DRAFT

STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

MAIN CONTENTS

Section- 1 General Note, Applicability and Project Specific

Information
Section- 2 General

Section- 3 System Description and Scope

Section- 4 Technical Specification - Mechanical Works

Section- 5 Technical Specification - Electrical Works

Section- 6 Technical Specification - Control &

Instrumentation Works
Section- 7 Technical Specification - Civil Works

Section- 8 Mandatory Spares

Section- 9 Quality Assurance Plan

Annexures

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

DETAILED CONTENTS
Clause No. Description Page No.
Section-1: General Note, Applicability And Project Specific Information
1.1 General note
1.2 Applicability
1.3 Brief details about power plant
1.4 Meteorological data
1.5 Salient technical data of existing power plant
Section-2: General
2.1 Intent of specification
2.2 Typical brief description of the existing flue gas path
2.3 Typical brief description of existing chimney
2.4 Design and guarantee conditions
2.5 General design requirements
2.6 Operational performance requirements
2.7 Layout requirements
2.8 General technical requirements
2.9 Spare parts
2.10 Quality assurance programme
2.11 Testing and inspection
2.12 Trial operation
2.13 Performance guarantees and acceptance tests
2.13.1 General requirements
2.13.2. Guarantees under Category- I
2.13.3 Guarantees under Category-II
2.13.4 Guarantees under Category-III
2.13.5 Auxiliary power consumption
2.13.6 Method of computing plant availability
2.13.7 Acceptance test
2.14 Integration of FGD system with the power plant units
2.15 Liquidated damages
2.16 Codes & Standards
Section-3: System Description and Scope
3.1 General description of wet limestone FGD system
3.1.1 Flue gas system
3.1.2 Absorber system
3.1.3 Limestone unloading, crushing & storage system
3.1.4 Limestone grinding, slurry preparation and storage
System
3.1.5 Gypsum dewatering, handling system
3.1.6 Waste water treatment & disposal system

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

3.1.7 Water supply for FGD system

3.1.8 Equipment cooling water system
3.2 Scope of supply
3.2.1 Mechanical works
3.2.2 Civil & structural works
3.2.3 Electrical works
3.2.4 Control & instrumentation works

3.3 Terminal points & exclusions

Section-4: Technical Specification- Mechanical Works
4.1 Flue Gas System and Duct works
4.1.1 General
4.1.2 Dampers
4.2 Booster fans
4.3 Wet limestone absorber system
4.3.1 Absorber
4.3.2 Mist eliminator wash water supply system
4.3.3 Slurry pumps
4.3.4 Oxidation air blowers
4.3.5 Agitators
4.3.6 Process water storage tanks & pumps
4.3.7 Other tanks
4.3.8 Seal water pumps
4.3.9 Elevator for absorber
4.4 Gypsum dewatering & handling system
4.4.1 Dewatering hydro-cyclones
4.4.2 Vacuum belt filters
4.4.3 Vacuum system
4.4.4 Filtrate system
4.4.5 Waste water treatment & disposal system
4.5 Limestone feeding and crushing system
4.5.1 Limestone data
4.5.2 Hoppers & chutes
4.5.3 Rack & pinion gates
4.5.4 Magnetic separator
4.5.5 Vibrating feeders
4.5.6 Skirt boards
4.5.7 Flap gates
4.5.8 Limestone conveying equipment
4.5.9 Lime stone crushers
4.5.10 Bucket elevator

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

4.5.11 Limestone silo/ bunker

4.5.12 Bunker shut-off gates
4.5.13 Gravimetric feeders
4.6 Wet ball mills
4.7 Limestone sampling units
4.8 Dust control system
4.9 Equipment cooling water system
4.10 Vertical sump pumps
4.11 Horizontal centrifugal pumps
4.12 Painting and protective coating
4.13 Ventilation and air conditioning system
4.14 Piping, valves and accessories
4.15 Thermal insulation
4.16 Instrument air compressors
4.17 Fire detection, protection & alarm system
4.18 Hangers and supports
4.19 Hoisting and lifting tackles
4.19.1 Mono rail and hoists
4.20 Wet chimney
4.21 Structural steel works
4.22 Control and operation philosophy of FGD plant
4.23 Drawings/technical data
4.24 Codes & Standards
Section-5: Technical Specification-Electric Works
5.1 11kV, 6.6kV AND 3.3kV Switchgears
5.1.1 Codes and standards
5.1.2 Technical parameters
5.1.3 Metering
5.1.4 General technical requirements
5.1.5 Spare feeders
5.1.6 Make of components
5.1.7 Tests
5.1.8 Drawings and data
5.2 11/0.433kv, 6.6/0.433kv or 3.3/ 0.433 kV LT oil/ dry
transformer
5.3 Type transformers
415V switchgears and non-segregated phase bus duct,
and DC Board
5.3.1 Codes and standards
5.3.2 Technical parameters
5.3.3 Metering
5.3.4 General technical particulars

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

5.3.5 Protection
5.3.6 Design and constructional features
5.3.7 Spare feeders
5.3.8 415V Non-segregated phase bus-duct
5.4 HT and LT Motors
5.4.1 Codes and Standards
5.4.2 General requirements
5.4.3 Type
5.4.4 Rating
5.4.5 Temperature rise
5.4.6 Operational requirements
5.4.7 Design and constructional features
5.5 HT/LT Power and control cables
5.5.1 Codes and standards
5.5.2 Design criteria
5.5.3 General technical requirements
5.5.4 Constructional requirements
5.5.5 Identification of cores
5.5.6 Arrangement of cables
5.5.7 Drums lengths
5.6 Installation of cables, earthing system and lightning
Protection system
5.6.1 Codes and standards
5.6.2 Design and constructional features
5.6.3 Equipment description
5.6.4 Installation
5.6.5 Earthing system
5.6.6 Lightning protection system
5.7 Lighting
5.7.1 Make of Equipment / Components
5.7.2 Normal service conditions
5.7.3 Lighting system
5.7.4 Main lighting board
5.7.5 Lighting distribution board
5.7.6 Ac/dc emergency lighting distribution board
5.7.7 Guidelines for design of lighting distribution system
5.7.8 Illumination level design factors and type of Luminaires
5.7.9 Description for each type of luminaire
5.7.10 Lighting distribution system design
5.7.11 Emergency lighting Distribution system
5.7.12 Spare feeders

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

5.7.13 Power socket outlets

5.7.14 Welding outlet
5.7.15 Drawings and Data
5.7.16 Standards
5.8 DC System
Section -6: Technical Specification For C&I Works
6.1 General
6.1.1 General requirements
6.1.2 Reliability and availability
6.1.3 Standardisation and uniformity of hardware
6.1.4 Operability & maintainability
6.1.5 Control & monitoring
6.1.6 Environmental conditions
6.2 PLC based control system
6.2.1 General requirements
6.2.2 Programmable logic based control system
6.2.3 Human machine interface system (HMIS)
6.2.4 Input/ output modules
6.2.5 Data communication system (DCS)
6.2.6 Control system requirements
6.2.7 Annunciation system
6.2.8 Historical storage and retrieval system (HSRS)
6.2.9 Printer
6.2.10 Furniture
6.2.11 Software documentation and software listings
6.3 Measuring instruments (primary and secondary)
6.3.1 General
6.3.2 Specification for electronic transmitter for pressure,
differential pressure (dp), flow and level
6.3.3 Specification for pressure gauge, differential pressure
gauge, temperature gauge and level gauge
6.3.4 Specification for guided wave radar type level
transmitter
6.3.5 Ultrasonic type level transmitter
6.3.6 Hart hand held calibrator
6.3.7 Temperature elements and accessories
6.3.8 Temperature transmitter
6.3.9 Specification for flow elements & flow meters
6.3.10 Analysers
6.3.11 Solenoid valves
6.3.12 Electrical actuators

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

6.3.13 Vibration monitoring system

6.3.14 Belt Protection Equipment
6.4 Control valves, actuators and accessories
6.4.1 Control valves
6.4.2 Valve actuators
6.4.3 Control valve accessory devices
6.4.4 Tests
6.5 Power supply system
6.5.1 General
6.5.2 Uninterruptible power supply (ups) system
6.5.3 Static inverters
6.5.4 Static switch and manual bypass switch
6.5.5 Step down transformer and voltage stabiliser
6.5.6 Ac distribution board (ACDB)
6.5.9 Battery health monitoring system (BHMS)
6.5.10 Battery racks
6.6 Process connection piping
6.6.1 Impulse piping, tubing, fittings, valves and valve
manifolds
6.6.2 Sample piping system
6.6.3 Air supply piping
6.6.4 Installation and routing
6.6.5 Piping/ tubing support
6.6.6 Shop and site tests
6.7 FGD control desk, system cabinets, local panels &
transmitters enclosures/ racks
6.7.1 General
6.7.2 FGD control desk
6.7.3 Cabinets, enclosures, panels
6.7.4 Local instrument enclosure and racks
6.8 CONTINUOUS emission monitoring system
6.8.3 Common Requirements for all Analysers
6.8.4 Specific requirements for Hot-extractive sampling type
SO2/NOx, CO2 & CO analysers
6.8.5 Specific requirements for Dilution Extractive type
SOx/NOx/CO2 & CO Analysers

6.8.6 Specific requirements for in-situ (Path) type SO2/NOx,

CO2 & CO analysers
6.8.7 Specific requirements for particulate emission (dust
density stack opacity) monitor
6.8.8 Specific requirements for continuous on- line mercury
analyser

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

6.8.9 Ultrasonic Flow Meter for Flue Gas Flow in Stack

6.9 Instrumentation cables
6.9.1 General requirements
6.9.2 Instrumentation cable specifications
6.9.3 Instrumentation cable interconnection and termination
philosophy
6.9.4 Fibre optical cables
6.9.5 Terminal blocks
6.9.6 Internal panels/cabinets/system cabinets wiring
6.9.7 Cable installation and routing
6.9.8 Cable laying and accessories & fittings
6.9.9 Field mounted local junction boxes
6.9.10 Conduits
6.10 Type test requirements
6.10.1 General requirements
6.10.2 Special requirement for solid state equipments/ systems

6.10.3 Type test requirement for C&I systems

Section-7: Technical Specification-Civil Works
7.1 General
7.2 Basic design criteria
7.3 Technical specification for earth work
7.4 Technical specification for cement concrete
7.5 Technical specifications for reinforcement
7.6 Technical specification for brick masonry works
7.7 Technical specifications for damp proof course
7.8 Technical specifications for plastering and pointing
7.9 Technical specification for flooring
7.10 Technical specification for water proofing of roofs
7.11 Technical specification for steel doors, panel
doors,steel windows, ventilators and rolling shutters
7.12 Technical specifications for plinth protections
7.13 Technical specification for miscellaneous steel
7.14 Technical specification for painting, acrylic emulsion
(interior)/weather proof acrylic emulsion (exterior) paint

7.15 Technical specification for grouting

7.16 Technical specification for supply, fabrication and
erection of structural steel
7.17 Technical specifications for sand filling
7.18 Technical specifications for pipes and pipe fittings

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

7.19 Technical specification for sanitary fittings

7.20 Technical specifications for open surface drain
7.21 Technical specification for painting and finishing
7.22 Technical specification for demolition & dismantling
work
7.23 Technical specifications for vibration isolation system
7.24 forspecification
Technical machine foundations
for pre-cast RCC slabs
7.25 Technical specification for metal sheet roofing, side
sheeting and accessories
7.26 Technical specification for G.I. Roof & side sheeting
and accessories
7.27 Technical specification for aluminium doors, windows,
ventilators & partitions
7.28 Chimney
Section-8: List of mandatory Spare Parts
8.1 Mechanical
8.2 Electrical
8.3 Control & instrumentation
Section -9: Quality Assurance Plan
9.1 Mechanical Systems
9.1.1 Flue gas system
9.1.2 Absorber
9.1.3 Limestone & gypsum handling system
9.1.4 Dust suppression & dry fog dust suppression
System
9.1.5 Bucket elevator
9.1.6 Silos/ bunkers
9.1.7 Ball mills
9.1.8 Vacuum belt filter system
9.1.9 Monorail and hoists
9.1.10 Ventilation system
9.1.11 Packaged, split and window air conditioners
9.1.12 Elevators
9.1.13 Fire detection & protection system
9.1.14 Fire detection & protection system
9.1.15 Low pressure piping, valves and fittings etc
9.1.16 Hangers and supports
9.2 Electrical systems
9.2.1 HT busduct
9.2.2 Auxiliary service transformers
9.2.3 Motors

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

9.2.4 11kV, 6.6kV and 3.3kV switchgear

9.2.5 415V switchgear and busduct
9.2.6 Power and control cables
9.2.7 Installation of cables, earthing system and lightning
Protection system
9.2.8 DC storage battery
9.2.9 Battery charger
9.2.10 VFD module
9.2.11 Station lighting
9.3 Control and instrumentation system
9.3.1 Measuring instruments (primary & secondary)
9.3.2 Process, connection & piping for C&I systems
9.3.3 Instrumentation cable
9.3.4 Control desk, plc panel, smoke detector, fire alarm &
Control system
9.3.5 Power supply for C&I systems (UPS/ voltage stabilizer)
9.3.6 Control valve actuators and accessories
9.3.7 Electrical actuators with integral starters
9.4 CIVIL WORKS
9.4.1 Sampling, Testing and Quality Assurance for Civil
9.4.2 General Works
QA Requirements
9.4.3 Piling Work (If Applicable)
9.4.4 Water Supply, Drainage & Sanitation
9.4.5 Architectural & Misc. Works
9.4.6 Pre Cast Concrete Works

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT

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