Sie sind auf Seite 1von 11



This Exhibit for one common Chimney with two independent liners includes the following:




Equipment and Services to be Furnished by Contractor


Codes and Standards


Design Data






Electrical Requirements


Obstruction Lighting


General Electrical Items


Instrumentations and Controls


Ash Handling Systems




This Exhibit covers the design, detailing, furnishing of all tools and materials, labour, delivery, and construction of one reinforced concrete one common chimney for both STG 5 and 6. The chimney shall have two independent steel flue stack, one for Unit 5 and one for Unit 6. Height shall be determined by contractor but it should not be lower than the existing STG 1,2,3,4 chimneys.


The chimney will consist of a reinforced concrete shell and two independent insulated steel flue stack with bottom hoppers, chimney shedder caps, interior and exterior lightning protection material, electrical equipment, and lighting for the chimney interior, outdoor aircraft warning lights, vents, embedded items, and roll-up doors. The space between the liners and reinforced concrete shell shall be prepared for ventilation.




Contractor shall design, furnish all material, and construct a reinforced concrete chimney shell and foundation including all embedded items therein. Included are the elevator, structural steel platforms and grating, ladders, steel roll-up door, and other doors and frames and piping, and all embedded inserts for attachment thereto. The exterior concrete surface of the chimney shall be coated with acid resistant material.


Contractor shall design, furnish, and install a complete lightning protection system, an obstruction lighting system, and an interior lighting and receptacle system, all as hereinafter specified, including lightning rods, flashing beacons,

P.O. Number : 7200018725

interior lighting fixtures, receptacles, transformer, and all control devices, hardware, and wiring required for the installation.

Contractor shall design, detail, fabricate, and erect two independent steel chimney liners, liner supports, hoppers, hopper lining, breeching sections, and chimney caps. Included with the liners are stainless steel chimney shedder caps, all inspection access doors, test ports, and instrument connections and liner insulation.

Contractor shall provide connections on the chimney liners for installation of the in-situ chimney gas monitoring system and grab sample connections for test probes. Provisions on the concrete chimney for walkways, ladders, electric power, and penetration of the concrete chimney for insertion and removal of grab sample probes shall be included at appropriate locations.




In addition to the codes and standards listed in the Specification, the following codes and standards shall apply:


Design and construction of the concrete chimney shall be in accordance with MARAFIQ Structural Code, Specification Sections 03300, 03200 and 03210 as well as the American Concrete Institute, ACI 307, Specifications for the Design and Construction of Reinforced Concrete Chimneys.


All structural and miscellaneous steel shall be designed, fabricated and erected in accordance with MARAFIQ Structural Code, Specification Sections 05120 and 05500.


Advisory Circular No. 70/7460-1E, Obstruction Marking and Lighting FAA/DOD, Specification L-856, High Intensity Obstruction Lighting Systems and Advisory Circular No. 150/5345-43B, issued by the Department of Transportation, Federal Aviation Administration.

Master Labelled Lighting Protection Systems UL 96A, eighth edition of Underwriters' Laboratories, Inc.

"Dynamic Design of Reinforced Concrete Chimneys" Title 64-47 of the ACI Journal.




Design requirements related to earthquake and wind shall be as stated in the MARAFIQ Structural Code. However, a minimum wind load of 150kg/m2 shall be considered -which is the minimum pressure recommended in ACI 307, Table



Design of the chimney shall include considerations of dynamic effects induced due to wind. The method described in the reference in paragraph 3.6 is suggested for these considerations. However, it is the responsibility of Contractor to choose an appropriate method.

P.O. Number : 7200018725


Design live load on grating platforms shall be 500 kg/m2.
















The maximum gross velocity at exit from the chimney shall be 23 m/sec.


Ventilation of the space between the liners and the reinforced concrete shell shall be provided to facilitate maintenance operations. Temperature within this space shall not exceed ambient by more than 6 o C (10.8 o F). All necessary preparatory work shall be built into the chimney for this concept.





Concrete, reinforcing steel, structural steel and miscellaneous steel materials shall conform to the respective specifications. Concrete is to be integrally collared with pigments matching the colour of the existing chimneys. The top 30m of the exterior of the concrete shall be coated with an epoxy-based acid resistant material to protect the concrete from the effects of downwash of flue gases. A mock-up concrete panel of the required colour shall be submitted for Marafiq review and approval. The ratio of pounds of pigments per sack of cement shall be approved by Marafiq.


steel placed in the space between the reinforced concrete shell and the

liners shall be galvanized. The galvanizing shall conform to ASTM A123.



Grating and grading treads shall conform to the requirements of Specification Section 05500.


Handrail shall be 38-mm (1½ in.) diameter pipe galvanized conforming to ASTM


120, Standard Specification for Black and Hot-Dipped Zinc-Coated

(Galvanized) welded and Seamless Steel Pipe for Ordinary Uses. Railing shall meet OSHA standards.


Insulation shall be semi rigid mineral Fibre Felt batts 96 kg/m3 (6 lb/ft3) density about 5-cm (2 in.) thick.


Flue stack plate shall conform to the requirements of ASTM A 242, Standard Specifications for High Strength Low-Alloy Structural Steel. Lining for the liner plate (flu stack) shall be borosilicate.


Stainless steel shall meet the requirements of ASTM A 167, Standard Specifications for Corrosion Resisting Chromium-Nickel Steel Plate, Sheet and Strip, Type 316 L and Type 302.


Cast iron items required for chimney construction shall conform to ASTM A 48, Class 40.


One roll-up door shall be provided at the base elevation installed in a vehicle opening and is to include the following specified items, externally mounted on

face of lintel and jamb, manually operated by chain. Door shall be non labelled

for a 3.05 m x 4.25-m (10 ft x 13.5 ft) opening. Curtain shall be of curved, wind

P.O. Number : 7200018725

locked steel plates, 20 gauge thickness, galvanized and finished, with manufacturer's standard baked-on enamel guided in standard steel angles. Door shall be made weather tight by baffles against the lintel and jamb. Gearing shall be cast iron, protected by cast iron brackets and No. 24 gauge sheet metal hood. A neoprene loop astragal shall seal the bottom of opening when door is closed. Cast iron wheel guards shall be provided at the base.


Hollow metal man doors shall be 0.91 m x 2.1 m (3 ft by 7 ft) to be provided as follows:

a) One door at the base elevation for access into the chimney, including all

necessary hardware and lock.

b) One door with hardware for access onto external platform at upper level


c) One door with hardware required for EPA instrument room.


Furnish and install the necessary number of louvered openings to be used for the ventilation of the space between the reinforced concrete shell and the liners. Furnish and install the proper number of louvers required for ventilation in accordance with Article 4.6.






The concrete shell shall have a uniform or variable taper from the base to the top. The exterior concrete surface shall be smoothed to avoid irregularities, and interior and exterior surfaces shall as a minimum be cured by the application of a spray coat of a curing compound. Sacking, rubbing, or special finishing of the concrete surfaces is not required, but a reasonably uniform and smooth surface must be obtained. The reinforcing steel in each face of the wall in the chimney column shall be made electrically continuous by careful and proper use of wire lap splices and bonded to the lightning protection system at both the top and the bottom of the stack. The shell shall be reinforced throughout its full height on both interior and exterior faces.


Embedded items shall be properly installed and anchored, capable of carrying all the loads and forces imposed on them. Embedded items include supports for all interior and exterior platforms, liner bands, elevator guides, snubbers, platforms, ladders, door frames, breeching openings, and vents. All embedded items shall be properly connected to the chimney grounding system.


Chimney wall access openings, other than man-doors or roll-up doors, for servicing and maintaining chimney accessories shall be closed with weather tight and airtight doors or closures. These shall be of stainless steel with fittings of bronze or similar non-corroding materials.


The platform level that services any emission monitoring instruments will require the construction of a room at that level for the protection of the installed instrumentation. The room is to be designed to completely isolate the high

P.O. Number : 7200018725

temperatures that could develop inside the space between the reinforced concrete shell and the liners. Either corrective ventilation or power fans shall maintain near-ambient temperatures with the room through louvers installed in the chimney shell wall.


In designing the concrete shell, the Contractor shall allow for a space between the insulated steel liners and the inside concrete wall of not less than 90 cm (36 in.) at the uppermost platform below the chimney cap.


All chimney openings, access, and vent openings shall be armoured around their entire perimeter with protective metal framing or plates. Stainless steel shall be used except at the truck openings where galvanized steel and cast iron wheel guards shall be used. A roll-up door shall be located on the exterior surface of the chimney. Mandoors letting into the chimney shell shall be on the interior surface.


Flue stack

The steel flue stack shall be full height, constant diameter, fabricated of steel plate conforming to ASTM A 242, except for the top 15 meters (50 ft). Each flue stack shall service one steam generator.


The flue stacks shall be completely independent of the chimney shell except for lateral guides, snubbers, and support framing. The liners shall be designed on the basis of being supported at or near the base. Vertical movement at the breeching shall be minimal.


The upper 15 meters (50 ft) of the liners including the chimney cap shall be Type 316L stainless steel conforming to ASTM A 167.


The flue stack plate shall be 6 mm (1/4 in.) minimum thickness and shall be suitably reinforced with stiffener rings and added reinforcing at all openings, guides, snubbers, and supports. Stiffeners shall be ASTM A 242.


Below the breeching, hopper sections shall be provided with a conical or sloped bottoms. Drains to be piped to a waste area shall be provided. The liner bottoms shall be designed and suitably reinforced.


A 90 cm x 60 cm (36 in. x 24 in.) hinged access door shall be provided at the elevation of the bottom of each breeching section. Inspection doors in the liners shall be 30 cm x 30 cm (12 in. x 12 in.) and shall be located at each platform level.


Hinged clean out and access doors of Type 316L stainless steel gasketed to insure tight closure shall be provided at the elevation of the bottom of the hoppers to permit the removal of deposited material and to permit inspection. Door size shall be 90 cm x 60 cm (36 in. x 24 in.).


Insulation shall be attached to the entire exterior surface of the liners completely covering projecting flanges of stiffeners and all members welded to the liners, hoppers, and doors. It shall be fastened by impaling on projecting studs and secured by wrapping with wire mesh or lath.

P.O. Number : 7200018725

6.2.8 Contractor shall design and furnish duct (breeching) sections attached to the chimney flue stack and extending through and beyond the concrete shell for a distance of 0.60 meters (2 ft) with the correct and proper interfacing with steam generator gas duct. The space between the duct and the concrete shell shall be sealed. The breeching sections shall be fabricated of steel plate conforming to ASTM A 242. All other steel sections used for stiffening the breeching shall be ASTM A 242 material.

6.2.9 Connections shall be installed in the breeching between the line and the chimney shell to accommodate the stack gas monitoring system and grab sample connections for monitoring NOx, SO2 and opacity as established by the EPA. This requirement conforms with the revised new source performance standards (40 CFR 60, subpart D) published in the June 11, 1979 issue of the Federal Register. Contractor shall also furnish and install the necessary ladders and platforms to provide access to these connections.

6.2.10 Contractor shall provide four 10 cm (4 in.) diameter capped couplings in the liners at 90-degree intervals, approximately eight stack liner diameters from the duct entrance, for emission test connections. At this level, a platform shall also be furnished with access to each capped coupling. Small stainless steel access doors shall be installed in the concrete shell in line with the test port to allow the operator to insert the probe into the liners. If there is a space between the liner plates and the inside of the chimney shell in excess of one half the liner diameter, these access doors are not required.


All steel shall be detailed, furnished, and fabricated in accordance with AISC Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings, and AISC Code of Standard Practice for Buildings and Bridges, latest revision. All welding, materials, and workmanship shall conform to the latest revision of the American Welding Society's requirements.


Elevator, Platforms, Ladders, and Chimney Cap


An elevator, ladder and platform system within the annular space shall be designed and installed by the Contractor. Elevator and ladder shall provide access to all platform elevations from the ground floor. Ladders shall be situated so that the climber faces the outer shell. Design shall provide access for inspection and maintenance of the top and interior of the chimney, the breechings, and the gas sampling and inspection holes.

Internal platforms around the full circumference shall be provided at the levels of the obstruction lights for inspection and servicing of the lights, and for the access to the liner inspection doors, liner snubbers, and guides, gas sampling ports, and instrumentation room. A full circumference exterior platform shall be provided near the top of the chimney with access from an interior platform at this level via a man door through the chimney wall.


Interior platforms and ladders shall be constructed of ASTM A 36 steel. Steel for platforms, ladders, grating, handrail, and toe plates shall be galvanized. Platforms, ladders, door, and all steel installed on the exterior of the chimney above the elevation of the uppermost platform shall be stainless steel, Type

P.O. Number : 7200018725

316L. All ladders shall be provided with safety cages and rest platforms located no more than 30 meters (98 ft) apart.


Internal safety handrails shall be furnished at all openings in floors.

A chimney and shedder shall extend above the top of the concrete shell and steel liners and cover the space. In cold position the cap shall overlap the concrete shell by an amount equal to 1.5 times the upward expansion of the liners.




Lightning Protection

The chimney shall be provided with a complete lightning protection system. Lightning rods and accessories shall be provided in compliance with the latest revision of the National Board of Fire Underwriters, UL 95A, Installation Requirements of Master Labelled Lightning Protection System and National Fire Protection Association (NFPA No. 78).


Air terminals shall be uniformly distributed and installed vertically at the top of the chimney shaft. Air terminals shall consist of lead-covered copper rods, each not less than 1.6 cm (5/8 in.) diameter and shall extend above the top of the chimney not less than 610 mm (24 in.) and not more than 760 mm (30 in.) in height. The air terminals shall be placed around the perimeter of the chimney shaft at intervals not exceeding 2400 mm (8 ft).


The air terminals shall be electrically connected together by a 4/0 AWG stranded copper conductor which forms a closed loop near the top of the chimney. The air terminals shall also be connected to the metal chimney cap to provide an electrically continuous bond between all metallic features.

At least two down conductors, each 4/0 AWG stranded copper cable, shall be provided and connected on opposite sides of the chimney. These down conductors shall be connected to the loop on the top and to a loop at the base of the chimney. The down conductors shall be cross-connected approximately midway between top and bottom and at intervals not exceeding 45 m (150 ft). Down conductors shall be carried down opposite sides of the chimney, and shall be embedded in the reinforced concrete or fastened to the outside of the chimney at intervals not exceeding 1.2 m (4 ft). Each down conductor shall be connected to the reinforcing steel at the top, middle and bottom of the chimney.


The electrical connection to the copper down conductors shall be made with a suitable connector. The electrical connection between the reinforcing rods shall be made by tie wires with not less than five tightly wrapped turns of soft-iron wire No. 16 U.S. Steel wire gauge 1.6 mm (0.0625 in.) or by an exothermic process.


Metal ladders and lining shall be connected to the nearest down comer at their upper and lower ends. Additionally, down comers shall also be connected to duct openings, platforms, and access doors.

P.O. Number : 7200018725


All connections, clamps, anchors, etc., of the lightning protection system shall be made of suitable copper or copper alloy fittings. All joints of copper-to copper, or any other form of electrical connections, unless otherwise specified, shall be clamped or bolted to form a connection of adequate current carrying capacity and mechanical strength. Soldered connections will not be permitted. Where lead covering is specified, connections shall be made from copper-to copper after lead covering has been removed. After copper-to-copper joints have been made, they shall be recovered with lead, so that bare copper will not be exposed on any part of the work.

Air terminals, conductors, connectors, clamps, fixtures, anchors, etc., exposed within 7.62 m (25 ft) of the top of the chimney shall have a continuous lead covering of a sheath of commercially-pure lead not less than 1.6 mm (1/16 in.) in thickness extruded and fused upon bared copper.





Provisions shall be made for the total servicing and maintenance of the obstruction lights through the chimney wall from the inside platforms provided for that purpose. Access openings thus provided shall have weather tight doors. Safety grilling, consisting of 13 mm (1/2 in.) round bars at 305 mm (12 in.) on centre each way, shall be attached to the exterior of the wall.


Obstruction lighting shall be provided in accordance with the regulations of the FAA with Advisory Circular No. AC70/7460-1E, entitled "Obstruction Marking and Lighting."


The obstruction lighting shall be the dual lighting system as defined in AC70/7460-1F, Chapter 4, paragraph 14. High-intensity white obstruction lights shall be used at the top and at half height level of the stack for daylight operation. Red flashing at the top and half height level plus red steady burning lights at the three-quarter height level shall be used for night time operation.


Contractor shall furnish a complete aviation obstruction lighting system.



Four flash heads with four adjacent power supplies shall be installed at 90- degree intervals of each level. Power supply shall be rated 480 V, three phase, solidly grounded.


A master controller panel shall be provided to determine and control the flash rate of flash heads and shall be located at the base of the chimney.


Control cabinets, power supplies, contractor, and alarm and transfer relays shall be of NEMA 4X construction.


The top level of obstruction lighting shall use Type 316 stainless steel for flash head housing.













P.O. Number : 7200018725


Contractor shall provide two common trouble contacts in the master controller for MARAFIQ's annunciators which will close upon malfunction of one or more systems. Contacts shall be rated for 125-Vdc pilot duty.


Contractor shall provide an intensity override switch. The switch shall be mounted on the control unit and may be used to regulate the light intensities manually in the event of malfunction of the automatic switching unit.


Exposed (not embedded in concrete) wiring shall be installed in rigid aluminium conduit.


The 480-V, 3-phase, solidly-grounded supply voltage may vary +10%, with a drop to 80% rated voltage during the start-up of certain large motors, for a duration of approximately 45 seconds. Contractor shall verify that the obstruction lighting system will operate satisfactorily during such occurrence.




Interior lighting fixtures shall be vapour tight with 100-W lamp complete with globe and guard as manufactured by Crouse-Hinds Company, catalogue No. VJ 275, form 100, or equal approved by MARAFIQ. Fixtures shall be located as follows:

a) Four equally spaced at each maintenance platform

b) Four at breeching access platform

c) Six equally spaced at analyzer platform


Convenience outlets shall be 3-wire, duplex-polarized grounding type rated 15 A, 125 Vac, American Standard configuration 5-15R (straight blade) as manufactured by Hubbell Company, catalogue No. 52CM62-GY, or equal approved by the MARAFIQ. Two outlets shall be located at each maintenance platform located 180 degrees apart, four outlets at the analyzer platform, and there shall be two at the breeching access platform and ground level.


Convenience outlet boxes shall be aluminium as manufactured by Crouse- Hinds Company, or approved equal with spring door and gasket.


All cable required shall be rated for 600 V and shall be pre-assembled 125°C (257°F) silicone rubber insulation, minimum size No . 12 AWG, copper conductor, continuous sheathed cable with outer neoprene jacket. Cable runs shall be secured to the inner wall of the reinforced-concrete chimney with suitable inserts and fasteners placed at intervals of 1220 mm (48 in.) to 1830 mm (73 in.) and within 610 mm (24 in.) from every box or fitting. Adequate cable supports for supporting the weight of the cable risers shall be provided at the upper end of each vertical cable run and at intervals of 30 meters (98 ft) maximum. Cable shall be Okoclad-Okotherm, type ALS (copper conductors) except with outer neoprene jacket manufactured by Okonite Company or equal as approved by the MARAFIQ. All cable fittings and cable supports shall be specifically approved for the application.

P.O. Number : 7200018725


Voltage drop on chimney circuits shall be limited to 3% from distribution panel board to the last outlet of each branch circuit.


Aluminium terminal boxes of NEMA 4X construction shall be mounted to the inner wall of the chimney at intervals of one-quarter of the stack height corresponding to the elevations of the obstruction and interior platform lighting levels. Boxes for cable risers shall be in the same vertical plane as the panel board.


Lighting mains between lighting panel and associated pull boxes shall be fitted with appropriate terminals for the aluminium sheathed neoprene jacketed cable. Terminator shall be of Appleton, Crouse-Hinds, Thomas Betts, or equal as approved by the MARAFIQ.


Branch circuit breakers of lighting panel board shall be single-pole, bolt-on type, thermal magnetic and rated 10,000 rms sym A. Panel and breakers used shall


subject to MARAFIQ's approval.


Power distribution panel board shall be 480 V, 3 phase, 3 wire, and fastened to the inner surface of the chimney shell.


Branch circuit breakers of power distribution panel board shall be rated 22,000 rms sym A. Panel and breakers used shall be subject to MARAFIQ's approval.


Distribution transformer shall be dry type, air cooled, 3 phase, 2 winding. Voltage rating shall be 480-208/120 V wye, 60 cycle.


Distribution transformer shall have four 2½% taps below and 2 taps above nominal, Class H insulation with an average temperature rise not exceeding 150°C (302°F) based on 40°C (104°F) ambient at full load.


Contractor will provide two 480-V, 3-phase, 60-Hz power circuits to a three- pole, double-throw automatic transfer switch furnished and installed by Contractor to select either of the incoming supplies to the chimney lighting system.


Automatic transfer switch shall be ASCO type or equal as approved by the MARAFIQ, rated 600 Vac, 100 A, 3 pole, double throw, and 22,000 rms sym A minimum withstand capability.



A continuous emissions monitoring system (CEMS) shall be provided by

Contractor for installation in each STG unit flue liner in the chimney. This

system shall include, l but not be limited to, all hardware and software to provide monitoring of sulphur dioxide (SO2), nitrogen oxide (NOx), opacity, carbon monoxide (CO) and oxygen (O2). The system shall include required ventilation, cooling and purging equipment, and shall be easy to access and calibrate, with data logging, storage, and transmission capability. A CEMS compartment shall

be provided near or in the base of the chimney to house the data logging and

storage systems; and shall be provided with heating, ventilation, and air conditioning, suitable for operating personnel occupancy. The CEMS data

P.O. Number : 7200018725

systems shall be compatible with and connected to the main plant unified control system and/or STG unit DCS.

All instrumentation provided by the Contractor shall be installed and calibrated prior to start-up of the plant and systems. Contractor shall provide documentation certifying the proper calibration in accordance with the instrumentation manufacturer’s recommended procedures, in accordance with the requirements of the MYAS Environmental Control Unit, and in accordance with the anticipated design and operating ranges of the equipment.


An ash removal and handling system for removal of ash from the pollution control equipment and chimney hopper for disposal offsite by trucks shall be provided by the Contractor. The ash removal system shall include, but not be limited to, an ash silo sized for all ash removal from two (2) STG units, piping, supports, blowers, valving, silencers, electrical, instrumentation and controls, enclosures, unloading station trucks and equipment, and civil works required for a complete and operable system.

Contractor shall submit details of the proposed ash removal and handling system including system sizing and frequency of ash removal and minimum of two trucks.

P.O. Number : 7200018725