project Supply and installation of new compressors and air circuit

 

POWER PLANT

PROJECT

SUPPLY & INSTALLATION OF NEW AIR CIRCUIT & COMPRESSORS

 Introduction:                                                                                  

The service air circuit, which was established during the construction of the station in the early eighties, constituted an important basic tool - within the station's assistance package - in the completion of periodic and emergency maintenance work. Among the most important uses of the system were the following:

 Saving air at the time of unit maintenance for equipment that operates on air pressure, such as the Torque Wrench and Impact Wrench, which operate at a pressure of 100 psi.

* Providing air for mechanical and electrical workshops.

After the expansion of the station and the addition of 6 new turbines, the need for more service air appeared to meet the maintenance requirements, which prompted the addition of two new compressors.

Now, after the old compressors have become obsolete and have frequent failures and their inability to meet the station’s need for service air, which causes delays in maintenance work, a project to supply and install heavy-duty air compressors (Heavy-Duty) has been approved, provided that this includes all accessories such as control and display panels, cooling Air, filters, tanks, pressure reducing platform, wiring and devices and all that the system requires to achieve the aforementioned requirements. And in the desire of the station to achieve higher returns from this system, the following requirements have been added

 Providing the appropriate amount of air to clean the air filters entering the turbine for 22 units, and cleaning the air filters for the turbine generator with six units (the new units), as the pulsing system was fed with service air after the compressors designated for the system failed at the time of the station’s construction.

 Providing air for the non-return valve test device, and the fuel injector test device at the mechanical maintenance workshop, where the workshop was supported with these two devices as part of the gas project

         Below, the general requirements, the technical requirements, as well as the cost schedule for the basic requirements are explained. Noting that the contractor is required to visit the station to get a better visualization of the system components and the proposed locations for the implementation of the compressor room and to see the old compressors to remove them as part of the project requirements, as well as to know the specifics of work in the station from safety procedures and others

To supply and install heavy-duty air compressors including all accessories like control panels, air coolers, redundant dryer, air vessels, pressure reduction skid, piping, and instrumentation, etc. to meet the following requirements:

  To provide enough air for pulsing to clean inlet air filters for 22-GT MS7001E/EA units and generator air filters for 6-GT MS7001EA units.

  To provide service air for testing of fuel check valves and fuel nozzles,

  To provide service air used for general maintenance: pneumatic tools like impacting and torque wrench working at 100-psi.

  To provide air for the mechanical and electrical workshops.

 

General Technical Requirement:                                   

The submitted offer must include complete plans for the supply, construction, installation, inspection, and testing of all civil, mechanical, and electrical works, and the provision of qualified labor to ensure the implementation of the installation and connection works for the proposed places indicated in the attached plan. These items:

 The initial technical specifications are attached to the application as possible, taking into account the technical preference in design.

  The contractor shall deliver the compressors and their attachments and all that the project needs to the site of the seventh station.

 The contractor must visit the station to inspect the site, take measurements, make the necessary studies, and attach them with the initial plans for all technical works (construction - mechanical - electrical) provided that they are handed over to the station for approval.

* The contractor must submit a plan for the training program necessary for two engineers and four technicians to be approved by the station. Note that the training will be on-site for operation and maintenance.

  All technical works (structural - mechanical - electrical) are the responsibility of the contractor.

  The construction works must comply with the degree of pressure bearing of the land on which the project is to be built, which will be submitted by the seventh station.

  Installation of the equipment must be in accordance with the specifications and rules of the factory.

  Before the initial receipt of the project, the performance of the system must be tested, with the need to clarify the method of testing within the offer.

  The Contractor shall provide all necessary equipment for installation, inspection, and testing.

* The Contractor shall provide a guarantee of effective performance of the supplied equipment and devices.

* The contractor shall provide a list of all spare parts included in the project, as well as a list of spare parts proposed for supply by the contractor as a stock for two years after the end of the warranty period - as part of the project costs - for review and approval by the station before awarding.

* The contractor shall provide a workmanship guarantee and the necessary spare parts for a period of two years, starting from the date of issuance of the initial receipt certificate in accordance with the provisions of the company's general conditions. There will be a delay fine of 2/10000 of the contract value for each day in case the maintenance team is late to be present to solve the problem within three working days of notifying the plant to the contractor by fax. Note that the delay in solving the problem and restoring the system to its normal state after three working days from arriving at the site will be considered a delay. In the event of a malfunction that requires a longer work period, then the contractor must submit a work plan for the station explaining the reasons. In the event that spare parts are needed from the parts list for a period of two years in the station, the contractor must compensate them after using them in the least possible period.

  The implementation period is 26 weeks from the date of handing over the worksite, which must take place within a week from the date of the baptism.

  Any deficiency in this offering does not excuse the Contractor from providing the required service for the station in an integrated and approved system. 

The scope will include supply, installation/erection, testing, and commissioning for all civil/mechanical/electrical works.

 The conceptual layout plan for all the jobs is attached herewith.
  The detailed outlines of the job will include but are not limited to the following:

  Technical Guidelines are enclosed to be considered where applicable.

  Supply of air compressors with all necessary accessories to the site.

  The contractor shall prepare his complete measurements, analysis, and proposed construction drawings for all civil/mechanical/electrical works upon visiting the site and submit his proposal approval.

  Contractor must provide a detailed outline of the training program for two engineers and four technicians.  Training will be held on-site for both operation and maintenance.

  All civil/mechanical/electrical works will be the responsibility of the contractor.

  Allowable soil bearing pressure will be provided by CRB to be considered in the construction.

  Installation of the equipment must be as per manufacturer specifications and recommendations.

  A performance test must be done before handing in the provisional certificate.  Documentation of the test procedure must be included in the bid.

  All necessary materials and equipment needed for installation, commissioning and testing are contractor responsibility.

  The contractor shall provide a performance guarantee for all machines and devices.

  The contractor shall provide a 2-year warranty, starting from the issuance of the provisional acceptance certificate, of workmanship and spare parts against supplied equipment and erection according -CRB general conditions.

If a part of the system malfunctions or any problem persists, the contractor or his representative has to show up within three working days after faxing to the contractor.

  A penalty of 2/10000 of the contract lump sum will be subtracted against each day after the three days if the contractor fails to show up.  If the contractor fails to put the system back into service or solve the problem within three days of his arrival, then each extra day will be counted in the penalty.

  If the problems require more than three days to solve, then the contractor must give his explanation and scope of work for approval and exemption from the late fee.

  Meanwhile, the contractor can utilize the

  the stock of two years' spare parts if needed.

  A replacement must be provided as soon as possible.

  All the spare parts list is to be included for review.  A list, recommended by contractor, of two years consumption spare parts is to be submitted for approval and delivery upon acceptance as part of the lumpsum.

  Delivery and total project period will be 26-weeks from the date of site delivery certificate and it will be implemented one week after placement of the purchase order.

  Any omission in this requirement SHALL NOT relief the bidder of his application to deliver a system that is complete and will operate satisfactorily, reliably and safely.

Main Technical Requirements:                                   

  Design Temp: The whole system is expected to run satisfactorily and safely at 55^oC.  Thus, all components of the design must meet this condition.  Compressors cooling skid must be dependent on the number of compressors running and the required heat rejection rate to the cooling effluent.

  The analysis must show the temperature upper and lower boundaries depending on the allowable delivered air temperature and the material thermal shock stresses.

  Air to be supplied from HEAVY-DUTY air compressors giving a total of…

Pressure: about 125-psi

Total Flow: about 2300-Cfm

Elec. Power: 460/3/60

Cooling:

 by water,

 cooled-down using chiller plant(s) for

 all units

 (redundant pumps &compressors).

 No water-cooled by fans.

Control Display: Digital; monitoring information and alarms & protections and making operating adjustments.

V-type compressors are preferred.  A substitute is negotiable.

  Compressors and chiller to share one digital control panel allowing for pressure-dependent compressors sequence loading and alarm monitoring.

  Compressors are to be enclosed in an isolated room.  Air is to be blown inside the room (+ve pres.) through fine air filters. 

 The tentative location is near unit# 8, outside the turbine hall. 

 The contractor is to advise on the location during his visit to the plant.

  Pressure drop and length of pipes in addition to location constraints and obstacles that limit the location.

  All accessories such as valves, switches, and differentials, etc. are included.

  Delivered air from the compressors is to enter 3-large air storage tanks (around 12.5-m³ each) through a well-designed manifold to allow for elongated compressors stand-by period.

  Air entering the manifold must be passed through an efficient air cooler and redundant dryer.

  Air is to be stored @ around 125-psi.  A pressure reduction to 100-psi must occur before air exits the storage tanks and enters the manifold leading to the mainline.

  Hung pipes should lay adjacent to the existing one. 

 The contractor should give a provision for the interconnection with the old lines. 

Connection with old pipes must be through isolation valves. 

 The contractor should advise on and include the points of isolation on the entire network to ease the leakage inspection and hence maintenance.

  Feed line branching locations (a list of minimum acceptable sizes is included; the contractor is to submit a list with calculations):

 

Units 21/22	2” x 120m line from compressors room
Turbine Hall	4” x 250m line from compressors room up to each end of the turbine hall.
Units’ Pulsing	2” x 25m line for 22 units from nearest point of 4” line to pulsing inlet air vessels.
GT 17-22 Generators	2” x 30m line from the nearest point of main the line to generator air filters pulsing system.
Mechanical Workshop & Check V/V Test Device	2” x 90m line from the nearest point of 4” line to workshop
Electrical Workshop	2” x 75m line from the nearest point of 4” line to workshop

  Compressed air must branch to the 22-gas turbines pulsing systems, new units generators’ air filters and to the maintenance outlets.

  Locations are as follows:

 

		Quantity	Branch Size (min.)
	Units	1-outlet each turbine side (44 sides)		1 ½” x 5m
	Units’ Pulsing	1-supply the line for each unit (22 units)		2” x 25m
	Mechanical Workshop	4-outlets		1 ½” x 5m
	Check V/V Test Device	2-supply lines		2” x 5m
	Electrical Workshop	2-outlets		1 ½” x 5m
	Generators	1-supply the line for each unit (6 units)		2” x 30m
Note: all lengths listed are approximate.  The contractor should make all necessary measurements on-site.

  The two existing compressors must be connected to the new network.  The three old compressors must be removed as part of the project.

  Pulsing system compressors for inlet air filters must be removed.

  Each of the outlets and pulsing lines will have a pressure gauge and a shut-off valve.  Outlets are all ¾” in size.

 

PRICE SCHEDULE

Item

Work Description

	Material(CIF)	Construction & Erection	Total (SR)
1	All civil works like a forced ventilated room with inlet air filters, foundations, etc.
2	5 no. of air compressors to provide the flow rate as per technical guidelines.
3	Supply and installation of pipes and piping components.
4	Control panel
5	Chillers
6	3 no. air storage vessels with dryers, instrumentation, and protection.
7	Two years spare parts list
8
9
10

Required manuals and drawings in addition to on-site training is part of the lumpsum price.

 

PRICE SCHEDULE

Item	Work Description	Material(CIF)	Erection	Total
1	All civil works like a forced ventilated room with inlet air filters, foundations, etc.	The Total Estimate is Given as a Reference.  These Two Fields are to be Filled by Bidders.  Documentations and Drawings and on-site training are Included for each item in its total cost.		240,000
2	5 no. of air compressors to provide the flow rate as per technical guidelines.			950,000
3	Supply and installation of pipes and piping components.			180,000
4	Control panel			85,000
5	Chillers			190,000
6	3 no. air storage vessels with dryers, instrumentation, and protection.			175,000
7	Two years spare parts list			180,000