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.

2 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. 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.

3 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. 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.

4 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. 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.

5 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.

6 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

7 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 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.

8 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 Limestone conveying equipment 94 Lime stone crushers, as applicable 97 STANDARD TECHNICAL SPECIFICATION for Retrofit of Wet Limestone Based Flue Gas Desulphurisation (FGD)

9 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.

10 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)