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MINISTRY OF ENERGY

IRAN POWER DEVELOPMENT COMPANY

I.P.D.C

PROJECT: SHIRVAN 6X159 MW GAS TURBINE POWER PLANT

TECHNICAL SPECIFICATION

FOR

CATHODIC PROTECTION MATERIALS

IN-HOUSE REVISIONSD

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0 FOR APPROVAL A.P. 2005.03.09 H.KH. 2005.03.09 E.A 2005.03.09Rev. DESCRIPTION DESIGNED DATE CHECK DATE APPR. DATE

MINISTRY OF ENERGY

ORIGINATOR:

KHERAD WATER TREATMENT CO.

MAPNA CO.

(PRIVATE JOINT STOCK)

IRAN POWER PLANT PROJECT MANACEMENT CO.

DOCUMENT NO.:

MP-SVG-31ED-04-AE0-001

Rev:

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PROJECT:

SHIRVAN 6X159 MW GAS TURBINE POWER

PLANTIntel. Rev.

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Rev. DESIGNATION DESIGNED DATE CHKD DATE APPROVED DATE

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IRAN POWER DEVELOPMENT COMPANY

I.P.D.C

PROJECT: SHIRVAN 6X159 MW GAS TURBINE POWER PLANT

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ORIGINATOR:


MAPNA CO.



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CONTENTS

1. SCOPE

2. REFERENCES

3. CLIMATIC CHARACTERISTICS

4. GENERAL

5. TRANSFORMER RECTIFIER

6. IMPRESSED CURRENT ANODES

7. BACK FILL

8.NEGATIVE RESISTANCE BOX

9.POSITIVE/ NEGATIVE BOND BOXES

ORIGINATOR:


MAPNA CO.



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1. SCOPE

This specification covers the minimum requirements for design, materials, fabrication, inspectionand preparation for shipment of cathodic protection materials to be used in SHIRVAN GASTURBINE POWER PLANT of IRAN POWER DEVELOPMENT COMPANY located inShiravn/Iran.

2. REFERENCES

The latest edition of standards and codes stated below to the extent specified shall be consideredas part of this specification:

- National Association of Corrosion Engineers (NACE)- British Standards (BS)- International Electrotechnical Commission (IEC)- American Society of Testing and Materials (ASTM)- Iranian Petroleum Standards (IPS)

In case of conflicting codes and /or standards, the stricter requirement shall govern.

3. CLIMATIC CHARACTERISTICS

Min. Absolute Temp. : -30 CMax. Absolute Temp. : + 42.3 CAverage humidity: 48%Elevation above sea level: 1115mDesign temperature: 15 C.Design wind velocity: 144 Km/h

4. GENERAL

Equipment shall be designed and installed for minimum maintenance throughout 25 years designlife of the plant.Equipment and materials of standard sizes and with a proven track record shall be used.

All ferrous items (other than stainless steel) shall be adequately protected from corrosion,internally and externally, in accordance with the project painting specification.

All drilling, cutting, forming, welding, etc. shall be completed before surface preparation and

coating application.

Use of wood in equipment shall not be permitted. All fixtures and fittings shall be manufacturedfrom corrosion resisting materials.

ORIGINATOR:


MAPNA CO.



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5. TRANSFORMER RECTIFIER

5.1 ELECTRICAL CHARACTERISTICS

- AC input: 400 V +10%, 3 PH + N+ E, 50 Hz- DC output : 50V,15A- Output maximum ripple voltage: 5%

5.2 CUBICLE

- Material: Steel sheet, 2.5mm thickness (min)- Ingress protection: IP 55- Installation: Outdoor, free standing (mounting frame to be supplied)- Door: Hinged lockable front door- Cable entry: Bottom through brass nickel plated cable glands with

Removable gland plate (glands to be supplied)- Cooling: Oil cooled

- Readings: The meters shall be easily visible with the door closed- Earthing: Through M8 earth boss

5.3 ADJUSTMENT

The output dc voltage shall be continuously (stepless) adjustable over the full range.The output shall be current constant type.

5.4 EQUIPMENT

5.4.1 The rectifier shall be silicon type and provide full wave rectification.

The rectifier shall be suitable for continuous use at the specified rating, rated at 200% ofnominal dc output current.The maximum recurring reverse voltage of the rectifier shall be at least six times the maximumdc working voltage and shall not be less than 800 V. The peak inverse voltage (PIV) of therectifier shall not be less than the MRRV.

5.4.2 Transformer shall be double winding type, class F. It shall comply with IEC 146.

5.4.3 Measuring instruments shall be as follows:- A dc ammeter with calibrated 100 mV shunt with two female pins at each connected in series

with positive output

- A Calibrated 100mV shunt with two female pins at each end connected in series with negativeoutput

- A dc voltmeter with two female test pinsThe range of meters shall be % 120 of maximum nominal values. The voltmeter shall be

protected by fuses.

ORIGINATOR:


MAPNA CO.



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5.4.4 Protection devices shall be as follows:

- 4 poles circuit breaker with magnetic and overload relays on main input circuit

- Ultra fast fuses on each phase of primary and secondary side of transformer

- Fuse and disconnect switch on dc output

- Surge (lightning) arrester 100 kA, 2.2 kV between positive and negative outputs

- Resistance capacitor (RC) circuits shall be connected in parallel to the rectifier- All metallic parts shall be electrically continuous and connected to earth terminal

- Insulating plates or caps shall be installed on power components to avoid direct contact for

personnel safety.

- An earth screen between primary and secondary windings.

5.4.5 Monitoring of power ON shall be with green light.

5.5 CONNECTIONS

Internal wiring shall be PVC insulated and suitably sized to suit power requirement and site

condition. The control wiring shall be with 1.5 mm wires. All wiring shall be ferruled and

marked with suitable cable/ core markers.

Output terminals shall be located in an accessible part in order to enable disconnection for tests

and controls. DC terminals shall be of rust proof brass nickel plated stud type with washers, nuts

and lock nuts.

The interconnection between different components shall be via suitable terminals for ease of

maintenance and repair.

The input /output terminals shall be as below:

Description No of terminals Tag Color

AC Supply 4 400V Supply

Earthing 1 EARTHING Yellow/green

DC Negative NEGATIVE Black

DC Positive POSITIVE Red

5.6 LABELSThe transformer rectifier shall be provided with fixed labels and name plates as below:

5.6.1 Inside the cubicle all measuring instruments, components, wirings and terminals shall be labeled.

ORIGINATOR:


MAPNA CO.



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5.6.2 Outside the cubicle:

- On the center of front door a min. 50 100mm label marked:

CATHODIC PROTECTION TRANSFORMER RECTIFIER 60EKD00GU01

- On the side of cubicle a name plate providing following minimum information:

Manufacturers name

Model No.Input & output characteristics (V, I, P)

Maximum Operating temperature

Total weight

Purchase order No & clients name

5.7 ACCESSORIES

The following accessories shall be furnished (but not limited to):

- An Auto Manual selector switch

- A timer and selector switch designed according to the rectifier characteristics for on/off control

of rectifier

- Mounting frame

- Lifting lugs

- Brass nickel plated cable glands for ac and dc cables

5.8 INSPECTION AND TEST

The following inspection and tests shall be applied to the transformer-rectifier:

-Conformity with requirements and documentation

-Visual inspection

-Insulation (dielectric) test at 2KV, 1 minute

-Function tests

-Operation tests with suitable resistor:

at %100 nominal dc output values during 12 hours (min)

Measurement of electric initial and final parameters (ac and dc) and temp. rise of

rectifier and transformer

-Ripple rate measurement at full power

-Efficiency test, for example at 25%, 50% and 100% of rated voltage and current

The inspection and testing in no way however, relieves the manufacturer of his responsibility for

meeting the requirements of this specification and applicable standard.

ORIGINATOR:


MAPNA CO.



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5.9 DOCUMENTATION

5.9.1 At quotation stage:

-General arrangement drawing showing outline dimensions

-Schematic and wiring diagrams

-Recommended commissioning and 1 year operation spare parts lists and prices

5.9.2 With order

-Documents mentioned in Para 5.9.1 above

-Mounting drawing and fixing material

-Elementary wiring diagram and part list

-Deviation list

5.9.3 Final documents

-As built dimensional drawings

-As built electric and wiring drawings-Unpacking, installation, testing, operation, maintenance and trouble shooting instructions

-Inspection and test report

One set of final documents must be located and fixed inside the cubicle before packing.

5.10 PACKING

-Transformer rectifier shall be prepared for on land transport and adequately packed to prevent

damage during transportation.-All surfaces subject to corrosion shall be coated with easily removable material.

-All external connections shall be protected with temporary plugs.

5.11 GUARANTEE

Manufacturer shall guarantee satisfactory performance of transformer rectifier in accordance

with this specification and standards for a period of 12 months of operation or 18 months after

shipment whichever is shorter.

6. IMPRESSED CURRENT ANODES

6.1 ANODE TYPE

High silicon-chromium cast iron anodes, rod type, with cable connection at the top as per

ASTM A 518 or BS 1591.

ORIGINATOR:


MAPNA CO.



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6.2 SIZE

Anodes shall be (3 ) 76.2mm (60 ) 1524mm.

6.3 WEIGHT

Anode weight shall be approx. 50 Kg.

6.4 COMPOSITION

The analysis of the material shall be within the following ranges:

Material % in weight

Silicon 14.25 15.25

Manganese 1.5 % max

Carbon 1.4 % max

Chromium 4% ~ 5%

Sulphur 0.1 % max

Phosphorous 0.25% max

Iron remainder

6.5 CABLE

600/1000V, XLPE /PVC, 1X16mm2, 3 meter long cable

6.6 CABLE TO ANODE CONNECTION

Cable connection shall be epoxy resin insulated and further protected with heat shrinkable tube

up to 75 mm over cable.


- Anodes shall be visually inspected against any metallurgical defects.

-Anodes to cable resistance shall be tested (not to be more than 3 milliohms).

6.8 DOCUMENTATION

-Anode dimensional drawings

-Installation instructions

-Test and composition certificates

ORIGINATOR:


MAPNA CO.



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6.9 PACKING

Anodes shall be delivered packed on shock absorbing material with cables protected, secured inwooden case.

7. BACK FILL

7.1 Metallurgical granular coke breeze shall have the following characteristics:

-Maximum resistivity 50 ohm-cm

-Carbon 83% - 90%

-Moisture 5% max

-Ash 7%

-Sulphur 1%

-Nitrogen 1%

-Volatilize 0.8%

-Density 600~850 Kg /m3

-Size 4-10mm

7.2 PACKING

Coke breeze back fill shall be delivered in double high resistant polyethylene bags, each 25 Kg

max, assembled on pallets not exceeding 1 ton.

Pallets shall be housed with thick thermoplastic sheet and circled with cross plastic straps.

8. NEGATIVE RESISTANCE BOX

8.1 CUBICLE

-Material : Steel sheet, 2.5mm thick

-Protection : IP 55

-Installation : Outdoor, free standing

-Door : Hinged lockable front door

- Cable entry: Bottom through brass nickel plated cable glands with removable gland plate

(glands to be supplied)

8.2 INTERNAL EQUIPMENT

- Insulating plate: 6mm thick minimum

- Links: Removable copper- Terminals: Brass nickel plated stud type with nut, washer and lock nut

- Bus: Copper bus bar

- Shunt: Calibrated 0.01 ohm, 10 ampere (for current measurement)

- Adjustable resistor: 1ohm, 100W (for potential adjustment)

ORIGINATOR:


MAPNA CO.



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8.3 LABEL

There should be a label attached on the door. The tag shall be marked as below:

CATHODIC PROTECTION NEGATIVE RESISTANCE BOX -60EKD00GH01


All boxes shall be checked for conformity with the requirements and documentations.

All boxes shall be visually inspected.

8.5 DOCUMENTATION

-Dimensional drawings

-Inspection and test reports

8.6 PACKING

Boxes shall be prepared for in-land transport and adequately packed to prevent damages during

transportation. All surfaces subject to corrosion shall be coated with easily removable material.

All external connections shall be protected with temporary plugs.

9. POSITIVE/ NEGATIVE BOND BOXES

9.1 CUBICLE

-Material : Metallic

-Protection : IP 55

-Installation : Outdoor , on steel support with 4 external fixing point at the back of box

- Door: front door- Cable entry: Bottom through explosion proof, brass nickel plated cable glands (glands to

be supplied)

9.2 LABELS

There should be a label attached on the door. The tag shall be marked as below:

Positive bond box: CATHODIC PROTECTION POSITIVE BOND BOX- 60EKD00GH02

Negative bond boxes: CATHODIC PROTECTION NEGATIVE BOND BOX-60EKD00GH03

CATHODIC PROTECTION NEGATIVE BOND BOX-60EKD00GH04

CATHODIC PROTECTION NEGATIVE BOND BOX-60EKD00GH05


All boxes shall be checked for conformity with the requirements and documentations.

All boxes shall be visually inspected.

ORIGINATOR:


MAPNA CO.



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9.4 DOCUMENTATION

-Dimensional drawings

-Inspection and test reports

9.5 PACKING

Boxes shall be prepared for in-land transport and adequately packed to prevent damages during

transportation.

All surfaces subject to corrosion shall be coated with easily removable material.

All external connections shall be protected with temporary plugs.

ORIGINATOR:


MAPNA CO.



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