NTT#2

N O T I C E T O T E N D E R E R S

Number Two Date: 22 July 2016 Reference: 80507610 Client Fiji Electricity Authority MWH New Zealand Ltd

Project Wailoa Power Station Generator Rehabilitation Tender No. MR58/2016

Q. In the specification it mentions the Contractor shall supply ALFLOC 2000 in the quantities and concentration specified in the manual. We cannot find this in the manual but may have found reference to a separate 3b) manual. Are you able to send this manual, or advise the quantity/concentration of ALFLOC 2000 required? A. Please find attached part of the cooling system manual detailing the requested information. We have reviewed other parts of the manuals and no further information is available.

SECTION 1 TIBB

CONTENTS.

1. Cooling Water System.

1.1. Description.

1. 2. Operation .

1.3. Maintenance.

1. 4. Dismantling.

DRAWINGS.

The following drawings are included at the end of this section:

UW 103.517 - Cooling Water System Schematic.

Fig 1-7 Arrangement of CW System Components and Piping.

UW 103.912 - CW Surge Tank.

UW 302.517 - Tailrace Water/Water Cooler .

l.

1.1.

-·-

SECTION 1 Page 1 of 6 TIBB

Cooling Water System

Description

The Cw system is shown diagramatically on drg. UW 103.517 and is arranged as illustrated in Figs. 1-6 included at the end of this-section.

The main elements of the system, as described in other volumes (refer equipment list Section 2·. l, are:-

4

1

1

1

1

Other

2

2

1

Generator air/water coolers

Generator upper bearing oil cooler

Generator lower . bearing oil cooler

Govenor oil/water cooler

Turbine bearing

Elements specific to this system are:-

CW pump + motor sets (one duty plus one standby)

Tailrace water/wat~r coolers

Surge tank

Flow and p ressure switches, etc.

Orifice plates are provided in the pipework system to achieve the correct flows to the generator and turbine coolers. The sizes of orifices required was determined during commissioning and recorded in Section 2.

The CW pipework and fittings in the tailrace (Figs. 1 & 2) fabricated from stainless steel while the remainder of the pipework is executed in carbon steel. In general, flanges are ASA 150 LB RF series and threaded connections to BSP.

Details of all individual valves, fittings and devices are provided in Section 2 and the completed CW system was pressure tested on site at 1 MPa (10 bar) .

( 1.

1.2.

1.2.1.

SECTION 1 Page 2 of 6 TIBB

Cooling Water System (cont'd)

Operation

Filling, Venting , Dosing & Draining

Each CW system is to be filled with clean filtered drinking quality water only via the supply line to the surge tank (Fig.6).

During filling, vent the generator air/ water coolers with the valves provided (Fig . 5); similarly for the generator bearings.

When the system has been filled, the float valve 553. will automatically maintain the level in the surge tank to compensate for temperature variations and any losses ..

On completion of filling, run each CW pump under the manual control (see below) for a short period to assist in expellirig any trapped air and co~tinue to vent and run the CW pumps alternately until the system is free of all trapped air and only water is released via the vent valves .

Dose the CW water charge using a product as Catoleum "Alfloc 2000" or comparable locally available product. Dosin~ chemicals to be mixed in concentrated liquid form and introduced into the CW $YStem by means of the hand pump provide<l (one between 4 units - temporarily connected to valve 552a when dosing is to be undertaken) .

Dosing should be undertaken with a CW pump running and the correct level of dosing ascertained using the maker's stipula ted testing methods by taking samples via valves 552 or 53lf.

1.

1. 2 .

1.2.l.

1.2.2.

1.2.3.

1.2.4.

SECTION 1 Page 3 of 6

Cooling Water System (cont'd)

Operation (cont'd)

TIBB

Filling, Venting, Dosing & Draining (cont'd)

Draining the system may be carried out in parts by isolating the section on which it is desired to carry out work using the valves provided. For convenience, an i solating valve has been provided in the downpipe from the surge tank. On reassembly of the CW system, open the isolating valve and vent any trapped air in the manner described above.

cw Pump Operation for Service

Selection and control of the pumps for service in automatic and manual modes are described in Volumes 5 and 7a. Starting and stopping of the selected pump in these modes are subject to certain preconditions associated with unit sequence control and interlocking requirements being met.

Low CW pressure is detected by pressure switch ne2" which, if the pressure does not recover after a short adjustable time delay, initiates the start of the standby pump and an alarm. If the pressure still does not r ecover after a further adjustable time delay , the unit is tripped. Monitoring of pump operation and of CW flows in the i ndividual cooling circuits for the generator and turbine are desribed in further detail in Volume 5.

CW Pump Operation for Test

Selection of an individual CW Pump for test is made using the CWP four position selector switch on the MCC (see Volume 7a . Section ) . The pump can then be started and stopped for test purposes , without the need for '' service" preconditions being met, using the CW Pump start/stop switch on the main contr ol panel.

Af:.r:ormal Operation

Abnormal operation with one tailrace heat exchanger out of service is forseen with unit loads up to 13 MW. No special precautions or adjustments are necessary.

/ 1.

1.3.

1.3.1.

1.3.2.

1.3.3.

SECTION 1 Page 4 of 6 TIBB Cooling Water System (cont'd)

Maintenance

Chemical Dosing

Check a satisfactory level of chemical dosing at intervals of approximately 3 months or on any occasion where there has been a significant loss of CW charge due to maintenance operations following the procedures described in the chemical supplier's recommendations. Correct dosing is important in order to prevent scale deposits in the CW System and to avoid corrosion of the metallic cornponen ts .· See Page 4a for procedure.

Protection Devices

Check the correct operation of the protection devices e2 - e327 on a routine basis in line with the time program established for similar work for the remainder of the plant.

Lubrication -

CW Pump

cw Motors -

Valve Spindles

check weekly and top up as necessary the oil leve l in the bearing housing­check with t he dipstick provided. Employ same gr ade of oil as for turbine and generator bearings.

dismantle bearing housings and check bearings after 3-5 years. If bearings are provided with removable dust caps then remove old grease and replace wi~h new. Repeat about every 3 years and replace the complete bearing when necessary but not later than after about 50,000 operating hours. I f fitted with fully sealed bearin9s it is recommended these be replaced after about 20,000 operating hours.

grease via the nipple provided on the yoke.

/

-

l.

2.

3 .

4.

5 .

6 •

7.

8.

9.

10.

11.

SECTION l Page 4a

MODIFIED SODIUM NI TRITE TEST METHOD FOR

USE AS LIMIT TEST FOR ALFLOC 2000 CONTROL .

TIBB

Collect sample of the circulating water, prior to next addition of Alfloc 2000 in plastic bottle supplied.

All testing equ i pment must be washed well with tap water (NOT TREATED WATER) and shaken to remove surplus water .

Assemble the 3.5 gram per l itre Sulphamic Acid burette and squeeze reservior to fill burette. The burette will return to zero when the reservior is released. (N . D. sulphamic solution may deteriorate anc fresh rea g ent solution should be made up every 4-6 weeks) .

Measure 25rnl sa~ple of the treate d jacket coo l ing water and transfer to the plastic cish.

Add two level teaspoons of Sodium Bisulphate powder to the d ish containing the measured sample.

Add one or two drops of sample (5) starch iodide test paper. A deep will develop if any Sodium Nitrite

to a piece of blue colour is present.

Add 8.0ml of 3 . 5 grams per litre of sulpharnic acid solution from the burette .

Stir for 20-30 seconds.

Immediately add one or two d rops of the stirred liquid (8 ) onto l~" - 2~ " of the starch iodide test pa per.

If the sodium nitrite level is above 800 ppm t he paper will turn blue to a very dark blue immediately.

Wash all equipment with fresh tap water and shake dry .

ACTION TO BE TAKEN BASED ON TEST .

(a) If paper (9} turns blue treatment lev el is satisfa c tor y .

(b} If paper does not turn blue, add a quart of Alf~ 'JC 200 0 f o r ev ery 10 gallons o f wate r in the system. Circulate system f e r one hour and test again.

NOTE : Fo r actua l sodium nitrite refer to Alf loc Test Me thod - T~·'l 8 5 .

CATOLEUM l='TV. LTCJ. HEAD OFFICE: ANDERSON STREET, BOTANY, N.S.W. 2019 Tel. 666 7733 SALES OFFICES: ASHFIELD Tel•phone 798 3000 NEWCASTLE Telephone 67 3293 MELBOURNE Telephone 489 8411 BRISBANE Tel•phone 48 0799 GLADSTONE Telephone 79 1010 TOWNSVILLE Ttlophone 79 3986 ADEL.AIDE Telephone 268 2422

e PERTH T•lephont 37 47SS • KARR.ATHA Telephone 85 1062 • HOB.ART Telephone 23 7336 • LAUNCESTON Telephone 2 4631 • WOLLONGONG Telephone 83 1651 e JAKARTA Telephone 2DIS6 e ROTORUA Telephone 53 461

RETYPED FOR I NSTRUCTI ON HANUAL~

This fnlcrm~tlon based u()on our testing and experlenc;t'I 1s <Jfferea without charge a.s (J tJtr of our 111r111ce ro customers. It Is tntenaac /01 u• • Oy persons /!aolng roc/lnleol ski/I at l/!elf own alsc retlon ana risk. W• do not guarantae favourao1e result:; and .,,,, a~sume no llablllly In conn&cllon with lt!J U!~ . This lntormst1on I! t10t lnttM ded a!I a licence to oDBrBl9 vncJer or a rttccmmencarlon 10 intr/1199 any p3tent.

I 1.

1. 3.

1.3 . 4.

1.3.5.

SECTION 1 . Page 5 of 6

Cooling Water System

Maintenance

CW Pump Glands

Adjust the gland follower to control the stuffing box leakage so that it i s always sufficient to lubricate the packing.

TIBB

Repack when the follower has entered the stuffing box by more than one packing width using locally available packing material and readjust .

Tailrace Water to Water Coolers

These coolers have been designed for use with clean water on l y and a fouling factor of 10% was allowed in the de~ign.

In case, due to unforeseen factors , fouling of the heat e~changer tube external surf aces occurs , cleaning ·by high pressure water jet may be carried out in-situ . Frequ ency of cleaning will depend on the rate of deter­ioration of the heat dissipation capacity which will · be indicated by high CW ret urn temperature s which in turn results in high lubricating oil temperatures ·and is indicated

.by the bearing oil temperature indicators .

I 1.

1. 4.

1.4.1.

1.4.2.

1.4.3 .

\

SECTION 1 Page 6 of 6 TIBB

Cooling Water System (cont'd)

Dismantling

Tailrace Cooler

Removal of tailrace water to water coolers can be undertaken via the turbine casing access door (see Volume 2) .

To assist this operation , the grid flooring beneath the turbine runner will need to be partially removed to allow the erection tackle for the turbine inlets (Volume 2, Section 4) to lift the cooler from the tailrace floor to a height above the grid floor sufficient to allow the introduction of a temporary floor tp support the cooler weight.

CW Pump

To dismantle the CW pump, first remove the complete pump from the bedplate to the workshop where the -pump body may be separated from the· bearing housing as shown in the . exploded sectional view included in the enclosures to the equipment list 2.7.

Motors

For motors of the size under consideration , it is cheaper to replace with new than repair~ The exception to this is dismantling for the maintenance and/or. replacement of the bearings, details of which are g~ven in Section 3 .

I ~I 0.1 a. I ~I

"' ~

CD

~

SURGE l.~~j TANK 543

S29o-m2 l .,Cl ~ I

~;;JI;~I~ ~ EFFICIEN~ = s Ti--o.~ _,.__.,.._ ..... ~ 'l><l><J !><l~I .,. y D I 112· ~ 501 528 ~ gj ~ ~6 '31:J7 ~ I I I I

52Bo-ml

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534 ls:JL.a

9 "'

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~ 4" I 112·

Water-Water Coolers Air Coolers IU. Bearing,L.Bearingl Bearing 'Governor Oil Cooler Oil Cooler Cooling Oil Cooler

TAILRACE GENERATOR TURBINE

~I I I~ Tille:

50L.,:05 500-503.506-511 512-521 522-525 526,527 528.529 530,531f 531-531e 552- 552b 532-532e 533-533c 534- 531.a 535 536 537 538 e4&e5 e140&e327 e8-e11 e2 e3 543 544-551 528a-m1 529a-m2 ® 553

Gate Valves 3" Gate Valves 4 n

Gate Valves 2 • Gate Valves 1" Gate Valves 314" /\b'\ Return Valves 4" Isolating Valves 11r Drain Valves 3/8" Tapping Point 1/2" Breathing Valves 3/8" Generator Air-Water Coolers Tail race Water-Water Coolers Generator Upper Bearing Oil Cooler Generator Lower Bearing Oil Cooler Turbine Bearing Oil Cooler Turbine Governor Oil Cooler Liquid Flow Monitor with Switch Liquid Flow Monitor with Switch Liquid Flow Monitor with Switch Pressure Switch Low Level Alarm Switch Surge Tank Flow Regulation Orifice Cooling Waterpump P1 Cooling Waterpurnp P2 Thermometer Pocket Float Valve 3/4 •

Numeric Device Numbers {e.g.536) correspond to the items in the Equipment List, Volume 3b, Section 2.

Alpha Device Numbers (e.g. e 140 l correspond to thE? items in the same Equipment List and ore also shown on the Field Terminat ion Diagram uw 390109.

e2.e4-e327 appear on Circuit Diagram USA 001990, Sht.2. e3 appears on Circuit Oiaqrarn USA 001995. Sht.3.

"O 0 4

SCHEMATIC

Sca le: I Drawn I D.K. ,tfE.(J;t

NIA -1a. •'4

Redrawn for 0 &M Manual FIJI ELECTRICITY AUTHORITY

DRAWING N'1

TIBB TECNOMASlO ITALIANO

eROWN BOVERI MllANO COOLING WATER SYSTEM luW 103 517

L

SUPPLY TO TAIL RACE WATER TO WATER COOLERS. (see lig 2)

.. f~--- ·-1

CW. PUMP SETS 528 & 529(see tig7)

xl

FEA-W/\.1' '"'/I. l - l.

C.W. SYS fEM

Illustration for Instruction Bool< Vol 3b S ect ion 1

To be read in conjunction with HYDRAULIC DIAGRAM AND

EqUJPMENT LIST UW103517

SUPPLY TO GOVERNOR OIL COOLER (see fig 3)

SUPPLY TO TURBINE --+- BEARING(see fig3)

~ I T_~ ~_l I

C.W. PIPEWORK PLAN VIEWS

FIG N~ l

'--

FEA-WAILnA 1-/,

·l~~.J"'~~-\1 ... ~ (OOLE.r\. ' ~

555 ·~-

125 l-1 J>O J till. I M' ~ _...s~a drowing UW 302511

vk,7i~::.2:/~7/ 0/J SUPPLY TO TAIL RACE WATER TO WATER COOLER

------11

C .W. SYS • C:M

lllustrolion for Instruction 800!1 Vol 3 b Section 1

To be r ead in conjunction with HYDRAULIC DIAGRAM AND

EQUPMENT LIST UW103517 I 1:

C.W. PIPEWORK ELEVATIONS

FIG N~ 2

\..._

Sed•ohAA (~1) f;IO.

--- 524

t ~

e5

l 125.15

~toro,.,q _ __y_----~·-~

- F.!

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FEA-V' ''.OA 1-1. ------1

C.W SYSTEM

Illustration for Instruction Book Vol 3b Section 1

To be reed in conjunction with

HYDRAULIC DIAGRAM AND

Eq'JIPMENT LIST UW103517

No's iri Brockels c;re Orifice Pla tes to• Flow Balancong

e317 rt-·_ 111":1~1·-

526 - o;_ l I (551) ;: ~1_ 11==--+----

524 (550)

To Turbin Bearing

From Tur birl!e Benr!ng

12a.oo " ' 1.,.00 ...L.J_ --- - .,. ·~- ,__ _ ___ _ ...__ ________ _J,___ _ _ ___ -j.-------1-

SU PPLl ES TURBINE BEAR ING, GENERATOR LOWER BEARING & GOVERNOR OIL COOLER .

CW PIPEWORK ELEVATIONS

FIG N~ 3

~

Tum\J"IO.b !.idt

~I

SUPPLY TO GENERATOR AIR/WATER COOLER

FEA -V .OA 1-1. -------!

C.W. SYS TEM

llluc;tratirn for Instruction Boo!< Vol 3b Section 1

To be read in conjunction with HYDRAULIC DIAGRAM ANO

EQUIPMENT LIST UW103517

Neis in Rracket s ore Orifice Ploles for Flow Balancing

C.W. PIPEWORK PLAN VIEW

FIG Ni:> 4

I.

I I

I

,, '

•..uO

L

~

View from X (f1':l<I)

I

+-++-I

SUPPLY TO GENERATOR AlR/WATER COOLER

S~c~ion A-A{f19 4)

JmL \/.____ ----

ti"lO

<1>39~0

t•tlD ~I

SUPPLY TO GENERATOR UPPER BEARING

FEA-\A OA1-i, ------1

.C.W SYSTEM

llluslralion for lnstrudion Book Vol 3b Section 1

To be read in conjunction with HYDRAULIC DIAGRAM AND

EOUIPMENT LIST UW103517

Nos in 8rockels are Ori lice Plates for Flaw Balancing

C.W. PI PEW ORK ELEVATIONS

FIG N~ 5

~ e3

'3G ~~o \

~SURGE TANK UW103912

\OVERFLOW A

SUPPLY '8 .

- 530

PLAN VIEW'c-c'

,/'" :co

FEA -WAILOA 1-4

C.W SYSTEM

Illustration for Instruction Book Vol 3b Section 1

To be read in conjunction with HYDRAULIC DIAGRAM

UW103517

~..U..U..___ __ CSOLATlll<G VALVE 51.0

OVERFLOW 'A. DRAINS TO ANNEXE ROOF

WATER SUPPLY '9' TO VIATER SLPFLY MAIN

r?C:""~S

~-___..._-~~==:f./ TO COQING 'MTER SYS TEl,f c'

SURGE TANK

VIEW X FIG Nt? 6

'120

/

FEA -WA ILOA 1- L.

C.W. SYSTEM

illustration for Instruct ion Book Vol 3 b Section 1

To be read in conjunction with HYDRAULIC DIAGRAM AND

EQUIPMENT LIST UW103517

C.W. PIPEWORK ELEVATION

FIG No 7

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t--~f 11 111 ~

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TIBB TECNOMASJO ITALIANO 6~0WN BOVE~I

Mll.ANO

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180

C.W. SURGE TANK

305

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Scale: IDrawri I I

REDRAWN for INSTRUCTION MANUAL

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M/\TCR IALS

SMOOTH TUIJES TUllE PLATES llEl\DER BOXES SIDE PANELS & SUPPORTS

DESIGll PERFORMANCE AT TAILRACE WATER TEMPERATURE 25°C

HEAT LOSSES PER COOLER kw

QUANTITY OF INTERNAL

19.05 ~ x I .066 THK - ALUMINIUM BRASS MUNTZ METAL

STAJNLESS SlEEL AISI 304

STAINLESS STEEL /\IS! 304

RJIT£D VAil 1

1001 LOAD AND MAX.LOAD lllTll

2 T/\ILRACE WATER/ GENERATOR AIR WATER COOLERS

317

COOLER OUT OF SERVICE

257

REC IRCULATED TRE/\TED WATER J.{n;n 686 630

INTE RNAL RECIRCULATED WAl ER INLET TEMPERATURE OC

OUTLET TEMPERATURE oc

QUANTITY OF EXTE RNAL ( ie TAIUU\CE) HATER m3 sec

INTERNAL PRESSURE LOSS

TA ILRACE W/\TER TO WATER COOLER SURFACE

OPERAllNG P~ESSURE

INTERNAL TEST PRESSU RE

COOLER WIGHT EMPTY FULL

33.7

27. l

APPllOX 4

32 .4

26 .6

/\PPROX 3

15m llEllD MAX

49 .4 m2

5 bar

10 bar for 30 min

1220 kg

1400 kg

VAR 2 MAX.LOAD WITft TAI LRACE WATER/ WATER COOLE R OUT OF SERVICE

514

1045

36.6

29.6

APPROX 3

Scale: IDrown l,---- - - - ---t

ll I 11 \] . 01 ::>:

TIBB TECNOMASIO IT/\UANO

anOWN 80VERI Mll/\NO

Title :

TAI L RACE WATER /WATER COOLE

REDRAW N for INSTRU TION MANUAL

uw 302 517