ICD EPC Volume 2 Final-ToC

Tender Document Volume 2 Employer’s Requirements

Contents

Pt. Indonesian Coal Development (ICD) East Kutai Mine Mouth Coal-Fired Power Station 1

1. General Description of Contracts Works 1

1.1 General 1

1.2 Plant Configuration 2

1.3 Design Life of the Power Plant 3

1.4 Standards 3

1.5 Approvals and Permits 3

1.6 Operation requirements 3

1.7 Environmental 4

1.8 Electrical Systems 5 1.8.1 Mine Supply 6

1.8.2 Port Supply 6

1.9 Water Systems 6

1.10 Coal Handling and Storage 7

1.11 Telecommunications Systems and Equipment, and Public Address System 7

1.12 Storage Facilities 7

1.13 Maintenance 8

1.14 Civil Work 9

1.15 Terminal Points 10

1.16 Scope of Works 11

1.17 General Particulars and Working Conditions 12

1.18 Plant Design Conditions 13 1.18.1 Location of the Site 13

1.18.2 Climatic Conditions 13

1.18.3 Seismic Conditions 14

1.18.4 Power Station 14

1.18.5 Coal and Ash Analysis 15

1.18.6 Emission limits 17

1.19 Operation and Maintenance 19 1.19.1 Warranty Engineer 19

1.19.2 Operations and Maintenance Support Option 19

1.19.3 Operations and Maintenance Package Option 19

2. Boiler Plant 20

2.1 Boiler Plant Scope 20

2.2 Specific Requirements 21 2.2.1 Coal Handling Plant 21

2.2.2 Boiler 21


2.2.3 Draft Plant 23

2.2.4 Stacks 23

2.2.5 Platforms 24

2.2.6 Chemical Clean and Steam Line Blow 24

2.2.7 Boiler Firing System 24

2.2.8 Chemical Dosing Systems 24

3. Turbine Alternator Plant 25

3.1 Specific Requirements 25 3.1.1 Turbine Alternator Sets 25

3.1.2 Condenser 27

3.1.3 Steam, Condensate and Feedwater Piping Systems 28

3.1.4 Feed Water Heaters 29

3.1.5 Deaerator 29

3.1.6 Feed Water Pumps and Regulating Valve 30

4. Electrical Plant 31

4.1 General 31

4.2 Electrical Studies 32 4.2.1 Load flow and Fault level studies 32

4.2.2 Lightning protection 33

4.3 Switchboards 33 4.3.1 11kV Switchboard 33

4.3.2 LV Switchboards/MCCs 34

4.4 Auxiliary Systems 34 4.4.1 Station AC systems 34

4.4.2 DC Systems 34

4.4.3 Control Circuits 34

4.4.4 UPS systems 34

4.4.5 Electrical Protection 35

4.4.6 Sync check provision 35

4.5 Unit transformers 35

4.6 Cabling 36

4.7 Earthing system 36 4.7.1 Equipment earthing 37

4.7.2 Structure earthing 37

4.7.3 Lightning protection 37

4.7.4 Indicating instruments 37

5. Controls and Instrumentation 38

5.1 Scope of Work 38 5.1.1 Outline Scope 38

5.1.2 Breadth of Scope 38

5.2 Control Philosophy 39 5.2.1 Local Control 39


5.2.2 Process (Unit) control 39

5.2.3 System Control 41

5.3 Control system performance, configuration and fault tolerance 42 5.3.1 Power failure 43

5.4 Performance Requirements 43 5.4.1 Availability and Reliability 44

5.4.2 Personnel Safety 45

5.5 Implementation 45 5.5.1 Function Specification 46

5.5.2 Software Specification 47

5.6 General Requirements 48 5.6.1 Man Machine Interface 48

5.6.2 System Spare Capacity 49

5.6.3 Data Acquisition and Monitoring 49

5.6.4 Secure Power Supplies 50

5.6.5 Protection Systems 50

5.6.6 Degrees of Environmental Protection for equipment 51

5.6.7 Communications Interfaces 51

5.7 System support documentation 52

6. Balance of Plant 53

6.1 Balance of Plant Scope 53

6.2 Specific Requirements 54 6.2.1 Compressed Air System 54

6.2.1.1 Compressors 54

6.2.1.2 Driers 54

6.2.1.3 Air Receivers 55

6.2.2 Cooling Water System 55

6.2.2.1 Cooling Tower 55

6.2.2.2 Cooling Water Circulation System 55

6.2.3 Seawater Reverse Osmosis Plant (or Equivalent Filter Plant) 56

6.2.4 Demineralised Water Plant 56

6.2.5 Potable Water System 56

6.2.6 Water Storage Systems 57

6.2.7 Sanitary Treatment Plant 57

6.2.8 Waste Water Treatment Plant 57

6.2.9 Ancillary Plant Cooling System (if required) 58

6.2.10 Fire Fighting Systems 58

6.2.11 Ash Handling System 59

7. Civil and Structural Works 60

7.1 General Requirements 60 7.1.1 General 60

7.1.2 Method statements 60


7.1.3 Planning and building regulation approvals 60

7.1.4 Scope of civil / structural works 60

7.2 Design Requirements 61 7.2.1 General 61

7.2.1.1 Structural Loading 61

7.2.1.2 Geotechnical Requirements 62

7.2.2 Earthworks 62

7.2.3 Foundations 62

7.2.3.1 General 62

7.2.3.2 Piling 63

7.2.4 Roads and hardstand areas 63

7.2.5 Drainage 64

7.2.5.1 General Drainage 64

7.2.5.2 Oily Water Drainage 65

7.2.5.3 Coal contaminated drainage 66

7.2.6 Concrete 66

7.2.6.1 General 66

7.2.6.2 Precast Concrete 67

7.2.6.3 Formwork 67

7.2.6.4 Reinforcement 67

7.2.6.5 Concrete Block Work 68

7.2.7 Structural steel 68

7.2.8 Cladding 68

7.2.9 Masonry 69

7.2.10 Piping 69

7.2.10.1 Plumbing and Drainage 69

7.2.10.2 Pressure Piping 69

7.2.10.3 Buried Pipelines 69

7.2.10.4 Precast Reinforced Concrete Pipes 69

7.2.10.5 Fibre-Reinforced Concrete Pipes 70

7.2.10.6 Piping Connections 70

7.2.11 Ladders, platforms, stairs and handrailing 70

7.2.12 Fences 70

7.2.13 Buildings 71

7.2.13.1 General requirements 71

7.2.13.2 Design requirements 71

7.2.13.3 Buildings to be Provided 72

7.2.13.4 Heating and ventilation 72

7.3 Materials and workmanship requirements 73 7.3.1 Codes and standards 73

7.3.2 Materials 74

7.3.3 Certification of materials 74

7.3.4 Storage of materials 74

7.3.5 Plant and equipment 74


7.3.6 Concreting strategy 74

7.3.7 Setting out and monitoring 74

7.3.8 Earthworks, excavation and filling 75

7.3.9 Roads, hardstandings, car parks and paths 76

7.3.10 Piling 76

7.3.11 Structural steelwork 76

7.3.12 Surface water drainage and buried pressure pipelines 76

7.3.13 Building drainage 76

7.3.14 Concrete, formwork and reinforcement 77

7.3.15 Brickwork and blockwork 77

7.3.16 Building works 77

8. Project Management & Quality Assurance 78

8.1 Project Management 78 8.1.1 Programmes and progress 78

8.2 Quality Assurance 79 8.2.1 General 79

8.2.2 Quality assurance and quality control 79

8.3 Controls System Quality Assurance 83 8.3.1 Hazard / Safety Integrity Level (SIL) Assessment 83

8.3.2 Change Management Plan 84

8.3.2.1 Release Process / Approval Process 84

8.3.2.2 Document Change Control 84

9. Site Details and Safety Requirements 85

9.1 Location of Site, Access and Use of Site 85

9.2 Site facilities 85

9.3 Site services during construction period 85 9.3.1 Site construction supplies 85

9.3.2 Water supplies 86

9.3.3 Other services 86

9.4 Safety 87 9.4.1 Hazards 87

9.4.2 Compliance with relevant safety legislation and Employer’s safety manuals/documents 87

9.4.3 Contractor’s Site Safety Procedures 88

9.4.4 Contractor’s Site Safety Procedures 88

9.4.5 Training 89

9.4.6 Safety equipment 89

9.4.7 Assistance to Employer 89

9.4.8 Confined spaces 90

9.4.9 Land owned by third parties 91

9.4.10 Temporary electricity supply 91

9.4.11 Fire precautions 91

9.4.12 Compressed gases 92


9.4.13 Access, fencing and safety barriers 92

9.4.14 Site rules 92

9.4.14.1 Statutory and other regulations 92

9.4.14.2 Personal Protective Equipment 93

9.4.14.3 Protection of hearing 93

9.4.14.4 Respiratory protective equipment 93

9.4.14.5 Maintenance of safety equipment 93

10. General Requirements 95

10.1 Design and Standardisation 95

10.2 Quality of Materials and Workmanship 95

10.3 Welding 95

10.4 Interchangeability 95

10.5 Threaded Fasteners and Associated Items 96

10.6 Tools and tackle for maintenance 96

10.7 Locks and keys for mechanical plant 97

10.8 Laboratory 97

10.9 Painting and corrosion protection 98 10.9.1 Corrosion protection 98

10.9.2 Painting 98

10.10 Provisions for Handling Plant 99

10.11 Lubrication 99

10.12 Labelling 99

10.13 Operating and Maintenance Instruction Manuals 100

10.14 Spares 102

10.15 Work Place Cleanliness 102

11. Drawings and Documents 103

11.1 General 103

11.2 Drawing Submittal 103

11.3 Drawing Control 103

11.4 Final Drawings 105

11.5 Availability of Documents 105

11.6 Confidentiality of Documents 105

11.7 As Built Drawings 105

12. Training 107

12.1 Basics 107

12.2 Operational Training 107

12.3 Maintenance Training 108

12.4 Trouble shooting Training 108

Appendix A Geotechnical Report 109

Appendix B Drawings 110