division of supply thai nguien 18.10.2010hh rev. 1 (1)
TRANSCRIPT
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ABB Switzerland Ltd.Business Unit Minerals
Thai Nguyen
Issued by department Date Lang. Revision Page
Heat Recovery Unit 2010-10-19 d A 1 (23)
Division of Supply
Project: Heat Recovery Unit DG Khan ABB ORC PowerPlant for Thai Nguyen Cement Plant
between: ABB Schweiz AG and Thai Nguien
Segelhofstrasse 9P Vietnam
CH-4505 Daden-Dttwil
FILE: 42426238.doc
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.ABB Switzerland Ltd; 2010
Revision
Rev. Who Function / Company Date Dep./Init.1 Hagen Head of sales 19.10.2010/HH
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Content
1 PROCESS EQUIPMENT .............................................................................................................3
2 ELECTRICAL EQUIPMENT .....................................................................................................5
3 ENGINEERING & PROJECT MANAGEMENT ....................................................... ......... ....5
4 TRANSPORTATION ............................................................................................................... ....5
5 SERVICES ON SITE ................................................................................................................ ....6
6 GENERAL OBLIGATIONS OF THE CUSTOMER / LOCAL SUPPLY .............................8
7 APPENDIX .................................................................................................................. ........ ........10
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1 Process Equipment
No.:HEAT SOURCE
R M E Remarks
1HEAT EXCHANGER PREHEATER(PH) & CLINKER COOLER (CC)
ABB ABB ABB
1.1 Heat Exchanger ABB ABB ABB
1.2 Adaptor / Connection to HEX LOCAL LOCAL ABB Refer to Appendix 7
2 HEAT EXCHANGER CC BYPASS ABB ABB ABB
2.1 Piping LOCAL LOCAL ABB Refer to Appendix 7
3 HEAT EXCHANGER ABB ABB ABB
3.1 Adaptor / Connection to HEX LOCAL LOCAL ABB Refer to Appendix 7
4 HEAT EXCHANGER PH BYPASS LOCAL LOCAL ABB Refer to
4.1 Piping LOCAL LOCAL ABB Refer to Appendix
5PRESSURE COMPENSATIONVENTILATOR
ABB ABB ABB
6 SEWER PORT ABB ABB ABB
7 SCREW CONVEYOR LOCAL LOCAL ABB Refer to Appendix 7
7.1 Conveyor Screw LOCAL LOCAL ABB Refer to Appendix 7
7.2 Motor LOCAL LOCAL ABB Refer to Appendix 7
7.3 Compensator LOCAL LOCAL ABB Refer to Appendix 7
8 DUCTING LOCAL LOCAL ABB Refer to Appendix 7
8.1 Extraction LOCAL LOCAL ABB Refer to Appendix 7
8.2 Feedback LOCAL LOCAL ABB Refer to Appendix 7
8.3 Bypass LOCAL LOCAL ABB Refer to Appendix 7
8.4 Engineering LOCAL LOCAL ABB Refer to Appendix 7
9 COMPENSATORS LOCAL LOCAL ABB Refer to Appendix 7
9.1 Heat Exchanger Bypass LOCAL LOCAL ABB Refer to Appendix 710 DAMPERS ABB ABB ABB
No.: WATER CIRCUIT R M E Remarks11 WATER CIRCUIT PUMP ABB ABB ABB
12 EXPANSION TANK LOCAL LOCAL ABB Refer to Appendix 7
12.1 Surge Tank LOCAL LOCAL ABB Refer to Appendix 7
12.2 Heating LOCAL LOCAL ABB Refer to Appendix 7
13 PIPING LOCAL LOCAL ABB Refer to Appendix 7
13.1 Straight Pipes LOCAL LOCAL ABB Refer to Appendix 7
13.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
13.3 Compensator LOCAL LOCAL ABB Refer to Appendix 7
13.4 Fittings LOCAL LOCAL ABB Refer to Appendix 7
13.5 Vent/Drain LOCAL LOCAL ABB Refer to Appendix 7
FILE: 42426238.doc
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.ABB ABB Switzerland Ltd; 2010
No.:Item
Description
ResponsiblePartyfordetail
eng,supply,,q
ualityand
claims,etc.
Material
Engineeringand/orPlanning
Remarks
Customer / Others =LOCAL = On Shore
ABB = Off Shore
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No.: FLUID CIRCUIT R M E Remarks14 FLUID CIRCUIT PUMP ABB ABB ABB
15 HEAT EXCHANGERS PROCESS ABB ABB ABB
16 POWER TRAIN ABB ABB ABB
17 CONDENSER ABB ABB ABB18 PIPING LOCAL LOCAL ABB Refer to Appendix 7
18.1 Straight Pipes LOCAL LOCAL ABB Refer to Appendix 7
18.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
18.3 Compensators LOCAL LOCAL ABB Refer to Appendix 7
18.4 Fittings LOCAL LOCAL ABB Refer to Appendix 7
18.5 Vent/Drain LOCAL LOCAL ABB Refer to Appendix 7
No.: SUPPORTINGCIRCUITS R M E Remarks19 LEACKAGE GAS RECOVERY ABB ABB ABB
21 COMPRESSED AIR LOCAL LOCAL ABB Refer to Appendix 7
21.1 Compressor LOCAL LOCAL ABB Refer to Appendix 7
21.2 Dehumidifier LOCAL LOCAL ABB Refer to Appendix 7
21.3 Air vessel LOCAL LOCAL ABB Refer to Appendix 7
21.4 Piping LOCAL LOCAL ABB Refer to Appendix 7
21.5 Fitting LOCAL LOCAL ABB Refer to Appendix 7
22 NITROGEN LOCAL LOCAL ABB Refer to Appendix 7
22.1 Bottle set LOCAL LOCAL ABB Refer to Appendix 7
22.2 Piping LOCAL LOCAL ABB Refer to Appendix 7
22.3 Fitting LOCAL LOCAL ABB Refer to Appendix 7
23 OPERATING FLUIDS LOCAL LOCAL ABB Refer to Appendix 7
23.1 Water fully desalinated LOCAL LOCAL ABB Amount spec. pending.
23.2 Organic Fluid LOCAL LOCAL ABB Refer to Appendix 7
23.3 Nitrogen LOCAL LOCAL ABB Refer to Appendix 7
23.4 Lubrication Oil LOCAL LOCAL ABB Refer to Appendix 7No.: ISOLATION R M E Remarks24 WASTE GAS CIRCUIT LOCAL LOCAL ABB Refer to Appendix 7
24.1 Heat Exchanger PH LOCAL LOCAL ABB Refer to Appendix 7
24.2 Adaptor LOCAL LOCAL ABB Refer to Appendix 7
24.3 Heat Exchanger CC LOCAL LOCAL ABB Refer to Appendix 7
24.4 Piping LOCAL LOCAL ABB Refer to Appendix 7
25 ORC POWER PLANT LOCAL LOCAL ABB Refer to Appendix
25.1 Expansion Tank LOCAL LOCAL ABB Refer to Appendix
25.2 Heat Exchangers Process LOCAL LOCAL ABB Refer to Appendix
25.3 Piping LOCAL LOCAL ABB Refer to Appendix
No.:STEELWORKS
R M E Remarks
26 WASTE GAS CIRCUIT LOCAL LOCAL ABB Refer to Appendix 7
26.1 Fundament gussets/strengthening LOCAL LOCAL ABB Refer to Appendix 7
26.2Water Treatment-Towergussets/strengthening
LOCAL LOCAL ABB Refer to Appendix 7
26.3 Heat Exchanger PH Sub Frame LOCAL LOCAL ABB Refer to Appendix 7
26.4 Heat Exchanger CC Sub Frame LOCAL LOCAL ABB Refer to Appendix 7
26.5 Heat Exchanger PH Platform LOCAL LOCAL ABB Refer to Appendix 7
26.6 Heat Exchanger CC Platform LOCAL LOCAL ABB Refer to Appendix 7
26.5 Piping LOCAL LOCAL ABB Refer to Appendix 7
27 ORC POWER PLANT LOCAL LOCAL ABB Refer to Appendix 7
27.1 Module LOCAL LOCAL ABB Refer to Appendix 7
27.2 Condenser LOCAL LOCAL ABB Refer to Appendix 7
FILE: 42426238.doc
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27.3 Piping LOCAL LOCAL ABB Refer to Appendix 7
27.4 Base Structure for E-Container LOCAL LOCAL ABB Refer to Appendix 7
2 Electrical EquipmentNo.: CONTAINER & EQUIPMENT R M E Remarks29 E-CONTAINER ABB ABB ABB Refer to Appendix 7
30 CONTROLLER ABB ABB ABB
40 POWER DISTRIBUTION ABB ABB ABB Refer to Appendix 7
50 CABLES LOCAL LOCAL ABB
60 MOTORS ABB ABB ABB
70 VARIABLE SPEED DRIVES ABB ABB ABB
No.: MEASUREMENTS R M E Remarks80 HEAT SOURCES ABB ABB ABB
90 WATER CIRCUIT ABB ABB ABB
100 FLUID CIRCUIT ABB ABB ABB
3 Engineering & Project Management102 PROJECT MANAGEMENT R M E Remarks
102.1 Overall project management ABB ABB
102.2 Training Overseas ABB ABB
103 ENGINEERING R M E Remarks103.1 Customer process plant analysis ABB ABB
103.2 Customers electrical architecture ABB ABB
103.3 Lead eng. for technical Coordination ABB ABB
103.4 Basic Engineering (Guidelines) ABB ABB
103.5Civil Engineering and Adjustment toexisting plant
LOCAL LOCAL
103.6 Detail Plant Engineering ABB ABB104 DOCUMENTATION R M E Remarks
104.1 Specifications ABB ABB ABB
104.2 As built drawings ABB ABB ABBOf ABB Scope &Responsibilities
104.3 Instruction Manuals ABB ABB ABB
104.4 Service Manual and Instructions ABB ABB ABB
104.5 Training Material ABB ABB ABB
105 APPROVALS R M E Remarks105.1 Construction authorities LOCAL LOCAL LOCAL
105.2 Environmental authorities LOCAL LOCAL LOCAL
105.3 Safety Conformity LOCAL LOCAL LOCAL
105.4 Shipping and custom paperwork LOCAL LOCAL LOCALDelivery by ABB toSeaport EU (ref. 4.Transportation)
4 TransportationNo.: SHIPPING & HANDLING Remarks
106All material within the scope of ABBwill be delivered FOB to EuropeanSeaport according Incoterms 2000
ABB ABB ABB
107All material within the scope ofCustomer will be available at plantsite according contractual schedule
LOCAL LOCAL LOCAL
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5 Services on Site
No.: CIVIL WORKS R M E Remarks120 ABANDONMENT LOCAL LOCAL ABB Specification
pending120.1 Steelwork LOCAL LOCAL ABB Refer to Appendix 7
120.2 Tower LOCAL LOCAL ABB Specificationpending
130 CONSTRUCTION (Civil&Steelwork)
LOCAL LOCAL LOCAL Refer to Appendix 7
130.1 Building Gussets/Strengthening LOCAL LOCAL LOCAL Specificationpending
130.2 Tower Gussets/Strengthening LOCAL LOCAL LOCALSpecificationpending
130.3 Ground Plate / Fundation LOCAL LOCAL LOCALSpecificationpending
No.:INSTALLATION &
COMMISSIONNINGR M E Remarks
140 SITE PREPARATIONS LOCAL LOCAL LOCAL Refer to Appendix 7140.1 Office Container LOCAL LOCAL LOCAL
Supplied, installed andoperated by LOCAL
140.2 Material Storage LOCAL LOCAL LOCALSupplied, installed andoperated by LOCAL
140.3 Fixed Crane LOCAL LOCAL LOCALSupplied, installed andoperated by LOCAL
140.4 Mobile Crane LOCAL LOCAL LOCALSupplied, installed andoperated by LOCAL
140.5 Installation Platforms LOCAL LOCAL LOCALSupplied, installed andoperated by LOCAL
140.6 Forklift LOCAL LOCAL LOCALSupplied, andoperated by LOCAL
150INSTALLATION OF WASTE GASCIRCUIT
LOCAL LOCAL ABBRefer to AppendixError: Referencesource not found
150.1 Heat Exchanger PH LOCAL LOCAL ABB Supervised by ABB
150.2 Heat Exchanger CC LOCAL LOCAL ABB Supervised by ABB
150.3 Ventilator LOCAL LOCAL ABB Supervised by ABB
150.4 Sewer Port LOCAL LOCAL ABB Supervised by ABB
150.5 Screw Conveyor LOCAL LOCAL ABB Supervised by ABB
150.6 Piping LOCAL LOCAL ABB Supervised by ABB
150.7 Steelwork LOCAL LOCAL ABB Supervised by ABB
160INSTALLATION OF ORC POWERPLANT
LOCAL LOCAL ABBRefer to AppendixError: Reference
source not found160.1 Fluid Circuit Pump LOCAL LOCAL ABB Supervised by ABB
160.2 Extension Tank LOCAL LOCAL ABB Supervised by ABB
160.3 Process Heat Exchangers LOCAL LOCAL ABB Supervised by ABB
160.4 Power Train ABB ABB ABB
160.5 Condenser LOCAL LOCAL ABB Supervised by ABB
160.6 Piping LOCAL LOCAL ABB Supervised by ABB
160.7 Steelwork LOCAL LOCAL ABB Supervised by ABB
160.8 E-Container LOCAL LOCAL ABB Supervised by ABB
170 CABLING & WIRING LOCAL LOCAL ABB Supervised by ABB
180 COMMISSIONNING ABB ABB ABB
180.1 Preparations ABB ABB ABB
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No.:Item
Description
Responsib
lePartyfor
detailwork,quality
andclaims,etc.
Material
Supervision
Remarks
Customer / Others =LOCAL = On Shore
ABB = Supervision
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180.2 Signal Testing ABB ABB ABB
180.3 Cold Start-up ABB ABB ABB
180.4 Warm Start-up ABB ABB ABB
180.5 Basic Test Run ABB ABB ABB
180.6 Load Test Run ABB ABB ABB
No.: HANDOVER & AFTERSALES R M E Remarks190 HANDOVER ABB ABB ABB
190.1 Documentation ABB ABB ABB
190.2 Training (on-/ off site) ABB ABB ABB
200 AFTERSALES SERVICES ABB ABB ABB
200.1According separate contract to beagreed upon
ABB ABB ABB
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6 General Obligations of the Customer / Local Supply
1. The Customer shall ensure that the necessary entry and exit, residence and work
permits and all other permits for the Supplier's personnel and the permits for theimport and export of tools, equipment, measuring and testing equipment andmaterials are granted in good time and remain valid.
2. The Customer shall carry out all construction and other preparatory workprofessionally and, if applicable, in accordance with any documentation supplied bythe Supplier. The Customer shall undertake all that is necessary in order thatServices can be commenced on time and carried out without hindrance orinterruption.
3. The Customer shall ensure that the transport access routes to the installation siteare usable, that access to the installation site is guaranteed, all necessary rights ofway are secured and that the installation site itself is in a condition allowing
installation work to commence.4. The Customer shall take all accident prevention measures required. If the Customer
fails to take such measures and if the safety of personnel is not guaranteed, theSupplier may at any time refuse or stop the provision of Services and order thereturn of its personnel. The Supplier may also refuse or stop the provision ofservices or order its personnel to return if the safety or health of personnel is notguaranteed for any other reasons. The Customer shall provide any necessaryassistance should any of the Supplier's personnel suffer an accident or become ill.
5. The Customer shall arrange for the provision of heated or air-conditioned, lockable,working, living and changing rooms for the Supplier's personnel, including suitablesanitary facilities throughout the period of provision of the Services. In addition, the
Customer shall provide lockable, dry rooms for the storage of tools, equipment andmaterial. All these rooms shall be located, if possible, in the immediate vicinity of theinstallation site.
6. The materials and spare parts to be used for the Services shall be stored inaccordance with the Supplier's instructions in such a manner that they are protectedfrom any damaging influences. Before the provision of the Services commences,the materials and spare parts shall be checked by the Customer for completenessand damage in the presence of a Supplier's representative. Should any material orspare parts be lost or damaged, they shall be re-supplied or repaired by theCustomer or, upon the Customers request, by the Supplier, at the Customer'sexpense.
7. The Customer shall provide the following in accordance with the Supplier's ins-tructions:
Qualified skilled and unskilled workers with the necessary tools andequipment. These workers shall comply with the working instructions of theSupplier personnel. In no event shall any employment or other legalrelationship to the Supplier be established by the giving of such instructions;
Cranes (must be capable to lift high loads ( 40t) and other lifting devices, ingood working order, with attendant personnel, appropriate scaffolding andmeans of transport for personnel and materials, appropriate workshopequipment and measuring equipment;
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All necessary consumable and installation materials (incl. energy forinstallation) , cleaning materials, lubricants and miscellaneous sundry items;
Electricity and lighting (including the necessary connections to theinstallation site), heating, compressed air, water, steam and fuel;
Sufficient means of communication, at least telephone and fax connections
and a PC modem;
8. The tools made available to the Supplier by the Customer shall be returned to theCustomer after completion of the services. Unless instructions to the contrary aregiven, these tools shall be kept available on the installation site, at the Customersrisk.
9. The Customer shall use the future operating personnel to assist during theinstallation of the Plant so that they become familiar with the Plant.
10.The Customer is liable for losses and damages caused by its personnel irrespectiveof whether the Supplier's personnel manage and supervise the works unless thelosses and damages can be proved to have been caused through grossly negligent
instructions or supervision by the Supplier personnel.
11.The Customer is liable for losses and damages caused by material, spare parts,tools and equipment provided by the Customer irrespective of the fact that theSupplier's personnel may have used them without complaint.
12.The Customer shall fulfill its obligations in time and correctly and without cost to theSupplier. If the Customer does not fulfill its obligations, in whole or in part, theSupplier may, in particular, fulfill such obligations itself at the Customers risk orhave them fulfilled by a third party. The costs shall be borne by the Customer in anyevent. The Customer shall release the Supplier from any liability for claims of thirdparties and indemnify the Supplier for any loss suffered there from.
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7 Appendix
a. WASTE GAS
After the preheater, the waste gas is currently led to the GCT.
For the installation of the ABB ORC power plant the waste gas has to be taken out.For that purpose a take out is installed in the downcomer, which leads the waste gasto the heat exchanger (HEX). There the gas is cooled to the temperature, which isrequired by the raw mill. After cooling, the gas is led into the duct after GCT (inlet offan) and then to the raw mill.
The yellow ducts and blue dampers (flaps) in the sketch (see attachment) are to bebuilt for the ORC plant.
The diameter of the new ducts is identical to the existing ducts. The isolation(thickness, material, installation) is the same as with the existing ducts.
For more details and typical drawing, refer to Document Annex T5 GA Drawingsenclosed
Pre heater HEX Inlet and Outlet Ducts
The clinker cooler air is taken after the cooler and led into a dust precipitator (cyclone)and then to the heat exchanger.
For more details and typical drawing, refer to Document Annex T5 GA Drawingsenclosed
AQC Boiler Inlet and Outlet Ducts
Screw conveyor or band-conveyor for the backfeed of the segregated raw meal andclinker shall be done by the screw conveyors. (Amount of raw meal & clinkersegregated not yet determined)
Compensators for the compensation of thermal expansion of piping material must beintroduced after PH in accordance to local standards and requirements.
Specification pending will be delivered at a later stage.
b. WATER CIRCUIT
design prone -
medium water -
max. operating temperature water 130 C
max. operating pressure 25 barg
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Integration of Heat Exchanger PH
Heat Exchanger Clinker Cooler
Screw Conveyor
Compensator
Expansion Tank
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density of water 959.9 kg/m3
volume 3000 l
temperature range -5/130 C
pressure range 1/25 barg
The pipes are designed for a nominal operating pressure of 25 barg.
Diameter 250 mm
Approximate total length 250 m
Detailed specification of piping pending will be delivered at a later stage.
Rough estimate Tubes between the HEX and ORC Plant
The estimation of distance and bends as well as supports has to be made
at actual plant situation!
c. FLUID CIRCUIT
Diameter* 150 mmApproximate total length 41 m
Diameter 250 mmApproximate total length 60 m
Diameter 350 mmApproximate total length 31 m
Diameter 450 mmApproximate total length 12 m
Diameter 500 mmApproximate total length 23 m
Diameter* 1000 mm
Approximate total length 44 m
The pies marked with * are to be designed for a nominal operating pressure of 16barg, all other pipes for 40 barg.
Detailed specification of piping pending will be delivered at a later stage.
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Piping
Piping
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d. SUPPORTING CIRCUITS
Support of compressed air from the local system including all fittings, mountings,
pipings valves and accessories.
volumetric flow 0.3 l/min
operating pressure 6 barg
compressed air reservoir 350 l
pressure condensation point at -25 C
volume flow 0.3 l/min
max. pressure 11 barg
Rough estimate Tubes within the ORC Power Plant
Tubes nominal specs
Temperature during operation: max 185 C
flanges technically tight, i.e. flanges with tongue and groove
diameter pressure length 90 bowsmm bar m #
600 8 24 6
350 40 10 2
250 40 14 6
250 8 24 3
200 8 30 10
80 8 15 10
Material Specs.
Insulation Specs
Support of nitrogen for the operation of the ORC Power Plant from a bottle setincluding all fittings, mountings, pipings valves and accessories.
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Compressed Air
Nitrogen
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Acquisition, ordering/purchasing and handling of the organic operation fluid(Isobutane).
Acquisition, ordering/purchasing and handling of the lubrication fluids. Specification of fluid and lubrication pending will be delivered at a later stage.
e. ISOLATION
The dimensions to connect the new ducts with the existing ducts and piping,shall be in principle, the same material and dimensions as already used andaccepted at the existing process installation. In addition, the material has to benot flameable, stable up to 320C. Stone wool or equal, Thickness of insulation
approx. 15 cm. Density approx. 30 kg/m3. Thermal conductivity 0.04 W/mK.Protection Alumina cover or equal.
For the execution, ABB will submit the detail specification.
In areas where condensation canbe expected, a condensation insulation has to be provided. Material PUR(flexible polyurethane) If liquids may freeze or crystallize at ambient temperature thenecessary components have to be provided with a trace heating. The
media temperature must at all times at least 5 C above thecrystallization temperature. If gases or gas components can vapour or condense at the lowestambient temperature the system components have to be insulated to cooldown and if necessary to provide a trace heating. This is particularlyimportant to avoid corrosion. cold spots are avoided by appropriate design of the insulation.
If there are no plant / country specific emission values given, the design
of the system components consider at a distance of 1 meter a soundpressure level of LPA max. 85 dB (A) (DIN 45641 & DIN 45645) .Thisdoes not include units in separate installation spaces with sound-absorbing surrounding walls or in sound-proof canopies.
Mineral fiber insulation in particular the following requirements shall complywith: Asbestos Free Non-flammable bulk density 80-180 kg/m3
thermal conductivity of 0.04 W / (m K) at 100 C mean temperature
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Operating Fluids
Waste Gas Circuit
cold - and condensation insulation
Sound Emissions
Material
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Structure, rot and vermin fixed Dimensionally stable at operating conditions and short-term moisture
Must not have adverse impact on the material cause or the coating of thesystem part binder must withstand the expected stresses during operations and may not
release toxic substances.For a good quality of installation fibrous mineral or rock wool mats, with oneside quilted on wire mesh have to be used in thicknesses of 30 to 100 mm.Wire mesh of galvanized steel wire with a mesh width of max. 20 mm and awire diameter of 0.7 mm. Alternatively, even aluminum alloy or stainless steelwire are used (
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f. STEELWORKS
For preliminary specification refer to: Integration of Heat Exchanger PH 7
A) Main base frame for the installation of the process technical equipment andone part of the condenser array.
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Waste Gas Circuit
ORC Power Plant
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Please refer to Excel File enclosed
I:\01_Projects\_Offers\HRU\29119
CONTAINER & ELECTRICAL EQUIPMENT
There is one E-Container according to the specifications in the picture below considered.
Not included, and therefore needed to be supplied by the Customer, is the base constructionof height 1500mm for the E-Containers.
PAuxiliaryConsumers= 200kW
Electric Room 6kV
Dept.resp.
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ASEABROWNBOVERI1993
Wereserveallrightsforthisdocumentandtheinformation
containedtherein.
Reproduction,useordisclosuretothird
partieswithoutexpressauthorityisstrictlyforbidden.
ASEABROWNBOVERI1993
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:
2010-09-27, R OHA0
... Auxiliaries Feeder
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. . .
MCC
PCoolers= 384kW
6kV
6kV
4.8MVA
6 / 0.4kV
2000kVA GCB
ABB
Customer
2010-09-27, ROHA
Fluid P1
461kW
M M
CC Pump
14kW
PH Pump
91kW
400V
ACS800
Multidrive
M
E-Container
Power Factor CompensationThe correction of the Power Factor (PF) is not included in the ABB scope
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Bill of Qty for Steel strucutres and Piping for Preheater and Clinker Cooler HEXConnection
Power Distribution
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g. ERECTION, ERECTION SUPERVISION & COMMISSIONING
ABB is ready to delegate qualified technical personnel for installation, supervision ofinstallation, start-up, commissioning and support of the customers performance testsof the equipment as per the scope of supply.
Normal working hours are 8 hours, 5 days per week.
The supplier (ABB) will delegate qualified technical personnel for installation,supervision of installation, start-up, commissioning and performance guarantee testsof the ABB equipment.
The number of personnel needed in Man*Months (mm) has to be defined incoordination with the Customer / Local Supplier.
The installation work basically begins with Mobilization on site, unloading of theequipment at the site and ends - with the exception of the remedial work oninstallation deficiencies - with the Certificate of Taking Over issued by the End userand De-Mobilization on site. It includes, however, disposal of existing equipment, thedismantling and restoration work of the lay down area as well as the cleaning work
after completion of the erection.
The work includes all material (tools, cranes, etc.) and services that are necessary forthe due fulfilment of the complete installation, erection and handing over of theproject such as:
Our offer is based on the assumption that the following services are provided freeissue for ABB by the customer or a third party.
Site preparation:
Land and places suitable and sufficient for the installation of the temporaryfacilities provided by Supplier and located at site;
Site access road;
Preparation of site, including levelling and compacting, sufficiently be advancedand be suitable for commencement of the work.
The Customer or a third party will provide the temporary facilities necessaryfor execution of the installation works, such as:
Accommodation for delegated personnel;
FILE: 42426238.doc
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General
Working Time
Estimated Personnel and Duration
Installation (Customer / Local Supply)
Site Preparation and temporary Facilities
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All Security and Healt and Safety Services necessary accordinginternational Standards to protect our delegates
Furnished office;
Access to the internet
Local transportation for personnel;
Canteen;
First aid station;
Storage area with fencing and guard post;
Warehouse and workshop;
Site security services
Car parking area;
Electrical power distribution system including temporary lighting;
Water distribution system
Compressed air system;
Sanitary and sewage system;
Fire fighting system;
Communication system and services;
The grouting of frames, supports, steel structures, machines, etc... on thecivil works constructions are effected by the construction company;
PVC pipes casted in concrete for electrical routing, if any;
The necessary equipment for fire proof (e.g. fire proof doors in tunnel,
sealing material for cables opening);
Doors with emergency and safety locks for all rooms (E-Rooms, ControlRooms, offices, etc.).
Transportation of the equipment from the port (EU) which port?
Unloading, unpacking, storage, and custody, at the site, of the equipmentand materials, according ABB storage instructions.
Visual inspection of the equipment for completeness and damages.
Assembling and installation of the equipment and materials, afterchecking the levels, dimensions, etc. of foundation and buildings.
Touch-up painting works for the equipment and materials erected andinstalled at the site.
Installation and preparation of all cable ways by supervision of ABB.
Pulling of cables according routing information given by ABB.
Insulation and continuity testing of cables.
Insulation testing motors, panels, distr. boards etc.
Earthing checks.
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Installation Work steps
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Battery preparations for UPS and DC Power supplies.
Lighting and socket outlet measurements.
Inspection of the equipment and materials erected and installed at thesite.
Loop test, this is a signal/wiring check from the field terminations up to I/Ochannels of the process control system. Test results are to be recorded on
appropriate test sheets.
Rotation tests of uncoupled LV-motors
Assistance for the Commissioning-Team.
Adjustment and rectification, if any, and finishing of the equipment andmaterials.
Cleaning-up of the site and removal of the temporary facilities and wastematerials from the site.
An end of installation certificate shall be filled out after all work above is
completed and signed by the customer, the installation company and theinstallation supervisory company.
The installation supervisors are responsible for the professional implementation of theInstallation work of ABBs scope of delivery and include the following:
Checking of all ABB equipment when opening the boxes at site and issuing ofcertificates about the conformity of the box contents with the packing lists,checking of damages and losses and issuing of respective reports, which are tobe signed by ABB and the customer.
Instruction and supporting of the personnel of the customer, contractors /
sub-contractors or third parties, in the technically correct execution of theinstallation in accordance with the ABB-Standards and the contractuallystipulated International technical standards.
Administration of installation documents such as diagrams, drawings,instructions necessary for the Supervision, their proper storage, for updatingthem with changes, and for the maintenance of a document register.
Modification of the installation documents according change orders incooperation with the ABB back offices resp. their technical department.
Advising and supporting of customer, contractor, sub-contractors, sub-suppliers etc. in handling and all aspects towards industrial safety-technical
interests in accordance with OHSAS 18001. Continuous monitoring if the Installation Standard fits the ABBrequirements and drawings.
Support of the Customer, Contractors / Sub-contractors or third parties inclarifying interface problems.
Continuous monitoring of the installation progress vs. the masterinstallation time schedule; immediate reporting of all recognised delays andunusual occurrences towards the site manager.
Forecasting of necessary resources and ordering of commissioningpersonnel in due time in accordance with the actual planning and the customers
approval.
FILE: 42426238.doc
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Responsibilities of Installation Supervisors (ABB Supply)
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Monitoring and administrating deficiency lists in cooperation withCustomer, Contractors / Sub-contractors or third parties.
Supervision of the working time of all assigned ABB Personnel on site.
Signing of end of installation certificate section-wise when theinstallation is concluded according ABB requirement.
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We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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Tools for CommissioningThe necessary special tools needed for commissioning are included in our proposal.These tools remain in the property of the Supplier.
Commissioning of the plant is done object by object and carried out by ABB. Anobject can be a fan, a pump, a belt conveyor etc. The object test is carried out afterrelated electrical auxiliaries are commissioned and the process control system is upand running. The object test includes:
Check of all signals belonging to the object. Signals are actuated orinjected in the field and verified on the screen of the process control system. Check of all interlocks and verify it on operator screen. Verification correct protection relays setting if applicable (e.g. comparerated current, which is indicated on the motor plate with the relays setting inMCC) Shortly energizing of the equipment and check for correct action e.g.correct rotation of a motor. Whether electrical drives need to be disengagedfrom the mechanical equipment for the fist run has to be decided case by case. The object is now released for local operation. The object is operatedfrom the field and proper functioning of the equipment is checked and recorded.Necessary adjustments, tunings, calibrations, run-in-tests, etc. are carried out asper instruction manuals for tested object.
Electrical equipment test consists mainly of a verification of finalization ofconstruction and the energizing of the equipment, with the result, that the completeelectrical supply system is ready for distribution of all necessary main and auxiliarypower to the plant. Suggested test procedures for the various devices will beprovided during project execution.
After all objects of a group have passed the object test, a group sequence testwithout material is carried out. Correct start up / shut down / flying change-over (if
applicable) are checked. Interlocks with the material stream are verified.
If all groups of a department have passed the no load test, the department is readyfor production. The groups are started up with material. Remaining adjustments,tunings, calibrations that couldnt be done earlier without material are carried out inthis last phase of commissioning. The plant will be finally tuned to its rated capacity.
Providing conformity between screen indications and analogue values.
Calibration of the instruments.
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Commissionning (ABB Supply)
Process Equipment Test
Electrical Equipment Test
Group Sequence No Load Test
Group Sequence Load Test
System Optimisation
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Adjustment and optimisation of control loops.
Until the end of the performance tests the electrical commissioning staff shouldsecure a technical assistance, with personnel on site in view to avoid that their
deliveries do not disturb the tests in the best possible time.A Preliminary Acceptance Certificate (PAC) shall be filled out after allcommissioning work above has been completed. The PAC shall be signed by ABB,the machinery supplier and the customer.
As per written change orders, the following additional work may be required:
Adjustment of operation method, if requested. Programming modifications required by the process specialists. On the job training for the plant maintenance team. Removal of deficiencies.
Normally 3 months after PAC, ABB will provide a complete set of as built andinstallation drawings under CD-ROM form (Autocad, Excel, Word, Acrobat reader).
Performance Tests
Other Commissioning Work
As Built Documents