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Tuesday, 24 March 2015

SAMPLE: GENERAL SPECIFICATION FOR MECHANICAL ENGINEERING



1.1         The objective of these specifications is to define the design basis and general technical requirements applicable to the mechanical design for Sembcorp Energy from Waste (EfW) @ Sakra.
1.2        General project information are as follows
1)     Project Name            :       Sembcorp Energy from Waste (EfW) @ Sakra
2)     Client                       :   Sembcorp Industries Limited
3)     Plant Capacity         :   575ton/day × 2unit
-  Boiler Capacity         :           80MWth (100% MCR @12MJ/kg, 575ton/day)
4)     Type of waste          :   Industrial and commercial waste
5)     Site Location               :           Jurong Island, Singapore
6)     Project area                 :           1.36ha (103m X 132m)

2.     SITE CONDITION
2.1             Temperature data
Highest recorded
35.8 deg C
Lowest recorded
19.4 deg C
Mean daily max.
30.7 deg C
Mean daily min.
23.7 deg C
Mean annual
26.6 deg C
2.2             Barometric pressure
Average daily minimum barometric pressure
1,002.2 mbar a
Average daily maximum barometric pressure
1,016.9 mbar a
Average means
1,009.4 mbar a
Design barometric pressure
1,010.0 mbar a
2.3             Relative humidity
Average daily minimum humidity
64.2 %
Average daily maximum humidity
94.4 %
Annual average humidity
84.6 %
2.4             Wind load
The extreme 3 second gust (wind) recorded for a return period of 100 years is 37.8m/s. Based upon this information; wind velocity for design was suggested to be at least 40m/s.
2.5             Rainfall
Classification
Maximum
Minimum
Average
mm/annum
3,542
1,,563
2388
Days/month
26
3
15
The design basis for the rain fall is as follows.
   
Period in minutes
Rainfall in(mm)
15
48
2.6             Design condition (for performance guarantee)
Dry bulb ambient temperature
32 deg C
Relative humidity
85 %
Altitude
5 m
Sea water temperature
30 deg C
Ambient pressure
1,010 mbar a
2.7             Extreme design condition (for equipment design)
Parameter
L. Value
H. Value
Units
Dry bulb ambient temperature
19
40
deg C
Relative humidity
50
100
%
Wind speed
0
40
m/s
Sea water temperature
27
33
deg C
Rain fall rate
0
120
mm/hr
2.8             Earth quake
              Seismic Zone : ZONE 1 (z=0.075)      
3.1            Power supply
Ÿ Incoming power                 :           22kV
Ÿ High voltage                                  :           6.6kV, 3phase, 50Hz (Above 185kW)
Ÿ Low voltage                                   :           400V, 3phase, 50Hz (Up to 185kW)
Ÿ DC power supply               :           110Volt DC
Ÿ Power supply for control    :           AC 230V
3.2            Cooling water
Ÿ Supply / return temperature            :           33 / 40 deg C
Ÿ Supply pressure                :           Max. 4.5kg/cm2.G
3.3            Compressed air
Ÿ Supply pressure                :           Max. 7kg/cm2.G
Ÿ Oil content                         :           None
Ÿ Minimum dew point                        :           - 20deg C (atmospheric condition)
3.4            Auxiliary Fuel Oil
Ÿ Type                                  :           Diesel
Ÿ Caloric Value                     :           9,134 ~ 9,454 kcal/L
3.5            Demi-water (at tie-in point)
Parameters
Units
Value
Temperature
deg C
30
Pressure
barg
5
pH
-
5.5 ~ 7
Conductivity (25 deg C)
μS/cm
< or = 0.1
Resistivity (25 deg C)
MOhms.cm
> or = 10
Cl-
ppb
5
SiO2 (reactive)
ppb
5
Fe
ppb
10
Cu2+
ppb
3
Na+
ppb
5
TOC
ppm
3.5
3.6            Boiler feed water (acc. to VGB R 450 L)
Parameters
Units
Value
Supply pressure at ECO inlet
bar.g
68.1
Supply temperature
deg. C
150
pH value at 25 deg. C
-
9.2 ~ 9.5
Acid Conductivity at 25 deg. C
μS/cm
< 0.1
Dissolved Oxygen as O2
ppb
5 ~ 20
Silica as SiO2
ppb
< 5
Total Iron as Fe
ppb
< 140
3.7            Boiler water (acc. to VGB R 450 L)
Parameters
Units
Value
pH value at 25 deg. C
-
9.5 ~ 10.0
Direct Conductivity at 25 deg. C
μS/cm
8~25
Acid Conductivity at 25 deg. C
μS/cm
< 50
Silica as SiO2
ppb
< 5
3.8            Steam Quality at S/H outlet
Parameters
Unit
Value
pH
-
6.0~9.2
Conductivity(25deg. C)
μS/cm
0.2~0.3
Fe2+
ppm, wt
< 0.02
Cu2+
ppm, wt
< 0.003
SiO2
ppm, wt
< 0.02
NH3
ppm, wt
0.1
Cl
ppm, wt
< 0.05
O2
ppm, wt
< 0.01
Na+
ppm, wt
< 0.01
TOC
ppm, wt
< 5
Total Solids
ppm, wt
< 1
3.9            NEWater
Parameters
Units
Value
A. Physical


Turbidity
NTU
< 5
Color
Hazen units
< 5
Conductivity
μS/cm
< 250
pH value
-
7.0 – 8.5
Total Dissolved Solids
mg/L
< 150
Total Organic Carbon
mg/L
< 0.5
Total Hardness (CaCO3)
mg/L
< 50
B. chemical


Ammoniacal nitrogen (as N)
mg/L
< 1.0
Chloride, Cl
mg/L
< 20
Fluoride, F
mg/L
< 0.5
Nitrate, NO3
mg/L
< 15
Silica, SiO2
mg/L
< 3
Sulphate, SO4
mg/L
< 5
Residual Chlorine, Cl, Total
mg/L
< 2
Total Trihalomethanes
mg/L
< 0.08
C. Metals


Aluminium
mg/L
< 0.1
Barium, Ba
mg/L
< 0.1
Boron, B
mg/L
< 0.5
Calcium,b Ca
mg/L
4 – 20
Copper, Cu
mg/L
< 0.05
Iron, Fe
mg/L
< 0.04
Manganese, Mn
mg/L
< 0.05
Sodium, Na
mg/L
< 20
Strontium, Sr
mg/L
< 0.1
Zinc, Zn
mg/L
< 0.1
D. Bacteriological


Total Coliform Bacteria
Counts/100
Not detectable
Enterovirus

Not detectable
Heterotrophic Plate Count
CFU/mL
< 300
Note) NeWater supply pressure from pub guaranteed at battery limit : min.1.2barg, ambient temperature
3.10          Tie in point
The tie in points of utilities are located as bellow picture.
Ÿ Battery limit conditions
-      DM water at 5bar.g, 30deg. C will be tied in to 8” pipe
-      NEwater at min 1.2bar.g and ambient temperature
-      Fire water at 10~12bar.g will be tied in to 18” pipe
-      Condensate return at 5~6bar.g will be tied in to 8” pipe
-      HP Steam will be tied in to 16” steam header
-      Waste water discharge at 7bar.g, ambient temp. will be tied in to 4” pipe
4.1            Input Industrial & Commercial Waste
Performance guarantees are stated according to the following ICW’s properties.
Parameter
Unit
Low
Design
High
LHV (as received)
MJ/kg
9.60
12.00
14.40
Proximate Analysis
Water (Moisture)
wt, %
41.81
36.74
24.63
Combustible
wt, %
38.59
45.84
55.62
Ash
wt, %
19.60
17.42
19.75
Total
wt, %
100.00
100.00
100.00
Ultimate Analysis (Dry Basis)
Carbon, C
wt, %
40.22
45.49
44.96
Hydrogen, H
wt, %
5.82
6.34
6.27
Oxygen, O
wt, %
18.58
19.13
21.24
Nitrogen, N
wt, %
1.15
1.07
0.96
Sulphur, S
wt, %
0.12
0.14
0.12
Chloride, Cl
wt, %
0.43
0.30
0.24
Ash
wt, %
33.68
27.53
26.21
Total
wt, %
100.00
100.00
100.00
4.2            Input Waste Physical Composition
Constituent
Low(%)
Design(%)
High(%)
Paper
Cardboard
0.0
0.0
0.0
Newspaper
0.0
0.0
0.0
Mixed paper
21.5
15.6
27.6
Subtotal paper
21.5
15.6
27.6
Glass & Inerts
Subtotal Glass & Inerts
6.2
4.1
3.5
Metal
Ferrous
2.2
1.7
1.0
Aluminum
1.6
0.8
0.7
Other metals
(batteries, wires, etc)
0.4
0.3
0.6
Subtotal metal
4.1
2.8
2.3
Plastic
PET
1.6
1.7
1.2
HDPE
0.9
1.6
0.8
LDPE
16.0
12.9
10.0
Mixed plastic
4.2
7.1
9.7
Subtotal plastic
22.6
23.2
21.7
Organic materials
Food waste
11.2
5.1
2.3
Wood/garden waste
5.0
4.1
4.0
Other organics
0.0
0.0
0.0
Subtotal organic materials
16.2
9.3
6.4
Other types of
waste
Rubber
0.1
0.0
0.0
Textile and leather
2.1
5.4
14.0
Styrofoam boxes,
foam padding
1.8
2.1
3.9
Subtotal others
4.0
7.6
18.0
Unidentifiable waste
Subtotal unidentifiable
25.3
27.5
20.5
Total all constituents
100.0
100.0
100.0
4.3            Special Waste Characteristics
At times in the future, Customer intends to combust small amounts of special wastes in the ICW Boiler Facility with the understanding that these special wastes, due to their high heat content, must be combusted in small amounts and only after thorough mixing with the normal industrial and commercial waste received.
Special waste will not be used for performance test, but boiler will be designed to treat special waste up to 10% of ICW input.

Parameter
Units
NO. 1
NO. 2
NO. 3
NO. 4
Name

Carbon Soot
Waste Cake
Biosludge
Biosludge
Type

Semi solid
Solid
Semi solid
Sludge
Calorific Value
Available Quantity
TPD
40
20
1
20
HHV
MJ/kg
31.47
20.22
19.64
13.79
LHV
MJ/kg
31.4
18.9
18.34
12.8
Solids
%
35.6
97.5
88.1
11.2
Combustible
%
34.6
45.4
76.5
8.3
Moisture
%
64.4
2.4
11.9
88.8
Ash
%
1.0
52.2
11.6
2.9
Ultimate Analysis (Dry Basis)
C
%
92.73
38.02
46.12
32.73
H
%
0.21
5.53
6.15
5.61
N
%
1.47
0.39
9.03
6.59
O
%
1.22
Neg.
24.59
26.62
S
%
1.65
2.55
0.63
1.45
Cl
%
0.08
0.01
0.37
1.28
Ash
%
2.64
53.50
13.11
25.72
Select Elemental Concentrations
Na
ppm
< 0.16
8551
6456
18741
V
ppm
-
68
56
79
Fe
ppm
2571
6611
13497
18600
Ni
ppm
4124
17
209
277
K
ppm
52
1276
1527
1308
Al
ppm
103
1186
1074
43326
Cr
ppm
31
41
36
125
Cd
ppm
< 5.5
5
< 5.5
5
Hg
ppm
< 0.5
2
< 0.5
2
Parameters
Units
Limits
Remark
Ammonia
mg/Nm3
30
11% O2 of dry
Antimony
mg/Nm3
5
11% O2 of dry
Arsenic
mg/Nm3
1
11% O2 of dry
Benzene
mg/Nm3
5
11% O2 of dry
Cadmium
mg/Nm3
0.05
11% O2 of dry
Carbon monoxide
mg/Nm3
100
11% O2 of dry
Chlorine
mg/Nm3
32
11% O2 of dry
Copper
mg/Nm3
5
11% O2 of dry
Dioxins and Furans
ng-TEQ/Nm3
0.1
11% O2 of dry
Ethylene oxide
mg/Nm3
1
11% O2 of dry
Hydrofluoric acid, HF
mg/Nm3
10
11% O2 of dry
Formaldehyde
mg/Nm3
20
11% O2 of dry
Hydrogen chloride
mg/Nm3
200
11% O2 of dry
Lead
mg/Nm3
1
11% O2 of dry
Mercury
mg/Nm3
3
11% O2 of dry
Oxides of nitrogen
mg/Nm3
350
11% O2 of dry
Particulate substances
mg/Nm3
10
11% O2 of dry
Styrene monomer
mg/Nm3
100
11% O2 of dry
Sulphur dioxide
mg/Nm3
300
11% O2 of dry
Sulphur trioxide
mg/Nm3
100
11% O2 of dry
Vinyl chloride monomer
mg/Nm3
20
11% O2 of dry
PAHs
mg/Nm3
N.A
11% O2 of dry
Total VOCs
mg/Nm3
N.A
11% O2 of dry

5.2            Noise Level (Boundary Noise limits)
Type of affected
premises
Maximum permitted noise level
(reckoned as the equivalent continuous noise level
over the specified period) in decibels (dBA)
Day
7 am - 7 pm
Evening
7 pm - 11 pm
Night
11 pm -7 am
Noise Sensitive
Premises
60
55
50
Residential
Premises
65
60
55
Commercial
Premises
70
65
60
Type of affected
premises
Maximum permitted noise level
(reckoned as the equivalent continuous noise level
over 5 minutes) in decibels (dBA)
Day
7 am - 7 pm
Evening
7 pm - 11 pm
Night
11 pm -7 am
Noise Sensitive
Premises
65
60
55
Residential
Premises
70
65
60
Commercial
Premises
75
70
65
Factory
Premises
75
70
65
Note) Singapore Code of Practice on Pollution Control (2000Edition) (with amendments in Feb 2001, Jun 2002, Feb 2004 and Feb 2009)) – Appendix 20
Pretreatment Standards for Discharging to the Customer`s Industrial Wastewater Treatment (IWWT) Plant.
No.
Parameter
Unit
Measurement
Pretreatment Standard
1
Temperature
oC
Range
20-30
2
pH
-
Range
3.5 to 8.0
3
Total Alkalinity
as mg/L CaCO3
Average (1)
16,490
4
BOD5
mg/L
Instantaneous Maximum
36,483
5
COD
mg/L
Instantaneous Maximum
72,105
6
TOC
mg/L
Instantaneous Maximum
27,896
7
Suspended Solids
mg/L
Instantaneous Maximum
50
8
Oil and Grease
mg/L
Instantaneous Maximum
20
  9
TKN
mg/L
Average(1)
1,149
10
NH3-N
mg/L
Average(1)
227
11
PO43- -P
mg/L
Average(1)
103
12
SO42-
mg/L
Instantaneous Maximum
1,782
13
Halogen
(Cl-, Br-, I-)
mg/L
Instantaneous Maximum
4,740
14
Total Dissolved Solids(TDS)
mg/L
Instantaneous Maximum
55,000
Note) (1) Over 24-hour period
5.4            Sanity discharge limits
Requirements for discharge of trade effluent into the Public sewers
Maximum concentrations of substances in trade effluent
List of Substances
Limit in mg/litter of trade effluent
(or otherwise stated)
Temperature of discharge
45oC
pH Value
6 - 9
Caustic Alkalinity (as CaCO3)
2,000
5 Day Biochemical Oxygen Demand (BOD) at 20oC
400
Chemical Oxygen Demand
600
Total Suspended Solids
400
Total Dissolved Solids
3,000
Chloride (as chloride ion)
1,000
Sulphate (as SO4)
1,000
Sulphide (as sulphur)
1
Cyanide (as CN)
2
Detergents (linear alkylate sulphonate as methylene blue active substances)
30
Grease and Oil (Hydrocarbon)
60
Grease and Oil (Non-hydrocarbon)
100
Arsenic
5
Barium
10
Tin
10
Iron (as Fe)
50
Beryllium
5
Boron
5
Manganese
10
Phenolic Compounds (expressed as phenol)
0.5
Fluoride (expressed as fluoride ion)
15
Cadmium
1
Chromium (trivalent and hexavalent)
5
Copper
5
Lead
5
Mercury
0.5
Nickel
10
Selenium
10
Silver
5
Zinc
10

5.5            Leaching test limits for landfill disposal
Parameters
Units
Value
Arsenic
mg/L
5
Barium
mg/L
100
Cadmium
mg/L
1
Chromium
mg/L
5
Copper
mg/L
100
Cyanide (total)
mg/L
10
Fluoride
mg/L
150
Iron
mg/L
100
Lead
mg/L
5
Manganese
mg/L
50
Mercury
mg/L
0.2
Nickel
mg/L
5
Phenol
mg/L
0.2
Selenium
mg/L
1
Silver
mg/L
5
Zinc
mg/L
100
AISC
AMERICAN INSTITUTE OF STEEL CONSTRUCTION
API
AMERICAN PETROLEUM INSTITUTE
AHRI
AIR CONDITION AND HEATING, AND REFRIGERATION INSTITUTE
ANSI
AMERICAN NATIONAL STANDARDS INSTITUTE
ASME
AMERICAN SOCIETY OF MECHANICAL ENGINEERS
ASCE
AMERICAN SOCIETY OF CIVIL ENGINEERS
ASLA
AMERICAN SOCITY OF LANDSCAPE ARCHITECTS
ACI
AMERICAN CONCRETE INSTITUTE
CICIND
COMIT INTERNATIONAL DES CHEMINES INDUSTRIELLES
ASTM
AMERICAN SOCIETY FOR TESTING AND MATERIALS
BS
BRITISH STANDARD
BS EN
BRITISH STANDARD/EUROPEAN STANDARD
IEC
INTERNATIONAL ELECTROTECHNICAL COMMISSION
ISO
INTERNATIONAL STANDARDS ORGANISATION
NEC
NATIONAL ELECTRICAL CODE
ISA
INSTRUMENT SOCIETY OF AMERICA
AWS
AMERICAN WELDING SOCIETY
AWWA
AMERICAN WATER WORKS ASSOCIATION
CTI
COOLING TECHNOLOGY INSTITUTE
CEMA
CONVEYOR EQUIPMENT MANUFACTURWERS ASSOCIATION
CMAA
CRANE MANUFACTURERS ASSOCIATION OG AMERICA, Inc.
HEI
HEAT EXCHANGE INSTITUTE
IEEE
INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS
NEMA
NATIONAL ELECTRICAL MANUFACTURES ASSSOCIATION
NFPA
NATIONAL FIRE PROTECTION ASSOCIATION
OSHA
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION
SJI
STEEL JOING INSTITUTE (SJI codes are part of the AISC Codes)
SSPC
SOCIETY OF PROTECTIVE COATINGS
TEMA
TUBULAR EXCHANGERS MANUFACTURERS ASSOCIATION
UBC
UNIFORM BUILDING CODE
UL
UNDERWRITERS LABORATORY
BSI
BRITISH STANDARDS INSTITUTE
US. EPA
ENVIRONMENTAL PROTECTION AGENCY
MSS
MANUFACTURER’s STANDARDIZATION SOCIETY OF THE VALVE AND FITTING INDUSTRY
EU
EUROPEAN STANDARD CODE
SINGAPOREAN BUILDING AND CONSTRUCTION CODES
7.1    Relevant laws and regulations
1)  Occupational Safety and Health Administration (OSHA)
2)  Singaporean Building and Construction Codes
3)  International Building Code (IBC)
4)  National Fire Protection Association (NFPA); (All applicable standards, including, but not limited to: NFPA 70 National Electrical Code; NFPA 850 Recommended Practice for Fire Protection for Electric Generating Plants and High Voltage Direct Current Converter Stations; NFPA 85 Boiler and Combustion Grate Systems Hazards Code.)
7.2      Grating Design specification
1)     Grating design load - Uniform live load shall be 5 KN/m²
2)     Grating material : SA-283, Melting galvanized
3)     Maximum Clear Span Deflection for Uniform Live Loads : 1/240 of span, but not more than 6 mm;
4)     Maximum Clear Span Deflection for Vehicle and Concentrated Loads : 1/180 of span;
5)     Maximum Fiber Stress : 124 N/mm²
6)     Minimum Size of Bearing Bars: Shall be within standard mill tolerance of that shown on the Load Tables in NAAMM MBG 531 or equivalent for applicable loading and deflection requirements. Depth shall not be less than 25 mm;
7)     Minimum Dimensions of Cross Bars: Shall be as shown in the tables of “Minimum Standard Cross Bars and Connecting Bars” in NAAMM MBG 531 or equivalent;
8)     Banding Bar Thickness: Shall be same as bearing bar to which it is attached;
9)     Bearing Bars and Banding Bars: Steel conforming to BS ISO 3573:1986;
10)  Cross Bars and Banding Bars: Steel conforming to BS 970 080M40; and,
11)  Frames: Steel conforming to BS 4360: 1986.
7.3      Others
1)     Hand rail : A53
-        Size of top, middle rail and post        :           32A
-        Size of kick plate                              :           FB100 x 6t
-        Height                                               :           1,100mm
-        Distance of each post                       :           Max.1,200mm
2)     Platform & Walkway
-        Width                                                :           Min. 1,000 mm
-        Height of each walkway                     :           200 mm ± 10 mm / 1 Step
3)     Ladder : A53
-        Width                                                :           Min. 300 mm


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