EMPLOYERS REQUIREMENTS

PART VIII

PARTICULAR TECHNICAL REQUIREMENTS – MECHANICAL

SECTION 4

COOLING WATER SYSTEM

Table of Contents

4. COOLING WATER SYSTEM.......................................................................................................1

4.1 GENERAL.............................................................................................................................................1
4.2 SCOPE OF WORKS..............................................................................................................................2
4.3 DESIGN & DESIGN DATA.................................................................................................................2
4.3.1 Primary Circuit..............................................................................................................................3
4.3.2 Secondary Circuit..........................................................................................................................3
4.3.3 Turbine Shaft Seal Water Supply System.....................................................................................4
4.4 SPECIAL CONDITIONS......................................................................................................................4
4.4.1 Operating Conditions....................................................................................................................4
4.4.2 Proposal Drawings........................................................................................................................5
4.4.3 Submission of Documents............................................................................................................6
4.4.4 Subcontract Orders........................................................................................................................6
4.5 MATERIALS AND WORKMANSHIP................................................................................................6
4.5.1 Type of Materials..........................................................................................................................6
4.5.2 Design Stresses.............................................................................................................................7
4.6 PARTICULAR DESIGN AND CONSTRUCTION REQUIREMENTS..............................................7
4.6.1 Coarse Strainer..............................................................................................................................7
4.6.2 Automatic Hydro-cyclone Filter...................................................................................................7
4.6.3 Plate Heat Exchanger....................................................................................................................7
4.6.4 Pumps............................................................................................................................................8
4.6.5 Expansion Vessel..........................................................................................................................8
4.6.6 Accumulators................................................................................................................................9
4.6.7 Valves and Piping.........................................................................................................................9
4.6.8 Valve Actuators...........................................................................................................................10
4.6.9 Local Control Board....................................................................................................................10
4.7 SPECIAL TOOLS AND SPARE PARTS...........................................................................................11
 4.7.1 Special Tools...............................................................................................................................11
4.7.2 Spare Parts...................................................................................................................................11
4.8 WORKSHOP TEST.............................................................................................................................12
4.9 SITE TESTS.........................................................................................................................................13
4.9.1 Commissioning Tests..................................................................................................................13
4.9.2 Trial Operation............................................................................................................................14
4. COOLING WATER SYSTEM

4.1 GENERAL

The Cooling Water System shall be provided for cooling purposes of the three generating
units and associated auxiliaries, including the following equipment:

- Generator air coolers

- Oil coolers of generator and turbine bearings

- Governor oil coolers

Further cooling water shall be supplied to the chillers units of the HVAC System.

The equipment for the provision of purified water for the turbine shaft seals is included in
this Section.

In addition, there shall be raw water branched-off to the Potable Water System and to the
Fire Fighting Water System.

The conceptual arrangement of the necessary equipment and the limit of supply to adjacent
works or systems of the power plant facilities are shown on the Tender Drawings and are
addressed in this Section.

Considering the nature of the raw water and the preference for a simplified maintenance,
the Cooling Water System shall be arranged in a two-loop configuration, consisting of
three open primary circuits connected by a header and one closed secondary circuit i.e., one
closed circuit for a set of three generating units.

The primary circuits shall transfer raw water through intermediate heat exchangers while
the secondary circuit shall circulate clean water through the coolers of the generating units
and the HVAC system, and transfer heat losses through the intermediate heat exchangers to
the raw water flow.

The water for the turbine shaft seals, the Potable Water System and the Fire-fighting Water
System shall be branched-off from the raw water when it has passed the hydro-cyclone
filters.

The Cooling Water System shall be designed for remote, automatic control, but it shall be
also possible to employ local, manual control of individual components, as well as local,
automatic control from the local control boards on the Turbine Floor near the cooling water
equipment.

The schematic arrangement of the equipment is shown in the conceptual schematic diagram
of the Cooling Water System.

4.2 SCOPE OF WORKS

The Scope of Work shall include the following supply and services:

- Three (3) primary circuits, each circuit including two raw water pump sets, one
hydro cyclone filter, one plate heat exchanger, motor-operated control valves,
discharge valves and associated auxiliaries.

- One (1) secondary circuit, including four circulating pump sets (3 sets plus 1
standby) for the generating units including appurtenances.

- One (1) lot of Motor-operated control valves, shut-off valves and instruments for
the individual sub-systems of the secondary circuit.

- One (1) lot of Piping, flanges, bolting material and valves for the raw water flow
and the clean water circuit, including supports, hangers, ceiling mounted lifting
lugs, etc.

- Three (3) booster pumps, automatic fine filters, accumulators, valves, piping and
instruments for the Shaft Seal Water Supply System.

- One (1) lot of Shut-off valves, hand-operated, for the raw water tapping points at
the turbine draft tube and to the tailraces.

- One (1) lot of foundation plates and frames, covering plates with frames, etc.

- One (1) lot of Instrumentation with cabling and wiring to locally arranged terminal
boxes designed to IP 67. All pressure switches and pressure gauges shall be
equipped with bleeder valves.

- One (1) local control board with external cabling to terminal boxes.

- One (1) lot of special tools and spare parts.

Accessories not specifically outlined in this Section, but necessary for the effective
operation of the system shall be included in the works.

4.3 DESIGN & DESIGN DATA

4.3.1 Primary Circuit

Each primary circuit shall be equipped with two horizontal, centrifugal pumps, taking raw
water from the corresponding turbine draft tube flange. Each pump shall be designed for a
100% cooling capacity of one generating unit and a 1/4 portion of the HVAC chillers
consumption. The pumps shall be operated in the lead/lag mode (one pump on duty and the
second pump in stand-by). The pump inlet pipes shall be fitted with coarse suction
strainers. The discharge side shall be equipped with check valve and butterfly valve. The
two discharge lines shall be routed to and connected with a manifold in front of the hydro
cyclone.

Each hydro cyclone filter shall be designed for the capacity of one heat exchanger.

The hydro cyclone filters shall all be connected to a header upstream of the heat
exchangers. Each plate heat exchanger with associated instruments shall primarily be
assigned to a generating unit, but all will be linked by the header. The flow through the heat
exchangers shall cool down the secondary circuit by at least 5°K. Motor-operated control
valves shall regulate the flow at the required rate.

Raw water of the header pipe shall be branched-off to the turbine shaft seals, the Potable
Water System and to the Fire-fighting Water System.

The raw water leaving the heat exchangers shall be discharged to the tailrace. The raw
water inlets and outlets shall be equipped with stainless steel screens suitable to prevent
entry of fish.

The equipment for the primary circuits shall be designed for a rated pressure of class PN10.
Pressure tests shall be performed at a pressure of 15 bars.

4.3.2 Secondary Circuit

The secondary cooling water circuit shall consist of a closed loop, circulating clean water
through the heat exchanger and the coolers of the turbine, generator, governor and chillers
units of the HVAC system. The interconnection of the sub-systems by means of a supply
header and a return header increases the availability of the individual components and
facilitates the adjustment of the water consumption.

The pumps shall be horizontal, single-stage centrifugal pumps, having an overhung

impeller and be separately coupled to the motor. The discharge side shall be equipped with
check valve and butterfly valve, the suction side with a butterfly valve.
The secondary circuit shall be provided with filling connections, expansion vessel, rust
inhibiter injection with dosage pump, drain valves and air relief valves as required by the
schematic layout.

All equipment for the secondary circuit shall be designed for a rated pressure of class PN
10. Pressure tests shall be performed at a pressure of 15 bars.

4.3.3 Turbine Shaft Seal Water Supply System

The system shall comprise one pressurised accumulator tank, three complete sets of booster
pumps, filters, valves, etc. and associated control equipment. The control equipment,
including motor starters, motor protection equipment, wiring and cabling between pumps,
flow-meters, pressure switches etc. shall be included in the supply of the local control
board.

The system shall be designed for fully automatic operation. The required capacity of the
accumulators and booster pumps has to be determined by the turbine designer depending
on the particular requirements of the seal design.

The filters shall be either of the automatic back-flushing type or of another proven
automatic, self-cleaning type requiring a minimum of maintenance. The minimum filtering
quality shall be 80 microns, or better if required by the seal design. The filters shall be
equipped with an alarm contact to indicate clogging of the filter.

The booster pumps shall be suitable for continuous operation or for frequent starts and
stops if required by the operating conditions.

The design pressure for all piping and armatures shall be 10 bar. The operation shall be
adequately monitored by flow-meters, pressure switches, flow sensors and pressure
sensors.

4.4 SPECIAL CONDITIONS

4.4.1 Operating Conditions

Raw cooling water shall be drawn from all three draft tube flanges, routed through the
Cooling Water System in the powerhouse, and be released to the tailrace bays of all three
turbines. The minimum and maximum internal water pressure is therefore affected by the
maximum and minimum water levels upstream and downstream of the powerhouse.
The maximum water temperature used for cooling purpose is expected at 25C. The raw
water flow through the heat exchangers shall cool down the clean water of the secondary
circuit by at least 5K. The permissible temperature rise of the clean cooling water flow is
anticipated at t = 5K.

The cooling water flow for electrical and mechanical equipment at a t = 5K has been
preliminary estimated at the following rates:

Generator losses (including bearings)65.0 l/s

Turbine guide bearing 0.5 l/s

Governor 0.3 l/s

Subtotal 65.8 l/s x 3 = 197.4 l/s

HVAC 16.00 l/s

Total cooling water 3 x 71.1 l/s = 213.4 l/s

Shaft seal water 3 x 0.90 l/s= 2.7 l/s

Branch – off for the Potable Water System = 0.15 l/s

Continuous total = 216.25 l/s ( 3x 72 l/s)

Normal rate of exceptional fire fighting water branch-off = 64.3 l/s ( 39 m3 total)

However, the definite calculation of the various components of the Cooling Water System
and turbine shaft seal water supply system has to be done by the Contractor based on
confirmed information on the water consumers.

The Contractor shall take and test as many water samples as he may require ensuring a full
knowledge of the conditions to be considered in his design.

4.4.2 Proposal Drawings

The Tenderer shall submit a draft piping and instrumentation diagram (P&ID). The
Tenderer shall also provide outline drawings of pumping sets, filters, intermediate plate
heat exchanger and motor-operated valves, a brief description of the filter strainer, heat
exchanger (documentation on design and operation) and conceptual layout of the Local
Control Board.
4.4.3 Submission of Documents

The Contractor shall submit, for the Employer’s Representative's approval, design
calculation notes and pertinent technical documents concerning the entire system. These
documents shall include in particular:

- Final statement on definite water flow requirements and corresponding sizing of the
equipment,

- Hydraulic calculation note for both steady flow and unsteady flow conditions,

- Dimensional design calculations for the main components,

- Piping & Instrumentation Diagrams (P&IDs),

- Component List,

- Sequence chart of automatic control sequences, including automatic lead/lag control

with manual override,

- Draft operation and maintenance manual at least three months before the beginning
of the Site tests.

4.4.4 Subcontract Orders

Should some parts of the equipment be supplied by a subcontractor, the Contractor shall
provide the Employer’s Representative with references of similar works executed by the
Subcontractor.

4.5 MATERIALS AND WORKMANSHIP

4.5.1 Type of Materials

The following information shall apply:

Pumps:

- Casing: Cast steel or ductile iron

- Impeller: Copper aluminum alloy or bronze

- Shaft: Forged stainless steel

Pipes:

All pipes shall be made of seamless steel pipes. Stainless steel shall be employed for pipes
smaller than 150 mm in diameter.
4.5.2 Design Stresses

- Under unusual loading, the maximum equivalent stress shall not exceed 50% of the
yield strength.

- Under unusual loading and hydrostatic test pressure, the maximum equivalent stress
shall not exceed 70% of the yield strength.

- The Plant shall be designed to safely withstand the earthquake forces outlined in the
Technical Specifications.

4.6 PARTICULAR DESIGN AND CONSTRUCTION REQUIREMENTS

4.6.1 Coarse Strainer

The coarse strainer shall be a trash rack; minimum distance of the bars shall be determined
by the designer of the Cooling Water System. The strainer shall be entirely made of non-
corrosive steel.

Adequate means of back flushing by pressure water or compressed air shall be provided.
Dismounting of the strainer shall be possible.

4.6.2 Automatic Hydro-cyclone Filter

One automatic hydro-cyclone sand separator shall be installed upstream of each heat
exchanger.

The automatic separator shall consist of sand separator, header, sand collector with
automatic siphon drain device, and the necessary instruments and electrical control box,
fully equipped for automatic operation.

The cyclone separator shall trap 99% of all particles bigger than or equal to 1.0 mm in size.

4.6.3 Plate Heat Exchanger

The plate heat exchangers shall be arranged on the Turbine Floor.

The heat exchanging elements, tube sheets and water boxes shall be of corrosion-resistant
metal.

Provisions shall be made to allow easy cleaning of the primary circuit side of the plate heat
exchanger. Drain sockets with valves and pipe connections through to the drainage gallery
shall be foreseen.

A temperature indicator and remote temperature detector shall be provided.

The heat exchangers shall be designed and tested according to an approved pressure vessel
code.

Two sets of special cleaning brushes and of all other necessary equipment to carry out
effective cleaning shall be included in the scope of supply.

4.6.4 Pumps

The pumps shall preferably have a speed of 1000 rpm, but the speed shall not exceed 1500
rpm. The overall pump-and-motor-efficiency shall not be below 60%.

Shafts sealed by packing glands shall be fitted with stainless steel sleeves. Seals shall be
exchangeable without extensive disassembly of the pump. Leakage water shall be directed
to suitable drainage facilities.

The pumps shall be equipped with non-return valves to prevent back-flow.

The capacity of the pump motors shall be higher than the maximum pump power input by
the following percentage:

10% for power input > 50 kW

15% for power input 10 kW to 50 kW

20% for power input 1 kW to 10 kW

30% for power input < 1 kW

The motor protection class shall be IP65.

The pumps shall be equipped with the necessary protections to prevent overheating, motor
overload, shortfall of permissible NPSH-value, etc. The relays required for these purposes
shall be furnished by the Contractor and installed in the relevant terminal boxes.

4.6.5 Expansion Vessel

In order to compensate for the pressure fluctuation during operation, the secondary system
shall be provided with a pressurized closed expansion vessel of bladder type or piston type
with suitable capacity at the selected pressure. The vessel or the filling system shall be
provided with automatic filling valve and safety valve, and a volume meter in the filling
line for monitoring of the volume of water introduced in the secondary circuit closed loop.
Pressure gauge and pressure switch for remote alarm indication shall be provided at the
expansion vessel.
4.6.6 Accumulators

The accumulators for the turbine Shaft Seal Water System shall preferably be standard
components of the Nitrogen (bladder) type, equipped with the necessary instruments and
valves for the monitoring of reliable operation.

4.6.7 Valves and Piping

The design of the piping shall ensure that the water flow velocity under normal operating
conditions does not exceed 2 m/s.

Welding of pipe joints and painting of the pipes shall be done in the shop as far as
practicable.

A sufficient quantity of flanged connections and threaded unions shall be provided to allow
dismantling and replacement of piping without welding work.

The connecting pipes of each unit of equipment, such as filters, heat exchangers, pumps,
etc., shall be equipped with shut-off valves.

Furthermore, shut-off valves, pressure gauges, pressure switches, pressure transducers,

temperature indicators, throttle valves, flow controllers, inlet and outlet connections, etc.
shall be installed in accordance with the cooling water diagram included in the tender
drawings.

All drainage and vent pipes shall be equipped with manually-operated shut-off valves and
shall discharge the water into the drainage system of the powerhouse. The pipes shall be so
arranged that no excessive vibrations or forces can occur and provisions shall be made to
prevent pulsations.

The following design criteria of components shall be considered:

(1) Gate Valves, Wedge Gate Valves

Ring seal type gate, carbon steel body, flanged ends, non rising stems, solid wedge.
Body seat rings and spindle of stainless steel. Threaded bush made of bronze. Wedge
seat rings of 13% Cr steel.

(2) Globe Valves

Cast steel body with flanged ends. Rotor shall be made of stainless steel.
(3) Non-Return Valves

Non-return valves shall be designed as to avoid water hammer on reverse flow. A dash-
pot has to be included to avoid any fluttering or slamming of the valve disc. Body seat
ring, disc facing ring, valve shaft and bolt shall be made of stainless steel.

(4) Butterfly Valves

The valve body shall be of fabricated steel or cast steel. The stainless steel seat ring
shall be replaceable. The trunnion bearings shall have self-lubricating bushes.

The valve disc shall be machined of cast steel or fabricated steel. It shall be designed to
a smooth shape, to minimize head losses and disturbances of the water flow.

The sealing shall preferably be of solid rubber-to-metal contact between the disc seal
and the body seat. It shall be possible to adjust the sealing contact and replace the seal
without dismantling the valve.

(5) Compression Type Couplings, or flange adaptors (for instance type Viking-Johnson), to
avoid unsuitable forces onto pumps and valves.

4.6.8 Valve Actuators

Self-contained with a high torque motor, power gearing, limit switches, torque limit switch
and auxiliary hand wheel for manual operation. Protection class shall be IP65.

4.6.9 Local Control Board

The control board shall be wall-mounted in a central location of the cooling water plant at
the Auxiliary Floor. It shall be designed for protection class IP65. The control board shall
accommodate the control equipment for the Cooling Water System and Turbine Shaft Seal
Water System, motor starters, protection equipment, rectifiers, a set of terminals with 20%
spare arranged on a terminal strip, electric switchboard heating, vapor-tight type lighting
inside of the switchboard to facilitate maintenance work, and a terminal for telephone
connection.

The control equipment shall include the following components:

- One key-operated selector switch, three positions, "Off", "Local" and "Remote", for
the Cooling Water System of each unit and associated main unit transformer.

- Key-operated selector switches, three positions, "Off", "Manual" and "Automatic",

for cooling water pumps, and back-flushing filters.
 - Push-buttons "On" and "Off" for all pumps and automatic back-flushing filters.

- Push-buttons "Opening" and "Closing" for all electrically operated valves.

- Two PLCs for the automatic local control of the water systems.

- Interface to the supervisory CCS of the power plant.

- Indication lamps "On", "Off" and "Failure" for all pumps, automatic back-flushing
filters, and "Open", "Closed" and "Failure" for all electrically operated valves.

- Operating hour counters for all pumps and automatic back-flushing filters.

- Manual selector switches for all motors and automatic back-flushing filters.

- Outputs of individual alarm signals for recording by sequence recorder.

- Collective alarm output.

4.7 SPECIAL TOOLS AND SPARE PARTS

4.7.1 Special Tools

One complete set of all special tools, necessary for the assembly, disassembly and
maintenance of the cooling water equipment and plan shall be provided.

4.7.2 Spare Parts

a) For various components:

- Two (2) control valves of each type.

- Two (2) check valves of each type.

- Two (2) measuring instruments of each type.

- Two (2) safety valves of each type.

- Two (2) pressure switches of each type.

- Two (2) complete actuators of each type.

- Three (3) sets of gaskets for the heat exchangers.

b) For each type of pump:

- One (1) pump complete with coupling and electric motor on common frame.

c) For the automatic hydro-cyclone filters and fine filters:

- One (1) actuator of each type.

 - Three (3) complete sets of seals.

- One (1) solenoid valve of each type.

4.8 WORKSHOP TEST

The Contractor shall prepare a table, listing all components to be tested and the tests to be
performed. The Employer’s Representative reserves the right to request additional tests if
necessary.

Test certificates for materials and equipment shall be provided in triplicate to the
Employer’s Representative. Shop tests shall include the following:

- Hydraulic pressure tests on all components under internal pressure. The test
pressure shall be 1.5 of the design pressure.

- Routine tests on purchased equipment.

- Insulation tests, operating tests, heating tests, load tests, etc. on electric motors, and
other electrical and mechanical components.

All plant shall be assembled for the inspection of functional tests. Exceptions may be
permitted if approved by the Employer’s Representative. All parts shall be correctly
doweled and match-marked to facilitate assembly at the Site. The Contractor shall give the
Employer’s Representative notice in writing of the date and place of inspection and testing
not less than two weeks before the parts are ready, and give the Employer’s Representative
full facilities for conducting or witnessing the tests. Three copies of the test reports shall be
provided to the Employer’s Representative.

At least and if so agreed, the following components shall be assembled in systems and
presented to the Employer’s Representative:

- Pump sets.

- Hydro-cyclone filters.

- Control valves.

- Non-return valves.

- Safety valves.

- Local control board.

- Plate heat exchangers.

The tests shall include the following:

- Check of conformity with approved documents.

- Operation of electric motors, limit switches, etc.

- Hydraulic pressure test.

- Setting and calibration of safety valves.

- Seal leakage check.

When the plant has passed the tests to the Employer’s Representative's satisfaction, he will
confirm that it is satisfactory, and that it can be disassembled, painted and packed for
shipment.

4.9 SITE TESTS

4.9.1 Commissioning Tests

The Contractor shall conduct the following commissioning tests to ensure that the
equipment has been correctly installed, all necessary adjustments and settings been made,
and that it is in sound condition to operate. The site tests are subdivided in preliminary
tests, and operation and performance tests.

a) Preliminary Tests

- Pressure test of piping system or sub-systems

- Electrical check of correct wiring and cabling
- Testing and setting of pressure switches, pressure transmitters and limit switches
- Measuring of insulation level on electrical plant
- Functional tests of the valves

b) Operation and Performance Tests

- Leakage test
- Final adjustment of pressure switches, indication instruments and interlocking
devices.
- Pump performance tests
4.9.2 Trial Operation

After successful completion of all commissioning tests, the Cooling Water and Shaft Seal
Water Systems shall be subject to a Trial Run. Trial Run Operation shall be carried out
under the supervision and responsibility of the Contractor.