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DIVISIONE INGEGNERIA E INNOVAZIONE

AREA DI BUSINESS SVILUPPO E REALIZZAZIONE IMPIANTI

Basic requirements

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TITOLO Title

Basic requirements for the Suppliers qualification – Merchandise Group FHIC12 –

Flue gas denitrification

Indice Sicurezza Security Index

Uso Aziendale

SISTEMA System

TIPO DOCUMENTO Document Type

TI DISCIPLINA Discipline

M FILE File

REV DESCRIZIONE DELLE REVISIONI / Description of Revisions

01

02

03

Chap. 4: revised the minimum value of MW realized

ISO 9001:2008 and some formal modifications

SNCR systems sub merchandise group inserted

03 08.10.2015 ES

02 22.08.2014 ES

01 28.06.2012 ES

APM APM APM

REV Data

Date

Scopo

Scope

Preparato

Prepared by

Collaborazioni

Co-operations

Controllato

Checked by

Approvato

Approved by

Casella di testo

approved in committee 27/10/2015

Basic requirements

Documento Document no.

999GG01834

Basic requirements Merchandise

Group FHIC12 Flue gas

denitrification

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INDICE

1. INTRODUCTION .................................................................................................... 3

2. DESCRIPTION OF THE MERCHANDISE GROUP ........................................................... 3

3. MAIN TECHNICAL CHARACTERISTICS ...................................................................... 3

4. Qualification Requirements ..................................................................................... 5

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1. INTRODUCTION

The present document describes synthetically the characteristics of the Merchandise Group ” FHIC12 – FLUE GAS DENITRIFICATION DeNOx”; it defines the technical and quality requirements necessary for the Suppliers to be included in ENEL’s qualified supplier list.

2. DESCRIPTION OF THE MERCHANDISE GROUP

The systems for the catalytic (SCR) and not catalytic (SNCR) denitrification of the flue gas produced by coal, lignite and fuel oil fired power plant boilers and industrial power producing plants belong to the Merchandise Group under consideration. The SCR systems consist of one or more catalytic reactors in parallel provided with an ammonia injection system (AIG or equivalent), one or more catalyst layers for NOx abatement and of the relevant auxiliaries. The SNCR systems consist of the reagent injection system in the furnace, reagent preparation, dosing, unloading and loading. In general, the catalyst is included in the supply for the SCR systems, while the gaseous ammonia production system is an optional supply. For both the above mentioned systems the control system is included in the scope of supply. Design, manufacturing, workshop and site tests, commissioning supervision and startup are included in the scope of supply.

3. MAIN TECHNICAL CHARACTERISTICS

Functional and manufacturing features of the merchandise group The denitrification system is intended to reduce the NOx concentration in the flue gas produced by coal, lignite or fuel oil fired boilers. SCR system The system consists of one or more identical catalytic reactors in parallel, each one containing one or more catalyst layers. The flue gas enters the reactor and after passing through the flow rectifiers it gets to the catalyst layers where the reaction between the NOx and the ammonia injected upstream takes places. Gaseous ammonia, before being injected in the flue gas by proper devices, is diluted with hot air produced by an appropriate system comprising air fans and air heaters. The gaseous ammonia production system can be of different typology; gaseous ammonia can be produced from urea, liquid anhydrous ammonia or ammonia solution. A clearing system, based on sonic horns or steam sootblowers, keeps the catalyst layers clean. The main components included in the scope of supply are listed below.

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- One or more catalytic reactors in parallel consisting of steel structural works and metallic plates, including inlet and outlet hoods

- Hoppers for ash collection - Reactor support structures. - Catalyst - Gaseous ammonia distribution and mixing system with the flue gas inside the

ducts - Reactor/reactors by-pass system - Baffles and flow rectifiers inside the ducts upstream and inside the reactor - Catalyst clearing system (sonic horns or steam sootblowers) - Gaseous ammonia dilution system with hot air - Physical model for the reactor/ducts flow dynamics simulation - Provisions for sampling systems (sampling grids, nozzles) - Gas analyzers (NOx, O2, NH3 etc) - Electric boards (PC and MCC, power and light boards) - HV and LV cables - Control system. - Gaseous ammonia production system – OPTIONAL SUPPLY

The customer can state at least the following parameters in the technical specification:

- Reactor/reactors position in the flue gas line (high dust, tail end) - Catalyst type (plates, honeycomb) - Maximum SO2 to SO3 conversion - Cleaning system type - Minimum catalyst pitch/thickness - Maximum allowable ammonia slip value during performance test and after a

period of some operating years or 16.000/24000 operating hours. SNCR system The system consists of reagent injection lances (urea or ammonia solution) in the furnace, reagent unloading and storage systems, preparation and dilution/mixing systems, forwarding and transfer systems. In general the components can consist of skids pre-assembled on a support frame, connected by pipes, wired and thermally insulated if necessary. The system consists of: - Urea/ammonia unloading system consisting of: pumps, piping, valves,

instruments, cables, electrical board, thermal insulation - Urea/ammonia storage system consisting of: tanks, piping, instruments, valves,

thermal insulation, wiring, stairs and walkways - Urea/ammonia circulation skid consisting of: pumps, piping, valves, instruments,

cables, electrical board, thermal insulation - Dilution water pumps skid (if any) consisting of: pumps, piping, valves,

instruments, cables, electrical board, thermal insulation

Formattato: Inglese (Stati Uniti)

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- Mixing and metering modules consisting of: pumps, piping, valves, instruments, cables, electrical board, thermal insulation

- Fixed or retractable urea/ammonia injection lances - Ammonia slip measurement instruments and furnace temperature monitoring

instruments - Urea/ammonia dosing and lances control system - Electrical boards and cables. Controls, workshop tests and acceptance tests

Besides the normal tests required by the regulations or by recognized standards the following tests will be required: - catalyst: characterization and acceptance test - structures: workshop erection of one or more frames - performance: performance test according ASME PTC38 or equivalent Italian or

European standard Standards and regulations

Reference standards and regulations for the components are as follows:

- Materials: EN, UNI, ASME - Pressure components: PED - Electrical equipment: IEC, CEI, NEMA - Test and performance tests: ASME (PTC 38), IEC - Fire fighting: UNI, NFPA

4. QUALIFICATION REQUIREMENTS

Requirements

The requirements necessary to be included in ENEL’s supplier list relevant to the present Merchandise Group are indicated hereinafter. The Supplier shall demonstrate the possession of the above mentioned requirements and shall prove it by providing appropriate documentation signed by his own legal representative. On the basis of the obtained information the Customer reserves the right to impose limitations on the qualification in particular with reference to the scope of supply.

The Merchandise Group is divided in two sub Merchandise Groups::

- Sub Merchandise Group A: SCR systems

- Sub Merchandise Group B: SNCR systems

Sub Merchandise Group A: SCR systems

http://www.wordreference.com/enit/characterization

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References With reference to the denitrification catalytic systems, high dust type, for the treatment of the flue gas produced by coal or lignite fired boilers or also fired by a mix of liquid and solid fuels (provided that coal and lignite are the predominant fuels), the Supplier shall have references in the last 12 years matching the following requirements: A: at least 3.000 MWe of SCR systems installed in power plants with at least design, flow model and catalyst included in the supply B: at least 1.000 MWe of the plant as per the above mentioned A requirement shall be turn-key supply (base design, detailed engineering, supply, erection, commissioning and start-up) C: at least 2 plants as per requirement A and at least 2 plants as per requirement B shall be rated more than 300 MWe. The references shall be considered valid provided that at least one year of operation with positive results has been achieved. In case of licence production, the above mentioned requirements shall be owned by the Licenser. As for the catalyst included in the scope of supply, the typology and the manufacturer’s references shall be not inferior to the above mentioned ones. For each reference the following details shall be given: main technical characteristics, scope of supply, contract value (in case of Temporary Grouping of Companies the pertaining amount), contract award date, plant start-up date, customer’s name.

Sub Merchandise Group B: SNCR systems

The sub Merchandise Group is divided in the two following subdivisions on the basis of the electrical power of the power plant.

Power plant or industrial plant > 200 MWe - References

The Supplier shall demonstrate to have designed and realized at least 1 (one) SNCR system over the last five years, already entered in service and optimized with a NOX abatement not less than 25%. ENEL reserves the right to extend the qualification to lower power values. Power plant or industrial plant < 200 MWe - References

The Supplier shall demonstrate to have designed and realized at least 3 (three) SNCR systems over the last seven years, already entered in service and optimized with a NOX abatement not less than 25%. For each of the above mentioned references the following details shall be given: main technical characteristics, scope of supply, contract value (in case of Temporary Grouping of Companies the pertaining amount), contract award date, plant start-up date, customer’s name.

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For both the sub Merchandise groups the following requirements shall apply:

- Design The Supplier shall be able to perform, inside his own structure, the design of the whole system. In particular the tools and the staff in order to perform the fluid dynamic design shall be available. - Workshop fabrication The Supplier shall utilize workshops provided with suitable equipment and specialized staff in order to perform the required manufacturing. The Supplier shall ensure the implementation of a suitable Quality Control System for the manufacturing activities performed in his own workshops or in the sub-suppliers’ workshop.

- Quality system The Supplier shall demonstrate the implementation of a Quality Management System fulfilling ISO 9001:2008 Standard. The certification of the Supplier’s Quality Management System released by a Notified Body, according to the model required for the Merchandise Group will be accepted by ENEL, however ENEL, if deemed necessary, reserves the right to verify the Supplier’s Quality System.

- Other requirements The Supplier shall demonstrate:

a) Compliance of the projects during the bid phase and during the realization phase with ENEL’s functional and manufacturing requirements.

b) Availability of design offices provided with the suitable staff and IT systems in order to perform the required activities. In case of license production, the Supplier shall demonstrate that his own project staff is suitable to get the “know-how”, to develop the detailed engineering phase, the construction phase and the fabrication and control plans according to the licenser’s manufacturing standards.

c) Availability of a management system suitable to perform the coordination and planning of the design phase and of the realization activities according to ENEL’s procedures.

d) Availability of a suitable after sale service in order to assure: - The supply of spare parts interchangeable with the original ones including

the updating that could arise from the licenser. - Suitable resources for the maintenance activities and for the component

overhaul. e) Workshop capacity and time required for realizing a system with

characteristics similar to those of the Merchandise Group considered in the present document

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