rutenberg power station, units 1 & 2 specification …...dampers, for primary air ducts (2...

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B"

Engineering Division SPEC.: ZM-104

ISSUE: FOR PROPOSAL

0020 - IEC - Anx - B - Specification ZM-104.doc B - 1

RUTENBERG POWER STATION, UNITS 1 & 2

SPECIFICATION FOR

AIR DAMPERS FOR PRIMARY AIR DUCTS

1. PURCHASER: The Israel Electric Corporation Limited (I.E.Co).

2. NAME OF ITEM: Air dampers for primary air ducts

3. LOCATION OF ITEM: RUTENBERG power station units 1&2,

Near Ashkelon.

4. SCOPE

The scope of work includes Engineering, Equipment and services for four (4) air

dampers, for primary air ducts (2 dampers for each unit)

4.1 Project description

The existing primary air and secondary air ducts, that provides air to the boiler,

are connected via duct which includes a louver damper. This damper shall be

replaced by a new damper in order to control the primary air that enters the

secondary air duct.

4.2 Scope of supply

The scope of work shall include, but shall not be limited to the following:

Within the scope of engineering and supply the contractor shall, as applicable,

design, develop, engineer, manufacture, preserve, assemble, shop test, pack

and furnish with export packing the following:

4.2.1 Basic Scope of Engineering, supply and services, for each unit:

4.2.1.1 Four (4) electrical motor air operated dampers including all required accessories

and appurtenances in order to achieve safe and reliable operation. The type of

dampers will be chosen by the contractor considering the technical requirement

specified in this specification.

4.2.1.2 All bolting, stud bolts, anchor bolts, nuts washers, gasket, flanges and any other

required accessories for damper installation will supplied by the contractor.

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: ZM-104 ISSUE: for Proposal


4.2.1.3 All equipment & accessories related to the electric actuator and local control

system.

4.2.2 The Equipment for each Unit shall be supplied complete with appurtenances and

accessories as specified herein, to form a complete system which will achieve

and assure safe and reliable operation with best overall performance at all loads

and modes of operation. All components, appurtenances and accessories shall

be of proven design, verified by Power Plant Operation.

4.2.3 Components that are herein specified in regard to manufacturer brand and

model or type shall be considered the standard of supply. It is not intended that

the Contract be limited solely to such characteristics. The Contractor may make

an appropriate substitution, but all substituted Components offered shall be

noted as EXCEPTIONS to this Specification and are subject to review,

comment, and approval by the Purchaser.

Additionally, while everything else being equal and without derogating from

Contractor's responsibilities under the Contract, the Contractor shall endeavor to

include in the scope of design and supply, components and accessories

manufactured in Israel.

4.2.3.1 Contractor shall provide, in the required format and form and in a timely manner,

all documentation required by this Specification and/or required by applicable

Standards and Codes and/or as specifically detailed in the Documentation

Submission Schedule (DSS), Annexure "J". A consistent nomenclature shall be

used project-wide in naming all component parts within the Scope of Work. This

shall apply to all drawings, Instruction Books, Bill of Materials, special

instructions, etc. Engineering design shall commence immediately after Contract

award. The cost of correcting inconsistent nomenclature shall be borne by the

Contractor.

4.2.4 Changes in design already approved by the Purchaser are normally unaccepted.

However, should such changes become necessary on an exceptional basis, the

Contractor shall obtain the Purchaser's approval prior to introducing any such

change.



4.3 Special Equipment, Tools and Instruments

4.3.1 Contractor shall provide all special equipment, tools and instruments required for

safe and secure transport of all components from ex works to final destination,

and for test and maintenance of Equipment provided under this Contract. Said

equipment, tools, and instruments should be in Contractor's Proposal where it

should be clearly stated which are provided on a loan basis and which are

included in the Contract Price.

4.3.2 The Contractor shall furnish all necessary special tools, instruments and/or test

equipment which are required to fulfill the approved test procedure for equipment

tested by Purchaser.

4.3.3 Maintenance equipment and tools provided under this specification shall be new

and of best quality. They shall be shipped to the job site in a suitable separate

box, clearly marked with the name of the equipment they are intended for.

4.4 Contractor Services

The Contractor shall provide the services listed in the following sub-articles as

part of the basic Scope of Work or as Purchaser’s option, at the per diem or

lump sum rates, all as stated in the Summary of Prices and Delivery Schedule,

Annexure “C1”. Field personnel provided by the Contractor shall be capable and

qualified to perform the required duties to the satisfaction of the Purchaser. They

shall be vested with authority to make decisions that could affect the status of

the Equipment and which are binding on the Contractor.

4.4.1 Erection Services:

Contractor shall provide the services of competent advisors to direct and instruct

Purchaser's personnel during erection, including, without limitation, identifying

the equipment, unpacking, intermediate storing, erection sequencing and

erection checking as may be required to assure proper and successful erection

and installation of the Equipment provided under this Specification.

4.4.2 Commissioning and Start-Up Services:

Contractor shall provide the services of competent advisors to direct Purchaser's

personnel and assure proper, complete and successful commissioning, starting,

combustion tuning and placing into service of the Equipment provided under this

Contract with the balance of equipment at the related power station Unit(s).



4.4.3 Training:

Contractor's personnel shall conduct a thorough training course pertaining to the

equipment furnished under this Specification, for Purchaser's personnel,

covering, without limitation, correct start-up, safe operation at all modes of

operation, safe shutdown and maintenance, design and engineering of electrical

and control systems. The Contractor shall verify that the trainees are completely

familiar with all phases of such procedures and are capable of operating and

maintaining the equipment successfully.

4.5 Work by Others (Facilities and Services to be provided by the Purchaser)

In performing its duties the Contractor shall not be required to provide facilities,

services and equipment as detailed below [further details with respect to

Purchaser's undertaking regarding qualifications, quality, quantities and

scheduling should be stated in Contractor’s proposal]:

4.5.1 On site and Engineering Services

4.5.1.1 Erection Services

Purchaser shall provide all the necessary labor force, general purpose tools and

facilities in order to dismantle, erect and install the Equipment provided under

this Specification, following Contractor’s instructions and according to

Contractor’s plans, procedures and supervision.

4.5.1.2 Commissioning, Start-up and Performance Test Services

Purchaser shall provide all the necessary labor force, general purpose tools and

facilities in order to perform commissioning and start-up of the Unit and to

perform performance tests following Contractor’s instructions.

4.5.1.3 Design Services

Provided that the Contractor shall submit in due time sufficiently complete design

to enable the Purchaser to perform the design and order the remaining

equipment in accordance with the DSS, the Purchaser shall perform the

following engineering documentation:



4.5.1.3.1 Electrical Engineering

Purchaser shall design the power and the control cables for the electric

actuators.

4.5.1.3.2 Control Engineering

Purchaser shall design the Control Logic Diagrams and C&ID’s for the dampers.

5. TERMINAL POINTS AND TERMINAL CONNECTIONS

Contractor shall terminate the Equipment provided under this Specification at the

agreed upon terminal points with the appropriate terminal connections.

6. CYBER & INFORMATION SECURITY: N/A

7. QUALITY ASSURANCE AND QUALITY CONTROL

7.1 Without derogating from the provisions of the General Conditions, Contractor's

quality system shall meet the requirements of Purchaser's Standard Q-APP-02-

PR, "Quality Requirements", and of the requirements of the Inspection and Test

Plan, all as further detailed in Annexure "M" to the Contract.

7.2 The Contractor and the main subcontractors shall be certified to ISO-9001-2000

by a certification body qualified to EN-45004 levels A or C or otherwise as may

be acceptable to the Purchaser.

7.3 The Contractor shall submit upon request a copy of its Quality Assurance

Manual including Quality Procedures.

7.4 The choice of main subcontractors shall be subject to Purchaser's approval and

the Contractor shall be responsible for assuring that their quality

assurance/quality control programs, including their organizations, procedures,

personnel qualifications, etc., meet Purchaser’s quality requirements.



8. STANDARDS AND SUPPLEMENTS

8.1 Standards and Codes referenced in this Specification and in the Supplements to

this Specification, form an integral part of this Specification - to the extent their

requirements are consistent and conform with the requirements specifically set

forth herein. All such Standards and Codes are to the issue, including all

amendments, supplements, etc., current as of the date of the Contract, unless

indicated otherwise. In the event of a variance between the requirements of the

Standards and Codes and the particular requirements set forth in the

Specification, the requirements specifically set forth in the Specification shall

take precedence.

8.2 The Equipment to be provided under this Specification, including all

appurtenances and accessories, shall be designed, fabricated, inspected,

tested, stamped and preserved to the extent indicated in said referenced

Standards and Codes. Where this Specification does not include such reference,

The Equipment, or any of its components, shall be designed, fabricated,

inspected, tested and preserved, as applicable, to comply with currently

recognized International and/or Contractor's Standards, whichever are tighter

and more restrictive.

8.3 The Contractor may propose Standards and Codes as alternates for, or

additions to those specified herein. A copy of each proposed Standard and

code, if any, shall be submitted (in English) for Purchaser's approval. In case

Purchaser's approval is granted, the Contractor shall remain responsible for the

compatibility of the design and the physical interfaces between the supplied

Equipment and the equipment supplied by others.

8.4 The Purchaser shall assist Contractor in identification of Israeli codes and

standards applicable to the Work. In all cases Contractor shall adhere to and

comply with the requirements of Israeli official standards found to be more

restrictive than those specified herein.

8.5 Subject to the provisions stated above, the equipment shall be designed,

manufactured, erected, tested operated and maintained in accordance with the

standards, regulations, directives and publications of the following agencies and

organizations:

ANSI: American National Standards Institute, Inc.

ASME: American Society of Mechanical Engineers.

ASTM: American Society for Testing and Materials.



NEMA: National Electrical Manufacturer's Association.

ABMA: American Boiler Manufacturer's Association.

AWS: American Welding Society.

NFPA: National Fire Protection Association.

ISA: Instrumentation, Systems and Automation society

IEC: International Electrotechnical Commission.

8.6 Furthermore, without derogating from the technical requirements stipulated in

this specification, the items listed bellow shall be designed in accordance with

the standards specified herein or their equivalents:

8.6.1 Metallic materials:

ASTM standards

8.6.2 Expansion joints:

EJMA Standard - "Standards of the Expansion Joint Manufacturers

Association", latest edition, Tarry Town, N.Y.

8.6.3 Fire detection and protection:

a. National Fire Protection Association Standards (NFPA) or

b. British Standards (Great Britain)

c. Local industry standards

8.7 Supplement

The following supplements are attached hereto and their requirements form an

integral part of this specification - to the extent they are consistent and conform

with the requirements specifically set forth herein. In the event of a variance

between the requirements of the Supplements and the particular requirements

set forth in the Specification, the requirements specifically set forth in the

Specification shall take precedence.

8.7.1 Purchaser's general documentation, quality assurance, quality control and RAM

requirements:

8.7.1.1 Standard 01-1E Standard Specification for Contractor’s Drawing

and Data Transmittal.

8.7.1.2 Q-APP-02-PR: Quality requirements from suppliers.

8.7.1.3 Numbering instructions for plant unit & equipment operational no.



8.7.1.4 Data sheet

8.7.1.5 Drawing of existing ducts & damper

8.7.2 Purchaser's standard electrical requirements and data sheets:

8.7.2.1 EPD-A.16 Motors and Operating Equipment used on Motor Operated

Valves.

8.7.2.2 EPD-19 Nominal voltage, frequency and phase rotation of instrument

and control units

8.7.2.3 EPD-20 Contracting of mechanical, electricalmechanical and solid-state

device.

8.7.2.4 Motor data sheet.

8.7.3 Purchaser's standard instrumentation requirements and data sheets:

8.7.3.1 List of Instrument Manufacturer req. by I.E.C. (XXO/M3-006-CK0002-00 Rev. B).

Paragraph 7

9. TECHNICAL DOCUMENTATION

The Contractor shall submit technical documentation in accordance with the

provisions of Annexure "J" – Documentation Submission Schedule.

9.1 Documentation Submission Schedule-General

9.1.1 Without derogating from Contractor's obligation to provide any other document

called for by the Contract, the Contractor shall provide the following

documentation in accordance with the general requirements set forth above and

the schedule as listed in annexure JA & JB (attached herein).

Annexure JA: A table that summarizes all required technical documentation

that will accompany the proposal.

Annexure JB: A table that summarizes all required technical documentation

that will be submitted after notification of award.



9.1.2 The table of annexure JB shall form the basis for a monthly report to

be submitted following Contract award showing the actual submission dates and

the respective Approval Status, and upon Purchaser's and Contractor's mutual

written consent shall be updated to account for any additional documents called

for by the Contract in the course of detail design or additional documents called

for by Change Orders.

10. TECHNICAL REQUIREMENTS

10.1 Environmental considerations & Site Conditions

10.1.1 Noise

The noise level of the supplied Equipment shall not exceed an A-weighted sound

level of eighty (80) dB(A) at a distance of one (1) meter from any major surface.

10.1.2 Environmental Data

Should the equipment to be furnished by the Contractor have discharge points to

the environment and/or generate waste materials that must be discharged to the

environment, the Contractor shall provide, upon Purchaser's request, a plan for

the treatment of the discharge/waste to meet current regulations of the U.S.

Environmental Protection Agency (EPA).

The Contractor shall submit, within thirty (30) days of demand, additional

information on noise and/or other environmental data. All information shall be

prepared in a manner acceptable to Israeli licensing authorities.

10.2 Mechanical Technical Requirements

10.2.1 General

10.2.2 Design and Construction

10.2.2.1 The Dampers will be design according to the data sheet attached in supplement.

10.2.2.2 The dampers will be throttling type.

10.2.2.3 The motor shall have capability to open the damper in any positions



10.2.2.4 The opening and closing duration will be 120 sec.

10.2.2.5 The dampers shall be designed structurally for the design temperatures,

maximum transient temperature, design pressures, and design differential

pressure in either the open or closed position.

10.2.2.6 All parts shall be serviceable without removing the damper frames from the

ductwork.

10.2.2.7 Dampers shall be provided with mechanical lockout for use when personnel

access to equipment is necessary.

10.2.2.8 Dampers shall be considered as structural members, and as such shall be

designed in accordance with the applicable provisions of the AISC and as

specified herein.

10.2.2.9 All dampers shall be capable of sufficiently tight shutoff on cross sectional area

at maximum unit operating conditions. Leakage across the blades shall be

minimized and shall not exceed 1.5% of the flow volume.

10.2.2.10 All the dampers shall have direct mounted power operators (actuators shall be

self supported).

10.2.2.11 Integral lifting lugs shall be provided on the damper frames.

10.2.2.12 Actuators shall be of NEMA 4X.

10.2.2.13 Construction Requirements:

a. Dampers external size shall be according to existing dampers and

ducts dimensions specified in supplement.

b. The connection of the new dampers to the existing ducts will be as specified in

the supplement, no modification of the ducts will be allowed

c. Allowable bending stress in any component shall not exceed 60% of yield at

design conditions.



d. The combined axial compressive and bending stress shall not exceed 60% of

yield at design conditions.

e. Deflection of frame components shall not exceed the length of the component

divided by 360 (L/360).

f. The clearance at the ends of the dampers shall be as required to suit damper

length and operating temperatures.

g. All dampers shall have extended shafts so as to be manually operable from

the nearest operating level.

h. The installation of the dampers shall be vertical in the horizontal ducts.

i. Dampers shall be of a design and construction approved by Purchaser.

Design and construction shall be in accordance with the highest commercial

standards and shall include graphite bearings.

10.3 Instrumentation and control for Dampers motor actuators

10.3.1 The Contractor shall furnish complete torque and limit switch data for electrical

actuator valve.

All technical requirements for electrical actuators shall be according to the

Purchaser Standard Specification EPD-A.16 "Motor and Operating Equipment

used on motor Operated Valves (MOV)" (Supplement 8.7.2.1).

10.3.2 The electric actuators shall be with digital integrated control and with local digital

display (on actuator)

10.3.3 Electrical power supply shall be according to the purchaser's Standard

Specification EPD-A.19 "Nominal voltage, Frequency and Phase Rotation of

instrument and Control Units" (supplement 8.7.2.2).

10.3.4 Actuators shall be suitable for indoor and outdoor use.

10.3.5 The actuator shall be capable to functioning in an ambient temperature ranging

from 4ºC to + 46ºC.

10.3.6 Contractor shall recognize that extremes of temperature, moisture, Vibration

and salt do exist in certain locations in the plant and the Electrical equipment

protection enclosure shall be at least NEMA 4X (or equivalent IP66 with

corrosion protection) double sealed.



10.3.7 The actuator gearing shall be totally enclosed in an oil - filled gear case suitable

for operation at any angle.

10.3.8 A hand wheel shall be provided for emergency operation, engaged when the

motor is declutched by a lever or similar means, the drive being restored to

power automatically by starting the motor. The hand wheel or selection lever

shall not move on restoration of motor drive. Provision shall be made for

hand/auto selection lever to be locked in both hand and auto position.

Local digital position indicators with 0%-100% scale shall be supplied and

installed on the actuators, and shall be clearly seen from the corresponding floor

level.

10.3.9 Limit switches shall be able to indicate and position of the damper; Provision

shall be made for the selection of a normally closed or open contact form.

Contacts shall maintain and update position indication during hand wheel

operation when all external power to the actuator is isolated.

10.3.10 The contactors (if any) shall be rated 3A, 250V AC.

10.3.11 The Contractor shall be fully responsible for the following requirements for each

electrical actuator:

A. Factory set of the electrical actuator torque switch to properly control and limit

the opening and closing travel of the actuator under the specified operating

conditions. The torque switch shall be electronic type.

B. Designate the torque and document the direct output torque reading in Newton-

meter for each setting.

C. Certify that the electrical actuator is properly sized and properly adjusted to

assure that the electrical actuator is absolutely tight on each closure and will

protect the actuator and dampers/vanes from damage under all conditions of

operation.

D. The driven equipment shall be capable of performing its required duty under

continuous operation when and if the frequency should become 49 hertz.

E. Torque switches shall be furnished and factory mounted. The torque switches

shall be factory set by the Contractor and shall be separately adjustable.

F. All the power and control cable connection to the actuators and form the

actuators and limit switches will be made through suitable plug connectors,

as approved by the Purchaser and should be provided with the junction box

for the Purchaser external cable connection.

G. Electrical actuator located outdoors shall be weatherproof construction and

shall be suitable to work in salt-laden polluted atmosphere when the fossil



or/combined Cycle Oil Fuel Power Plant is located near the sea shore, and

according to the fuel type, 100% humidity and at ambient temperature

ranging from 4ºC to 46ºC.

Space heaters (factory mounted) shell be part of the actuators.

H. In case of modulating control or throttling control: the actuators should be

positioned during both open and closing movements at a various modulating

positions. The positions are measured by the digital position transmitter,

supplied with actuators and preset positions are adjusted electronically within the

main control system.

All electrical actuator shall be furnished with declutching mechanism and hand-

wheel or operating lever which will allow one person to locally produce specified

drive unit torques. This is in addition to remote manual operation from the control

room. In addition, the actuator shall be provided with means for stopping during

either closing or opening operation.

I. Electrical actuator shall be designed so that burned out bearings and/or actuator

motor will not prevent hand wheel operation of valves.

J. In case of modulating control or throttling control: the Electrical actuator shall

provide a 4-20mADC position indication signal to be used in the control room to

show the actual position of each electrical actuator. Position transmitters shall be

of the digital type, operated directly from final drive and mounted on electrical

actuator. It shall not be satisfactory merely to show voltage as an indication of

where the electrical actuator should be. Position transmitters shall be furnished

and factory mounted by contractor and shall be suitable for operation at 24V DC,

two wires, 4-20mA output signal.

K. Electrical actuators shall be furnished with rigid covers for protection against

outside stroke during erection time.

L. In case of Modulating Control: the electrical actuator is to be controlled by solid

state switching.

No mechanical reversing contractors are to be supplied. All control equipment for

the modulating motor operation shall be electronic and based on thyristors type.

M. All motors shall be of the continuous duty type and shall be self protected.



N. Control actuators and ON/OFF actuators required to remain into intermediate

position, between the fully opened and fully closed one, shall be equipped with

electronic digital encoder position transmitters.

O. Electromechanical brakes shall be used only when the actuators are driven in

remote manual mode or in case of power failure.

P. Actuator motors shall be sized with a safety factor of not less than 1.3.

Q. The travel time of the electrical actuator selected by the Contractor shall be

suitable for the overall control loop performance and according to the attached

data sheets.

R. All a.m is an addition to the specific requirements in the control valve Data

Sheet.

S. The gear box and bearings and the trust units shall be with life time lubrication

type, maintenance free service.

T. The contractor shall fill in all the required data requested in the Data Sheets.

U. All the a.m is in addition to the electrical requirements to the drive units, see the

Purchaser's standard specification EPD A.16, EPD A-19, EPD A-20

(Supplements 5.1.5, 5.1.6 and 5.1.7)

10.4 Painting requirements

All equipment shall be supplied painted with prime and top coating (final paint).

The equipment will be located at a Semi-polluted marine type environmental

conditions involving ambient temperature of 1-46C and relative humidity up to

90%.

Paint system (3 layers):

Prime – Reach Zinc Epoxy (SSPC Paint 20) - 100 µ

Mid – H.B. Epoxy - 150 µ

Top – Aliphatic Polyurethane - 50 µ

Total DFT: 300 µ minimum.

Strip coating on all sharp edges and welds.

Pull off Test (ASTM D4541) shall be 7 MPa minimum.

10.5 Safety

The Equipment supplied under this Specification shall meet the U.S.

"OCCUPATION, SAFETY, AND HAZARD ADMINISTRATION" (OSHA)

requirements or equivalent.



11. TESTS AND INSPECTIONS – PLEASE REFER TO PARAGRAPH 7 ABOVE.

12. PACKAGING & DELIVERY

The Contractor shall comply with the requirements for Shipment and Handling of

Equipment set forth in Annexure "R" to the Contract and additionally with the

following supplementary requirements:

12.1 All components or accessories shipped detached for field mounting or field

assembly shall be suitably tagged to allow easy identification. Tags shall be

stamped with cross reference data such as Manufacturer's Name, Contract No.,

Power Station, Unit No., reference drawing and Equipment Designation, and

shall be exceptionally durable and securely tied to items by wire or other

methods approved by Purchaser.

12.2 Major pieces of Equipment (such as motors, pumps, fans, valves, actuators)

shall be supplied with securely tied nameplates (Adhesive fastening is not

acceptable) including manufacturer’s name, model number, serial number and

additional information, such as voltage, frequency, etc.

12.3 Unless specially designated, all Equipment and other items shall be packaged

for outdoor storage until erection. Where required by the nature of the

Equipment, the Contractor shall furnish and install necessary covers to protect

the Equipment from sand, rain, hail, wind, dust and salt spray. Equipment shall

be adequately sealed and protected during shipment to prevent corrosion and

entrance of foreign matter. All exposed machined surfaces shall be protected

where required with a suitable antirust compound or covers before shipment, for

shipment and storage until erection.

12.4 All temporary supports, lifting lugs and other temporary parts shall be painted in

yellow.

12.5 The equipment components shall be supplied as large as possible to reduce

field welds and erection time.

13. STORAGE & HANDLING



14. NAMEPLATE & MARKING

- The Contractor shall use a nameplate (Manufacturer’s marking) in reference

to an instrument or a device on drawings, correspondence and manuals,

where applicable.

- The nameplate (Manufacturer’s marking) tag shall include the following

identifying data:

* manufacturer’s name,

* model number,

* serial number;

* additional information, such as voltage, frequency, etc.

- Construction of nameplate (Manufacturer’s marking):

For field mounted instruments the Manufacturer’s Marking Data shall be

stamped on a tag fastened permanently to the instrument. Adhesive fastening

is not acceptable.

Name plate material will be stainless steel.

15. NOTES

16. SPECIAL REQUIREMENT

– F I N A L –

rutenberg power station, units 1 & 2 specification …...dampers, for primary air ducts (2...

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