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CONSULTANT:
CONTRACTOR :
MISCELLANEOUS
The supplier / vendor's scope shall include but not be limited to the following as a minimum:
a. Engineering, design, fabrication, assembly, and deliver Diesel Engine Generator
package, including:
Diesel generator package, complete with diesel engine, synchronous generator, silenced
enclosure and all necessary auxiliaries.
All necessary facilities for diesel engine control and monitoring including air inlet
system, governor, etc.
Local gauge panel, instrumentation and related control system.
Complete electrical, Instrumentation and Control system.
Unit Control Panels, covering excitation, monitoring, control, indication, and protection
system.
Structural skid base-plate, Drip Lips and 2" drain connection.
Fuel daily tank with capacity enough for 24 hours operation, complete with local gauge
and low level switch for fuel control monitoring / alarm indication.
Coupling & guards.
Lubrication and cooling systems, for engine and generator.
Exhaust system including expansion joint, silencer and spark arrester.
Diesel Fuel System including Fuel Filter System, Air Intake and Exhaust System.
Electric starting system.
Dry cells batteries with associated controls, instrumentation, charger and battery rack
assembly.
All necessary cables and wiring, termination, glands, junction boxes, earthing and
bonding within the package.
Autostart and loading, will be used when main power is of just for selected load.
Accessories as specified in the data sheet.
First fill of lubricants, coolants and any miscellaneous, separately packaged (separately
quoted as an option).
b. The diesel engine-generator package shall be supplied in accordance with ASME B15.1
c. All equipment and components shall be new, of current manufacture and with a proven
service record for the intended application.
d. SUPPLIER documentation including documents required for MIGAS certification,
operation & maintenance manuals, and other related certificates.
e. Inspection and testing at SUPPLIER's premises.
f. SUPPLIER assistance for installation, pre-commissioning, and start-up at site.
g. Training for COMPANY'S operation and maintenance personnel.
h. Spare parts for pre-commissioning and start-up.
i. Spare parts for two (2) and five (5) years operation (separately quoted).
j. Special tools for erection, installation, testing, operation, and maintenance (separately
quoted).
k. Full load package testing.
1.3 Conflicting Requirements
In case of conflict between the technical requirements defined by codes, standards, etc,
specification etc., the most stringent requirement shall govern.
All apparent conflict shall be immediately reported to the COMPANY for resolution before
proceeding with design and construction.
2 ABBREVIATION
The Contractor shall provide equipment and materials that fully comply with the
requirements specified in this section. It is recognized that the Contractor may have
standardized on the use of certain components, materials, processes, or procedures
different than those specified herein. The Contractor shall clearly indicate the standard
items proposed, the specific exceptions to the specifications, and the price change
applicable for supplying such standard items. In cases where the Contractor's standard
is acceptable the contract documents will specifically make reference to the Contractor's
standard equipment.
Unless specifically provided otherwise in each case, all materials and equipment furnished
in the work shall conform to applicable standard specifications and shall be new, unused,
and undamaged. Asbestos containing materials are not Allowed.
Individual parts shall be manufactured to standard sizes and gauges so that repair parts,
furnished at any time, can be installed in the field. Like parts of duplicate equipment
shall be interchangeable.
3.3 Identification
All correspondence, shipping notices, specifications, engineering data, and other documents
pertaining to the equipment and materials furnished under these specifications shall be
identified by the Owner's name, the project name, and the unit number.
All shipments of hazardous materials shall be identified on the materials list. A copy of
the hazardous materials documentation shall be included with the materials list and shall
also be included with the shipping papers attached to the shipment.
Equipment and materials shall be complete in all respects within the limits herein outlined.
All errors or omissions required to be corrected in the field shall be done by the
manufacturer or his duly authorized representative at no additional expense to the Owner.
3.7 Nameplates
The Contractor shall assemble shipping units composed of those items of materials and
equipment which he obtains from subcontractors. Each item shall be tagged with its
individual identification used on the drawings for this Contract and shipped as part of a
shipping unit to the construction site. All shipments from the Contractor's shipping unit
assembly location shall be packaged and identified as indicated in this section. The
Contractor shall indicate the minimum quantity of materials and equipment he will
assemble as a shipping unit, his proposed tagging system for individual items of material
and equipment included as part of a shipping unit, and the assembly location for shipping
units.
Spare parts shall be protected from damage due to moisture and sand accumulation during
an extended storage period by use of special coatings, airtight membranes, bags of
desiccant, or other means acceptable to the Owner.
Each box shall be apparently marked for shipment and identification of contents.
A weatherproofed itemized list of the contents shall be attached to the outside of each
container. A similar list shall be inside each box.
3.10 Protection
All equipment shall be boxed, crated, or otherwise protected during shipment, handling,
and storage. Equipment having antifriction or sleeve bearings shall be protected by
weathertight enclosures.
Coated surfaces shall be protected against impact, abrasion, discoloration, and other
damages. Surfaces which are damaged shall be repaired.
Electrical equipment, control panels, instruments, enclosures, and insulation materials, shall
be protected against moisture and water damage. All external gasket surfaces and flange faces,
couplings, rotating equipment shafts, bearings, and like items shall be thoroughly cleaned,
coated with rust-preventive compound, and protected with wood, metal, or other substantial
type covering to ensure their full protection. All exposed threaded parts shall be greased
and protected with metallic or other substantial type protectors.
All piping, tubing, and conduit connectionson equipment and other equipment openings shall
be closed with rough usage covers or plugs. Female threaded openings shall be closed with
forged steel plugs. The closures shall be taped to seal the interior of the equipment. Open
ends of piping, tubing, and conduit shall be sealed and taped. Returnable containersand special
shipping devices shall be returned by the Contractor.
3 . 1 1 Tools
One set of all special tools shall be furnished and shipped with each piece of equipment for
dismantling, maintenance, adjustment, and calibration of the equipment. A weatherproofed
itemized list of the contents shall also be attached to the outside of each container.
The maintenancetools shall include all special handling rigs, bars, slings, cable and all
specialized equipment for control system maintenance such as extender boards, scopes, and
all software and hardware. All maintenance tools shall be in new and unused condition
and shall become the property of the Owner. The Contractor's tender shall include the list
of maintenance tools which shall be furnished with the equipment.
In addition to the tools for maintenance and dismantling, all special tools shall be furnished
for erection of the equipment. Maintenance tools shall not be used by the Contractor for
erection. Erection tools shall remain the property of the Contractor and all shipping costs to
and from the jobsite shall be at the Contractor'sexpense. Erection tools for each piece of
equipment shall be boxed separately. Erection tools shall not be boxed with maintenance tools.
Tools and test equipment shall be new and of good quality.
The Contractor shall furnish a complete set of tools for erection and commissioning at his own
expenses. However if major special tools and test equipment become necessary during
erection,the Owner will, if agreed, hand over the tools and test equipment to the attention
and responsibility of the erection supervisor. The tools and test equipment shall be returned in
good condition or shall be replaced at the Contractor's expenses.
All hardware which has a life of less than one year shall be replaced with new hardware
by the Contractor at the time of taking over and shall be tested immediately prior to taking-
over.
All rotating equipment, except electric motors, shall be factory balanced to a level such
that vibration displacement in microns peak-to-peak is not more than indicated under
"FAIR" on IRD Mechanalysis, Inc. Curve 305D, "General Machinery Vibration Severity
Chart," or as required for reliability and longevity, whichever requirement, as determined
by the Owner, is the more stringent. Electric motors shall be balanced by the manufacturer
in accordance with appropriate standards.
Vibration limits shall apply to the overall reading and any single frequency. The equipment
shall be within the required vibration limits throughout the warranty period. Alignment
records shall be maintained by the Contractor for each piece of equipment. Records shall
be made available upon request by the Owner.
3.14 Lubrication
ENGINEERING DOCUMENT
PLTMG PACKAGE 3
ENG-DED-AAA-MS- EQUIPMENT SPECIFICATION FOR GENERAL
12 of 19
SPE-001 EQUIPMENT & MATERIAL REQUIREMENT
All equipment lubrication systems shall be provided with a connection with piping and valve
to a location easily accessible to permit periodic sampling of the lubricant by the Owner's
operation and maintenancepersonnel. The connectionsshall be located where a representative
sample can be obtained. The sample pipe ends shall be capped. All sample connections shall
be properly labeled.
Grease connectionson each piece of equipment shall be provided with easily accessible self-
relieving grease fittings at each lubricationpoint. Grase connections on guged shall be
accessible from one side.
Each gear drive unit shall be capable of with standing the motor torques developed during
start, acceleration, and decelerationif stalled.
3.17 Equipmentbases
A cast iron or welded steel base plate shall be provided for on skid equipment. Baseplates that
are to be filled with grout shall be furnished with provisions for installing grout. Each
baseplate shall extend under all parts of the equipment mounted thereon, shall support the
unit and its drive assembly, and shall be of a neat design with pads for anchoring the units.
Baseplates for equipment subject to water or oil leakage shall be provided with a raised lip
all around, shall slope toward one or both ends, and shall have a threaded drain connection at
each end toward which the baseplate is sloped.
3.18 Piping
All piping, including all control and instrument piping, furnished with equipment shall be
in accordance with the requirements for piping materials, fabrication, support, and erection
as specified in Design Criteria. Equipment manufacturer's standard piping components will
be acceptable only if specifically accepted under the appropriateequipment specification
section.
3.19 Instrumentation
All the control and instrumentation components furnished with the equipment shall be in
accordance with the requirements of Design Criteria and shall be constructed to with stand
the environmental and process conditions encounteredin the actual service. Explosionproof
construction shall be furnished where required by applicable code or the specifications.
If at the time of the Contractor's tender, the instrument manufacturers specified herein have
an upgraded product from that specified in these specifications and documents which
meets or exceeds the specified instrument requirements, the Contractor shall provide the
upgraded model in lieu of the instrument model specified.
3.21 Anunciators
Visual annunciator equipment shall be provided for individual alarming of process conditions
on local control panels. Each annunciator shall have a sufficient number of windows to
properly identify all incoming alarms. A minimum of 20 percent spare windows shall be
provided on each annunciator for future use. Critical alarms shall be red and all others white.
Each annunciator shall be complete with test, silence,reset, and acknowledge push buttons and
audible device.
An adjustable time delay relay shall be incorporated in the annunciator audible device
circuit to cause automatic silencing of the audible device after a manually selected time period.
Means of silencing the audible alarm without turning the flashing lamp to steady state shall
also be provided. When an alarm occurs, the window shall continue to flash, even if the alarm
clears itself, until acknowledged by the operator by means of the acknowledge push button.
The annunciator stations shall, however, remain lighted until the operator resets the station
by means of the reset push button. The annunciator alarm contacts shall be designed
to accept either normally open or normally closed trouble contacts by a simple field
adjustment. An interlock shall be provided to require an acknowledgement of an alarm
before alarms can be reset. The annunciator shall include electrically isolated Form C contact
per station for remote annunciation. This auxiliary contact shall be wired to panel mounted
terminal blocks for external connection. This common alarm contact shall operate any time
the annunciator has an unacknowledged alarm.
A test push button shall be provided to reveal any defects in the annunciator system.
Operationof the test push button shall simulatethe sequence of operationas in the case of any
fault contact.
3.22 Electricalenclosures
Unless indicated otherwise in these specifications, electrical enclosures, except junction
boxes and pull boxes 100 mm trade size and smaller,shall be as follows:
Location Enclosure Type
Indoor
(Nonhazardous)
Dryareas IP52
Areas where moisture conditions IP55
are more severe than those for
which IP 52 enclosuresare intended
Outdoor (Nonhazardous) Same as indoor moist
areas
Hazardous areas In accordance with the
requirements of the
appropriate codes and
standards for the
location.
Electrical enclosures, except those of cast metal and fiberglass, shall be constructed from
steel plate reinforced as required to provide true surface and adequate support for devices
mounted thereon. Enclosures shall be of adequate strength to support mounted components
during shipment and to support a concentrated load of 90 kg on their top after erection.
All junction boxes or pull boxes 100 mm trade size or smaller in any dimension shall be
galvanized malleable iron or acceptable equal cast ferrous metal.
3.23 Weatherproofing
All outdoor electrical equipment and all appurtenances shall be designed for satisfactory
operation under all ambient conditions. All exposed unpainted parts shall be fabricated of
corrosion-resisting metal. All ventilating openings shall be louvered on outdoor electrical
equipment to prevent entrance of rain under indicated weather conditions. All ventilating
openings on outdoor electrical equipment shall be equipped with fine mesh filters and
stainless steel bug screens.
Internal wiring in factory prewired electronic systems cabinets may be installed according
to the manufacturer's standard as to wire size, insulation, and method of termination on
internal equipment except that insulation for all wiring (including circuit board wiring,
back plane wiring, and power supply wiring) shall be flame retardant. Interconnecting cables
between devices shall be flame retardant. Identification of conductors shall be in accordance
with the manufacturer's identification system. Terminal blocks for connection of external
circuits into factory prewired electronic systems cabinets shall meet all the requirements
of this section.
"Factory prewired" shall denote equipment that is standard stock material, identifiable by
manufacturer catalog number. It shall not apply to equipment that is fabricated to order.
It shall also not apply to manufacturers who have a standard design but routinely or
optionally will fabricate to order.
The following requirements shall be applicable to all free-standing cabinets and panels
utilized to mount operator interface equipment for process control or monitoring, excluding
all control room operator's consoles.
All cabinets and panels shall be reinforced as required to ensure true surfaces and adequate
support for instruments mounted thereon. All instrument cutouts, mounting studs, and
support brackets shall be accurately located. All welds on the exposed surfaces shall be
ground smooth. Finish surfaces shall be free from waves, bellies, or other imperfections.
Edges and bends shall be visually straight, uniform, and free from discontinuities hen sighted
along the edge or bend. All panels and cabinets with equipment mounted thereon that are
located in conditioned environments and are not IP 55 rated shall be furnished with
ventilation louvers with filter kits. If louvers do not provide adequate cooling, ventilation
fans shall be provided.
All cabinets and panels shall prevent the entrance of insects, lizards, and rodents when
closed and secured.
Devices installed within the panels and cabinets shall be mounted on suitable racks and
shall be arranged for convenient access for adjustment and maintenance.
The Contractor shall standardize on a supplier of PLC equipment for the ease of inventory
management. The programmable logic controllers shall be capable of receiving status
intelligence, performing logic functions, issuing control commands, and providing alarms
and status information as required for their associated systems described in these
specifications and documents, and as required by the Contractor's design.
Each PLC shall consist of a solid-state control system which has user programmable
memory for storage of instructions to implement specific functions such as input/output
control, Boolean logic, and information. The CPUs shall be capable of interfacing with
other programmable logic timing, counting, arithmetic, and data manipulation. The PLCs
shall be purposely designed as an industrial control system which can carry out the necessary
sequence control functions. The PLCs shall also perform all additional functions such as
modulating as required by their associated system. Each PLC shall be furnished with a
portable programming unit complete with programming, documentation, and
communication interface software.
The PLCs shall be fully compatible with other equipment. The Contractor shall be
responsible for any changes in any PLCs which are required because of defective equipment,
incorrect internal connections, or incorrect selections of equipment.
All software shall be easy to understand and troubleshoot. The Contractor shall develop
tested software for the system according to the requirements of these specifications and
documents. Software shall provide counter and timer functions without additional hardware.
Programs shall be fully labeled and commented. At a minimum, all variables and states
shall be labeled, and each state shall be given a brief comment indicating its function. All
Boolean expressions shall be commented.
The Contractor shall furnish two final copies of all PLCs' operating programs clearly
marked with program title, revision number, and last revision date. The Contractor shall
furnish six hard copy printouts of all final operating programs for each PLC in relay ladder
format, complete with documentation as described in these specifications and documents.
Unless specifically stated otherwise, each PLC shall conform to the latest applicable
standards of ISA, ANSI, IEEE, EEi, and SAMA as to ratings, construction, and operation.
Any conflict between standards shall be referred to the Owner acceptance.
PLCs utilizing fuzzy logic may be submitted by the Contractor during his tender. All
PLCs utilizing fuzzy logic must be acceptable to the Owner.
3.28 Memory
Memory in each PLC shall be user-programmable and changeable with means to guard
against unauthorized changes or entry. The complete memory capacity specified shall be
available to the Owner. All memory capacity requirements for timers, counters, and internal
outputs shall be provided by the Contractor in addition to the memory capacity
requirements specified in these specifications and documents.
Memory shall be sufficient to provide 20 percent spare capacity after all programming has
been entered and system tuning accomplished. All memory shall be battery backed RAM.
DCS to programmable logic controller interface shall be used to allow the Contractor to
generate interactive VDU graphic displays within the DCS for operator control of the
balance of plant control system equipment as required. The DCS shall be capable of
performing control, alarming, and monitoring functions of the PLC. All control logic for
the Contractor's equipment shall reside in its associated PLC. The only logic in the DCS
will be that required to emulate the control functions required to interface with the
Contractor's control logic.
Transmitted data from each PLC shall include all information necessary for the DCS to
monitor, alarm, and control the process and the PLC. Such data may include pertinent
analog and digital status information, interlocks, alarms, and maintenance conditions.
Each PLC system shall be provided with 10 percent spare 1/0 wired out to terminal blocks
as well as spare slots for 10 percent future, additional 1/0 modules wired out to terminal
blocks.
The programmable logic controllers shall operate from power provided by the Essential
Service AC System.
Each PLC shall be grounded in strict accordance with the PLC manufacturer's
recommendations and as per the universal system grounding practices.In the event of power
failure or malfunction of components in a controller, control signal outputs shall be
commanded to a defined status, as defined by the Contractor, via safeguard circuitry, thereby
rejecting operating equipment to a predetermined status. Operator initiation shall be required
to restart the system.
6. INSPECTION AND TESTING