PLTU MALUKU UTARA

{2X7 MW)
TIDORE, MALUKU UTARA

ENGINEERING SPECIFICATION FOR

CHLORINATION UNIT

1At 12t08

PT. PLN (PERSERO)

CONSULTANT:

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GROUP CORPORATION

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TIDORE, MALUKU UTAM

ET.IGINEERING SPECIFICATION FOR CHL

SHEET OF

DWGtjo. i 1804-00-hl-05-GBN-001-01-0

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 SHEFT 2 OF IO

v
JOBNO.:08.1804 REV

ENGINEERING $PECIFICATION FOR o0c,M0. :

CHLORINATION UNIT 1 8fl4-m-M{6-GBN-{01 l}1 4

DATE 8Y CHKO TFVD
10/r2n008

SECTION
EAgE

1. GENEML 3

2. PERFORMANCE J

3. DES'GN CONDITIONS 3

4, DESIGN REQUIREMENTS 5

5, BUILDING AND STRUCTURES g

6, BAIfERY LIMITAND TIE-IN POINTS 10

7, SHOP INSPECTTON AND TEST 10

A^;
 SHEET 3 OF IO

JOB NO.: B8-18C4 RF1/

ENGINEERING SPECIFICATION FOR

CHLORINATION UNIT
DOC.NO.
1
:

804-00-[,r45-GSN"001 -0't

DATE trI
4
CIIKD
V
APVD

10/1??008

1. GENERAL

This specification covers the requirement for design, engineering, fabrication, test and supply of
Chlsrination plant for PLTU MALUKU UTARA 2x7 MW Coal-fired power plailt, located in
TERNATE, MALUKU UTARA.

2. PERFORMANCE
Production Rate of Chlorine

The Chlorination plant to be supplied under this specification shall have production capacity o{
5.5 kglh per one electrolysis cell bank as 100% chlorine.'The quantity of chloiination plant to be
$upplied shall be 1 x 100% dug, i.e : 'l x 5.5 kg/h.

Quality of Chlorine in Hypochlorite Solution

The qualily shall be maximized so as the sea water input can be minimized and produce E.S kg/hr
as effective chlorine, and shall be specified by vendor.

3. DESIGN CONDITIONS

Clirnatic Conditions

{1) The clirnate is tropical with long rainy season, Anrbient air temperature, both dry and wet
bulb changes relatively slowly.

tz! Ambient Air Temperature conditions :

Maximum ternperature : 35oC
Minimum temperature : 25oC
Design basis : 30 oC
{3) Relative Humidity (RHi
Maximum 90%
Minimum 80%
Design basis 87o/o

{4) Design wind velocity 32 m/s

(5) Barometricpressure 1.013 bar

Ji "',
 SHEEi 4 OF iO

JoBN0":08'1804 REV

ENGINEERING SPECIFICATION FOR 00c.N0. :

CHLORINATION UNIT I 80440-1,4-05-SBN-001 -01 {

DATE EY Lf,hU AFVD

1A12j2g0B

(6) $eismic Design :

Steel Structures, building, pressure vessels, storage tanks, etc. shall be designed for
seismic forces in accordaRee with 'Design Guide line of Seismic Restrain for Building
Construction'ilndonesian Standard)SNl.03-1726 -z}A|forzone 4 conditions, with peak
ground acceleration of 0.20 G { at base).

t7) Others
Provision for Winlerizing : Not required
Provision for Snowfall : Not required
Provision for marine exposure : Required
Provision fo r Sandstorm : Not required
Provision tor lightning : Required
Provision lo r Tropicalization : Required

{8) Hazardous Area classification

The chlorination plant shallbe unclassified iNon hazardous) area, excepi 1.5 m radius and
around Vents releasing sodium hypochlorite produced from the electrolysis celtbank shall
have an area classifieation of Class 1. Div 2. Gr D.

Utility Conditions

(1) Etectricity
Frequency :50H2
For motor above 150 kW : 6300 V, 3 phase
For motor 150 kW and smaller : 380V, 3 phase
For control systern :220 VAC, 1 phase,50 Hz
110 VDC, 1 phase,50 Hz
{2} lnstrument Air
$upply pressure :7 bar
Mech. Design pressure : 10 bar
$upply temperature :35.C
Mech. Design temperature :65"C
QualitY : OilFree
Dew Foint : -24 "C at 7.0 kg/crn?G

Seawater Supply Conditions

Required Flow ratg ; To be specified byVendor

Conditions
Pressure : 2 barG
Mech. Design pressure : 7.0 barG
Temperature : 30"C
i,
,ll'* zt
 SHEET $ OF 10

JOBN0.: 0S-1804 R:V

ENGINEERING SPECIFICATION FOR 00c,No, : \ o,/

E04ll0-tit-0SGBN-001 -0 -C
CHLORINATION UNIT 1 1

DATE BY cHl(D APVD

lcJle?o{a

Mech. Design temp. : 70"C

Qualitv:
pH (20.C) : 7.BG
Total dissolved solids : 61346 ppm
Sulphate : 2774.5 ppm as SO4-
Total lron : 0.15 ppm as Fe
Ammonia : 0.546 ppm as NH r
Fluoride , 1.143 ppm
Conductivity : 87500 uSlcm

Design Basis

{1) Seawater flowrate to be injected with chlorine : 5500 m3lh

(2) Dosing raie of Chlorine

Non"nal : 1,0 ppm, continuous
Shock : 2 pprn, for 30 minutes every 12 haurs

{3) Dosing Bressure

To be speeified by vendor, considering effective distribution of chlorine at seawater intake
basin for normal dosing and at dosing point {line pressure : 4.0 bat) for shock dosing.

{4i Seawater iniake basin

No.ofchannel :1 or2
Total Channelwidth : 18 m
Channelheighi :7 m

4. DESIGI.IREQUIREMEHTS
General

(1) The chlorination unit shall mainly consist o{ seawater strainer, electrolysis cell, transforner,
rectifier, hypochloriie slorage iank, pumps, and related piping and instrumentation / control
panel.

(2) The unit shall be well deslgned and fabricated using the vendor's proven standard of the
equipment and cornponents havlng proven pedormance and reliability to ensure a satisfactory
continuous operaiion of at least five year. Also, the design of ihe major equipment shall have
been proven in the same service and at a comparable capaciiy ai least two years successful
comnereial operation.

;* &
 SHEEI 6 OF]O

JOBH0.:08-1804 REV

ENGINEERING SPECIFICATION FOR DCC.NO. :

804-00-M-05-GBN-001 41 -S
CHLORINATION UNIT 1

DATE 8Y CHKO APVD

1Ai12J2W8

(3) Utility and chemical consumption shal' be minimized and the required consumption shall be
spocified in detail by Vendor.

Unit Type

(1) The unit shall be Eleetrolysis type.

{2} lt shall be suitabh for outdoor operation under the specitied climatic and rnetecrological
conditions.

Process Design

(1) The seawater lifted up by main seawater pumps shall be supplied to the chlorination unit
through the seawater distribution header.

{2) After removing solid padicles through seawater strainer, the feed seawater shall be fed inio
the electrolysis cell banks to convert chloride in the seawater into sodium hypochiorite, and
ihen delivered it into the hypochlorite storage tank.

i3) For normal dosing of chlorine, the hypochlorite solution stored in the tank shall fu discharged
by gravity effects into the upstream of bar screen in the sea water intake basin.

{4) For shock dosing, the grafity feed method shall be injection the sodium hypochlorite into
seawater header downstream of branch o{ seawater line. The shock dosing pump shall
automatically and intermittently operates for 30 minutes every 12 hours (30 I 12 operation).

{5) DC power shall be supplied to electrolysis cell bank afier rectification by reclifier control.

Materials

(1i Materials of equipment and cornponent shall be selected by vendor by taken into account
conditions specified in this specification and characteristic of fluid handted. Furthermore,
marine exposure to salt spray shall be considered, especially for copper maierial shall be
silver coating.

{2) Material shall conform to ASTM standards, however, use of other matefials equivalent to
ASTM rnay be acceptable, bui subject to REKADAYA's approval.

Seawater Strainer

{1) Two sets of simplex strainers shall be provided with differential pressure indicatar and alarm.

(2) The strainer shallbe sized for one electrolysis cell banks operating.
 SHEET 7 OF iO

JOB N0. : 0E1804 REV

ENGINEERING SPFCI FICATION FOR 00c.N0. :

S04-00-F;1-C5-GBN-00 1 -01 -0
CHLORINATION UNIT 1

DATE tt CHKD AFVO

1AtI2nfrAA

(3) Piping shall be designed s0 made that one strainer can be cleaned while the other is in
operation {no need to stop the chlorination unit}.

{4) The strainer shall have size 840 micron of straining elemeni made of Perforated. The
strainer body shall be from SS 304.

Electrolysis Cell

(1) The Cell bank shall be shop-fabricaied as a compleie package supply.

{2} Flectrolysis cell bank shall be so designed that the assembly and disassembly can be easily
performed and acid cleaning will be effectively canied out. To ensure continuous operalion of
these units at fullcapaciiy, self cleaning tubular-iype electrode shall be used.

(3) The life of ansde and caihode and the maximum turndown ratio of the cell bank shall be
specified by vendor.

{4) Velociiy between anode and cathode shall be decided reflecling lhe unit efficiency, scale
formation and materials selected.

{5) Each bank shall be sized in consideration of passible reduction 0n capacity in long term
operation and in concentration due to decompositicn during storage under normal operation.

(6) The generating cells shall have a design pressure of at least 7.0 bar at 65 oC and will be able
to withstand tesi pressure of '10 bar at 25 oC. The operating pressure is around 5 bar.

(7) The hypochloriie generatot electrolysis cell shall be made of metallurgical-grade Titanium.
Stainless steel or Copper cathodes are not acceptable due to their susceptibility to sever€
piiting conosion when in contact with stagnant chloride solution.

{B) The anode and cathode in the electrolysis cell shall have at least 5 years life time under
normal operating and maintenance following the 0 & M Manual. Vendor shall provide 5 year
prorata warranty for the anodes and also be protected with protective coating, which shall be
guaranteed to have at leasi 5 years life time.

{g) Bolts, Nuts flat washers and lock washers used 0n the electrolytic cells shall be type 316
Stainless Steel.

,i..t n
 SFiEET B OF JO

JOBl'10.: 0B-1804 HFV

ENGINEERING SPECIFICATION FOR 00c.No. : \ o,/

8C4-SO-t 1{r5-GBN-30 -0i -0
CHLORINATION UNIT 1 1

DATE Ln r\U AFVD

1 0t1 2J20BB

Hypochlorite $torage Tank

{1) One sei of hypochloriie storage Tank sized for storage oi hypochioriie soiuiions for 4 hsurs
contiRuous normal dosing plus 1 {one) time shock dosing shall be provided.

(2) Tank siaing shall be determined by Vendor. However, calculated tank heighi shall take into
account the fluld head required for the sodium hypochlorite solutions io be discharged by
gravity effects to the sea water intake basin, at the upstream of bar screen.

(3) Finished tank foundation level shall also take into account the graviiy effects required ta
deliver the sodium hypochloilte solutions to sea water intake basin,

(a) The tank shall be vertical, ilat bottom, open top construction. Material of the Tank shall be
fiberglass reinforced plastic (FRPi with a minimum of 2.5 nrm conosion barrier of vinyl ester
resin 0r equivalent. Also, colour shall be selected considering possible reductian in
hypochlorite concenlration due to decomposition during storage.

{5) FRP grating shal} be instatled in the top of the tank to prevent debris and foreign materials
from entering the tank

(6) The Tank shall be suitable for outdoor installation and resist ultraviolet degradation.

Pumps

{1) All pumps to be supplied for the Chlorination plant shall be horizontal, cenirigal pumps, driven
by electric molor.

(2) As a general rule, all pumps shallbe provided with block valve, suction strainer, check valve
and pressure gauge on discharge line.

(3) Pumps to be supplied for the Chlorination plant shall have the following duties :

- Sea water booster pumps shall be 2x100% duiy

{4) The sea water booster pumps materials shail be SS 304 {for casing), 304 Stainless steel
iimpelle$ and 304 stainless steet (shaft). Altenatively, FRP pumps icasing, impeller) might
also be used subject to Vendor's recommendation.

Piping

i1) Piping up to hypochlorite storage tank shall be sized for the electrolysis cell banks to be
capable of operating at 100% capacity.

li\
 SFIFET S OF IO

JoBN0 : 08-1804 R'V

ENGINEERING SPECIFICATION FOR DOC. l'l0. : \o/

E04-00-t\i'05-G gN40i -01 4
CHLORINATION UNIT 1

UAiT SY CHHD AWD

10112i?68

i2) The material selected for piping (pipes, fitiings, {langes, valves, eic) shall taken into account
the corrosive nature of sea water and sodlum hypochlorite solutions. The rnaterial of piping
containing sea waier or sodium hypochlorite soluiions shail be UFVC and JIS $tandard,

i3) Special precautions shall be made in the design of shock dosing piping. ii is recommended
that the thickness ol shock dosing piping should be higher than the thickness of normal
dosing piping,

(4) lnstrument air piping and tubing inside the chlorination unii shall be 316 SS

{5) $ampling point shall be provided at ouilet of production of each cell bank.

lnstrumentation

i1) The unit shall be capable of operating among any operation msdes. Sufficient insirumeni lor
easy and safe operation shall be installed based on the design concept for the proposed unil.
As a minimum, the following instrumentation shall be included :
r Flow lsolating value shall be provided for continous dosing mode.
r Flow lsolating valve and molorized valve shall be provided for shock dosing mode.
Flow switch shall be provide at the incoming sea lvater pipe line to the Electrolyzer for
" tripping the DC Power Supply should the flow rate into the electrolyzer is dropped.
r An alarm shall be provided agains imbalance cellvoltage.
. Level swilch at storage tank io siop dosing pumps automaticaliy when the level
decreases below very low level.

i2) The produciion rate ol hypochlorite solutions shall be controlled by manual adjustrnent of
Rectifier current output.

{3) Control Panel shall be complleted with PLC for controliing, supervising, and moniioring the
unii operation. The Control Panel wil be installed next to the Transformer Reciifier Cabinet. A
MCCB shall be installed in front of the transformer for tripping the unit and should trouble
occur with the unii. The capacity of the MCCB to be decided by Vendor.

t4) Necessary alarm will be transmiHed to DCS, which will be provided by REKADAYA.

i5) Control Valve for shock dosing line shall be rnotorized valve.

5. BUILDING AHD STRUCTURES

(1) The chlorination unit shall be installed in concrete floor facilitate equipment foundations,
access for operation & maintenance personnels, etc,

,l^ /-n
 SHEET 10 OF IO

JOBN0.:0d-1604 REV

ENGINEERING SPECI FICATION FOR DOC. NO- : \ o,/

80440-[r-trc8N-001 -01-0
CHLORINATION UNIT 1

OATE BY CHKS AFVD

1 0112?C08

i2) All concrete floor and se\#er which rnight be exposed to sodiurn hypochlorite and acid
solutions isuch as spill, leak, drain, etc) shall be coated with suitable chemical-resistant
coating, in order to prevent damage of the concrete struciures,

{3} Concrete partiiion shall be provided for acld cleaning facility io preveni leakage or splllage of
acid solutions {rom exposing other equipment and material not designed for acid-resistant.

6. BATTERY LIMIT AND TIE.IN POINTS

Battery limit of the scope of work shall be refened to the attached drawing,

Piping

All piping up to the terminal connections within the battery limit shall be supplied by vendor
including drain down to the funnel at grade and vent line up to the sale location,

lnstrument
Tenninal points of wiring shall be at terminal conneelion inside local panel. Terminal point of
instrurnent air shall be at distribution header inside local panel.

Electric Power

Terminal points for motors shall be at each motor lerminal box. Terminal points for electrical
and instument shall be at junction box inside local panel. Terminal points for transformer shall
be at its primary terminal. Terminal points for Rectifier shall be at Rectifier panel with Air circuit
Breaker (motorized)

7. SHOP INSPECTION AND TEST

Vendor shall be responsible for lest and inspection of each component and the complete unit.
Vendor shall submit the shop inspection procedures including shop inspection item list, based
on REKADAYA's.Shop lnspection Procedure'(to be submitted laier).