s terminal junction box for cabling.

2.3 The Supplier shall accept full responsibility for his works and for the works of his Sub-suppliers including design, Drawings, performance, quality control, fabrication, preparation of installation, operation and maintenance instruction, testing and inspection, cleaning and painting, shipment and delivery, certifications, etc. in compliance with this Specification.

2.4 EQUIPMENT AND SERVICES BY PURCHASER

The Purchaser will provide the following :

1) Foundation civil works and installation

2) External piping to the Supplier’s terminal points

3) External power wiring to the Supplier's terminal points

4) Motor starters

5) Instrument and control wiring external to the Supplier's terminal points

6) Start-up and field test

7) Touch-up painting at site

3. CODES AND STANDARDS

The Supplier must ensure that the Construction of all equipment, facilities, components and systems which form part of the Facility shall be in accordance with internationally recognized standards and codes. Refer to ‘General Technical Requirement-General’.

4. DESIGN AND OPERATING CONDITIONS

4.1 Site Climatic and Utility Conditions

Refer to ‘General Technical Requirement-General’.

4.2 Leading Specification

4.2.1 General

Items Units Specification

1) Number of pumps sets Two (2) ×100% / Dump condenser = 2 sets

2) Pump type - Horizontal, centrifugal type

3) Driver type - Electric motor

4) Frequency Hz 50

5) Location - Indoors / Outdoors

6) Performance test Code - Hydraulic Institute

7) Service - Continuous

8) Seismic condition - UBC Zone 1

9) Plant operating life year 30

4.2.2 Performance and design conditions (data shown per one pump basis)

Items Units Normal Rated Runout (for best eff.) (for guarantee)

a. Fluid handled - Condensate Condensate Condensate

b. Flow rate m3/h - 245 294

c. Fluid temp. oC 111.3 111.3 111.3

d. Total head mWC * 115 *

e. Suction pressure barg 1.90 1.90 -

f. Condenser pressure bara 1.5 1.5 -

NOTE : 1. Operating condensate temperature will range from 10 oC to 60 oC . 2. Peak efficiency should occur close to the normal flow condition, and higher efficiency range should be between the normal flow rate and 80% of it. 3. The item with * shall be filled in by the Supplier. 4. NPSHa at the pump suction nozzle center line : 0.4 m

5. DESIGN AND CONSTRUCTION REQUIREMENTS

5.1 General

5.1.1 All equipment shall be designed and constructed according to the requirements of attached General Technical Requirements – General, Mechanical, Electrical and Control & Instrumentation in addition to this Specification.

5.1.2 All steel flanges shall be per ANSI, of class appropriate for the design pressure and temperature of the flanged connections.

5.1.3 The seismic requirements in the General Technical Requirements – General shall be applied to the equipment design.

5.1.4 Necessary noise prevention measures shall be provided to meet the noise limits in accordance with the Attachment 1, ‘General Technical Requirements – General’.

5.1.5 In no case shall the acceptable force & moment reactions on equipment nozzles due to thermal loading and seismic, be lower than maximum allowable nozzle forces and moments shown on API 610 – table 2.

5.1.6 Suitable lifting lugs and attachments shall be provided by the Supplier to allow the equipment to be safely and efficient handled, shipped, hoisted, and installed.

5.1.7 The condensate extraction pumps will take suction from the condenser hotwell and supply condensate to the low pressure drum of HRSG and other miscellaneous condensate users.

5.1.8 Pumps shall be of the horizontal, wet suction, “can” type. The pumps will be located near condenser with pump base plates in the steam turbine building.

5.1.9 The Purchaser reserves the right to change the pump total discharge head-capacity and suction conditions within reasonable limits prior to fabrication without any price increase.

5.1.10 The condensate pump minimum flow requirements will be met by a minimum flow recirculation control valve which will be furnished by other supplier.

5.1.11 Pumps shall be free from excessive vibration, flashing, and cavitation at all discharge rates.

5.1.12 Each pump shall operate satisfactorily from minimum flow to runout flow. Pumps shall be hydraulically stable both axially and radially at all outputs from minimum flow to the runout capacity.

5.1.13 Pumps shall be designed with a head-capacity characteristic which rises steadily from the design capacity to shutoff.

5.1.14 The first critical speed of the pump shall not lie within a region of 125 percent of rated speed, or at any speed within the operating range of any variable speed pump.

5.1.15 The suction level in the condenser hotwell shall be maintained by a DCS level control system, consisting of a recirculation control valve.

5.1.16 The NPSH required at the specified runout flow shall be at least 1 m less than the NPSH available.

5.1.17 Pumps shall be capable of stable operation at any flow rate between the pump minimum recirculation flow up to and including the pump rated flow without any adverse effects.

5.1.18 The plant control system monitors the operating pumps. If a pump failure is detected, the standby pump shall be started automatically. The pumps shall be designed to operate simultaneously and in parallel.

5.1.19 The start-up of the pump shall be possible without warm-up.

5.1.20 Pumps shall be free from excessive vibration, flashing, and cavitation. The maximum limit for vibration as measured on the shaft shall be kept within those limits stated in HIS or approved

equivalent international standard for pumps with sleeve bearings. Normal and maximum permissible operating vibration amplitude limits shall be provided by Supplier. The Supplier shall provide the vibration detector whose maker shall be reputed with proven track records.

5.1.21 Temperature instruments (RTD or T/C) and transmitters for the control and monitoring of the pump’s and motor’s bearing and winding temperature shall be provided. The signals shall be connected to the plant DCS. Each point of temperature sensing shall be comprised of dual redundant temperature sensors which are 1 out of 2 voting logic.

5.2 Design Requirements

Two 100% condensate extraction pumps shall be provided each capable of delivering the maximum condensate requirements of the combined cycle block. The pumps shall be arranged with one pumps on duty supplying all HRSG units via the common feedwater system and the second pump on automatic standby. The pumps shall supply condensate, through deaerator level activated control valves, to the common deaerator/feedwater storage tank.

Each condensate extraction pump shall be provided with an automatic flow recirculation valve to ensure a safe minimum flow through the pumps at all times.

Each condensate extraction pumps shall be capable of delivering the maximum condensate requirements under the roost unfavorable operating conditions, with a minimum margin of 10 % including during 100 % bypass operation with spray attemporation and a 3 % boiler make up requirement. The Supplier shall state the design margins included in his condensate extraction pump design.

The condensate extraction pumps shall be constant speed electrically driven multistage designs. However horizontal multistage centrifugal pumps are also acceptable. The Supplier’s selected pump design shall be suitable for condensate extraction service having low suction head requirements and shall be the Manufacturer’s standard product for such applications with a proven record in utility power plant duties. The condensate extraction pumps shall be capable of retaining stability while operating in parallel with each other.

Pump glands shall be suitably sealed to prevent the ingress of air into the condensate under all operating conditions.

Full flow strainers shall be fitted to the suction of each condensate extraction pump to prevent any foreign matter being discharged into the condensate system.

The pumps shall be capable of operating under all plant operating conditions without vibration or cavitation.

The pumps shall be arranged for automatic start-up of the standby unit in the event of failure of the running pump.

The pumps shall be designed to withstand an inadvertent reverse flow situation such as might occur on the failure of a pump when operating in parallel and a failure of its associated non-return valve.

The Supplier shall provide the Purchaser the requirements for pump minimum flow protection and the means to prevent cavitation, bearing in mind that the forward flow will vary from zero up to that corresponding to combined cycle peak load.

Each pump shall be driven by an electric motor(air cooled) which shall be designed with 10 percent over-capacity and be suitable for multiple starts per hour without degradation. Forced lubrication is not required. A suction strainer shall be provided with provisions for connection of differential pressure alarm and backwashing facility.

The pumps shall be in accordance with Attachment 2, ‘General Technical Requirements - Mechanical’.

5.3 Construction Requirements

5.3.1 Material requirements

1) Casing : A216 Gr. WCB

2) Impeller

- 1st Stage : A743 CA15 or equivalent - further Stage : A743 CA15 or equivalent

3) Shaft Sleeve : A276 Gr.316 or equivalent

4) Shaft : A276 Gr.410

5.3.2 Lubrication

1) Type for Guide Bearings : self lubrication

2) Type for Lower Bearings : self lubrication

5.3.3 Suction and discharge branches are horizontally arranged above the pump can. This allows easy handling of the pump for maintenance purpose.

5.3.4 Mechanical seals shall be used.

5.3.5 Can shall be a cylindrical, horizontal type tank suitable for housing and supporting a horizontal pump. Can shall be designed and fabricated to withstand full vacuum in addition to all other loads to which it is subjected. The pump shall be fully shop assembled.

5.3.6 Pump impeller shall be enclosed and statically balanced. The pump rotating assembly shall be dynamically balanced. The rotating assembly may be balanced as an assembled unit or by balancing individual components such that vibration of the rotating assembly is restricted to the limits defined in the Hydraulic Institute Standards.

5.3.7 Pump shaft shall be sized to transmit the maximum power requirements of the pump with adequate design margin.

5.3.8 If provided, journal sleeves shall be supplied, complete with bearing temperature sensors under sleeve bearings and shall be securely attached to the shaft. All pump bearings shall be lubricated by the condensate being pumped.

5.3.9 Pump bowl sections shall be joined by bolted flanges. Screwed joints will not be acceptable.

5.3.10 Suitable vent connections shall be provided.

5.3.11 Pump/motor coupling shall be of flexible, adjustable, spacer type. Shaft couplings shall be sized to transmit the maximum power requirements of the pump.

5.3.12 All coupling halves for equipment furnished under this Specification shall be shop-mounted.

6. ELECTRICAL

Electrical equipment shall be complied with the General technical requirement – Electrical.

7. INSTRUMENTATION & CONTROL

Instrumentation & Control equipment shall be complied with ‘General technical requirement - Instrumentation & Control.’

8 TEST AND INSPECTION

8.1 General

1) Test and inspection requirements shall be in accordance with ‘General Technical Requirements - Mechanical’.

2) Equipment shall be tested and inspected in accordance with the requirements of Hydraulic Institute latest edition at the date of the award.

3) The Supplier shall prepare and submit to the Purchaser the test and inspection procedures/plan for approval.

4) All equipment shall be neatly finished and free of burrs and fins.

5) Requisite factory tests shall be given to each component as necessary to determine that works and materials are free defects and to establish that the design and construction meet the requirements of this Specification.

6) All castings and forgings shall be subjected by the Supplier to chemical analysis, material tests and inspections in accordance with the appropriate American Standard except where otherwise agreed by the Purchaser. Inspection should be scheduled in order to detect defects as early as possible, to avoid unnecessary delay in manufacture and delivery of the equipment. In case of a rejection influencing the delivery time, written and certified notice must be given in due time to the Purchaser.

7) The Purchaser reserves the right to examine and witness acceptance tests, prior to and following weld repairs and subsequent post weld heat treatment, mechanical tests, etc., at the material suppliers works.

8) Weld repair procedures are subject to approval of the Purchaser.

9) Pumps shall be shop tested with their contract motors.

8.2 Shop Tests

8.2.1 If the shop tests indicate that the equipment fail to comply with the performance guarantees, the Supplier shall immediately proceed with developing proposed equipment modifications to obtain the guaranteed performance. Proposed modifications shall be subject to the Purchaser’s review and acceptance prior to implementation. Modifications which do not comply with this Specification, or in the opinion of the Purchaser could result in a decrease in pump reliability, will not be acceptable.

8.2.2 If the Supplier’s proposed modifications are acceptable, the Supplier shall immediately proceed with such modifications and retesting. Acceptance does not relieve the Supplier of the responsibility for meeting guarantees, however.

8.2.3 When witness testing is required, the test required shall be witnessed by the Purchaser or its authorized representative unless waived in writing, and the equipment shall not be shipped until it has been approved for shipment by the Purchaser.

8.2.4 Material test certificate shall be submitted.

8.2.5 Pump rotors shall be subject to ultrasonic examination in the rough machined condition and magnetic particle or dye penetrating examination in the final machined condition unless otherwise agreed by the Purchaser.

8.2.6 Dynamic balance shall be carried out on the completed rotor and performance tests carried out on the completed pumps.

8.2.7 The Supplier shall shop test each pump in accordance with Hydraulic Institute Standards for head, capacity, power requirements, NPSH requirements, and efficiency at each of not less than five points including rated flow, normal flow, minimum recommended flow and 115% of rated flow. Vibration tests will also be performed at each of the above points.

8.2.8 If head instability is observed at any test point, that point shall be retested with the best possible accuracy. Also, two additional tests shall be made adjacent to the point of instability, one each at flow rates less than and greater than at the point of instability.

8.2.9 If pump suction conditions (pressure and/or temperature) differ from the conditions listed under design conditions, appropriate correction factors shall be applied to the observed test curve, and a corrected curve shall be indicated. This corrected curve shall then represent expected pump performance with the suction conditions listed under design conditions.

8.2.10 Pumps shall be hydrostatically tested at no less than 125 percent of pump shutoff pressure or 150 percent of the head at the specified design pressure, whichever is greater. Hydrostatic test pressure shall be maintained for at least 1 hour. No leakage shall be permitted during such tests.

8.3 Field Tests

The running tests at site shall be carried out before the performance test of the entire Power Unit. During these tests the Supplier shall demonstrate satisfactory smooth operation without vibrations under all possible operating conditions.

8.4 Test reports

Certified test reports shall be prepared and submitted to the Purchaser. The report shall include test arrangement, instrumentation and calibration data, test procedure, test data, and test results.

Pump characteristic curves shall be submitted within 2 weeks after test. Curves shall indicate total head, efficiency, brake horsepower, and required NPSH as ordinates, with capacity in ton per hour. The NPSH plotted shall include suction can losses. The guaranteed design performance, maximum run-out operation, and test water temperature shall be stated on the curve. These curves shall be submitted for the design, maximum, and minimum diameter impellers which may be fitted to the pump casing. Speed-torque curves for the pumps shall also be submitted.

9 DELIVERY REQUIREMENT

The Supplier’s supply of equipment shall meet all the Purchaser Specification Requirement.

1) Pre-assembly & Prefabrication Maximization at Supplier’s workshop and factory

2) The Supplier shall maximize pre-assembly & pre-fabrication works and supply maximized module type of the equipment and material at Supplier workshop/factory prior to shipment to Project site without impacting his own manufacturing & delivery schedule. The Supplier shall submit his pre-assembly maximization plan for equipment and material in supply of his own scope and then get approval from the Purchaser prior to Purchase Order.

3) The Supplier shall supply construction allowance Spares for steel structures, steel plates, duct steel plates, gallery steels, bolts & nuts, grating and handrails, refractory & bricks, insulation & laggings, piping, fittings, site-run pipes, gaskets, flanges, cables, insulators, touch-up painting materials and what deems to be necessary. The Supplier shall itemize all construction allowance spares required from his past experience and propose percentage(%) or quantity in his proposal enough not to hamper the construction schedule.

The construction allowance spares shall be required for required modification, remedy works due to field design change, field crash and shop design error, if any, and etc, and replacement of damaged one during transportation and erection. This will be essential to absolutely assist in minimizing unexpected time loss during project execution.

4) The supplier shall provide all counter flanges/bolts/nuts/gaskets/washers necessary for the connection at the terminal points.

10. PERFORMANCE AND GUARANTEE

10.1 Completed equipment and auxiliaries furnished by the Supplier shall be guaranteed by the Supplier to be suitable for the services described herein, shall conform to all applicable codes and standards and shall safely meet all conditions of performance and design specified herein and in Section 5.

10.2 The Supplier shall guarantee that the equipment will meet all the performance and service requirements under all design conditions identified in this Specification.

10.3 Each condensate extraction pump shall be guaranteed for stable operation over the entire capacity operating range and for the specific performance guarantees listed in this Specification.

10.4 The Supplier shall guarantee that the condensate extraction pump will be capable of operating

continuously and automatically at any rate from start-up to normal operation of the Plant under all normal conditions and transient operating conditions during pump starting up without unstable phenomenon, noise, vibration, cavitation, pitting, etc.

10.5 The following performance parameters shall be guaranteed within specified tolerances :

Items Unit Tolerances plus minus

a. Capacity at rated point head and speed % +10 -0

b. Total head at the rated point % +3 -0

c. Maximum NPSH req. at rated point with specified suction temperature and pressure mWC +0

d. Efficiency at rated point % -0

e. Electric power consumption at motor terminal kW +0

10.6 Noise levels at 1 meter from source shall be less than 85 dB(A).

10.7 The Purchaser will have the right to reject the faulty equipment at deterioration of guarantee values.

11. DRAWING AND DOCUMENT REQUIREMENTS

The Supplier shall submit together with his proposal, Drawings, diagrams, graphs, curves and all such information which is necessary to fully understand the proposal from technical, financial and administrative point of view including the Supplier’s data.

As a minimum requirement the following drawings, design data, performance curves, information, etc in addition to the Supplier’s data required by other parts of the attachments of this Specification shall be supplied with each copy of the proposal in sufficient detail to fully describe the scope of work and the services offered.

a) Technical Data Schedule

b) Data sheet using Supplier’s standard

c) Technical description with specification, data, curves, drawing which is explaining the design and manufacturing, construction, start-up and operating features

d) List of applied Codes and Standards

e) P&I diagrams showing the terminal points for scope of supply

f) Dimensional outline and general arrangement (plan & section) of each of equipment

g) Foundation design information including static & dynamic loads at each anchor bolt location

h) Utility consumption and Electric load list

i) Supplier’s experience or reference list with specific model / type

j) Manufacturer's catalogues and literature to supplement the drawings and documents.

k) Deviation or Exceptions to the Specification, if any.

l) The Supplier shall provide the following documents with the bid;

  Preliminary outline drawing of motor   Preliminary motor data sheets   Total weights

m) The Supplier shall provide the following documents after award of the contract;

  Outline and sectional drawing of assembled motor that specifies dimensions   Description of weather protection features of motors   Motor data sheets   List of additional data that the Supplier requires to design completely for specific motors   Description of the Supplier’s test procedures   Weights and anchor bolt projection for foundation   Supplier’s performance specification including guaranteed efficiency and power factor data   Terminal arrangement drawing   Starting characteristic curve   Speed vs Torque curve   Speed vs Current curve   Thermal limit curve (Hot & Cold Condition)   Weights, dimensions and centers of mass

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