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 REVISIONS
D C B A 0
Rev.

FOR APPROVAL DESCRIPTION

A.P. DESIGNED

2005.03.09 DATE

H.KH. CHECK

2005.03.09 DATE

E.A APPR.

2005.03.09 DATE

D C B A 0 Rev. FOR APPROVAL DESIGNATION A.P. DESIGNED 2005.03.09 DATE H.KH. CHKD 2005.03.09 DATE E.A. APPROVED 2005.03.09 DATE

MINISTRY OF ENERGY
ORIGINATOR: MAPNA CO.
(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 1 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

IRAN POWER DEVELOPMENT COMPANY PROJECT:

REVISION C D

I.P.D.C SHIRVAN 6X159 MW GAS TURBINE POWER PLANT

REVISION C D

PAGE

REMARKS

PAGE

REMARKS

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ORIGINATOR: MAPNA CO.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 2 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 3 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

1.

SCOPE This specification covers the minimum requirements for design, materials, fabrication, inspection and preparation for shipment of cathodic protection materials to be used in SHIRVAN GAS TURBINE POWER PLANT of IRAN POWER DEVELOPMENT COMPANY located in Shiravn/Iran.

2.

REFERENCES The latest edition of standards and codes stated below to the extent specified shall be considered as 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 C Max. Absolute Temp. : + 42.3 C Average humidity: 48% Elevation above sea level: 1115m Design temperature: 15 C. Design wind velocity: 144 Km/h 4. GENERAL Equipment shall be designed and installed for minimum maintenance throughout 25 years design life 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 manufactured from corrosion resisting materials.

ORIGINATOR: MAPNA CO.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 4 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

5. 5.1

TRANSFORMER RECTIFIER 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: Ingress protection: Installation: Door: Cable entry: Steel sheet, 2.5mm thickness (min) IP 55 Outdoor, free standing (mounting frame to be supplied) Hinged lockable front door Bottom through brass nickel plated cable glands with Removable gland plate (glands to be supplied) Oil cooled The meters shall be easily visible with the door closed Through M8 earth boss

- Cooling: - Readings: - Earthing: 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% of nominal dc output current. The maximum recurring reverse voltage of the rectifier shall be at least six times the maximum dc working voltage and shall not be less than 800 V. The peak inverse voltage (PIV) of the rectifier 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 negative output - A dc voltmeter with two female test pins The range of meters shall be % 120 of maximum nominal values. The voltmeter shall be protected by fuses. ORIGINATOR: MAPNA CO.
(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 5 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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
Earthing DC Negative DC Positive 5.6 LABELS 1 1

4
1

400V Supply
EARTHING NEGATIVE POSITIVE Yellow/green Black Red

The 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.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 6 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 7 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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. 6.1 IMPRESSED CURRENT ANODES 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.
(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 8 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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 Silicon Manganese Carbon Chromium Sulphur Phosphorous Iron 6.5 CABLE

% in weight 14.25 15.25 1.5 % max 1.4 % max 4% ~ 5% 0.1 % max 0.25% max remainder

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. 6.7 INSPECTION AND TEST - 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.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 9 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

6.9

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

7. 7.1

BACK FILL 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 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. NEGATIVE RESISTANCE BOX 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) INTERNAL EQUIPMENT Insulating plate: Links: Terminals: Bus: Shunt: Adjustable resistor: 6mm thick minimum Removable copper Brass nickel plated stud type with nut, washer and lock nut Copper bus bar Calibrated 0.01 ohm, 10 ampere (for current measurement) 1ohm, 100W (for potential adjustment)

7.2

8. 8.1

8.2

ORIGINATOR: MAPNA CO.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 10 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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

8.4

INSPECTION AND TEST 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 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.

8.6

9. 9.1

POSITIVE/ NEGATIVE BOND BOXES 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) 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

9.2

9.3

INSPECTION AND TEST All boxes shall be checked for conformity with the requirements and documentations. All boxes shall be visually inspected.

ORIGINATOR: MAPNA CO.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 11 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

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.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-04-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 12 OF 12

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.