General Technical Report 05

GENERAL TECHNICAL REPORT
Equipment:
DETAILED ENGINEERING
Order: VEC001101
Customer:ROYAL GK PTE LTD
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
General technical report
VEC001101
CUSTOMER
ROYAL GK PTE LTD
- CONTENTS 1 2 3 PURPOSE ............................................................................................................ 1 GENERAL DESCRIPTION ................................................................................ 3 CIVIL ENGINEERING ........................................................................................ 4 3.1 Prior Data ................................................................................................... 4 3.2 Foundations ................................................................................................ 5 3.3 Electrical Installations and Pits................................................................. 7 3.4 Drainage System ...................................................................................... 10 3.5 Exterior Flooring ...................................................................................... 12 3.6 Interior Flooring ....................................................................................... 14 3.7 Fencing ...................................................................................................... 15 3.8 Metallic Structure .................................................................................... 15 3.9 Faades ...................................................................................................... 20 3.10 Roofs .......................................................................................................... 20 4 OPERATIONAL CONDITION AND TERMS ............................................... 22 4.1 Electrical power generation.................................................................... 22 4.2 Fire& gas leak detection .......................................................................... 25 5 ENGINE AND GENERATOR ASSEMBLY .................................................... 36 5.1 Engine features ......................................................................................... 38 5.2 Alternator features .................................................................................. 40 6 ENGINE FLUE SYSTEM .................................................................................. 43 6.1 Exhaust silencer ....................................................................................... 44
CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, GUASCOR POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 6.2 Exhaust chimney ...................................................................................... 44 6.3 Piping and fittings ..................................................................................... 44 6.4 Design and definition chart ..................................................................... 46 7 ENGINE COOLING SYSTEM ......................................................................... 52 7.1 Engineering basis of design ..................................................................... 53 7.2 Electrical water pumps ............................................................................ 54 7.3 Expansion vessels ..................................................................................... 54 7.4 Double core air cooler ............................................................................. 55 7.5 Piping& fittings ......................................................................................... 56 7.6 Testing & inspection ................................................................................ 59 7.7 Design & definition chart ........................................................................ 60 8 ENGINE LUBE OIL SYSTEM .......................................................................... 73 8.1 Blowby gases exhausting system ............................................................ 74 9 ENGINE VENTILATION SYSTEM ................................................................ 77 9.1 Description of the engine room ventilation .......................................... 77 9.2 Ventilation system ................................................................................... 78 10 NATURAL GAS FUEL SUPPLY ..................................................................... 80 10.1 General description ................................................................................. 80 10.2 Engineering basis of design ..................................................................... 90 10.3 Testing & inspections............................................................................... 91 11 FIRE & GAS LEAK DETECTION SYSTEM ................................................... 93 11.1 Basis of design........................................................................................... 95 11.2 Design & definition ................................................................................... 97 11.3 Technical specifications .........................................................................105
ii
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 12 ELECTRICAL GENERATING SYSTEM ...................................................... 117 12.1 General description ...............................................................................117 12.2 Grounding grid ....................................................................................... 129 12.3 Engineering basis of design ...................................................................130 12.4 Supporting calculations .........................................................................131 12.5 Testing & inspection ..............................................................................138 13 ANCILLARY SERVICES.LOW VOLTAGE SYSTEM. ................................ 139 13.1 General description ...............................................................................139 13.2 Engineering basis of design ...................................................................145 13.3 Electrical design & definition ................................................................ 145 13.4 Testing & inspection ..............................................................................161 14 ENVIRONMENTAL POLLUTION SOURCES AND MEASURES .....................................................................................................162 14.1 Standards basis of design.......................................................................162 14.2 Location ..................................................................................................163 14.3 Raw and auxiliary materials ..................................................................163 14.4 Air Pollution-Emission sources............................................................. 165 14.5 Noise Sources ......................................................................................... 166 14.6 industrial sewage water .........................................................................167 14.7 Industrial residues .................................................................................. 168 14.8 Environmental measures for the site soil ............................................169
iii
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
PURPOSE
This project envisages the construction of a 26MW natural gas generation power plant in the Republic of the Union of Myanmar. This power plant is conceived as a back-up to increase the already existing power generation capacity that supplies the national grid in the Yangon Region. The power plant will be based on internal combustion engines technology. Although the power plant will be managed as a single unit from a central control station, the design is based on 26 gas gensets of 1MW, which can be also managed as independent generation units. The main advantage of this design is that using 1MW gensets the plant will have higher degree of power availability in case of maintenance or reparations of the units than using bigger sized gensets. The plant has been designed foreseeing a future expansion with a second phase of another 26 gensets. If this second phase is implemented the final capacity of the plant will be of 52MW. This new plant will be built adjacent to the existing Hlawga Gas Power Plant, which at present day is composed by 3 gas turbines and a steam turbine, which have a total available power capacity of 154,2MW. The gas supply for the new power plant will be diverted from the MOGE gas regulation station that serves to the turbines. The power plant is also adjacent to a power substation of YESB, where the turbines are connected to Myanmars National Grid. The interconnection of the new power plant will be made at the same busbar of 33kV as the turbines, using an available spare feeder. Future expansion would require a second feeder in the same busbar.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
HlawgaPowerPlant (Turbines)
YESB Substation (33kV) Interconnectionfeeder
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
GENERAL DESCRIPTION
The power plant is composed by two warehouse buildings. Each of them will house 13x1MW electrical generators. Between these buildings, there will be a space where the transformers and a MV switchboard box are located. These elements are used to step-up the power to 33kV. Surrounding these buildings there will be a 7-metre wide road and then, further beyond and parallel to the warehouses, there will be installed the air coolers for the cooling system of the gensets. On one side of the plot, perpendicular to the warehouses, there will be a gas regulation and measurement station (GRMS) and, on the other side, next to the plot entrance, there will be a building with offices, warehouse, the main control station and other facilities. Close to the entrance, there will be two large transformers and also some MV protection switchboards. The size of the power plant will be of 107m (length) x64,8m (width). General lay-out can be viewed in the plan No.:31.01The future expansion requires the duplication of these elements, except the building of the offices, warehouse, and main control station, which will be common to all the installation. View plan No.: 39-01.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
CIVIL ENGINEERING
In the following chapter of this report is made the description of the Civil Engineering works necessary to build the plant. Related drawings 41-01 to 41-06 describe the necessary works for the urbanization of the plant area, foundation, underground works, piping, slabs, etc.. Related drawings 42-01 to 42-17 describe the construction of the three main buildings; the two engine rooms and the auxiliary services building. In general terms this chapter describes the previous steps of the necessary works to perform the plant construction; before strictly speaking, the generation plant equipment is installed (generators, generator cooling system, electrical equipment and wiring, gas installation, etc..) Constructor should take in consideration that some works and installation not directly described in this chapter should be performed in parallel to the underground civil works. Notably underground installations like the buried grounding grid (view Plan 24-01) and some buried water (view Plan 61-02 to 61-05) and gas (view Plan 62-03) pipes.
3.1
PRIOR DATA
The project will be on a horizontal area of levelled ground, which must be executed so that it has volumetric stability without any settlement or shrinkage due to insufficient compaction and without any increase in volume or expansivity. This levelled ground has to be a regular surface in order to support the surface and the shallow and deep foundations to avoid the undesired distribution of differential tensions and settlement which may affect the layout of the facilities, the foundations of the buildings and the foundations of the equipment. It must also be resistant to the erosion caused by water, both the surface and underground water, and the levelled ground must prevent it from sliding down the hillside. The construction of the levelled ground is not part of this project and must be carried out in accordance with the technical specifications of the project engineer and backed by a local geotechnical study. The levelled grounds design will also depend on the construction techniques and available materials, as well as on the functional and structural aspects and on the locations height.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The levelled ground must ensure that the terrain has a bearing capacity of 1.5 kg/cm2 (0.15 MPa) on the base of the buildings footing and on the base of the shallow foundations, as well as the ballast module indicated in the plans. Regarding the plot where the road will be located, the levelled ground must be a category E2, i.e. its compressibility module in the second bearing cycle obtained by a "Plate bearing trial" must be > than 120 MPa. CBR>10. Note: The design of civil engineering described in the following document was done according these premises and with shallow foundations. After the visit of November 2012 to the site it was stated that the critical buildings required deep foundations (piles) in order to avoid any collapse possibility in case of earthquake. A study was done to argue this statement. This document, the related calculations and a foundation design with piles are included as appendixes of this project. (View Appendix Civil Enginnering- Pile design) Customer has decided not to follow this recommendation and thus a complete design of the metallic structures based in these foundations was not done. The following document describes a shallow foundation design.
3.2
FOUNDATIONS
Once the levelled ground has been approved, the necessary excavation will be made in order to build the foundations for the buildings, whose support height is deeper. The shafts for the foundations and the ditches for the centring beams will be excavated. It will be checked that the terrains bearing capacity in the foundation base is 1.5 kg/cm2 (0.15 MPa). The ballast module will be 1,000 - 3,500 T/m3. All the reinforced concrete elements will be on a base of blinding concrete that is 10 cm thick. The excavations will be in accordance with the instructions of the geotechnical study, so that the embankments are stable. It will be possible to consider placing reinforcements and shoring in the deep excavations. The design of the foundations has been made in accordance with the Instruction on Structural Concrete (EHE-08) and the Basic Documents on Structural Safety (DB-SE), Structural Safety of Foundations (DB-SE-C), Structural Safety of Steel (DB-SR-A) and Structural Safety on Building Actions (DB-SE-AE) of the Spanish Technical Building Code (CTE).
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
3.2.1.1 Footings
The two warehouses where the generators and the ancillary services building are located will have insulated rigid footings made with HA-20 reinforced concrete (f'c=200 with fck resistance = 200 kp/cm), whose depth will be in accordance with the plans in order to prevent interferences. The dimensions, reinforcement and characteristics of the concrete will be in accordance with the plans. The footings will be joined by the centring beams. The footings will have anchor plates for the metal pillars, whose dimensions and characteristics are detailed in the plans, and will be secured to the concrete with bolts. The metal posts have to be placed before filling and tamping the excavations. The separating walls between the 35 MVA transformers will be made of reinforced concrete, whose dimensions will be in accordance with the plans (View plan No.: 41-06) and their foundations will have continuous footing of 150 x 50 cm. of section. The supporting height of these walls will be the same as that for the transformer tanks. The walls have R120 fire resistance. The air coolers will have a reinforced concrete footing on which concrete pillars will be built in accordance with the plans (View plan No.: 41-05).
3.2.1.2 Concrete Slab Foundations

The foundations for the transformers, the main cell box, the line input cell room and the GRMS will be made of concrete slabs, whose dimensions and depths will be in accordance with the plans. (View plan No.: 41-05, 41-06.) Apart from the GRMS which will be directly supported by the slab, the other elements will be supported by the corresponding slabs through walls, thus providing tanks to collect the oil in the case of transformers as well as pits in the cell boxes through which the installations will pass. The generators will have a reinforced concrete bedplate which will serve as the foundations and settlement, carrying out the function of seismic mass, thus isolating the vibrations of the surroundings.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
3.3
ELECTRICAL INSTALLATIONS AND PITS
In parallel to the generator rooms, along the lengthwise axis between them, a ditch will be built for the electrical cables, with a minimum interior free height of 147 cm. Its construction will base on reinforced concrete slabs and walls, with a thickness of 15 cm, except in the cell box area and the prefabricated concrete caps. The cabling ditch will have slopes towards the ends, where there will be a drainage system connected to the rainwater sewage network to evacuate the water that may enter from outside. Inside the generator warehouses, pits will be built for the electrical cabling under the location of the control and power panels. Its construction will based on reinforced concrete with anti-slip diamond plate caps with a thickness of 3 mm. They will have a drainage system on the base through a PVC tube of 110 mm over a gravel bag. The underground electrical installations go from these pits to the transformers and the air coolers. The plots other installations will be buried in ditches, whose design has been made in accordance with the Spanish Technological Regulations (NTE) and Iberdrolas specific regulations in the case of the electrical pits. The electrical pits, lighting and water pipes from the generator warehouses to the air coolers will be made with HM-20 mass concrete to protect the pipes, and their support height will be that stated in the development plans.
3.3.1
Electrical Pits
The electrical pits will be formed by corrugated polyethylene pipes whose diameters are defined in the corresponding plans (View plans No.:41-02, 41-04 Detail Trenches 1 to 6), covered by an HM-20 mass concrete tray, whose dimensions and depth will depend on the number of pipes that they have, and by a fill compacted to 100% of the S.P. (standard Proctor) up to the level of the levelled ground. They will have boundary tapes in the compacted fill. The corrugated polyethylene pipes with a 200 mm connection between the electrical conduits and the transformers will have a minimum turning radius of 40 cm, and those which connect the transformers with the main cabling pit will have a minimum turning radius of 72 cm.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD There will be inspection hatches for the electrical pits, whose dimensions are specified in the plans (View plans No.:41-02, 41-04 Detail Trench (electrical)) and they will be made of prefabricated concrete with a prefabricated concrete cover with a metal frame. These inspection hatches will have a drainage system on the base through a PVC tube of 110 mm over a geotextile gravel bag.
3.3.2
Pits for the Lighting
The pits for the lighting will connect the planned lamppost system and will be formed by 2 corrugated polyethylene pipes, with a diameter of 90 mm, covered by an HM-20 mass concrete tray, whose dimensions and depth are defined in the plans (View plans No.:4102, 41-04 Detail Trench 7), and by a fill compacted to 100% of the S.P. up to the level of the levelled ground. They will have boundary tapes in the compacted fill. There will be inspection hatches for the pits for the lighting, which will coincide with the lampposts positions, their dimensions are specified in the plans (view plan 41-04 detail Foundation with street lamp), and they will be made of prefabricated concrete with a prefabricated concrete cover with a metal frame. These inspection hatches will have a drainage system on the base through a PVC tube of 110 mm over a gravel bag.
3.3.3
Pits for Electricity, Data and Other Conduits
These pits are those which will connect the generator warehouses with the air coolers. They will be formed by a row of conduits, covered by an HM-20 mass concrete tray, whose dimensions and depth are defined in the plans (View plans No.:41-02, 41-04 detail Trench 8 to 11), and by a fill compacted to 100% of the S.P. up to the level of the levelled ground. They will have boundary tapes in the compacted fill. The development plans define the polyethylene pipes that will protect the water pipes, which will be made of stainless steel. The depth has been established at 120 cm from the axis of the pipes to the floor of the generator warehouses (height: +0.00).
3.3.4
Pits for Water Supply
A water supply network has been planned with water hydrants that help to clean the roads. This network will go from the plots connection through the ancillary services building and will be through a DN 50 mm polyethylene pipe.
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The pits for the water supply network will be made with a sand base, which will have the polyethylene pipe inserted, and a fill compacted to 100% of the S.P. up to the level of the levelled ground. They will have boundary tapes in the compacted fill. The dimensions and depth of the pits are defined in the plans. (View Plans 41-02, 41-04 details Trench for water pipe under the road,Trench for water pipe out of the road)
3.3.5
Sewage Pits
To determine the width and depth of the pit, it is necessary to know the diameter of the pipes, the geotechnical characteristics of the terrain and the possible mobile bearings that can be transmitted to the subsoil, apart from the instructions from the site management. To facilitate manipulation inside the pit, a minimum width has been defined for the lowest point of the pit as the diameter of the tube plus 60 cm. There will be a 10 cm-thick bed of granular materials to avoid contact with the sharp elements that may deteriorate the pipe and, therefore, alter its sealing, resistance and other characteristics. It will also be used to make a correct levelling of the terrain in order to ensure the desired slope. Once the pipe has been laid out, the pit will be filled with selected material compacted to 95% of the S.P. with a height of 30 cm over the line following the highest parts of the pipe. The rest of the pit will be completed with a fill compacted to 100% of the S.P. The compaction in any of the filling phases must be made with a lightweight tamper and on both sides of the pipe, without compacting the central area that corresponds to the pipe's projection. The sewage network conduits with a diameter of 400 mm or less will be PVC SN4 compact pipes, while those with a diameter of more than 400 mm will be PVC SN8 compact pipes. The inspection hatches and manholes of the sewage network will be prefabricated, except the drains under the gutters and the grease separators. There will be inspection hatches for the pits for the lighting, which will coincide with the lampposts positions, their dimensions are specified in the plans (view Plan 41-02, 41-04 detail Trench for sanitation water & others), and they will be made of prefabricated concrete with a prefabricated concrete cover with a metal frame. These
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD inspection hatches will have a drainage system on the base through a PVC tube of 110 mm over a gravel bag.
3.4
DRAINAGE SYSTEM
The drainage system has been designed to separate fecal waters, rain water and oily water. The drains correspond to the items or surfaces where oil could have been discharged.
3.4.1
Fecal Water Drainage System
Fecal waters to be drained come from the locker rooms and washrooms located in the auxiliary services building. The water will flow to a septic tank equipped with a siphon collection box at the beginning and a sampling collection tank at the end where a discharge pipe is connected to an external channel with treated water. (view Plan 41-2, 41-04 detail Siphonic Trench)
3.4.2
Oily Water Drainage System
An oily water drainage system has been designed for the inside of each engine room. The system is comprised of sumps that collect water originating from cleaning buildings, water circuit spillage and engine base plate drains which is discharged via the sump drains. The collection boxes are connected to each other via PVC pipes and drain to external oil separator collection boxes where oil-free water goes to the rainwater drainage system. Furthermore, rainwater that falls into the transformer basins will go to a collection box controlled by a shutoff valve which will allow rainwater to be discharged or if there is an oil spillage, it shall blocked until it can be removed by an authorized handler. Collection boxes with shutoff valves are found in accessible locations in order to for waste removal to be performed without having to be near restricted access areas located near the transformers.
3.4.3
Rainwater Drainage System
Rainwater that falls upon the roofs of the buildings will be collected in pipes located outside the building and transported by downpipes, attached to the facade, towards the underground system.
10
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The road and the transformers are located between two buildings; this area will have a 2% slope angle which leads towards concrete ditches. These ditches will have a longitudinal slope which is higher than 0.5% and which will lead towards sumps connected to the underground network. Sump grating will be placed at engine room access points in order to avoid rainwater from entering. The central electrical cable trench will drain into the underground rainwater drainage system. The electricity collection boxes and gutters are designed with a drainage channel located at the bottom, which is connected to a bed of gravel on ground-level.. The rainwater drainage system will discharge into the ground, in the sloppy area which in turn discharges into the lake located on the west side of the lot.
3.4.3.1 Rainwater system sizing

Rainwater flow (Q) to be drained will be indicated in L/s and will depend on the following factors: The average run-off coefficient: Depends on the run-off coefficients for different types of surfaces and areas considered. A coefficient of 0.85 is used for asphalt and concrete pavements. Rainfall intensity that corresponds to the maximum precipitation for a specific return period and the length corresponding to the period of concentration time, which is the necessary time needed to ensure that the maximum flow for discharge arrives to the section considered. A 100 year return period has been established since flooding could cause serious damage. This means that the intensity is set at a 1.91 coefficient. The period of concentration is estimated at a maximum of 10 minutes. Rainfall intensity calculations are estimated at 120 mm/hour and the maximum average intensity is 360 mm/hour for 10 minute intervals. Surface area for wastewater areas at the point considered.
11
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The rainwater drainage system is calculated based on severity patterns and a minimum slope of 0.5%. The drainage pipes need to be partially filled when in operation in order to ensure adequate sewage network ventilation. The percentage of filling of the drainage pipes will depend on the flow intake at each moment but the project has considered a filling level of h=0.8Di, where Di corresponds to the inner diameter of the pipe. Another determining factor for correct evacuation is the circulation speed. The minimum speed has been set at 0.5 m/s which prevents sedimentation and a maximum speed of 2.5 m/s which prevents abrasion. Full flow piping calculations were made based on the Manning Formula and the Thorman and Franke Table was used to determine the relationship between, velocities, flows and filling levels in partially filled circular conduits. Mannings roughness coefficient was considered at 0.008.
3.5
EXTERIOR FLOORING
Once the foundations had been executed and pipes buried, the next step is the urbanisation of the plots exterior flooring. First the base of graded crushed aggregate will be laid with the thickness and gradients as defined in the plans (view Plan 41-01, 41-05).
3.5.1
Roads
Given that at the time of the transport and installation of the engines and equipment, heavy vehicles are going to circulate for a short period, a type of traffic D, medium light T4.1, is established, corresponding to the movement of between 25 and 50 heavy vehicles/day in low-traffic industrial areas. 25 cm. of graded crushed aggregate will be spread over the platform, with a density of not less than 98% of the maximum reference obtained in the modified Proctor test, according to UNE 103501. The graded crushed aggregate to be used is a granular material, of continuous aggregate grading consisting of totally crushed particles made from quarry stone or natural gravel. Its cleaning coefficient according to annex C of UNE 146130 must be less than two. The sand equivalent (Se) according to UNE-EN 933-8 must be greater than 30. According to
12
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD UNE-EN 1097-2 the Los Angeles coefficient of aggregates must be no greater than 35. Limit of non-plastic Atterberg. CBR>20. Above the graded crushed aggregate a surface treatment will be given with a prime coat with a firm coat of hot bituminous mix on top. The hot bituminous mix will be formed by a base coat AC 32 BASE 50/70 G LIMESTONE, 8 cm thick, adhesive primer, an intermediate layer AC 22 BIN 50/70 S SILICA, 6 cm thick, adhesive primer, and a wearing course of AC 16 SURF 50/70 S OPHITE, 4 cm thick. (Designation according to UNE-EN 13108). The road will have at its perimeter a trowelled concrete ditch with smooth finish with white cement and edged with a border of grey concrete.
3.5.2
Flooring in front of premises
Flooring in front of the premises at the entrance for the engines will consist of two layers over the platform. The base will be graded crushed aggregate compacted to 98% of Modified Proctor 20 cm thick. Over the shingle will be placed HA-20 concrete (fc=200 type with fck = 200 kp/cm resistance), 20 cm thick, with 10 mm diameter reinforced wire mesh in a 20x20 cm grid with B 400 S steel (Grade 60 type with fyk = 4200 kp/cm resistance). Between the two layers will be a 150 micra layer of polyethylene and a anti-puncture geo-fabric. The mesh will be placed on the upper part of the sill, with a coating of at least 3 cm. The concrete will have a mechanical trowelled finish sprinkled with non-slip grey quartz aggregate.
3.5.3
Flooring of the Transformer Area y Front of the GRMS and the auxiliary services building
The flooring around the transformers between the premises, the transformers and line entry cell room, the ERM and the auxiliary services building, will consist of two layers over the platform. The base will be graded crushed aggregate compacted to 98% of the Modified Proctor, 20 cm thick Over the shingle will be placed HA-20 concrete (fc=200 type with fck = 200 kp/cm. resistance), 15 cm thick, with 10 mm reinforced wire mesh, grid diameter 20x20 cm, with B 400 S steel (Grade 60 type with fyk = 4200 kp/cm resistance). Between the
13
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD two layers will be a 150 micra layer of polyethylene and an anti-puncture geo-fabric. The mesh will be placed on the upper part of the sill, with a coating of at least 3 cm. The concrete will have a mechanical trowelled finish sprinkled with non-slip grey quartz aggregate.
3.5.4
Air Coolers Area
There will be no flooring in these areas, a 10 cm thick layer of aggregate with 20-40 mm diameter grading will be spread over the platform.
3.6 3.6.1
INTERIOR FLOORING Engine Room
Once the platform has been accepted, a base of graded crushed aggregate will be spread on top, compacted to 98% of the Modified Proctor, 20 cm thick. Over the shingle will be placed HA-20 concrete (fc=200 type with fck = 200 kp/cm resistance), 20 cm thick, with 10 mm diameter reinforced wire mesh in 20x20 cm grid with B 400 S steel (Grade 60 type with fyk = 4200 kp/cm resistance). Between the two layers will be a 150 micra layer of polyethylene and an anti-puncture geo-fabric. The mesh will be placed on the upper part of the sill, with a coating of at least 3 cm. Retraction joints will be placed every 25 m2 and will be sealed with elastic material. The ground will be finished with non-slip Epoxy paint.
3.6.2
Auxiliary Services Building
Once the platform has been accepted, a base of graded crushed aggregate will be spread on top, compacted to 98% of the Modified Proctor, 20 cm thick. Over the shingle will be placed HA-20 concrete (fc=200 type with fck = 200 kp/cm resistance), 15 cm thick, with 10 mm diameter reinforced wire mesh in 20x20 cm grid with B 400 S steel (Grade 60 type with fyk = 4200 kp/cm resistance). Between the two layers will be a 150 micra layer of polyethylene and an anti-puncture geo-fabric. The mesh will be placed on the upper part of the sill, with a coating of at least 3 cm. The concrete will have a mechanical trowelled finish sprinkled with non-slip grey quartz aggregate.
14
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD In the remaining premises considered permanent staff work stations the concrete sill will be covered with 5 cm thick extruded polystyrene thermal insulation, and a 5 cm thick levelling layer of mortar cement and will be finished with ceramic tiles.
3.7
FENCING
The 2.50 m high perimeter fencing will be made of a chain link wire mesh made of 3 mm diameter, galvanised and plasticised wire. The pylons will be 3 m apart at most and will be 50x50 mm section galvanised, painted metal cemented into fingers in 50x50x50 cm HM20 mass concrete (f'c=200 type with fck = 200 kp/cm resistance). The upper of the fencing will be fitted with a security wire with anti-intruder spikes.
3.8
METALLIC STRUCTURE
The structure of all the buildings designed is screwed metal. Design has been done according European Standard profiles. (HEB-120, HEB-200, UPN-300, IPE-100, IPE-160, IPE-200,IPE-300, etc) Steel of the sections and plates is S 235 JR (JO in tubular sections) with tensile yield strength of fy= 235 N/mm2. The steel of the screws is 8.8 with tensile yield strength of fy= 640 N/mm2 and tensile strength at break of fu= 800 N/mm2. The metal structure will have two layers of antioxidant primer and two layers of enamel finishing paint.
3.8.1
Engine Buildings
Will consist of porches in HEB-200 laminated steel pylons and IPE-300 lean-to beams with a slope of 10%. The porches will be braced by a continuous UPN-300 on each longitudinal faade. The roofing bars will be IPE-160.
15
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
3.8.2
Auxilliary Services Building
Will consist of porches in HEB-120 laminated steel pylons and IPE-200 lean-to beams with a slope of 10%. There are three circular 168.3 mm diameter, 8 mm thick pylons, on which HEB-120 will be placed where they meet the beams. The roofing bars will be IPE-100. The whole structure of this building will be protected with intumescent fire-resistant paint with a resistance of R15
3.8.3
Basis for calculation of the Structure
Design and calculation of the structure is according to the Code on Structural Concrete (EHE-08) and the Basic Document on Structural Safety (DB-SE), Structural Safety Actions in Buildings (DB-SE-AE), and Structural Steel Safety (DB-MRS) of the Technical Building Code (TBC). Auxiliary services building With enclosure on roof - Enclosure weight: 25.00 kg/m - Enclosure load (maintenance): 40.00 kg/m With enclosure on sides - Enclosure weight: 50.00 kg/m With roofing bars - Weight of roofing bars: 10.00 kg/m
Wind Data Basic speed: 26 m/sec Level of roughness: IV. Urban, industrial or forest area
16
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Period of service (years): 50
Snow data No snow action (less than and not concomitant with load in use)
Earthquake Modal spectral analysis Acceleration a=0.06g Ductility=1 Engine rooms
With enclosure on roof - Enclosure weight: 25.00 kg/m - Enclosure load (maintenance): 40.00 kg/m With enclosure on sides - Enclosure weight: 50.00 kg/m With roofing bars - Weight of roofing bars: 15.00 kg/m Wind data Basic speed: 26 m/sec Level of roughness: IV. Urban, industrial or forest area Period of service (years): 50
17
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
Snow data No snow action (less than and not concomitant with load in use)
Earthquake Modal spectral analysis Acceleration a=0.06g Ductility =1
Walls separating between 35 MVA transformers
Wind data Basic speed: 26 m/sg Level of roughness: IV. Urban, industrial or forest area Period of service (years): 50
Cell cubicle foundation
18
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
Loads According to technical specifications.
Thrust in walls Angle of repose 0.00 Degrees Apparent density 2.00 t/m Submerged density 1.10 t/m Internal angle of friction 30.00 Degrees Drainage evacuation 100.00 %
Load in transformers Type: Uniform Value: 1.00 t/m Earthquake Modal spectral analysis Acceleration a=0.06g Ductility=1
Foundations of transformers
19
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Loads According to technical specifications.
3.9
FAADES
Will be formed by sandwich type sheet panels with rock wool core. The model will be Panel with concealed fixings, acoustic ACH, 100 mm. Fire resistance RF-120 and fire stability EI-120. Acoustic insulation Ra = 35.6 dBA and Rw = 36.0 dB. Panel weight 23.6 kg/m2. External sheet finish will be 35 micra thick High Durability Polyester (HDS35) coloured Metallic Silver RAL 9006. The inside of the perforated sheet interior will be Pyrenean white colour with 25 micra Polyester finish. Finishes will be galvanised steel lacquered in Metallic Silver RAL 9006 colour. Panels will be screwed to a structure formed by rectangular tubular profiles 100.50.3.
3.10 ROOFS
Will be formed by sandwich type sheet panels with rock wool core. The model will be Panel 5 roof tiles with 100 mm thick acoustic ACH E100. Fire resistance RF-120 and fire stability EI-120.
20
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Acoustic insulation Ra = 35.6 dBA and Rw = 36.0 dB. Panel weight 23.6 kg/m2. External sheet finish will be 35 micra thick High Durability Polyester (HDS35) coloured Metallic Silver RAL 9006. The inside of the perforated sheet interior will be Pyrenean white colour with 25 micra Polyester finish. External finishes and gutters will be galvanised steel lacquered in Metallic Silver RAL 9006 colour.
21
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
4 4.1
OPERATIONAL CONDITION AND TERMS ELECTRICAL POWER GENERATION Description of the power generation
4.1.1
The generators of the power plant are SFGM560 gas gensets of the Guascor-Dresser Rand brand with a power capacity of 1MW. These are 4-stroke Miller-cycle internal combustion engines with a 400Vac brushless synchronous alternator coupled. The power output of each genset is wired to his LV power switchboard. Each of these switchboards will include his own synchronization and genset protection equipment. The gensets will be connected and synchronized to Mains at this LV switchboard independently. So they can be managed as independent generation units. Each two gensets will be connected to a step-up transformer that will increase voltage output to 33kV. These step-up transformers will be protected with MV switchboards with overcurrent protections. The whole power output of the gensets will be conducted to an outgoing switchgear. As total power output will be monitored at this point, the central control system of the plant will be able to manage a power plant power setting, deciding the power setting of each single gensets or eventually the disconnection of some gensets if the power requirement is too low. Isolation transformers have been foreseen at the outgoing of the power plant basically to reduce the high short circuit current from Mains and isolate the power plant from the grid. From the feeder a buried 33kV line will connect the substation with the plant. A switchboard will protect this line at the power plant incoming. Theres foreseen a partial redundancy of the common elements of the power plant (isolation transformers, outgoing switchboards) to make sure that no failure of these elements would shut-down the whole plant. Full redundancy is not possible due to lack of available interconnection feeders at the substation. Basically the working procedure will be that the gensets will synchronise to Mains and go after frequency and voltage values of the Mains, controlling the active and reactive power output with the set-up and adjustable values.
22
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD If any Mains electrical value (voltage, frequency, vector shift) would go beyond the protection settings, the gensets protections would trip the LV genset switchboard and the genset would stay in idle-running for a while, until Mains values would come back to proper values. During the idle-running, gensets cooling power supply should be connected to the gensets power generation to allow a durable idle-running. This will be made turning manually a switch in the control panel. A maximum 1Hr idle-running is foreseen. After this time gensets will shut-down. In case of genset shut-down is possible to restart the gensets without having power from the grid, due to the use of batteries powered prelube, gas train and engine cranking system. If Mains condition returns to proper values the gensets may be re-synchronized to Mains and continue exporting power to the grid.
4.1.2
Island mode procedure
Island mode is considered the working procedure in which gensets will control the frequency and voltage of the grid instead of controlling the active and reactive power supplied by them to the grid. This working procedure is used in the cases in which the gensets are the main or sole suppliers of a factory, plant or grid. In the case of the Hlawga power plant no island mode procedure is foreseen, although design allows the gensets to work in this mode, controlling frequency and voltage of the factory and making the load sharing between the single gensets of the plant. An hypothetical upgrade to this working procedure would require a detailed study of the load requirements of such island to check if the gensets would withstand the load changes; it should be studied also the way in which such island would be made (which switches have to be disconnected to feed the required loads), which kind of protections would be available to avoid unexpected/unsynchronised connections with other gensets and also should be agreed some kind of feedback/information system to inform to the control system of an island/parallel to Mains situation. All these considerations are external to the power plant and not included in the scope of this project.
23
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
4.1.3
Normal operation of the plant
Each genset will have its own power and control cabinet which is supplied with the gensets scope of supply and, should be located in the engine room close to the gensets. The documents IO-C-M-AP-00 and IO-G-M-AC-00 include a description of the functionalities fulfilled by these cabinets. These local control panels will be interconnected with a plant control panel which will monitor all the local panels and also information coming from other elements of the plant (MV substations, GMRS, fire detection system, etc..). This plant control panel will coordinate the information of these different locals control systems. Management of the gensets will be possible thus locally and remotely from the central control system. The engine-generator sets have two operation modes: 1) Automatic: A digital signal is generated for each engine-generator set from the main control system in the plant. This digital signal has two position: Remote start Remote stop Moreover, the main control system will send a signal with proper safety positions for start-up. By means of this additional signal each generation engine will be enabled to operate whenever required. 2) Manual: the operator will separately start or stop each engine-generator from the control panel at man-machine terminal. An automatic/manual selector switch will be provided for selection of operation mode of each engine-generator set. When this selector switch is on manual position, it will be possible stopping the engine-generator set on remote mode, but not starting it. Likewise, if alternator protection devices detect any problem in waveform quality, the related circuit breaker will be triggered. If alternator protection devices detect that the electrical conditions in the system are normal, the alternator will be resynchronized and the circuit breaker reset.
24
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
4.1.4
Start-up
Commonly, each generation set will be started in automatic mode by means of a remote command from control system. Each generation set will be started according to the following sequence 1) The system will verify whether the related engine is ready for operation or not. If not ready, a warning signal will be activated. After started, the system will try to start the next engine in the preset sequence. 2) The control system will proceed to perform the following tasks: a) Start-up of pumps for cooling circuits. b) Start-up of cooling fans in generation set room. c) Verification that the related circuit breaker is open. 3) If the auxiliary equipment is properly operating and there is no problem, the control system will proceed to start the generation set. Otherwise a signal alarm will be activated and the engine will not be started. 4) From this moment the control system will proceed to synchronize the generation set and couple it to the electric network.
4.1.5
Stop
Commonly every generation set is stopped in remote mode. The stop sequence for the generation set and auxiliary equipment will be determined by the control system of each generation set.
4.2 4.2.1
FIRE& GAS LEAK DETECTION Operation
The activation signal of a fire sensor will have priority over the pre-alarm or a monitoring signal failure.
25
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The activation of one of these elements will cause the following (upon confirmation): a) Local acoustic indication. b) Message announced on the screen, indicating the date, time, location, nature of the alarm and action message. c) Printing of the nature of the alarm, type, date and time (requires external printer). d) Store the alarms until they are recognised and the system has been reset. At any moment it will be possible to view the current status of the peripherals on the screen, which ones are on alarm or have failed and print the information on a printer. It will also be possible to pull up historical data of alarms, etc. and print them. All of the detection circuits will be monitored for cable failures.
4.2.2
Fire protection system
4.2.2.1 Fire detection system

The fire detector signal is sent to the PLC. This activates the alarm sequence of each genset and, at the same time, an alarm is send to the central control system. The central control system starts the emergency stop protocol, as described below, and switch on the general alarm light and horn located on the outside of the control room where is located this central control system and SCADA.
4.2.2.2 Fire extinguisher system

Will be installed 5 and 10 Kg CO2 fire extinguishers in the transformers surroundings and 6 and 12 kg multipurpose dry powder fire extinguishers in the gensets building. In the plan 35-01 are indicated the extinguishers needed according to standards; this layout must be checked on field with the firefighter service. The location of portable fire extinguishers will be readily visible and accessible; will be located to points where more likely to start a fire and in evacuation routes. The path from any point to the nearest fire extinguisher must be less than 15 m.
26
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
4.2.3
Control and signaling equipment (fire detection centre)
This element is the heart of the system where all of the incidents from the site are collected and which, using the resident programme, will decide on the activation of devices. The Centre will be analogical and smart with its own microprocessor, memory and power supply and batteries. The Centre will supervise each sensor and module of the smart loop individually, such that the alarms, pre-alarms and malfunctions are announced independently for each element in the smart loop. It will have the capacity for programmable outlets. It will be located in a metal cupboard and will be equipped with optic indicators to view the status of the panel. It will supply power to all of the sensors and modules connected to it. The memory data, events and programming will be kept in a non volatile memory. The control centre will allow the programming of its output devices (sirens and control modules) in such a way that the facility can be evacuated in a logical manner following the evacuation plan. To do this it is necessary for the sirens to be individually operable. The Fire Detection Centre will be installed in a building with the following characteristics: It shall have easy access, a simple architecture and be located in the vicinity of the main access or of the one usually used by firemen. It will be protected by sensors. It shall be well lit and shall be protected from vibrations and overcurrents.
4.2.4
Loops and equipment of analogical systems
4.2.4.1 General.
Each sensor, manual alarm button and module shall have a unique address assigned to it. This will be done manually. The location of the equipment in the loop will not be conditioned by the address in the loop (e.g. sensors can be added to the loop using an address that is not being used, without the need to re-programme the existing equipment). Plan 27.02 shows the layout of the detection loop with the equipment included in the loop. For the future expansion of the plant a second loop should be made. Each detection loop will be a couple of braided shielded wires usually with a section of 1.5 mm, wired in open or closed loop and on which the analogical fire sensors, alarm buttons,
27
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD warning sirens and digital modules that are required for the monitoring and control operations of the rest of the devices that make up the system (loudspeakers, electromagnets, extinguishers, smoke control, HVAC control, etc.) are installed directly. The capacity of the detection loop will be 198 analogical/programmable points of which 99 addresses are reserved for the sensors and the other 99 for buttons and modules. The cable lines shall be laid in an independent pipe with an isolated wire for a nominal voltage of 500V. The type of cable required will be: o Name: Loop Cable o Type of cable: Hose cable o Number of wires: Couple of braided and shielded wires. o Section: 1 to 2.5 mm2(standard = 1.5 mm2). o Length of loop: Up to 3000 m. 1800 m. with 1.5 mm2section cable 3000m with 2.5 mm2 section cable o Braids: 20 to 40 turns per metre. o Shielding: Aluminium Shield with drain wire. o Resistance: Max. 40 Ohm. for the whole loop. o Capacity: Min. 0,5 f. The diameter of the tube (D) will be sized in accordance with the number of wires arranged inside it, thus: No. of wires
2 16
4 16
6 20
8 25
10 25
METRIC
Similar alternatives that require more than 2 communication wires with the sensors will not be acceptable.
28
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Similar alternatives, in which the address of the equipment is automatic thus implying that in possible extensions or modifications of the system or changes of the sensor reprogramming is required, will not be acceptable.
4.2.4.2 Smart analogical sensors.

All of the smart analogical sensors will be assembled on the same base so as to facilitate the interchange of sensors of different types (if a different type of sensor were required). Each sensor is assigned a unique address by means of a device which is simple to understand and operate consisting of two rotating selectors numbered from 0 to 9 (not binary type switches or using jumper breakers). The procedure of automatic addressing according to its position on the loop was discarded as when equipment is added in the near future, it would be necessary to reprogramme the existing addresses with the corresponding loss of flexibility and economic cost. Each sensor will have two LEDS that will make it possible to see the status of the sensor from any position. The will flash each time of asking by the Detection Centre. From the centre it will be possible to override the flashing of the sensors in idle status. If the sensor is on alarm, these LED will be permanently lit up. Each sensor will respond to the Centre with information and identification of its type (multi criteria, optic or thermal). If there is a discrepancy about the information between the sensor and the centre, a failure condition will appear. Each sensor will respond to the Centre with analogical information related to its measurement of the fire phenomenon. The values at which the sensor will go to pre-alarm and alarm will be programmable by the user; these values can be changed manually by programming or automatically by the centre based on the environment in which the sensor is located or by following the hourly programme made by the system.
29
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD All of the sensors have a micro switch that can be activated by a magnet in order to carry out a local operation test. This test must also be carried out automatically and periodically from the centre. The sensors will be wired with1 2 x 1.5 mm2 hose cable with a common section, braided and shielded and shall provide both the power and communications required. 4.2.4.2.1 SMOKE SENSORS. The smoke sensors shall respond by measuring the density of the smoke. Each element can respond with different ranges of sensitivity that are adjustable. The type of smoke sensor will be ionic when there are visible or invisible aerosols, coming from all combustion and without the need for a rise in the temperature. The characteristics of an ionic sensor make it more appropriate for the detection of fires that spread quickly and which have combustion particles to the order of 0.01 to 0.3 micras. The type of smoke sensor selected will be optic when there are visible aerosols, coming from all combustion and without the need for a rise in the temperature. The characteristics of an ionic sensor make it more appropriate for the detection of fires that spread slowly and which have combustion particles to the order of 0.3 to 10 microns. For highly sensitive applications where it is necessary to detect fires at a very early stage the laser technology optic sensor will be used. This detects invisible combustion particles (aerosols). The infrared smoke sensor will be installed in those areas in which, due to the elevated height of the ceiling, point smoke sensors are not appropriate.
1See
section 4.1
30
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 4.2.4.2.2 MANUAL ALARM BUTTONS. The manual buttons may be included in the smart detection loop as they are programmable. They should make it possible to voluntarily provoke and transmit a signal to the control and signaling centre, in such a way that the area in which the button has been activated is easily identifiable. The buttons will be of the glass breaking type. The glass will be protected by a plastic membrane to prevent its activation from being interrupted. Resettable buttons will not be used, unless resetting involves the checking of the button by qualified personnel.
4.2.4.3 Control module.

These modules will be installed in the smart loop to make it possible to control the auxiliary elements of the fire detection system such as: alarm loudspeakers, magnetic retainers, fire dampers, extinguishing systems, etc. and to give relay signals to auxiliary equipment. The control module will provide supervision to the peripheral circuit which is controlled by the module. It will have an LED indicator of its status. It will be capable of working in 3 statuses: As NA, CN relay outputs As supervised 24 V outputs. In this case they will need 24 Vdc power additional to the loop cable. As evacuation loudspeaker output, which will require supply from the audio amplifier.
4.2.4.4 Monitor Module.

These modules will be installed in the smart loop, to direct the digital inputs of the type of those provided by conventional buttons, pressure switches, flow sensors, technical signals, etc. The monitor module will provide supervision to the peripheral circuit which is controlled by the module. It will have an LED indicator of its status.
31
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD It will not need auxiliary power.
4.2.4.5 Programmable Sirens.

The sirens will be programmable which means they will have two rotating selectors numbered from 0 to 9 ((not binary type switches or using jumper breakers) for the assignation of their address. They will have 4 programmable tones and a sound current no higher than 103 dB. Depending on the model, the sirens will be able to work in the following manner: Supplied directly from the analogical loop. Supplied with 24 vdc additional to the 2 loop wires.
They will be distributed as indicated in the previous paragraph.
4.2.5
Operation mode in case of emergency
4.2.5.1 Operation mode in case of gas leak

The following describes the protocol in case of severe alarm from Gas Leak Detection. 4.2.5.1.1 ENGINEROOMS o Genset running: an alarm of any gas detector above the gen-sets is send to the general control system and triggers the following sequence: Severe engine stop Start of all ventilation fans at full capacity. Shut off of the natural gas electrovalve located in the header that feeds all gen-sets of the building. This electrovalve is located in the Regulation and Metering Gas Station. Activation of optical and acoustic alarms o Genset off: an alarm of any gas detector above the gen-sets is send to the general control system and triggers the following sequence:
32
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Blocking of the gen-set start-up order Start of all ventilation fans at full capacity Shut off of the natural gas electrovalve located in the header that feeds all gen-sets of the building. This electrovalve is located in the Regulation and Metering Gas Station. Activation of optical and acoustic alarms 4.2.5.1.2 OPERATION MODE IN R.M.S The gas detector is monitoring continuously the CH4 content in the building. If presence of CH4 is detected in the Regulation and Metering Station, the protocol will be the following o Regulation and Metering Station; the alarm is received by general control system and triggers the following sequence Blocking of all gen-sets start-up order Shut off of the two natural gas electrovalves located in Regulation and Measurement Gas Station that feeds each gensets buildings. Activation of optical and acoustic alarms
4.2.5.2 Operation mode in case of fire detection

Following is described the protocol in case of fire alarm. 4.2.5.2.1 ENGINE PERFORMANCE Infrared fire detectors are monitoring each building of gen-sets. If a fire is detected by any of them, the group of affected gen-sets will follow the following protocol o Genset running: the alarm of the fire detector installed in the gen-sets building is send to the general control system and triggers the following sequence; Severe stop for all gen-sets of the building,
33
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Shut off of the natural gas electrovalve located in the header that feeds all gen-sets of the building. This electrovalve is located in the Regulation and Measurement Gas Station. Activation of optical and acoustic alarms o Genset off: the alarm of the fire detector installed in the gen-sets building is send to the general control system and triggers the following sequence: Blocking of the start-up order of gen-set in the building Shut off of the natural gas electrovalve located in the header that feeds all gen-sets of the building. This electrovalve is located in the Regulation and Measurement Gas Station. Activation of optical and acoustic alarms 4.2.5.2.2 OPERATION MODE IN R.M.S Fire detectors are monitoring the Regulation and Metering Station. If a fire is detected the protocol will be the following o Regulation and Measurement Natural Gas Station; the alarm is received by general control system and triggers the following sequence Blocking of the start-up order of all gen-set of both buildings Shut off of the two natural gas electrovalves located in Regulation and Measurement Gas Station that feeds each gen-sets buildings. Activation of optical and acoustic alarms 4.2.5.2.3 GENERAL SERVICES BUILDING A fire detection system will be monitoring the building. In case of fire in the control room the protocol will be the following: o The fire alarm is received and sent to the general monitoring system Blocking of the start-up order of all gen-set of both buildings
34
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Shut off of the two natural gas electrovalves located in Regulation and Measurement Gas Station that feeds each gensets buildings. Activation of optical and acoustic alarms
35
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
ENGINE AND GENERATOR ASSEMBLY
The generators of the power plant are SFGM560 gas gensets of the Guascor-Dresser Rand brand with a power capacity of 1MW. These are 4-stroke Miller-cycle internal combustion engines with a 400Vac brushless synchronous alternator coupled. Main features are listed below. For further information see technical instructions The plans 31-01, 31-02 and 31-11 to 31-14 layout drawings indicate the location and installation position of the gensets in the plant with their closer auxiliary equipment. Sizes of the genset and installation instructions can be consulted in the Genset Installation Manual. The gensets will be supplied with two configurations; cable output left side of the alternator and cable output right side of the alternator. (13 gensets with one configuration and 13 with the other) Depending of the configuration, alternator cable connection bars will be at one or other side of the alternator. The alternator will be identified with a label of the suited cable output position At the moment of the installation of the gensets, the installer should be careful to put each genset in the place of the layout where his cable output position would be facing the electrical trench. Beside the genset in itself and the electrical installation necessary to export the generated power there are some auxiliary installations which are essential to keep the gensets in working order. These installations are described in the chapters 6 to 10 of this specification. These mechanical auxiliary installations of the gensets are: Engine fuel (natural gas) supply system. Engine cooling system. Engine lube oil system. Engine Flue system. Engine room ventilation system.
36
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The circuits related to these systems are described in the Genset Flow Diagram (view Plan 12-01).
37
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
5.1
ENGINE FEATURES
38
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Tabla1.Engine power rating
The Genset Installation Manual includes more detailed information about the characteristics of the SFGM560, working and installation procedure of these genset.
39
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
5.2
ALTERNATOR FEATURES
Each GenSet has a synchronous generator to 400V, which is connected to the low voltage terminal of a power transformer with a double port in this side: each transformer is connected with two generators. During normal operation,the installation will export all generated energy Gensets are equipped with alternators LSAC 502 TR L8 C6S/4: main features are listed below. For further data view Alternator Information attached to the Genset Installation Manual.
Below we can see main electrical parameters of the alternator.
40
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
41
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
42
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
ENGINE FLUE SYSTEM
The function of this circuit is basically to conduct safely the exhaust gases from the engine to the outside of the building. Exhaust gas flow from each genset is of 5170 kg/h at full power with an estimated temperature of 496C. At partial load the exhaust temperature may be over 550C The pipes and elements of the circuit have been designed to allow the evacuation of these exhaust gases keeping a maximum admissible exhaust backpressure of 450mm of water column. The document IT-C-A-40-001e of the genset installation manual describes the requirements that a correct installation should fulfill. Design of the engine flue system is described in the following drawings: 12-01: General Flow Diagram. 13-04: Exhaust Gases P&I diagram. 61-02 to 61-05: Lay out of pipes (exhaust circuit in pink color) 62-02: Lay-out of pipes genset area typical detail (the exhaust circuit is shown in pink color) 63-21: Exhaust Pipes design. 51-01 to 51-06: Metallic structures for silencer and conduits support The main elements of these circuits are: U-3: the exhaust adapter commonly called the trousers, because it resembles some trousers. Its supplied with exhaust flexibles as loose item of the genset and has to be installed at the engine exhaust connection. U-4: the exhaust silencer. Also supplied as loose item of the genset. Regarding engine flue circuit should be taken in consideration that there will be four typical layouts with different pipeline designs. Type A (for genset 1), type B (for gensets 2 to 13), type C (for genset 14) and type D (for gensets 15 to 26).
43
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
6.1
EXHAUST SILENCER
The pipeline for exhaust evacuation must be provided with a silencer (U-4 in the drawings), which has the task of reduce the noise produced by the engine toward levels allowed in current Standards. Description of the exhaust silencer supplied by Guascor is included in the genset installation manual. (view IC-C-D-40-002e and IT-O-A-2-001110-05e). The exhaust silencers require supporting structures. These supporting structures are shown in the drawings 51-01 to 51-06.
6.2
EXHAUST CHIMNEY
Exhaust line ends with vertical pipe protected from rain with a gate. A sampling module has to be placed, according to current environmental standards, after the silencer.
6.3
PIPING AND FITTINGS

Table 2.Exhaust chimney. PIPE MATERIAL SPECIFICATIONS SPECIFICATIONS N B10
Rev. 00
SERVICE:
ExhaustGases (EG)
PIPING MATERIAL: 0 bar; 20 C
ENDS FROM TO
NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
Stainless steel
1 bar; +502C
TO:
ITEM
150
PIPE FLANGES
SIZE
DESCRIPTION
Seamless Pipe EN ISO 1127 thickness 2mm; Material EN 1.4301 (AISI 304) EN 1127 Seamless Pipe EN ISO 1127 thickness 3mm; Material EN 1.4301 (AISI 304) Flange LJ EN 1092-1, type 02, face A PN10; Material Group 4E0 EN 10216-2 Elbows, tee, reducer and cap carbon steel Seamless EN 10253-3 material EN 1.4301 (304) Other accessories: malleable iron threaded ASA B16.11, material EN 1.4301 (304), thread s/EN
250 400 400
BE BE Type A (FF) Beveled
300 150
FITTINGS
150
400
44
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD SPECIFICATIONS N B10

Rev. 00
PIPE MATERIAL SPECIFICATIONS

SERVICE: ExhaustGases (EG) NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: PIPING MATERIAL: 0 bar; 20 C
ENDS FROM TO
Stainless steel
1 bar; +502C
TO:
ITEM
SIZE
DESCRIPTION
10226 Screws EN 4014 (DIN931) Material Alloy Steel quality 8.8 Nuts EN 4032 (DIN934) Material Alloy Steel quality 8.8 Gasket plate PN10 s/EN 1092; Asbestos free gasket material like Klingersil 4430 or equivalent
BOLTING
GASKET
45
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
6.4
DESIGN AND DEFINITION CHART

Table 3.Engine flue system.
NP DN S (") 15 0 40 0 35 0 Mass Flow Rate (kg/h) 2.585,0 6 0 5.170,0 16 0 5.170,0 14 0 Tem p. (C) Pressur Lengt e P(mm.w.c h (m) (mm.w. .) c g) 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.02 16 "-B10-EG021.02 14 "-B10-EG021.02 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.03 16 "-B10-EG021.03 14 "-B10-EG021.03 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.04 16 "-B10-EG021.04 14 "-B10-EG021.04 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.05 16 "-B10-EG021.05 14 "-B10-EG15 0 40 0 35 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 14 5.170,0 11397,900 496,0 6 15 15 15 450 78 199 251,659 10,873 21,146
GENSE T
Tag Line 6 "-B10-EG0U3.01 16 "-B10-EG021.01 14 "-B10-EG021.01
Mass Flow Rate (Lb/h)
01
5698,9502 496,0 34 11397,900 496,0 47 11397,900 496,0 47
Total 01 02
Total 02 03
Total 03 04
Total 04 05
46
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Mass Flow Rate (kg/h) 0 Pressur Lengt e P(mm.w.c h (m) (mm.w. .) c g) 283,678 6 "-B10-EG0U3.06 16 "-B10-EG021.06 14 "-B10-EG021.06 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.07 16 "-B10-EG021.07 14 "-B10-EG021.07 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.08 16 "-B10-EG021.08 14 "-B10-EG021.08 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.09 16 "-B10-EG021.09 14 "-B10-EG021.09 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.10 16 "-B10-EG021.10 14 "-B10-EG021.10 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678
GENSE T
Tag Line 021.05
NP DN S (") 0
Mass Flow Rate (Lb/h) 47
Tem p. (C)
Total 05 06
Total 06 07
Total 07 08
Total 08 09
Total 09 10
Total
47
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Mass Flow Rate (kg/h) Pressur Lengt e P(mm.w.c h (m) (mm.w. .) c g) 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.12 16 "-B10-EG021.12 14 "-B10-EG021.12 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.13 16 "-B10-EG021.13 14 "-B10-EG021.13 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.14 16 "-B10-EG021.14 14 "-B10-EG021.14 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.15 16 "-B10-EG021.15 14 "-B10-EG021.15 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG15 6 2.585,0 5698,9502 496,0 15 450 251,659
GENSE T 10 11
Tag Line
NP DN S (") 15 0 40 0 35 0
Tem p. (C)
6 "-B10-EG0U3.11 16 "-B10-EG021.11 14 "-B10-EG021.11
2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6
Total 11 12
Total 12 13
Total 13 14
Total 14 15
Total 15 16
48
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Mass Flow Rate (kg/h) 0 5.170,0 16 0 5.170,0 14 0 Pressur Lengt e P(mm.w.c h (m) (mm.w. .) c g) 15 15 78 199 10,873 21,146 283,678 6 "-B10-EG0U3.17 16 "-B10-EG021.17 14 "-B10-EG021.17 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.18 16 "-B10-EG021.18 14 "-B10-EG021.18 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.19 16 "-B10-EG021.19 14 "-B10-EG021.19 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.20 16 "-B10-EG021.20 14 "-B10-EG021.20 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.21 16 "-B10-EG15 0 40 2.585,0 5698,9502 496,0 0 34 16 5.170,0 11397,900 496,0 6 15 15 450 78 251,659 10,873
GENSE T
Tag Line 0U3.16 16 "-B10-EG021.16 14 "-B10-EG021.16
NP DN S (") 0 40 0 35 0
Tem p. (C)
34 11397,900 496,0 47 11397,900 496,0 47
Total 16 17
Total 17 18
Total 18 19
Total 19 20
Total 20 21
49
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Mass Pressur Tem Flow Mass Flow Lengt e P(mm.w.c p. Rate Rate (Lb/h) h (m) (mm.w. .) (C) (kg/h) c g) 0 47 5.170,0 11397,900 14 496,0 15 199 21,146 0 47 283,678 6 "-B10-EG0U3.22 16 "-B10-EG021.22 14 "-B10-EG021.22 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.23 16 "-B10-EG021.23 14 "-B10-EG021.23 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.24 16 "-B10-EG021.24 14 "-B10-EG021.24 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.25 16 "-B10-EG021.25 14 "-B10-EG021.25 15 0 40 0 35 0 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 5.170,0 11397,900 14 496,0 0 47 6 15 15 15 450 78 199 251,659 10,873 21,146 283,678 6 "-B10-EG0U3.26 16 "-B10-EG021.26 14 "-B10-EG15 0 40 0 35 2.585,0 5698,9502 496,0 0 34 5.170,0 11397,900 16 496,0 0 47 14 5.170,0 11397,900 496,0 6 15 15 15 450 78 199 251,659 10,873 21,146
GENSE T
Tag Line 021.21 14 "-B10-EG021.21
NP DN S (") 0 35 0
Total 21 22
Total 22 23
Total 23 24
Total 24 25
Total 25 26
50
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Mass Flow Rate (kg/h) 0 Pressur Lengt e P(mm.w.c h (m) (mm.w. .) c g) 283,678
GENSE T
Tag Line 021.26
NP DN S (") 0
Mass Flow Rate (Lb/h) 47
Tem p. (C)
Total 26
The exhaust gas pipes are designed in the drawings 63-021.
51
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
ENGINE COOLING SYSTEM
The function of this system is to dissipate the heat generated by engines internal combustion while gensets are running. Treated water is used as coolant fluid. The SFGM560 gensets have a double cooling circuit. A main high temperature (HT) circuit is responsible for cooling most engine components. A second circuit with lower temperature (LT) is used to cool the air/fuel mixture and the oil cooler. In the case of a SFGM560 genset at full load the HT circuit needs to dissipate 524kW of heat power while the LT circuit needs to dissipate 179kW. Design temperature for these circuits is 90C for the HT and 55C for the LT circuits. The document IT-C-A-20-003e of the genset installation manual describes general information about the cooling system for Guascor engines. In this project cooling is done by means of air coolers. The air coolers are from the double core type, which allow with the same cooler to dissipate energy from two independent circuits of different temperature. Electrical pumps will impulse the water from the engine to the air coolers and back. The cooling system includes thus two independent closed circuits filled with pressurized water. The cooling water has to comply the requirements of the product information IO-C-M20-001e (Cooling Water Quality and Treatment). Design of the engine cooling system is described in the following drawings: 12-01: General Flow Diagram. 13-01: Engine Cooling System P&I diagram. Note that in this drawing is shown the scope of the Pump set or Pump kit already supplied and assembled from Guascor factory. 60-02: Lay out of pipes section (cooling circuits in green colour) 61-02 to 61-05: Lay out of pipes (cooling circuits in green colour) 62-01: Lay-out of pipes air cooler typical detail (green colour) 62-02: Lay-out of pipes genset area typical detail (green colour) 63-01,-02: HT circuit pipes design. 63-04,-05: LT circuit pipes design. The main elements of these circuit are:
52
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD P-1/P-2: centrifugal pumps for the HT and LT circuits. These pumps will be installed in a Pump kit that will be installed attached to genset bedplate. This kit will be already supplied mounted from Guascors facilities. (in the first 8 gensets supplied. the components of this kit will be supplied as loose items and have to be mounted at factory. The drawing of this kit is included in the genset installation manual (Ref. 40.20.E80)) TK-2/TK-3: Expansion vessels. E-1: Air cooler.
7.1
ENGINEERING BASIS OF DESIGN
This project was completed in compliance with the following standards: UNE-EN ISO 15607 Specification and qualification of welding procedures for metallic materials UNE-EN 287 Qualification test of welders UNE-EN 25817 Arc-welded joints in steel. Guidance on quality levels for imperfections (ISO 5817:1992). UNE-EN ISO 13920 Welding. General tolerances for welded constructions. Dimensions for lengths and angles. Shape and position. (ISO 13920:1996). ASME Code UNE-EN 10255 Non-Alloy steel tubes suitable for welding and threading Technical delivery conditions UNE-EN 10216 Seamless steel tubes for pressure purposes - Technical delivery conditions UNE-EN ISO 1127 Stainless steel tubes. Dimensions, tolerances and conventional masses per unit length
53
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
7.2
ELECTRICAL WATER PUMPS
Water flowing through each cooling circuit is pumped with the following features: 1) Main water circuit or high temperature circuit (one per engine): Type .................................................................................................. centrifugal Motor drive........................................................................................ electrical Flow (m3/h) .................................................................................................... 70 Nominal temperature (C) ......................................................................... 90 2) Auxiliary water circuit or low temperature circuit (one per engine): Type .................................................................................................. centrifugal Motor drive........................................................................................ electrical Flow (m3/h).................................................................................................... 25 Nominal temperature (C) ......................................................................... 55 Information regarding the technical specifications and installation instructions of the pumps are included in the genset installation manual, IT-C-A-20-011e (Installation Manual), IC-G-D-20-067e (data sheet HT circuit water pump) and IC-G-D-20-066e. (data sheet LT circuit water pump).
7.3
EXPANSION VESSELS
In each one of the two water circuits, is provided an expansion tank to support the volume increase of water with the temperature variations. 1) Main water circuit or high temperature circuit (one per engine):: Thermal load (kW) ....................................................................................524 Static pressure (bar) ................................................................................... 2,2
54
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 2) Secondary water circuit or low temperature circuit (one per engine): Thermal load (kW) ....................................................................................179 Static pressure (bar) ................................................................................... 2,2 The genset installation manual includes a document (IT-O-A-2-001110-07e) with the expansion tank adaptation installation instructions.
7.3.1
Relief
In both cooling circuits, safety-relief valves will be installed at engine outlet, set to 3.5 bar in order to ensure that this pressure is the maximum working pressure in these cooling circuits.
7.4
DOUBLE CORE AIR COOLER
A double core air cooler will be installed in each engine to dissipate the heat input in main and auxiliary cooling circuits and resulting from flue gases generated during engine operation. 1. Type .................................................................................... Double core air cooler 2. Main circuit i. Thermal load (kW) ..................................................................524 ii. Flow (m3/h)................................................................................... 70 iii. Range of temperature (C)................................................. 90/83 3. Auxiliary circuit i. Thermal load (kW) ..................................................................179 ii. Flow (m3/h)................................................................................... 25 iii. Range of temperature (C)................................................. 62/55
55
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The genset installation manual includes following information regarding the air coolers: IT-C-20-016e- Installation and user manual for Guascor standard dry-coolers. 76.73.625- Drawing of the supplied air coolers IT-G-A-20-020e User and installation manual for Standard air coolers. (TGR model)
7.5
PIPING& FITTINGS
Table 4.Auxiliary circuit specification. PIPE MATERIAL SPECIFICATIONS SPECIFICATIONS N
Rev. 00
S01
stainless steel
9 bar; +120C
SERVICE: Cooling water (CW), NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
SIZE
PIPING MATERIAL:
0 bar; 0 C
ENDS
TO:
ITEM
15 32
DESCRIPTION
EN 1127 Seamless Pipe EN ISO 1127 thickness 2mm; Material EN 1.4301 (AISI 304)
FROM
TO
PIPE FLANGES
250 250
BE Type A (FF) BE
FITTINGS
15
250
BOLTING
GASKET
Flange LJ EN 1092-1, tipo 04, cara A PN10; AluminumMaterial Elbows, tee, reducer and cap carbon steel EN 10253-3; material EN 1.4301 (AISI 304). Other accessories: malleable iron threaded ASA B16.11, material AISI 304, thread s/EN 10226 Screws EN 4014 (DIN931) Alloy Steel Material ,quality 5.6 Nuts EN 4032 (DIN934) Alloy SteelMaterial quality 5.6 Gasket plat PN10 s/EN 1092; Asbestos-free gasket material, Klingersil 4430 or equivalent
56
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD SPECIFICATIONS N

Rev. 00

SERVICE: Cooling water (CW), NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
SIZE
ENDS FROM TO
S01
stainless steel
9 bar; +120C
PIPING MATERIAL:
0 bar; 0 C
TO:
ITEM
15 BALL 32 VALVES 50 BUTTERFLY 200 15 CHECK 50
DESCRIPTION
Body and ball EN 102134 1.4408 (316) Body cast iron EN-GJL250; stainless ball ; length EN558-1 Series 27 Dry Lever Manual wheel type (Reduction gear operate ) disk Dimensions as EN 1983 2 pieces Full bore Drive lever
25
female thread Flanged
40 150 250 40 250
lug Wafer Wafer
cast iron EN-GJL-
Dual plate
250; length EN558-1 Series 20 Cast iron EN-GJL-250 disk andstainless spring Body and plates cast iron EN_GJL250; Length EN558-1 series 16
Table 5.Main circuit specification. PIPE MATERIAL SPECIFICATIONS

SERVICE: Natural Gas (NG)& Cooling Watert (CW) NOMINAL PRESSURE: PIPING MATERIAL: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: 0 bar; 0 C TO:
SPECIFICATIONS N
Rev. 00 Carbon Steel 9 bar; +120C
A10
ITEM
SIZE DN (mm)
ENDS FROM TO
DESCRIPTION
EN 10255 (DIN 2440) Seamless Pipe EN 10255 medium series M; Material EN 1.0026 S195T Seamless Pipe EN 10216-2 series 1 EN 10216 normalized thickness; Material (DIN 2448) P235GH EN 1.0254 Flange SW EN 1092-1, type 01, face A PN10; Material P235GH EN 10216-2 Elbows, tee, reducer and cap carbon seamless steel EN 10253-1 material EN P235TR1 (st 37). Other accessories: malleable iron threaded ASA B16.11, material A-105, thread s/EN 10226
15
PIPE
40 250 250
PE BE Type A (FF) Beveled
50 32
FLANGES
FITTINGS
15
250
57
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER


A10
ITEM
BOLTING
SIZE DN (mm)
ENDS FROM TO
DESCRIPTION
Screws EN 4014 (DIN931) Alloy SteelMaterial, quality 5.6 Nuts EN 4032 (DIN934) Alloy Steel Material, quality 5.6 Gasket plate PN10 s/EN 1092; Asbestos free gasket material like Klingersil 4430 or equivalent.
GASKET
58
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER


A10
ITEM
SIZE DN (mm)
ENDS FROM TO
DESCRIPTION
Body and ball EN 102134 1.4408 (316) Body cast iron EN-GJL250; ball inox. ; length EN558-1 Series 27 Dry Lever Manual wheel type (Reduction gear operate ) disk Dimensions as EN 1983 2 pieces Full bore Drive lever
15 BALL 32 50 VALVES BUTTERFLY 200 15 CHECK 50 15 FILTERS 32
25 40 150 250 40 250 25 150
lug Wafer Wafer female thread
cast iron EN-GJL-
Dual plate
Tipe Y
250; length EN558-1 Series 20 Cast iron EN-GJL-250 disk andstainless spring. Body and plates cast iron EN_GJL250; Length EN558-1 series 16 Cast iron EN_GJL-250, sieve steel. Body cast iron EN_GJL-250, Stainless Sieve; Length EN558-1 series 1
Flanged
7.6
TESTING & INSPECTION
For the final acceptance of the in site assembly of pipelines installations, a hydraulic pressure test is needed, considering each circuit as whole system. Test pressure will be 1.5 times the design pressure. Before the hydrostatic test, equipment will be isolated in flanges using all the needed elements for it(by-pass, closures, blind flanges, gaskets, etc..) After pressure test, there will be a final cleaning of pipes, inside and outside of each one. Once the hydrostatic test has finished, installation will be emptied in order to remove metallic chips and dirt in line. Finally, before proceeding to final filling of each hydraulic circuit, water is circulated by pumps, with basket filters placed at the entrance of each equipment to protect them (one per pump, exchanger, genset, expansion tank, etc.).
59
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
7.7
DESIGN & DEFINITION CHART

Table 6.Water cooling circuit.
Volumetric flow rate (m3/h) Volumetric Flow Rate (ft3/h) Equivalent Length (m) Temp. (C) Pressure (bar) Pressure (psi) P (m.w.c.) P (bar) Velocity (m/s)
NPS (")
Tag Line
01
5 5 3 3
"-S01-CW-001.01 "-S01-CW-002.01 "-A10-CW-003.01 "-A10-CW-002.01
125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80
DN
GENSET
5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3
70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25
2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00
34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72
1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23
1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55
60
0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05
1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91%
3 "-A10-CW-001.01 2 "-A10-CW-004.01 3 "-S01-CW-004.01 3 "-S01-CW-005.01 1 1/2"-A10-CW-005.01 2 "-A10-CW-008.01 02 5 "-S01-CW-001.02 5 "-S01-CW-002.02 3 "-A10-CW-003.02 3 "-A10-CW-002.02 3 "-A10-CW-001.02 2 "-A10-CW-004.02 3 "-S01-CW-004.02
P (%)
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Volumetric flow rate (m3/h) Volumetric Flow Rate (ft3/h) Equivalent Length (m) Temp. (C) Pressure (bar) Pressure (psi) P (m.w.c.) P (bar) Velocity (m/s) NPS (") P (%)
Tag Line
DN
GENSET
3 "-S01-CW-005.02 1 1/2"-A10-CW-005.02 03 2 "-A10-CW-008.02 5 "-S01-CW-001.03 5 "-S01-CW-002.03 3 "-A10-CW-003.03 3 "-A10-CW-002.03 3 "-A10-CW-001.03 2 "-A10-CW-004.03 3 "-S01-CW-004.03 3 "-S01-CW-005.03 1 1/2"-A10-CW-005.03 2 "-A10-CW-008.03 04 5 "-S01-CW-001.04 5 "-S01-CW-002.04 3 "-A10-CW-003.04 3 "-A10-CW-002.04 3 "-A10-CW-001.04 2 "-A10-CW-004.04 3 "-S01-CW-004.04 3 "-S01-CW-005.04
80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80
3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3
25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25
883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00
27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72
1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22
0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56
0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05
0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91%
61
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
1 1/2"-A10-CW-005.04 2 "-A10-CW-008.04 05 5 "-S01-CW-001.05 5 "-S01-CW-002.05 3 "-A10-CW-003.05 3 "-A10-CW-002.05 3 "-A10-CW-001.05 2 "-A10-CW-004.05 3 "-S01-CW-004.05 3 "-S01-CW-005.05 1 1/2"-A10-CW-005.05 06 2 "-A10-CW-008.05 5 "-S01-CW-001.06 5 "-S01-CW-002.06 3 "-A10-CW-003.06 3 "-A10-CW-002.06 3 "-A10-CW-001.06 2 "-A10-CW-004.06 3 "-S01-CW-004.06 3 "-S01-CW-005.06 1 1/2"-A10-CW-005.06
40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40
1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2
25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25
883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00
3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4
5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05
1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80
0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18
2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94%
62
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
07
2 "-A10-CW-008.06 5 "-S01-CW-001.07 5 "-S01-CW-002.07 3 "-A10-CW-003.07 3 "-A10-CW-002.07 3 "-A10-CW-001.07 2 "-A10-CW-004.07 3 "-S01-CW-004.07 3 "-S01-CW-005.07 1 1/2"-A10-CW-005.07 2 "-A10-CW-008.07
50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50
2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2
25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25
918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00
3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38
2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98
0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52
0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05
0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85%
08
5 "-S01-CW-001.08 5 "-S01-CW-002.08 3 "-A10-CW-003.08 3 "-A10-CW-002.08 3 "-A10-CW-001.08 2 "-A10-CW-004.08 3 "-S01-CW-004.08 3 "-S01-CW-005.08 1 1/2"-A10-CW-005.08 2 "-A10-CW-008.08
63
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
09
125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125
5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5
70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70
2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00
34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29
1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35
1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06
0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10
1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73%
10
11
5 "-S01-CW-001.11
64
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
5 "-S01-CW-002.11 3 "-A10-CW-003.11 3 "-A10-CW-002.11 3 "-A10-CW-001.11 2 "-A10-CW-004.11 3 "-S01-CW-004.11 3 "-S01-CW-005.11 1 1/2"-A10-CW-005.11 2 "-A10-CW-008.11 12 5 "-S01-CW-001.12 5 "-S01-CW-002.12 3 "-A10-CW-003.12 3 "-A10-CW-002.12 3 "-A10-CW-001.12 2 "-A10-CW-004.12 3 "-S01-CW-004.12 3 "-S01-CW-005.12 1 1/2"-A10-CW-005.12 13 2 "-A10-CW-008.12 5 "-S01-CW-001.13 5 "-S01-CW-002.13
125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125
5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5
70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70
2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00
29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79
1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34
0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65
0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06
1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06%
65
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
3 "-A10-CW-003.13 3 "-A10-CW-002.13 3 "-A10-CW-001.13 2 "-A10-CW-004.13 3 "-S01-CW-004.13 3 "-S01-CW-005.13 1 1/2"-A10-CW-005.13 2 "-A10-CW-008.13 5 "-S01-CW-001.14 5 "-S01-CW-002.14 3 "-A10-CW-003.14 3 "-A10-CW-002.14 3 "-A10-CW-001.14 2 "-A10-CW-004.14 3 "-S01-CW-004.14 3 "-S01-CW-005.14 1 1/2"-A10-CW-005.14 2 "-A10-CW-008.14 15 5 "-S01-CW-001.15 5 "-S01-CW-002.15 3 "-A10-CW-003.15
80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80
3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3
70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70
2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00
3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34
3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63
0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51
0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05
0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84%
14
66
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
3 "-A10-CW-002.15 3 "-A10-CW-001.15 2 "-A10-CW-004.15 3 "-S01-CW-004.15 3 "-S01-CW-005.15 1 1/2"-A10-CW-005.15 16 2 "-A10-CW-008.15 5 "-S01-CW-001.16 5 "-S01-CW-002.16 3 "-A10-CW-003.16 3 "-A10-CW-002.16 3 "-A10-CW-001.16 2 "-A10-CW-004.16 3 "-S01-CW-004.16 3 "-S01-CW-005.16 1 1/2"-A10-CW-005.16 17 2 "-A10-CW-008.16 5 "-S01-CW-001.17 5 "-S01-CW-002.17 3 "-A10-CW-003.17 3 "-A10-CW-002.17
80 80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80
3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3
70 70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70
2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00
3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34
3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63
0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51
0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05
0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84%
67
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
3 "-A10-CW-001.17 2 "-A10-CW-004.17 3 "-S01-CW-004.17 3 "-S01-CW-005.17 1 1/2"-A10-CW-005.17 2 "-A10-CW-008.17 18 5 "-S01-CW-001.18 5 "-S01-CW-002.18 3 "-A10-CW-003.18 3 "-A10-CW-002.18 3 "-A10-CW-001.18 2 "-A10-CW-004.18 3 "-S01-CW-004.18 3 "-S01-CW-005.18 1 1/2"-A10-CW-005.18 2 "-A10-CW-008.18 19 5 "-S01-CW-001.19 5 "-S01-CW-002.19 3 "-A10-CW-003.19 3 "-A10-CW-002.19 3 "-A10-CW-001.19
80 50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80
3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3
70 25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70
2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00
3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34
3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65
0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51
0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05
0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84%
68
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
2 "-A10-CW-004.19 3 "-S01-CW-004.19 3 "-S01-CW-005.19 1 1/2"-A10-CW-005.19 20 2 "-A10-CW-008.19 5 "-S01-CW-001.20 5 "-S01-CW-002.20 3 "-A10-CW-003.20 3 "-A10-CW-002.20 3 "-A10-CW-001.20 2 "-A10-CW-004.20 3 "-S01-CW-004.20 3 "-S01-CW-005.20 1 1/2"-A10-CW-005.20 2 "-A10-CW-008.20 21 5 "-S01-CW-001.21 5 "-S01-CW-002.21 3 "-A10-CW-003.21 3 "-A10-CW-002.21 3 "-A10-CW-001.21 2 "-A10-CW-004.21
50 80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50
2 3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2
25 25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25
918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00
12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76
2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98
4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75
0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47
7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77%
69
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
3 "-S01-CW-004.21 3 "-S01-CW-005.21 1 1/2"-A10-CW-005.21 2 "-A10-CW-008.21 22 5 "-S01-CW-001.22 5 "-S01-CW-002.22 3 "-A10-CW-003.22 3 "-A10-CW-002.22 3 "-A10-CW-001.22 2 "-A10-CW-004.22 3 "-S01-CW-004.22 3 "-S01-CW-005.22 1 1/2"-A10-CW-005.22 2 "-A10-CW-008.22 23 5 "-S01-CW-001.23 5 "-S01-CW-002.23 3 "-A10-CW-003.23 3 "-A10-CW-002.23 3 "-A10-CW-001.23 2 "-A10-CW-004.23 3 "-S01-CW-004.23
80 80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80
3 3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3
25 25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25
918 883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00
27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72
1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23
0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55
0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05
0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91%
70
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
3 "-S01-CW-005.23 1 1/2"-A10-CW-005.23 24 2 "-A10-CW-008.23 5 "-S01-CW-001.24 5 "-S01-CW-002.24 3 "-A10-CW-003.24 3 "-A10-CW-002.24 3 "-A10-CW-001.24 2 "-A10-CW-004.24 3 "-S01-CW-004.24 3 "-S01-CW-005.24 1 1/2"-A10-CW-005.24 2 "-A10-CW-008.24 25 5 "-S01-CW-001.25 5 "-S01-CW-002.25 3 "-A10-CW-003.25 3 "-A10-CW-002.25 3 "-A10-CW-001.25 2 "-A10-CW-004.25 3 "-S01-CW-004.25 3 "-S01-CW-005.25
80 40 50 125 125 80 80 80 50 80 80 40 50 125 125 80 80 80 50 80 80
3 1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2 5 5 3 3 3 2 3 3
25 25 25 70 70 70 70 70 25 25 25 25 25 70 70 70 70 70 25 25 25
883 883 918 2507 2472 2472 2472 2507 918 918 883 883 918 2507 2472 2472 2472 2507 918 918 883
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00
27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72
1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22
0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56
0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05
0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91%
71
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Tag Line
DN
GENSET
1 1/2"-A10-CW-005.25 2 "-A10-CW-008.25 26 5 "-S01-CW-001.26 5 "-S01-CW-002.26 3 "-A10-CW-003.26 3 "-A10-CW-002.26 3 "-A10-CW-001.26 2 "-A10-CW-004.26 3 "-S01-CW-004.26 3 "-S01-CW-005.26 1 1/2"-A10-CW-005.26 2 "-A10-CW-008.26
40 50 125 125 80 80 80 50 80 80 40 50
1 1/2 2 5 5 3 3 3 2 3 3 1 1/2 2
25 25 70 70 70 70 70 25 25 25 25 25
883 918 2507 2472 2472 2472 2507 918 918 883 883 918
3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50 3,50
87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02 87,02
55,00 55,00 90,00 90,00 90,00 90,00 90,00 55,00 55,00 55,00 55,00 55,00
3,4 3,38 34,29 29,79 3,34 3,34 3,34 12,76 27,72 27,72 3,4 3,38
5,05 2,98 1,35 1,34 3,63 3,63 3,65 2,98 1,23 1,22 5,05 2,98
1,80 0,52 1,06 0,65 0,51 0,51 0,51 4,75 0,55 0,56 1,80 0,52
0,18 0,05 0,10 0,06 0,05 0,05 0,05 0,47 0,05 0,05 0,18 0,05
2,94% 0,85% 1,73% 1,06% 0,84% 0,84% 0,84% 7,77% 0,91% 0,91% 2,94% 0,85%
72
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
ENGINE LUBE OIL SYSTEM
The function of this system is to ensure oil is available in all the lubricating circuits of the engine, so that oil pressure quickly builds up a sufficient level for correct operations in those applications where the engine is expected to develop its full power after the start command. For this application a single prelubrication process of 10 minutes is recommended prior to any cold start operation. This operation is done with an electrical pump which is supplied installed in an external oil tank of 300L. Its a 24Vdc pump, thus it will be feed from genset batteries allowing a start in a blackout condition of the plant. Once the genset is started the mechanical oil pump of the genset will build up the oil pressure of the engine. Lube oil system includes four lines for connection of the engine and Lubricant oil tank. The engine has three openings to connect the lubrication: 1. Filling 2. Pre-lubrication 3. Emptying Connections are implemented under polyethylene pipes. System includes a multifunctional pump with a set of valves defining the function to perform. In normal operation the valves will allow the prelube operation, but the pump may be used also to fill the engine with oil or empty it, being useful for the oil change operations. Technical instructions will be provided in further information for operation of this system. The oil recommended for the lubrication is the Guascor Motoroil 3040 Plus Lube Oil for Natural Gas-Fuelled and Ethanol engines. Design of the oil prelube system is described in the following drawings: 12-01: General Flow Diagram.
73
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 13-02: Lube Oil P&I diagram. 62-04: Lay out of pipes Lube Oil Typical Detail Genset installation manual includes also information about the oil tank, automatic engine oil level controller and oil level indicator. Table 7.Lube oil specification. PIPE MATERIAL SPECIFICATIONS
SERVICE: Lube oil (LO)
SPECIFICATIONS N
Rev. 00
PE2
Multilayered Plastic polymer/aluminium (Al)/crosslinked polyethylene pipes (PE-X)
10 bar; +95C
NOMINAL PRESSURE:
PIPING MATERIAL:
CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
20 bar; 20 C
ENDS
TO:
ITEM
PIPE
SIZE
FROM TO
DESCRIPTION
Multilayered Plastic polymer/aluminium (Al)/crosslinked polyethylene pipes (PE-X) UNE-EN ISO 21003 Copper; press fitting or Sliding sleeve Galadiator system.
20x1,9mm 20x1,9mm
PE
FITTINGS
8.1
BLOWBY GASES EXHAUSTING SYSTEM
In parallel to oil prelube system it should be also be taking in consideration the blowby gases exhausting system, also known as crankcase breathing. The blowby gases are the portion of fire gases that enter the engine oil casing through the combustion chamber sealing segments. These gases increase the pressure of the crankcase casing over the atmospheric pressure and thus should be removed. They have to be also conducted outside the engine room to avoid risks of explosion or fire, the clogging of the filters or the creation of a polluted environment. The document of the genset installation manual IT-C-A-25-001e makes a description of this installation. These drawings show the design of this blowby exhausting circuit. 13-02: Lube Oil P&I diagram. 61-02 to 61-05: Lay out of pipes (blowby gases circuit in blue colour)
74
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 62-02: Lay-out of pipes genset area typical detail (blowby gases circuit is shown in blue colour) 63-20: Blowby exhaust gases pipes design. Table 8.Blowby exhaust gas pipe specification. PIPE MATERIAL SPECIFICATIONS
SERVICE: Blowby Gases NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
SIZE
ENDS FROM TO
SPECIFICATIONS N
Rev. 00
S01
stainless steel
9 bar; +120C
PIPING MATERIAL:
0 bar; 0 C
TO:
ITEM
15 32
DESCRIPTION
EN 1127 Seamless Pipe EN ISO 1127 thickness 2mm; Material EN 1.4301 (AISI 304)
PIPE FLANGES
250 250
BE Type A (FF) BE
FITTINGS
15
250
BOLTING
GASKET
Flange LJ EN 1092-1, tipo 04, cara A PN10; Aluminum Material Elbows, tee, reducer and cap carbon steel EN 10253-3; material EN 1.4301 (AISI 304). Other accessories: malleable iron threaded ASA B16.11, material AISI 304, thread s/EN 10226 Screws EN 4014 (DIN931) Alloy Steel Material ,quality 5.6 Nuts EN 4032 (DIN934) Alloy SteelMaterial quality 5.6 Gasket plat PN10 s/EN 1092; Asbestos-free gasket material, Klingersil 4430 or equivalent
75
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER

Rev. 00

SERVICE: Blowby Gases NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
SIZE
ENDS FROM TO
S01
stainless steel
9 bar; +120C
PIPING MATERIAL:
0 bar; 0 C
TO:
ITEM
15 BALL 32 VALVES 50 BUTTERFLY 200 15 CHECK 50
DESCRIPTION
Body and ball EN 102134 1.4408 (316) Body cast iron EN-GJL250; stainless ball ; length EN558-1 Series 27 Dry Lever Manual wheel type (Reduction gear operate ) disk Dimensions as EN 1983 2 pieces Full bore Drive lever
25
40 150 250 40 250
lug Wafer Wafer
cast iron EN-GJL-
Dual plate
250; length EN558-1 Series 20 Cast iron EN-GJL-250 disk andstainless spring Body and plates cast iron EN_GJL250; Length EN558-1 series 16
76
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
9 9.1
ENGINE VENTILATION SYSTEM DESCRIPTION OF THE ENGINE ROOM VENTILATION
The ventilation of the engine room should satisfy two fundamental functions: Guarantee the environmental conditions, which permit the optimum performance level of the engine and equipment. Provide the most comfortable environmental conditions possible for the people who have to work in the engine room. In designing a ventilation system, the same importance should be given to the necessary volume of air as to the flow direction. The ventilation system must be able to provide sufficient combustion air and to remove radiation heat from the rest of the facility. Generally, the air flow direction in an engine room will match the following pattern The entry of air in the engine room should be from the area furthest away from any sources of heat. The fresh air should be able to flow freely from the point of entry to the sources of heat, in its circulation towards the point of exit. The expulsion of hot air should be at a point directly above the most important sources of heat, avoiding the intake of the exhaust gas. Where the temperature of the engine room or, in particular, of the crankcase gases return lines to the intake manifold is too low, the said lines must be heatinsulated so as to prevent condensation in the said piping section. In all cases, the hot air should be forced out of the engine room by means of an outlet duct, without allowing it to mix with the fresh ventilation air. The detailed information of the lay out and the ventilation system assembly is available in the Annex (Ventilation System. Assembly Manual).
77
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
9.2 9.2.1
VENTILATION SYSTEM Forced ventilation (pusher fan)
We recommend this ventilation system for all machine rooms in general. Both air inlet and outlet depend on the location of the air intake filters and alternator, as the following picture shows:
ALTERNATOR SIDE
78
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The air flow through each engine is guaranteed for a motor-fan located above every single engine. These fans will be flowing fresh air when the engine is running. There is a circular duct mounted to the motor-fan in order to improve the fresh air direction blowing through the Gensets.
9.2.2
Ventilation module feature
The Air input module will contain the following elements: Plenum Dimensions ....................................................... 1,600x1,400x1,847 mm Motor Driven Fan Model ................................................... S&P TGT 4/800 6/18 Flow Rate .............................................................................................. 25,000 m3/h Airflow speed ............................................................................................... 13.7 m/s Available Static Pressure .............................................................................. 150 Pa Nominal Input ................................................................................................... 3 kW Speed of Rotation .................................................................................... 1400 rpm Voltage & Frequency ................................................................... 3P 400 V 50 HZ Nominal Current ..............................................................................................6.5 A Degree of Protection ........................................................................................ IP55 Electrical insulation class ........................................................................................ F Refer to the general drawing (35-02) for further information.
79
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
10 NATURAL GAS FUEL SUPPLY 10.1 GENERAL DESCRIPTION

The Natural Gas is distributed inside the power plant through a pipelines network. In the regulation and metering station (R.M.S.), the natural gas is filtered and adjusted to appropriate pressure level, in order to provide at the engines the power needed for electrical generation. The R.M.S. is provided with a non continuous gas analyzer whose function is to monitor CH4, O2 and CO2 content in natural gas, and the communications output will be through digital modbus and 4-20 mA signal. Also, 2 electrovalves will be installed at R.M.S. outlet, which will be actuated in case of serious alarm caused by loss of gas quality, gas leakage or fire. This electrovalves will be supplied by 24Vdc batteries set located at the R.M.S. control panel to allow their control also in situations of black-out or power supply shortages. After the R.M.S., natural gas is sent into the two power generation engine rooms through pipe internal network. Every engine is fed from a manifold located outside the engine room,it means that there is one pipe entering the building for each engine. Head losses in pipes are allowed while the pressure level at the inlet of the feeding ramps is adequate in order to ensure proper running of the engine. These drawings show the design of the Natural Gas Fuel Supply circuits 12-01: General Flow Diagram. 13-03: Natural Gas P&I diagram. 61-01: Lay-out of pipes area GRMS 61-02 to 61-05: Lay out of pipes (natural gas circuit in red colour) 62-02: Lay-out of pipes genset area typical detail (natural gas circuit is shown in red colour) 62-03: Section Pipes area GRMS 63-16 to 63-18: Natural gas pipes design. 65-01: General connection.
80
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
10.1.1 Internal connection.

The Service Pipes includes the whole of pipelines and fittings between the Service Key (main supply valve), excluding this, and the Buildings Key (shut off valves at the entrance of engine rooms facility), including these, in case of gas receiver installations supplied from distribution pipe network.
10.1.2 Service pipes 10.1.2.1 General features

The Service Pipes of Natural Gas involves the different gas pipes with its fittings and auxiliary items between the Regulating and Metering Station (R.M.S.) and the gas train of every engine. The R.M.S. is located in the south side of the Power Plant. It has two pipe outlets to provide natural gas, one for each engine room. TheService Pipes is formed by the following stretches: 1) R.M.S. output:Stretch comprised between R.M.S. and the engine rooms area. Both pipes run parallel each other and in a buried stretch for crossing the road. Once the road is crossed, the pipes get out to the surface and runs through an aerial stretch, above a lintel, up to the engine rooms. 2) Engine rooms: The pipes are separated, each one toward their own engine room with a symmetric route. The pipes goes down to the ground at the entrance of the engine rooms, where there are shut off valves (building keys) to lock the gas supply.The pipe distribution in the engine rooms is through an aerial stretch, 3 m above the ground and supported in metallic structures fixed in the pillars of the building. 3) Gas supply to engines:Stretch between the pipe distribution and the gas train of the engines. At the inlet of the gas train, there are a shut off valve to isolate the engine from the gas supply.
81
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
10.1.2.2 Calculations
10.1.2.2.1 INSIDE DIAMETER CALCULATION The output pressure from the R.M.S. will be 3 bar g, and it will be the design pressure for the gas distribution pipelines of the power plant. The external gas service arrives at the power plant with a range between 10 and 40 bar g so the design pressure will be 10 bar g because is the pressure that produces higher velocities. The procedure to calculate the inside diameter of the pipe is to establish an initial diameter and apply the formula to determine the flow velocity and head loss to ensure that the obtained values are according to the current Standards. 10.1.2.2.1.1 DESIGN ASSUMPTION The design foundations are the following: R.M.S. pressure output (bar g) ........................................................... 3 Max. Volumetric flow rate (Nm3/h): Pipe distribution Engine Room 1........................................ 6.250,00 Pipe distribution Engine Room 2........................................ 6.250,00 Gas supply to engines (1-26)........................................................481 Max. Design Velocity (m/s) ............................................................... 20 10.1.2.2.1.2 HEAD LOSS The procedure to calculate the head loss in each stretch of the installation is through applying the RENOUARD formula:
PA
2
PB
51,5 S L Q1,82 D -4,82
The parameters descriptions are as follow: PA: Absolute pressure at the beginning of the stretch.
82
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD PA- PB = Head loss (differential pressure between A and B) S: Corrected density Q: Volumetric flow rate (Nm3/h) D: Pipe inside diameter (mm) L: Length. 10.1.2.2.1.3 VELOCITY The procedure to calculate the maximum velocity inside pipes is through applying the following formula:
V = 378
The parameters descriptions are as follow: V: Velocity m/s Q: Volumetric flow rate Nm3/h Z: Compressibility factor P: Absolute pressure (bar) D: Inside diameter (mm)
Q Z P D2
10.1.2.2.1.4 PIPE THICKNESS CALCULATION The procedure to calculate the minimum thickness of the pipe is through applying the formula indicated in the Standard UNE 60309:
e=
P d 20 Q e F C
The parameters descriptions are as follow: P: Calculated absolute pressure (bar).
83
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Qe: Yield strength of the pipe material (N/mm2). e: Theoretical thickness of the pipe (mm). d: Outside diameter of the pipe (mm). F: Coefficient for calculations. Indicated in the Standard UNE 60305 = 0,4 C: Welding efficiency = 1 1) The minimum thickness of poliethylene pipes (HDPE) for gas are according to the current standards so it is allowed to use in the specificated pressure range in the plant. 10.1.2.2.1.5 MEASUREMENT TABLE The calculation results are shown in the following table. As the table shows, the velocity values obtained in the calculations are under the maximum velocity allowed by Standards for each stretch, 20 m/safter the R.M.S, and the thickness of the selected pipes are above the minimum allowable thickness required by the Standard. The R.M.S. will adjust the pressure to 3 bar g, and thus this will be the nominal pressure used for all gas pipelines installed in the plant. The pipelines with tag OTHER1, 2 or 3 correspond to the power plant main connection of natural gas, before the R.M.S. For those pipelines the maximum velocity allowed by the Standard is 30 m/s. Gas supply at natural gas take-off will have a pressure between 10 and 40 bar g, and thus design pressure for these pipelines will be 10 bar g as this is the pressure at which the maximum flow rates are produced.
84
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Table9.Gas pipeline dimensions

InitialPress ure (bar a) Final Pressure (bar a) Equivalent Length (m) Pipe Thickness (mm) Minimumt hickness (mm) 4,65 2,97 2,97 1,16 1,16 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 P (mbar)
85
Flow Rate (Nm/h)
Flow Rate (ft3/h)
Temp. C
Pressure (bar g)
Pressure (psi g)
Tag Line
8 "-A300-NG-OTHER1 5 "-A300-NG-OTHER2 5 "-A300-NG-OTHER3 8 "-PE1-NG-017 8 "-PE1-NG-018 8 "-A10-NG-017 8 "-A10-NG-018 2 1/2"-A10-NG-16.1 2 1/2"-A10-NG-16.2 2 1/2"-A10-NG-16.3 2 1/2"-A10-NG-16.4 2 1/2"-A10-NG-16.5 2 1/2"-A10-NG-16.7 2 1/2"-A10-NG-16.8 2 1/2"-A10-NG-16.9 2 1/2"-A10-NG-16.10 2 1/2"-A10-NG-16.11 2 1/2"-A10-NG-16.13 2 1/2"-A10-NG-16.14 2 1/2"-A10-NG-16.15
200 125 125 200 200 200 200 65 65 65 65 65 65 65 65 65 65 65 65 65
8 25.000 882.866,66 5 12.500 441.433,33 5 12.500 441.433,33 8 6.250 220.716,66 8 6.250 220.716,66 8 6.250 220.716,66 8 6.250 220.716,66 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20 2 1/2 481 16.978,20
10 10 10 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
145,03 145,0333 145,0333 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51
25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
270,31 10,62 10,62 20,32 20,32 145,1 145,1 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14
22,92 11,00 10,50 505,21 12,70 28,28 11,00 10,95 53,91 9,52 28,28 11,00 10,95 53,91 9,52 18,75 4,00 3,99 12,93 11,90 18,75 4,00 3,99 12,93 11,90 13,70 3,99 3,95 42,48 5,90 13,70 3,99 3,95 42,48 5,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90 9,18 3,95 3,94 8,19 2,90
Velocity (m/s)
NPS (")
DN
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

InitialPress ure (bar a) Final Pressure (bar a) Equivalent Length (m) Pipe Thickness (mm) Minimumt hickness (mm) 2,90 2,90 2,90 2,90 2,90 2,90 2,90 2,90 2,90 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 0,40 P (mbar) 8,19 8,19 8,19 8,19 8,19 8,19 8,19 8,19 8,19
86
Flow Rate (Nm/h)
Flow Rate (ft3/h)
Temp. C
Pressure (bar g)
Pressure (psi g)
Tag Line
2 1/2"-A10-NG-16.16 2 1/2"-A10-NG-16.17 2 1/2"-A10-NG-16.19 2 1/2"-A10-NG-16.20 2 1/2"-A10-NG-16.21 2 1/2"-A10-NG-16.22 2 1/2"-A10-NG-16.23 2 1/2"-A10-NG-16.25 2 1/2"-A10-NG-16.26
65 65 65 65 65 65 65 65 65
2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2
481 481 481 481 481 481 481 481 481
16.978,20 16.978,20 16.978,20 16.978,20 16.978,20 16.978,20 16.978,20 16.978,20 16.978,20
3 3 3 3 3 3 3 3 3
43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51 43,51
25 25 25 25 25 25 25 25 25
16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14 16,14
Velocity (m/s) 9,18 9,18 9,18 9,18 9,18 9,18 9,18 9,18 9,18
NPS (")
DN
3,95 3,95 3,95 3,95 3,95 3,95 3,95 3,95 3,95
3,94 3,94 3,94 3,94 3,94 3,94 3,94 3,94 3,94
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
10.1.2.3 Pipes & fittings specification.

The following table shows the material specifications for the pipes and fittings: Table 10. Pipe specifications for internal gas supply. PIPE MATERIAL SPECIFICATIONS
SERVICE: Natural Gas (NG) NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: PIPING MATERIAL: 0 bar; 0 C
ENDS FROM TO
SPECIFICATIONS N
A10
TO:
ITEM
15
PIPE
SIZE
DESCRIPTION
EN 10255 (DIN 2440) Seamless Pipe EN 10255 medium series M; Material EN 1.0026 S195T Seamless Pipe EN 10216-2 series 1 EN 10216 normalized thickness; Material (DIN 2448) P235GH EN 1.0254 Flange SW EN 1092-1, type 01, face A PN10; Material P235GH EN 10216-2 Elbows, tee, reducer and cap carbon steel Seamless EN 10253-1 material EN P235TR1 (st 37). Other accessories: malleable iron threaded ASA B16.11, A-105material, thread s/EN 10226 Screws EN 4014 (DIN931) Alloy SteelMaterial, quality 5.6 Nuts EN 4032 (DIN934) Alloy Steel Material ,quality 5.6 Gasket plat PN10 s/EN 1092; Asbestos free gasket material like Klingersil 4430 or equivalent.
40 250 250
PE BE Type A (FF) Beveled
50 32
FLANGES
FITTINGS
15
250
BOLTING
GASKET
87
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER


SERVICE: Natural Gas (NG) NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: PIPING MATERIAL: 0 bar; 0 C
ENDS FROM TO
A10
TO:
ITEM
15 BALL 32 50 VALVES BUTTERFLY 200 15 CHECK 50 15 FILTERS 32
SIZE
DESCRIPTION
Body and ball EN 102134 1.4408 (316) Body cast iron EN-GJL250; seamless ball ; length EN558-1 Series 27 DryLever Manual wheel type (Reduction gear operate ) disk Dimensions as EN 1983 2 pieces Full bore Drive lever
25
femaleth read Flanged
40 150 250 40 250 25 150
lug Wafer Wafer femaleth read
castiron EN-GJL-
Dual plate
250; length EN558-1 Series 20 Cast iron body EN-GJL-250 disk and stainless spring. Body and plates cast iron EN_GJL250; Length EN558-1 series 16 Body cast iron EN_GJL-250, sieve steel. Cast iron body EN_GJL-250, stainless sieve; Length EN558-1 series 1
Tipe Y Flanged
Table 11.Gas supply at natural gas take-off. PIPE MATERIAL SPECIFICATIONS

SERVICE: Natural gas (NG) NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: PIPING MATERIAL: 0 bar; 20 C
ENDS FROM TO
SPECIFICATIONS N A300
TO:
ITEM
PIPE FLANGES FITTINGS
SIZE DN (mm)
DESCRIPTION
Seamless Pipe XS ANSI B36.10; ASTM A106Material Flange WN 300# ANSI B16.5; Material ASTM A105 ANSI B16.9, A234 WPBmaterial
65 65 15
300 300 250
BE RF BE
88
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD SPECIFICATIONS N A300


SERVICE: Natural gas (NG) NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM: PIPING MATERIAL: 0 bar; 20 C
ENDS FROM TO
TO:
ITEM
SIZE DN (mm)
DESCRIPTION
Other accessories: malleable iron threaded ASA B16.11, material A-105 Screws ANSI B18.2.1, A 193 B7material Nuts ANSI 18.2.2, material A194 2H Gasket flat 300# ANSI B16.21; Asbestos free gasket material like Klingersil 4430 or equivalent.
BOLTING GASKET
Table 12.Buried gas pipelines. PIPE MATERIAL SPECIFICATIONS

SERVICE: Natural gas (NG) PIPING MATERIAL: 0 bar; 0 C
ENDS FROM TO
SPECIFICATIONS N
Rev. 00
PE1
Polyethylene (HDPE)
7 bar; +60C
NOMINAL PRESSURE: CORROSION PERMISSIBLE: SERVICE LIMITS FROM:
TO:
ITEM
15 32 15
SIZE
DESCRIPTION
Polyethylene (HDPE) PE80 S5/SDR11 UNE EN 1555 Flange LJ EN 1092-1, type 04, face A PN10; Aluminum Material Bend 90 PE80 S5/SDR11 But fusion Flange adaptor; PE100 S5/SDR11 Screws EN 4014 (DIN931) Alloy Steel Material, quality 5.6 Nuts EN 4032 (DIN934) Alloy Steel Material, quality 5.6 Gasket plate PN10 s/EN 1092; PTFE Material
PIPE FLANGES
250 250 250
PE Type A (FF) BE
FITTINGS
BOLTING GASKET
89
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
10.1.3 Engine gas trains

The description of the gas trains for the engines are shown in the plan 2.000553.040 of the Genset Installation Manual
10.1.4 Identification of pipelines

The identification of gas pipelines will be according with the Standard UNE 1063and which base color will be yellow.
10.2 ENGINEERING BASIS OF DESIGN

The installation for natural gas supply has been designed according to the following standards and regulations: UNE 60670, including all of its parts, Gas installations pipework supplied at maximum operating pressure (MOP) up to and including 5 bar. UNE 60620, including all of its parts, Natural gas receiving installations with pressure supply over 5 bar. UNE-EN 437, test gases test pressures. Appliance categories. UNE 1063, identification pipelines according to the fluid conveyed. UNE 60305, steel gas pipelines, security areas and design factors. UNE 60309, gas pipelines. Minimum wall thickness for steel pipes. UNE 60311, gas supply systems. Pipelines for maximum operating pressure up to and including 5 bar. UNE-EN 1555, plastics piping systems for the supply of gaseous fuels. Polyethylene (PE). UNE-EN 12007, gas supply systems. Pipelines for maximum operating pressure up to and including 16 bar. 2) Standards to take into account in the in site mechanical assembly of pipelines:
90
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD UNE-EN ISO 15607 Specification and qualification of welding procedures for metallic materials. UNE-EN 287 Qualification test of welders UNE-EN 25817 Arc-welded joints in steel. Guidance on quality levels for imperfections (ISO 5817:1992). UNE-EN ISO 13920 Welding. General tolerances for welded constructions. Dimensions for lengths and angles. Shape and position. (ISO 13920:1996). ASME Code. UNE-EN 10255 Non-Alloy steel tubes suitable for welding and threading Technical delivery conditions. UNE-EN 10216 Seamless steel tubes for pressure purposes - Technical delivery conditions. UNE-EN ISO 1127 Stainless steel tubes. Dimensions, tolerances and conventional masses per unit length.
10.3 TESTING & INSPECTIONS

Following test will be done in the natural gas installation: 1) Mechanical strength testing; i) Fluid ................................................................... N2 or Air (according to EN 437)
ii) Test pressure .............................................................................................. 4,2 bar g iii) Test time ............................................................................................................ 1hour 2) Tightness testing: i) Fluid ..................................................................... N2or Air (according to EN 437)
ii) Test pressure .................................................................................... at least 1 bar g iii) Test time ........................................................................................................... 6 hour
91
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The test must be verified using an electronic or digital manometer of 0 to 10 bar range. The time test could be of 10 minutes if the stretch is lower than 10 meters. All components will be factory tested. However, a final test will be also carried out after assembled on site.
92
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
11 FIRE & GAS LEAK DETECTION SYSTEM

In this paragraph will be described the fire protection installed in the power plant. The Fire gas & Gas leak detection system is described by the drawings 35-01 (layout of detection equipment) and 27-02 (related electrical installations).The purpose of the projected automatic fire detection system is to warn of the start of a fire in a timely and efficient manner. Basically, the fire detection system comprises the following elements as indicated in the figure below:
A B C D E F G
Sensors Control and signaling equipment Fire alarm devices Alarm buttons Fire alarm transmission device Fire alarm reception area Control of automatic fire protection systems
93
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD H J K l Automatic fire protection system Malfunction warning transmission device Malfunction warning reception area Power supply
Some of the elements indicated represent the most important parts of a fire detection system. These are: a) Fire sensors (fire alarm devices) and manual alarm button that are distributed around the site and are capable of indicating the presence of a fire in its initial phase. b) Fire detection centre (control and signaling equipment) where the alarms are centralized and a series of programmed preventive actions are carried out: Acoustic transmission of alarm or any operation that may be started by means of electrical transmission. Transmission of emergency signals to a remote position located on the Control Desk in order to control the site using graphs. The installation of all of this equipment is subject to the standards and regulations that describe in which type of premises their implementation is necessary, as well as the type of sensor and their location being the most appropriate according to the nature of the risks to be protected. Following recommendations of a general nature, the installation of fire detection and alarm shall comply with the following conditions: a) There will be manual fire alarm buttons in the areas of circulation and inside the premises. b) Sensors that are appropriate to the type of fire expected inside the premises and in the circulation areas shall be provided.
94
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The sensors shall be smoke sensors except in those areas in which thus type of sensor could provoke false alarms, in which case heat or flame sensors will be installed. c) The control and signaling equipment shall have a device that will allow manual and automatic activation of the alarm systems and will be located in a permanently guarded place. The automatic activation of the alarm systems must be adjustable so that it takes place a maximum of 5 minutes after the activation of a sensor or a button. d) The alarm warning system will be acoustic and shall be comprised of two tone sirens that will allow the transmission of local alarms and of a general alarm.
11.1 BASIS OF DESIGN

This project was completed in compliance with the following standards: Technical Edification Code -CTE-. Basic Document: SI Safety in the case of a fire. ROYAL DECREE 314/2006, of 17th March 2006. Regulation on Fire Protection Installations. ROYAL DECREE 1942/ 5th November 1993. Regulation on Fire Safety in Industrial Establishments. ROYAL DECREE 2267/2004 of 3rd December 2004. UNE Standard 23.007/1. Fire detection and alarm systems. Part 1. Introduction. UNE Standard 23.007/2. Fire detection and alarm systems. Part 2. Control and signaling equipment. UNE Standard-EN 54/3. Fire detection and alarm systems. Part 3. Fire alarm devices. Sound alarm devices.
95
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD UNE Standard 23.007/4. Fire detection and alarm systems. Part 4. Power supply. UNE Standard-EN 54/5. Fire detection and alarm systems. Part 5. Heat sensors. Point sensors. UNE Standard 23.007/7. Fire detection and alarm systems. Part 7. Smoke sensors. Point sensors that work according to the principle of diffuse light, transmitted light or by ionization. UNE Standard 23.007/9. Fire detection and alarm systems. Part 9. Sensitivity tests in households. UNE Standard-EN 54/10. Fire detection and alarm systems. Part 10. Flame sensors. Point sensors. UNE Standard-EN 54/11. Fire detection and alarm systems. Part 11. Manual alarm buttons. UNE Standard-EN 54/12. Fire detection and alarm systems. Part 12. Line sensors that use an optic light beam. UNE Standard 23.007/13. Fire detection and alarm systems. Part 13. Evaluation of the compatibility of the components of a system. UNE Standard 23.007/14. Fire detection and alarm systems. Part 14. Planning, design, installation, implementation, use and maintenance. UNE Standard-EN 54/16. Fire detection and alarm systems. Part 16. Control of the alarm by voice and indicating equipment. UNE Standard-EN 54/17. Fire detection and alarm systems. Part 17. Short circuit isolators. UNE Standard-EN 54/18. Fire detection and alarm systems. Part 18. Input /Output devices. UNE Standard EN 54/20. Components of the automatic fire detection systems. Part 20. Smoke aspiration sensors. UNE Standard-EN 54/21. Fire detection and alarm systems. Part 21. Alarm transmission equipment and warnings of failures.
96
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD UNE Standard-EN 54/24. Fire detection and alarm systems. Part 24. Components of the voice alarm systems. Loudspeakers. UNE Standard-EN 54/25. Fire detection and alarm systems. Part 25. Components that use radioelectrical links. UNE Standard-EN 12.094/1. Fixed fire protection systems. Components for fire extinguishing using gas agents. Part 1. Test requisites and methods for automatic and electrical control and delay devices. UNE Standard-EN 12.094/3. Fixed fire protection systems. Components for fire extinguishing using gas agents. Part 1. Test requisites and methods for manual trip and shutdown devices. Municipal ordinances and standards from the regional authorities on Fire Protection Conditions. Low Voltage Instructions. Electrotechnical Regulation and Complementary Technical
The system will also be designed in accordance with the following recommendations:
Technical Rule CEPREVEN R.T.3.-DET. Technical Rule for Automatic Fire Detection installations.
11.2 DESIGN & DEFINITION 11.2.1 Smoke and heat point sensors
The number of smoke and heat point sensors is determined in accordance with the stipulations of UNE Standard 23007/14, Annex A. The sensors must be located such that their sensitive elements are less than 5% from the top of the room. Due to the possible existence of a cold limit layer, the sensors shall not be embedded in the ceiling. The heat sensors must be located below under the ceiling. For point sensors the indication is that they must be distributed in such a way that no point of the ceiling or of the roof is at a horizontal distance from the sensor greater than the values of Dmax indicated in table A.1.
97
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD If there are unfavourable temperature gradients on the protected surface, the plume of cloud rising from the fire can be suffocated and form a layer before reaching the ceiling. If the height of this layer is foreseeable, sensors can be installed at the expected stratification height as well as those sensors that are installed near the ceiling. In narrow corridors and ceiling spaces that have a width of less than 3 metres, the distances between sensors may be as follows: For heat sensors, up to 10m (5m for detection with coincidences or for extinguishing systems); For smoke sensors, up to 15m (11m for detection with coincidences or 7.5m for extinguishing systems). The horizontal distance between the sensor and the wall or the ceiling must not be greater than half of the above mentioned distances. The maximum area of authorized monitoring must not be greater than the added values indicated in Table A.1. Table 13.Distribution of smoke and heat point sensors.
Surface of the premises in m2 SL 80 SL > 80 Type of sensor Height of the premises in m h 12 h 6 6 < h 12 h 7,5 h6 h 7,5 h6 Slope 20 Sv (m2) 80 60 80 20 20 30 30 Dmax (m) 6.6 5.7 6.6 3.5 3.5 4.4 4.4 Slope >20 Sv (m2) 80 90 110 40 40 30 30 Dmax (m) 8.2 8.7 9.6 6.5 6.5 5.7 5.7
UNE-EN54/7 UNE-EN54/7 UNE-EN54/5, class A1
SL > 30
UNE-EN54/5, class A2, B, C, D, E, F, G UNE-EN54/5, class A1
SL 30
UNE-EN54/5, class A2, B, C, D, E, F, G
98
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
Dmax Dmax
Incorrectdistribution
Normal distribution
Reduceddistribution
Key
Sv Dmax
Monitored surface Max.horizontal distance from any point to the sensor
99
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
The SV monitoring area must be corrected according to the type of risk. Thus, the area protected by sensors used in coinciding detection must be reduced by at least 30% and for sensors aimed at activating a fixed extinguishing system it must be reduced by at least 50%. A space of at least 0.5m must be left in all directions below each sensor.
11.2.2 Linear sensors

The lineal sensors comply with UNE 23007/12. The distance between the emitter and the receiver shall vary between 10 metres as a minimum and 100 m as a maximum. The maximum distance of lateral cover of the ray is that indicated by the following table extracted from UNE 23007.14:
100
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Table 14.Maximum distance.

Slope 20 Height of premises in m Distance in m, Distance in m, Maximum covered surface D A in m2 Dv (m) UNEEN54/12 UNEEN54/12 UNEEN54/12 Key D, maximum distance covered by the beam from the barrier A, maximum distance between to lineal sensors Dv, vertical distance from the beam of the barrier to the ceiling Dv (m) Slope >20
Type of sensor
h6 6 < h 12 12 < h 25
100 100 100
12 13 15
1200 1300 1500
0.3 a 0.5 0.4 a 0.6 0.4 a 0.6
0.3 a 0.5 0.5 a 0.8 0.5 a 0.8
In order to calculate the required number of elements we will have to take into account their maximum area of coverage and the maximum lateral distance between sensors. In the case of sloped ceilings, the lateral distance between lineal sensors will start to count from the lintel where one device must be placed and measure between barriers using it as a reference. For buildings with ceiling with special forms such as saw tooth ceilings, a set of sensors shall be installed for each tooth. The sensor will be located at a distance from the ceiling between 0.3 and 0.8 m depending on the height of the building, in order to avoid the thermal cushion of hot air.
11.2.3 Buttons
The distribution of buttons shall take into account the rules laid down in UNE-23007-14: The buttons are located in such a way that it will not be necessary to move more than 25 metres to reach one. In those premises in which the users may be disabled, this distance should be reduced. They are located at between 1.2 and 1.6 m from the floor.
101
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
11.2.4 Sound alarms

These elements are distributed in such a way that guarantees the minimum sound levels expressed in UNE Standard 23007-14. The sound level of the alarm shall be at least 65 dB(A) or 5 dB(A) above any sound that is expected to last more than 30 s. If the idea of the alarm is to wake people who are asleep, the minimum sound level shall be 75 dB(A). This minimum level must be guaranteed in all parts of the enclosure. The sound level must not exceed 120 dB(A) at any point which is more than 1m from the device. The number of devices to be installed will be determined in accordance with the following: The number of sirens/bells must be sufficient to reach the above mentioned sound level. The minimum number of devices will be two per building and one per fire sector. In order to avoid excessive levels in some areas it is preferable to place more sirens with less power. The tone used by the sirens to warn of a fire must be exclusive for that purpose.
102
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
11.2.5 Cabling
The following specifications indicated in the Electrotechnical Low Voltage Regulation were taken into account in the installation of the cabling required for the connection of the elements with the control desk. A braid shield wire with the following characteristics will be used as a communications bus for the smart elements: cable: braided and shielded for two wires. braid: with 20 to 40 turns per meter. shield: Mylar aluminum with drain wire. total resistance of the loop cable: less than 40 ohms. capacity: less than 0.5 microfarads. The cable section was selected in accordance with the following table: Length of loop up to 1500 metres up to 2200 metres
Section 2 x 1.5 mm2 2 x 2.5 mm2
The power cable of the auxiliary equipment is a conventional single wire type. In order to calculate the section required we will calculate the voltage drops in accordance with the formula: E=2PL/KSv Where: e: voltage drop in volts P: is power P= V x i L: is the length of the cable in meters k: for copper 56 and for aluminum 35
103
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD s: section of the cable in mm2. V: voltage in volts.
11.2.6 Power and battery calculations

Power sources:
The UNE standards require the system to be equipped with a double power supply. This is normally resolved by supplying the system directly from the general electrical grid of the building and by using a group of batteries connected to a charger as standby. These will be used if the main system fails. Duration: according to UNE the emergency power supply in the case of failure shall meet the requirements of the following table: CONDITIONS Always There is a local or remote monitoring service with a commitment to repair in 24 h. There are spare parts on site and personnel and an emergency generator
STANDBY 72 hours 24 hours 4 hours
ALARM 30 min. 30 min. 30 min.
104
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Calculation of the capacity:
The following formula was used to calculate: Cmin = (A1 x t1 + A2 x t2) ampshour where: t1 and t2 are the operating times on idle and on alarm respectively. A1 and A2 are the consumptions of the system in amps on standby and alarm.. 25% extra should be considered for the ageing of the batteries which means that the total capacity will be: 1.25 x Cmin. For the calculation of A1, we add the consumptions of all the elements that make up the detection system and in order to determine A2, we calculate the consumption in alarm of all the elements that intervene simultaneously.
11.3 TECHNICAL SPECIFICATIONS 11.3.1 Smart analogical centres / accessories 11.3.1.1 Fire Detection Centre. ID3002
The analogical and algorithmic fire detection centre may be configured to be adapted to the needs of each site. The size of the system will be defined by the number of loops (2 loops, 396 points of detection/control, individually identifiable and controllable). Each loop will support 99 analogical sensors plus 99 programmable modules complying with the requisites of EN 54 A and B cabling standards. It will be able to support sensors of the following types: ionic, photo-electrical photo-thermal, high sensitivity lasers, thermal and analogical sensors of an ionic or photo-electrical type. The modules can be: programmable monitors for NA or NC contact reading, control modules for programmable outputs, short circuit isolating modules and conventional area monitor sensor modules.
Characteristics of the System
Automatic compensation of the dirt in the analogical smoke sensors.
105
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Function for automatic adaptation of each sensor to the environment. 10 levels of sensitivity. AWACS algorithms for the control and stability of the sensors. Automatic or manual testing of the system that activates and verifies each system sensor.
Completely programmable and configurable in the field from the panel keyboard. It will not require a special computer. It will allow automatic programming by default.
Customized messages for each point. Programmable functions by events: Predefined programming blocks. Monitoring / interlocking selection. Management of no alarm points (low priority).
Time function control for actions on a specific day and time. Programming delays and output pulse times. Historical archive in non volatile memory of 600 events which can be viewed on screen or printed.
Non volatile clock for indicating the date and time of all events. Uploading and downloading program using a PC. Three levels of access with different and selectable passwords. Self programming of the elements of the loops. Operation test with an equipment meter and identification of 2 sensors assigned to the same address. While the test is being carried out on the rest of the system it still provides fire protection. Timer to stop the test.
Automatic maintenance alert function for sensors that are dirty before a false alarm occurs.
Manual or automatic adjustment of the day/night sensitivity of the sensors.
106
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Enabling and disabling of all equipment. Status report for all the system equipment including sensitivity and check totalizer. Programmable silencer, alarm silence and alarm check. High efficiency 24 V and 2.5 amp power supply Liquid crystal screen with 240 x 64 pixels living complete on screen information about the system.
30 key alphanumerical keyboard.
11.3.2 Smart analogical sensors 11.3.2.1 Super flat Analogical Optic Smoke Sensor. NFX/ISO-OPT
The white coloured analogical photo electrical smoke sensor with isolator will have an optic sensor camera and will use the dispersion of light as its main principle for detection. It detects the presence of smoke through the light dispersed by the smoke particles inside the camera of the sensor. Associated with the photoelectrical sensor, is the recognition circuit that provides a threshold for a predetermined level of smoke in the system initialisation circuit. The direction of each sensor will be assigned by rotating switches. Each sensor reports its direction, its type and its analogical type in order to give an idea of the measured value and its status. The sensor will have two LEDS, which make it possible to see its status from any position. The LEDS will flash in normal operation and remain on in the case of an alarm. As an option, flashing can be eliminated when the system is used in rooms. It includes a micro switch that is activated by a magnet to check that the equipment alarm works. The sensors will be assembled on a common bayonet type base with an interlocking device to prevent their accidental extraction. They may be assembled on a base with a built in horn to provide a local acoustic indication.
107
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Technical Characteristics:
Operating voltage Consumption Environmental conditions
15 - 28Vdc 0.2mA Temperature 10 to 60C Humidity 10 to 93 %
Nominal Sensitivity Speed Test Certifications
1.5 % o or 0.3 m. darkening. 8 m/s with constant flow. By magnet. Complies with Standards EN54, BSI, LPC, VDS, UL, FM.
11.3.3 Smart digital modules and buttons 11.3.3.1 Single Entry Monitor Module. M710
The monitor module will provide a programmable input for devices that give potential free contact signals and will supervise and manage voltage free contacts, either normally open (NA) or normally closed (NC). It assigns an address to the element that it manages inside the smart loop, so that the Centre knows the exact location of the element that whose alarm is on. The control circuit can be wired as Class B (closed) or Class A (Open). In the Class A circuits the circuit will be supervised with an end of line resistance. The length of the activation circuit must be less than 1000 metres [Rmax of the circuit 20W]. The direction of each module will be assigned by rotating selectors. They have a LED that flashes each time they communicate with the Centre. The LED will remain on in the case of an alarm and an indication will be sent to the Fire Centre. It is supplied directly by the SLC communications loop. No additional supply is needed. It must be protected against noise from interferences and must be easy to connect.
108
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD It includes a micro switch which is activated by a magnet to check that the alarm is working. It has an isolator at both loop inlets. Programmable action.Possibility of assembly on a DIN rail using the M200DIN accessory.
Consumption: Environmental conditions:
2.8 mA on alarm, 660 Ain normal conditions Temperature: -20 to 60C Humidity: 5 to 95%, not condensed.
Dimensions: Certifications:
93mm (height) x 94mm (width) x 23mm Complies with standards prEN 54-17, Vds 2489, approved by CEA GEI 1-082 and GEI 1-084.
11.3.3.2 6 Relay output Control Module. CR6

The control module will provide up to six output orders to elements such as sirens, electromagnets, etc. The connection of each circuit must be voltage free using a double NA/NC contact. Each output will have a direction assigned, using rotating selectors so that when it receives an order from the Centre, its internal relay is activated and will switch to NA or NC. The control module will act on each of the relays in the cases indicated. The relay contacts are of the SPDT type and set at 28 vdc and 2A. There is a LED for each direction that flashes each time it communicates with the centre. The LED remains on in the case of an alarm and indicates it to the Fire Centre. The direction of each module will be assigned using rotating selectors.
Consumption: Contacts:
7.6 mA on alarm, 1.45 mA in normal conditions. NA/NC, 2A to 28Vdc, 0,35 power factor.
109
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
Environmental conditions:
Temperature: -10 to 49C Humidity: 10 to 93%, not condensed.
Dimensions: Certifications:
185mm (height) x 147mm (width) x 25mm (depth) Complies with standards EN 54.
11.3.3.3 Programmable button. M700KAC-IFF/C

Manual alarm button assembled on a plastic red box made with impact resistant synthetic material. It will be resettable and will have an in built short circuit isolator. It will have a plastic cover or similar and shall have a key for testing. It will be surface mounted. Certified in accordance with EN54 part 11. It shall have extractable terminals to facilitate installation. The direction of each button will be assigned using rotating selectors. The button will have an LED that flashes each time it communicates with the centre. This LED will go remain on when an alarm condition is detected. Protection level IP44.
Technical Characteristics (Monitor) Module:
Consumption Temperature conditions:
7.6 mA on alarm, 160 A in normal conditions Temperature: -10 to 49C Humidity: 10 a 93%, non condensing
Certifications:
Complies with standards EN54.
110
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
11.3.4 Infrared barriers 11.3.4.1 Infrared Light reflection analogical smoke sensor
The linear optic beam reflector type analogical smoke sensorLPB700T is compatible with all of the Notifier ID Seriescentres. Based on the principle of darkening, it uses an infrared light beam. Optic beam smoke sensors are especially appropriate for the protection of large areas, for example: industrial warehouses, theatres, buildings with very high roofs where the installation of point sensors is not easy. The LPB700Tsensor includes a transmitter and a receiver in the same unit and can be connected directly to the analogical Notifier programmable loop without the need to have an external power source, which is a considerable saving in the cost of installation as it is only necessary to wire the emitter/receiver unit. The infrared transmitter generates an invisible ray of light that towards the high efficiency reflector and it returns the beam to the receiver of the LPB700Tsensor where an analysis is made of the signal received. The change in the power of the signal received determines the condition of the alarm. The sensitivity of the sensors can be adjusted between 25% and 50% darkness. This option makes it more adaptable to the different environments in which it is installed. As well as the four fixed alarm thresholds, the sensor can be programmed to adjust automatically to the environmental changes, within a known range of sensitivity, thus reducing the number of possible unwanted alarms that could be generated because of local activities in the protected area. The LPB700T sensor is equipped with automatic dirt compensation, which means that it will adapt its detection thresholds according to the signals received from the beam caused by environmental contaminants. Once the sensor reaches its compensation limit, the panel can identify and signal this condition.
111
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD LPB700T lineal beam analogical reflection smoke sensor with an integrated sensitivity test function.
Operating voltage Consumption Idle Alarm Alignment Environmental Conditions
15-32 Vdc (15-28 Vdc with isolators) 2 mA. 8.5 mA 20 mA Temperature -30 to 55C Humidity 10% to 95% without condensation
Sensitivity Certifications
6 levels of sensitivity. Complies with standard EN54/12
11.3.5 Warning elements 11.3.5.1 Alarm siren and loop flash. AWSB32/R/R-I
Siren with flash and isolator included, individually programmable, connected directly to the communications loop of the analogical systems. Two rotating selectors are used for direction. It will use the supply of the analogical loop. Certified in accordance with the requirements of EN54 standard, Part 3. 3 different volume adjustments can be selected using the micro switch. Capability for 32 different tones. The ABSB32/W/C-I model will allow for a base to be assembled on the siren forming a sensor-siren set. AWSB32/R/R-I.Supplied from analogical loop. Compatible with ID50, ID60, ID3002 and ID3000 centers
112
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Operating voltage Consumption Sound power Selectable sounds
15 a 33 Vdc +/- 25% AWSB32/R/R 5 mA 83 - 103 dBA Continuous buzzing Rapid frequency Slow frequency
Temperature conditions: Humidity Certifications
Temperature: -10 to 60 C 10 to 93%, not condensed Complies with standard EN 54, BASEFA
11.3.6 Accessories 11.3.6.1 Auxiliary power supplies . HLSPS50

The power supplies will be autonomous, providing auxiliary backup supply to the fire control systems that cannot be supplied from the main power supply on the fire control panel due to a lack of capacity or to avoid power losses along the cables. They will have batteries through which in the case of a temporary loss of the main supply the power supply is maintained. In this way the correct operation of the equipment that requires 24 vdcsupply is guaranteed in an alarm. This includes optic and acoustic announcers, electromagnetic retainers, extinguishing circuits, etc. The power sources will be connected and controlled by a microprocessor which supervises the supply, indicates any type of failure or irregularity and are protected against short circuits. They will have outlets so that they can be monitored from the fire control panel. Characteristics: Input voltage 230 V ~ 10% 50/60 Hz
113
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Maximum absorbed current 0.5 A; 0.9 A; 1.8 A Output voltage 27.6 V 1% Nominal current 1.4 A2.5 A5.0 A Maximum current supplied 1,2 A; 2.0 A; 4.0 A Maximum current per output 1.8 A Autonomy with a 2A charge 8 hours Battery box 2 x (12 V 17 Ah) Voltage thresholds: 22 V to 34 V Charger cut off threshold 19 V Operating temperature 5 to 40 C Isolation level Class I
11.3.6.2 Fire resistant cable . 2x1,5 LHR

It must be capable of resisting the effects of the fire for at least 30 minutes as indicated in standard UNE 23007-14 section A.6.11.3. The cable will be red and will be made of flexible polished copper, class 1, fire resistant, free from halogens, low smoke emission and low corrosiveness. Characteristics: Class 1 polished copper wire Silicon isolator Nominal isolation thickness 0.7 Drainage of rigid tinned copper 0.50 mm2.
Electrical resistance of the wire at 20 C ( /Km) 13.1
114
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Electrical resistance of the isolation at 20 C ( /Km) Capacity between wires (pf/m) 130 Characteristic impedance ( ) 50 20
11.3.7 Gas detection systems 11.3.7.1 Flammable gas sensor . SMART 3

The flammable gas sensor will be designed to act in atmospheres in which the main component is air. The presence of combustible substances will be expressed in % of the lower explosiveness limit (%LEL). The sensor shall be catalytic and semi wire type will not be accepted. It will admit watertight assembly (DUST IP55) and fireproof assembly (EXD) in compliance with ATEX standards. It shall include an 8 bit microprocessor for the Management of the following algorithms: Self diagnosis to guarantee the correct operation of all parts of the sensor. Zero level control to compensate the variations due to atmospheric conditions. Digital filter of the values obtained and hysteresis cycle
TECHNICAL CHARACTERISTICS: Resolution Work temperature Sensor Measuring range Power Catalytic or Electrochemical 0-100% LIE or 999 ppm according to the scale 12-24 Vdc +/- 15% Consumption 180 mA max. at 12 Vdc -10 C to 55 C (Catalytic) Relative humidity Air speed 1024 points 20% a 90% a 40 C
< 6 m/s
115
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Stability time Repetition < 1 hour +/- 1.5 % F.S.
116
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
12 ELECTRICAL GENERATING SYSTEM 12.1 GENERAL DESCRIPTION

The power plant will consist of twenty-six generators of 1 MW and 400V that supply electric power to a 33 kV network through a power line from a switching substation The connection point with MV distribution network begins in the incoming switchgear stall. It is a room which houses the input cabinet and two additional cabinets for protection of insulation transformers. Because of existing short circuit power of the public network nd potential increase in the future, it was decided to install 2 insulation transformers of 35 MVA and 33.000/33.000 V. One of them will be for stand-by. From these transformers two lines are connected to a main cabinet room. These lines enter in a protection cabinet in which busbars are connected to the protection cabinet of 13 step-up transformers for gensets and one protection cabinet for auxiliary services of power plant. The step-up transformers are provided in low voltage end with two connection busbars. Step-up transformers are of 2500/1250/1250 KVA and 33000/400-400V. Each busbar is connected to a genset. Each genset is operated through a control and protection switchboard cabinet in which a system for synchronization with network and management switch is located.
12.1.1 Connection line to company power substation of 33 kV

The connection line to the overhead power line of the company consists of a circuit provided with 3(2(1x240) mm2 Cu 19/33 kV CU/XLPE/CU TAPE/PVC/AWA/PVC cables. The line will be laid in pipes from the substation. The line will come protected against overvoltage from the substation. Main features of cables: 1) Insulation: .......................................................................................... 19/33 kV 2) Cross-section (mm2):................................................................................240
117
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 3) Number of cables per phase: ...................................................................... 2 4) Approximate permissible current (A): .................................................750 5) Conductor: .......................................................... Stranded Copper Wires 6) Conductor screen ....................................... Semi-conductive compound 7) Insulation: ............................................ Cross-linked polyethylene (XLPE) 8) Insulation screen ......................Strippable Semi-conducting compound 9) Screen Layer ........................................................................... Copper Tape. 10) Separation sheath ............................................................ Polyvinyl chloride 11) Armor .................................................................................. Aluminum wires 12) Binder............................................................................................ Binder tape 13) Outer sheath ...................................................... Polyvinyl chloride - Black
12.1.2 Incoming switchgear stall

The line from the substation enters in C17cabinet, and is connected to the busbars in protection cabinet for the two insulation transformers of 35 MVA. The cabinets will be of compact type with all equipment inside a metal enclosure. The insulation voltage is 36 kV. The main characteristics of these cabinets are the following:: 1) Insulation voltage (kV) ................................................................................ 36 2) Rated current of switchgear cabinets (A) ......................................... 1000 3) Rated current of main busbars (A)..................................................... 1000 4) Rated current of output switches (A) ............................................... 1250 5) Rated short-time withstand current1 sec. (kA) ................................31,5 6) Insulation level at industrial frequency 1 min. (kV).............................. 70 7) Insulation level at lightning pulse (kV) ..................................................170
118
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The Cabinets are modules of medium voltage with air insulation, metal enclosure and built according to IEC-62271-200. Nominal performance values are guaranteed for the following environment conditions: minimum environment temperature - 5 C, maximum environment temperature + 40 C, maximum relative humidity 95%(without condensation). The operation voltage of auxiliary equipment in cabinets is the following: Operation voltage of auxiliary system + protection equipment: 48Vdc Operation voltage of load engines-springs: 230 Vac Operation voltage of indoor lighting: 230Vac Operation voltage of condensation prevention system: 230Vac
12.1.3 Line from protection cabinets to insulation transformers

The connection line between protection cabinets in line input room and the transformer consists of a circuit for each transformer, provided with3(2(1x240) mm2 Cu 19/33 kV CU/XLPE/CU TAPE/PVC/AWA/PVC. cables The line will be laid in pipes from the input switchgear stall. Main features of cables: 1) Insulation: .......................................................................................... 19/33 kV 2) Cross-section (mm2):................................................................................240 3) Number of cables per phase: ...................................................................... 2 14) Approximate permissible current (A): .................................................750 4) Conductor: .......................................................... Stranded Copper Wires 5) Conductor screen ....................................... Semi-conductive compound 6) Insulation: ............................................ Cross-linked polyethylene (XLPE) 7) Insulation screen .................... Strippable semi-conductinve compound 8) Screen Layer ......................................................................... Copper tape.
119
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 9) Separation sheath ............................................................ Polyvinyl chloride 10) Amour.................................................................................. Aluminum wires 11) Binder............................................................................................ Binder tape 12) Outer sheath ...................................................... Polyvinyl chloride - Black
12.1.4 Insulation transformer 35 MVA 33/33 kV

Two insulation transformers will be installed to limit short circuit power inside the power plant. They cannot be simultaneously operated One transformer is for stand-by. The main features are the following: 1) Rated capacity (kVA) ONAN:......................................................... 35.000 2) Rated voltage (KV) HV side ...................................................................... 33 3) Rated voltage (KV) LV side ....................................................................... 33 4) Tap voltage HV side (%) ................................................................. 8x1,25 5) Connection ................................................................................ Delta wye 6) Vector Diagram ................................................................................... Dyn11 7) Impedance voltage(%) at 75C ................................................................. 12 8) Winding material (HV/LV):................................................................ Cu/Cu 9) Insulation level of winding (kV) Impulse (HV/LV) ......................170/170 10) Insulation level of winding (kV) AC (HV/LV) .................................. 70/70 11) Connection method ....................................................................Cable box 12) Efficiency (100% load) ........................................................................... 99,40 13) Efficiency (75% load) ............................................................................. 99,51 14) Efficiency (50% load) ............................................................................. 99,59 15) Efficiency (25% load) ............................................................................. 99,58
120
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Protection functions of transformers. All the alarms will be monitored by the plant control system: 1) Magnetic oil level gauge with alarm contacts 2) Dial type oil thermometer with alarm and trip contacts 3) Buchholz relay (flange type) with alarm and trip contacts. 4) Pressure relief device with trip contact. 5) On Load Tap Changer with Motor Drive. Remote control from the central power system to increase/decrease Tap position. 6) Neutral of insulation transformers will be connected to a separate ground system through a cabinet provided with resistance batteries and current transformers for detection of earth derivation current.
12.1.5 Lines between insulation transformer and transformer cabinet

The connection line between insulation transformers and transformer cabinet room consists of a circuit for each transformer provided with2(1x240) mm2 Cu 19/33 kV CU/XLPE/CU TAPE/PVC/AWA/PVC cables. The line will be laid in a pipe through the central gallery to transformer cabinet room. Main characteristics of cables: 1) Insulation: ..................................................................................... 19/33 kV 2) Cross-section (mm2): ..........................................................................240 3) Number of cables per phase: ................................................................ 2 15) Approximate permissible current (A): .................................................750 4) Conductor ...................................................... Stranded Copper Wires 5) Conductor screen ............................... Semi-conductinve compound 6) Insulation: ....................................... Cross-linked polyethylene (XLPE) 7) Insulations screen ............. Strippable semi-conductinve compound
121
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 8) Screen Layer ........................................................................ Coppertape. 9) Separation sheath ...................................................... Polyvinyl chloride. 10) Armor ............................................................................. Aluminum wires 11) Binder ...................................................................................... Binder tape 12) Outer sheath .................................................Polyvinyl chloride Black The rated current conducted by this circuit is 455 A. Cos 1. With voltage 33kV. The rated current conducted by this circuit is 568 A. Cos 0,8. With voltage 33kV.
12.1.6 Transformer cabinet room

A cabinet stall will be located in the center of power plant, housing the following equipment: Two cabinets of medium voltage, line and 35MVA transformers protection.(C15 and C16). Cabinets C15 and C16 will be interlocked . 13 Protection cabinets for generation (step-up) transformers. (C1 to C13) One protection cabinet for power plant auxiliary services transformer (C14). The cabinets will be of compact type with the equipment located inside a metal enclosure. Insulation voltage 36kV. Equipped with powered automatic circuit breakers and line disconnector switches with earthingswitch . Main features: 1) Insulation voltage (kV) ................................................................................ 36 2) Nominal current of the switchgearcabinets (A) .................................630 3) Nominal current of main busbars (A) ..................................................630 4) Nominal current of output switches (A) .............................................630 5) Rated short-time withstand current 1 sec. (kA) .................................. 25 6) Insulation level at industrial frequency 1 min. (kV).............................. 70 7) Insulation level at lightning pulse (kV) ..................................................170
122
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The cabinets are modules for medium voltage, with air insulation, metal enclosure and built according to IEC-62271-200. Nominal performance values are guaranteed for the following environmental conditions: minimum environment temperature - 5C, maximum environment temperature + 40C, maximum relative humidity 95%(without condensation). The operation voltage of auxiliary equipment in the cabinets is the following: Operation voltage of auxiliary system + protection equipment: 48Vdc Operation voltage of load engines-springs: 230 Vac Operation voltage of indoor lighting: 230Vac Operation voltage of the condensation preventing equipment: 230Vac
12.1.6.1 Output switch cabinets and protection of transformer 35 MVA

There are two output cabinets housing measurement and protection equipment for transformers of 35 MVA (C15 y C16) consisting of: 1) One three-pole breaker circuit breaker of the following characteristics: a) Nominal voltage (kV) .......................................................................... 36 b) Nominal current (A) .........................................................................630 c) Breaking capacity (kA) ........................................................................ 25 d) Opening time of contacts (ms) ......................................................... 60 2) One three-pole breaker line disconnector switch of the following characteristics: a) Nominal voltage (kV) .......................................................................... 36 b) Nominal current (A) .........................................................................630
123
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD c) Location ......................................................................................... Indoor 3) Three current transformers of the following characteristics: a) Transformation ratio (A) ............................................. 1000 / 1-1-1A b) First secondary .................................................................20 VA Cl 0,5 c) Second secondary ........................................................... 20 VA 10P10 d) Third secondary .............................................................. 20 VA 10P10 e) Rated voltage (kV) ............................................................................... 36 f) Location ......................................................................................... Indoor
4) For both protection cabinets there are three voltage transformers of the following characteristics: a) Transformation ratio (V)........................ 33.000:3 / 100: 3 -100:3 b) Power (VA) ........................................................................................... 20 c) Accuracy class...................................................................................... 0,5 d) Rated voltage (kV) ............................................................................... 36 e) Location ......................................................................................... Indoor 5) One earthing switch, interlocked with the line disconnector switch. 6) One set of voltage collectors to control voltage presence. 7) One ferroresonantresistance for closure of delta circuit in one secondary voltage transformer. These cabinets are equipped with the following equipment: 1) One protection relay whose functions are the following:
124
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD a) 50 Instant overcurrent b) 51 AC Time overcurrent relay c) 51N AC Neutral Time overcurrent relay d) 67 AC Directional overcurrent relay e) 67N AC neutral directional overcurrent relay f) 87 Differential protective relay
12.1.6.2 Protection switchgear cabinets or generation transformers and Aux. S.

There are 14 protection cabinets for generation transformers and auxiliary services transformer in power plant, consisting of:: 1) One three-pole automatic circuit breaker of the following characteristics: a) Nominal voltage (kV) .......................................................................... 36 b) Nominal current (A) .........................................................................630 c) Breaking capacity (kA) ........................................................................ 25 d) Opening time of contacts (ms) ......................................................... 60 2) One three-pole line disconnect or switch of the following characteristics: a) Nominal voltage (kV) .......................................................................... 36 b) Nominal current (A) .........................................................................630 c) Location ......................................................................................... Indoor 3) Three current transformers of the following characteristics (for the genset transformers):
125
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD a) Transformation ratio (A) ...........................................................600 / 1 b) First secondary ................................................................. 20 VA 10P10 c) Assigned voltage (kV).......................................................................... 36 d) To be installed in the wiring. 4) Three current transformers (for the auxiliary services transformer) a) Transformation ratio (A) ...........................................................300 / 1 b) First secondary ................................................................. 20 VA 10P10 c) Assigned voltage (kV).......................................................................... 36 5) One earthing switch, interlocked with the line disconnector switch.. 6) One set of voltage collectors for control of voltage presence. These cabinets are equipped with the following items: 2) One protection relay having the following functions: a) 50 Instantaneous overcurrent b) 51 AC Time overcurrent relay
12.1.7 Lines from protection cabinets to power generation transformers and auxiliary services in the plant.
The line connecting protection cabinets at the input room and transformers consists of one circuit per transformer provided with 3(1x95) mm2 Cu 19/33 kV CU/XLPE/CU TAPE/PVC/AWA/PVC cables. The line is laid in a cable pipe from central gallery to transformer. Main characteristics of cables: 1) Insulation: .......................................................................................... 19/33 kV
126
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 2) Cross-section (mm2):.................................................................................. 95 3) Number of cables per phase: ...................................................................... 1 4) Approx. permissible current (A): ..........................................................235 5) Conductor: ........................................................... Stranded Copper Wires 6) Conductor screen ..................................... Semi-conductinve compound 7) Insulation: ............................................ Cross-linked polyethylene (XLPE) 8) Insulation screen ................... Strippable Semi-conductinve compound 9) Screen Layer ............................................................................ Copper tape. 10) Separation sheath ........................................................... Polyvinyl chloride. 11) Armor .................................................................................. Aluminum wires 12) Binder............................................................................................ Binder tape 13) Outer sheath ......................................................Polyvinyl chloride Black The current conducted by these circuits is 43,73 A (Voltage 33kV)
12.1.8 Generation transformers of 2500 kVA 33/0,4/0,4 kV

13 step-up transformers of 33000/400/400V and 2500 kVA, two windings of 1250 KVA each one. Main features: 1) Rated capacity (kVA) ONAN:........................................2500/1250/1250 2) Cooling ................................................................................................ONAN 3) Rated voltage (KV) HV side ...................................................................... 33 4) Rated voltage (KV) LV 1 side................................................................... 0,4 5) Rated voltage (KV) LV 2 side................................................................... 0,4 6) Tap voltage (KV) HV side (%) .......................................................... 2x2,5
127
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 7) Connection (HV/LV/LV) ................................................Delta - wye - wye 8) Vector Diagram (HV/LV/LV) ................................................... Dyn11yn11 9) Impedance voltage(%) (HV/LV) .............................................................. 5,4 10) Impedance voltage(%) (LV1/LV2) ............................................................. 9 11) Winding material (HV/LV):................................................................ Cu/Cu 12) Insulation level of winding (kV) Impulse (HV/LV/LV) .................. 170/-/13) Insulation level of winding (kV) AC (HV/LV/LV) ........................... 70/3/3 14) Connection method ....................................................................Cable box The transformers have a DGPT2 relay having the following protection functions: 1) 26 thermal control devices 2) 63 Pressure relay 3) 71 level relay
12.1.9 160 kVA 33/0,4 kV transformer for auxiliary services

Transformer of 33000/400V, 160 kVA to supply power to auxiliary services in the plant. Main features: 1) Rated power (kVA) ONAN: .................................................................160 2) Cooling ................................................................................................ONAN 3) Rated voltage (KV) HV end ...................................................................... 33 4) Rated voltage (KV) LV end....................................................................... 0,4 5) Connection (HV/LV).................................................................. Delta - wye 6) Vector Diagram (HV/LV/LV) ............................................................ Dyn11 7) Impedance voltage (%) (HV/LV)................................................................ 4 8) Winding material (HV/LV):................................................................ Cu/Cu
128
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 9) Connection method ....................................................................Cable box The transformer has a relay 26 thermal control device.
12.2 GROUNDING GRID

For protection against accidental contacts of persons with energized circuits, a grounding grid is defined with the features specified in the plan Diagram of Buried grounding grid distribution 24-01. This grid has been designed to provide a safety system for persons and also to ensure good conductivity with the ground so all protection devices will correctly operate. In general, the grounding grid must comply with the following requirements: 1) The grounding grid must be buried at 800 mm of depth. 2) Will consist of naked copper wire of 70 mm2 section. 3) Steel and copper rods 16x1800 mm will be used. 4) Every connection of the buried grid will be made using thermo welding. 3) In the plan 24-02 Grounding grid typical details are showed the construction
details of the grounding grid. The distribution of the grounding grid is according a TN-S ear thing scheme. Every metal pieces unbound with the main circuits, and every devices and equipment installed will be connected to the protection grounding grid Cable bridges of 50 mm2 will be made between the buried grid and the reinforcement of the concrete structure. A surface grounding grid over the trays will be made, formed by naked copper wires of 50 and 35 mm2 that will be connected with the buried grounding grid through the connection bars. Cable bridges of 35 mm2 will be made from surface grid up to the bars of grounding protection, casing of cabinets, doors, metal closures, etc. Therefore, protection grounding grid will be connected with the following items:
129
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Frames and casings of the operation devices. Pipes, trays and metal structures. The whole enclosures of metal cabinets. Grid closures (if it exists) and protection of transformer and rails. Structures and reinforcements of the different buildings. Grounding grid for HV cables. The service grounding will be connected with the general grounding grid. Also, the secondary of the measurement instruments will be connected to that system (voltage and current transformers).
Every item in the Regulation and Metering Station (R.M.S.) located between dielectric joints of input and output, must be connected permanently with the same electric potential and with the ground, with a resistance lower than 20 ohms an according with the allowed in the current standards. That grounding outlet only must be used by the R.M.S, so this grounding grid is separated from the general and lightning grounding grids of the power plant. This grounding grid will be formed by three rods installed with a minimum distance of 15 meters of the general and lightning grounding grids. The neutral of the insulation transformers will be connected to ground outlet. This grounding grid will be formed by three rods installed with a minimum distance of 15 meters of the general and lightning grounding grids.

This project was completed in compliance with the following standards: IEC 60129, Alternating current circuit breakers and ground-fault interrupters. EN 60265-1, high-voltage switches. Part 1: switches for rated voltages above 1 kV and less than 52 kV. EN 50102, degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code).
130
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD IEC 60076, including all of its parts, power transformers. Application guide. EN 60044, including all of its parts, instruments transformers. EN 60099, including all of its parts, surge arresters.
12.4 SUPPORTING CALCULATIONS 12.4.1 Short circuit

For the calculations of the current that causes a short circuit, it will be taken into account the short circuit power of M.V. network, whose value have to be provided by the electric company. Due to lack of that value, we have assumed that it is about 2.000 MVA. For this calculation was used the impedance method with the following starting data: Table 15. Short circuit calculations
Network impedance in the connection point Data: Scc = UAT = 2000 MVA 33 kV
Connection from station to transformer of 35 MVA Data: Section = 240 mm2 Length = 0,34 Km Type= N cond/phase Cu ) 2
Inside impedance of the transformer of M.V. / L.V.. Data: %Ucc = 12 % U20 = Sn = Cos = n= 33000 V 35000 kVA 0,8 1
Connection from 35 MVA transformer to transformer cabinet room Data: Section = 240 mm2
131
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Length = Type= N cond/phase 0,1 Km Cu ( Cu Al) 2
Connection from transformer cabinet room to 2,5 MVA transformer Data: Section = 95 mm2 Length = 0,02 Km Type= N cond/phase Cu ( Cu Al) 1
Inside impedance of the M.V. / L.V. transformer Data: %Ucc = U20 = Sn = Cos = Resistive drop n= Connection from transformer to genstet Data: Section = Length = Type= No. of wires =
5,4 % 400 V 2500 kVA 0,8 0,00 % 1
240 mm2 12 m Cu ( Cu Al) 4
Genset Data: Pn = Xsubt = Un = 1250 kVA 13,2 % 400 V
The breaking capacity needed for the protection cabinets of the genset transformers is the value of a three-phase short circuit occurred in the circuit of the power plant auxiliary services.
Short circuit current in cabinet bars XE = RE = ZE = ICC = 2629,29 m 57,328 m 2,630 7,978 kA
132
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD The short circuit current in busbars in transformer cabinet room is 8 kA. These cabinets have a breaking capacity of 25 kA.
12.4.2 Grounding grid calculations 12.4.2.1 Maximum grounding voltage and extinguishing time
A ground mat will be provided for protection against incidental contacts. This ground mat will be designed to ensure full operator protection and provide proper grounding, ensuring correct operation of all protection devices. To verify the ground mat, the following calculations have been performed for substantiation purposes: First, network fault current is determined. To limit the MV network fault current the neutral of the MV isolation transformers will be grounded with a 381 resistor. Where: Id = network fault current - A Rt = grounding resistance- 381 U = rated voltage - 33.000 V Xn = grounding reactance -
Id
The result obtained is: Id = 50 A
U 3 (R t
2
Xn
12.4.2.2 Grounding resistance

The underground ground grid consists of a 70 mm2 naked copper wire and ground rods drove into the ground to a depth of 0.8m. Considering a ground resistivity of 100 .m
133
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Network electrical data Network frequency Environment temperature Fault removal time Existing voltage levels 50Hz 35 C 0.5 s 33 kV
Ground data Thickness of surface layer Resistivity of surface layer Ground resistivity 0.1 m 3000m 100 m
Geometrical data Total area occupied by ground mat Ground mat depth Length of ground mat larger side Length of ground mat smaller side Number of wires parallel to ground mat larger side Number of wires parallel to ground mat smaller side Average spacing between parallel wires Wire length Number of ground rods Ground rod length 6848m2 0,8m 107m 64 m 4 8 5m 2400 m 27 1,8 m
12.4.2.3 Determination of grounding resistance

1.Grounding resistance.
134
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
Rt
Where:
4.r
4 L l
= ground resistivity in ohms per meter L = total length of underground wires
l = total length of ground rods. 34x1.8=61,2 m

r = radius of a circle equivalent to the area covered by the ground mat
Rt
100 4 x 46,7
4 x 100 0,698 2400 48,6
The ground grid provided in the plant will be connected to the ground grid of existing lighting arresters, thus improving grounding resistance.
12.4.2.4 Allowed maximums voltages to ground rules according

To verify the ground mat, the following calculations have been performed for substantiation purposes: The maximum permissible step and touch voltages are the following: 1) Step and touch voltages at the area in which the transformers are located: Where: s = concrete resistivity - 3.000 . m = ground resistivity - 100 . m t = opening time - 1 s n=1 k = 72 Vp= step voltage - V Vc= touchvoltage - V
135
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Step voltage:

Vp 6 s 10 k 1 n 1.000 t
Touchvoltage:
Vc 1,5 s k 1 n 1.000 t
From which the following is obtained:
Vp
10 72 6 3000 1 =13.680 V 1.000 1 72 1,5 3000 1 = 396 V 1.000 1
Vc
12.4.2.5 Determination of step and touchvoltages

To determine fault and ground currents we should take into account the way in which the neutral is connect to ground in MV section. For networks with the neutral connected to ground, either rigid or through an impedance, we should consider the applied contact or step voltage and the grounding current (IE) which causes an increase of grounding system potential. Step and touchvoltages are defined by the following equations:
Vp Kp . Ki . . I L
Vc
Kc . Ki . .
I L
Kp = 1/ ( 1/2h + 1/(D+N) + 1/2D + 1/3D +......+ 1/(N-1)D
136
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Ki = ( 0,65 + 0,172N) Kc= 1/2 Ln(D2 /16hd) + 1/ Ln [(3/4) (5/6) (7/8).........(2N-3/2N-2)] Where: D = Spacing between parallel wires h = Depth at which ground grid is buried d = Diameter of ground grid wires N = Maximum number of parallel wires in a direction for step voltage N = Geometric average value of wires in both directions for contact voltage = Ground resistivity L =Total length of buried wire The coefficients have the following values Kp = 0,324 Ki = 2,026 (for step voltage) Ki = 1,68 (for touch voltage) Kc = 1,74
Thus, the resulting step and touch voltages are the following:
Vp 0,324 . 2,026 .100 . 50 1,36V 2400
Vc
1,68 . 1,74 . 100.
50 2400
6,09V
137
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
12.4.2.6 Criteria for model validation

Step voltage: Up = 1,36 V < Touch voltage: Uc = 6,09 V < Uc max = 396 V All requirements are met Upmax = 13.680 V All requirements are met
12.5 TESTING & INSPECTION

Measurements and verifications that are to be performed at the commissioning stage 1. Wire identification 2. Measurements on ground grid 3. Measurements on transformer insulation a. MV MV 5000 VDC b. MV- LV5000 VDC c. MV G 5000 VDC d. LV- G 500 VDC The system is considered defective when a reading is below 1000 xV 1. Verification for correct setting of protection relays by means of the required test and related documentation. 2. Measurement of step and contact voltages at least on fencing, areas of frequent passage, transformers and especially on components that could transfer voltages to external areas.
138
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13 ANCILLARY SERVICES.LOW VOLTAGE SYSTEM. 13.1 GENERAL DESCRIPTION

The plant consist of 26 gen-sets spread over two buildings; 13 on each one The transformer secondaries are connected with the power switch-board of each gen-set by wires housed in tubes. In the power switchboard of each gen-set include the main switch that connects the genset to the grid and the feedings for the gen-set auxiliary equipment. There is also a main auxiliary switchboard in the social building feeded by the transformer of auxiliary services T14. From this switchboard, several local switchboards are feeded all around the plant
-SWITCHBOARD ENGINE ROOM 1 -SWITCHBOARD ENGINE ROOM 2 -CABINET ROOM SWITCHBOARD. ENTRANCE -CABINET ROOM SWITCHBOARD. GEN. CABINETS -R.M.S. SWITCHBOARD -ACCESS CONTROL SWITCHBOARD -WATER PUMPS SWITCHBOARDS (Future) -OIL PUMPS SWITCHBOARDS (Future) -WORKSHOP SWITCHBOARD
13.1.1 Connection from genset transformers up to genset switchboards and gensets

The power distribution line from each of the transformer secondaries at 400 volts to each power breaker will be installed under tube till the channel below the power switchboard of the gen-set. From the power switchboard to the gen-set the line goes through a tray within an inspectable channel The power distribution line consists of 4 cables by phase 240 mm2 Cu RV-K (XLPE insulated, PVC sheathed single core cable. Cable main characteristics: 1) Insulation: ........................................................................................... 0,6/1 kV
139
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD 2) Section (mm2): ............................................................................................240 3) Cables by phase: ............................................................................................ 4 4) Maximum intensity allowed (A): ......................................................... 1820 5) Material: ............................................................................................... Cooper 6) Nominal intensity. .............................................................................. 1804A The power breaker will be regulated at a maximum of 1820 A
13.1.2 Protection and operation switchboards of gensets

Each genset has an operation and control switchboard composed by two cabinet modules. The left module includes the power part of the switchboard composed basically by a main automatic circuit breaker for the shut-off and synchronism command of the genset and also a feeder to supply the auxiliary services of the genset. These auxiliary services can be supplied either from the genset generating power or from the power coming from Mains, being possible to choose one of these supplies by a manual switch included inside the panel. The right cabinet includes the protection and control devices of the auxiliary services and the genst controlling system. The genset will switch on through the following orders: Time programming. Ordered manually by de SCADAs operator. Control panel of each genset. The synchronism system will verify the synchronism at both sides of the connection switch and it will close automatically once the synchronism has been accomplished. The auxiliary services that are supplied directly from the genset control panels are those related with their cooling system. Table 16.P&CC
Circuit No. P&CC Description Conductor 3[4(1X240)]+G Description of protections CB4P 2000 A
140
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Description of protections GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 9-14A GV 3P 4-6,3A GV 3P 6-10A
Circuit No. P&CC-C1 P&CC-C2 P&CC-C3 P&CC-C4 P&CC-C5 P&CC-C6 P&CC-C7 P&CC-C8 P&CC-C9
Description AERO FAN 1 AERO FAN 2 AERO FAN 3 AERO FAN 4 AERO FAN 5 AERO FAN 6 MAIN CIRC. WATER PUMP AUX. CIRC. WATER PUMP AERO ROOM FAN
Conductor 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5 3(1X2,5)+G2,5
CB Masterpact circuit breaker GV Motor circuit-breakers.
13.1.3 General switchboard of power plant auxiliary services

The plant disposes of a general switchboard of distribution for electric power supply to the auxiliary services of the plant. The power supply up to this cabinet is through cable from the auxiliary services transformer (T14) formed by one cable per phase of 120 mm2 of copper RV-K 0,6/1kV. This cabinet has a molded case circuit breaker (MCB) of 250 A, and residual current adjustable deviceRH99 with toroidal transformer. Also, it has a network analyzer and overcurrent protection. Where the outputs are the following: Table 17. GSP switchboard
Circuit No. GSP-P1 GSP-P2 GSP-P3 GSP-P4 GSP-P5 GSP-P6 GSP-P7 Description SWITCHBOARD ENGINE ROOM 1 SWITCHBOARD ENGINE ROOM 2 CABINET ROOM SWITCHBOARD. ENTRANCE CABINET ROOM SWITCHBOARD. GEN. CABINETS R.M.S. SWITCHBOARD ACCESS CONTROL SWITCHBOARD OUTSIDE LIGHTING LAMPOST Wire 4(1X35)+G16 4(1X35)+G16 4(1X6)+G6 4(1X6)+G6 4(1X6)+G6 4(1X6)+G6 4(1X6)+G6 Description of protections MCCB4p 100A MCCB4p 100A MCCB4p 20A MCCB4p 25A MCCB4p 20A MCCB4p 25A MCCB4p 20A + RCCB 4p 25A
141
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Circuit No. Description of protections 300mA MCCB4p 20A + RCCB 4p 25A 300mA MCCB 4p 40A + RCCB 4p 40A 300mA MCCB 4p 40A + RCCB 4p 40A 300mA MCCB 4p 40A MCCB 4p 32A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A + RCCB SI type 2p 25A 300mA MCCB 2p 16A + RCCB SI type 2p 25A 300mA MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 4p 32A + RCCB 4p 40A 300mA MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB2p 10A
Description
Wire
GSP-P8
OUTSIDE LIGHTING. ENGINE ROOM FRONTAGE WATER PUMPS SWITCHBOARDS
4(1X6)+G6
GSP-P9
4(1X10)+G10
GSP-P10 OIL PUMPS SWITCHBOARDS GSP-P11 WORKSHOP SWITCHBOARD GSP-P12 RESERVE POWER OUTLET. MEETING ROOM AND GSP-P13 MANAGER OFFICE GSP-P14 POWER OUTLET. CONTROL ROOM. POWER OUTLET. VARIOUS AND CONTROL GSP-P15 ROOM GSP-P16 RESERVE GSP-P17 POWER OUTLET. VARIOUS DINING ROOM. GSP-P18 POWER OUTLET. DINING ROOM. GSP-P19 POWER OUTLET. DINING ROOM. GSP-P20 POWER OUTLET. BATHROOM. GSP-P21 POWER OUTLET. OUTSIDE. GSP-P22 RESERVE GSP-P23 UPS SCADA
4(1X10)+G10 4(1X10)+G10 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5
GSP-P24 FIRE-FIGHTING ALARM CONTROL POWER OUTLET. COMPUTERS MEETING ROOM MANAGER OFFICE POWER OUTLET. CONTROL ROOM COMPUTERS. POWER OUTLET COMPUTERS CONTROL ROOM POWER OUTLET COMPUTERS DINIDG ROOM RACK PHONE CONTROL UNIT RESERVE
2(1X2,5)+G2,5
GSP-P25 GSP-P26 GSP-P27 GSP-P28 GSP-P29 GSP-P30
2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 4(1X10)+G10 2(1X1,5)+G1,5 2(1X1,5)+G1,5 2(1X1,5)+G1,5 2(1X1,5) 2(1X1,5)+G1,5
GSP-P31 AIR CONDITIONING SWITCHBOARD GSP-L1 GSP-L2 GSP-L3 GSP-E1 GSP-L4 LIGHTING MEETING ROOM MANAGER OFFICE LIGHTING CONTROL ROOM DINING ROOM BATHROOM LIGHTING EMERGENCY LIGHTING FLUORESCENT LIGHTING TIGHT PORCH 1
142
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Circuit No. GSP-L5 Description of protections MCCB2p 10A
Description FLUORESCENT LIGHTING TIGHT PORCH 2
Wire 2(1X1,5)+G1,5
MCCB Thermal-magnetic miniature circuit breaker. RCCB= Residual current circuit breaker.
13.1.4 Engine room switchboard 1

Table 18. EN-1 switchboard
Circuit No. EN1-L1 EN1-L2 EN1-E1 EN1-L3 EN1-L4 EN1-L5 EN1-P1 EN1-P2 EN1-P3 Description HALL LIGHTING HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE RESERVE Wire 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X1,5) 2(1X2,5)+G2,5 2(1X2,5)+G2,5 4(1X16)+G16 Description of protections MCCB2p 10A + SR 2p 25A MCCB2p 10A + SR 2p 25A MCCB2p 10A MCCB2p 10A + SR 2p 25A MCCB2p 10A + SR 2p 25A MCCB2p 10A MCCB4p 63A MCCB2p 16A MCCB2p 16A
MCCB Thermal-magnetic miniature circuit breaker. SR= Step-Relay.
13.1.5 Engine room switchboard 2

Table 19. EN-2 switchboard
Circuit No. EN2-L1 EN2-L2 EN2-E1 EN2-L3 EN2-L4 EN2-L5 EN2-P1 EN2-P2 EN2-P3 Description HALL LIGHTING HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE RESERVE Wire 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X1,5) 2(1X2,5)+G2,5 2(1X2,5)+G2,5 4(1X16)+G16 Description of protections MCCB2p 10A + SR 2p 25A MCCB2p 10A + SR 2p 25A MCCB2p 10A MCCB2p 10A + SR 2p 25A MCCB2p 10A + SR 2p 25A MCCB2p 10A MCCB4p 63A MCCB2p 16A MCCB2p 16A
MCCB Thermal-magnetic miniature circuit breaker.
143
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD SR= Step-Relay.
13.1.6 Workshop switchboard

Table 20. WP switchboard
Circuit No. WP-L1 WP-L2 WP-L3 WP-E1 WP-P1 WP-P2 WP-P3 WP-P4 WP-P5 WP-P6 WP-P7 Description WORKSHOP LIGHTING WAREHOUSE LIGHTING OIL STORAGE LIGHTING EMERGENCY LIGHTING POWER OUTLET WORKSHOP POWER OUTLET WAREHOUSE POWER OUTLET WAREHOUSE RESERVE POWER OUTLET 3P+N+T 16A 400V RESERVE POWER SOCKET Wire 2(1X1,5)+G1,5 2(1X1,5)+G1,5 2(1X1,5)+G1,5 2(1X1,5) 2(1X2,5)+G2,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 4(1X2,5)+G2,5 4(1X10)+G10 Description of protections MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 4p 16A MCCB 4p 16A MCCB 4p 40A
MCCB Thermal-magnetic miniature circuit breaker.
13.1.7 Access control switchboard

Table 21. ACS switchboard
Circuit No. ACS-L1 ACS-L2 ACS-P1 ACS-P2 ACS-P3 ACS-P4 ACS-P5 Description ACCESS CONTROL LIGHTINT EMERGENCY RESERVE POWER OUTLET RESERVE POWER OUTLET COMPUTERS RESERVE AUTOMATIC GATE SWITCHBOARD Wire 2(1X1,5)+G1,5 2(1X2,5)+G2,5 2(1X2,5)+G2,5 4(1X6)+G6 Description of protections MCCB 2p 10A MCCB 2p 10A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 4p 10A + RCCB 4p 25A 300mA
MCCB Thermal-magnetic miniature circuit breaker. RCCB= Residual current circuit breaker.
144
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

This project was completed in compliance with the following standards: UNE 211435 Guidance on the selection of distribution cables for rated voltages up to and including 0,6/1 kV. UNE 21123 Industrial cables of rated voltage 0,6/1 kV. All parts UNE 21144 Electric cables. Calculation of the current rating. All parts UNE 36582 Rigid steel conduit, zinc coated for use in electrical raceway UNE-EN 50085 Cable trunking systems and cable ducting systems for electrical installations. All parts. UNE-EN 50086 Conduit systems for cable management. All parts. UNE EN 60309 Plugs, socket-outlets and couplers for industrial purposes. All parts. UNE-EN 60423 Conduit systems for cable management - Outside diameters of conduits for electrical installations and threads for conduits and fittings. UNE-EN 60439 Low-voltage switchgear and controlgear assemblies. All parts. UNE-EN 60598 Luminaires. All parts. UNE-EN 60947 Low-voltage switchgear and controlgear. All parts.
13.3 ELECTRICAL DESIGN & DEFINITION

The estimated power for all auxiliary services in the plant is 54 kW. The table below shows the relationship between power values and simultaneity coefficients considered for calculation purposes.
145
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Table 22. Electric power calculations

Circuit No. Description GSP SWITCHBOARD ENGINE ROOM 1 SWITCHBOARD ENGINE ROOM 2 CABINET ROOM SWITCHBOARD. ENTRANCE CABINET ROOM SWITCHBOARD. GEN. CABINETS R.M.S. SWITCHBOARD ACCESS CONTROL SWITCHBOARD OUTSIDE LIGHTING LAMPOST OUTSIDE LIGHTING. ENGINE ROOM FRONTAGE WATER PUMPS SWITCHBOARDS OIL PUMPS SWITCHBOARDS WORKSHOP SWITCHBOARD RESERVE POWER OUTLET. MEETING ROOM AND MANAGER OFFICE POWER OUTLET. CONTROL ROOM. POWER OUTLET. VARIOUS AND CONTROL ROOM RESERVE POWER OUTLET. VARIOUS DINING ROOM. POWER OUTLET. DINING ROOM. POWER OUTLET. DINING ROOM. POWER OUTLET. BATHROOM. POWER OUTLET. OUTSIDE. RESERVE UPS SCADA FIRE-FIGHTING ALARM CONTROL POWER OUTLET. COMPUTERS MEETING ROOM MANAGER OFFICE Load Pn (W) 53792,498 9760,56 9767,76 2500 4000 2500 1059,4 4500 3600 0 0 7470,3 0 3680 3680 3680 0 3680 3680 3680 3680 3680 0 1000 300 3680 Simultaneity coefficient Simult. 100,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 20,00% 20,00% 20,00% 70,00% 20,00% 20,00% 20,00% 20,00% 20,00% 20,00% 50,00% 100,00% 20,00%
146
Pn Switchboard(W) 53792 8785 8791 2250 3600 2250 953 4050 3240 0 0 6723 0 736 736 736 0 736 736 736 736 736 0 500 300 736
GSP-P1 GSP-P2 GSP-P3 GSP-P4 GSP-P5 GSP-P6 GSP-P7 GSP-P8 GSP-P9 GSP-P10 GSP-P11 GSP-P12 GSP-P13 GSP-P14 GSP-P15 GSP-P16 GSP-P17 GSP-P18 GSP-P19 GSP-P20 GSP-P21 GSP-P22 GSP-P23 GSP-P24 GSP-P25
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Circuit No. GSP-P26 GSP-P27 GSP-P28 GSP-P29 GSP-P30 GSP-P31 GSP-L1 GSP-L2 GSP-L3 GSP-E1 GSP-L4 GSP-L5 EN1-L1 EN1-L2 EN1-E1 EN1-L3 EN1-L4 EN1-L5 EN1-P1 EN1-P2 EN1-P3 EN2-L1 EN2-L2 EN2-E1 EN2-L3 EN2-L4 EN2-L5 EN2-P1 EN2-P2 Description POWER OUTLET. CONTROL ROOM COMPUTERS. POWER OUTLET COMPUTERS CONTROL ROOM POWER OUTLET COMPUTERS DINIDG ROOM RACK PHONE CONTROL UNIT RESERVE AIR CONDITIONING SWITCHBOARD LIGHTING MEETING ROOM MANAGER OFFICE LIGHTING CONTROL ROOM DINING ROOM BATHROOM LIGHTING EMERGENCY LIGHTING FLUORESCENT LIGHTING TIGHT PORCH 1 FLUORESCENT LIGHTING TIGHT PORCH 2 HALL LIGHTING HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE RESERVE HALL LIGHTING HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE Load Pn (W) 3680 3680 3680 500 0 0 518 1144 712,8 115,2 417,6 417,6 1461,6 1461,6 72 1461,6 1461,6 0 22170 0 0 1461,6 1461,6 72 1461,6 1461,6 0 22170 0 Simultaneity coefficient Simult. 20,00% 20,00% 20,00% 100,00% 0,00% 100,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 90,00% 20,00% 100,00% 90,00% 90,00% 90,00% 100,00% 90,00% 90,00% 100,00% 20,00% 100,00%
147
Pn Switchboard(W) 736 736 736 500 0 0 466 1030 642 104 376 376 1315 1315 65 1315 1315 0 4434 0 0 1315 1315 72 1315 1315 0 4434 0
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

Circuit No. EN2-P3 WP-L1 WP-L2 WP-L3 WP-E1 WP-P1 WP-P2 WP-P3 WP-P4 WP-P5 WP-P6 WP-P7 ACS-L1 ACS-L2 ACS-P1 ACS-P2 ACS-P3 ACS-P4 ACS-P5 Description RESERVE WORKSHOP LIGHTING WAREHOUSE LIGHTING OIL STORAGE LIGHTING EMERGENCY LIGHTING POWER OUTLET WORKSHOP POWER OUTLET WAREHOUSE POWER OUTLET WAREHOUSE RESERVE POWER OUTLET 3P+N+T 16A 400V RESERVE POWER SOCKET ACCESS CONTROL LIGHTINT EMERGENCY RESERVE POWER OUTLET RESERVE POWER OUTLET COMPUTERS RESERVE AUTOMATIC GATE SWITCHBOARD Load Pn (W) 0 417,6 1252,8 417,6 57,6 3680 3680 3680 0 11085 0 22170 306 0 3680 0 3680 0 0 Simultaneity coefficient Simult. 90,00% 90,00% 90,00% 90,00% 100,00% 20,00% 20,00% 20,00% 100,00% 10,00% 100,00% 10,00% 90,00% 100,00% 20,00% 90,00% 20,00% 90,00% 100,00% Pn Switchboard(W) 0 376 1128 376 58 736 736 736 0 1109 0 2217 275 0 736 0 48 0 0
148
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.3.1 Calculation of short-circuit current 13.3.1.1 Calculation of short-circuit current in generator panels
The maximum short-circuit current on busbars of generator panel depends on the shortcircuit current input by the grid through the transformer and the generator of this transformer through the contiguous LV windings.
Internal impedance of MV/LV transformer
Data:
MV-LV winding Ucc= U20 = Sn = LV-LV winding Ucc= U20 = Sn = 9 % 400 V 1250 kVA 5,4 % 400 V 1250 kVA
Engine-generator Data: Pn = Xsubt = Un = 1250 kVA 13,2 % 400 V
Short-circuit current in generator panels is 41,53 KA.
149
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.3.1.2 Calculation of short-circuit current in Auxiliary Services panel

The maximum short-circuit current on busbars of auxiliary services panel is determined by T14 transformer.
Internal impedance of MV/LV Data: %Ucc = U20 = Sn = 4 % 400 V 160 kVA
The maximum short-circuit current that could occur in auxiliary services line is 5,77 kA. The switchgear provided in auxiliary services panel will have protection devices with a breaking capacity above 5,77 kA.
13.3.2 Calculation of voltage drop

The rated voltage for the equipment to be installed in the plant is determined as a function of supply voltage and considering a maximum voltage drop in internal circuits of 3% for lighting system and 5% for other equipment, according to the requirements of LV regulations, For plants directly supplied at high voltage by means of a separate distribution transformer, the internal LV system will originate at the transformer outlet. In this case, the maximum permissible voltage drop is 4,5% for lighting system and 6,5% for other users.
13.3.2.1 Calculation of wire cross-section

(1) Current The currents circulating through the wires in three-phase and single-phase systems are determined from the following equations, respectively:
P I 3 U cos and
P U cos
where:
150
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD I: current (A) P: active power (W) U: rated power (V) cos : power factor (2) Voltage drop Voltage drop throughout the wires in three-phase and single-phase systems is determined from the following equations, respectively:
e 3 L I cos e S and
2 L I cos S ,
where: e: compound voltage drop (V) L: wire length (m) I: current in each phase or neutral (A) cos : power factor : wire electrical conductivity (m/ S: wire cross-section (mm2) The percentile value of voltage drop is: mm2)
e(%) 100
e(V ) U (V ) .
for Cu and Al
We have considered an electrical conductivity of 56 and 35 m/ respectively.
151
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.3.3 Voltage drop

Table 23.Voltage drop. Circuits of auxiliary services plant
D U% Tot 0,25% 0,25% 0,40% 0,53% 0,60% 0,11% 1,07% 0,73% 0,09% 0,09% 0,29% Nominal I(A) Supply System D U Tot 0,99 0,99 1,62 2,14 2,41 0,45 4,29 2,92 0,35 0,35 1,16 Length
Load Pn(W)
Circuit No.
Description
Description of protections
GSP-P1 GSP-P2 GSP-P3 GSP-P4 GSP-P5 GSP-P6 GSP-P7
SWITCHBOARD ENGINE ROOM 1 SWITCHBOARD ENGINE ROOM 2 CABINET ROOM SWITCHBOARD. ENTRANCE CABINET ROOM SWITCHBOARD. GEN. CABINETS R.M.S. SWITCHBOARD ACCESS CONTROL SWITCHBOARD
400 400 400 400 400 400
9760,56 9767,76 2500 4000 2500 1059,4 4500
17,61 17,62 4,51 7,22 4,51 1,91 6,50
60 60 80 70 130 15 110
4(1X35)+ G16 4(1X35)+ G16 4(1X6)+G 6 4(1X6)+G 6 4(1X6)+G 6 4(1X6)+G 6 4(1X6)+G 6 4(1X6)+G 6 4(1X10)+ G10 4(1X10)+ G10 4(1X10)+ G10
104 104 36 36 36 36 36
MCCB 4p 100A MCCB 4p 100A MCCB 4p 20A MCCB 4p 25A MCCB 4p 20A MCCB 4p 25A MCCB 4p 20A + RCCB 4p 25A 300mA MCCB 4p 20A + RCCB 4p 25A 300mA MCCB 4p 40A + RCCB 4p 40A 300mA MCCB 4p 40A + RCCB 4p 40A 300mA MCCB 4p 32A
0,64 0,64 1,27 1,79 2,07 0,10 3,94
0,16% 0,16% 0,32% 0,45% 0,52% 0,03% 0,99%
OUTSIDE LIGHTING LAMPOST GSP-P8 OUTSIDE LIGHTING. ENGINE ROOM FRONTAGE
400 3600 400 0 0,00 0 5,20 90
36
2,58
0,64%
GSP-P9 WATER PUMPS SWITCHBOARDS GSP-P10 OIL PUMPS SWITCHBOARDS GSP-P11 WORKSHOP SWITCHBOARD 400 400 400
50
0,00
0,00%
0 7470,3
0,00 11,98
0 25
50 50
0,00 0,81
0,00% 0,20%
152
D U%
Imax
Wire
DU
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

D U% Tot 3,40% 2,47% 2,47% 3,40% 3,17% 3,40% 4,22% 3,64% 0,38% 0,19% 2,47% 1,89% 1,89% 2,47% Nominal I(A) Supply System D U Tot 7,83 5,69 5,69 7,83 7,29 7,83 9,70 8,36 0,88 0,45 5,69 4,36 4,36 5,69 Length Load Pn(W) D U% 3,25% 2,32% 2,32% 3,25% 3,02% 3,25% 4,07% 3,48% 0,23% 0,04% 2,32% 1,74% 1,74% 2,32%
153
Circuit No.
Imax
Wire
Description
Description of protections MCCB 4p 32A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A + RCCB 2p 25A 300mA MCCB 2p 16A + RCCB 2p 25A 300mA MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A
GSP-P12 RESERVE POWER OUTLET. MEETING ROOM GSP-P13 AND MANAGER OFFICE GSP-P14 POWER OUTLET. CONTROL ROOM. POWER OUTLET. VARIOUS AND GSP-P15 CONTROL ROOM GSP-P16 RESERVE POWER OUTLET. VARIOUS DINING GSP-P17 ROOM. GSP-P18 GSP-P19 GSP-P20 GSP-P21 POWER OUTLET. DINING ROOM. POWER OUTLET. DINING ROOM. POWER OUTLET. BATHROOM.
400 230 230 230 230 230 230 230 230 230 230
0 3680 3680 3680 0 3680 3680 3680 3680 3680 0 1000
Error 16,00 16,00 16,00 Error 16,00 16,00 16,00 16,00 16,00
0 28 20 20 0 28 26 28 35 30 0
POWER OUTLET. OUTSIDE. GSP-P22 RESERVE GSP-P23 UPS SCADA GSP-P24 GSP-P25 GSP-P26 GSP-P27 GSP-P28 FIRE-FIGHTING ALARM CONTROL POWER OUTLET. COMPUTERS MEETING ROOM MANAGER OFFICE POWER OUTLET. CONTROL ROOM COMPUTERS. POWER OUTLET COMPUTERS CONTROL ROOM POWER OUTLET COMPUTERS DINIDG ROOM
2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5
0 22 22 22 0 22 22 22 22 22 0 22
7,48 5,34 5,34 7,48 6,95 7,48 9,35 8,01 0,53
4,35
230 300 230 230 230 230 230 3680 3680 3680 3680 16,00 16,00 16,00 16,00 20 15 15 20 1,30 5
22 22 22 22 22
0,10 5,34 4,01 4,01 5,34
DU -
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

D U% Tot 0,30% 0,09% 0,65% 1,27% 1,18% 0,43% 0,55% 0,45% 3,20% 3,33% 0,66% 2,12% 3,46% 1,45% 3,20% Nominal I(A) Supply System D U Tot 0,68 0,35 1,49 2,91 2,72 0,98 1,27 1,04 7,37 7,66 1,53 4,87 7,95 5,80 7,37 Length Load Pn(W) D U% 0,14% 0,00% 0,50% 1,12% 1,03% 0,28% 0,40% 0,30% 2,77% 2,90% 0,23% 1,69% 3,03% 1,20% 2,77%
154
Circuit No.
Imax
Wire
Description
GSP-P29
RACK PHONE CONTROL UNIT GSP-P30 RESERVE GSP-P31 GSP-L1 GSP-L2 GSP-L3 GSP-E1 GSP-L4 GSP-L5 EN1-L1 EN1-L2 EN1-E1 EN1-L3 EN1-L4 EN1-L5 EN1-P1 EN1-P2 EN1-P3 EN2-L1 AIR CONDITIONING SWITCHBOARD LIGHTING MEETING ROOM MANAGER OFFICE LIGHTING CONTROL ROOM DINING ROOM BATHROOM LIGHTING EMERGENCY LIGHTING FLUORESCENT LIGHTING TIGHT PORCH 1 FLUORESCENT LIGHTING TIGHT PORCH 2 HALL LIGHTING HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE RESERVE HALL LIGHTING
230 230 400 230 230 230 230 230 230 230 230 230 230 230 230 400 230 230 230
500 0 0 518 1144 712,8 115,2 417,6 417,6 1461,6 1461,6 72 1461,6 1461,6 0 22170 0 0 1461,6
2,17
10 0
0,00 2,25 4,97 3,10 0,50 1,82 1,82 6,35 6,35 0,31 6,35 6,35
0 20 20 30 50 20 15 65 68 68 40 71 0
32,00
70 0 0
6,35
65
2(1X2,5)+ G2,5 4(1X10)+ G10 2(1X1,5)+ G1,5 2(1X1,5)+ G1,5 2(1X1,5)+ G1,5 2(1X1,5) 2(1X1,5)+ G1,5 2(1X1,5)+ G1,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X1,5) 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 4(1X16)+ G16 2(1X2,5)+ G2,5
22 0 50 16 16 16 16 16 16 22 22 16 44 22 0 66 0 0 22
MCCB 2p 16A MCCB 2p 16A MCCB 4p 32A + 4p 40A 300mA MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A MCCB 4p 63A MCCB 2p 16A MCCB 2p 16A MCCB 2p 10A + SR 2p 25A
0,33 0,00 1,15 2,57 2,37 0,63 0,92 0,69 6,38 6,67 0,54 3,88 6,97 4,81 6,38
DU
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

D U% Tot 3,33% 0,66% 2,12% 3,46% 1,45% 0,66% 1,73% 0,94% 0,58% 1,32% 1,55% 3,75% 0,70% 0,97% 0,28% Nominal I(A) Supply System D U Tot 7,66 1,53 4,87 7,96 5,80 1,52 3,98 2,17 1,33 3,03 3,56 8,64 2,79 3,88 0,65 Length Load Pn(W) D U% 2,90% 0,23% 1,69% 3,03% 1,20% 0,16% 1,23% 0,44% 0,08% 0,81% 1,05% 3,25% 0,41% 0,68% 0,09%
155
Circuit No.
Imax
Wire
Description
Description of protections MCCB 2p 10A + SR 2p 25A MCCB 2p 10A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A + SR 2p 25A MCCB 2p 10A MCCB 4p 63A MCCB 2p 16A MCCB 2p 16A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 10A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 4p 16A MCCB 4p 16A MCCB 4p 40A MCCB 2p 10A
EN2-L2 EN2-E1 EN2-L3 EN2-L4 EN2-L5 EN2-P1 EN2-P2 EN2-P3 WP-L1 WP-L2 WP-L3 WP-E1 WP-P1 WP-P2 WP-P3 WP-P4 WP-P5 WP-P6 WP-P7 ACS-L1
HALL LIGHTING EMERGENCY LIGHTING M1-M6 LIGHTING M7-M13 LIGHTING RESERVE POWER SOCKET ENGINE ROOM RESERVE RESERVE WORKSHOP LIGHTING WAREHOUSE LIGHTING OIL STORAGE LIGHTING EMERGENCY LIGHTING POWER OUTLET WORKSHOP POWER OUTLET WAREHOUSE POWER OUTLET WAREHOUSE RESERVE POWER OUTLET 3P+N+T 16A 400V RESERVE POWER SOCKET ACCESS CONTROL LIGHTINT
230 230 230 230 230 400 230 230 230 230 230 230 230 230 230 230 400 230 400 230
1461,6 72 1461,6 1461,6 0 22170 0 0 417,6 1252,8 417,6 57,6 3680 3680 3680 0 11085 0 22170 306
6,35 0,31 6,35 6,35
68 68 40 71 0
32,00
70 0 0
1,82 5,45 1,82 0,25 16,00 16,00 16,00
8 20 22 28 7 9 28 0
16,00
7 0
32,00 1,33
24 6
2(1X2,5)+ G2,5 2(1X1,5) 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 4(1X16)+ G16 2(1X1,5)+ G1,5 2(1X1,5)+ G1,5 2(1X1,5)+ G1,5 2(1X1,5) 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 4(1X2,5)+ G2,5 4(1X10)+ G10 2(1X1,5)+
22 16 44 22 0 66 0 0 16 16 16 16 22 22 22 0 21 0 50 16
6,67 0,54 3,88 6,97 4,81 0,37 2,82 1,01 0,18 1,87 2,40 7,48 1,63 2,72 0,20
DU
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

D U% Tot 1,01% 1,12% 0,11% 0,23% 0,27% 0,27% 0,27% 0,27% 0,27% 0,27% D U% Tot Nominal I(A) Supply System D U Tot 2,32 2,59 0,45 0,91 1,10 1,10 1,10 1,10 1,10 1,10 D U Tot Length Load Pn(W) D U% 0,81% 0,93% 0,00% 0,23% 0,27% 0,27% 0,27% 0,27% 0,27% 0,27%
156
Circuit No.
Imax
Wire
Description
EMERGENCY ACS-L2 ACS-P1 ACS-P2 ACS-P3 ACS-P4 ACS-P5 AUTOMATIC GATE SWITCHBOARD 400 RESERVE POWER OUTLET RESERVE POWER OUTLET COMPUTERS RESERVE 230 230 230 230 230 0 3680 0 3680 0 0 0,00 16,00 16,00 0 7 0 8 0 0
G1,5 2(1X2,5)+ G2,5 2(1X2,5)+ G2,5 4(1X6)+G 6 0 22 0 22 0 36 MCCB 2p 10A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 2p 16A MCCB 4p 10A + RCCB4p 25A 300mA 1,87 2,14 0,00
Table 24.Voltage drop. Circuits of power and control cabinet

Nominal I(A) Supply System Length Load Pn(W) Circuit No. Description Description of protectons D U% Imax Wire DU 0,91 1,10 1,10 1,10 1,10 1,10 1,10
P&CC P&CCC1 P&CCC2 P&CCC3 P&CCC4 P&CCC5 P&CCC6 AERO FAN 1 AERO FAN 2 AERO FAN 3 AERO FAN 4 AERO FAN 5 AERO FAN 6
400 400 400 400 400 400 400
1000000 1800 1800 1800 1800 1800 1800
1443,38 3,25 3,25 3,25 3,25 3,25 3,25
33 40 40 40 40 40 40
3[4(1X240 1820 )]+G 3(1X2,5)+ 21 G2,5 3(1X2,5)+ 21 G2,5 3(1X2,5)+ 21 G2,5 3(1X2,5)+ 21 G2,5 3(1X2,5)+ 21 G2,5 3(1X2,5)+ 21 G2,5
CB4P 2000 A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A GV 3P 4-6,3A
DU
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD

D U% Tot 0,37% 0,14% 0,12% Nominal I(A) Supply System D U Tot 1,48 0,57 0,46 Length Load Pn(W) D U% 0,37% 0,14% 0,12%
157
Circuit No. P&CCC7 P&CCC8 P&CCC9
Imax
Wire
Description
Description of protectons
MAIN CIRC. WATER PUMP AUX. CIRC. WATER PUMP AERO ROOM FAN
400 400 400
5500 2200 3000
9,92 3,97 5,41
17 17 10
3(1X2,5)+ G2,5 3(1X2,5)+ G2,5 3(1X2,5)+ G2,5
21 21 21
GV 3P 9-14A GV 3P 4-6,3A GV 3P 6-10A
1,48 0,57 0,46
DU
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.3.4 Lighting
The equipment in lighting circuits consuming power is listed below.
13.3.4.1 Engine bay

The lighting equipment consists of hermetically sealed fluorescent luminaries of 2x58W The lighting system is controlled by means of push-buttons which actuate onstep relays. The average luminance in these bays at working level is 407 lux. The following picture shows the horizontal lighting matrix. Work plane. Values in lux.
158
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.3.4.2 Social building

The lighting system in social building consists of hermetically sealed fluorescent luminaries. Lighting of various compartments in this building will be controlled by means of switches. Average luminance in office areas at working level will be above 500 lux. Average luminance in warehouses and workshops at working level will be above 300 lux.
13.3.4.3 Outdoor lighting system

The outdoor lighting system will consist of two circuits. GSP-P7 circuit- Outdoor Lighting Lampost GSP-P8 circuit Outdoor lighting. Engine bay frontage. Outdoor lighting will be controlled by mean of an astronomical clock. GSP-P7- Outdoor Lighting Lampost This lighting system consists of luminaries provided with 250W sodium vapor lamps supported by a lamppost 12 m high. The luminance measured at working level is of about 22 lux. The following picture shows the horizontal lighting matrix. Work plane. Values in lux.
159
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
GSP- P8 Outdoor lighting. Engine bay frontage. This lighting system consists of luminaries provided with sodium vapor lamps and fixed to bay frontage. Average luminance at working level is of about 48,2 lux. The following picture shows the horizontal lighting matrix. Work plane. Values in lux.
160
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
13.4 TESTING & INSPECTION 13.4.1 Verification by checking

Checking the installed material no showing visible damage affecting safety. Verify that are installed under current regulations and instructions of the manufacturer Existence and calibration of protective and signaling devices. All are correctly identified. Existence and availability of schemes, warning and information panels Check the correct execution of the lead connections
13.4.2 Checksbymeasurement or test

Earthground resistance test Protective conductor continuity test insulation resistance test between live conductors Dielectric testing Checking the tripping time and current of differential relays Phase sequence test
161
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
14 ENVIRONMENTAL POLLUTION SOURCES AND MEASURES 14.1 STANDARDS BASIS OF DESIGN

The following directives and standards have been taken into account in environmental matters: Directive 2011/92/EU of the European Parliament and the Council of 13 December 2011 about assessment of aftermath of the effects of certain public and private projects on the environment. Directive 2010/75/EU of the European Parliament and of the Council of 24 November 2010 about industrial emissions (prevention and integrated control of the pollution). Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 about waste and derogation of certain Directives. Directive 2004/35/CE of the European Parliament and of the Council of 21 April 2004 about environmental liability related with the prevention and repairing of environmental damages. Directive 2002/49/EC of the European Parliament and of the Council of 25 June 2002 about assessment and management of environmental noise. Directive 2001/80/EC of the European Parliament and of the Council of 23 October 2001 about limitations of air emissions of certain pollutants from large combustion plants Council Directive 96/61/EC of 24 September 1996 about prevention and control of contamination. EN-15259:2007 Air quality. Measurement of stationary source emissions. Requirements for measurement sections and sites and for the measurement objective, plan and report.
162
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
14.2 LOCATION
The installation of 26 engines is located in industrial zone. Near the location of the power plant does not exists towns or villages. Near the power plant installation there is located a thermal power plant. Picture 1. Location
14.3 RAW AND AUXILIARY MATERIALS

The raw material used is the engine fuel, natural gas. For operation and maintenance of existing equipment, engines and transformers, are needed lubricating oils, coolants and the own oil of the transformer. The substances used are described below: The safety data sheets are attached in Annex 1.
163
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Table 25. Substances used Material Use Identification of hazards Means of extinction Storage conditions Storage temperature between 5 and 20 C. Store in original container protected from direct sunlight in a dry, cool and wellventilated area Store in original container protected from direct sunlight in a dry, cool and wellventilated area Storage temperature between 5 and 40 C.
Corrosive (C) Sulfuric acid Loads of storage Reacts violently 37-38% batteries with water
Water spray Foam Dry chemical CO2 Sand
Lubricant oil (Guascor Lubricant oil for Not classified as motoroil engines hazardous 3040 plus) Antifreeze for cooling circuits in internal combustion engines
Water spray Foam Dry chemical CO2 All extinguishing agents are allowed
Antic. Cc 30%
Harmful (Xn)
E-225 Hardener
Urki-Nato
Storage temperature Alcohol Harmful (Xn) between 5 and 30 resistant foam Hardener for Hazardous for C. CO2 paintings and/or the environment Store in a dry, well Powder varnishes (N) ventilated place Water Flammable (R10) away from sources spray/mist of heat ignition and direct sunlight Storage temperature Alcohol between 5 and 30 resistant foam C. Products for CO2 Flammable (R10) Store in a dry, well mixing systems Powder ventilated place Water away from sources spray/mist of heat ignition and direct sunlight
There are two warehouses for substances storage.
164
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD One of them is an enclosed fenced area, under cover and properly identified. The substances are stored in closed containers such as the distributor provides. In storage substances are not handled. In this area are stored lubricant oils which are not dangerous. The other warehouse is a storage building together at the oil storage, which keep the other substances. This warehouse is protected with photoelectric smoke sensors. The warehouses are located at the ending of the general services building next to the parking. The locations of the stores are identified in the plan No.: 31-01.1
14.4 AIR POLLUTION-EMISSION SOURCES

The power plant has 26 natural gas engines, each one with its own emission source of the combustion gases. The total thermal power associated with the 26 engines is higher than 50 MW (approximately 67.26 MW, 2.6 MW each engine). The total height of the smokestacks from the ground is 10.5 m. This height allows a good dispersion of pollutants emitted. The inside diameter of the smokestacks is 400 mm. All of the smokestacks have the same dimensions. The pollutants emitted into the atmosphere are NOx, CO and non-methane hydrocarbons, (NMHC). The emission control is done by measuring the gaseous pollutants in the sampling holes above the silencers. View plan No.: 60-02. The emissions balance emitted from smokestacks corrected to 5% O2 based NWMH C1, are the following: Table 26. Exhaust values
165
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
14.5 NOISE SOURCES

The noise associated with each generation engine at 1500 rpm with fuel full load according to the manufacturer is: Table 27. Total sound level with engine running continuously, at 1500 rpm and 100% power.
The exhaust chimneys have a silencer to reduce the noise of exhaust gases, and the closure of the engine rooms has been built with sound deadening materials. With these measures of insulation, the noise distribution map obtained is the following: Picture 2. Noise distribution map
166
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD Its possible to improve the noise level installing at the air ventilation inputs and outputs, acoustic barriers that would improve the acoustic isolation. Ventilation has been designed to allow this kind of improvement. Picture 3. Noise distribution map with acoustic isolation at the air ventilation system.
In this case the noise level reached in the surrounding industrial activities is lower than 45 dB (A). This level of noise is according with the current standards in noise matters for industrial areas.
14.6
INDUSTRIAL SEWAGE WATER
The industrial sewage water associated with industrial activity carried out by power generation of natural gas engines are the following: o Network of sanitary sewage, from the existing toilets and showers. The sewage is directed to a septic tank. It is a primary treatment unit of domestic sewage, inside is performed the separation and physical-chemical transformation of solid matter contained in those water. It is cleaned periodically by local operators. o Network of rainwater from the downspouts from buildings. These waters do not carry hazardous substances from the activity and go directly to the environment, Hlawga Lake.
167
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD o Network of rainwater from collection bunds of transformers. They are guided to the intermediate manholes for each of the transformers. The manhole has valves that are always closed so in case of accidental spill it can keep the residue in a safe place pending of its removal. The spill is pumped into containers and taken to a local operator for appropriate treatment. In case of rain, the manhole is checked to ensure that it does not have any residue, and then the valve can be opened to drive the rainwater to the network. o Network of oil water from spills in the engine rooms, after passing through the grease decanter. The waters spill from engines are carried to grease decanters where the oil is separated from water by density and then the clean water passes to final discharge. Greases are collected periodically for treatment by local operators. o In the plan No.: 41-02, you can see the different wastewater networks.
14.7 INDUSTRIAL RESIDUES

The wastes generated in the activity are the following: Table 28. Wastes generated Waste Motor oils and lubricants used Waste coolant (water glycols) Empty containers with remnants of hazardous substances Absorbents and cleaning cloths Origin Leaking engine and motor circuits Accidental leakage transformers Containers of substances Clean spills Storage In closed containers in the warehouse In closed containers in the warehouse In closed containers in the warehouse In closed containers in the warehouse Management Treatment by local manager Treatment by local manager Treatment by local manager Treatment by local manager
There is an area identified for waste storage under deck and over concrete floor into the warehouse. The hazardous waste is regularly managed by local operators.
168
DATE
DOCUMENT
ORDER
Nov-2012 INDEX
VEC001101
CUSTOMER
ROYAL GK PTE LTD
14.8 ENVIRONMENTAL MEASURES FOR THE SITE SOIL

Industrial activity due to the power generation of the plant through gas fuel engines is placed on native soil that never has hosted any other previous activity. The plant has been designed according to an engineering basis 100% Environmentally Friendly, with the most advanced techniques in environmental matters. The location where takes place the industrial activity has a concrete pavement that protects the ground from spills of hazardous substances, and it is provided with a drainage pipelines to avoid the uncontrolled spills. There are two points of risk for ground contamination, spills from engines and transformers. The spill risk is taken under control through the following measures: The rooms where are placed the engines has a closures such as decks and walls, and the floor is provided with a drainage network to drive the spills toward a grease decanter manhole, which separate the oil from the water. The water treated can be discharged in the lake near the plant and the grease will be collected through pumps for its future management. The engines will be assembled over a foundation to protect the ground of the building from vibrations and also the accidentally spills. The transformers are placed inside concrete cubes with the purpose of keeping any oil spill and avoid its dispersion. These spills are driven to separation manholes, one for each transformer, which are connected to another larger manhole by valves that are always closed. In case of rain, the content of the manholes is checked to ensure that there are not any spills from transformers, and then the valve can be opened to discharge the water in the large manhole, which is connected with the rain water network.
169

General Technical Report 05

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

General Technical Report 05

Hochgeladen von

Copyright:

Verfügbare Formate

GENERAL TECHNICAL REPORT

Customer:ROYAL GK PTE LTD

General technical report

ROYAL GK PTE LTD

General technical report

General technical report

General technical report

ROYAL GK PTE LTD

General technical report

ROYAL GK PTE LTD

YESB Substation (33kV) Interconnectionfeeder

General technical report

ROYAL GK PTE LTD

General technical report

ROYAL GK PTE LTD

General technical report

General technical report

ROYAL GK PTE LTD

3.2.1.2 Concrete Slab Foundations

General technical report

ROYAL GK PTE LTD

ELECTRICAL INSTALLATIONS AND PITS

General technical report

Pits for the Lighting

Pits for Electricity, Data and Other Conduits

Pits for Water Supply

General technical report

General technical report

Fecal Water Drainage System

Oily Water Drainage System

Rainwater Drainage System

General technical report

3.4.3.1 Rainwater system sizing

General technical report

General technical report

Flooring in front of premises

General technical report

Air Coolers Area

INTERIOR FLOORING Engine Room

Auxiliary Services Building

General technical report

General technical report

ROYAL GK PTE LTD

Auxilliary Services Building

Basis for calculation of the Structure

General technical report

ROYAL GK PTE LTD Period of service (years): 50

Earthquake Modal spectral analysis Acceleration a=0.06g Ductility=1 Engine rooms

General technical report

ROYAL GK PTE LTD

Earthquake Modal spectral analysis Acceleration a=0.06g Ductility =1

Walls separating between 35 MVA transformers

Earthquake Modal spectral analysis Acceleration a=0.06g Ductility =1

Cell cubicle foundation

General technical report

ROYAL GK PTE LTD

Loads According to technical specifications.

General technical report

ROYAL GK PTE LTD Loads According to technical specifications.

Earthquake Modal spectral analysis Acceleration a=0.06g Ductility =1

General technical report

General technical report

ROYAL GK PTE LTD