STANDARD TECHNICAL SPECIFICATION FOR …

1 STANDARD TECHNICAL SPECIFICATION . FOR. main PLANT PACKAGE. OF. SUB- CRITICAL THERMAL POWER PROJECT. 2x (500 MW OR ABOVE). Government of India Ministry of Power Central Electricity Authority New Delhi SEPTEMBER, 2008. RAKESH NATH. Chairperson Central Electricity Authority &. Ex-officio Secretary Government of India FOREWORD. An unprecedented growth is being witnessed by the power sector with a capacity addition of over 78,000 MW envisaged during 11th Plan and about 80,000 MW in 12th Plan. A programme of this magnitude requires that every possible opportunity for enhancing pace of capacity addition is explored and fully exploited. In this context, there has been a long felt need to standardize the TECHNICAL SPECIFICATION of thermal power stations with a view to reducing the time for pre-award activities, design & engineering and the manufacturing by equipment manufacturers.

2 Thus, a Committee was set up by CEA under the chairmanship of Member (Thermal) in May 2007 with participation from major utilities and manufacturers for developing STANDARD TECHNICAL specifications for main plant equipment for coal based thermal power plant having 500MW and higher capacity sub-critical units. I would like to bring out here that the committee under Dr. Kirit S. Parikh, Member (Energy) Planning Commission has also recommended that CEA should finalize STANDARD specifications covering scope of work, broad specifications and design criteria which should be flexible to attract wider participation of equipment suppliers and competition for main plant as well as balance of plant. Several project specific factors like dimensions and orientation of land, quality of inputs, (cooling water, coal), location (coastal/non-coastal) soil & seismic conditions etc.

3 Make standardization of the entire plant difficult. Thus, the standardisation of main plant (Steam generator, turbine-generator and auxiliaries) was taken up as a first step. Having completed the same, the task to develop broad design criteria for balance of plant (BoP) coal handling plant (CHP), ash handling plant (AHP), water treatment system, etc. is being taken up in the next phase. I am glad that the STANDARD TECHNICAL SPECIFICATION for main Plant Package has been finalized by the Committee. The document reflects pooled experience and knowledge of participating engineers from CEA, utilities and main plant equipment manufacturers. I am sure that utilities as well as equipment manufacturers would find it useful in expediting the execution of thermal power projects having unit size of 500 MW or higher capacity. New Delhi September, 2008 (RAKESH NATH).

4 R. DAHIYA. Member (Thermal). Central Electricity Authority &. Ex-officio Additional Secretary Government of India P R E F AC E. Standardisation is an established and important tool for faster execution of the projects in a cost effective manner. In the present power scenario, need of the hour is to ensure timely commissioning of a large capacity targeted in 11th and 12th Plans to meet the gap in the demand and supply of electricity in the country. Standardisation is expected to reduce the pre-award time and help in optimising manufacturing cycle thus leading to improved delivery schedules and reduction in overall cost. I am glad that the Committee constituted by CEA in May 2007 having representation from major utilities and equipment manufacturers, has completed its task of finalizing STANDARD TECHNICAL SPECIFICATION for main Plant Package for a coal based thermal power project having 2x (500MW or above) sub-critical units.

5 The SPECIFICATION covers scope, design criteria, equipment features, quality assurance plans, performance guarantee tests, spares etc. and includes steam generator, turbine- generator alongwith auxiliaries and associated electrical, C&I and civil works. Commercial and contract conditions have not been included in the document as utilities normally prefer to prescribe their own STANDARD conditions. Also, site and project specific aspects viz. coal quality, cooling water source (river or sea), soil properties etc. which affect the design of main plant package have been indicated as foot notes so that utilities could incorporate the same in the bid document suitably. I am sure that both utilities as well as equipment suppliers would find this document useful for adoption for their future projects. I wish to express my appreciation and sincere thanks to all the members of the Committee from CEA, NTPC, BHEL, MAHAGENCO, APGENCO, WBPDCL, REL, Tata Power and Alstom for sharing their experience and making valuable contribution in bringing out this document.

6 New Delhi (R. DAHIYA). September, 2008. STANDARD TECHNICAL SPECIFICATION for Sub- critical Thermal Power Project - 2x(500MW or above). main Plant Package STANDARD TECHNICAL SPECIFICATION FOR main . PLANT PACKAGE OF 2x(500MW OR ABOVE). SUB- CRITICAL THERMAL POWER PROJECT. main CONTENTS. SECTION- 0 SITE SPECIFIC INFORMATION. SECTION- 1 GENERAL. SECTION- 2 STEAM GENERATOR AND AUXILIARIES. SECTION- 3 STEAM TURBINE AND AUXILIARIES. SECTION- 4 PIPING, VALVES, THERMAL INSULATION AND. MISCELLANEOUS SYSTEMS/ EQUIPMENT. SECTION- 5 ELECTRICAL WORKS. SECTION- 6 CONTROL AND INSTRUMENTATION WORKS. SECTION- 7 CIVIL WORKS. SECTION- 8 QUALITY ASSURANCE PLAN. SECTION- 9 MANDATORY SPARES. DRAWINGS. STANDARD TECHNICAL SPECIFICATION for Sub- critical Thermal Power Project - 2x(500MW or above). main Plant Package DETAILED CONTENTS. Clause No. Description Page No. Section- 0 : Site Specific Information Project Name 0- 1.

7 Location 0- 1. Climatological Data 0- 2. Fuel 0- 3. Source of fuel 0- 3. Coal and ash analysis 0- 3. Secondary liquid fuels 0- 4. Water System 0- 5. Demineralised Water for Power Cycle Make-up 0- 5. Section- 1 : General Intent of SPECIFICATION 1- 1. Scope of Supply 1- 3. Steam generator and auxiliaries 1- 3. Steam turbine and auxiliaries 1- 17. High pressure/ power cycle piping, valves and miscellaneous 1- 21. systems/ equipments Electrical works 1- 26. Control and Instrumentation works 1- 28. Civil works 1- 30. Spares 1- 33. Erection, commissioning and performance guarantee testing 1- 33. Tools and tackles 1- 34. Consumables, oils and lubricants 1- 35. Terminal Points and Exclusions 1- 36. Terminal points 1- 36. Exclusions 1- 37. General TECHNICAL Requirements 1- 38. Layout Considerations 1- 42. Performance Guarantees 1- 46. General requirements 1- 46.

8 Guarantees under category- I 1- 47. Guarantees under category- II 1- 52. Guarantees under category- III 1- 52. Performance guarantee/ acceptance test 1- 61. Spare Parts 1- 70. Mandatory spares 1- 70. Recommended spares 1- 70. Start up and commissioning spares 1- 71. General 1- 71. Testing, Inspection and Quality Assurance Plan 1- 73:76. i STANDARD TECHNICAL SPECIFICATION for Sub- critical Thermal Power Project - 2x(500MW or above). main Plant Package Clause No. Description Page No. Section- 2 : Steam Generator and Auxiliaries Design/ Sizing Criteria 2- 1. Type of steam generator 2- 1. Contractor's responsibilities 2- 1. Unit operation range 2- 1. Codes and standards 2- 1. Steam generator rating 2- 2. Fuels 2- 3. Cooling water 2- 6. Ambient air 2- 6. Limiting parameters for steam generator design 2- 7. Minimum load without oil support for flame stabilization 2- 7.

9 Loading/ unloading pattern and adoptability for sudden load 2- 7. changes/ load throw off Operation without HP heaters in service 2- 8. Operation with/ without turbine HP-LP bypass system 2- 8. Mode of steam generation operation and rate of loading 2- 8. Provision for future installation of FGD system 2- 9. Furnace 2- 9. Pressure parts 2- 10. Superheaters and reheaters 2- 11. Economiser 2- 12. Air pre-heaters 2- 12. Steam coil air preheaters (SCAPH) 2- 13. Auxiliary steam PRDS 2- 13. Coal firing system 2- 14. Fuel oil preparation and firing system 2- 17. Draft plant 2- 18. Flue gas ducts and air ducts 2- 20. Electrostatic precipitator design data 2- 21. TECHNICAL Requirements 2- 24. Steam generator enclosure 2- 24. Super heaters and reheaters 2- 30. Economiser 2- 33. Air heaters and steam coil air preheaters 2- 35. Coal preparation and firing system 2- 38.

10 Coal burners 2- 44. Primary air fans 2- 45. Balance draft system 2- 47. Fuel oil system 2- 50. Duct work and dampers 2- 57. Steam generator integral piping, valves, fittings and mountings 2- 64. Soot blowing system 2- 66. ii STANDARD TECHNICAL SPECIFICATION for Sub- critical Thermal Power Project - 2x(500MW or above). main Plant Package Clause No. Description Page No. Blow down tanks (BDTs) 2- 68. Auxiliary steam pressure reducing and desuperheater stations 2- 69. (PRDS). Walk ways, platforms and stairs etc. 2- 70. Electrostatic precipitator 2- 72:78. Section- 3 : Steam Turbine and Auxiliaries Steam Turbine 3- 1. Equipment sizing criteria 3- 1. Type of steam turbine 3- 4. Turbine design and construction 3- 5. Steam admission valves (emergency stop, reheat stop, 3- 8. interceptor stop valves and control valves). Non return valves 3- 9. Insulation (steam turbine and BFP drive turbine) 3- 10.