1336422199753582 FORTUM Częstochowa Fly Ash Handling System Technical Specification 23 11 2016 rev 1

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AMEC FOSTER WHEELER ENERGIA POLSKA Sp. z o.o.

ul. Chmielna 85/87, 00-805 Warszawa

ul. Chmielna 85/87, PL 00-805 Warsaw, Poland

Tel. 022 581 0036, Fax 022 581 0958

Tel. +48 22 581 0036, Fax +48 22 581 0958

Biuro w Sosnowcu:

Office in Sosnowiec:

ul. Staszica 31, 41-200 Sosnowiec

ul. Staszica 31, PL-41200 Sosnowiec, Poland

Tel. 032 3681517, Fax 032 266 9777

Tel. +48 32 3681517, Fax +48 32 266 9777

Siedziba firmy: Warszawa, KRS 0000065443

Domicile Warsaw, Business ID 0000065443

www.fwc.com

Project:

FGT for

FORTUM Częstochowa – Poland

Subject:

INVITATION TO BID

– System – Fly Ash Handling System

Author:

Tomasz Ortman

Checked by:

Michał Mączko

Approved by:

Anna

Jasińska

Customer:

FORTUM Częstochowa

Customer reference:

Action:

Invitation to offer

Other information:

Revision remarks

Revision: Revision date: Revised information:

Pages:

Revised

by:

Checked

by:

Approved

by:

10.11.2016

Original document

ORT

MMA

ADJ

23.11.2016

Revised document

AST

MMA

ADJ

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TABLE OF CONTENTS:

1

GENERAL ................................................................................................................................... 3

MECHANICAL ............................................................................................................................ 3

2.1

CE-Marking ................................................................................................................................. 3

MECHANICAL ............................................................................................................................ 3

SITE CONDITIONS ..................................................................................................................... 4

STANDARDS, RULES AND RECOMMENDATIONS ................................................................ 4

DESIGN DATA ........................................................................................................................... 5

6.1

Fabric Filter Data ......................................................................................................................... 5

6.2

Boiler Fly Ash Analysis................................................................................................................ 5

6.3

Boiler Fly Ash Particle Size Distribution ...................................................................................... 5

6.4

Final Fly Ash Composition (at the Fabric Filter Hoppers outlets) ............................................... 6

6.5

Compressed air ........................................................................................................................... 6

EQUIPMENT SPECIFICATION .................................................................................................. 6

7.1

Fly ash handling system

– separate pneumatic transmitters ...................................................... 8

7.2

Fly ash handling system

– common cumulative collector ........................................................... 9

7.3

Fly ash handling system

– chain conveyor ............................................................................... 10

7.4

Instrumentation and Control Equipment

– requirements .......................................................... 11

7.5

NTE Loads ................................................................................................................................ 11

7.6

Operation and Performance ...................................................................................................... 11

SCOPE OF SUPPLY ................................................................................................................ 11

DELIVERY LIMITS ................................................................................................................... 13

CONTENT OF THE OFFER ..................................................................................................... 13

10.1

Pricing ....................................................................................................................................... 14

PERFORMANCE AND OPERATION GUARANTEES ............................................................ 14

11.1

Time of Guarantee .................................................................................................................... 14

11.2

The following values should be guaranteed:............................................................................. 14

11.3

Vibration .................................................................................................................................... 15

11.4

Noise ......................................................................................................................................... 15

11.5

Avaliability ................................................................................................................................. 16

11.6

Documentation .......................................................................................................................... 17

ENCLOSURES ......................................................................................................................... 17

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GENERAL

Overall, the European standards and codes are preferred in the engineering, design,

manufacturing, supervising of erection and erection of all equipment.

Mechanical equipment shall be designed according to EN/PED standards. Electrical equipment

and installations shall be designed and built in accordance with the IEC norm and regulation valid

in Poland.

MECHANICAL

The equipment shall be designed to conform to the provisions of ISO Standards and valid safety

regulations.

Special attention is paid to reliability and ease of maintenance.

The equipment shall be safe in use, successfully proven in power plants and correctly dimensioned

to its operation. The delivery and equipment shall meet the environmental and technical

requirements of the applicable directives and harmonized standards. Additionally, health and safety

requirements and the functional safety of safety related systems (IEC 61508), ATEX-requirements

etc. shall be fulfilled.

2.1 CE-Marking

Compliance has to be demonstrated by CE marking affixed to the equipment and supported by EC

declaration of conformity signed by the manufacturer or his representative within the community.

CE marking carries a presumption of compliance with the requirements of relevant directives. In

case the pressure equipment directive (PED) is applied, a reference to EC type examination

certificate, EC design-examination certificate or EC certificate of conformity is required. The

Contractor is responsible to select his equipment and documentation in respect of the categories

of conformity assessment. CE marking on an electronically controlled and electrically powered

machine shall indicate compliance with the applicable directives. The technical documentation shall

show the directives that have been applied.

MECHANICAL

This specification outlines the basic requirements for a Fly Ash Handling System and accessories

to be designed, manufactured, inspected, tested and delivered for use with an industrial air

pollution control system for Amec Foster Wheeler Energia Polska.

The Fly Ash Handling System is dedicated for the new Fabric Filter.

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SITE CONDITIONS

Site

Site location

Czestochowa,
Poland

Elevation above sea level

260

Ambient air

Pressure

mbar

984

Temperature, annual average

C

Temperature, minimum

C

-20

Temperature, maximum

C

Relative Humidity:

Annual average

Minimum

Maximum

100

Characteristically load of Wind

250

Characteristically load of Snow

kN/m

0.7

Rain data

mm/year

678

STANDARDS, RULES AND RECOMMENDATIONS

The delivery and the equipment in it are designed to meet the requirements of the following codes
and standards valid at proposal date in Poland. Following codes and standards will be used:

Pressure part design,
manufacturing, inspections and
testing according to:

EU PED (2014/68/EC), EN Standards: EN12952,
EN13445 or AD 2000, EN13480.

The Contractor is responsible for conformity in
accordance with local laws, regulations, standards
and requirements by local authorities including
acceptance by local authorities.

In case the requirements of the laws, regulations,
standards or requirements by local authorities
regarding manufacturing, inspections and testing are
more restrictive than the requirements said in the
PED (2014/68/EC), EN12952, EN13445 or AD 2000,
EN13480 the Purchaser is responsible for conformity
and acceptance by authorities of those.

Machinery

Machinery Directive 2006/42/EC

Electrical equipment

IEC or ISO

Automation

VDI/VDE recommendations

P&I Diagrams

DIN-EN ISO 10628 Flow diagrams for process
plants - general rules

Civil/Steel Structures

EURONORM

Unit-system

SI-system and unit derived from it (bar means
overpressure unless marked otherwise)

Coding system

KKS, according to Purchaser KKS book

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DESIGN DATA

6.1 Fabric Filter Data

Number of compartments:

Compartment (module) dimensions (width x depth):

4 m x 7.5 m

Distance between hoppers:

about 4 meters

Distance between hopper outlet and ground surface:

about 3 meters

Hopper outlet size:

300 mm x 300 mm

Amount of hoppers:

Hoppers enclosure:

Yes, 4 sided

Volumetric density fly ash:

800 kg/m

Structural density fly ash:

1500 kg/m

Operating temperature:

140

°C (peak 180°C)

6.2 Boiler Fly Ash Analysis

1 -

100%

MCR

nominal

coal

– 100%

MCR

worst coal

(max ash

Cl S, min

LHV)

– 100%

MCR

nominal

coal /

nominal

RDF

–

guarantee

point

– 100%

MCR

nominal

coal / min
LHV RDF

20 - 100% MCR

worst coal (max ash

Cl S, min LHV) / worst

RDF (max ash Cl S

Hg, min LHV)

CaCO3

wt-%

1.85

2.60

1.25

1.41

2.53

CaO

wt-%

15.38

15.48

12.58

12.45

14.05

MgO

wt-%

1.64

1.57

2.16

2.18

2.04

MgCO3

wt-%

0.08

0.10

0.11

0.14

0.20

CaSO4

wt-%

11.58

13.22

11.61

11.55

16.67

Inert

wt-%

0.41

0.44

0.50

0.49

0.66

Fuel Ash

wt-%

62.88

61.62

66.47

66.52

60.07

Unburned carbon

wt-%

6.18

4.97

5.33

5.27

3.78

Na equivalent

wt-%

0.00

6.3 Boiler Fly Ash Particle Size Distribution

Fly Ash PSD

1 -

100%

MCR

nominal

coal

– 100%

MCR worst

coal (max

ash Cl S,

min LHV)

– 100%

MCR

nominal

coal /

nominal

RDF

–

guarantee

point

– 100%

MCR

nominal

coal / min
LHV RDF

20 - 100% MCR worst

coal (max ash Cl S,

min LHV) / worst RDF

(max ash Cl S Hg, min

LHV)

< 63

µm

wt-%

71.54

71.79

70.24

70.04

70.90

63-125

µm

wt-%

22.06

22.26

22.92

22.97

23.29

125-180

µm

wt-%

4.90

4.66

5.26

5.36

4.60

180-500

µm

wt-%

1.50

1.29

1.58

1.64

1.21

500-2000

µm

wt-%

0.00

>2000

µm

wt-%

0.00

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6.4 Final Fly Ash Composition (at the Fabric Filter Hoppers outlets)

Flue Gas Treatment Installation will include Dry Sorbent Injection System (DSI) and Activated

Carbon Injection System (ACI) so the final Fly Ash Composition at Fabric Filter Hoppers outlets will

include also the products of these systems.

The maximum content of DSI product in the final Fly Ash Composition will be 15.5 weight %.

Composition of DSI product:

 unreacted Ca(OH)

(mostly)

 CaSO

∙1/2 H

 CaSO

∙2 H

 CaCl

(also a significant share)

6.5 Compressed air

Parameters of compressed air supplied by Customer:

Pressure

bar

7.3

– 7.6

Dew point

° C

-20

EQUIPMENT SPECIFICATION

Fly Ash Handling System will be provided for fly ash discharging from fabric filter hoppers to existing

fly ash silo.

Fabric Filter is equipped with five hoppers. The distance between hoppers outlets is around 4 (four)

meters. The distance between surface (ground) and outlet of the individual hopper equals 3 (three)

meters.

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There are three possible ways to design this system:

 First – each fabric filter hopper will be equipped with its own pneumatic transmitter. There

will be five separate discharging lines from fabric filter hoppers to one inlet box at the silo

top.

 Second – each fabric filter hopper will be connected to the common cumulative collector

and from this collector fly ash will be transported to the fly ash silo (inlet box at the silo top).

 Third – each fabric filter hopper will be connected to the chain conveyor and from this chain

conveyor fly ash will be transported to the fly ash silo (inlet box at the silo top).

Fly ash from fabric filter may be discharged to the fly ash silo only with pneumatic transport (positive

displacement).

There are also two possible options for transportation air supply:

 The Contractor will use compressed air supplied by Client.
 The Contractor will use additional blowers for fly ash transportation.

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7.1 Fly ash handling system

– separate pneumatic transmitters

Number of pneumatic transmitters:

5 pcs (one for each hopper)

DIM mass flow rate from each hopper:

1 kg/s

Transport air:

Basic option:

compressed air
supplied by the Client;
please specify air
consumption

Additional option (separate
price):
-

transport air blowers
delivered by Supplier;
please specify proper
blowers and provide
prices for them

Distance between hoppers and silo
(transport distance):

Line 1: about 68 [m]
Line 2: about 64 [m]
Line 3: about 58 [m]
Line 4: about 55 [m]
Line 5: about 55 [m]

Silo Inlet Box:

Inlet Box design and
delivery required

All necessary equipment for this system should be specified and delivered by the
Supplier (in accordance to Supplier experience).

Please take also into consideration that whole system will be heated, thus each
device and each pipeline has to be prepared to apply heating.

In the Supplier scope is also the design and delivery of inlet box for existing silo.
Existing silo details

– see attachment number 5.

Flow diagram:

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7.2 Fly ash handling system

– common cumulative collector

Number of common cumulative
collectors:

1 pc

DIM mass flow rate from collector to silo:

5 kg/s

Transport air:

Basic option:

compressed air
supplied by the Client;
please specify air
consumption

Additional option (separate
price):
-

transport air blowers
delivered by Supplier;
please specify proper
blowers and provide
prices for them

Distance between collector and silo
(transport distance):

About 59 [m]

Silo Inlet Box:

Inlet Box design and
delivery required

– see attachment number 5.

Flow diagram:

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7.3 Fly ash handling system

– chain conveyor

Number of chain conveyors:

1 pc

DIM mass flow rate from chain conveyor
to silo:

5 kg/s

Transport air:

Basic option:

compressed air
supplied by the Client;
please specify air
consumption

Additional option (separate
price):
-

transport air blowers
delivered by Supplier;
please specify proper
blowers and provide
prices for them

Distance between chain conveyor and
silo (transport distance):

About 59 [m]

Silo Inlet Box:

Inlet Box design and
delivery required

– see attachment number 5.

Flow diagram:

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7.4 Instrumentation and Control Equipment

– requirements

All the I&C equipment for Fly Ash Handling System should meet requirements specified in
Specification of Instrumentation and Control Equipment (attachment no. 6).

7.5 NTE Loads

Supplier should supply load diagram (Not To Exceed loads) for the equipment all together with
foundation layout. In the calculation should be included site conditions (point 4) from this
specification. All equipment installed outdoors should face the site conditions (point 4) from this
specification.
The bottom of the steel is 0,4m above the concrete slab.

All the instruments needed for proper operation of the Fly Ash Handling System are included
in scope of supply.

In case the above specified items which are not within your delivery scope please send
information indicating which are excluded.

7.6 Operation and Performance

The Fly Ash Handling System shall be designed for automatic operation without periodic

operator input. Operator input will be required for system startup or shoutdown or whenever

there is an alarm.

The Fly Ash Handling System shall be capable of operating for 24 hours per day and 7 days

per week on full automatic control.

SCOPE OF SUPPLY

Scope of supply shall include the design, manufacturing, factory testing, erection supervision

and instructions, training staff instructions, commissioning supervision and test run, O&M

instructions for the equipment delivered by Supplier.

Fly Ash Handling System shall be furnished with all the required equipment and accessories,

including, but not limited to, the following:

 Complete Fly Ash Handling System with all necessary mechanical, electrical,

measurement systems, auxiliary equipment and pipelines

 Equipment shall be furnished with all necessary supports
 Anchor bolts
 Support structure for pipelines
 Design documentation for supplied equipment
 Acoustic hood covering the entire unit made of galvanized steel sheet plate with oil

drip pan, forced ventilation by fan driven by independent shaft, acoustic hood for

indoor installation;

 Lubrication units, if applicable;

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 Service kit with first fill of lubrication;
 Logic Diagrams & Functional Descriptions;
 Erection, Commissioning and Maintenance Instructions (English and Polish

language);

 Any certificates required by EN/PED;
 CE marking;
 Declaration of conformity with Machinery Directive 2006/42/EC;

 special tool requirements for installation start-up, operation, and maintenance (if

any);

 wear and spare parts for start up and commissioning (separate price);

 wear and spare parts, which are prerequisite for the availability guarantee during

the mechanical guarantee period of 2 years (separate price).

Requirements for option with transport blowers:

Transport air blower shall be furnished with all the required equipment and accessories,

including, but not limited to, the following:

 Steel base plates for blower and motor;
 Anchor bolts;
 Anti-vibration pads;
 Coupling;
 Silencer on pressure side;
 Flexible joints;
 Safety valve;
 Check valve (damper);
 Maintenance/operational valve between lines;
 Acoustic hood covering the entire unit made of galvanized steel sheet plate with oil

drip pan, forced ventilation by fan driven by independent shaft, acoustic hood for
indoor installation;

 Lubrication units, if applicable;
 Local pressure meters;
 Vibration sensors for bearings and shaft;
 Static and dynamic balancing for rotor;
 Test runs at factory;
 Service kit with first fill of lubrication;
 Erection, commissioning and maintenance instructions (Polish & English

language);

 Fire protection assumptions for design (if any);

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 Any certificates required by EN/PED;
 CE marking;
 Declaration of conformity with Machinery Directive 2006/42/EC;

 special tool requirements for installation start-up, operation, and maintenance (if

any);

 wear and spare parts for start up and commissioning (separate price);

 wear and spare parts, which are prerequisite for the availability guarantee during

the mechanical guarantee period of 2 years (separate price).

In case the above-specified items are not within your delivery scope please send information
indicating which items are excluded.

DELIVERY LIMITS

Fly Ash Handling System:

Inlet:

outlets of fabric filter hoppers

Outlet:

outlet from inlet box at silo top

Electrification



equipment power supply terminals

I & C



signal terminals in field junction boxes

CONTENT OF THE OFFER

At least the following data should be given in the proposal:

Scope of supply;

Delivery limits;

Technical data and specifications of equipment;

Weights and dimensions of components;

Arrangement drawings;

Main flow diagram showing all equipment provided;

List and price of wear and spare parts for start up and commissioning (separate
price);

List and price of wear and spare parts, which are prerequisite for the availability

guarantee during the mechanical guarantee period of 2 years (separate price);

Option - erection supervision

–separate price;

Option - commissioning supervision

– separate price;

Media consumption list.

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10.1 Pricing

The pricing for the system should be done according to the table below:

SYSTEM

PRICE (EURO)

1. Fly Ash Handling System

–

separate pneumatic transmitters

Option for item 1: Transport air
blowers

2. Fly Ash Handling System

–

common cumulative collector

Option for item 2: Transport air
blowers

3. Fly Ash Handling System

– chain

conveyor

Option for item 3: Transport air
blowers

Spare parts for Start Up and
Commissioning

Spare parts for 24 months (2 years)

Option: Erection supervision

Option: Commissioning supervision

TOTAL PRICE

PERFORMANCE AND OPERATION GUARANTEES

The Supplier is responsibility for design and construction of the supply. The Supplier shall guarantee

that the supply is according to the specification. All equipment must be new and not used before, free

of any error or defect of design or materials. All guarantees are absolute unless informed otherwise.

11.1 Time of Guarantee

The warranty period for the Equipment is 24 months starting from Taking Over protocol, 48

months for replaced or repaired parts. Replaced Equipment or parts thereof, shall be supplied

by Supplier at its cost, in line with the original delivery term. Dismantling, installation and on-site

repairs of defective parts shall be performed by Supplier at Supplier’s cost.

11.2 The following values should be guaranteed:

Fly Ash Handling System with separate pneumatic transmitters:

1) Each pneumatic transmitter capacity: 1 kg/s
2) Power consumption for Guarantee Point (see item 6.2 and 6.3)

– XX kW –

TBD and guaranteed by Supplier

– each pneumatic transmitter capacity in

GP: 0.39 kg/s

3) Maximum Power Consumption: XX kW

– TBD and guaranteed by Supplier -

each pneumatic transmitter capacity: 1 kg/s

4) Air consumption (case 1: compressed air supplied by Customer

–

parameters: see item 6.4) - XX m

(n)/h (TBD by Supplier; amount

–

guaranteed value)

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5) Air consumption (case 2: transport air blowers) - XX m

(n)/h (TBD by

Supplier; amount

– guaranteed value, parameters (dry/wet, temperature of

pressure dew point of air))

Fly Ash Handling System with common cumulative collector:

1) Mass flow rate from collector to silo: 5 kg/s
2) Power consumption for Guarantee Point (see item 6.2 and 6.3)

– XX kW –

TBD and guaranteed by Supplier

– mass flow rate from collector to silo in

GP: 1.95 kg/s

3) Maximum Power Consumption: XX kW

– TBD and guaranteed by Supplier

– mass flow rate from collector to silo: 5 kg/s

4) Air consumption (case 1: compressed air supplied by Customer

–

parameters: see item 6.4) - XX m

(n)/h (TBD by Supplier; amount

–

guaranteed value)

5) Air consumption (case 2: transport air blowers) - XX m

(n)/h (TBD by

Supplier; amount

– guaranteed value, parameters (dry/wet, temperature of

pressure dew point of air))

Fly Ash Handling System with chain conveyor:

1) Mass flow rate from chain conveyor to silo: 5 kg/s
2) Power consumption for Guarantee Point (see item 6.2 and 6.3)

– XX kW –

TBD and guaranteed by Supplier

– mass flow rate from chain conveyor to

silo in GP: 1.95 kg/s

3) Maximum Power Consumption: XX kW

– TBD and guaranteed by Supplier

– mass flow rate from chain conveyor to silo: 5 kg/s

4) Air consumption (case 1: compressed air supplied by Customer

–

parameters: see item 6.4) - XX m

(n)/h (TBD by Supplier; amount

–

guaranteed value)

5) Air consumption (case 2: transport air blowers) - XX m

(n)/h (TBD by

Supplier; amount

– guaranteed value, parameters (dry/wet, temperature of

pressure dew point of air))

11.3 Vibration

Blower power

≤ 15 kW

Blower units shall be able to achieve the vibration criteria defined in the following standards:

PN ISO10816-1: 1998, PN ISO10816-1: 2009 and ISO 7919-3:2009.

Blower power > 15 kW

Blower units shall be able to achieve the vibration criteria defined in the following standards:

PN ISO10816-3: 2009 and ISO 7919-3:2009.

11.4 Noise

The sound pressure level (L

) from an individual apparatus in the scope of supply shall not

exceed 85 dB(A). The sound pressure level (L

) is defined in accordance with EN ISO

3746:2011 and measured at 1 m distance from the individual apparatus.

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11.5 Avaliability

The guaranteed average availability (A

) shall not be less than 99,70% per year during the

Availability Period (24 months).

The guaranteed annual availability shall be the average of yearly availabilities, which shall be
calculated in accordance with the equation shown below. First year starts from the date of
Taking Over. The annual average availability shall be calculated after the Mechanical
Guarantee period has ended.

The guaranteed average annual availability shall be calculated on percentage basis with the
following equation:

(%)





The guaranteed annual availability shall be calculated on percentage basis with the following
equation:

100

8760

(%)

exp







main

Where:

8760

Number of hours per year

Availability during the first year of the Mechanical Guarantee Period

Availability during the second year of the Mechanical Guarantee Period

main

Total time of planned outages during the year

unexp

Total time of unplanned outages during the year

The Works shall be considered to be in operation:

1. If the Works can be operated within its specified operating range without any restrictions to

load caused by any equipment or system forming a part of the Works and providing that the
environmental requirements are met.

2. If the Works would meet the conditions set in item 1 above, but are actually not in operation

due to reasons not attributable to the Contractor, such as:



No outside electricity to start-up the Works;



No personnel available to operate the Works (such as illness, operator not available);



Governmental decision or declaration not to operate or start the Works ;



Damages due to operator fault (e.g., faulty operation and maintenance, combustion of
fuel other than specified in the Contract);



Lack of reagents, consumables or no reagents. consumables available at all;



Plant outage caused by failure in parts not included in the Works.

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11.6 Documentation

Final documents and drawings shall be delivered in size are in accordance with ISO A-series.

Documentation requirements will be given after choosing Supplier of Fly Ash Handling System.

The measures of all documents shall be given in SI units.

12 ENCLOSURES

1. Fly Ash Handling System with separate pneumatic transmitters

– flow diagram -

FWH++++++-MFB0001.pdf

2. Fly Ash Handling System with common cumulative collector

– flow diagram - FWH++++++-

MFB0002.pdf

3. Fly Ash Handling System with chain conveyor

– flow diagram - FWH++++++-MFB0003.pdf

4. Overall layout of FGT

– O11059_Revf.pdf

5. Drawing of existing silo

– 221001.pdf

6. Specification of instrumentation and control equipment.pdf