STANDARD TECHNICAL SPECIFICATION FOR …

1 STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD) SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT central ELECTRICITY authority NEW DELHI December, 2017 STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD) SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT central ELECTRICITY authority NEW DELHI December, 2017 P. D. Siwal, Member (Thermal) central Electricity authority F O R E W O R D Ministry of Environment, Forest and Climate Change (MoEF & CC) vide Notification dated has brought out new emission norms for thermal power stations. To meet the new emission norms, installation of flue gas desulphurization (FGD) system has become essential in new as well as existing thermal power plants.

2 There has been a demand from stake holders that CEA, as an apex body in the power sector, should bring out a STANDARD TECHNICAL SPECIFICATION of FGD system which can be used as a guiding document by the utilities for installation of FGD system in their power plants with reduced time for pre-award activities, design & engineering and equipment manufacturing. In line with above objective, CEA constituted a committee under Chief Engineer (TE&TD) in July, 2017 with participation from major utilities and manufacturers for developing STANDARD TECHNICAL specifications for wet limestone based FGD system as majority of thermal power plants in the country are expected to be provided with wet limestone based FGD system. I am glad that CEA has finalized the document titled, STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based FGD System in a Typical 2 x 500 MW Coal Based Thermal Power Plant with valuable inputs from the committee members.

3 This document can be used for installation of FGD system in a new thermal power plant also. The document reflects pooled experience and knowledge of participating engineers from CEA, utilities and FGD system manufacturers. I hope that the utilities would find the document quite useful for retrofit/ implementation of FGD system in thermal power plants in an expeditious manner towards compliance of MoEF & CC notification on new emission norms. I wish to express my appreciation to all the members of the Committee viz. CEA, NTPC, BHEL, UPRVUNL, TANGEDCO, Toshiba, L&T and Alstom (GE) for sharing their experience and making valuable contribution in bringing out this document. New Delhi December, 2017 (P.)

4 D. SIWAL) STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant MAIN CONTENTS Section- 1 General Note, Applicability and Project Specific Information Section- 2 General Section- 3 System Description and Scope Section- 4 TECHNICAL SPECIFICATION - Mechanical Works Section- 5 TECHNICAL SPECIFICATION - Electrical Works Section- 6 TECHNICAL SPECIFICATION - Control & Instrumentation Works Section- 7 TECHNICAL SPECIFICATION - Civil Works Section- 8 Mandatory Spares Section- 9 Quality Assurance Plan Section -10 Annexures STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant i DETAILED CONTENTS Clause No.

5 Description Page No. Section-1: General Note, Applicability and Project Specific Information General note 1 Applicability 7 Brief details about power plant 7 Meteorological data 8 Salient TECHNICAL data of existing power plant 8 Section-2: General Intent of SPECIFICATION 11 Typical brief description of the existing flue gas path 12 Typical brief description of existing chimney 13 Design and guarantee conditions 13 General design requirements 14 Operational performance requirements 17 Layout requirements 19 General TECHNICAL requirements 21 Spare parts 30 Quality assurance programme 33 Testing and inspection 36 Trial operation 40 Performance guarantees and acceptance tests 41 General requirements 41 Guarantees under category- I 42 Guarantees under category-II 42 Guarantees under category-III 43 Auxiliary power consumption 45 Method of computing plant availability 46 Acceptance test 47 Integration of FGD system with the power plant units 49 Liquidated

6 Damages (LD) 49 Section-3: System Description and Scope General description of wet limestone FGD system 50 Flue gas system 50 Absorber system 50 Limestone unloading, crushing & storage system 51 Limestone grinding, slurry preparation and storage System 51 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant ii Gypsum dewatering, handling system 52 Waste water treatment & disposal system 52 Water supply for FGD system 52 Equipment cooling water system 52 Scope of supply 53 Mechanical works 53 Civil & structural works 56 Electrical works 59 Control & instrumentation works 62 Terminal points & exclusions 65 Section-4: TECHNICAL SPECIFICATION - Mechanical Works 67 Flue Gas System and duct works 67 General 67 Dampers 70 Booster fans 72 Wet limestone absorber system 74 Absorber 74 Mist eliminator wash water supply system 79 Slurry pumps 79 Oxidation air blowers 80 Agitators 82 Process water storage tanks & pumps 82 Other tanks 82 Seal water pumps 83 Elevator for absorber 84 Gypsum dewatering & handling system 88 Dewatering hydro-cyclones 88 Vacuum belt filters 89 Vacuum system 89 Filtrate system 90 Waste water treatment & disposal system 90 Limestone feeding and crushing system 90 Limestone data 90 Hoppers & chutes 91 Rack & pinion gates 91 Magnetic separator 92 Vibrating feeders 93 Skirt boards 93 Flap gates 93

7 Limestone conveying equipment 94 Lime stone crushers, as applicable 97 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant iii Bucket elevator, as applicable 98 Limestone silo/ bunker 98 Bunker shut-off gates 99 Gravimetric feeders 99 Wet ball mills 99 Limestone sampling units 101 Dust control system 101 Equipment cooling water system 102 Vertical sump pumps 103 Horizontal centrifugal pumps 103 Painting and protective coating 108 Ventilation and air conditioning system 110 Piping, valves and accessories 111 Thermal insulation 115 Instrument air compressors 116 Fire detection, protection & alarm system 117 Hangers and supports 118 Hoisting and lifting tackles 118 Mono rail and hoists 119 Wet chimney 120 Structural steel works 121 Control and operation philosophy of FGD plant 121 Drawings/ TECHNICAL data 123 Codes & standards 124 Section-5.

8 TECHNICAL SPECIFICATION - Electrical Works 11kV, AND Switchgears 131 Codes and standards 131 TECHNICAL parameters 132 Metering 135 General TECHNICAL requirements 136 Spare feeders 145 Make of components 146 Tests 146 Drawings and data 146 Auxiliary service transformers 147 415V switchgears and non-segregated phase bus duct, and DC Board Dc boards 150 Codes and standards 150 TECHNICAL parameters 151 Metering 151 General TECHNICAL particulars 152 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant iv Protection 156 Design and constructional features 156 Spare feeders 157 415V Non-segregated phase bus-duct 157 HT and LT Motors 158 Codes and Standards 158 General requirements 159 Type 159 Rating 159 Temperature rise 160 Operational requirements 160 Design and constructional features 161 List of type tests to be conducted 162 List of tests for which reports have to be submitted 163 HT/LT Power and control cables 163 Codes and standards 163 Design criteria 164 General TECHNICAL requirements 165 Constructional requirements 166 Identification of cores 167 Arrangement of cables 167 Drums lengths 167 Installation of cables.

9 Earthing system and lightning Protection system 168 Codes and standards 168 Design and constructional features 169 Equipment description 169 Installation 173 Earthing system 177 Lightning protection system 179 Lighting 180 Make of Equipment / Components 180 Normal service conditions 180 Lighting system 180 Main lighting board 180 Lighting distribution board (LDB) 181 AC/DC emergency lighting distribution board (ELDB) 181 Guidelines for design of lighting distribution system 181 Illumination level design factors and type of Luminaires 181 Description for each type of luminaire 182 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD) System in a Typical 2x500 MW Thermal Power Plant v Lighting distribution system design 183 Emergency lighting Distribution system 184 Spare feeders 184 Power socket outlets 184 Welding outlet 185 Drawings and data 185 Standards 185 DC system 185 Section -6.

10 TECHNICAL SPECIFICATION - Control & Instrumentation Works General 190 General requirements 190 Reliability and availability 190 Standardisation and uniformity of hardware 191 Operability & maintainability 191 Control & monitoring 192 Environmental conditions 192 PLC based control system 193 General requirements 193 Programmable logic based control system 193 Human machine interface system (HMIS) 196 Input/ output modules 200 Data communication system (DCS) 202 Control system requirements 203 Annunciation system 211 Historical storage and retrieval system (HSRS) 211 Printer 212 Furniture 212 Software documentation and software listings 213 Measuring instruments (primary and secondary) 214 General 214 SPECIFICATION for electronic transmitter for pressure, differential pressure (DP), flow and level 216 SPECIFICATION for pressure gauge, differential pressure gauge, temperature gauge and level gauge 217 SPECIFICATION for guided wave radar type level transmitter 218 Ultrasonic type level transmitter 219 HART hand held calibrator 220 Temperature elements and accessories 221 Temperature transmitter 222 SPECIFICATION for flow elements & flow meters 224 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD)