Volume I - 20120905 With Coverpage

8/9/2019 Volume I - 20120905 With Coverpage

1/13

Frame 9BE Upgradation Project

Dubai Aluminum (DUBAL),

Dubai, UAE

Bid Specification


2/13

FRAME 9BE GAS TURBINE

UPGRADATION PROJECT

L&T – SARGENT & LUNDY LIMITED

BID SPECIFICATION

FRAME 9BE UPGRADATION PROJECT

DUBAI ALUMINUM (DUBAL),

DUBAI, UAE

PROJ. NO. : T726000

REVISION SUMMARY

REVISIONNO. R00 R01 R02

NAME DATE NAME DATE NAME DATE

PREPAREDSM/PMC/DS/HP/NP

14-Aug-12SM/PMC/DS/HP/NP

01-Sep-12SM/PMC/DS/HP/NP

04-Sep-12

REVIEWED RK/RDD 17-Aug-12 RK/RDD 03-Sep-12 RK/RDD 05-Sep-12

APPROVED RK 18-Aug-12 RK 04-Sep-12 RK 05-Sep-12


3/13


4/13


UPGRADATION PROJECT

Volume I Page 1

VOLUME I

PROJECT INFORMATION


5/13


UPGRADATION PROJECT

Volume I Page 2

CONTENT LIST

SL. NO. DESCRIPTION PAGE NO.

1 PROJECT INFORMATION 03

2 PROJECT BACKGROUND 08

3 INSTRUCTIONS TO BIDDERS 09


6/13


7/13


UPGRADATION PROJECT

Volume I Page 4

Therefore it is essential to design the plant according to the climatic conditions

described as below and to select construction materials carefully in order to preventcorrosion and erosion problems –

Fog and Dew

During certain periods of the winter months’ nights and early mornings fog iscommon. This may persist from two hours after sunset until two hours after dawnwhen it lifts.

Winds

While no clearly defined yearly course of the wind direction exists, its daily course

shows regular variations. At night wind from land is prevailing from south-east,while from noon to evening winds from north-west are typical.

Sandstorms

Sandstorms are occasionally experienced mainly between January to March and August to October.

Sea Shore Conditions

With the normal stiff sea breeze in the afternoon considerable quantities of saltspray is blown shoreward thus producing severe corrosion conditions. The dew isalso somewhat saline and exhibits corrosive characteristics.

Hydrological Data

Dubai Municipality Datum (DMD) is the local Government approved Datum &shall be considered.

Ground Water

The highest ground water table was established at an elevation of approximately+ 2.0 m DMD, which is approximately 4.4 rn below the ground level of the existing

stations.

Seismic Data

The Design shall also be performed according to the latest UBC but with theseismic zone required by DUBAL Municipality which is zone 2A.

Soil thermal Resistivity

The Value is 2.0°C m/W according to previous Soil investigation Report. DUBALbears no responsibility of the above stated Soil Report Data. Bidder shall confirmthe trueness of the above mentioned data.


8/13


UPGRADATION PROJECT

Volume I Page 5

1.3 SITE AMBIENT CONDITIONS

Item Unit Value

Minimum Ambient Temperature °C 7

Maximum Ambient Temperature °C 48

Average Ambient Temperature °C 38

Ambient Relative Humidity % 20-100

Barometric Pressure mbar 1013

Maximum Rainfall (for a duration of one hour)Rainfall (for a duration of one day)

mm/hmm/day

75155

Wind Km/h 160

Seismic Data G(m/s2) 0.07

1.4 GENERAL DESIGN REQUIREMENTS

Please refer to Volume II.

1.4.1 EXECUTION OF WORK

All designs shall be prepared in accordance with the very best current engineeringpractice and are to have regard to the appropriate National Codes of Practice andStandards approved by the Engineer in so far as they are applicable and up-to-date. Any departure from the appropriate Codes and Standards must be fully explained inwriting for the Engineer’s approval.

All work has to be executed according to the approved drawings unless variationsare instructed by the Engineer.

The civil engineering works (if any) shall be carried out to a standard of workmanshipcompatible with the best industry practice Attention is drawn to the extremely aggressive environment. High ambienttemperatures, humidity, and sand-storms necessitate close attention to design andchoice of materials.

1.4.2 STANDARDIZATION

For simple maintenance and to reduce the spare parts on stock to a minimum, thedetail design of equipment and related parts have to be standardized as far as

possible


9/13


UPGRADATION PROJECT

Volume I Page 6

1.4.3 CODES AND STANDARDS

The following latest applicable codes may be used:

DIN Codes of Practice ACI Codes of Practice AISC Codes of Practice ASTM Codes of PracticeBS Codes of PracticeEC European CodesISO International StandardsIEC Standards ANSI/IEEE Standards ASME Standards & Codes

The Bidder shall show in his offer the codes and standards proposed to be used forthe different kinds of work. There is no mixing of standards allowed within the samespecific work.

1.4.4 POWER SUPPLY CONDITIONS

Sl.No.

System Variation Fault level (kArms)

Purpose

1.0 High VoltageSystem

132kV, 3 Phase,50 Hz

Voltage Variation:-5% & +5%Frequency variation: (+) 5to (- ) 5%Combined Voltage &Frequency variation: 5%

40 kA for 3second Evacuation ofpower

2.0 Medium VoltageSystem11 & 3.3kV, 3Phase, 50 Hz

a) Voltage Variation:(+/-) 10%b) Frequency variation : (+)5% to (-) 5%c) Combined Voltage &Freq. variation: 5%

25 kA for 3second

For Motors above200kW

3.0 Low VoltageSystem380V, 3 Phase,3W, 50 HzNeutral effectivelyearthed

a) Voltage Variation:(+/-) 10%b) Frequency variation : (+)5% to (-) 5%c) Combined voltage &freq. variation: 10%

50 kA for 3second

a) Motors up to200 kW.


10/13


UPGRADATION PROJECT

Volume I Page 7

Sl.

No.

System Variation Fault level (kA

rms)

Purpose

4.0 Low VoltageSystem220V & 110, 1Phase, 50 HzOne side earthed

Voltage Variation:(+/-) 10%b) Frequency variation : (+)5% to(-) 5%Combined voltage & freqvariation : 10%

- For small power,Lighting, welding,space heating.

5.0 DC system125 V DC

(+/-) 10% Voltage variation - Control powersupply.

Control System

1.4.5 LOCAL AUTHORITY COMPLIANCES

Bidder shall comply with all local statutory requirements.

1.4.6 NOISE LIMITS

Equipment noise level shall not exceed 85 dB 1 meter from the equipment boundary.

As per local requirements the emission of noise from premises at the plant boundary

limits shall not exceed 55 dB (A) from 7 am to 8 pm, and 45 dB (A) from 8 pm to 7am.

1.4.7 SAFETY, HEALTH AND ENVIRONMENT

DUBAL’s “Safety Health and Environmental Requirements for Contractors” have to

be followed.

Selected Bidder shall attend, adopt, follow, get trained in Dubal safety

rules and regulations, Permit To Work authorization, course conducted by

Dubal safety department etc.

The Bidder shall take responsibility of their staff working in Dubal, for

medical test, gate passes, transportation, any other logistics, local officewhatsoever etc.

Please refer to Volume III - Annexure 7 for more information.


11/13


UPGRADATION PROJECT

Volume I Page 8

PROJECT BACKGROUND

The captive power plant at DUBAL complex, Dubai consists of combined cycle unitsand cogeneration units to generate electrical power for smelter and other facilitiesand process steam for desalination plant.

DUBAL is carrying out GT Upgrade in five (5) of their GE frame 9B gas turbines inorder to improve the power output and thereby overall power reserve of the plant.The GT upgrade is expected to improve the power output of the gas turbines from 80MW to 88 MW at 35°C ambient. The GT upgrade, called frame 9BE, will allow higherfiring temperature up to 2055°F, improving power output and heat rate. The GTupgrade of all five units is expected to increase the reserve capacity of the plant by40 MW from the original capacity. Four (4) of the GT units, GT 9, GT 11, GT 12 & GT13 have already undergone the GT upgrade.

A preliminary check on the capability of plant HV system for injection of additionalpower was carried out and the system was found to be adequate.

The upgraded gas turbines (GT 9, GT 11, GT 12 & GT 13) are currently beingoperated at a lower firing temperature of 1965°F. The firing temperature could not beraised to the maximum firing temperature of 2055°F (1125°C) due to the limitation inthe GT generator, associated electrical equipment and boiler (HRSG).

The GT upgrade is expected to give a life extension of 25 years to the frame 9B gas

turbines. DUBAL engaged Tractebel Engineering to study the limitations of theassociated equipment and to suggest the mitigation measures to overcome thedesign limitations of the equipment, so as to operate the GTs at base load andmaximum firing temperature of 2055°F.

Based on the Study, the equipment recommended for replacement includes but notlimited to-

HRSG including control system - 5 units

GT Transient Duct – 5 units

GT Generator – 3 units

GT Generator Step-up Transformer – 3 units

Isolated Phase Bus Ducts- 3 units

HV Cable / Switchgear- 3 units

In addition, Bidder shall propose new de-aerator and feed water system along withnecessary piping and instruments capable of meeting the requirements of new five(5) HRSGs.


12/13


UPGRADATION PROJECT

Volume I Page 9

3.0 INSTRUCTION TO BIDDERS

3.1 GENERAL

Bidder shall quote for the entire project on EPC basis as if all the specifications arebound together to form one seamless specification. All terminal points and interfacebetween the different sections indicated in the specifications need to be read as onesingle system without having any boundary in between. The Bid documents havebeen prepared and grouped in different Volumes / sections for convenience only.

Bidder shall indicate after sales service packages as well.

Bidder shall provide offer for the following two options

Complete Package as per Technical Bid Specification

HRSG & Auxiliaries as Standalone Package

3.1.1 DOCUMENT INFORMATION

Though adequate care has been taken while preparing the Bid Documents, theBidder shall satisfy himself/itself that the Bid Documents are complete in all respects.It may be noted that none of the Owner, Owner’s Engineer or their directors,employees or advisors/consultants make any representation or warranty, express orimplied, or accept any responsibility or liability, whatsoever, in respect of any

statements or omissions made in the Bid Documents, or the accuracy, completenessor reliability of information contained therein, and shall incur no liability under anylaw, statute, rules or regulations as to the accuracy, reliability or completeness ofsuch documents even if any loss or damage is caused to the Bidder by any act oromission on their part.

Apart from technical bid specification (Vol. II), Bidder to refer standard engineeringspecification of DUBAL and incorporate the details as per applicability. Please referVolume III - Annexure 6.

In case of discrepancy between technical specifications (Vol. II) & Dubal standardengineering specification, DUBAL specification shall take preference. However,

Bidder shall categorically indicate such points.

3.1.2 SUBMISSION OF BID PROPOSAL

3.1.2.1 BID LANGUAGE

Bid shall be submitted in English language only.


13/13


UPGRADATION PROJECT

Volume I Page 10

3.1.2.2 BID EVALUATION CRITERIA

TECHNICAL CRITERIA

The Bid Evaluation Team will carry out a detailed evaluation of the Bids previouslydetermined to be substantially responsive, eligible and qualified for the performanceof the EPC Contract in order to determine whether the technical aspects are inaccordance with the requirements set forth in the Technical Specification.

In order to reach such a determination, the evaluation team will examine andcompare the technical aspects of the Bids taking into account the following technicalevaluation criteria

Overall completeness and compliance with the Technical Specifications anddrawingsHRSG OutputTransformer lossesIPBD LossesGenerator Efficiency

The Bids shall be considered responsive if they comply, without material deviation,objection or reservation with the terms and conditions of the requirement.

A material deviation, objection or reservation is one:

That affects in any substantial way the scope, quality or capability of performanceof the worksThat is inconsistent with the RFP (Request for Proposal), sets substantiallimitations on the Employer’s rights or the Bidder ’s obligations duringperformance of the EPC Contract orWhose rectification would affect unfairly the competitive position of other Bidderspresenting substantially responsive Bids.

The Evaluation Team reserves the rights-

To waive any minor informality, nonconformity or irregularity in a Bid which does

not constitute a material deviation and does not prejudice or affect the relativeranking of any Bid as a result of the technical evaluationTo decide whether a deviation is one, which makes the Bid substantiallynonresponsive,To reject any Bid containing at least one material deviation.

Only Bids, found in general compliance with the requirement (as satisfactory clarifiedfor missing or misinterpreted data) will be further evaluated commercially.