IRAQ POWER RECONSTRUCTION - SMC Consortium · 2008. 2. 2. · 4.3.6 Drawing sheet numbers 4.11...

Document No. 62010/IPA/000001 Rev A FRONTPAGE.DOC/S1/1/PMO

IRAQ POWER RECONSTRUCTION

GAS TURBINE POWER STATION VOLUME 1 TECHNICAL SPECIFICATION VOLUME 2 TECHNICAL SCHEDULES VOLUME 3 ENQUIRY DRAWINGS VOLUME 4 APPENDICES AUGUST 2004

IRAQ POWER RECONSTRUCTION GAS TURBINE POWER STATION VOLUME 1 TECHNICAL SPECIFICATION AUGUST 2004

IRAQ POWER RECONSTRUCTION GAS TURBINE POWER STATION VOLUME 1 TECHNICAL SPECIFICATION AUGUST 2004

Document No. 62010/IPA/000001 Rev A 0654S000.DOC/S1/2/PMO

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LIST OF REVISIONS

Current Rev.

Date Page affected

Prepared by

Checked by (technical)

Checked by (quality

assurance)

Approved by

A

Aug 2004

All

J GOLDSMITH C JACKSON

J SAMS S WATT

J LIDDLE

MA MITCHELL

J LIDDLE

Original

Aug 2004

All

REVISION DETAILS

Original issue as Document No. 62010/IPA/000001

A

Aug 2004

All

Final issue as Document No. 62010/IPA/000001


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CONTENTS

Page

LIST OF ABBREVIATIONS

1. PROJECT DESCRIPTION 1.1

1.1 General 1.1 1.2 Site Description 1.1 1.3 Target project start and completion 1.1

2. PLANT DESIGN CRITERIA 2.1

2.1 General 2.1 2.2 Unit rating 2.1 2.3 Site layout 2.2 2.4 Plant operating philosophy 2.2

2.4.1 Site conditions 2.2 2.4.2 Fuel/water supplies 2.3 2.4.3 Grid conditions 2.3

2.5 Seismic design 2.3 2.6 Performance criteria 2.3

2.6.1 Output and heat rate 2.3 2.6.2 Plant start up 2.4

2.7 Environmental criteria 2.4

2.7.1 Noise 2.4 2.7.2 Emissions to air 2.6 2.7.3 Ambient air quality 2.7 2.7.4 Aqueous emissions 2.7 2.7.5 Visual impact 2.8

3. SCOPE OF WORK 3.1

3.1 Summary of main scope and services 3.1 3.2 Terminal points 3.6

3.2.1 Fuel supplies 3.7 3.2.2 Water supplies 3.7 3.2.3 Electrical connections 3.7 3.2.4 Communications 3.7 3.2.5 Drainage 3.7 3.2.6 Security fencing and access roads 3.8

4. GENERAL REQUIREMENTS 4.1

4.1 Programmes and progress 4.1

4.1.1 Programme requirements 4.1 4.1.2 Progress reporting 4.3

4.2 Design and standardization 4.5 4.3 Drawings and documents 4.8


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Page

4.3.1 Drawings enclosed with the Specification 4.8 4.3.2 Schedules 4.8 4.3.3 Drawings and documents to be submitted by the

Tenderer 4.9 4.3.4 Drawings and documents to be submitted by the

Contractor 4.9 4.3.5 Drawings and document format 4.10 4.3.6 Drawing sheet numbers 4.11 4.3.7 Drawing and document revision 4.11 4.3.8 Drawing and document status 4.12

4.4 Operating and maintenance instructions 4.12 4.5 HAZOP studies 4.17 4.6 Places of manufacture, testing and inspection 4.17 4.7 Packing and marking on packages 4.17 4.8 Training 4.17

4.8.1 General 4.18 4.8.2 Content of training 4.18

4.9 Spare parts 4.19 4.10 Special tools and lifting devices 4.20 4.11 Warranty engineer 4.20

5. SITE DETAILS AND SAFETY REQUIREMENTS 5.1

5.1 Location of Site, access and use of Site 5.1 5.2 Site facilities 5.2 5.3 Site services during construction period 5.3

5.3.1 Site construction electricity supplies 5.3 5.3.2 Water supplies 5.3 5.3.3 Other services 5.4

5.4 Health and safety at work 5.4

5.4.1 Risk assessment 5.5 5.4.2 Specific risks produced by contractor activities 5.5 5.4.3 Documents 5.6 5.4.4 Contractor's safe systems of working 5.6 5.4.5 Training 5.7 5.4.6 Safety equipment 5.7 5.4.7 Assistance to Owner 5.8 5.4.8 Confined spaces 5.8 5.4.9 Land owned by third parties 5.9 5.4.10 Temporary electricity supply 5.9 5.4.11 Fire precautions 5.9 5.4.12 Compressed gases 5.9 5.4.13 Access, fencing and safety barriers 5.9 5.4.14 Site rules 5.9 5.4.15 First aid and medical facilities 5.11 5.4.16 Emergency evacuation of the Site 5.11 5.4.17 Safety management 5.11 5.4.18 Cranes, hoists, lifting equipment and scaffolds, etc 5.11 5.4.19 Electrical safety conditions 5.11

6. MECHANICAL PLANT AND SYSTEMS 6.1


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6.1 Gas turbines 6.1

6.1.1 General 6.1 6.1.2 Turbine 6.2 6.1.3 Compressor 6.2 6.1.4 Casings 6.2 6.1.5 Turbine and compressor rotors 6.3 6.1.6 Blading 6.3 6.1.7 Burners and combustion system 6.3 6.1.8 Couplings 6.4 6.1.9 Compressor cleaning 6.4 6.1.10 Starting equipment 6.5 6.1.11 Rotor barring 6.5 6.1.12 Auxiliary gear 6.5 6.1.13 Gas turbine generator lubrication system 6.6 6.1.14 Combustion air inlet system 6.9 6.1.15 Gas turbine exhaust 6.11 6.1.16 Gas turbine enclosure 6.13

6.2 Fuel systems 6.16

6.2.1 Fuel gas supply system 6.16 6.2.2 Fuel oil supply system 6.24

6.3 Water supply and waste water systems 6.29

6.3.1 General 6.29 6.3.2 Scope of work 6.30 6.3.3 Raw water supply 6.30 6.3.4 Service water 6.30 6.3.5 Demineralized water 6.32 6.3.6 Potable water system 6.33 6.3.7 Chemicals 6.35 6.3.8 Laboratory 6.36 6.3.9 Waste water systems 6.37

6.4 Closed circuit cooling water system 6.38

6.4.1 General 6.38 6.4.2 Scope of Work 6.39 6.4.3 System design and operation 6.39 6.4.4 Air blast cooler 6.40 6.4.5 Header tank 6.42 6.4.6 Cooler controls 6.42

6.5 Fire protection and detection 6.42

6.5.1 General requirements 6.42 6.5.2 Scope of Supply 6.43 6.5.3 Fire water supply 6.43 6.5.4 Fire fighting systems 6.45

6.6 Instrument and service air systems 6.52

6.6.1 General 6.52 6.6.2 Scope of work 6.53

6.7 Painting and protection against corrosion 6.57


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6.7.1 Painting 6.57 6.7.2 Galvanising 6.57

6.8 Cathodic protection 6.58 6.9 Cranes and lifting equipment 6.58

6.9.1 General 6.58 6.9.2 Electrical overhead travelling cranes 6.58 6.9.3 Mobile cranes 6.58 6.9.4 Runway beams and lifting facilities 6.59 6.9.5 Testing 6.59 6.9.6 Use of cranes for initial erection 6.59

6.10 Workshop, stores and equipment 6.59

6.10.1 General 6.59 6.10.2 Workshop compressed air system 6.60 6.10.3 Stores equipment 6.60

6.11 General plant requirements 6.60

6.11.1 Plant referencing 6.60 6.11.2 Nameplates and labels 6.61 6.11.3 Plant vibration 6.62 6.11.4 Sunshades 6.62 6.11.5 Special tools and tackle for maintenance 6.63 6.11.6 Locks and keys for mechanical plant 6.63 6.11.7 General mechanical requirements 6.63 6.11.8 Erection of pipework 6.66 6.11.9 Pipe supports and expansion 6.66 6.11.10 Low pressure pipework 6.66 6.11.11 Steelwork 6.83 6.11.12 Safety guards for plant and apparatus 6.85

6.12 Packing and marking on packages 6.85

6.12.1 Receipt and storage at site 6.85 6.12.2 Erection mark 6.86

7. ELECTRICAL 7.1

7.1 Generators 7.1 7.2 Excitation system and equipment 7.2 7.3 Generator main connections, neutral earthing and switchgear 7.3

7.3.1 General 7.3 7.3.2 Generator switchgear 7.3

7.4 Transformers 7.4

7.4.1 General 7.4 7.4.2 Dry type transformers 7.4 7.4.3 Oil filled transformers 7.4

7.5 Switchgear 7.6

7.5.1 General 7.6


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7.5.2 MV switchgear 7.6 7.5.3 LV and dc switchgear 7.7

7.6 Current transformers 7.8 7.7 Voltage transformers 7.8 7.8 DC supplies system 7.8 7.9 Uninterruptible power supply equipment 7.9 7.10 Protection 7.9

7.10.1 General 7.9 7.10.2 Generator protection 7.10 7.10.3 Generator transformer protection 7.10 7.10.4 Unit transformer protection 7.11 7.10.5 Dry type transformer protection 7.11 7.10.6 Black start/emergency diesel generator protection 7.11

7.11 Synchronizing 7.12 7.12 Black start/emergency diesel generator 7.12 7.13 Metering 7.13 7.14 Motors 7.13 7.15 Earthing 7.13 7.16 Cabling 7.14

7.16.1 General 7.14 7.16.2 Medium voltage cables 7.15 7.16.3 Low voltage cables 7.15 7.16.4 Control and instrumentation cables 7.15 7.16.5 Optical fibre cables 7.15 7.16.6 Telephone cables 7.15 7.16.7 High temperature cables 7.16 7.16.8 Intrinsically safe cables 7.16 7.16.9 Mineral insulated cables 7.16 7.16.10 Cable installation 7.16

7.17 Static frequency converter 7.18 7.18 Electrical equipment for hazardous areas 7.18

8. CONTROL, INSTRUMENTATION AND COMMUNICATIONS 8.1

8.1 Introduction 8.1 8.2 Scope of supply 8.1 8.3 Objectives 8.2 8.4 Operational philosophy 8.3 8.5 Control and monitoring of plant 8.4

8.5.1 Gas turbine 8.4 8.5.2 Auxiliary plant 8.5 8.5.3 Generator 8.5 8.5.4 Electrical distribution system 8.6

8.6 Plant control system 8.7

8.6.1 General system design 8.7 8.6.2 Operator’s facilities 8.8 8.6.3 Engineer’s workstation 8.8 8.6.4 System response times 8.9 8.6.5 Spare capacity 8.9 8.6.6 Software 8.9


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8.7 Metering 8.12 8.8 Uninterruptible power supply 8.12 8.9 Condition monitoring 8.13 8.10 Plant performance monitoring 8.13 8.11 Emissions monitoring 8.14 8.12 Station clock system 8.14 8.13 Load dispatch 8.15 8.14 Fire detection and alarm system 8.15 8.15 Gas detection system 8.16 8.16 Private automatic branch exchange (PABX) 8.16 8.17 Public address system 8.17 8.18 Closed circuit television, intruder detection and site access control

systems 8.17 8.19 Weather station 8.18 8.20 General requirements 8.19

8.20.1 Introduction 8.19 8.20.2 Environmental requirements 8.19 8.20.3 Hazardous areas 8.19 8.20.4 Insulation and isolation 8.19 8.20.5 Electromagnetic compatibility (EMC) 8.20 8.20.6 Identification 8.20 8.20.7 Installation 8.20 8.20.8 Flow measurements 8.21 8.20.9 Level measurements 8.21 8.20.10 Pressure measurements 8.22 8.20.11 Temperature measurements 8.22 8.20.12 Position measurements 8.23 8.20.13 Quality measurements 8.23 8.20.14 Vibration measurements 8.23 8.20.15 Control valves and actuators 8.23 8.20.16 Motorized valves 8.24 8.20.17 Manual valves 8.24 8.20.18 Pneumatic actuators/positioners 8.24 8.20.19 Cubicles and racks 8.25

9. CIVIL WORKS 9.1

9.1 General requirements for civil works 9.1

9.1.1 General 9.1 9.1.2 Civil programme and method statements 9.1 9.1.3 Planning and building permits/approvals 9.1 9.1.4 Site investigations 9.2 9.1.5 Ground contamination 9.2 9.1.6 Design and construction 9.2

9.2 The site specific data 9.3

9.2.1 General 9.3

9.3 Scope of civil engineering and building works 9.3

9.3.1 General 9.3 9.3.2 The Contractors enabling works 9.3 9.3.3 Scope of main civil engineering and building works 9.4


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9.4 Design of the works 9.16

9.4.1 General 9.16 9.4.2 Preferred structural design concept 9.18 9.4.3 Materials 9.23 9.4.4 Civil design parameters 9.23

9.5 Specific building and architectural requirements 9.34

9.5.1 Cladding and decking 9.34 9.5.2 Metal doors and frames 9.39 9.5.3 Internal doors and frames 9.40 9.5.4 Internal vision panels 9.41 9.5.5 External walling 9.41 9.5.6 Internal masonry walling 9.42 9.5.7 Suspended ceilings 9.42 9.5.8 Damp proofing 9.43 9.5.9 Stairs 9.43 9.5.10 Sanitary ware 9.43 9.5.11 Finishes 9.43 9.5.12 Flat roof waterproofing systems (if required) 9.45

9.6 Materials and workmanship 9.46

9.6.1 Codes and Standards 9.46 9.6.2 Materials 9.46 9.6.3 Certification of materials 9.46 9.6.4 Storage of materials 9.47 9.6.5 Plant and equipment 9.47 9.6.6 Concrete 9.47 9.6.7 Setting out and monitoring 9.51 9.6.8 Earthworks, excavation and filling 9.52 9.6.9 Roads, hardstandings, car parks and paths 9.52 9.6.10 Piling 9.52 9.6.11 Structural steelwork 9.53 9.6.12 Surface water drainage and buried pressure pipelines 9.57 9.6.13 Building drainage 9.57 9.6.14 Brickwork and blockwork 9.57 9.6.15 Builder’s work 9.58 9.6.16 Access 9.58 9.6.17 Fencing 9.58 9.6.18 Landscaping 9.60 9.6.19 Laydown area 9.61

9.7 Electrical building services 9.61

9.7.1 Scope of works 9.61 9.7.2 Lighting systems 9.61 9.7.3 Small power installation 9.70 9.7.4 Distribution system 9.72 9.7.5 Cables and wiring 9.73 9.7.6 Lightning protection system 9.74

9.8 Mechanical Building Services 9.75

9.8.1 Scope of Works 9.75 9.8.2 Design information 9.76 9.8.3 Quality control 9.77 9.8.4 Domestic hot and cold water services 9.77


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9.8.5 HVAC systems 9.78

9.9 Subcontractors 9.85 9.10 Functional requirements 9.85 9.11 Record drawings 9.86

10. QUALITY CONTROL, INSPECTION AND TESTING 10.1

10.1 General 10.1 10.2 Extent of work 10.2 10.3 Document submission 10.2 10.4 Inspection notification and right of access 10.4 10.5 Inspection and tests 10.4 10.6 Non-conformances 10.5 10.7 Quality control records, certificates and certificates of conformance 10.6 10.8 Specific tests and inspections 10.7

11. COMMISSIONING, START-UP AND TESTS ON COMPLETION 11.1

11.1 General 11.1 11.2 Commissioning 11.1

11.2.1 Commissioning procedures 11.1 11.2.2 Precommissioning 11.2 11.2.3 Commissioning 11.3 11.2.4 Tests on completion 11.3 11.2.5 Start up guarantee tests 11.4

11.3 Guarantee and performance tests 11.4

11.3.1 Output and heat rate performance guarantee tests 11.4 11.3.2 Environmental performance guarantee tests 11.9 11.3.3 Reliability test 11.10

11.4 Test records 11.10

____________________________


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LIST OF ABBREVIATIONS % percent °C degrees Celsius A ampere ac alternating current AGI above ground installation AVR automatic voltage regulator barg bar gauge BMS Building Management System BoP balance of plant BS British Standards C&I control and instrumentation CCGT combined cycle gas turbine CCR central control room CCTV closed circuit television CO carbon monoxide CT current transformer dB decibel dc direct current DGP data gathering panels EHV extra high voltage EMC electromagnetic compatibility EN Euro Norme EPA Environment Public Authority EPC engineer, procure, construct EPR ethylene propylene rubber EWS engineer’s workstation GIS gas insulated switchgear GMT Greenwich mean time GPS global positioning system GRP glass reinforced plastic GT gas turbine HCFC single hydrochlorofluorocarbon compound HMI human machine interface HRSG heat recovery steam generator HV high voltage HVAC heating ventilation and air-conditioning Hz hertz I/O input/output IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IP International Protection IPB isolated phase busbar ISDN integrated service digital network ISO International Standards Organisation kg kilogram km kilometre kV kilovolt LSF low smoke and fume LV low voltage m metre mA milliampere mb millibar MCB miniature circuit breaker MCC motor control centre mg milligram MICC mineral insulated copper cable mm millimetre mm2 millimetre squared


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MV medium voltage MVA megavolt ampere MVAr megavolt-ampere reactive MW megawatt MWe megawatts electrical NCC National Control Centre Nm3 normal metres cubed NOx oxides of nitrogen O2 oxygen OCGT open cycle gas turbine ONAF oil natural air forced ONAN oil natural air natural PA public address PABX private automatic branch exchange PCS plant control system PCS plant control system PSTN public switched telephone network PTZ pan-tilt-zoom PVC polyvinyl chloride RH relative humidity rms root mean square RSO recurrent surge oscillogram RTD resistance thermometer detector SF6 sulphur hexafluoride SFC static frequency converter SMACNA Sheet Metal and Air Conditioning Contractors National Association SO2 sulphur dioxide SOE sequence of events SPN single phase neutral TEWAC totally enclosed water cooled TPN three phase neutral TV television UHF ultra high frequency UPS uninterruptible power supply UV ultra violet V volt VCR video cassette recorder VDE Verband Der Elektrotechnik Elektronik Informationstechnik e.V VDU visual display unit VOC volatile organic compounds VT voltage transformer WB World Bank WTP water treatment plant XLPE cross linked polyethylene XLPE cross linked polyethylene


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1. PROJECT DESCRIPTION

1.1 General

This Specification is intended to assist the Contractor for the design, manufacture, delivery, off-loading at Site, erection, painting, setting to work, testing and attention to defects of the [ ] open cycle gas turbine power station, to be located at [ ].

The station will be constructed on a turnkey basis and shall include all equipment, work and services in order to render the power plant fully complete and functional for safe, reliable and commercial operation under all conditions and respects.

1.2 Site Description

The site is located:

[ ]

1.3 Target project start and completion

The Works are expected to commence [ ], and the plant shall be complete and ready for Taking Over having successfully completed all the tests on completion as defined in Section 11 by [ ].

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2. PLANT DESIGN CRITERIA

2.1 General

This Specification requires a gas turbine power plant design that is modern, well proven, safe, economically attractive both in capital cost and running cost and offering a high availability with low forced outage rate. The plant shall be fully automated and require minimum operator intervention for normal operation. The Contractor shall comply with the Specification unless compliance would for any reason put at risk safety, reliability and economy due to deviation from standard practice of the Contractor. However, the intent of the Specification shall always be complied with.

Any deviations from the Specification shall be clearly identified in Schedule F, which shall be completed and returned as part of the Tender. The meaning of all terms is as defined in the [EPC Contract Document].

Equipment shall be designed and selected to ensure high reliability and availability of the complete plant with low forced outage rates and minimal maintenance over the lifetime of the power station, which shall be defined as 25 years.

An appropriate level of redundancy shall be included in each system; the Works shall be designed so that no single auxiliary plant failure within any gas turbine unit shall result in the total loss of the unit generating capability. In this context, it is required that with agreed exceptions, all unit auxiliaries will be provided with at least one installed spare (N+1). For the station auxiliaries, no single equipment failure shall result in any loss of station generating capability.

Prototype plant will not be acceptable, and plant that is offered with limited operating experience must be fully supported by manufacturer’s warranties and indemnities.

2.2 Unit rating

The station configuration shall be based on two open cycle gas turbine units, with a base load capacity of {240-340} MW net output at the site base reference conditions as defined in Schedule C Part 1.

The gas turbine units shall be selected to ensure that the guaranteed performance at the base reference conditions can be maintained whilst firing with the specified fuels without inlet air enhancement or power augmentation. This shall be the basis of the ‘base’ offer in the Tender.

The Tenderer may offer inlet air enhancement technology or power augmentation as alternatives to the base offer, but this shall not be part of the base offer, and shall be separately identified in the price schedules, in order that, in the event that the Owner may choose to procure such a solution, this can added. The price shall include all mechanical, electrical, I&C and civil materials and works. If inlet air enhancement technology is offered, additional performance schedules, technical data sheets and guarantees as required by the Specification shall be completed for the plant with and without this technology. The Tenderer shall include, in the above respects, full details of all additional demineralized water equipment and storage facilities and changes to the service water system, etc. that may be required as a result; again, all appropriate technical data sheets, pricing sheets, etc. shall be completed and included in the offer. The Tenderer shall prepare additional sheets and add these in the same format as provided in the relevant sections.

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2.3 Site layout

The Contractor shall provide a layout generally in accordance with the conceptual site layout provided in Volume 3, conversant with good operating practise, so that maintenance access is fully available to any part of the plant.

If requested by the Owern/Engineer, the Contractor shall take account of the future possibility that the plant may be converted to combined cycle operation. The Contractor shall therefore lay out the plant accordingly with space allocation for heat recovery steam generators on a per set basis, condensing steam turbine and generators, steam turbine generator building, cooling facilities, additional switchgear, pipework, cabling, controls, etc, to form a complete, fully functional, easily maintained, combined cycle power station.]

The open cycle layout shall be based on an ‘outdoor’ type GT installation. The site layout, including plant, buildings, roads, gates, laydown areas etc shall take into consideration the requirement for heavy vehicles and cranes required for installation and future maintenance of the plant can gain access to carry out the necessary work. The site layout shall be subject to approval of the Owner/Engineer.

2.4 Plant operating philosophy

The Plant shall be designed for base load and two shifting operation. The intended operating regime for the immediate future will be base load, operating [8000 to 8150] hours per annum equating to a typical annual availability of [91 to 93] per cent. In addition, the plant shall also be capable of operating on a two-shift operating regime, based on one start per day.

Plant normal start-up and shutdown will be initiated from the main control room. The gas turbine and other BOP equipment will be operated primarily from the PCS in the main control room. Each gas turbine unit shall also have the capability to be monitored and controlled via the control systems local to each unit. The plant will be automated to reduce the manual intervention required by operations staff.

The gas turbines shall be capable of start-up, shutdown and continuous operation on the fuels as defined in Schedule A, and each gas turbine shall have cold and hot start up capability and be able to operate either individually or in parallel. The plant shall be provided with a black start capability.

2.4.1 Site conditions

Equipment shall be designed and installed to enable safe and flexible operation of the Works over the entire range of operating modes and conditions as defined in this Specification and shall operate safely and reliably over the full range of site ambient conditions listed in Schedule A of this specification.

The Contractor shall be responsible for sourcing all site meteorological data to facilitate the design of the plant, including such air sampling on site as is necessary to ensure the correct design of the gas turbine air intake filters.

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2.4.2 Fuel/water supplies

Indicative analyses of the fuel and water supplies to the plant are provided in Volume 2, Schedule A for information. However, the Contractor is responsible for obtaining sufficient data regarding the fuel/water supply conditions, including analyses as necessary for his design of fuel/water treatment plant and handling/storage facilities, in order to ensure that the required quantity and quality of fuel/water is supplied to the gas turbines.

2.4.3 Grid conditions

The voltage variation on the transmission system will normally remain within the limits stated in Schedule A.

The frequency of the transmission system will be nominally 50 Hz, and will normally be controlled within the limits stated in Schedule A.

Each generation unit shall have, as a minimum, the following capabilities:

• operate continuously maintaining its active power pro rata to transmission system frequencies within the range [49.5] Hz to [50.5] Hz;

• remain synchronized to the transmission system at transmission system frequencies within the range [47.5] Hz to [52] Hz for a duration of [60] minutes;

• remain synchronized to the transmission system at transmission system frequencies within the range [47] Hz to [47.5] Hz for a duration of [5] seconds required each time the Frequency is below 47.5 Hz;

• remain synchronized to the transmission system during rate of change of transmission system frequency of values up to and including [0.5] Hz per second;

• sustained operation at the specified minimum stable generation within the range [49.8] Hz to [51] Hz.

For requirements regarding the design of the generators, refer to Section 7.1.

2.5 Seismic design

Iraq is an area of relatively high seismicity and all plant items shall therefore be designed to resist seismic loads.

For further details of seismic requirements, refer to Section 9.

2.6 Performance criteria

2.6.1 Output and heat rate

The Contractor shall guarantee the corrected net electrical power output (NPO) and corrected net plant heat rate (NPHR) at the base reference conditions as specified in Schedule C, based on the following definitions:

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Net electrical power output: The net plant output is the total plant net output measured at the tariff meter, located on the HV side of the step up transformers, net of all site auxiliary loads, and transformer losses, corrected to base reference conditions.

Net plant heat rate: shall be based on the lower heating value of the fuel and corrected to the base reference conditions

The Tenderer shall also provide all necessary curves necessary for correcting power output and specific heat rate from the test conditions to the guarantee base reference conditions in his tender:

a. Variation in barometric pressure

b. Variation in ambient temperature

c. Variation in relative humidity

d. Variation of generator efficiency with power factor

e. Variation in fuel LCV and C/H ratio

f. Variation in grid frequency.

2.6.2 Plant start up

The Tenderer shall guarantee and demonstrate the time for one gas turbine to reach full load, and for the block (two gas turbines) to reach full load. Start up curves for the plant shall be provided in the Tender.

2.7 Environmental criteria

The plant shall conform as a minimum with the current World Bank guidelines, the requirements of the local environment authorities in Iraq and with all other relevant consents and regulations.

2.7.1 Noise

2.7.1.1 General

The facility shall be designed and constructed such that construction workers and operators are exposed to a minimum level of noise. The Contractor shall take appropriate steps to minimize noise exposure through equipment attenuation and procurement of inherently quieter equipment.

All noise limits specified in this document are to be evaluated as LAeq levels. This is the energy weighted average of measured noise level as averaged over a specified time period. All sound levels are expressed in terms of decibels as referenced to a sound pressure level of 20 micropascals.

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The absolute limit of any measured sound pressure level anywhere in the work area shall not exceed 85 dB(A).

In locations where it is necessary for operational attendants to make routine examinations closer than 1 m to an accessible part of a running machine which is between 80 and 85 dB(A), the Owner will wish to adopt hearing protection aids. Therefore the Contractor is required to draw specific attention to portions of the plant where this situation may be encountered and fix appropriate warning labels or signs.

Noise within buildings shall comply with the limits specified in Section 9 Civil.

2.7.1.2 Construction noise

The maximum noise level caused by construction noise outside the nearest window of the nearest occupied house shall be:

Daytime 70 dB(A)

Evening 60 dB(A)

Night 40 dB(A).

Noise levels at all time periods during public holidays shall not exceed 40 dB(A).

During construction, BS 5228 shall be adopted as the approved Code of Practice in relation to noise and vibration.

Noise levels shall be limited to 80 dB(A) or lower at a distance of 1 m from all construction equipment and activities to the fullest extent feasible. If a noise level exceeding 85 dB(A) is likely to occur in any area, warning signs shall be predominantly displayed in that area, indicating that a noise hazard exists and hearing protection must be worn. Any area where noise levels could exceed 90 dB(A) shall have controlled access to prevent unprotected personnel from entering the areas.

Peak or intermittent noises such as those resulting from pile driving shall occur during daytime periods only and maximum noise levels shall not exceed 70 dB(A) at the nearest inhabited dwelling.

2.7.1.3 Far field noise during operation

The Contractor shall identify the location of the nearest residential, institutional or educational location and establish the background noise level. The noise level including background and contribution from the plant during operation shall either (a) raise background noise level by a maximum of not more than 3 dB(A) or (b) not exceed the following limits, consistent with the World Bank Guidelines:

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Maximum allowable Leq (hourly) in dB(A)

Receptor Daytime (0700 to 2200) Night time (2200 to 0700)

Residential, institutional, educational 55 45

Industrial, commercial 70 70

A noise test procedure shall be submitted by the Contractor, outlining the proposed

method of noise testing, to demonstrate compliance with the stated environmental noise limits.

The on-site and environmental noise levels shall be assessed by the Contractor using his own and subcontractor’s data in order to comply with the site requirements relating to noise emissions.

The gas turbines shall be enclosed in acoustic enclosures to ensure noise limits within the building are achieved. The Contractor shall ensure that noise emissions are minimized, not only for GT plant, but also for the balance of plant equipment.

2.7.2 Emissions to air

2.7.2.1 Emissions during construction

The Contractor shall ensure that suitable site practices are employed to ensure that atmospheric dust contamination generated by the construction works do not exceed levels which could constitute a health hazard or nuisance to those persons working on the site or living nearby.

2.7.2.2 Emissions during operation

The World Bank has set emission limit for gaseous emissions from thermal power plant and gas turbines for NOx, SO2 and particulate matter. The table below presents the maximum emission limits for each pollutant based on combustion turbine units.

Maximum value Parameter

Fuel Gas Distillate fuel oil

Oxides of nitrogen* 125 mg/Nm3 165 mg/Nm3

Sulphur dioxide * 2000 mg/Nm3

Particulate matter 50 mg/Nm3

* The emission limits are referenced to 15 per cent O2, 0°C, 1 atm, and dry flue gases.

In addition the total SO2 emissions from the power plant shall be less than 0.2 tonnes per day per MWe of plant output.

The Contractor shall install appropriate abatement measures on the proposed gas turbines to comply with the NOx limits above, the details of which shall be provided in the Tender.

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Continuous monitoring of NOx, SO2, CO, O2 and H2O to correct to dry flue gases shall be made from the main stacks of each gas turbine and displayed on the PCS. Any exceedances of limit values shall be alarmed.

Sampling points and safe access adjacent to the monitoring points shall be included.

Any natural gas vent stacks required shall be at a height sufficient to ensure that the concentration of gas at ground level is significantly less than the explosive limit.

Emissions of volatile organic compounds from the fuel oil tanks shall be limited by installation of appropriate VOC removal plant, such as active carbon filters.

2.7.3 Ambient air quality

The World Bank (WB) has set ambient air quality guidelines for nitrogen dioxide (NO2) and SO2. The guide values from the WB are set out below.

WORLD BANK AIR QUALITY GUIDE VALUES (micrograms/cubic metre)

Parameter Reference period Recommended ground level concentration guide value

Nitrogen dioxide Short term exposure (24 hour mean) 150

Long term exposure (annual average) 100

Sulphur dioxide Short term exposure (24 hour mean) 150

Long term exposure (annual average) 80

The plant shall not lead to either the airshed dropping into the category of poor air quality

or an increase of more than 5 mg/m3 in the annual mean level of particulates and/or SO2 for the entire airshed.

The Contractor shall be responsible for suitable stack design of sufficient height, temperature and velocity to ensure that the above ambient air quality guidelines are not exceeded in combination with all other contributing sources in the vicinity of the proposed plant.

The Contractor shall be responsible for the assessment of the existing background air quality through monitoring data, or where none is available through a modelling exercise.

2.7.4 Aqueous emissions

The discharge of any effluents during construction, including site drainage, shall be the responsibility of the Contractor who shall reach agreement with the regulatory authorities and the local sewerage authorities with regard to the detailed methods of disposal.

Aqueous emissions from the plant shall be treated and discharged in accordance with the following quality limits, consistent with the World Bank Guidelines:

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Parameter Maximum, mg/l (except pH and temperature)

pH 6 to 9

total suspended solids 50

oil and grease 10

total residual chlorine 0.2

chromium (total) 0.5

copper 0.5

iron 1.0

zinc 1.0

temperature increase at the edge of the mixing zone 3

°C

Aqueous discharges shall be segregated into storm drains, process effluent and domestic

sewage streams. Each shall be provided with an appropriate monitoring and treatment system to ensure that the discharge limits are not exceeded.

The effluent from the water treatment plant shall be bulked, mixed and neutralized before discharge to the site effluent tank to be provided under this Contract. Filter wash water shall also be discharged to the site effluent tank.

Any areas of the plant that may be subject to oil spillage shall be drained to an oil interceptor and the clean water discharged with the surface water drainage system.

A package sewage treatment facility shall be installed for the operational phase, sized for the number of operating and maintenance personnel.

All fuel oil and lubricating storage tanks shall be bunded to contain 110 per cent of the contents of the largest tank.

Gas turbine compressor wash effluent shall be segregated and stored at a suitable location for off-site disposal.

2.7.5 Visual impact

All reasonable measures shall be taken to minimize visual impact of the plant. Structures and buildings shall meet the standards generally accepted for a facility of this type and shall be in accordance with all applicable local and national consents relating to appearance. Final architectural arrangements shall be submitted for approval to the Owner/Engineer.

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3. SCOPE OF WORK

3.1 Summary of main scope and services

This Contract provides for the design, manufacture, construction, supply, testing in works, packaging for export, shipping, transport, delivery to Site, unloading at Site, complete erection, health and safety management, painting, commissioning and putting into operation, performance and reliability testing on completion, instruction of the Owner’s personnel and obligations for the defects liability period of the gas turbine open cycle power plant.

The station will be constructed on a full design and build, turnkey basis, and it will be the responsibility of the Contractor to ensure that all equipment, scope of work and services are provided in order to render the power plant fully complete and functional for safe, reliable and commercial operation under all conditions and respects.

All material, plant and equipment shall be new and of a class suitable for the purposes specified. Equipment shall be selected to ensure high reliability and availability of the complete plant with low forced outage rates and minimal maintenance. Permanent, safe access to all items of plant shall be provided for inspection, operation and maintenance.

Unless specifically excluded from the scope of work, interconnecting cabling, pipework etc between items of equipment and plant described in this specification shall all be included under this contract, as shall the installation, testing and commissioning of the same.

Generally, the main supply will include but not be limited to the following (refer to specific sections for further details):

a. Two gas turbine generator units including

Gas turbine air inlet systems, including filtering, ducting and silencers.

Fuel pressure regulation and conditioning equipment

Gas turbine combustion system

Water injection system (if required) for NOx suppression for operation on fuel oil

On-load and off-load compressor washing system

Gas turbine generator starting system

Condition monitoring and performance system

Gas turbine generator instrumentation, control and protection system

Acoustic and weatherproof enclosures

Fire detection and protection system including, CO2 systems, gas detection system and alarm panels

Enclosure ventilation fans, ducts and silencers

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Lubricating oil cooling systems

Generator air cooling system

Gas turbine exhaust system including ducting, exhaust stacks and silencers.

Continuous exhaust gas emissions monitoring equipment

Insulation and cladding

b. Auxiliary equipment and systems

All necessary auxiliary equipment and systems including, but not limited to, the following:

Fuel gas supply system required to deliver gas to the gas turbines at the required conditions including as necessary gas compressors, heaters, pressure regulation, filters, metering, condensate disposal, venting and inert gas purging system, distribution piping and valves.

Fuel oil supply system required to deliver fuel oil at the required conditions to the plant consumers, including as necessary storage, treatment, pumping, pressure control and metering, distribution piping and valves.

Water supply, metering, treatment, storage and distribution systems to deliver water at the required conditions to the plant for all raw, fire, potable and demineralized water consumers.

Waste water treatment storage, monitoring and disposal systems.

Gas turbine cooling system, comprising closed circuit circulating water system, including heat exchangers, pumps, fin/fan coolers, interconnecting piping and valves.

Fire protection and detection systems for the complete plant and buildings, including fire pumps, buried hydrant system, hydrant outlets, sprinkler systems, deluge water spray system, foam/water deluge /spray systems, hose reel and equipment cabinets, portable extinguishers, alarm panels and control system.

Instrument and service air system including air compressors, filters, driers, coolers, receivers and distribution pipework.

Heating, ventilation and air conditioning systems.

Cathodic protection systems.

Cranes and lifting equipment for maintenance of all equipment, including electric overhead travelling crane in the workshop.

All necessary interconnecting pipework and valves, including insulation, cladding and trace heating (where necessary) for all services.

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Complete structural steelwork, foundation bolts and plates, anchors, guides, lifting facilities and sundries.

Facilities for storage of lubricating oils and greases, chemicals and all other consumables as required for the plant.

c. Electrical equipment

Three phase 50 Hz enclosed generators arranged for air/water cooler duty.

Generator phase isolated busbars and connections

Generator circuit breakers

Generator transformers

Unit transformers

Auxiliary and emergency transformers

Auxiliary power supplies, including MV/LV switchgear, MCCs and distribution boards

Essential supplies including batteries and UPS system.

Protective relaying and metering systems including CTs and VTs.

Lighting and small power systems and equipment.

MV and LV power, control and instrumentation, telephone and emergency cabling systems.

Earthing and lightning protection including station earthing grid

Instrumentation

Fault recording and diagnostic systems

Neutral earthing system

Black start/emergency diesel generator complete with all ancillary plant and fuel oil storage tank

d. Control and instrumentation

Complete control, protection and monitoring systems for the plant provided, including, but not limited to:

Plant control system including all necessary hardware and software for monitoring and control of the plant from the central control room

Control desks, operator workstations, engineering workstation and printers

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Gas turbine local control station

Condition monitoring system for the gas turbines

PABX telephone system

Public address system

Closed circuit television and perimeter security system

Weather station providing measurement and records of ambient temperature, pressure and humidity

Tariff metering panels and equipment

All required control and instrumentation for safe, reliable and efficient operation of the plant

e. Civil Works

All civil works associated with the above equipment, including but not limited to:

Geo-technical and topographical surveys of the site, including ground pollution report.

Data collection including verification of design data provided in the tender documents

Site preparation – excavation and filling, site grading

Site access roads, car parks and footpaths

Utilities pipework

Acoustic attenuation where required to meet noise limits.

Storm, foul, oily and plant drainage systems

Utilities and underground services

Security works during construction and operational phases

Fencing and gates

Hard landscaping

Site services, (ie power, water, sewage and telephone) for the Contractor and Owner office accommodation during the construction period.

Office accommodation during the construction period for the Contractor, and the Owner Building works, foundations, structures and associated facilities:

Buildings to be included as a minimum, in the civil works as follows:

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• Administration, including toilets and mess rooms, prayer, clinic and central control room

• Workshop and stores

• Fuel oil pumping/treatment plant

• Fire station and ambulance

• Fire water pump house

• Water treatment plant

• Security gatehouse

• Emergency/black start diesel generator.

Building services, including air conditioning of the local control rooms and central control building.

Foundations and associated works for:

• Gas turbine generators

• Transformer compounds

• Emergency/black start diesel generator

• Fuel gas treatment, metering and handling equipment

• Fuel oil storage tanks and handling equipment

• Service/fire water, potable and demineralized water storage tanks

• Fire fighting foam equipment

• Compressed air equipment

• Miscellaneous plant and equipment

• Service ways, ducts and trenches, pipe racks and bridges.

All necessary foundation bolts, supports, access ladders, walkways, handrails etc for the safety of personnel during plant operation and maintenance.

Bunded areas for all lubricating and other oils and chemicals

Rain shelters over all bunded areas

Sump pumps

Site sewage system.

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f. General services

All necessary services associated with the above scope, including, but not limited to the following:

Quality control inspection and testing

Painting and finishing

Spare parts

Tools, lifting tackle and special appliances

Contract documents and drawings

Quality Control, inspection and testing

Operation and maintenance manuals

Training of the Owner’s staff in the operation and maintenance of the Works.

Local lifting beams and manual hoists

Special tools and maintenance equipment for all plant and equipment

All flushing facilities and flushing oils

First charge of all chemicals, lubricating oils and lubricants

Consumable spare parts (covering the Works up to Take Over).

The Contract shall include the whole of the aforementioned work which is described in or implied by the Specification and all matters omitted from the Specification which may be inferred to be necessary for the safe, reliable and efficient operation, stability and completion of the Works shall be deemed to be included in the Contract Price. All plant, equipment, materials and works shall be provided to complete the installation ready for commercial operation whether or not specifically called for herein.

3.2 Terminal points

The Contractor shall be responsible for obtaining sufficient data regarding the interface conditions for the plant, to ensure safe, efficient and reliable operation of the Works within the environmental limitations, under all operating modes and climatic conditions as defined in Section 2.

The Contractor shall be responsible for making the connections, including breaking into other systems, as necessary.

The Contractor shall assess the proposed termination points for all services and shall agree with the Owner an appropriate tie-in point and tie-in schedule. The location and schedule shall, where applicable, be designed to minimise inconvenience to other users of the systems. The

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Contractor shall clearly identify in the Contract Programme the date he requires the terminal points to be available.

3.2.1 Fuel supplies

The Contractor shall be responsible for the connection of the fuel supplies to an agreed termination point located adjacent to the site boundary. The exact location of the termination point will be finalized during Contract negotiations.

An indicative analysis of the fuels is included in Schedule A for information. However, the Contractor shall be responsible for the provision of sufficient data regarding the fuel supplies for the plant, including analyses as necessary to ensure the appropriate design of treatment and handling/storage facilities to provide the requisite flow and quality of services as required by the gas turbines and other users within the site.

3.2.2 Water supplies

The Contractor shall be responsible for the connection of the water supply to an agreed termination point located adjacent to the site boundary. The exact location of the termination point will be finalized during Contract negotiations.

An indicative analysis of the raw water is included in Schedule A for information. However, the Contractor shall be responsible for the provision of sufficient data regarding the water supplies for the plant, including analyses as necessary to ensure the appropriate design of treatment and handling/storage facilities to provide the requisite flow and quality as required by the gas turbines and other water users within the site.

3.2.3 Electrical connections

Electrical power from the gas turbine generator packages shall be exported to, and be compatible with, the electrical connection provided by the Owner under a separate connection contract with the Ministry of Electricity. The HV terminals of the generator transformers will be the terminal point.

The Contractor shall establish communication protocols and liaise with the Ministry of Electricity to ensure that all appropriate safety requirements are fulfilled.

3.2.4 Communications

All connections to the public telephone network shall be the responsibility of the Contractor. The Contractor shall ensure that all communication systems used during construction and operation of the Site meet appropriate regulations and do not cause interference with any communication or electrical equipment on the surrounding site.

3.2.5 Drainage

The termination points for the drainage systems shall be sub-divided into surface water, foul water, chemical and oily water systems. Details of the drainage specification are given in Section 9.

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3.2.5.1 Surface water

The surface water system should collect precipitation of the whole station into a system of underground pipes, manholes and discharge it into an existing system if available, providing sufficient capacity is available. If no existing surface water system is available, the discharge shall be arranged to a soakaway to be agreed with the Owner. The civil engineering requirements are detailed in Section 9.

3.2.5.2 Foul water

A package type sewerage treatment plant shall be provided to process the foul drainage on site. The specification of the mechanical plant is described in Section 6. Where there is an existing public foul drainage system available, the treated fluid may be discharged into the public system, otherwise the treated effluent shall be pumped to an evaporation pond which is to be supplied as part of this Contract.

3.2.5.3 Chemical and oily water

All chemical discharge from the gas turbine operation and water treatment plant must be neutralized in a neutralization pond and recorded before releasing to a public drainage system. Oil water shall be intercepted so that oil is screened and recovered before discharging cleaned water to the public system, when the specified environmental limits are met. Where no facility is available for discharge of the effluent, the chemical and oily water shall be routed to an evaporation pond which is to be supplied as part of this Contract.

3.2.6 Security fencing and access roads

The Contractor shall provide site security fencing, access roads and a main site access gate. The Contractor shall also ascertain the requirements of the Ministry of Electricity and gas supplier and provide additional security fencing, access roads and access gates to the gas supply compound and for electrical equipment compound. The detailed requirements of nominated gas supplier and the Ministry of Electricity shall be determined by the Contractor in discussions with the two organizations. Details of the civil engineering work requirements on fencing and access road are provided in Section 9. The alarm, surveillance and security requirements are detailed in Section 8.

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4. GENERAL REQUIREMENTS

4.1 Programmes and progress

4.1.1 Programme requirements

The programmes supplied by the Contractor will be used by the Engineer to monitor the overall progress of the project. Primavera project management software shall be used for all programmes for the duration of the Contract. The programmes supplied by the Contractor as part of this Project shall fully interrelate design, procurement, manufacture, erection and commissioning activities. Key events shall be clearly identified on all programmes and be integrated in to the program logic.

All programmes issued throughout the Project by the Contractor shall be provided electronically in Primavera format, to allow full interrogation by the Engineer. Print or plot files will not be acceptable.

The approved programme shall be adhered to by the Contractor and shall not be changed except as agreed by the Engineer. If at any time during the execution of the project it is found necessary to modify the approved programmes, the Contractor shall inform the Engineer and submit the modified programmes for his approval. Any approval or changes to the approved programmes shall not constitute approval of an extension of the guaranteed completion date, nor any approval of claims for increases in the EPC price.

4.1.1.1 Tender programme

The tender submission shall be supported by a Tender programme (bar chart format) conforming with the outline project programme included in this Specification and in sufficient detail to indicate the Contractor’s intention for executing the Works, and must cover major items relating to design, procurement, manufacture, delivery, erection, setting to work and commissioning. The critical path shall be clearly shown. Long lead manufacturing items and the dates for placing the main subcontracts shall be identified.

Key contract, programme and interface events shall be identified in the tender programme, including dates for access data and release of terminal points, that involve the Engineer, Owner or other Contractors.

Key dates of despatch, delivery to site and completion shall be identified in Schedule B.

The tender programme shall be resourced with the site labour requirements segregated into trade categories to meet the Tender Programme.

4.1.1.2 Contract programme

The Tender Programme shall be updated to include any modifications negotiated and agreed during the period up to award of contract and shall have the detail further expanded and developed prior to being submitted for approval by the Engineer within [30] days of the Letter of Acceptance. The programme shall be of at least level 2 detail, resourced and capable of producing manning histograms for each phase of the works, covering design, procurement, manufacture,

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construction, erection and commissioning. Activities of over eight weeks duration are unacceptable and shall be broken down in detail to acceptable sub-tasks. Following approval by the Engineer, this programme shall become the contract programme, and following the creation of a baseline, shall be used as the basis for measuring and reporting progress throughout the project timescale.

The approved contract programme shall be adhered to by the Contractor and shall not be changed, except as agreed by the Engineer. If, at any time during the performance of the contract, the Contractor has failed or is seen to be failing to perform the works in accordance with the contract programme, then the Engineer may direct the Contractor in writing to allocate additional resources or accelerate the works at the Contractor’s cost.

The Contractor shall be instructed to maintain his programme to reflect the current status of progress and to issue the required updated bar charts and associated reports etc, ‘S’ curves and histograms with each monthly progress report.

‘S’ curves shall be directly produced from the contract programme and be based on appropriate quantitative information. This may include, but not be limited to:

a. Number of design documents

b. Quantity of procurement components

c. Proportion of contract price for each plant area or construction activity

d. Metres of pipework erected

e. Metres of cables installed

f. Number of cable terminations completed

g. Commissioning packages.

4.1.1.3 Design schedule

The Contract Programme shall incorporate design activities that identify the sequence of work for the project and the submission of drawings, studies and reports etc. The Design Schedule shall be electronically extracted from the Contract Programme and shall contain all major documents and drawings to be submitted for review by the Engineer, their submission dates and durations for review as specified by the Engineer, and shall meet the requirements of the Contractor and other contractors engaged on the project.

4.1.1.4 Procurement and manufacturing schedule

The Contract Programme shall incorporate a Procurement and Manufacturing Schedule, which identifies as a minimum:

a. Details of suborders and target dates for placing subcontracts

b. Any detailed design required within the manufacturing period

c. Long delivery items.

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d. Information to be supplied by the Engineer/Owner submission dates.

The Procurement and Manufacturing Schedule shall be electronically extracted from the Contract Programme and shall be in sufficient detail to enable the work to be adequately progressed. This schedule shall meet the requirements of the Contractor and other contractors engaged on the project.

4.1.1.5 Preliminary Construction Schedule

The Contract Programme shall incorporate a preliminary construction schedule, which should identify in sufficient detail the Contractors intended construction strategy. The programme shall satisfy the following criteria:

a. Contain full details of all civil/mechanical/electrical terminal point release requirements.

b. Identify when services are required for commissioning purposes.

c. Include an outline setting to work and commissioning schedule.

The Preliminary Construction Schedule shall be electronically extracted from the Contract Programme.

4.1.1.6 Construction Schedule

Within 90 days of Contract Award, the Contract Programme shall incorporate a detailed level 3 Construction Schedule, expanding the detail in the Preliminary Construction Schedule and be electronically extracted from the Contract Programme. In addition to the detail outlined in 4.1.1.5, this schedule shall be in sufficient detail as agreed by the Engineer, to enable the work to be adequately progressed and monitored. This to include long duration activities of over 30 days to be broken down into sub-tasks of no more than 30 days duration. This schedule shall meet the requirements of the Contractor and other contractors engaged on the project.

4.1.1.7 Commissioning schedule

During the progress of the works, the Contractor shall develop the outline setting to work and commissioning schedule into a detailed level 3 Commissioning Schedule, in sufficient detail to enable the work to be adequately progressed. Activities of over two weeks duration are unacceptable and shall be broken down into acceptable sub-tasks. This schedule shall be electronically extracted from the Contract Programme and submitted to the Engineer for approval 3 months prior to the start of any commissioning activities and shall be approved not later than 1 months before the start of any commissioning activities. This schedule shall meet the requirements of the Contractor and other contractors engaged on the project, and shall be integrated with the contract programme.

4.1.2 Progress reporting

Monthly progress reports shall be produced by the Contractor and submitted to the Owner from the commencement of the Contract. The format is to be approved by the Engineer. They shall be submitted within one week of the report cut-off date to be agreed during negotiations. The report

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shall address design, procurement, manufacturing, construction, setting to work and commissioning issues. The reports shall include but not be limited to the following:

a. Executive summary.

b. Schedule of forecast and actual key events.

c. Three month look-ahead programme (extracted from the Contract Programme).

d. Progress to date in narrative format.

e. Areas of concern and details of corrective action being taken.

f. Actual resources against planned.

g. Updated ‘S’ curve.

h. Contract programme updated to show progress achieved. Programme progress updates shall also be provided in the form of a fully working Primavera electronic file, which will allow analysis by the Engineer. Electronic print or plot file are not acceptable.

i. Planning and consents.

j. Safety issues and industrial relations.

k. Colour photographs of progress in digital format. Each set shall comprise a total of 20 colour photographs, individually marked with the date taken, a description of the subject and the direction of view.

l. Contract financial status.

The Contractor may be required to include additional schedules and charts considered necessary by the Engineer to adequately monitor the Contract.

Hard copies of progress reports are to be issued to the Engineer and Owner in accordance with Schedule E. An electronic copy shall also be submitted to both the Engineer and the Owner.

Following mobilization at site, the Contractor’s site office shall submit weekly progress reports to the Engineer in accordance with Schedule E. The report shall summarize site activities, indicate numbers of the various classes of workmen employed on site, the plant and equipment on site and record any areas of concern and details of corrective action being taken. Daily activity reports shall also be provided summarizing the main activities to be undertaken each day, noting any special activities that require witnessing, together with full particulars and details of all obstructions, modified or additional work, incidents and the number of men employed in each of the several portions of the work in progress, in accordance with Schedule E.

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Access to the Contractor’s or subcontractor’s works shall be granted to the Engineer at any reasonable time for the purposes of ascertaining progress. The Engineer shall also have access to the Contractor’s daily activity reports.

The Engineer may request the Contractor to provide additional reports when in his opinion they are warranted.

Where there is an agreement to pay by time and material rates, the Contractor shall keep records of labour, materials and equipment. Such records shall be valid only when signed by both parties.

For work of a disputed or uncertain nature, sheets shall be signed by both parties as an agreed record of work done. The sheets shall be annotated “For record purposes only” and shall not imply any commitment concerning payment.

4.2 Design and standardization

The Works shall be designed to ensure satisfactory operation in which continuity of service is the first consideration and to facilitate inspection, cleaning and repairs. All equipment supplied shall be designed to ensure safe and satisfactory operation under the atmospheric conditions prevailing at the Site, and under such variations of load and pressure as may be met with under working conditions. In doing so the Contractor shall be responsible for and shall carry out HAZOP studies or other studies deemed necessary by the Engineer as part of the design process. The Works and all equipment and materials forming part of this Contract shall comply in all respects with any relevant statutory regulations, by-laws or orders currently in force where the Plant is to be erected.

Although the Works shall generally comply with international standards, any instruction in this Specification that a particular aspect of the Works shall comply with a named code or standard shall take precedence, and that particular aspect of the Works shall comply with the named code or standard. International standards are those standards such as BS, IEC, ISO, ANSI/ASME, API, NFPA, JIS, TRD, DIN and EN etc which are in common use throughout the world for this type of application.

In the event of any conflict in standards, the hierarchy of standards shall be as follows, with the standards occurring first in the list taking precedence over any standards later in the list:

a. Standards named in the Specification

b. International Standards

c. Other standards approved by the Engineer.

The Contractor may offer Works which comply with international standards, or internationally recognized codes or standards, which differ from those specified. However the Contractor may offer Works which comply with the different standards or codes only if he is able to demonstrate to the Engineer’s satisfaction that the Works offered are equal or superior to that which would have resulted had the specified code or standard been used. This substitution of codes or standards for those specified will only be acceptable if the manufacturing organization in question has extensive experience with the alternative code or standard offered. If requested to do so by the

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Engineer, the Contractor shall supply to the Engineer, at his own cost, two copies in English of the relevant code or standard which he proposes to substitute for that specified.

The Contractor shall be responsible for ensuring that all standards used are current, the use of superseded or obsolete standards is unacceptable. The ruling date for current standards are those in place at the time of Contract signature.

The Contractor shall be responsible for submitting all statutory calculations for the third party verification and for all other calculations required by the Engineer.

The International System of Units (SI) shall be used in connection with this Contract and the provisions of ISO 31 and ISO 1000. All materials, fittings, components, items of plant and equipment supplied for incorporation in the Works shall be standardized accordingly. If, after making diligent enquiries, the Contractor is unable to obtain an item standardized in SI units, written approval shall be obtained from the Engineer to supply non-standard material.

The principal units shall be as follows:

Parameter Units Remarks

Pressure bar absolute All calculations relating to plant performance

bar gauge All pressure gauges

millibar Gauges below atmospheric pressure

Temperature °C

Volume l (m3) litre

Mass kg (t) (metric tonne)

Flow – mass kg/s (t/h)

Flow volume l/s (m3/h)

Flow – gas kg/s (Nm3/h) (measured at 0°C 1.013 bar a)

Rotational speed rpm

Power kW

Enthalpy kJ/kg (MJ/Nm3)

Vibration mm (amplitude peak to peak)

Head m of H2O (mm Hg)

Heat rate kJ/kWh

Emissions level kg/m3

Alternative units indicated in brackets, may be used with the agreement of the Engineer.

SI units shall be used in all correspondence, documentation, calculations, drawings, measurements etc. If reference has to be made to non-standard items, the SI units shall be quoted followed by the non-standard units in brackets.

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The Contractor shall standardize mechanical and electrical equipment as well as instrumentation. Corresponding parts shall be made to gauge and shall be interchangeable wherever possible. When required by the Engineer the Contractor shall prove this quality by actually interchanging the various parts.

Particular attention must be paid to internal and external access in order to facilitate inspection, cleaning and maintenance. The Works shall be arranged such that each major item, plant, or group of minor plant items, can be safely isolated from all hazards for maintenance, if necessary, whilst the remainder of the plant remains in service.

The design shall conform to the best current engineering practice. All plant shall be of the manufacturer’s standard design, provided that this design is in general accordance with the Specification and shall use components proven to be satisfactory by previous experience.

The design dimensions and materials of all parts shall be such that they will not suffer damage as a result of stresses under the most severe service conditions. The materials used in the construction of the Plant shall be of the highest quality and selected particularly to meet the duties required of them. The plant shall be designed and constructed to minimize corrosion. Workmanship and general finish shall be of the highest class throughout.

All equipment shall be designed to minimize the risk of fire and damage which may be caused in the event of fire.

The equipment shall also be designed to prevent ingress of all vermin, accidental contact with electrical live parts and minimize the ingress of dust and dirt.

The Contractor shall provide the services of an approved Classification Society or Insurance Inspection Company subject to the Engineer’s approval and which shall include:

a. the certification of designs and drawings and the checking of scantlings of the components of pressure and vacuum containing parts

b. the certification of designs and drawings of lifting equipment and any other items of plant and equipment which in the opinion of the Engineer requires insurance inspection

c. the inspection and certification that all such components and plant items are manufactured, constructed and tested in accordance with the accepted standards

d. the inspection and certification of pressure or vacuum containing parts, lifting equipment, welding and associated non-destructive testing of such welding, during erection and commissioning on Site.

All certificates shall be distributed in accordance with the requirements of this Specification.

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4.3 Drawings and documents

4.3.1 Drawings enclosed with the Specification

A list of the drawings to be read in conjunction with the Specification is given in Volume 3. The drawings issued by the Engineer with the Tender Specification and forming part of the documents for tendering purposes are intended to be descriptive of the character of the Works and used in conjunction with the requirements of the Tender Specification and shall in no way limit the responsibility of the Contractor to supply all plant and equipment and services necessary to provide for a complete and functional complex. Any omission from both drawings and the Tender Specification or express reference to any detail or work necessary and obviously intended shall not relieve the Contractor of his responsibility to include that detail or work.

The sizes of the buildings shown on the Tender Specification drawings are approximate, since the actual size will depend on the size and shape of the plant, equipment and materials forming the Contractor’s Works and the space required for installation, maintenance, lay down, storage, access, etc.

The drawings depicting Civil Works do not portray exact requirements but are intended to be an indication of the type of work required.

When measurements are affected by conditions already established, the Contractor shall take and be responsible for field measurements notwithstanding any information given on the Tender Specification Drawings.

4.3.2 Schedules

The following technical schedules, contained in Volume 2, have been prepared on IBM compatible computers using Microsoft Word and Excel, and are available via DC ROM.

Schedule A Site particulars

Schedule B Dates of despatch, delivery to site and completion

Schedule C Manufacturer’s technical particulars

Schedule D Suppliers of materials, manufacturers, places of manufacture, testing and inspection

Schedule E Drawings and documentation

Schedule F Variations from Specification

Schedule G Tests and inspections

Schedule H List of recommended and optional spare parts

Schedule J List of special tools and equipment

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The Tenderer is required to complete the required technical schedules (including prices, where applicable) and return these via CD ROM with the completed schedules of their Tender. A signed print out of the schedules shall be used as original. The completed schedules have precedence over the disks.

The details provided in Schedule C1 – Manufacturer’s Guarantee Particulars shall take precedence over any other technical information provided in the Tender.

Schedule F (Deviations from Conditions of Contractor or from Specification) has been prepared on Microsoft Excel on the CD ROM. Tenderers are required to complete and return all Comments and Deviations on a CD using the format as provided, ensuring that all items are referenced to the relevant Volume/Section and Page of the Specification, and are uniquely numbered.

Unless a specific variation is detailed in Schedule F, the Tenderer shall be deemed to comply fully with the requirements of the Specification.

4.3.3 Drawings and documents to be submitted by the Tenderer

A list of the drawings and documents to be included within his Tender is included in Schedule E.

4.3.4 Drawings and documents to be submitted by the Contractor

A list of the drawings and documents to be submitted by the Contractor during the Contract implementation stage is specified in Schedule E. The Contractor shall also submit any further drawings or documents as may be reasonably required by the Engineer, during the design and construction of the Works. The Contractor shall prepare and submit to the Engineer review drawings (including dimensioned general arrangement, layout and detailed design drawings), and documents (including schematics, Process and Instrumentation Diagrams (P&IDs), data sheets, descriptions, plans and schedules) of all the plant and equipment specified in the Specification. Drawings and documents already submitted by the Contractor and reviewed by the Engineer, and such drawings and documents as shall be thereafter submitted by the Contractor and reviewed by the Engineer, shall not be departed from without the written instructions of the Engineer.

Copies of each drawing, calculation and data shall be submitted in accordance with the programme given in the Schedule of Contract Drawings. If the Contractor requires early review of any drawing or document to avoid delay in the delivery of the Contract Works, he shall advise the Engineer to such effect when submitting the drawing or documents. The sequence of submission of items shall be such that all information necessary for assessing each item is available at the time when received. In all cases, the drawings or documents shall be submitted in sufficient time to permit modifications to be made if such are deemed necessary by the Engineer without delaying the delivery of the Contract Works.

As soon as practicable, and not later than 20 working days after receipt, the Engineer will advise the category of the drawing as “Reviewed”, “Reviewed as Noted”, or “Returned for Correction”, as may be appropriate. The categories “Reviewed” and “Reviewed as Noted” authorize the Contractor to proceed with manufacture of the equipment covered by such drawings subject to the corrections, if any, indicated thereon. Where prints of drawings have been “Returned for Correction”,

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or “Reviewed as Noted” the Contractor shall make the necessary revisions on the drawings and submit further copies for approval in the same procedure as for the original submission of drawings.

Drawings shall be submitted for review at all stages of revision. The Contractor shall supply copies of each drawing for revision as detailed in the appropriate Schedule.

Following review, additional copies shall be provided for use at Site as required by the Engineer. .

All dimensions marked on drawings are to be considered correct, although measurements by scale may differ there from. Detailed drawings reviewed by the Engineer are to be acted upon where they differ from the general drawings.

Drawings showing the physical location of all devices and a plot plan showing the location of all equipment shall be provided.

Drawings shall not be “typical” but shall actually represent the equipment provided. Drawings shall be corrected to “as built” before final unit acceptance.

Approval of drawings shall not relieve the Contractor of any of his obligations under the Contract.

All legends and notes on drawings provided by the Contractor shall be in the English language. All drawings shall be dimensioned in millimetres (or metres) and drawn to one of the preferred scales quoted in Table 7 of BS Publication PD6031 and on paper of the appropriate size from the International series of A sizes.

4.3.5 Drawings and document format

Each drawing and document shall bear a unique drawing/document number. Individual items of equipment forming a part of a drawing shall be clearly identified by means of tables or other approved methods.

Each drawing shall incorporate the following information:

a. Location.

b. Drawing title (shall contain no abbreviations).

c. Original drawing sheet size ie A0, A1, A2, A3 or A4.

d. Drawing status.

e. Drawing number with provision for sheet and revision suffixes.

f. Drawing date.

g. Identity of persons carrying out the draughting, checking and approval.

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h. Scale or not to scale.

i. Project/contract number.

j. Revision.

k. North point on geographically related drawings.

The Owner’s information shall be in the form of the Owner’s Drawing Information Box. This box shall be located at the bottom right-hand corner of the drawing.

Documents submitted for review or approval shall incorporate the following information:

i. Document title (shall contain no abbreviations)

ii. Document status

iii. Document number

iv. Identity of person carrying out the preparation, checking and approval

v. Project/Contract number

vi. Revision.

4.3.6 Drawing sheet numbers

All drawings shall have a two digit sheet number.

Where only one sheet exists the sheet number shall be 00, where more than one sheet exists the sheets shall be numbered from 01 to 99 accordingly.

4.3.7 Drawing and document revision

All drawings and documents shall have a two digit revision number and all changes shall be clearly indicated by the addition of the following: appropriate revision number, revision date; identity of persons carrying out the draughting, checking and approval; concise details of the modification.

First issues have a revision status of 00, subsequent changes shall increase the revision status from 01 to 99 accordingly.

The change of drawing status shall result in a revision increase of one, whether there are changes to the drawing or not.

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4.3.8 Drawing and document status

Status definitions shall be used on all drawings and documents. The status shall not be part of the drawing or document title. The definitions are as follows:

a. For approval

b. For review

c. For information (for non-project/contract drawings)

d. For tender purposes

e. For construction (includes manufacturing)

f. As built and records.

All revisions of drawings shall be submitted in the following formats as detailed below:

i. A contract drawing list giving the Contract number, manufacturer’s number, sheet number, revision and title of each drawings.

ii. Paper prints of each drawing - full size.

iii. Paper prints of each drawing - A3 size.

iv. AutoCAD ACAD 2000 drawing file.

v. Drawings in PDF format.

The Contract drawing list shall be submitted by the Contractor for review by the Engineer who will indicate thereon the Owner’s requirements. On completion of commissioning, all drawings shall be updated and marked ‘as built’. These shall be supplied as final record drawings.

The AutoCAD ACAD 2000 drawing files referred to above shall be imported and exported on media such as Digital Linear Type (DLT) or CD. Each media shall be clearly labelled and accompanied by a transmittal sheet showing all file details.

Where the file format is restricted, the transmittal sheet shall clearly show how filenames relate to drawing numbers.

4.4 Operating and maintenance instructions

The Contractor shall supply complete and detailed Operating and Maintenance manuals in English covering the operation and maintenance of the plant and equipment as required by the Contract.

The contents of the operating and maintenance instructions, together with all drawings, illustrations and diagrams shall refer specifically to the plant and equipment being supplied under the

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Contract, and shall be specially prepared where necessary. General instructions referring to a range of equipment is not acceptable.

Operating instructions shall detail all integrated plant normal pre-start checks, starting up, running and shutting down procedures, for the various modes of operation of the plant from cold, warm or hot conditions, emergency operating procedures and any precautions recommended to prevent plant deterioration during periods of non-operation. Operating instructions shall cover local/remote and manual modes of operation and shall also include action on receipt of alarms.

The Contractor shall prepare a comprehensive commissioning schedule for each plant item and check lists to record the completion of these activities. Copies of all settings and/or calibrations of instruments and controls, pressure switches, trips and alarm settings confirmed and recorded in the commissioning schedules shall be forwarded to be included in the Operating Instructions.

[Five] sets of draft copies of the manuals shall be submitted to the Engineer for review [6] months before commissioning commences. They shall be submitted as complete texts. In the event that amendments or alterations to the draft manuals are required, the Contractor shall submit revisions for review without delay so that the final documents can be supplied within the date specified. [Eight] sets of the final documents shall be submitted within 4 months after the Taking Over Certificate.

The whole of the operating and maintenance instructions shall be securely bound in approved covers and provided with an index for easy reference.

The O&M manuals shall be provided in paper hard copy and in electronic copy on CD-ROM to a standard document reader format (ie Adobe Acrobat Reader).

The instruction manuals shall conform to the following format:

a. Index

The index system shall provide rapid and easy access to particular subjects, drawings and illustrations. It should include a master index and a sub-index to each main section of the manual.

b. Description

This section shall include basic data on the Plant.

i. Descriptions of the Plant both for individual items and for the systems into which items are assembled.

ii. Drawings sufficient for the understanding of descriptions.

iii. Flow sheets or single line and block diagrams which explain the functioning and logic of the system. Where related systems are shown on composite diagrams, individual systems shall be identified by colour, or coding as agreed.

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iv. Schedules which assemble references to items of a like kind, eg valve schedules, piping schedule, operational limit schedule, switchboard outline schedule, etc.

v. Data sheets which assemble in a concise format relevant technical details of a plant item or system. The purpose of a data sheet is to provide quick reference to the essential facts omitting all reference to general descriptions, operating or maintaining principles and instructions.

c. Operation

This section shall include basic step-by-step instructions on how to operate the Plant both with regard to individual items and to systems under all patterns of normal and abnormal conditions. The instructions shall include reference to the applicable operation limits.

Precautions and warnings relative to the safety of life and equipment shall be included where relevant.

d. Maintenance

This section shall include the following:

i. Build-up and assembly of systems and description of plant items.

ii. Schedule of equipment giving manufacturer’s name, the make/model No/catalogue No and parts list including any special spares ordering instructions. Spare parts catalogues shall be provided for the various items of equipment supplied.

iii. Routine maintenance schedule.

iv. Preventative maintenance and schedule of inspections.

v. Details necessary

IRAQ POWER RECONSTRUCTION - SMC Consortium · 2008. 2. 2. · 4.3.6 Drawing sheet numbers 4.11...

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Transcript of IRAQ POWER RECONSTRUCTION - SMC Consortium · 2008. 2. 2. · 4.3.6 Drawing sheet numbers 4.11...