TABLE OF CONTENTS L._ INTRODUCTION wn TI. GENERAL DESIGN FACTORS. A, Locations... B. Plant Development C. Design Criteria D. Cycle Auxiliaries: L Testing: De B. Turbine-Generator Unit (Supply and Ineall me Contrast) C. Start-up Bypass System: D, Alloy Piping roan E, Boiler Feedwater Systems: F. Condensate System:.... G. Circulating Water System: Hi, Fuel System: a 1. Coal Handling (Contract 211) J, Limestone System: K. Flue Gas System: L. Combustion Air System:.. M.Ash Syst : N. Extractions ystem (Supply and Install by Contract 28 O. Boiler Cycle Water Makeup and Overflow System (Supply and Install by Contract 281) P. Service Water System (Supply and Install by Contract 281): Q. Clarified Water System: : R. Closed Cooling Water System (Supply and install by Contract 281): S. Fire Protection Water System... TT Air System (Supply and Install by Cor D: U. Turbine Lubricating Oil System (Supply and lnstall by Contract 281), ‘V. Generator Hydrogen and Carbon Dioxide Systems (Supply and Install by Contract 281) ~W-Potable Water System... ‘X. Plant Waste and Effluent Systern Soya and Install by ‘Contract 81) Y. Equipment Erection: Z. Bridge Crane (Supply by Contrac! AA. Balance of Plant (Contrast 281). BB. System Cleanin; IV. ELECTRICAL. A. Plant Electrical System: B. Plant Voltages: C. Motors and Control:.. D. Generator (Contract 1):.. E. Large Power Transformers (Contract 131): F. Medium Power Transformers (Contract 131B) Distribution Transforms (Conic 1310); H, Grounding Resistors: las me83:18500:DesignOutine doe i Staley Casula, ne marr ww1. Generator Breaker and Isophase Bus (Contract 132):......, vo ee J Metal-Clad Switchgear, Secondary Unit Substations, and Non-Segregated Bus Duct (Contract 146) K_ Electrical Work (Contract 311)... — V. INSTRUMENTATION AND CONTROLS, A, General : : B. DCS Features: : C. DCS and Turbine Control System: D. Room Arrangements and Features: E. Instrumentation: F, Contract 36 Controls: a G. Following systems will not be interfaced with plant DCS., VI. BUILDING. D. Materials and Construction: E. Building Services: SITE WORK. F. Soil Borings: G. Site Access: Project Schedule... ‘A. Heat Balances. B, Windrose. ©. Coal Data D. Motor List secon E, Project Schedule. F. Drawings sn G. Specifications, = HL List of Variances to Kentucl L Insulation Thickness Table... tiling Code 2002 Inset 8500-DesignOutine doc Staney Constants, ie |L INTRODUCTION ‘A. This outline provides a general description of the basic design for the first coal-fired steam-electric generating unit, designated as Smith Station Unit 1, to be installed at Smith Station for East Kentucky Power Cooperative (EKPC). las: me 18500-DesgeOusine doe 1 Stanley ConstanteI. GENERAL DESIGN FACTORS A Locati 1: Clark County, Kentucky. 2 Approximately 15 miles southeast of Winchester, Kentucky, and 3 miles west of Tapp, Kentucky. 3. Close to the CSX Railroad. 4, Near Kentucky State Highway No, 89 5. On the Kentucky River. B. Plant Development: 1.” Existing: 4% Units 1-7: Gas-fired simple cycle combustion turbine-generator units. 2 New: Unit 1: 293,597 KW steam-electric generating unit, coal-fired, 3. Future: 4% Units 2 and 3: 300,000 kW each steam-eleetric generating unit, fossil fuel-fired b. Unit 8-12: Gas-fired simple eyele combustion turbine-generator units, C. Design Criteria: 1. Turbine-generator unit maximum capability (gross): 305,846 kW. 2 Guaranteed, with rated inlet and reheat steam conditions, 2.5-inch Hg. abs, 0% makeup: 703.597 KW per General Electric Co, Heat Balance 94389-Rated dated November 19, 2001 (included in Appendix A). 3. Expected, with valves wide open, rated inlet and reheai steam conditions, 25-inch He. a 0% makeup: 305,846 kW per General Electric Co, Heat Balance 94389-VWO dated ‘November 19, 2001 (included in Appendix A), D. Cycle Auxiliaries 1. Designed to produce maximum capabilities indicated above, with design throttle flow of 2,018,142 Ib/hr at rated stearn pressure. 2. Sized to maintain valves-wide-open steam generating capability with station service electrical frequency not less than 58.5-hertz 3. Basic cycle flow diagram: Drawing No. 18500-XMO1, 4. Minimum design load (gross): Approximately 120,000 kW. 'jve83:18800:DesgnOutne doe 2 Sanity Constants In.1 Wie _inealo’ E, _ Kentucky River Data (Lock 10): 1, Look & Dam 10 located approximately 10.9 miles downstream of the project site Lock 10 is not operational. 3, Normal pool: Bl. $65.7 feet (Daturn); El. 567.6 feet (Kentucky River Datum), 4. Approximate water surface elevation information provided by the Kentucky River Authority: 8, 10-year flood: Bl. 7594.2 feet (National Geodetic Vertical Datum). b, 50-year flood: El. $92.7 feet (National Geodetic Vertical Datum). F. Plant Conditions: 1. Elevation (ground floor): El. 790 feet (USGS Datum). 2. Barometer, in. Hg, abs.: 29.08, 3. Ambient temperatures, F: a. Maximum mean dry bulb: 95, b. Minimum mean dry bulb: -7, Design wet bulb: 79. 4. Wind: a, Wind rose: See Appendix B. G. Permitting: 1, Environmental, air, FAA, landfill, building, and water permits by East Kentucky Power Cooperative. 2, _ EKPC has previously received a permit to construct a raw water pumping station in the floodplain of the Kentucky River. A NPDES permit hes been issued forthe site. 3. Kentucky Division of Water, Water Quantity Management Section, requires a “Water Withdrawal Permit” forall withdrawals of surface water greater than 10,000 gallons per day with the exception of steam-powered electrical generating plants whose retail rates are regulated by the Kentucky Public Service Commission, 4. Kentucky's DEP stormwater program requires all construction sites disturbing more than one acre to obtain a permit. Numeric treatment requirements specific to stormwater have not een established at the state level, but water quality parameters will be established on asite- by-site basis when the risk of contamination is present. Owners of construction activities ‘must develop and implement construction site erosion control and storm Water management plans. 5. Contractors are responsible for obtaining permits required to perform their work, H. Codes Covering Work: ‘vines 19800-DesignOntine doe 3 Stanley Congutans, ne rane1 Building werk: 2002 Kentucky Building Code and 2003 Supplements. % Seismic, wind, and snow loading design parameters, se Section VI, BUILDING. 2, Plumbing work: Kentucky State Plumbing Code, 3. Electrical work: National Electrical Code. 4. ASME Boiler and Pressure Vessel Code. 5. ASME Code for Pressure Piping, & Safety: Occupational Safety and Health Act of 1970, as amended, L Testing: 1 Bauipment acceptance tests willbe performed in the Fld by the Contractor supplying the equipment including; & Cooling towers. b. Turbine-generator. 2 Equipment acceptance tests will be performed inthe fel by the Owner for items including: a. Feedwater heaters, Db. Condensing equipment. © Certain pumping equipment. d Steam generating unit. © Flue gas cleaning system, f. Ash conveying system, & Coal conveying system. hs Fans, ‘isin 18800-DesignOutline doc 4 ‘Staley Consultants, nePucnanenre | imal ir! 4. Equipment and material suppliers will conduct shop tests on items including: a. Certain electric motors. Auxiliary and main power transformers. ' ©. Performance tests on certain pumps. | d, Pressure testing of certain code vessels. © Simulated performance testing of shop assembled components of certain control systems £ Inspection of shop primed structural steel I & Structural steel and reinforcing steel certified mill tests. : h. Piping certified mil tests. 5. Onsite construction testing and other services will be performed by independent testing i agencies employed by EKPC for items including: i a. Excavation, grading, and backfill. E F ‘b.—Plantroads. ©. Concrete reinforcement. 4. Concrete and concrete materials, | routs. | £ Masonry materials, 8. Structural stee! welding and bolted connections. Buried piping coating inspection and cathodic protection, i, Paints and coatings 6. Onsite construction testing and other services will be performed by independent testing agencies employed by the contractors for items including: a. Nondestructive testing for piping. b. Paint film thickness i ©. Roofing system. : 4 VAC system testing, © Establishment of line and grade and other miscellaneous field survey work, Slaline 49: 1850DevenOatine doe qj Stanley Consutans, ne7. Construction contractors will perform field tests on the following: 2. Insulation resistance tests on motors, power cables, and control systems. b. Continuity checks on electric and contol citeuts. ©. Grounding system checks. 4. Other items as listed in Seotion TV, ELECTRICAL, 8. Owner will conduct tests separately to comply with ECAR dynamic model requirement +0 comply with contractual obligations with interconnecting utilities. ‘tne 18500:DesgnOutine doe 6 Stanly ConusI, MECHANICAL A. Steam Generating Unit (Supply and Install by Contraet 201): 1. Type: a b Circulating Fluidized Bed (CFB). ‘Single reheat, balanced draft furnace. 2. Design conditions at rated continuous capacity: Steam flow from supetheater outlet, Ibfir: 2,018,142 Steam flow from reheater outlet, tb/hr: 1,765,260. Pressure at superheater outlet, psia: 2,535, Pressure at high-pressure turbine outlet, psia: 704.3. Reheater pressure drop: 39 psi Pressure at combined reheat valve inlet, psia: 633.9, ‘Temperature at superheater outlet, °F: 1,005. ‘Temperature at reheater inlet, °F: 672. ‘Temperature at reheater outlet, °F: 1,005. Temperature of feedwater at economizer inlet, °F: 502.2. ‘Maximum gross boiler heat input: 3,000 MBtw/r. 3. Fumace and boiler enclosure, pressure-fired type construction: ’. ©. Welded gas-tight, water-cooled furnace and boiler envelope. Continuously welded. finned tubes. Insulation. Aluminum lagging, 4, Beonomizer: », ‘Type: Horizontal, continuous loop, bare tubed. Cleaning: Steam sootblowing. 3. Airheater: ‘Vene818500:esignOutne doe Number: One. 7 Stanley Constants, le. oarType: Regenerative: (1) Nertical shaft 2) Main drive: Electric motor. @) Auxiliary drive: 460-vott, 20 hp ac motor. (4) Sootblowers: Steam, with provisions for out-of-service fire protection water washing (5) Air maintenance drive, 6. —_Sootblowers and soot cleaning equipment: a b. c. 4 Control: Variable automatic sequential, with control through the DCS. Blower drives: Electric motors, 460 volts Blowing or cleaning media: Superheater, reheater, and economizer tube surfaces: ‘Steam, 2,660 psig at source downstream of LTSH. Alll sootblowing equipment, piping, valves, and traps included with sootblowers. B. _Turbine-Generator Unit (Supply and Install by Contract 1): 1. Turbine: i ‘Type: Tandem compound, double flow, single reheat, with 33.5-inch last stage blades. ‘Throttle steam pressure, psig: 2,400. ‘Throttle steam temperature, °F: 1,000, Reheat steam temperature, °F: 1,000. Rated exhaust pressure, in. Hg. abs.: 2.5. VWO rating, kW: 305,846. Guaranteed capability, kW: 293,597. Speed, rpm: 3,600, Number of extraction openings: Seven. Governor type: Digital 2. Turbine-generator supply and erection: ‘tine 00.DevenOutine doe Manufacture, ship, receive, store, and install steam turbine-generator and associated equipment: 8 Stanley Conslans, ne a ee eee ee,(1) Steam turbine-generator unit. (2) Erection of all turbine-generator supplied equipment, piping, and accessories. @) Inspecting, flushing, and cleaning of steam turbine-generator lube oil system to turbine-generator manufacturer's specifications. C. Start-up Bypass System: 1. Description of System: A bypass is provided at 15% of total steam flow to keep steam. ‘lowing through the reheat section of boiler while warming up and during a turbine trip. An added benefit is to start and warm up the turbine by the intermediate section ofthe turbine. 2. Material: (Supply and install by Contract 281): a, Reducing valve and desupetheater between main steam and cold reheat, , Reducing valve and desupetheater between hot reheat and condenser. ©. Evacuation valve to condenser. 4. Equalizer lines from intercept valves and condenser. 3. Design: a, 15% of main steam flow at 1,250 psi. b. Reduce to 160 psi @ 600°F. €. _ Hotreheat from the boiler 150 psi @ 820°F. 4, Reduce to 100 psi @ 400°F to condenser. D. Alloy Piping: 1. Material: (Supply by Contract 101) a. Main steam: A335 P22. b. Hot reheat: A335 P22, © Cold reheat: A106 Gr B. 2. Accessories: a. Safety valves: (Supply by Contract 201, install by Contract 281). b. Blackout valves: (Supply by Contract 201, install by Contract 281). ©. Cold reheat desupeheater: (Supply by Contract 201, install by Contract 281). 4a steam block valve: (Supply and install by Contract 281), 3. Install by Contract 281 (Set by Contract 271). Slyhnesj2500:Design Outline doe 9 Stanley Consultan te.EB. Boiler Feedwater Systems: 1, Tubular Feedwater Heaters 5 through 7 (Supply by Contract 6): a. General design: Beater Pressure Drain Cooler Desuperheating No, Class ‘Type Section Section 5 Intermediate Horizontal Integral Included 6 High Horizontal Integral Included 7 High Horizontal Integral Tneluded b. Arrangement: (1) Feedwater heaters 5, 6, and 7 will be bypassed individually, 2) Feedwater heaters 5, 6, and 7 will be located on the operating floor. G) All feedwater heaters will drain to condenser as required during start-up, No rain pumps will be provided. ©. Terminal temperature differences: (1) Heaters with desuperheating sections: .@ Heaters 5 and 6: 0°F maximum, () Heater 7: -3°F maximum, Q) Drain coolers: 10°F maximum. 4. Tube materials: (1) Medium-pressure heater: ASTM SA-688 Type 304, @) High-pressure heaters: ASTM SA-688 Type 304N, © Install by Contract 281 (set in steel by Contract 271), 2. Deaerating Feedwater Heater (Supply Contract 8) Capacity, Ib/hr (outlet flow): 2,018,142, b. Design pressure: 100 psig. © Design temperature: 650°F. 4. Heater section: Horizontal, cylindrical, way type, © Trays: Type 430 stainless steel, ASTM A240, £. Vent condenser: Intemal, direct contact. ‘Vines 18500>esigpOutne doc 10 Stanley Constants nehb, Storage tank: (Type: Horizontal, cylindrica. (2) Size: Diameter: 11.5 ftx 48 ft tangent length. @) Capacity at normal operating level, cu. : 4,261 (Seven minutes at rated Toad). Install by Contract 281 (Set by Contract 271). 3. Boiler Feed Booster Pumps (Contract 21): Number of pumps: Two (each 50% capacity). Capacity of each pump, gpm: 2,420 ‘Total dynamic head, f: 960. ‘Temperature of feedwater at suction: 291.3°F. Booster pump net positive suction head available: 30 feet. ‘Type: Horizontal, double suction, single-stage, split-case centrifugal Drive: Pump is driven off the main boiler feed pump motor. Speed, rpm: 3,600 rpm. Install by Contract 281 (Set by Contract 271). 4, Boiler Feed Pumps (Supplied by Contract 21): b ‘keine }:18S00;DasignOutne doe Number of pumps: Two (each 50% capacity). Capacity of each pump: (1) Suction flow, gpm: 2,480. 2) _Interstage flow, gpm: 100. (8) Discharge flow, epm: 2,380. ‘Total dynamic head, ft: 6,980. ‘Temperature of feedwater at suction: 337.1°F. ‘Type: Horizontal, double-cased, multi-stage, centrifugal Characteristics: Shut-off head not less than 115% nor in excess of 130% of rated. head, Drive for the pump: Electric motor, 13,200 volts, Speed, rpm: 3,600 rpm (max.). n Stanley Const, tei Fluid coupling: (1) Type: Scoop tube design. 2) Location: Between the motor and main feed pump. @) — Tumdown: 4 to 1 Installation by Contract 281 (set by Contract 271), 5. Piping (Supply and Install by Contract 281): 6. Valves: a b, . a Materia: (1) Between deaerator and boiler feed pump: AL06 Gr B. @) Boiler feed pup discharge to economizer: A106 Gr C. Feedwater stop valve (Contract 201), Feedwater check valve (Contract 201). All other valves (Contract 281). Install by Contract 281. F. Condensate System: 1. Condenser (Supply by Contract 11, Install by Contract 281): a, ‘shine: 8500DesignOutne doe Design conditions: oO Q) @) Tubes: Q Q) @) o 6) Turbine exhaust steam flow, Ib/hr: 1,347,092. Heat transfer, Btu per sec.: 367,500. [Exhaust pressure at turbine maximum capability, in. Hg abs. with 89°F circulating water (79°F wet bulb): 3.15, Outside diameter, in.: 0.75, Effective area, sq.ft: 135,700. ‘Wall thickness; BWG: 22. Material: Stainless steel, ASTM A249, Grade TP304. Effective length, fz 48 max. n Staiey Constants fe(© Number: 14,400. (1) Cleanliness factor, %: 90. ¢. Circulating water: () Number of passes: One. Pirin 30 2 OH Vh @) Quantity of normal flow, gpm: 133,000. =) @) Circulating water inlet temperature at turbine maximum capability: we winger wet 3 OC L Ltert#© [ ©) HR with 50°F wet bulb aC / 4. Water boxes: i (1) Type: Divided. t @) Diameter of main inlets and outlets, inches: 66. : © Hotwell: L () Type: Deserating @Q) Construction: Integral part of condenser shell. @) —-Minimum active storage capacity: 5 minutes at full load £ Tube cleaning system: Continuous re-circulated ball system with automatic ball collecting screen cleaning sequencing control system. System will not be installed i bbutprovisions are to be made for future installation. . i 2. Tubular Feedwater Heaters 1 and 2 (Supply by Contract 11) and 3 (Supply by Contract 6) FE (Install all heaters by Contract 281): L a General design: Heater Pressure Drain Cooler Desuperheating No. Class ‘Section. Sectic 1 ‘Low Horizontal in Integral None Condenser neck* 2 Low Horizontal Integral None Condenser neck* 3 Low Horizontal Integral None “Heaters 1 and 2 in common shell. i sve S00 DeigrOune doe 1B Suey ContaArrangement: (i) Feedwater heaters | and 2 will be bypassed together. Peedwater heater 3 will be bypassed individually. (2) Feedwater heater 3 will be on intermediate floor, @) All feedwater heaters will drain to condenser as required during start-up. No drain pumps will be provided. c. Terminal temperature differences: (1) Heaters without desuperheating sections: 5°F maximum. Q) — Draincoolers: 10°F maximum. 4 Tube Materials: (1) Low-pressure heaters: ASTM SA-688 Type 304. 3. Condensate Pumps (Supplied by Contract 17, Install by Contract 281): a, Type: Vertical turbine type, multi-stage, wet suction, “can” type. b. Number: Two (each 100% capacity). ©. Piping connections: Flanged, aboveground. 4. Design conditions (each pump): (Capacity, gpm: 3,250. (2) Total dynamic head, ft: 600, @) Maximum speed, rpm: 1,800. | Motor: (2) Type: Vertical @) Voltage: 4,000. 4, Vacuum Pumps (Supply and Install by Contract 281) 4. Use: Condenser evacuation. b. Type: Electric motor-driven rotary. ce. Number: Two, Stetme 1 8S00DesignOutine doe 14 Saniey Conta neCapacity, sefm (each pump): (1) Hogging at 10 in. Hg abs.: 350. 2) Holding at 1.0 in. Hg abs. 20. & Motor: 460-volt, three-phase, 60 hertz, 5. Pipe (Supply and Install by Contract 281): a Material: A106 Gr B. G. Circulating Water System: 1. Description of system: Re-circulating system with cooling tower; pumps at tower basin with underground pressure lines fo condenser and closed cycle cooling water heat exchangers, and refurn to cooling tower. 2, Source of Makeup: Clarified river water. 3. Circulating Water Pumps (Supply by Contract 16, Install by Contract 281) i a. Type: Vertical, mixed flow, motor driven. i b. Number: Two (each 50% capacity), | ©. Capacity (each), gpm: 73,000. I d, Total dynamic head of each pump, ft: 62. Motors: (1) Type: Vertical 2) Voltage: 4,000. 4, Cooling Tower (Supply and Install by Contract 222) a. Type: Bight-cell, induced draft, counter-flow. b. Design conditions: (1) Flow, gpm: 146,000. 2) Hot water temperature, F: 109. @) Cold water temperature, °F: 89. @ — Wetbulb temperature, °F: 79.0. } (S) —Drife%: 0.0005, i tihglineay.L8SOnDesignOwtine doe 1s Sunley ContaConstruction: (1) Treated Douglas fir framing. @ Polyvinyl chloride (PVC) fill. 3) Fiberglass casing. Concrete basin. ‘Arrangement: (Q) Isolated cells with two-speed fans; velocity recovery stacks, 10 feet ‘minimum height. (2) Water to tower in single underground supply header with risers at each tower cell, Each riser will have a manual isolation butterfly valve. (3) Cold weather bypass: Approximately one-half full flow; manual isolation valve. Fire protection: Closed head, dry pipe system, pilot actuated; with fire retardant ‘wood treatment. Fire protection system will be divided into four separate zones s0 no ‘more than two cells are controlled by the same deluge valve. 5. Cycle Treatment (Supply and Install by Contract 281): e ‘ine: 8500.DesignOutine doe Sulfuric acid for pH control: (1) Outside storage tank with transfer pumps. @) Day tank with metering pumps. Dispersant and scale inhibitor; (1) Storage tanks provided by chemical supplier. @ Metering pumps. ‘Shock chlorination (sodium hypochlorite) for algae control: (1) Storage tanks provided by chemical supplier. @ — Metering pumps. Dilution pumps: (2) One pump for acid ditution. (2) One pump for balance of chemicals dilution, 3) Service water backup to dilution pumps. 16 Stniey Constans,ne7 i ! 8. “Aboveground: Stee! pipe with coal tar epoxy internal coating (Supply and Install by Contract 281). b. Underground: Pre-stressed concrete embedded cylinder pipe (Supply and Install by Contract 223), Fuel System: APOEIn 2 1. Maximum Gross Boiler Heat Input: 3,000 MBtuftr.. —> l i 2. Performance fuel: Coal. Blend of 50% Irvine Refuse and 50% Hazard 9 Coa | 3. Coal Analysis: See Appendix C. B&B 7488 Bha [Me oo 4. Coal Size: See Appendix C. 5. Supplemental: a. Petroleum coke: 50% maximum based on boiler heat imput. b. Chipped tires: 10% maximum based on boiler heat input, c. Biomass: 10% maximum based on boiler heat input. 6 Startup: Natural gas. a. Natural gas analysis: See Appendix C. (1) Heating value (HEV), Bru/lb: 23,060 ~ 23,290, b. Boiler equipment (Supply and Install by Contract 201): (1) Burners: Four. @) Load, heat input of each bummer: 200 MBtu/. G) _Purgeair: 30 sofm @ 5 psi for each burner when burners are off (4) Bumer ignition system: Gas igniter. (5) Natural gas requirements at inlet to main burner skid: (@) Pressure to main bumer skid inlet: 70 psig (tolerance -0, +10 psi) (b) _Bumer system design pressure: 100 psig. (©) Minimum temperature: 35°F ‘tie 16500:DeienOutine doe 7 Stee Consus,©. Gas supply (Supply and Install by Contract 281): (1) Natural ges heater: @ — Beetic (b) Heater sized for one boiler. Future heater to be installed with additional boilers. @) Regulator station reducing from supply of 375 to 450 psi to bumer pressure of 70 psi (3) Regulator station sized for one boiler. Future regulator station to be installed with additional boilers, @) Piping: (@) Material: A106 Gr. B with underground coated and cathodic protected: 1) Cab retin by Contact 31. 2) ‘Underground piping designed for “pigging” cleanout. 7 mal resin (omen a0iy a. Number required: Eight. b ‘Type: Gravimetric, including provisions for continuous weighing of coal fed. ¢. ‘Capacity: Sized for full load operation with one feeder out of service, * Getstetepeesa ba tn a ‘Number required, Four. % Si movant pte wip antopeng sion) L Coal Handling (Contract 211) 77> oo a. ‘See drawings in Appendix F for diagram of coal handling system. b. Rail ear dumper and stack out equipment will unload a 120 car unit train in 4 hours, 3,000 tons per hour. © Coal is unloaded from rail car dumper and moved to one of two stockpiles. Each stock ple is sized to accommodate, starting atthe ple drawn down condition, unloading a unit train without interruption to move coal away from stack out location. 4 Two coal stock piles will be oriented near and above existing concrete tunnel and foundation openings. ‘eve 14500dDesignOutine doe 18 Stanley Consults neGoo e. Reclaim equipment wil be sized to fill Unt 1 bunkers (silos) in four nours4200. /o | os pes (00% aes) 2 {Reclaim hoppers, feeders and conveyors willbe installed within existing conerete tunnel and foundation openings. g. Existing tunnel uider cast reclaim hopper can accommodate only one conveyor, The } ‘hue! widens under west reclaim hopper and can accommodate two conveyors; West elaim feeder will be arranged to load to either conveyor RC-1 or RC-2 (Future) te Coal reclaim conveyor RC-I (and future RC-2) supply two 600 tons per hour (50% capacity) reversible hammer-mill crushers, CHC-1 and CHCC-2, via single surge ce rovisions will be made in Crusher Building to enlarge the surge bin and install two additional 50% capacity crushers (CHC-3 and CHC-4) to support future units yada reliability to the system. The first set of crushers and associated equipment ‘will be installed on east side of Crusher Building to allow expansion to west, i. Crushers will provide coal sized in accordance with sizing distribution curve in Appendix C. j. _ Basterushers, CHC-1 and CHIC.2, will fed a single 1,200 tons per hour 10076 capacity) conveyor, UFC-1, UFC-1 will transfer coal from the usher to tipper conveyor TC-1. 1 ke Conveyor TC-1 (future TC-2) receive sized coal from unit feeder conveyor UFC-1 { and fill the unit silos. 1. Silo itis accomplished through a single chute located near the centerline ofthe silo. Sile fil conveyor TC-I (future TC-2) and associated tripper cariages are arranged arth one on each side ofthe silo chute. The tipper carriages will not be capable of (@ Collection points: All conveyor transfer points and the surge bin ul passing by each other. (0) Location: Upper elevation of Crosher Building. (©) System type: Fan and baghouse collector. @) Tripper floor: (@) Collection points: All conveyor transfer points and silos im. Coal chutes: Stainless steel lined with abrasion resistant plate in impact areas and ceramic lined in sliding areas, n. Dust collection: (2) Crusher Building: (©) Location: Boiler Building roof. (©) Systemtype: Fan and baghouse collector ume 84:18500-DesignOutine doe 19 Staley Constants Ie10 ailear dumper: } Collection points: Railear hopper. I i ) System type: Fan and baghouse collector or fog without surfactant. ©. Fire Protection for Coal Equipment: (1) Subject to approval of Owner's insurance carrier and authority heving jurisdiction. 2) Internal Systems: Hose outlets with 100-foot hose reels located to cover general areas of buildings at major levels. 3) Automatic sprinkler systems, wet pipe systems: (@) Underground tunnels. (©) Crusher Building. (© Railear Dumper Building. (4) Automatic sprinkler systems, dry pipe systems: @ Conveyor belt J. Limestone System: 1. Limestone: a Received by truck, b. Maximum particle size: 1.5-inch with occasional 2-inch piece. ©. Use at full load when firing performance coal and performance limestone: (@) 40.2 tons per hour/965 tons per day/6,754 tons per week. 2) Truck cepacity: 22 tons. (3) Truck operation (6 hours per day, 5 days per week): 10.5 trucks per hour average. 2, Limestone Preparation System (Contract 201): 8. _Just-in-time limestone milling system consisting of mills, feeders, duets, and other required equipment. b. Capacity: 2 x 100% continuous operation, when firing performance coal and performance limestone © Tworraw feed liméstone silos: (©) Capacity: 23 hours Une: 18500:DesgnOutine doe 20 Stanley Const ic,sirvie:t8S00DesignOutne doc ‘Limestone Handling (Contract 211): See drawings in Appendix F for diagram of limestone handling system. Limestone delivery will be by truck with provisions made in rail ear dumper equipment design to accommodate receipt by rail in future, “A hopper-ess drag conveyor, LSRF-1, wil be installed tallow limestone fo be ‘shed by dozers or vertically discharged ftom loaders o ucks. LSRF-1 discharges {0 transfer belt conveyor LSC-1. {LSC-1 will discharge to sil fill conveyor PC-1. Provisions will be made to also discharge to future conveyor PC-2 via a flop gate Silo fill is accomplished in same manner as coal “Limestone chutes: Stainless steel lined with abrasion resistant plate in impact areas ‘and ceramic lined in sliding areas. performance limestone, except as noted i a | a a a wi K. Flue Gas System: 1. Emission limits at stackcat 70% boiler load to MCR when firing performance fue and Particulate: 0.012 Ibs/MBtu heat input PM/PMyo filterable, Sulfur dioxide (SO): 0.07 Tos/MBtu heat input. ‘Nitrogen oxides (NO,) 0.07 oyu heat input 85% to MCR and 0.10 TbsMBiu ‘eat input 70% to 85%. Carbon monoxide (CO): 0.10 Ibs/MBtu heat input, Ammonia: 10 ppmvd at 3% 0, (85% to MCR). 2. Spray Dryer Absorber (SDA) Baghouse (Supply and Install by Contract 01: a. Flue gas: 2,807,000 Ibsthr at 274°F bb. Design dust inlet loading: 13 grains per actual eu R. ‘ cc. Compartments: Eight. 4. Gas velocity: 3,000 fpm at the air heater outlet e. Location: Outside; weatherproof walk-in top SDA and baghouse enclosure(s) £ Gross air-to-clothratio: 3.2. 5. Bagleaning method: Pulse air, fnsrument at, 80 psi toa single poet bh. 63 ftiameter spray dryer vessel “Taree ~350 kp operating atomizers with 1 uninstalled spare with Stainless Stecl atomizer Lube System. 2 Staley Consults, ne.i SDA access walloway from boiler building (J-1 building line). k. SDA lime preparatiowrecyele/storage system: a) Q) @) @ 6) © mM @) o (Go) ay (a2) ‘System design is for 100% lime usage and for mix of lime and reeycled ash, One lime silo storage system, ‘Two 100% detention slakers with lime feeders. One lime slurry tank. ‘Two 100% lime grt screens. ‘Two 100% lime sturry pumps. ‘Two 100% SDA feed tanks with reoycle grit screen(s). ‘Two 100% SDA feed pumps. One recycle silo (by others). ‘Ash pre-mix tank(s) system(s). ‘Ash-mix tank(s) system(s). ‘SDA feed tank(s) system(s). 3. Selective Non-Catalytie Reduetion System (SNCR) (Supply and Install by Contract 201) a, Reagent: Aqueous ammonia. b, Ammonia pump. Dilution water pump. 4. Cooling air blower. ©. Piping from storage tanks to SNCR. (Inside boiler enclosure — Contract 201; outside boiler enclosure ~ Contract 281.) 4, Aqueous Ammonia Storage for SNCR(Supply and Install by Contract 281): @ Storage: 30,000-gallon tank sized for 16 days storage of Unit 1 usage. Future storage: Three additional 30,000-gallon tanks. $. Induced Draft Fan (Supply by Contract 46, Install by Contract 201): a, Number: One, b. Type: Centrifugal; backward-curved air foil blading; double inlet, for outdoor installation, ‘whines 18S00DesignOutine doc a Stanley Consulta i el& bh Bearings: Sleeve type, oil-cooled, pressure oil system with air-cooled heat exchangers and stainless steel lube oil piping. Speed: 1,200 rpm maximum, ingle-speed electric motor, 13,200 volts. Drive: Design conditions: (1) Capacity: 1.20 times calculated combustion gas mass (including 9.3% air heater leakage) at maximum continuous boiler rating. 2) Static pressure: 1.30 times gas side static pressure (system resistance) ~ required at maximum continuous boiler rating, G) Flue gas temperature: Fan volume and static pressure based on temperature at maximum continuous boiler rating plus 25°F. Volume control: Inlet vanes. Lube oil system: Common system for fan and motor. Location: Outdoors. 6. Chimney (Supply and Install by Contract 221): a. Outer shell: Reinforved concrete. Inner liner: Independently supported carbon steel Size: (1) Height: 475 feet above ground floor elevation in plant. (2) Outlet size: 15 feet diameter. Ductwork (Supply and Install by Contract 201); ID fan evase to chimney connection, Continuous Emissions Monitoring System (by East Kentucky Power). L. Combustion Air System: 1. Primary Air Fan (Supply by Contract 46, Install by Contract 201) a b, 4 ime 8800:DesgnOurine doo PRR HR MRM MRRP ee ee ee ee ee = ‘Number: One. ‘Type: Centrifugal; backward-curved air foil blading; single or double inlet arranged for direct connection to inlet duct, for non-heated weather enclosure installation. Bearings: Sleeve type, oil-cooled, pressure oil system with air-cooled heat exchangers and stainless steel lube oil piping. Speed: 1,800 rpm maximum, 2B Sankey Consens ne.Drive: Constant speed electric motor, 13,200 volts. £ Design conditions: (1) Capacity: 1.20 times calculated mass of required combustion ar (inchuding 9.3% air heater leakage) at maximum continuous boiler rating, 2) Static pressure: 1.30 times air side static pressure (system resistance) at maximum continuous boiler rating, ) Air temperature at fam inlet: $2° to 102°F, Fan volume and static pressure i based on 102°F; motor horsepower based on 52°F. Volume control: Inlet vanes. | b, Inlet silencers with meximum of L.5-inch w.g. delta pressure. i, Lube oil system: Common system for fan and motor, | 2. Secondary Air Fan (Supply by Contract 46, Install by Contract 201): | & Number: One, >. Type: Centrifugal; backward-curved air foil blading; single or double inlet arranged | for direct connection to inlet duct, for non-heated weather enclosure installation, ©. Bearings: Sleeve type, oil-cooled, pressure oil system with air-cooled heat exchangers and stainfess steel lube ol piping, | @Speéd: 1,800 rpm maximum, © Drive: Constant speed electric motor, 13,200 volts. I £ Design Conditions: : | (1) Capacity: 1.20 times caloulated mass of required combustion air (including Hy 9.3% air heater leakage) at maximum continuous boiler rating. ©) Sutepreme 120tierscsie tate pes omens ‘maxintum continuous boiler rating, @) Air temperature (at fan inlet): $2° to 102°F, Fan volume and static pressure I based on 102°F; motor horsepower based on 52°F. 8 Volume control: Inlet vanes. I 4b, Inletsilencers with maximum of 1.5-inch wg, delta pressure. i. Lube oil system: Common system for fan and motor. I 3. Boiler Fuidizing Air Blowers, FBHE (Supply and Install by Contzact 201): 4. Number: Four blowers, three blowers in operation with one standby, i b. Type: Centrifugal ]I i a i pm maximum. Ls e-speed clectrie motor, 4,000 volt. i £ Design conditions (cach blower): (1) Capacity: Approximately 1.30 times caleulated fluidizing air volume at i ‘maximum continuous boiler rating. 2 Static pressure: Approximately 1.15 times air side static pressure (system. resistance) required at maximum continuous boiler rating, i & Volume control: Inlet dampers i 4. Ductwork (Supply and Install by Contract 201), M. a i b. 35% bed ash 2, Ash Handling i a. Unit Lash: Conditioned and transported to landfill. u b. ‘Trucks: Off-road style trucks, net capacity approximately 50 tons. ©. Ash generation and handling for Unit 1 including spent limestone when fring performance coal and performance limestone: a (1) 99.5tons per hour at full load. “B a4 Y. ath ; i @)73.04ons per hour fly ash. (@) 365 tons per hour bed ash i (4) 15.0 tons per hour water added et unloading. (5) Truck operation offroad trucks (7 hours per day, 6 days per week): 63 a trucks per day, nine trucks per hour ash 3, Fuidized Bed Ash Screw Coolers (Supply and Install by Contract 201): u a. Type: Water-cooled serew. b. Number: Six 20% capacity exchangers designed for 34% ash ful a ¢. Cooling media: Closed loop cooling water system. ——— s eee a |4, Ash Handling Equipment (Supply by Contract 71, Install by others): a. Flyash system: Pneumatic dilute phase transport (0) Capacity: Designed for 80% of maximum ash generation. @ Two 100% blowers.” @) Minimum elbow hardness of 450 Bhn. Bed ash system: Pneumatic diute phase transport: (1) Total Capacity: Designed for 50% of maximum ash generation, (2) Two 100% blowers. (8) Minimuma elbow hardness of 450 Bhn. 5. Ash Storage: (Supply and Install by Contract 264): a. Bedash: Stee silo: () 60 hours storage. 2) Toxtoursysteris, four times fill rate b. Flyash: Stee silo: (1) 60 hours storag (2) Load out system, four times fill rate. N. Extractions Steam System (Supply and Install by Contract 281): Piping: a. Material (1) Heater 6 extraction: A335 P22. (2) Other heater extractions: A106 Gr B ©. Boiler Cycle Water Makeup and Overflow System (Supply and Install by Contract 281): 1, Makeup Source: Existing demineralized water system at CT site. Piping required to Unit site 2. Demineralized Water Supply: A new demineralized water supply line will be tied into a suction line from existing demineralized water storage tank. Suction tap to be provided by Owner. Two new demineralized water pumps will supply demineralized makeup water to the Unit 1 condenser. UiainesL8500.DesienOutine doe 26 Stanley Consultan, te. te3. Demineralized Water: b. ‘Two-50% pumps with piping for one futur Pe : 250 gpm each @ 80 ft head, Capac 4, Condensate Storage: e. Feedwater Cycle Drain. One storage tank @ 100,000 gallons. Future: Two additional tanks @ 100,000 gallons each. ‘Two 50% transfer pumps with piping for one future pump. Capacity: 500 gpm each @ 55 fthead. 5. Cycle Additive Treatment: Neutralizing amine for condensate pH control: (1) Two 100% capacity pumps to feed to the condensate pump discharge. 2) Day tank with mixer provided on pump skid. (3) Amine supplied to pump skid from totes provided by chemical supplier. ‘Phosphate/dispersant for deposit control: (1) Two 100% capacity pumps to feed to the boiler steam drum. 2) Day tank with mixer provided on pump skid. @) Phosphate supplied in dry form to the pump skid. Hydrazine for dissolved oxygen control: (1) Two 100% capacity pumps to feed to the condensate pump discharge. (2) One 100% capacity pump to feed to the boiler feed booster pump discharge. @) Day tank with mixer provided on pump skid. (4) Hydrazine supplied to pump skid from totes provided by chemical supplier. P, Service Water System (Supply and Install by Contract 281): 1, Desoription of System: tyne 3:18500Deg2Outne doe This system will pump main service water from the existing CT service water storage tank for Unit | boiler auxiliary requirements with provisions for expansion for future boilers. The system will be separate from the existing pumps which feed ‘the combustion turbine demineralizer trains. This system will be variable speed to a Staley Consulteehandle a wide range of flow demands while maintaining a header pressure of 80 psig at Unit 1 first floor. The design will have provisions for future looping of the system to maximize system availability. Suction tap in storage tank to be provided by Owner. Install booster pumps to serve Unit 1 baghouse and SDA flow/pressure requirements. Provisions will be made to allow for expansion system and to be added to for furure boilers. Existing: () One $00,000-gallon CT storage tank, (250,000 gallons service water, 250,000 gallons firewater). 2) Two pumps, 375 gpm @ 180 ft head, located next to 500,000-gallon CT storage tank to feed combustion turbine demineralized water system, 3) Two pumps; 760 gpm @ 188 ft head, located in clarifier building to feed combustion turbine demineralized water system, New: (1) Three 50% variable speed main service water pumps, 915 gpm @ 175 ft head. @) Two 100% variable speed low flow main service water pumps, 150 gpm @ 175 ft head. (3) One booster pump, 5 gpm @ 40 ftheed. (One booster pump, 60 gpm @ 40 ft head (final per spray dryer absorber requirements). Future: (1) One additional main service water pump. Q Clarified Water System: 1, River Water Makeup Pumps: (Supply and Install by Contract 285): ‘tlie 18500 DesienOutne doe Purpose: Supply water to new and existing clarifiers. River water pumps require high reliability to prevent plant shutdown. All water necessary for plant requirements will be from river water except potable water. Description of system: (1) Install 38 fect diameter eaisson at rivers edge with Johnson inlet screens at low level river intakes, Extend caisson 20 feet above 100-year flood level @) Inlet sereen elevation: 552 feet (14 feet below normal water level) 28 Stanley Constants, teRiver water pumps: (1) Type: Vertical turbine, motor driven, submersible. (2) Number: Two. Total of five 25% capacity on build out. (3) Capacity (each), gpm: 6,000. (4) Total dynamic head of each pump, ft: 400. (5) Motor, hp: 700. @ Type: Submersible. (&) Voltage: 4,000V. (©) Piping: (®) Pump discharge will tie into existing underground 36-inch line to plant. (b) Extend existing line at plant to clarifier location (by Contract 281). 2. Clarifier: (Supply and Install by Contract 281): a ‘Type: Solids Contact Unit. Effluent quality: < 10 NTUs Capacity: 6,000 gpm, Number: One. Future: Three at 6,000 gpm. 3. Clarified Water Pump System (Supply and Install by Contract 281): a ‘lyvine 18500 DesignOutine doe Description of system: Clarified water will flow into concrete basin and be pumped to cooling tower basins or existing sand filters Clarified water basin design: Four clarifiers and four vertical pumps fora total future flow of 24,000 gpm (Includes future clarifiers and pumps). Basin design to accommodate variable water demand from system while keeping clarifiers near steady state conditions (flow rate changes adversely affect clarifier operation). Clarified water pumps: (1) Type: Vertical, turbine, 2) Number: Two, @) Capacity (each), gpm: 6,000. » Stanley Consults fe(4) Total dynamic head of each pump, ft: 65 (5) Motors: (Type: Vertical. (&) Voltage: 460V. 4, Clarifier Sump System: a, Description of system: Sludge removal and drains from clarifiers, Clarifier sump will discharge by gravity to existing drain pipe. 5. Piping: a. Extend existing line at plant to clarifier. b. Piping from clarifier to clarified water pumps. cc. Piping from clarified water pumps to cooling tower and to existing sand filter. 4 Chemical feeds to clarifier. ©. Drain from sump to existing drain pipe. 6. Clarifier Chemical Treatment (Supply and Install by Contract 281): a. Polymer system: (Q) Two 100% capacity pumps to feed to the clarifier. @) Storage tank sufficient for two clarifiers. 3) Polymer tank provided by chemical supplier. b. Sodium hypochlorite system: (1) Tobe used for iron removal and biological control. (2) Tote and feed pump to be supplied by chemical supplier: (@) Piped to clarifier. R. Closed Cooling Water System (Supply and Install by Contract 281): 1. Closed eycle cooling water (CCCW) system provides cooling water needs for plant equipment. 2, Equipment coolers will be designed for a maximum CCCW temperature of 105°F. 3. Design pressure for the CCCW system is 125 psig. 4, Major equipment to be cooled: a. Generator hydrogen coolers. gine 8500.DererOutine doe 30 Stanley Constants, hePPR eee eee eee V30—e ee ee ne 8:18500-DsignOutine doe ‘Turbine oil coolers. ‘Bearing cooling. Boiler feed pump coolers. ‘Vacuum pumps. ‘Air compressors. Fluid bed ash screw coolers. & Chillers. i. Miscellaneous equipment cooling. 5. Closed Cyele Cooling Water Pumps: a, Number: Two. b. Capacity: 100% c. Type: horizontal centrifugal pumps. 6. Closed Cycle Cooling Water Heat Exchangers: a. Number: Five b. Capacity: 25%. ‘Type: Plate and frame type. 7. Head Tank. $. Fire Protection Water System: 1. Water Supply: General service water. 2, Existing: Service water $00,000-gallon storage tank in Combustion Turbine area (half is dedicated to fire protection). Diesel fire pump and jockey pump for combustion turbine area, Construction fire pump. service water 250,000-gallon storage tank near Unit 1 boiler location. Underground piping. Fire protection equipment (subject to approval of Owmer’s insurance company and authorities having jurisdiction): 31 Staney Corts he.3. Diesel and electric fire pumps will be changed out if higher flows are dictated by the insurance carrier. 4. Relocate underground piping in preparation for construction (Supply and Install by Contract 3). 5. Fire protection water supply: Relocate and loop existing piping systems supplied by existing diesel fire pump and existing elettic pump. Pipe into the building to be used as general service water. 6. General service water (Eire protection) water piping will be used for: a. Airheater washing, b. Coal conveyor washing. © Fire hose reels 4. Sprinkler systems. 7. External System: Underground header with hydrants located not more than 300 feet from gay parton of any structure requiring fire protection (Supply and Install by Contracts 3 and 8. Internal Systems (Supply and Install by Contract 281): a, Install a new booster fire pump in the boiler building to increase pressure to the upper area fire hose reels. b. Hose outlets with 100-foot hose reels located to cover general areas of plant at major levels, Carbon dioxide fire hose reels for specific hazard areas as determined. ©. Automatic sprinkler systems. 4. Turbine oil systems and storage tanks: Dry pipe system. © Hazardous storage areas as determined: Wet pipe system. f. Tripper floor: Wet pipe system. T. Air System (Supply and Install by Contract 281): 1. Services Provided: Instrument air, service air, nd baghouse air. Due to the small quantity of air required for service air, all users will be provided with dry air: a. Design: 150 psig. 2. Air Compressors: a. Users: Instrument air, baghouse pulse air, and service ai. b, Number: “Three 50% units. Space for two future units. ©. Type: Multi-stage screw with water-cooled intercoolers. (ne :18500 DesgnOutine doe 2 Stanley Comune4. Capacity, sefim: 2,650 cach. 2, Operating pressure, psig: 125. £ Control: Modulating 70% to 100% of rated capacity, load-unload, and energy saver shut down of multiple compressors. g. Drive: 4,000-volt electric motor, Hp 600 Air Receiver: a. Number: Two. ‘>. Dry storage receivers for optimum modulation of the compressors. c. Cylindrical with dished heads. 4. ‘Size: Approximately 6 ft diameter x 20 ft length. Space for additional pulsation receiver with future compressors. Air Dryers: a. Regenerative air dryers to use heat of final compression of compressors for drying. ‘Dryers will include pre-filters and after-filters as required. b. Dryers will produce air at 40°F dew point, Dew point will be monitored to only switch towers as needed. Two 100% capacity. da Capacity each set: 7,000 scfm. eSpace for additional air dryer with future compressors Service air through backpressure regulators to provide 100 psig nominal supply and cut off if supply air drops below 85 psig, Baghouse Pulse Air and SDA System: 2, Description of system: Dryed air to pulse jet system. b. Supply pressure: (1) Minimum: 80 psig. (2) Nominal: 100 psig. Instrument Air System: Description of system: Provide dried air to instrument air system. ‘yom 8500DesignOutine doe 3 Stney Consultan, ne. i {tevin 8500-DesgeOutine doe 34 b. Supply pressure (Q) Minimum: 80 psig, 2) Nominal: 100 psig. 8. Service Air System: a, Description of system: Provide ar to: (1) Plant air hose bibs. Q) Airheater maintenance drive. 3) Airheater leakage control. ‘Turbine Lubricating Oil System (Supply and Install by Contract 281) 1. Lubricating Oil Batch Storage Tanks: a. One 5,000-gallon clean tank, b. One 5,000-gallon dirty tank. 2. Lubricating Oil Centrifuge. 3. System Arrangement: a. Arranged for either continuous recirculation of batch processing of turbine lubricating oi b. Piping arranged for connection to future units. Generator Hydrogen and Carbon Dioxide Systems (Supply and Install by Contract 281): 1. Hydrogen: Storage, manifolds, and pressure reduction facilities to be located exterior to Boiler Building: 8, Hydrogen storage will be on a rented tube trailer with a small amount of bottles to allow tube trailer change out or refilling. b. Piping to turbine-generator gas control valve assembly. 2. Carbon Dioxide: Bottle storage, manifolds, and pressure reduction facilities to be located exterior to Boiler Building: a. Piping to turbine-generator gas control valve assembly. b. Piping to fie protection carbon dioxide hose reels Potable Water System: 1. Existing supply from East Clark Water District. Sankey Consultan, ne.TRE RRR RE RR PRR ee eee eee 1 Piping as required for drinking and consumption us and Install by Contract 281). as X. Plant Waste and Effluent System (Supply and Install by Conuavs avy. ‘Waste Treatment Facilities: 2. Liquid discharges from plant are subject to effluent limitations as defined in the ‘Effluent Guidelines and Standards for the Steam Electric Power Generating Point Source Category 40 CFR 423. Boiler blowdown: ‘To new plant primary drain system which will discharge to existing settling basins. cc. Plant drains: safmetj18500DesignOutine doc 35 (1) Plant drains will flow by gravity to plant drains header. Q) Drains serving points of potential cil spillage wil flow through an oily water plant drain lite to a common plant oil/water separator. Separator will low by gravity to existing settling basins. ‘Ash Unloading Area: a, _Ashunloading area will tench drain to a large, front loader cleanable sump in rea. ‘Water will decant to the plant drain system which will flow to the existing waste water settling basins. b, — Sump size: 20 fx 20 ftx 4 ft deep. Spray Dryer Absorber Lime Storage and Slaking Area: a. Area will trench drain toa large, front loader cleanable sump. Water will decant to the plant drain system which will flow to the existing waste water settling.basins. b. Sump size: 40 fix 150 fx ftdeep. Cooling Tower Blowdown: Blowdown will low to a catch basin for use in the ash unloading system, Overflow will be pumped into an existing 18-inch line back tothe river: 8. Modify existing basin for storage and pumps. b. Blowdown return water pumps: (1) Pumps: (2) One~ 600 gpm @ 320 fthead. (b) One ~6,000 gpm @ 320 fthead. (©) One ~6,000 gpm @ 320 fthead. Standby. (2) Future blowdown will flow to same location, Surly Contant, ne¢. _Ashunloading water will come from blowdown return water pumps, 4, A truck fill station will also come from blowdown return water pumps, Coal Pile Runoff: &, 40. CFR 423 limits: pH 69, TSS (total suspended solids) 50 mg/l max. b. Coal pile size: 19 acres. ce. _ Design storm: 10-year, 24-hour, 4.36 inches. ) (1) Existing active storage capacity: 123,800 gallons, 4d. —-Runoff: SCS Curve Number 91. €. Existing coal pile runoff retention basi @) New pumps willbe located in basin sump to increase active storage capacity. £ New pumps: Two-2,500 gpm capacity each. Limestone Pile Runoff: 4 Limestone pile size: 3.3 acres, b. Design storm: 10-year, 24-hour, 4.36 inches, ©. Runoff: SCS Curve Number 91 4. Runoff to be routed to coal pile retention basin} Sanitary Wastes: To existing sanitary waste treatment facilities. Owner to rehabilitate and retum existing facilities to service. Discharge to existing wastewater setting basins. Plant Effluent System: This system will reat liquid waste streams (resulting from normal plant operation, accidental spills, equipment maintenance and contaminated rainfall runoff) as ‘required using self neutralization and natural settling to meet the regulations and NPDES discharge permit. Removal of oil and grease will be by dedicated oil separators installed upstream of the existing wastewater settling basins: a. Existing facilities (1) Three concrete wastewater settling basins: (@) Two basins: 230 feet long, 50 feet wide, 16.625 feet deep, having a net volume of 185,931 cubie feet (1,390,864 gallons). (©) One basin: 230 feet long, 50 feet wide, 12.125 feet deep, having a net volume of 131,825 cubic feet (986,122 gallons) @) Oil separation basin attached to the settling basins, (3) Effluent pump wet well attached to the setting basins. vine 81 850-DesignOutne doe 36 ‘Staley Conan ieb, New plant effluent pumps: (1) Basins will be pumped into an existing 18-inch line back to the river. New line will be added between the basin pumps and the 18-inch tine. @) Number: Two, ) Capacity: 4,500 gpm each @ 350 ft head. Equipment Erection: 1. Contract 271 will set the following equipment: a. Feedwater heaters 3, 5, 6, and 7 (Contract 6). >. _Deaerator and deaerator storage tank (Contract 8). c. Turbine erane (Contract 82). 2. Contract 201 will set the following equipment: Primary air fan, secondary air fan, and induced draft fan (Contract 46). Bridge Crane (Supply by Contract 82): 1. Deseription: Common bridge crane system to be installed in turbine bay for turbine ‘maintenance and construction. Crane rails will be extended to future units when constructed, Bach hook to be on different cross trolleys. 2. Capacity: Main hook 100 tons; second hook 25 tons. Provide separate trolleys for main and secondary hoists. 3, Blestric motor operated for both horizontal traverse directions as well as vertical 4, Installation: By Contract 281 (Crane rails installed and bridge crane set and secured in structure by Contract 271.) Balance of Plant (Contract 281): 1. Receive, unload, transport, store, install, and erect in place the following Owner-furnished ‘mechanical equipment: a rd ‘heaters (Contracis 6 and 11). (Set and secured in structure by Contract b.Deaerator (Contract 8). (Set and secured in structure by Contract 271), ©. Condenser (Contract 11). 4. Circulating water pumps (Contract 16). ©. Condensate pumps (Contract 17). f Boiler feed pumps (Contract 21). Ulan 9:1 8500:DesignOatinedoe 7 ‘Staley Consultan, ne.& b ‘Ash handling equipment (Contract 71). Alloy piping (Contract 101) (Set and secured in structure by Contract 271). 2. Equipment Supplied and Erected by Balance of Plant Contractor: 3. Piping: Utne 1 8500-DesignOatne doe ‘Miscellaneous pumps: As required. Boiler blowdown tank: Insulated steel vessel vented fo atmosphere; water-cooled Grain to waste. Balance of plant piping will be in accordance with ASME B31.1 ~ Power Piping. Material selection will be based on design pressure, temperature, and service conditions. Piping materials will be in accordance with applicable ASTM and ASME standards and local codes. Materials selected for use with main cycle systems will be free of copper materials to allow cycle to be treated at optimim pH for corrosion protection of carbon steel components. Corrosion and structural allowances: (1) Main steam, hot reheat, cold reheat: 0.0625 inches. 2) Allother systems: Varies, generally 0.0625 inches. @) Piping 3-inch and smaller: Structural allowance of 0.0625 inches will be ‘generally be used. Power piping systems: 2) Main stearn, (2) Cold reheat steam. @)— Hotreheatsteam. @ Condensate. () Boiler feedwater. (© Cycle makeup and overflow. @) Cycle chemical feed. (8) Condenser air extraction. ©) Cireulating water. (10) Circulating water chemical feed. (11) Auxiliary cooling water. (12) Closed cycle cooling water. 38 Starty Const hePp. Miscellaneous Piping Specialties: Strainers. ‘Traps. Air-vents Orifices. ‘Thermowells. Misceflancous, as required. Special valves and control devices. Flow control. Pressure reducing. ‘Temperature contro ‘Desuperheaters. Solenoid operators. Motor operators. Air operated non-resum. Relief. “Miscellaneous, as required. 6. Instruments (locally mounted): b, Pressure gages, ‘Thermometers. ‘Thermocouples. Level indicators. Alarm devices. Miscellaneous, as required. 7. Thermal Insulation: a. ‘Line :18502:DesignO tine doe Furnish and install insulation and aluminum jacketing materials to minimize heat losses, provide personnel bum protection, provide freeze protection, and prevent sweating, 40 Stanly Consulta ne. kn = ee meEEE ERE ERR RRR RR RRR ESS f Materials: (1), Main steam, cold reheat, hot reheat, steam scals: Calcium silicate. (2) Allother systems: Mineral fiber. @) —Anti-sweat: Fiberglass. Insulation will be placed on equipment that has normal operating temperatures greater than 140°F except internally refractory lined components, such as eyclones, FBHE, ash retum and associated ductwork. Piping which is subject to freezing will be protected with electric heating cable. Insulation thickness will be per Mechanical Standard No. M-1002 for the balance of plant equipment and piping (Contract 281). Aluminum jacketing on all insulation except over sprayed-on insulation, BB. System Cleaning: 1. Boiler Pressure Parts: b. Initial: Hot detergent flush (by Contract 201). Waste disposal and detergent by Owner. ‘After initial fire on coal: Chemical clean (by Owner). 2, Main steam and reheat steam lines: Steam blow. 3. Condensate and boiler feed piping and equipment in pre-boiler circuit: Detergent flush (Contract 281), 4, Closed Cycle Cooling Water: Fresh water flush and drain, ive 8s00-DexignOatine doe a Stniey Contant, beTv. ELECTRICAL A. Plant Electrical System: 1 ‘The plant electrical system is dictated by the project overall electrical one-line diagram, included in Appendix F. Electrical connection to EKPC 345 kV transmission line: a. Plant electrical connection point to transmission line from 345 kV CT Substation (by EKPC): At the Generator Step-up (GSU-1) Transformer's high side terminal ‘bushings. § é b, ‘The phase arrangement at the 345 KV CT Substation: A-B-C South-to-North; Bast-to-West, ©. Thephase connections at the Generator Step-up (GSU-1) Transformer’s high side ‘bushings: HI to Phase A, H2 to Phase B, and H3 to Phase C. 4. Generator phase sequence and line configuration: The generator terminal voltage and phase rotation will be such that each phase will reach its positive maximum value in the order of 1 (Phase-A), 2 (Phase-B), 3 (Phase-C), with the generator rotating in the clockwise direction viewing from the collector end of the generator. © System available fault current atthe 345 KV CT Substation Bus: 63 KA (design value), B. Plant Voltages: 1 2, Generator: 18,000 volts. ‘Transmission connection voltage: 345,000 vols. 2.34, vv v Unit auxiliary power: 13,800, 4,160, and 480 volts nominal, for standard 13,200-, 4,000-, and 460-volt motors. AC Tar Control voltage: 125 volts de. ‘Emergeney motor voltage at 125 volts de: Generator emergency lube oil pump. Emergency motor voltage at 480 volts ac: Air pre-heater auxiliary motor, reheat blackout ‘vent valve, and supetheat blackout vent valve. C. Motors and Control: ‘Motors supplied by Contract 20] shall be the same design criteria for the same applications as for Gilbert 3 and Spurlock 4. For all other contracts the following apply: 8. Motors approximately 7,000 lp and larger: (2) Supply at 13,800 volts. @) Starting and protective equipment in metal-clad switchgear. ‘Uhlir :18500-DesignOurtie doe a Stanly Conan, fe a a LMEBREHREHEHEHHEHEHRHEHRH EERE EEE EE lane 8: 8500DesienOutine doe @) @ ) © a ® o (10) a) (12) (13) (4) (as) Reduced voltage reactor starting ‘Remote control via DCS. RIDs provided in stator and bearings. ‘Vibration probes provided for motors. Motor surge arzesters provided at motor terminals. ‘Motors shall meet the requirements of ANSI C50.41-2000 and NEMA MG- L Insulation class: F. Allowable motor temperature rise: B. Service factor: 1.15. Ambient temperature rating: 50°C. ‘Torque characteristics to permit successful acceleration from rest at reduced voltage. Application to specific motors to be determined during design. ‘Motor space heaters will be provided and operate when motor is off, ‘Motor efficiency test: IEEE 112, Test Method E. ‘Motors approximately 2,000 to 7,000 hp: @ @ @) @) ©) © ” ®) o (10) ay (12) ‘Supply at 13,800 volts Starting and protective equipment in metal-clad switchgear. Full voltage across the line starting. Remote control via DCS. RTDs provided in stator and bearings. Vibration probes provided for motors. ‘Motor surge arrestors provided at motor terminals, ‘Motors shall meet the requirements of ANSI C50.41-2000 and NEMA MG- 1 Insulation class: F. Allowable motor temperature rise: B, Service factor: 1.15. Ambient temperature rating: 50°C. 43 Staley Consens te.‘late :18500-DesignOutin doe (13) ‘Torque characteristics to permit successful acceleration from rest at full voltage. (14) Motor space heaters will be provided and operate when motor is off. (18) Motor shall be provided with provision for mounting IRIS Power Engineering bus couplers for partial discharge detection. (16) Motor efficiency test: IEEE 112, ‘Test Method E, Motors approximately 400 to 2,000 bp: (1) Supply at 4,160 volts. @) Starting and protective equipment in metal-clad switchgear. @) Full voltage across the line starting except for motors required to be started and operated FVR or via variable frequency drive. (Remote control via DCS. (5) RTDs provided in stator and bearings. (© Vibration probes provided for motors as required. 7) Motor surge arrestors provided at motor terminals. (Motors shall meet the requirements of ANSI C50.41-2000 and NEMA MG- 1 (9) Insulation class: F. (10) Allowable motor temperature rise: B. (11) Service factor: 1.15. (12) Ambient temperature rating: 50°C. (13) Torque characteristics to permit successful acceleration from rest a full voltage. (14) Motor space heaters will be provided and operate when motor is off. (15) Motor efficiency test: IEEE 112, Test Method B. ‘Motors approximately 200 to 350 hp: () Supply at 480 volts. (2) Starting and protective equipment in 480-volt secondary unit substation, ‘metal-clad switchgear. (3) Full voltage across the line starting. @) Remote control via DCS. “4 Stvy Constants(5) General purpose motors: Severe duty (©) Insulation class: F. (7) Allowable motor temperature rise: per NEMA MG-I unless specified otherwise. (8) Service factor: 1.15. (©) Ambient temperature rating: 50°C. (10) Motors shall meet the requirements of NEMA MG-1, MG-13, and IEEE 841 (11) Torque characteristics to permit successful acceleration from rest at full voltage, Motors approximately 150 hp and smaller: (1) Supply at 480 volts @) Started and controlled by motor starters located in motor control centers. @) General purpose motors: Severe duty. (4) Insulation class: F. () Remote control via DCS. (© Allowable insulation temperature rise: per NEMA MG-1 unless specified otherwise, () Ambient temperature rating: 50°C. (8) Motors shall meet the requirements of NEMA MG-1, MG-13, and IEEE 841 £— Ontttoor motors: (2) NEMA Type I weather-protective enclosure for large motors; equip with space heaters. 2) Totally-enclosed fan-cooled for medium and small motors; equip with breather drain. g _Speoial purpose motors: NEMA design type and enclosure to fit application, D, Generator (Contract 1): 1. Design: In accordance with NEMA MG-1, IEEE 85, ANSI C50.10, ANSI CS0.13, IEEE 421.1, IEEE 115. 2. Capability: To match steam turbine across its operating range. 3. Power factor: 0.85 at rated cooling, 4, Voltage: 18,000 volts, nominal. ‘iinet 800 DesignOniee doe 4s Staniey Consular, ne10. UL. 12. 13, 4 Frequency: 60 Hz, Phase: Three, Rotor: Cylindrical IRIS Power Engineering slot couplings for partial discharge. Connection: Wye. Short-ircuit ratio at rated cooling: 0.52 minimum, ‘Waveform deviation: Per NEMA MG-1 Insulation: Class F with B allowable temperature rise. Cooling: Totally enclosed, hydrogen-to-water-cooled. Exciter: a. ‘Type: Static type with power potential transformer and rectifiers, associated controls, and protection systems. b. Mounting: ()_Allexcitation equipment and protection in single enclosure. @) Separate power potential transformer with eable connections. Control System: (1) Digital AVR and controls. @) Manual and automatic controls. : 4.” Operating Features and Protection: (1) Reactive droop compensator for parallel operation. @) Minimum excitation limite. @) Maxim excitation limiter. (@ Generator field ground detection. (5) Field voltage transducer, 4.20 mA de output. (6) Field current transducer, 4-20 mA de output. (Shaft voltage suppressor circuit (Surge protection. ©) Field de-excitation cireuit, titi me BS00DesignOwtne dae 46 Stanley Consatans, e(10) Over excitation limiter (OEL). (11) Over excitetion protection (OLOTIOET). (12) Under excitation limiter (VEL). (13) Volts per hertz limiter (Vitiz LIM). (14) Volts per hertz protection (246), (15) Sensing PT failure detector (PTFD).. (16) Generator field ground detector (64%). (17) Generator field temperature calculation. ‘Automatic Voltage Control Modes: Voltage control. Communications: Protection and control systems shall have provision for remote indication, control, set points, and communications for DCS. 15, Excitation power potential transformer: b. bh i, Voltage: 13,800-940 volts. ‘Type: Cast coil, dry-type transformer, Rating: 2,650 VA. Enclosure: NEMA 1. Connection: Wye ungrounded-Deita. ‘Temperature Rise: 80°C, Basic insulation level: (1) Low-voltage insulation level: 10 XV BIL. @)__ High-voltage insulation level: 95 KV BIL. Location: Ground floor. Power Source: 13,8 kV SWGR-IB on intermediate floor. 16, Neutral grounding equipment: ime 18500-DesienOuttine dee ‘Type: Distribution transformer with secondary resistor. 47 ‘Staley Constants fef 48 Resistor: (1) Construction: Dry type naturally ventilated. (2) Rating: 0.63 ohms and 318A for I minute. Enclosure: NEMA 1. Connection: To generator neutral terminal cubicle by cable, ‘Terminations: Cable connection to ground grid. E, Large Power Transformers (Contract 131): (\ Le Generator Step-Up (GSU) Transformer GSU-1: —— ‘ine 1 8S00.DesigrOwtne doe MVA: 405 at 65°C, Class ODAF. 30000 Voltage: 18,000/3624250 volts with four 2.5% full capacity no-load taps, Basic insulation level (BIL): (1) Hiigh-voltage: 900 KV. 2) Low-voltage: 150 KV. Molti-ratio current transformers: (1) Located in each bushing of the transformer primary and secondary. 2) Two 2) sets of relay accuracy. @) One setof metering accuracy. Connection: (1) High-voltage: Wye-ground. @) Low-voltage: Delta. 3) Connect low-voltage to lag the high-voltage by 30 degrees. High-voltage surge arresters: (2) Rating: 276 KV MCOV. @) Class: Station type. 48 SunleyConsukans, ne.& @) Mounting: Tank-mounted. (4) Type: Metal oxide. Impedance: 8.75% at base rating of 360 MVA at 55°C. Medium Power Transformers (Contract 131B): @)\ 1, General: Guaranteed transformer losses will be evaluated in determining low bid Color: Light gray (ANSI 70). 2, Unit Auxiliary Transformer UAT-1A: e £ savas 1357187225 265°C (12/16)20 MVA at 55°C), Class ONAN/ONAP/ONAF. ‘Vottage: 18,000/4,370 volts with four 2.5% fall eapacity no-load taps Basic insulation level (BIL): (Q)— Bigh-voltage: 150kV. (2) Low-voltage: 75 kV. Connection: (1) High-voltage: Delta. @) Low-voltage: Wye, neutral resistance grounded. (8) Connect for low-voltage leading high-volinge by 30 degrees Impedance: Estimated 6.5% at 13.5 MVA base rating t 55°C ‘Multi-ratio current transformer on each high- and low-voltage bushing. 3. Unit Auxiliary Transformer UAT-IB: Une 8500esignOutine doe MIVA: 36/48/60 at 65°C. (32/42.7153.3 MVA at 55°C), Class ONAN/ONAPIONAF. Voltage: 18,000/14,490 volts with four 2.5% full eapacity no-load fap. Basie insulation level (BIL): (1) High-voltage: 150 kV. (2) Low-voltage: 110 kV. Connection: (1) High-voltage: Detta 49 ‘Stanley Consus, re£ @ Low-voltage: Wye, neutral resistance grounded. GB) Connect for low-voltage leading high-voltage by 30 degrees, Impedance: Estimated 6.5% at 36 MVA base rating at 55°C. Multi-ratio current transformer on each high- and low-voltage bushing. G. Distribution Transformers: (Contract 131C): 1, Cooling Tower 1 Service Building Transformer XFMR-OAI: a b. e f. KVA: 7,500 at 65°C, Class ONAN. Voltage: 13,800/4,160 volts with four 2.5% fall eapacity no-load taps. ‘Basie insulation level (BIL): @)—High-voltage: 1OkV, @) Low-voltage: 75 kV. ‘Connection: (1) Hiigh-vottage: Wye @) Low-voltage: Wye, neutral resistance grounded with delta tertiary, B) Connect for 0° phase shift between high and low voltage. Impedance: 6.5% at 7.5 MVA base rating at 65°C, Multi-ratio current transformer on each high- and low-voltage bushing, 2. Crusher Building Transformer XPMR-OA2: a b, Une 1es0DesenOtlne doe VA: 7,500 at 65°C, Class ONAN. Voltage: 13,800/4,160 volts with four 2.5% full capacity no-load taps, Basic insulation level (BIL): ()— High-voltaze: 110 kV. @ Low-voltage: 75 KV. Connection: ()— High-voltage: Delta @) Low-voltage: Wye, neutral resistance grounded. (3) Connect for low-voltage lagging high-voltage by 30 degrees, 50 Sany Consians,e ee ee a a ee ne ~ eT am3. ‘tame :18500-DesignOutinedoe SI e._ Impedance: 6.5% at 7.5 MVA base rating at 65°C. £ Maltisatio eurent transformer on exch high- and low-voltage bushing, River Water Intake Purp Building Transformer XEMR-OA3: a. KVA: 5,000 at 65°C, Class ONAN, bb. Voltage: 13,800/4,160 volts with four 2.5% full eapacity no-load taps. c. Basie insulation level (BIL): (1) High-voltage: 110 KV. (2) Low-voltage: 75 KV. 4 Connection: (1) High-vottage: Delta. @) Low-voltage: Wye, neutral resistance grounded. @) Connect for low-voltage lagging high-voltage by 30 degrees. e. _ Impedance: 6.5% at 5 MVA base rating at 65°C. {. Multicratio ourent transformer on each high- and low-voltage bushing ‘Wastewater Electrical Building Transformer XEMR-OA4: a. KVA: 5,000 at 65°C, Class ONAN. tb. Voltage: 13,800/4,160 volts with four 2.5% full capacity no-load taps. c. Basic insulation level (BIL): (1) High-vottage: 110 kV. @ Low-voltage: 75 KV. 4 Connection: (0) High-vottage: Delta, @) Low-voltage: Wye, neural resistance grounded. ©) Connect for low-voltage lagging high-voltage by 30 degrees. e. Impedance: 6.5% at 5 MVA base rating at 65°C. { Multi-atio curent transformer on each high- and low-voltage bushing. Interconnection to CT Plant Transformer XFMR-OAS: a. KA: 5,000 at 65°C, Class ONAN. taney Consultants beVoltage: 12,470/13,800 volts with four 2.5% full capacity no-load taps. ©. Basic insulation level (BIL): (2) Hiigh-voltage: 110 kV. 2) Low-voltage: 110 kV. 4 Connection: (1) High-voltage: Wye, neutral resistance grounded, @) Low-voltage: Delta (3) Connect for low-voltage leading high-voltage by 30 degrees. ©. Impedance: 6.5% at 5 MVA base rating at 65°C. £ _Multi-rato current ransformer on each high- and low-voltage bushing. H. Grounding Resistors: 7 1 Outdoor type connection for neutrals of Unit Auxiliary Transformers UAT-1A and UAT-1B, Cooling Tower 1 Services Building Transformer XFMR-OA1, Crusher Building Transformer ‘XFMR-0A2, and River Water Intake Pump Building Transformer XFMR-OA3, Wastewater Electrical Building Transformer XFMR-OA4, and Interconnection to CT Plant Transformer XEMR-0OAS. Size to limit line-to-ground current on 4,160-volt system and 13,800-volt system to 1000 amperes, Ratings, 2,400 volts line-to-neutral: 2.4 ohms, 10 seconds, initial current 1000 amperes, temperature rise 750°C. Ratings, 8,000 volts line-to-neutral: 8 ohms, 10 seconds, initial current 1000 amperes, temperature rise 750°C. Generator Breaker and Isophase Bus (Contract 132); Generator Breaker 52-G1: @ Rated maximum voltage: 30 KV. ». Rated continuous current: 23 kA. ©. Rated insulation level: () Power frequency withstand: 80 kV. 2) Lightning impulse withstand: 150 KV. 4. Rated current withstand and interrupting capability: (1) Rated peak withstand current (peak): 390 kA. ‘laine 18500-esignomine doe 2 Stanley Contant be@) Closing and latching capability (peak): 390 kA. @) Rated short-time withstand current (35): 140 kA. (4) Rated short-cieuit breaking current (ems): 160 KA. (5) Rated interrupting time: 56 ms, e. —_Disconnector: (1) Rated peak withstand current: 390 kA. 2) Rated short-time withstand current (38): 140 KA. @) Operating time: 2s. £ Grounding switeh: (1) Rated peak withstand current: 390 kA. @Q) Rated short-time withstand current (15): 140 KA. 3) Operating time: 2. Current transformers: (1) Located on generator (1) and transformer (1) side, fh, Voltage transformers: (1) Loated on generator (2) and transformer (2) side i, Surge arrestor: () — Metal-oxide (2) Rated discharge current (8/20Hs): 20 kA. @) Impulse withstand current (4/10u8): 100 kA. j. Capacitors: (PCB Eee. @ Transformer side: 260 nF. (3) Generator side: 130 nF. 2. Isolated phase bus: 2. 14,000 ampere continuous rating, self-cooled. b. Voltage: 18 KV. c. Basic insulation level: 125 KV. hanes j8S00DesignOutne doe 33 Stanley Constants, ne4 Short-circuit capability (asymmetrical): 200 kA. Bolted links for disconnecting generator and transformers from main bus for test and ‘maintenance, 3. Generator terminal equipment: a b, ‘Mounting: Below generator on ground flocr. Generator connection to terminal equipment. Location: Top connected. ‘Type: Isolated phase bus duct. Voltage: 25 kV class. Continuous rating: 14,000 amperes, self-cooled, Short-circuit capability (asymmetrical): 200 kA. Basic insulation level (BIL): 125 kV. Enclosure: NEMA 1 Contains (1) Bquipment provided by generator manufueturer. @) Connection intemal to cabinet. (3) Side conneetion for conduit, J. Metal-Clad Switchgear, Secondary Unit Substations, and Non-Segregated Bus Duct (Contract 146): 1. Switchgear 1A (Main Plant): ‘Nominal voltage: 4.16 kV resistively grounded system. b. ile 81 8500-DesgnOutine doo Continuous current rating: 3,000 amperes. Breakers: (1) Type: Drawout vacuum type. - (2) Nominal voltage: 4,160 volts 3) Operating voltage: 4,160 volts, Continuous current rating: 1,200 A or 3,000 A. (3) Interrupting capacity: 50 kA minimum. 54 ‘Staley Consants te.a. (©) Operation: Electrical. (7) Remote racking. Enelosure: NEMA 1. 2. Switchgear 1B (Main Plant): sn Inde oO A - Nominal vottage: 13.8 KV resistvely grounded system, Continuous eurent rating: 3,008 amperes Breakers: us (1) Type: Drawout vacuum type 2) Nominal voltage: 13,809 volts. @) Operating voltage: 13,800 vols. (4) Continuous current rating: 1,200 A, 03,000 A. (5) Interrupting capacity: 40 kA minimum, (© Operation: Electrical. (Remote racking Reduced voltage starters (for motors over 7,000 hp): (1) Reactor taps available at 50%, 65%, and 80%. Enclosure; NEMA 1. 3, Switchgear 1A1 (Air Compressor, Baghouse, and Electrical Building): ‘Sine 18500;DesignOatne doe Nominal voltage: 4.16 kV resistively grounded system. Continuous current rating: 1,200 amperes. Motor Starter (1) Type: Full voltage non-reversing. 2) Nominal voltage: 4,160 volts. (3) Operating voltage: 4,160 volts. (4 Continuous current rating: 400 A. () Operation: Contactor. 35 Striey Conus, teBreakers: (2) Type: Drawout vacuum type. @) Nominal voltage: 4,160 volts. @) Operating voltage: 4,160 volts. @ Continuous current rating: 1,200 A. (8) Interrupting capacity: 40 kA minimum, (© Operation: Electrical, () Remote racking. Enclosure: NEMA 1 4, Switehgear 142 (Cooling Tower 1 Service Building): a b. c. 4a Nominal voltage: 4.16 kV resistively grounded system, Continuous current rating: 1,200 amperes. Breakers: (1) Type: Drawout vacuum type. (2) Nominal voltage: 4,160 volts. @) Operating voltage: 4,160 volts. @ Continuous current rating: 1,200 A. (6) Interrupting capacity: 30 kA minimum, (© Operation: Electrical. (Remote racking. Enclosure: NEMA 1. 5. Switchgear 0A (Common Utilities Switchgear): stave. 6500DesignOatne doc Nominal voltage: 13.8 kV resistvely grounded system, Continuous current rating: 1,200 amperes. Breakers (2) Type: Drawout vacuum type. @) Nominal voltage: 13,800 volts. 56 Sey Constantsa b. 4 b. ‘sume :18500DesignOatinedoe TREE RMR ee eee ee eee eB HE = - @) Operating voltage: 13,800 volts. (4) Continuous current rating: 1,200. (6) Interrupting capacity at operating voltage: 40 KA minimum, (©) Operation: Electrical. (Remote racking. Enclosure: Metal-clad enclosed aisle switehgear. 6. Switchgear OA1 (Cooling Tower I Service Building): Nominal voltage: 4.16 kV resistively grounded systern. Continuous current rating: 1,200 amperes. Breakers: (1) Type: Drawout vacuum type. 2) Nominal voltage: 4,160 volts. (3) Operating voltage: 4,160 volts. (4 Continuous current rating: 1,200 A. (5) Interrupting capacity: 30 KA minimum. (©) Operation: Electrical. (1) Remote racking, Enclosure: NEMA 1. 7. Switchgear OA1A (Air Compressor, Baghouse, and Electrical Building) ‘Nominal voltage: 4.16 KV resistively grounded system. Continuous current rating: 1,200 amperes. ‘Motor Starter: (1) Type: Full voltage non-reversing. 2) Nominal voltage: 4,160 volts. (3) Operating voltage: 4,160 volts. (4) Continuous current rating: 400 A. (5) Operation: Contactor, 37 Srl Consus, IeBreakers: ao @ 6) 4 6) © a) ‘Type: Drawout vacuum type. Nomiral voltage: 4,160 volts, Operating voltage: 4,160 volts. Continuous current rating: 1,200 A. Interrupting capacity: 40 kA minimum. Operation: Electrical. Remote racking. 8, Switchgear 0A2 (Crusher Building): sine 8500-DeignOwtine doe Nominal voltage: 4.16 KV resistively grounded system, Continuous current rating: 1,200 amperes. Motor Starter: (1) Type: Full voltage starter reversing. Q) Nominal voltage: 4,160 volts. @) Operating voltage: 4,160 volts, (4) Continuous current rating: per design HP rating. (5) Operation: Contactor. : Breakers: () Type: Drawout vacuum type. Q) Nominal voltage: 4,160 volts. @) Operating voltage: 4,160 volts. (4) Continuous current rating: 1,200 A. (5) Interrupting capacity: 30 kA minimum, (©) Operation: Hlectrical (1) Remote racking, Enclosure: NEMA 1. eal Staley Consultants, ne — ee eee ee9, Switchgear 0A3 (River Water Intake Pump Building): a. Served from Clark REC with EKPC backup b. Nominal voltage: 4.16 KV resistively grounded system. ¢. Continuous current rating: 1,200 amperes. @ Motor Starter: (1) Type: Reduced voltage starter. (2) Nominal voltage: 4,160 volts. GB) Operating voltage: 4,160 volts. (4) Continuous current rating: per design HP rating (8) Operation: Contactor. ©. Breakers: (1) Type: Drawout vacuum type. 2) Nominal voltage: 4,160 volts. (3) Operating voltage: 4,160 volts. (4) Continuous current rating: 1,200 A. (5) Interrupting capacity: 30kA minimum. (6) Operation: Electrical. @ Remote racking, Enclosure: NEMA I 10. Switehgear 0A4 (Wastewater Blectrical Building): 2. Nominal voltage: 4.16 kV resistively grounded system. >, Continuous current rating: 1,200 amperes. c. Breakers: (1) Type: Drawout vacuum type. (2) Nominal voltage: 4,160 volts. (3) Operating voltage: 4,160 volts. (4) Continuous current rating: 1,200 A. Stanley Constants, ne ‘ie: 18800:DesignOutine doe 9a (5) Interrupting capacity: 30 kA minimum, (©) Operation: Electrical. (D) —_ Remote racking, Enclosure: NEMA 1 11, Switchgear OAS (Distribution Switchgear in Clarifier Treatment and Electrical Building): a Nominal voltage: 13.8 kV. Continuous current rating: 1,200 amperes. Breakers: (2) Type: Drawout vacuum type, (2) Nominal voltage: 4,160 volts. @) Operating voltage: 4,160 volts. (4) Continuous current rating: 1,200 A. (5) Interrupting capacity: 40 kA minimum, ©) Operation: Electrical. (2) Remote racking. Enclosure: NEMA 1 12, Protective Relaying: ‘laine 18500-DesigOutine doc ‘Motor breaker: a 2 ‘Type: Multifunction microprocessor-based. SEL 701. Functions: (@) Instantaneous phase overcurrent (50). ©) Locked rotor (508), (©) Negative sequence unbalance (46). (@ Voltage phase reversal (47) (not on reversing starter) (©) Thermal overload (49). (Phase overcurrent (51?) (@) © Undervoltage (27). (H) — Overvoltage (59). 0 Stanley Constants, ne = eeePER RERMERRR Re RR ee ee eee [nc 8500:DesignOutne doe (@ Neutral overcurrent (51N). () Under frequency (810). @) RID inputs (4) S232 and RS485 communication ports. (5) Events record, (©) Waveform capture. Feeder breakers: (1) ‘Type: Multifunction mieroprocessor-based, SEL 551. (2) Functions: (Phase overcurrent (51). (©) Instantaneous phase overcurrent (50) (feeders only). (©) Neutral overcurrent (SIN) (For grounded systems only). Main and tie breakers: (1) Type: Mulifimction microprocessor-based, SEL 351 @ Functions: (@) Synch check (25). (©) Undervottage (27). (©) _ Instantaneous phase overcurrent (50). (@ Phase overcurrent (51P). (© Neutral overcurrent (51N). (© Overvottage (59), (@) Under frequency (81U). (3) Lockout: Electro switch LOR. (1) Undervoltage: Solid-state, SEL 351. (2) Syne-check: Solid-state, SEL 351 G) Differential: Solid-state, SEL-587Z. 61 Stniey Consultan,13. Digital Power Monitor: ‘shvne'3}:18800-DesignOutline doe Description: (1) Microprocessor-based, three-phase, revenue quality power monitor unit with display and touch keys 2 Accuracy: Revenue Class. @) Power display: Local and remote. (4) Memory: Nonvolatile memory. (5) Clock: IRIG-B clock communications. Quality assurance: UL listed; mect requirements of ANSI 3790.1 for surge withstand and fast transient voltage. Parameter accuracy tolerances refer to one cycle performance in accordance with ANSI C12.16 for revenue metering, ‘Parameters measured (minimum): Q ® @) @ © © Mm (8) ® (10) an ‘Volts line-line and line-neutrl for all phases, 0.5% accuracy. ‘Phase current for each phase and neutral, 0.3% accuracy. Kilowatis each phase and total, 0.5% accuracy. Kilovars each phase and total, 0.5% accuracy. Kilovolt-amperes each phase and total, 0.5% accuracy. Kilowatt hours total 0.5% accuracy. Kilovar hours total, 0.5% accuracy. ‘Time and date tagged peak demand amperes, 0.3% accuracy. ‘Time and date tagged peak demand kilowatts, 0.5% accuracy. Power factor cach phase and total, 1.0% accuracy. Frequency in hertz, 0.1% accuracy. “Measurement criteria: @ @) @) Demand kilowatts calculations shall have adjustable window of 5 to 30 minutes. Frequency: Suitable for $0 or 60 Hz systems, Unit shall be suitable for 3- or 4-wire systems, a Srey Consultan, ne,BRRBEBEEHEREHE HRB BBP eB wee ew Bs = = casa m@ xv lg Can. mM & (4 Measurements shall be real time RMS values, except peak demand quantities. Inputs: (1) Voltage: 120 volts secondary potential transformers. (2) Current; 5 amperes secondary current transformers. @) Transformer ratios shall be locally programmable. Data communications: Standard front RS-232 and rear RS-485 communications & ports. Mounting: (1) Suitable for semi-recessed switchboard front instrument panel mounting, (2) Temperature range: -25° to 70°C. i Power supply: 125 volts de j.. Time synch: Provide IRIG-B input for time synch for sequence of events recording 14. Control Power: 125 volts de from station battery. 15, Connections: As shown on one-line diagram. 16. Voltage Transformers: a. Type: Draw-out >. Number and ratio: As shown on one-line diagram. 17. Miscellaneous: a. Equip switchgear units with test blocks to permit connection of test meters. b. Provide spare fuses. c. Test stations: Provide near switchgear and in electrical shop. 18, Unit Substations: | Main plant: (1) Load center type with dry type, epoxy cast, self-cooled transformers and air circuit breakers (2) Transformer temperature rise: 115°C above 40°C ambient. @) Naber and kVA rings: Six — 2,000 KVA rated AA, two~2,500 kVA rated ‘ine 8: 18500DesigOuinedoe 6 Stanley Constants, i‘tm 18500.DesignOutne doe ® 6) © om @) ° (10) ‘Switchgear: One main secondary breaker rated 3,200 amps unit connected to ‘transformer. Breakers: Draw-out type air circuit breakers; 480 volts, with 65 KAIC current and interrupting ratings; protective equipment as follows: ‘Motor control center and lighting feeders: Static type selective over current protection. Functions: Instantaneous (50), time over current (51), and ground fault over current (51N). Motor breakers: SEL 701 motor protection relay. Functions: Instantaneous (50), overload (51), ground fault (51N). Provide each unit substation with high resistence ground fault detection system to detect and isolate ground faults on the 480-volt system, Connections, supply and load: Unit connected switchgear to transformer and insulated cable for loads. “Mount unit substations on 4-inch raised housekeeping pads, Other site support facilites: (1D) Load center type with dry type, epoxy cast, self cooled transformers and air cirouit breakers. @) Transformer temperature rise: 115°C above 40°C ambient, G) Number and kVA ratings: Five ~2,000 kVA rated AA (4) Switehgear: One main secondary breaker rated 3,200 amps unit connected to ‘ransformer. (5) Breakers: Draw-out type air circuit breakers; 480 volts, with 65 KAIC ‘current and interrupting ratings; protective equipment as follows: (©) Motor control center and lighting feeders: Static type selective over current proteetion. Functions: Instantaneous (50), time over current (51), and ‘ground fault over current (SIN). (7) Motor breakers: SEL 701 motor protection relay. Functions: Instantaneous (50), overload (51), ground fault (S1N), (8) Provide each unit substation with high resistance ground fault detection system to detect and isolate ground faults on the 480-volt system. ©) Connections, supply and load: Unit connected switchgear to transformer and insulated cable for loads. (20) Mount unit substations on 4-inch raised housekeeping pads. Coal handling area: (1) Rating: Sized to accommodate new loads associated with each facility oa Surly Contents ne. a@ @) @ 6) ©) @ tiie 1850: DesignOutine doe BHEEREEHRHRHREBEHREHRBEHRHEHRE RHR RRB Re ee Load center type with dry type, epoxy cast, selfcooled transformers and air circuit breakers. ‘Transformer temperature rise: 115°C zbove 40°C ambient. Breakers: Draw-out type air circuit breakers; 480 volts, with 65 KAIC current and interrupting ratings; protective equipment as follows: (®) Motor control center and lighting feeders: Static type selective overcurrent protection. Functions: Instantaneous (50), time over ccurrent (51), and ground fault over current (SIN). (©) Motor breakers: SEL 701 motor protection relay. Functions Instantaneous (50), overload (51), ground fault (51N), (©) Provide each unit substation with high resistance ground fault detection system to detect and isolate low-level ground faults on the 480-volt system Connections, supply and load: Unit connected switchgear to transformer and insulated cable for loads. ‘Mount unit substations on 4-inch raised housekeeping pads. 19. Generator Protection Pane! and Transformer Protection Panel: a. Generator protection relay: Beckwith M3425. Functions: (a) Distance (21). ) Over excitation (24). © ‘Undervoltage (27TN). (@)__Reverse power (32). © Loss-of-field (40). (Negative sequence (46) @ Inadvertent energizing (50/27). (h) ‘Voltage-restrained time overcurrent (51V). @ Overvoltage (59). @ ‘Stator ground fault (59N). (&) __Loss-of-synchronism (78). @ ‘Under frequency (810). (x) Differential (87). 6s Sink Consults ie@) (©) ©) @ ‘Breaker failure (SOBF), Voltage/current balance (60). Ground Detection (64). Overfrequency: (810), (2) Location: GE GPP2100 panel. . Generator Step-up Transformer (GSU-1) protection relay: SEL-387R. @)— Funetions: (@) Over excitation (24), () —Undervoltage (27). © Ground overcurrent (516). @ — Overvoitage (59). (©) Under and over frequency (81). (© Differential (87). © Unit Auxilisry Transformers (UAT-1A) and (UAT-1B) protection relays: SEL-387. (1X) Funotions: Differential (87) 20. Unit Auxiliary Transformer (UAT-1A)Non-Segregeted Bus Duct: 4. 3,000 ampere continuous rating, self cooled. bd. Voltage: 4.16 kV, ©. Basic insulation level: 60 kV, 4 Short-cirouit capability symmetrical: 60 KAIC. 21, Unit Auxiliary Transformer (UAT-1B) Non-Segregated Bus Duet: 4. 3,000 ampere continuous rating, self-cooled. b. Voltage: 13.8kV. ©. Basic insulation level: 110 kV. 4. Short-circuit capability symmetrical: 60 KAIC, Electrical Work (Contract 311): 1. Receive, unload, store, instal, and erect in place Owner-furished electrical equipment as follows: ‘ihaline :18500-DesignOwtne doe 66 Stanley Constants, rev. Indoor and outdoor metal-clad medium-voltage switchgear. ‘Secondary unit substations. Non-segregated bus duct. 2. Motor Control Centers: a b, i. Starters: Full-voltage non-reversing and full-voltage reversing with motor circuit protectors and ground fault protection. Overload devices: Electronic type. Control circuit transformer with each starter to provide 120-volt control. Provide volt-ampere capacity required for associated solenoid valves, timers, and other control devices. Wiring: NEMA Type B, Class 1. ‘Mechanical latching type control for essential motors to assure automatic restart following momentary supply failure. “All.welding receptacles from motor control centers to have ground fault protection. ‘Motor control centers will uilize a three-phase, three-wire service. Local-off-remote selector switch for motor loads. ‘Hard-wire control to DCS. 3. DC Auxiliary System: vine 85:18500-DesienOaine doe ‘Plant battery: Provide a 125-volt battery system connected to supply 125-volt panels; size for Unit 1. Supply generator emergency de motors and uninterruptible power systems at 125- volts de. Supply switchgear and unit substation de controls at 125-volts. Supply DCS and control equipment with an uninterruptible 120 volts ac ‘Type of batteries: Lead acid. Main plant system: (1) Chargers: 125-vott automatic, self-regulating, one for each atiery. (2) Configuration: Standby charger and arrange circuitry so that a standby ‘charger ean be switebed into service in place of any active charger (3) Rating: Chargers to carry estimated continuous load plus 25% of batteries (4) Recharge time: 12 hours while supplying connected loads or Stanley Consuls Ie© (6) a Station battery system duty cycle: 240 minutes.(120 min for emergency bearing oil pump; simultaneous breaker (trip or close) operation for the largest switchgear bus (SWGR-1A). Uninterruptible ae power: 125-volt dc to 120-volt ac inverters from the plant battery system to provide 100% redundant ac power supplies, Uninterruptible ac panelboards: 120-volt ac panel boards to supply ac power to critical ac plant loads including: (@) Common and nit specifie DCS panels. (b) Turbine control system panels and computers. (©) Common and unit specific DCS network and server cabinets. (@ Engineering and operator workstations. © Vibration monitoring equipment. 4, Air Pre-Heater and Blackout Vent Valve Emergency System: a Rating: One 100 kVA, three-phase, 480 VAC to 480 VAC uninterruptible system. (1) 2) @ Connected loads: (@) —_Airpreheater auxiliary motor. ©) Reheat blackout vent valve. © Superheat blackout vent vaive. Station battery system supply time: 4 hours after a plant blackout. Recharge time: 12-hours while supplying connected loads, 5. Essential Services Supply System: a ‘ene 8500-DesgnOutlne dae Duplicate 480-volt, three-phase essential service motor contol centers a) 2 GB) Turbine oil pumps, seal oil pumps, tuning gear drive, and similar essential three-phase devices. Battery chargers and uninterruptible power supply systems, 120/240-volt, single-phase system for control solenoids, recorder charts and other similar critical ac auxiliary devices. Rating: 480¥/277 VAG, four-wire, three-phase. Lighting panelboard: 480-volt, three-phase, four-wire lighting bus. ‘The essential service busses and lighting panel wll be configured to readily accept 480-volt, three-phase power from an alternate sourve to be installed in the future. 68 Santy Conlin, ne. :HDPE ERR RR RRR RRR BRE 6. Electrical Equipment Use in Hazardous Locations: 2. Electrical equipment used in hazardous locations shall be UL listed for use in ‘dentified hazardous locations. b, __ Installation of electrical equipment and circuit wirings per NEC, 7. Plant Interface Panel (PIP) and Substation Interface Pane! (SIP): a. Plant Interface Panel (PIP) located in the Generator Electrical Room provides central interconnection terminations for electrical circuits between the 345 kV substation and the plant. >. Substation Interface Panel (SIP) located in the 345 KV substation control building provides central interconnection terminations for clectrical cireuits between the 345 KV substation and the plant. 8 Plant Site Electrical and Mechanical Equipment Buildings: Power supply: Plant switchgear and Secondary Unit Substations. See Single Line Diagram. ». Power distribution: (1) Mediurn-voltage switchgear, 3-phase, 3-wire service (Resistance Grounded System), @) Secondary Unit Substations, 3-phase, 3-wire service (High Resistance Grounded System). @) Motor Control Centers, 3-phase, 3-wire service (High Resistance Grounded System). (4) Power Distribution Panel, 480¥/277 V, 3-phase, 4-wire (Solidly Grounded), (5) Distribution transformer, 480V-208Y/120V. (© Load distribution panels, 208¥/120 V, 3-phase, 4-wire (Solidly Grounded). ©. Lighting: (1) Mlumination per TES recommendations. 2) Fluorescent Fixtures. G) LED exit lights. (4) Emergency lights: Wall-mounted emergency power-pack units. a. Standards and codes: Applicable codes and standards of NEC, NESC, ANSI, ‘NEMA, and IPCEA. b. Generator main leads: Isolated phase bus. ‘ihspine:18500:DesignOutine doe eo ‘Stanley ConstantsShine 8500DesienOutne doe High capacity 4,160-volt supply circuits: Non-segregated phase bus duct. 4,160-volt and 13,800-volt power wiring: @ Cable size, minimum: 2/0 AWG, copper. (2) Cable insulation: Ethylene-propylene rubber (EPR), 5,000-volt or 15,000- ‘volt insulation level. (3) Cables in dry locations: Single-conductor shielded in metallic conduit or ‘three-conductor non-shielded interlocked armor in cable trays. (Cables in moist locations or underground: Single-conductor shielded cables in conduit. () Provide fireproofing for cables in manholes. 480-volt power wiring: Single-conductor, stranded copper conductor, 90°C, 600-volt, cross-linked polyolefin insulation Lighting wire: NEC Type XHAW in metallic conduit, Control cable, flame- and heat-resistant nulti-conductor, ethylene-propylene insulation with overall neoprene jacket, or similar construction: (1) No. 14. AWG for alarm circuit @ No, 14 or No, 12 AWG for control circuits, @) No. 12 AWG for potential cireuits (@) No. 10 AWG for current transformer secondary circuits. Boiler control wire: Silicone rubber or similar high-temperature insulation, Cable tray: (1) Use for instrumentation and control cables, 5 KV interlocked armor cable, 5 KV single conductor cable, 15 KV interlocked armor cable, 15 kV single ‘conductor cable, and 480-volt power cables. (2) Expanded metal mesh bottom, welded, ladder type with maximum 6-inch ‘rung spacing with 6-inch rail height, @) Install no single-conductor wire smaller than No. 10 AWG in tray; use mnulti- ‘conductor cables for smaller conductors. (4) Bond sections of tray and between gaps in tray to make electrically continuous; bond conduit taps to tray. (S) Cable trays will have four designations and shall be suitable for either 5 or 15 KV cable, 600 V power cable, 600-volt control cable, or instrumentation cable. (© Cable tray will be attached to structure using beam clamps, 0 Stanley Contant, te ee oe = So0. ‘Installation: Seal all openings in floors and walls around air-conditioned Control Room and Electrical Equipment Room area following installation of wiring system. Provide nameplate for thermocouple cold end reference junction boxes identifying circuits. Provide spares at all terminal connection points at panels and junction boxes. ‘Mark each conduit in all multiple conduit exits from walls or floors to identify circuits enclosed in each conduit. ‘Maric all cables with circuit identification corresponding to cable schedules. Provide physical separation of redundant circuits. 10. Plant Lighting: a, b. ‘Turbine Room: Metal-halide. Boiler Room and other service areas: Metal-halide. Emergency lighting in main plant: ‘Three emergency lighting battery systems to provide lighting for 90 minutes to the turbine and boiler island, Emergency lighting in remote buildings: Self-contained battery, charger, and charge indicator. Outdoor lighting: Weatherproof fixtures as required to provide adequate visibility and security ighting; mount on building and on lighting standards. Construction lighting: Provided by Contract 311, the construction lighting shall ‘maintain a $ fe minimum at oor, platform or stair level. Any task lighting for ‘unusual locations or for scaffolding above shall be provided by the contractor ‘working in these locations. Ilumination levels: The permanent lighting levels shall be designed per NESC recommendation for electric supply stations. Lighting transformers: Three-phase, dry-type, 480-208Y/120 volts for 120-volt supply to incandescent and convenience outlet circuits; supply fluorescent and metal ‘halide lighting at 277 volts. Use cirouit breaker type panel boards Panel switching in all general areas, Outdoor lighting shall be photo cell and lighting contactor controlled. 11, Site Lighting: b. ine sy 18800DesignOutine doe Outdoor lighting shall be designed to minimize light pollution subject to OSHA requirements Roadway lighting: None. al Stanley Consus, ne.Security lighting: (1) Site access A: As currently exists @) Site access B: Manually controlled by existing Guardhouse. G) Other Areas: None. Parking lots: (1) Parking lot lighting shall be per IBS recommendation at minimum lighting level @) HID fixtures with sharp cut off beam spread away from residential housing. @) Control: (@) Pressure sensitive switches buried in access drives, with timer for a delay off ©) Lighting contactors/Manual switches at doors. (©) Photocell supervised for dusk to dawn use only. Plant and building areas: (1) Wall mounted General Area Lighting: None. @) Cooling Towers: Manual contro! at stairway access. @ Coal Handling: Manual control at main access points 12. Grounding: ines: 800-DexignOutine doe Design grounding system per IEEE 665 - 1995. Utilize concrete slab steel rebar mesh to establish plant ground grid with supplemental copper ground grid below sla. A Tow resistance earth ground connection will be established through a series of ground rods connected to the copper grid. The use of ground wells and/or soil ‘enhancement may be required to establish a low resistance earth ground connection. ‘Use copper for grounding materials below grade, Tin-coated copper ground grid conductor and rods will be used for enhance corrosion protection. Size grounding conductors for available short-circuit currents Equipment grounding taps as large a, or larger than, NEC requirements, Grounding philosophy: (2) Medium-voltage, 3-phase, 3-wire distribution system: low resistance grounding (limit ground fault to 1000A). 2 Sey Coast, re(2) Low-voltage, 3-phase, 3-wire distribution system: high resistance grounded mit ground fault to less than 104). (3) Low-voltage, 3-phase, 4-wire, and single phase: solidly grounded. 13. Preparation for Operation: Jnsulation resistance tests on motors, power cables, bus duct, and complete control systems before energization. Require furnishing of test reports. Complete equipment operational tests. Phasing tests on all equipment, Include complete tests of all protective devices prior to energization of protected ‘equipment. Factory tests for main medium voltage switchgear and secondary unit ‘substations may be used in liew of field testing Include specific information in specifications on extent of proof and acceptance tests to be performed by contractors. Calibration and testing of protective relays and metering devices will be performed bby Owner based on settings provided by Engineer. 14, Cathodie Protection: ». Design by Owner nominated consultent. Performance based specification designed and installed under the Balance of Plant Contract 311. 15. Distributed Control System Power Design: ‘te s:28500-DesignOutine doe DCS Equipment Room: Boiler DCS Room: Power supplies from essential service motor control center and ‘uninterruptible ac power from station batteries. DCS Server Room: Power supplies from essential service motor control center and ‘uninterruptible ac power from station batteries Distribution: (1) Transformers: Ventilated dry type transformers, one for each main power supply to derive a new ground, connected directly to the ground grid, in the ‘DCS Equipment/Generator Electrical Room on the intermediate floor. (2) Panels: Two panels fed from each transformer with 30 breaker provisions. Control Room: Provide one main 120 VAC feed from essential service motor control centers as well as one main 120 VAC feed from the unintecruptible station battery system. These main feeds will serve lighting panels through two isolation (1:1) transformers which will derive a new ground, connected direetly to the plant ground arid. B Stanley Cons, ne16. Lightning Protection: a b, Air terminal rod, down conductors, and grounding electrode system, Buildings/Structures: (1) Main Plant Building Q) Stack @)—_Baghouse. (8) Air Compressor, Baghouse, and Electrical Building, (5) Crusher Building, (©) Rail Car Dumper Building. Coal Handling Electrical Building. ®) Cooling Tower 1 Service Building. ©) Wastewater Electrical Building. (10) Clarifier Treatment and Electrical Building, (11) Service Water Transfer Building, (12) River Water Intake Pump Building. 17. Communications Systems: ‘hyve 8:1 850:DesignOusinedor Plant process control and monitoring communication installed by Contract 311: (1) Fiber-optic links for DCS equipment, (2) Fiber-optic links to Combustion Turbine Plant Area. b, _Allplant communications systems will be designed, supplied, and installed by EKPC including: (2) Plant intercom and telephone communications systems. @) Plant Intranet communications. 18, Security: Video Surveillance: (1) Video Cameras @ ~ Low-light sensitive. (©) Continuous monitoring, ” Sanley Constants, = a eee ee ee ee(©) Remote tit, plan, and zoom, (@ Location: Site access B. 2) Monitors and Controls: (a) Monitors: Single monitor. (b) Location: Existing Guardhouse. Remote Control Gate: (1) Location: Site access B. 2) Controls: (@) Location: Existing Guardhouse. (b) Operation: Remote open/close. 19. EKPC Electrical Scope of Work: ‘yhuline:18500-DesignOitne doe ‘The 345 kV substations, 345 KV transmission lines, and 345 KV dead-end structures. ‘The 69 KV substation to be used for construction power and partial load backup 13.8KV power source to the plant. Connection of 13.8 kV circuit from 69 kV substation to the 13.8 KV plant distribution circuit will be at designated manhole. ‘The existing 12.47 kV electrical distribution system. Construction Power: a @ @) All construction and construction site power supply will be designed, supplied, and installed by EKPC including: (@) Transformers, (©) Unit substations. (©) Cirouit cabling and raceway. Individual contracts will be responsible for providing cabling from ‘construction unit substations to their distribution locations and/or work areas. Construction lighting will be supplied by Contract 311, Power Supply to the River Water Intake Pump Building: o @ Coordinate power requirement with Clark REC to supply power to the River ‘Water Intake Pump Building Clark REC service connection point will be at the manhole next to the pad- ‘mounted service transformer. fa taney Conta, fe t t‘Whne:18500-DesignOutine dor @) @ Provide 13.8 kV feeder circuit from plant switchgear SWGR-OA to the River Water Intake Pump Building. Provide fiber-optic communication cable from Plant site to the River Water Intake Pump Building, 6 Stanley Consus, eee eeERHREHEEREHRE BERR RRB BPR eee se = = v. sive 800-Desgn Outing doe 1 INSTRUMENTATION AND CONTROLS A B 1 General: Contract 36 (DCS) procurement documents will include speeificetions, conceptual network diagrams, control system description, input/output listings for Balance of Plant (BOP) «systems end turbine island and ancillary systems, and reference documentation, ‘Contract 201 (Boiler Island) shall provide documentation pertaining to Burner Management System (BMS), Combustion Control System (CCS), Selective Non-Catalytic Reduction (SNCR), and sootblowers for inclusion in Contract 36 as reference documents. a. Contract 201 shall review and comment on the following: (1) BMS strategy and DCS integration of BMS strategy. 2) — CCS strategy and DCS integration of CCS strategy. (3) __ SNOR strategy and DCS integration of SNCR strategy. (4) Soofblower strategy and DCS integration of sootblower strategy. b. Documents provided by Contract 201 shall include, but not be limited to: Q) P&IDs. (2) Inputfoutput listings. (3) SAMA logic diagrams for BMS, CCS, SNCR, and sootblowers. Contract 201 (Boiler Island) shall provide documentation pertaining to Spray Dryer Absorber (SDA) PLC controls interface requirements to DCS for inclusion in Contract 36 as reference documents. Contract 281 (Building & Mechanical Work) documents will include P&IDs, specifications, instrument index, instrument location plans, and instrument installation details. Contract 311 (Electrical & Instrumentation) shall be responsible for electrical installation of Contract 281 instrumentation and Contract 36 equipment, Contract 311 documents will include specifications, instrument index, circuit schedule, instrument location plans, termination drawings, and loop drawings. DCS Features: Provide Human-Machine Interface (HMI) between operator and plant systems. Provide control, indication/monitoring, status, trending, sequence of events, and alarmning fictions. ‘Redundant processors, power supplies, and network communications to achieve a high level of system reliability Remote Input/Output modules sball be utilized for selected applications. Sasley Consultants, ne.5. Input/Output for Switchgear (SWGR), Secondary Unit Substations (SUS), and Motor Control Center (MCC) shall be hard-wired to DCS I/O cabinets 6. Sequence of events (SOE) input eards shall be utilized for selected process variable inputs 7. Digital serial communications shall be utilized to integrate individual package systems, Historical trending shall be provided in data historian package, 9. Asset management software shall be provided for performance calculations. 10. Separation of common unit and unit-specific controls, Common unit control cabinets shall contain V/O associated with common unit systems only, 5. Unit-specific control eabinets shall contain 1/0 associated with a specific unit only. C. DCS and Turbine Control System: 1. Turbine controls will consist of dedicated vendor-furnished turbine control system with HMI. based operator workstations located in both Control Room and DCS Equipment Room, 2, Turbine control interface willbe from turbine control system HMI workstations only. 3. Supervisory signals (via serial data link between DCS and Turbine Control system) will be utilized for coordinated turbine/boiler control. D. Room Arrangements and Features: 1. Control Room (Drawing XG-03): Location: Operating floor. Layout: Sized and configured for centralized control of Unit 1, Combustion ‘Turbines, and future Units 2 and 3. ©. Ergonomic operator console fumiture shall be utilized based on Evans Console Corporation products. 4. Hard-wired emergency trip pushbuttons shall be provided to allow tripping of boiler and turbine independent of DCS. © Dedicated boiler remote drum level indication shall be provided independent of DCS. 2. DCS Server Room (Drawing XG-04). 4 Location: Above Control Room on Deaerator Floor. b. Layout: Sized and configured for Common Unit, Unit 1, and future Units 2 and 3 Contains cabinets for DCS servers and network communication switches. 3. DCS Equipment Room (Drawing XG-02): 8. Location: Intermediate Floor. ‘vine: 850- Designline do 8 Stanley Const, reLayout: (1) Sized and configured for Unit 1 DCS InpuvOutput cabinets and workstation area. (2) Engineering workstations shall be provided for programming and configuration activities. 4, Generator Electrical Room (Drawing XG-02): b. Location: Intermediate Floor, Layout: Sized and configured for Unit 1 Turbine Control System, Excite, and Relay Panels, Generator Protection Panel (GPP), Plant Interface Panel (PIP) and Unit 1 Feedwater Pump Vibration Monitoring Panel. 5. Boiler DCS Room (Drawing XG-02): a > Location: Boiler Intermediate Floor near Instrumentation Shop. Layout: Sized and configured for Unit 1 DCS Input/Output cabinets associated with Bumer Management System (BMS) and Combustion Control System (CCS); and Fan (Secondary Air, Primary Air, and Induced Draft Fans) Vibration Monitoring Panel. 6. Instrumentation Shop (Drawing XG-02): Engineering workstations shall be provided for programming and configuration activities, E. _ Instrumentation: 1. Engineer will specify instruments for turbine island and ancillary systems. 2. All4-20 mA field instruments will utilize HART digital communications protocol. 3. Vibration monitoring equipment supplied by East Kentucky Power installed by Contract 311: ‘iret BS0:DesignOutine doe ‘Common unit systems: (1) Cooling Tower 1 Service Building: Wastewater pumps. 2) Clarifier Treatment and Blectrical Building: Clarifier water pumps. ) Wastewater Electrical Building: Effluent pumps. Unit specific systems: (1) Cooling Tower 1 Service Building (@) Cooling tower fins. (©) Circulating water pumps. @) Boiler DCS Room: (®) Primary Air (PA) fan ” Staley Constants, ne(®) Induced Draft (1D) fan (©) Secondary Air (SA) fan. (@ __ Fluidized Bed Heat Exchanger (FBHE) blowers. 4. Contract 281 instruments will be of same manufacturers and models as those specified for Spurlock Station Units 3 and 4 as much as practicable. Refer to Table V- for summary. ‘Table V-1 — Instrumentation List INSTRUMENT TYPE DEVICE FEATURES PRESSURE Gauges ‘Bourdon tube 4-172" dial 1/2" NPT process connection 316 SS construction Switches ‘Snap-acting Direct mount Diaphragm sealed piston SPDT NEMA 4X enclosure ‘Transmitters 4 to 20mA de output Coplanar flanges Stainless steel vents/drains/flanges Pipe stand mounting “Manifolds Pressure: Two-valve Differential Pressure: Three-valve 1/2” NPT process connection TEMPERATURE RID 100 ohm platimum Three-wire Spring-loaded Nipple-union-nipple extension ‘Thermocouples Type E Single-clement, ungrounded ‘Spring-loaded Nipple-union-nipple extension ‘Thermometers Bimetallic sensing element 5S” dial 1/2" NPT stem thread Adjustable angle mounting ‘Thermowells Use for all invasive thermal measurement devices 0.26” bore Material compatible with process pipe, (ot 316 SS construction as applicable. Switches Snap-acting Direct mount Vapor pressure actuated SPDT switch element NEMA 4X enclosure ‘vine 8500:DeignOutine doe 80 ‘Sey Consultan, te me a reEREEEEEEEEBEHE HE HE HF Be es = = = INSTRUMENT TYPE DEVICE FEATURES, | ‘Orifice + Weld-end flange Flow Nozzle [+ Weld-end flange | FLOW © Beveled ends DP V-Cone In-line Sight Flow «Through view/propeller © 304 S$ chamber construction © Magnetostrictive transmitter with 4- Gauge Assembly 20 mA de output Transmitter © Float indicator Switches ¢_DPDT switch elements, Gauge Glass Reflex style 2 Tempered borosilicate glass ‘Steamn/ Water Detection ‘© Electrode type ‘© Two SPST switch elements "44020 mA de output Guided Wave Radar © HART communications protocol «Local digital displa © 40 20 mA do output Ultrasonic © HART communications protocol Local digital display 120 volts ac powered LEVEL Capacitance —Point © Two SPDT switch elements «NEMA 4X enclosure Globe ‘© Buttweld end connections ¢ _Spring-opposed diaphragm actuator Ball © Buttweld end connections * _ Spring-opposed diaphragm actuator Butterfly © Flangeless end connections ¢_Spring-opposed diaphragm actuator Positioners © Single-acting © 4-20 mA input © 4.20 mA output (feedback) © 6-30 psi output «HART communications protocol Solenoids = 120 volts-ae MISCELLANEOUS | Vibration ‘© Modbus serial communications interface Notes: 1, List is suggested design guideline and may change based on equipment availability, technology updates, cost, and other factors related to design process. 2. List may not include all instrumentation required, Additional instrumentation and devices may be specified as required for detailed design. siibmess:18S00DesignOutine doe Saney Conta, neF. Contract 36 Controls: 1. Coordinated plant control: Inputs from electric load, steam flow, turbine valve position, steam pressure, and feedwater temperature shall be evaluated within control logic subsystem to control both turbine throttle steam control valves and boiler firing rate. 2, Steam Systems Main stearn: (1) Lowpoint drain control. (2) Main Steam to Cold Reheat (bypass) pressure control (3) Main Steam to Cold Reheat (bypass) temperature control. Cota reheat: (1) Low point drain control. (2) Turbine exhaust check valve (bypass system) control Hot reheat: (1) Hot Reheat to Condenser (bypass) pressure control. @) Lowpoint drain control 3. Feedwater Heaters: a tains j18500:DesignOutinedoe ‘Turbine Water Induction Prevention (TWIP) methods: (1) Normal and emergency level control. 2) Extraction steam isolation (except low-pressure feedwater heaters 1 and 2) (3) __Feedwater isolation and bypass control (required for low-pressure feedwater heaters 1 and 2 and additional protection for low-pressure feedwater heaters 3,5, 6,and7). Extraction steam low point drain control. Deaerating feedwater heater: () TWIP methods: (@ Water source isolation. (©) Extraction steam isolation. 2) Extraction steam low point drain control. 2 ‘Staley Constants, ine. a Se eee ss ee ee eee eee eeTERRE RRR RRR RR eee eee ee Boiler Feedwater/Booster Pump: a. Boiler feedwater/booster pump start/stop control. b. Boiler dram level (pump variable speed control). ©. Minimum flow control 4, Start-up level control €. Boiler feed pump drains tank level control. Condensate: 8. Condensate pump startstop control. b. Condensate pump minimum flow control ©. Hotwell normal and emergency level control. 4. Hotwel overfill evel control. €.—_Deaerating heater level control. f£— Deacrating heater minimum flow control. & —_ Demineralized water makeup control. Condenser: 8. Vacuum pump start/stop control. b. Vacuum breaker control Closed Cooling Water: Closed cooling water pump start/stop control. >. _ Differential pressure control. c. Head tank level control. d.—_ Normal/backup (CCW/SW) cooling water source control (air compressors, air dryer aftercooler, and chiller condensers), ‘Turbine-Generator Ancillary Systems: a, Bearing oil pump starv/stop control. b. Turbine lube vapor extractor start/stop control. . Hydraulic fluid pump start/stop control 4. Gland exhauster blower start/stop control ‘Glin y:18SONDesignOxtine doe 3 Stanley Consultants, ne