BESTWAY CEMENT LIMITED - CHAKWAL WASTE HEAT RECOVERY POWER PLANT Design Discrepancies

Sr.#
1

Equipment
Generator Space Heaters

Reference
BCL/CH/Elect./WHRPP/08/48 dated August 20, 2009. BCL/CH/Mech/WHRPP/ dated 06.08.2009 Kawasaki letter # 24164-AOE884 dated 06.08.2009.

Description
No arrangement of installation of space heater is available in generator frame; also the Clarence between space heater and 6.3 KV terminals is too low. The Inlet Gas Dampers supplied were inferior quality/design. It will caused more time consumed on rectification of these dampers. Standby pump is an essential part of cooling tower to keep operation smooth, if some problem happened with any one of to running, but not mentioned in drawings. It should be included in drawings from very first day, we believe. Cooling Tower Water Treatment unit including Sulphuric Acid Storage Tank, Acid Transfer Pumps, Acid Dosing Pumps, pH and Conductivity Meter etc are the integral parts of Cooling Tower System. But this whole unit not designed and supplied by Kawasaki. Cooling Tower Louvers are essentional to maintian clean cooling water in the system but nothing has been mentioned in design/drawings. Side stream filtration system is an integral part of cooling tower to avoid the foreign object to the cooling water system. But in your design there is nothing mentioned. No standby pump has been provided for chemical dosing to Waste Heat Exchangers, Cooling Tower and inside T.G Building. In case of failure of any pump, the required quality of steam and water cannot be maintianed. The design/ drawings of return cooling water lines from 4 Nos boilers to T.G Buildings was not given. Also 02 Nos of booster pumps had to installed for return water piping. These Piping should be seamless, whereas Kawasaki drawings show welded which cause oil flushing prolonged. Gas Analyzer is an essential part of testing of Boilers hot gas. It should be provided by Kawasaki. One operator station for DEH and one engineering station is provided by M/s Kawasaki but its control desk is missing. Regarding the rubber expansion joint of cooling tower, cooling water pump Kawasaki given no design data. As it is a matching part of the pump, Kawasaki should had been specified proper specifications of the said joint. As we faced so much problem during purchasing, as there was no proper specifications mentioned in the drawing.

Inlet Gas Dampers

Cooling Tower

Cooling Tower Water Treatment

Cooling Tower Louvers

Cooling Tower steam Filtration

BCL/CH/Mech/WHRPP/ dated 17.08.2009

Standby Chemical Dosing Pumps for Cooling Tower and Boilers (08 Nos.)

Booster Pump & Return Cooling Water Pipe Line

BCL/CH/Mech/WHRPP/ Dated 04.06.2009 & 18.08.2009

Control Oil and Lube Oil Piping

10

Gas Analyzers for testing of hot gases for Boilers AQC & PH Desk for DEH missing

11

12

Flexible Joint of Cooling Water Pump