35760865-Bypass-HP

8/7/2019 35760865-Bypass-HP

1/11

8/7/2019 35760865-Bypass-HP

2/11

KARNATAKA POWER CORPORATION LIMITED SECTION: D1 .6TITLE SHEET 9 OF 20MECHANICAL SYSTEMS -

SPEC. NO. STEAM AND WATER CYCLE EQUIPMENTC ETO-8 IOADI-EPC-OO 1(i) load is either temporarily lost on the steam

turbine generator or is rapidly reduced,(ii) steam turbine generator is tripped.(b) Rapid matching of steam and turbine metaltemperatures during start-up of the turbine or duringstart-up of the other HRSG if the turbine is already runningwith one HRSG.(b) Serving as a pressure relief system to reduce the risk ofHRSG safety valves lifting when rapid load reduction onthe steam turbine generator occurs.(c) Continuous operation of the steam turbine at part loadwith HRSGs operating at 100% MCR condition.(e) Start-up/shutdown of associated HRSG while otherHRSG is on load.

6.7.2 Each pressure level of bypass station shall be designed for themaximum steam pressure, i.e. the safety valve set pressure in therespective section and sized for maximum steam capacity generated.In addition to the above, necessary margin for the condensateinjection shall be considered. Each bypass station shall comprise aquick acting stop valve and a pressure control valve on steam line(operated by separate actuators), a desuperheater, a stop valve anda control valve on spray water injection line (operated byseparate actuators), necessary instrumentation and controlequipment, all necessary piping, valves and fittings . Bidder shallindicate the arrangement made for dumping the bypass steam into thecondenser and the same shall be subject to Owner / Owner'sRepresentative approval.

6.7.3 The bypass control valves shall have the stroking time of not more than3-4 seconds for fast opening and 10-15 seconds for normal stroking.The spray water system for temperature control shall be compatible withthese HP bypass control valve requirements . They shall be providedwith electro-hydraulic actuators. If the oil system is a self contained unit,it shall have 100% standby oil pump connected to main system withnecessary valves -for isolation and maintenance. Hydraulicaccumulators shall be provided on the hydraulic system to ensurepositive supply of oil to hydraulic actuators even when hydraulic oilpumps are not available . Accumulator shall be adequately sized toensure supply for two complete stroking operation of all connectedactuators. All control valves shall be 0'; tight shut-off design and theactuators shall be designed for maximLii(\ shut-off differential press1lj-lr-l;-Po_-IISSUE

RO

8/7/2019 35760865-Bypass-HP

3/11

KARNATAKA POWER CORPORATION LIMITED SECTION: 01.6~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ TITLE SHEET 10 OF 20MECHANICAL SYSTEMS-SPEC. NO . STEAM AND WATER CYCLE EQUIPMENTCETO-BI OADI-E PC-001

acting across the valve . Low noise trim shall be provided to limit thenoise level to 85 dBA at a distance of 1.5 m from outline of valve at alloperating conditions.

6.7.4 The HP-IP-LP bypass system shall rapidly shutdown upon detection oflow spray water pressure, high steam temperature downstream ofdesuperheating stations and high reheater / condenser pressures.6.7.5 Special attention shall be paid to provision of warming up drains asclose to the bypass valves as possible in order to minimise thermalshock on bypass valves and upstream pipe work when bypass comesinto operation.6.7.6 The systems downstream of bypass valves shall be capable ofwithstanding the thermal shock due to failure of spray water.6.8 Excess Condensate Dump System

Excess condensate dump system shall dump the excess condensate incondenser hotwell to the condensate storage tank through an excesscondensate dump line downstream of condensate extraction pumpdischarge. The excess condensate dump line shall be provided with anexcess condensate dump control valve sized for not less than 10percent steam turbine MCR flow.6.9 General Process Requirements for Control Valves

All control valves for entire contract shall be sized such that the valvesare controllable over entire operating regime viz. low load to full load.The control valves which require to be operated during cold, warm andhot start conditions shall also be controllable during this mode ofoperation. To meet the above requirements if CONTRACTOR providesmore than one control valve, the controllable ranges of the controlvalves shall overlap to ensure bumpless transfer from one control valveto other. For other requirements of control valve refer relevant C&Isections.6.10 General Requirements Of Auxiliary Coolers

All the auxiliary heat exchangers provided for the entire contract shallbe designed to meet the requirements of TEMA unless otherwisespecifically mentioned.6.11 General Requirements Of Centrifugal Pumps

All the c(;ntrifugal pumps for entire contract shall .meet the requirementsof API 610 standard unless otherwise speCifically mentioned. r--IS-S-U-E- l

RO

8/7/2019 35760865-Bypass-HP

4/11

8/7/2019 35760865-Bypass-HP

5/11

KARNATAKA POWER CORPORATION LIMITED SECTION D 1.6Spec. NoCETD-BlDADI-EPC-OO 1

DATA SHEET - A1.6.1

SL. NO. DESCRIPTION1.191.201.211.22

Minimum tube support plate thicknessMinimum steam impingement bame thicknessWater box liltingTube sheet cooling on CW side

1.23 Type of protection for tubes againstimpingement of steam from

1.241.25

1.261.271.281.28.11.28.21.28.31.28.41.28.51.28.61.28.71.28.81.28.91.28.101.28.111.29

1.301.30.11.30.21.30.31.30.41.30.5

2.0

2.1

(a) Main turbine exhaust(b) HP lI P I LP bypass exhaust(c) DrainsType of tube sheet to shell jointType of condenser neck to steam turbine exhausjointLateral movement of condenser compensated byCorrosion allowance on ferrous pansMaterials Of ConstructionCondenser shell, hotwell and condenser neckWater boxStructuraL par tsTube sheetsTubes in coodensing sectionTubes in air cooling sectionTube support platesGaskets on water sideBoltsNutsDummy tubes I rodsAccessoriesConductivity Measurement Provision cathodicprotectionCodes And StandardsHeat Exchange Tnstitute Stand ards for SteamSurface CondensersAmerican Society of Mechanical EngineersASME Performance Test Code for CondensersAmerican Society for Testing MaterialsOther established material or internationalcodes and standards equal or superior to theabove listed standards.

CONDENSER AIR EVACUATION EOPT.& ACCESSORIESNumber

UNITSmmmm

mm

SHEET 12 OF 22VALUES I REQUIREMENTS

12103 mm fibre reinforced epoxyEpoxy coating

Higher thickness tubes / dummy tubesBaffles / steam throw-off device (as required)BafflesWeldedWeldedSpring supports3.2Carbon steel to SA 51 6 Gr. 70 or equivalentCarbon steel to SA 516 Gr. 70 or equivalentCarbon steelCarbon steel to SA 516 Gr .70 or equivalentSS 316SS 316Carbon steel to SA 516 Gr. 70 or equivalentNeopreneASTM A. 193-B7 or equivalentASTM A. J94-2H or equivalentTwo rows of SS 316

Required

Two)( 100% capacity; During nonnaloperation one pump will be in operation

8/7/2019 35760865-Bypass-HP

6/11

KARNATAKA POWER CORPORATION LIMITED SECTION D 1.6Spec. No DATA SHEET - Al.6 .1CETD-B!DADI-EPC-OO1 SHEET 13 OF 22

SL. NO .2.22.32.4

2.52.5.12.5.2

2.62.72.82.92. \02.10 .1

2. \0.2

2.\0 .3

2.112.1l.!2. ll.22.11.32. J 1.42. \1.5

DESCRIPTIONDutyVapour to be handledHE] standard pressure and temperatureconditions for air suctiooCapacityCapacity of pump

Capacity of pump during hogging

Source of sealing waterType of couplingAcceptable noise level at all operatingconditionsAllowable vibratioo level at all operatingconditionsMaterial of ConstructionVacuum pumps(a) Casing(b) Shaft(c)(d)

impellerShaft sleeves

Seal Water Recirculation Pumps (i frequired)(a)(b)(c)

CasingShaftImpeller

Heat Exchangers(a)(b)(c)

ShellTubesTube sheet

Codes an d StandardsHEr Standards for Steam Surface CondenserHEI Standards - Performance Standard forLiquid ring vacuum pumpsAS ME Performance Test CodeTEMA StandardsH ydraul ic Institute Standards

UNITS VALVES I REOUlREMENTSContinuousMixture of air, steam and non-condensablegases0 .034 kg/sq.cm (a) and 21.\ deg .C

Shall be not less than 120 percent the capacityobtained from HEI standardsShall be able to maintain vacuum upto 0.35kg/sq.cm(a) within 20 minutes with both thevacuum pumps in operation, from atmospherepressure.CondensateFlexible coupling

dBA Not to exceed 85 at a distance of 1.5m fromthe outline of equipment

mm/sec 7 peak

Cast ironCarbon steel EN-8Nodular ironNodular iron

Cast ironCarbon Steel EN-8Nodular iron

Carbon steelStainless SteelCarbon steel with epoxy coating as required

8/7/2019 35760865-Bypass-HP

7/11

8/7/2019 35760865-Bypass-HP

8/11

KARNATAKA POWER CORPORATIONLIMITED

SECTION D 1.6Spec. NoCETD-BIDADI-EPC-OOI DATA SHEET- AI .6.2

SL. NO.1.141.\5

1,161.171.181.191.201.211.221.23

1.24

DESCRIPTIONSuction specific speedCondensate pHInternal elementType of lubricationType of couplingSuction nozzle locationType of sealsT1uustbearingtypeThrust bearing locationReverse rotation protection

Load sharing between pumps1.25 Materials of CODstruction1.25.11.25.2J .25.31.25.41.25.51.25.61.25.71.25.81.261.26.1\.26.21.26.3

2.0

2.1

2.2

Mounting flangeDischarge elbow, Column pipeSuction bell, Bowl or casing, Discharge casingDiffuser & guide vanes, cannisterImpellerShaft sleevesPump shaftSuction strainerCodes And StandardsAmerican SocielY for Testing & MaterialsHydraulic Institute StandardsASME Performance Test Code for CentrifugalPumps

HRSG FEED PUMPS & ACCESSORIES

Number of -JRSG feed water pumps for eachfeed water pumping system

Multi-shaft configuration

Number of feed water pumping systemsTriple pressure

SHEET J 5 OF 20UNITS V ALU ES I REQUIREMENTSUS units Not greater than 11,000

8.6 CO 9.2 during normal operation and II to12 during alkaline flushingRemovableSelfFlexible typeBelow n\ounting flange (lOp of suction pipingelevation shall be same as ground level)Mechanical sealsKingsbury or equivalentBetween pump and motorCapable of withstanding reverse rotation dueto discharge NRV failure while system is atmaximum discharge pressureNo t exceeding 5% over entire operating rangewhen operating with one or both pumps

Carbon SteelCarbon SteelCast IronCarbon steelStainless steelI I - J3% chrome steelII - 13% Forged chrome steelStainless steel

Two, (One working and one standby) for eachHRSG

Combined HP feed water pump system withinter-stage tap-off for IP feed water system

an dLP feedwater pumping system

8/7/2019 35760865-Bypass-HP

9/11

KARNATAKA POWER CORPORATIONLIMITED

SECTION 0 1.6Spec. NoCETD-BJDADI-EPC-OOJ DATA SHEET- Al.6.2

SL. NO. DESCRIPTION2.3 Type of pump $c t2.3 . 1 Type of pump

2.3.2 Drive transmission

2.4

2.5

2.62.7

2.8

2.9

(a) HP / IP Pumps

(b) LP PumpsMode

Liquid handledMinimum temperatureRated capacity of each pump

Best effic\et\cy point of each pump

Total dynamic head at rated capacity

2. 10 NPSH available at (booster) pump centre linefor HP / rP pump and pump centre line for LPpump (min)

2.10.1 Normal operation

UNITSSHEET 16 OF 20

VALUES / REQUIREMENTS

- Centr ifugal mul ti stage of : Barrel type main pump with horizontally

split type single stage booster pump forHP / IP feed water system (i f required)

Ring section type for LP feed watersystem.

Electric drive with Variable speed hydrauliccoupling

Direct electric driveContinuous, either in single or in parallel,from minimum flow to runout flowFeed water and undeaerated feed water duringstart-up .AmbientTotal combined flow of nonnally workingpump(s) shall be 110% of the total feedwaterflow to each HRSG or any other conditioncausing maximum feed water flow, roundedoff to nearest higher 10 cubic metre per hour.Shall be of at feed water flow of each HRSGcorresponding to 100% TG MCR and 1%MUShall include 10% margin on equipment andpiping pressure drops for MeR condition or100% HP-IP-LP bypass operation and shall berounded to next higher 5 mlc.Shall be selected such that:- Normally working pump would be

capable of meeting the TG MCRrequirement during an under frequencyoperation of 47.5 Hz.

- NOlmaJly worlcing pump would becapable of rt1eeting the requirements ofHRSG's MeR flow when drum highestset pressure safety valve is relieving

Shall not be less than three hundred percentNPSH required at J% head break by boosterpump for HP / IP pumps and LP pumps

8/7/2019 35760865-Bypass-HP

10/11

KARNATAKA POWER CORPORATIONLIMITED

SECTION D 1.6Spec. NoCETD-BIDADI-EPC-OO I DATA SHEET - A 1.6.2

SL. NO.2.10 .2

2.112. 11.12.11.2

2.12

2.13

2.142.152.16

2.17

2.182.192.202.212.222.23

DESCRIPTIONTransient operation

Design speed for pumpsfor booster pump ofHP/ lP pumps and LPpwnpFor barrel type main pump of HP/IP pumpswith variable speed hydraulic coupling.

Maximum suction specific speed

Shut-oIT head

Load sharing between pumpsMinimum capacity of low flow recirculationType of recirculation control

Maximum noise level at all operatingconditions for the pump set comprising mainpumps, hydraulic coupling, booster pump,drive motor

Maximum vibration level at all operatingconditionsType of impellerSealsShaft CouplingType of thrust bearingStrainer

2.24 Materials of Construction2.24.12.24 .2

2.24.32.24.4

2.24.5

Outer casing applicable for barrel type pumpInner casing applicable for barrel type pumpand all stage casingg for ring section typepump,ImpellersWearing rings

Stuffing box bushing& stuffing box

SHEET 17 OF 20UNITS VALUES / REQUIREMENTS

Shall not be less than onc hundred an d twentyfive percent the NPSH required aL 3% headbreak by booster pump for HP I IP pumps andLP pumps

rpm 1500rpm Around 5000

US units Preferably not greater than 9500.

Sball be continuously rising from runout toshut of f and shut-off head shall be not lessthan 120 and oot greater than 125 percentNot exceeding 5% over entire operating rangewhen operating in parallel with other pumpsNot less tban 25% of pump rated capacitySeparate modulating type / automaticmodulating type recirculation valve (ARC)Not to exceed 85 dBA at a distance of 1.0 Infrom outline of equipment. Tf maximum noiselevel exceeds same, an accoustic enclosureshall be provided. Accoustic enclosure ifprovided, shaH be of pre-fabricated modulartype with ease for assembly / disassemblyVDI 2056 group G degree ' Good'EnclosedMechanical seal confirming to API 682Flexible typeKingsbury type or equivalent typea) Fine mesh type with mesh size such that

same is less than minimum internalclearance of the pumps duringconunissioning.

b) Normal operation coarse strainer meshsize as recommended by manufacturer

Forged Carbon steelASTM A743 CA 6 NM

ASTM A 743 CA 6 NM13 - 17% Chrome steel (Material shaH be nongalling type with differential hardness not lessthan 100 BHN)13% chrome steel

8/7/2019 35760865-Bypass-HP

11/11