Sea Water Intake System System Description [PDF]

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OWNER



OWNER’S ENGINEER



SubC Power Facility EPC CONTRACTOR



DESIGNER



PROJECT



AL DUR II IWPP 02/03/2020



UPDATED AS PER HAYA COMMENTS



RCC



DLA



ELB



1



27/01/2020



UPDATED AS PER HAYA COMMENTS



RCC



DLA



ELB



0



16/05/2019



First issue for approval



RCC



DLA



ELB



A



30/04/2019



First issue



RCC



DLA



ELB



REV



DATE



DONE



CHECKED



APPROVE D



STATUS



2



FOR INFORMATION FOR APPROVAL VALID FOR PURCHASE FOR CONSTRUCTION AS BUILT



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM00673



DESCRIPTION DOCUMENT OWNER



EPC CONT.



DATE



DOCUMENT NAME



SEA WATER INTAKE SYSTEM DESCRIPTION



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



2 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION CONTENTS 1. 2.



3.



4.



5.



6. 7.



AIM ................................................................................................................. 3 GENERAL DESCRIPTION ............................................................................. 4 2.1. MAIN FUNCTIONS ..................................................................................... 4 2.2. DESCRIPTION ........................................................................................... 4 2.3. MAIN EQUIPMENT .................................................................................... 9 INTERFACES ............................................................................................... 12 3.1. GENERAL ................................................................................................ 12 3.2. SUPPORT SYSTEMS .............................................................................. 12 3.3. DEPENDENT SYSTEMS ......................................................................... 12 OPERATION CONCEPT .............................................................................. 13 4.1. NORMAL OPERATION ............................................................................ 13 4.2. START-UP ............................................................................................... 14 4.3. SHUTDOWN ............................................................................................ 16 INSTRUMENTATION AND CONTROL ........................................................ 17 5.1. INSTRUMENTATION ............................................................................... 17 5.2. CONTROL ................................................................................................ 17 REFERENCE DOCUMENTS ........................................................................ 37 ANNEXES .................................................................................................... 39



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



3 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 1. AIM



The aim of this document is to provide a description of the Sea water intake System for Al Dur II IWPP project, to be erected by SEPCOIII for Haya Power & Desalination Company B.S.C. in Bahrein. The document defines the purpose, characteristics, control and protection philosophy for the above-mentioned system.



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



4 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 2.



GENERAL DESCRIPTION



2.1.



MAIN FUNCTIONS The main function of the Sea water intake System is to provide water for below needs:



A. Power Plant 



Remove the heat rejected from the Closed Cooling Water System (CCWS) thru the corresponding plate heat exchangers (PHX), using this water (partially or totally) to cover the Cooling Towers (CT) make-up needs.







Travelling band screen cleaning







Chlorination plant



B. Desalination facilities The sea water intake for the desalination plant is placed besides the seawater intake for the power plant, and out of the scope of this document as it’s being designed by the corresponding contractor. 2.2.



DESCRIPTION



2.2.1. General The system is composed by the following parts/equipment: 



2 offshore raw seawater intake with stop gates (existing from phase I)







2 x 100% channels common for all power plant pumps intake (existing from phase I)







2 stop gates for the inlet side of the channels (one for each channel - existing from phase I)



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



5 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 



2 x 100% bar screens with mechanical rakes for debris removal (one for each channel)







2 x 100% motorized travelling band mesh screens for debris removal (one for each channel), with two 2x100% seawater intake wet pit pumps for screening equipment cleaning, referred to from hereinafter as “SP seawater pumps”







2 stop gates for the outlet (one for each channel)







Four 4x33% seawater intake wet pit pumps for the Power Blocks (CCWS and CT make-up) referred to from hereinafter as “PB seawater pumps”, with a common minimum flow recirculation line and control valve







4 stop gates (1 per PB seawater pumps)







Two 2x100% self-cleaning filters at PB seawater pumps common discharge header







Two 2x100% seawater intake wet pit pumps for the chlorination plant, referred to from hereinafter as “CP seawater pumps”







One common stop gate for CP seawater pumps and SC seawater pumps.







Discharge line to seawater outfall that collects the blowdown of both CTs and the seawater coming from CTs make-up bypass line.







Shock and continuous dosing system in seawater intake pits







All associated accessories such as pipework, ON/OFF valves, a bypass line to CTs with a control valve to convey the seawater for CCWS not needed for CTs makeup, a recirculation line at pumps for CCWS / CT make-up discharge, instrumentation and controls



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



6 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION



2.2.2. PB seawater pumps (00PAS11/12/13/14AP001) The system includes four 4x33% seawater vertical wet pit pumps. These pumps discharge water into a common header, which supplies cooling water for CCWS PHXs and CT make-up. For the number of pumps in operation in each scenario, see ch. 5.2.3 and the Annex 1, where a table is included showing it. Each pump outlet is provided with two pressure transmitters, one pressure indicator, one check valve and one isolation valve (ON-OFF motorized) and trifunctional vents. The four pumps discharge into a common header fitted with two pressure transmitters and a recirculation line that conveys seawater back to the intake pit by means of a control valve (motorized – modulating type) (00PAR20AA101). 



Flow: 2060 m3/h (each)







TDH: 53.5 m (each)



2.2.3. Seawater self-cleaning filters (00PAR21/22AT001) Downstream the minimum flow recirculation line, there are two (2x100%) selfcleaning filters, along with the corresponding differential pressure transmitters and inlet – outlet isolation valves (ON-OFF motorized) (00PAR21/22AA101/102). These filters are fitted with an automatic drain valve (00PAR21/22AA103) to remove the dirt from the system during the cleaning process, this stream is discharged into an existing trash container from Al-Dur phase I. 



Mesh size:1500-micron absolute filter



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



7 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION



2.2.4. Seawater common header and distribution system In the common header, downstream the self-cleaning filters, there are two flowmeters to measure the flow conveyed up to the CTs basin filling line with the corresponding isolation valve (ON-OFF motorized) (00PAR55AA101) and CCWS PHXs (3x50%) (00PGD11/12/13AC001); before the split to each CCWS PHX unit there is one pressure transmitter and one temperature transmitter; then the header is split in three branches, on for each CCWS PHX unit (3x50%). Each CCWS PHX unit is provided, in the cold side, with one isolation valve (manual) and one pressure indicator at the inlet, one differential pressure transmitter, and one pressure relief valve, one temperature transmitter, one temperature indicator and one isolation valve (ON-OFF motorized) at the outlet (00PAR31/32/33AA101). For other details see doc AD2-C1-00-PG_-PSD-IDM-00763 CCW System description. CCWS PHXs outlets are merged in a common header, and from this common header three lines convey seawater: one line to power block 1 CT make-up with one control valve (motorized – modulating type) (10PAR40AA101) and one flowmeter (connected to power block 1 CT return line), one to power block 2 makeup with one control valve (motorized – modulating type) (20PAR40AA101) and one flowmeter (connected to power block 2 CT return line), one to bypass the CTs with one control valve (motorized – modulating type) (00PAR50AA101) to convey seawater directly to the CT blowdown line where the CTs blowdown control valves are placed (10/20PSB10AA101). Trifunctional valves are foreseen throughout this system to allow the filling, emptying and to tackle transient events (e.g. PB pumps trip).



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



8 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION Below is shown a simplified diagram for a better understanding:



CTs make-up and blowdown control valves are mentioned in this document, but the detailed description of these items will be included in document AD2-C1-00PA-PSD-IDM-00733 Circulating Water System. System Description.



2.2.5. Direct discharge line to seawater outfall The CTs blowdown is based on gravity flow from CTs basins to the existing seawater outfall with one control valve for each (motorized - modulating type) CT basin (10/20PSB10AA101) to modulate the blowdown. On the other hand, the CTs bypass line conveys water directly to the discharge line to seawater outfall (downstream CTs blowdown valves) when the CTs are not available (e.g. power blocks on open cycle mode), or if being on duty, the CTs make-up needs are much lower than CCWS cooling needs (see doc.



AD2-C1-00-GA_-PCR-IDM-00672



Seawater intake system Design Calculation Note). A manual valve is foreseen before the interface point with SIDEM’s discharge to the existing water outfall.



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



9 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION



2.2.6. Seawater screening system This system is a packaged supply. For further details see the corresponding vendor’s documentation. 



Flow:6180 m3/h (each channel – total: 2)







Water speed ≤ 0.6 m/s







Filtration degree ≤ 5 mm



2.2.7. Seawater sampling system A sample point is foreseen to check the water quality for chlorine dosing, this point is placed in the single header to CCWS PHX. Sampling system is a packaged supply. For further details see the corresponding vendor’s documentation



2.2.8. Seawater intake dosing – Electro-chlorination plant These items are part of a packaged supply of the new chlorination facility. For further details see the corresponding vendor’s documentation.



2.3.







Chlorine production capacity: 27 kg/h (each train – total 2)







Sodium hypochlorite tanks: 80 m3 (each – total 2)







Pumps o



PB Continuous/shock dosing: 33 m3/h (each – total 2)



o



DP shock dosing: 270 m3/h (each – total 2)



MAIN EQUIPMENT



2.3.1. PB seawater pumps KKS: 00PAS11/12/13/14AP001 Type of equipment: pump



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



10 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION Maintenance: if needed, during the plant normal operation Control function: Provides more / less flow to the system by starting and stopping the third pump based on the number of pumps that are on duty in the CCW system. Reference drawings: -



AD2-C1-00-GAF-MDW-FLS-03009 Pump GA drawing



-



AD2-C1-00-GAF-MDS-FLS-03015 Pump datasheet



-



AD2-C1-00-GAF-MDW-FLS-03011 P&ID



2.3.2. Seawater self-cleaning filters KKS: 00PAR21/22AT001 Type of equipment: self-cleaning filter with motorized scraper blades Maintenance: if needed, during the plant normal operation Control function: based on the differential pressure across the filter, the equipment PLC starts the self-cleaning process with the unit on duty. Reference drawings: -



AD2-C1-00-PAR-MDW-SDF-03001 GA drawing



-



AD2-C1-00-PAR-MDS-SDF-03003 Datasheet



2.3.3. Seawater screening system KKS: N/A Type of equipment: packaged supply Maintenance: if needed, during the plant normal operation Control function: yes, the screening mesh panels are normally in rotation and are washed periodically (by means of a dedicated pumping station) when obstructed by debris. Reference drawings: -



AD2-C3-00-Y-MGP-SEPM-03000 Travelling band screen assembly



-



AD2-C3-00-Y-MGP-SEPM-03001 Bar screen and raking beam assembly



-



AD2-C3-00-Y-MGP-SEPM-03005 Channel stop gate assembly



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



11 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION -



AD2-C3-00-Y-MGP-SEPM-03007 Pit stop gate assembly



-



AD2-C1-00-PAA-MDW-SYD-04000 P&ID



2.3.4. Seawater intake dosing – Electro-chlorination plant KKS: N/A Type of equipment: packaged supply Maintenance: if needed, during the plant normal operation Control function: yes, the electro-chlorination plant produces and stores chlorine, dosing it periodically at an appropriate rate to keep under control the biological fouling Reference drawings: -



AD2-C1-00-PBN-MDW-QSR-00501 GA drawing



-



AD2-C1-00-PBN-MDS-QSR-00500 Datasheet



-



AD2-C1-00-PBN-MDW-QSR-00500 P&ID



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



12 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 3.



3.1.



INTERFACES



GENERAL The interfaces of the Sea water intake System with other systems or related equipment are described below. The interfaces are classified according to those which are necessary for the operation of the system (support systems) or according to those that are provided by the system and are necessary in other to allow other systems to carry out their functions (dependent systems).



3.2.



SUPPORT SYSTEMS Mechanical systems o



Chlorination facility



o



Existing seawater outfall system



o



Plant drains system, for collection of drains of the system



Electrical systems o



Medium voltage system, for operation of the pumps



o



Low voltage system, for operation motorized valves



Control systems o 3.3.



Distributed Control System (DCS)



DEPENDENT SYSTEMS Mechanical systems o



CCW System



o



Circulating water System



o



Chlorination facility



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



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13 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 4.



OPERATION CONCEPT



The seawater intake system is common for the entire plant and is required in all operation modes, so it’s considered a critical system and must be always in operation.



4.1.



NORMAL OPERATION In normal operation the status of the main equipment and components will be as follows: 



The seawater intake screening equipment will be on duty, with both channels in open position (stop gates removed), and the travelling band screen with the mesh panels in rotation to remove the dirt. As channels are designed for a 100% capacity each one, power plant can operate with just one channel on duty.







All pump bays will be in open position (stop gates removed).







The electro-chlorination plant will be on-duty, dosing at the appropriate rate.







PB seawater pumps. Three/two pumps will be on duty, depending on the number of CCWS pumps running, the other one/ones will be isolated (spare). o



System starts with two pumps on duty as the CCW starts with one pump on duty, in case the second pump of the CCWS is started, the third pump of seawater intake system is also started.



o



Being with three pumps on duty in the seawater intake system, in case the second pump of the CCWS is stopped, the third pump of the seawater intake is also commanded to stop.



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



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14 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION For pumps on duty the outlet isolation motorized valve will be in open position, and in closed position for shut-down pumps 



The recirculation control valve will be controlling the pressure at the supply common header to consumers according to the specified SP.







The isolation valve for the CT basin filling will be in closed position.







One self-cleaning filter will be on duty, with the other one isolated (spare). The corresponding automatic drain valves will be in closed position, opening if requested by the equipment PLC (self-cleaning process) based on the differential pressure transmitter measurement.







CCWS PHXs. Two PHXs will be on duty with the corresponding motorized valves at the outlet in open position, with the other one isolated (spare). Manual valves at the inlet will be in open position in the three units in both, the cold side and hot side.







The CT bypass control valve will be controlling the flow in the supply common header to consumers according to the specified SP.







The CT make-up control valves will be controlling the corresponding CT basin levels according to the specified SP.







The CT blowdown control valves will be controlling the corresponding circulating water system conductivity according to the specified SP.



4.2.



START-UP For the start-up of this system, the following conditions are required: 



Electrical and control systems are operating/available







Piping distribution system is full of water and air is properly vented from all high points, with all motorized valves in closed position



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



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02/03/2020 PAGE



15 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 



The seawater intake screening package already started and on duty as per vendor’s procedure.







The electro-chlorination plant package already started and on duty as per vendor’s procedure







All pump bays will be in open position (stop gates removed)



Start-up of this system is done automatically and is summarized in the following events: 



Two PHXs will be on duty with the corresponding motorized valves at the outlet in open position, the other one isolated (spare). Manual valves at the inlet in open position for the three units in both







One self-cleaning filter will be on duty, with the other one isolated (spare). The corresponding automatic drain valves control loop is put in auto.







PB pumps discharge valves are in closed position







CT bypass, make-up and filling line valves are in closed position.







Minimum recirculation control loop is put in auto.







One PB pump is started and the corresponding discharge motorized valve is commanded to open.







Once the first pump is on duty, the second pump is started, and the corresponding discharge motorized valve is commanded to open.







CT bypass and make-up valves control loops are put in auto.



Rev.: 2



PROJECT



DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



16 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 4.3.



SHUTDOWN The shutdown of this system should be done only after all systems are shutdown as this system provides cooling water to the CCWS of the whole plant, and makeup water to circulating water system of both power blocks. The shutdown of the system is done automatically and is summarized in the following events: 



All consumers are stopped, meaning no cooling is required in the CCWS and no make-up is required in the circulating water system of both power blocks.







CT make-up valves in commanded to close, if not yet







CT bypass valve commanded to close







Minimum recirculation control loop is kept in auto, so all water being pumped is recirculated to the pumps’ intake







PB pumps running are stopped one by one.







All control and on-off valves are positioned in initial/default position



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



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SEA WATER INTAKE SYSTEM DESCRIPTION 5.



5.1.



INSTRUMENTATION AND CONTROL



INSTRUMENTATION Instruments are represented on the following diagram:  AD2-C1-00-GA_-PDW-IDM-00671 Seawater intake system P&ID



5.2.



CONTROL In this section, descriptive narrative is provided for the control and protection of the system. For details on the logics of this system refer to the following document:  AD2-C1-00-GA_-IDW-IDM-06758 Sea Water Intake System. Logic Diagrams. The table below summarizes the actuators of this system: KKS



Service



Type



Notes



00PAS11AP001



PB Seawater intake pump 1



Constant Pump



speed



00PAS12AP001



PB Seawater intake pump 2



Constant Pump



speed



00PAS13AP001



PB Seawater intake pump 3



Constant Pump



speed



00PAS14AP001



PB Seawater intake pump 4



Constant Pump



speed



00PAR11AA101



PB Seawater intake pump 1 outlet valve



ON-OFF valve (motorized)



-



00PAR12AA101



PB Seawater intake pump 2 outlet valve



ON-OFF valve (motorized)



-



00PAR13AA101



PB Seawater intake pump 3 outlet valve



ON-OFF valve (motorized)



-



00PAR14AA101



PB Seawater intake pump 4 outlet valve



ON-OFF valve (motorized)



-



00PAR20AA101



PB Seawater intake pumps



Modulating valve (motorized)



-



-



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION KKS



Service



Type



Notes



Rev.: 2



minimum recirculation control valve 00PAR21AA101



Self-cleaning filter 1 inlet valve



ON-OFF valve (motorized)



-



00PAR22AA101



Self-cleaning filter 2 inlet valve



ON-OFF valve (motorized)



-



00PAR21AA102



Self-cleaning filter 1 outlet valve



ON-OFF valve (motorized)



-



00PAR22AA102



Self-cleaning filter 2 outlet valve



ON-OFF valve (motorized)



-



-



Self-cleaning filter 1



Package supply



-



00PAR21AT001



Filter



Filter with motorized scraper blades



00PAR21AA103



Automatic drain valve



ON-OFF valve (motorized)



-



-



Self-cleaning filter 2



Package supply



-



00PAR22AT001



Filter



Filter with motorized scraper blades



00PAR22AA103



Automatic drain valve



ON-OFF valve (motorized)



-



-



Seawater screening facilities



Package supply



-



-



Electro-chlorination Package supply plant



-



00PAR31AA101



CCWS 1 outlet valve (cold side)



ON-OFF valve (motorized)



See doc. AD2C1-00-PG_PSD-IDM00763



00PAR32AA101



CCWS 2 outlet valve (cold side)



ON-OFF valve (motorized)



See doc. AD2C1-00-PG_PSD-IDM00763



00PAR33AA101



CCWS 2 outlet valve (cold side)



ON-OFF valve (motorized)



See doc. AD2C1-00-PG_PSD-IDM00763



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AL DUR II IWPP OWNER



EPC CONTRACTOR



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SEA WATER INTAKE SYSTEM DESCRIPTION



Rev.: 2



KKS



Service



Type



Notes



00PAR50AA101



CTs bypass valve



Modulating valve (motorized)



-



10PAR40AA101



CT 1 make-up valve



Modulating valve (motorized)



See doc. AD2C1-00-PAPSD-IDM00733



20PAR40AA101



CT 2 make-up valve



Modulating valve (motorized)



See doc. AD2C1-00-PAPSD-IDM00733



Notes: The travelling band screen cleaning system, chlorination plant and self-cleaning filters are packaged supplies, so for further details see the corresponding vendor’s documentation.



5.2.1. Seawater Functional Group (00PAR01EE100) Seawater functional group is in charge of managing the start/stop or open/close of each individual device to respond to the measured parameters of the Seawater system. The actuators / drives included in this functional group are shown in the table of paragraph ¡Error! No se encuentra el origen de la referencia. Seawater Functional Group receives the AUTO order from the Automatic Plant Sequencer. The below table summarizes the logic for the Seawater Functional Group:



00PAR01EE100



Seawater Functional Group



Manual Reject



N/A



Auto permitted



Always permitted



On permitted



Always permitted



Off permitted



Always permitted



Auto Selection



Seawater Group ON Command from Automatic Plant Sequencer 00PAR01EE10: XA61)



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AL DUR II IWPP OWNER



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SEA WATER INTAKE SYSTEM DESCRIPTION Auto On command



Seawater Group ON Command from Automatic Plant Sequencer 00PAR01EE10: XA61, as pulse) (for certain time delay)



Auto Off command



N/A



Force On



N/A



Force Off



N/A



No Discrepancy



All pump drives and actuators in AUTO AND 4ACT Potable Service Water pumps manager No Discrepancy (00PAS10EE200)



5.2.2. Seawater Pumps Pumps Manager (00PAS10EE200) Seawater Pumps manager’s function is to manage the automatic change over (ACO) between the Seawater Pumps, to select the lead / lag pump motor and define the number of required pump motors to be in service following the requirements of the system. The below table summarizes the logic for the Seawater Pumps Manager (4ACT): 00PAS10EE200



Seawater Pumps Manager (00PAS10EE200)



Change Over Required



N/A



4 Actuators Required



Seawater Group ON Command (00PAR01EE100:XA91) AND Seawater Pump Group 4 actuator required (00PAS10EE200:XA74) AND [Seawater Pump 1 NOT OFF Force (00PAS11AP001:XB56) OR Seawater Pump 2 NOT OFF Force (00PAS12AP001:XB56) OR



Rev.: 2



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DOCUMENT OWNER



AL DUR II IWPP OWNER



EPC CONTRACTOR



DOCUMENT NUMBER



AD2-C1-00-GA_-PSD-IDM-00673 DOCUMENT NAME



DATE



02/03/2020 PAGE



21 / 39



SEA WATER INTAKE SYSTEM DESCRIPTION 00PAS10EE200



Seawater Pumps Manager (00PAS10EE200) Seawater Pump 3 NOT OFF Force (00PAS13AP001:XB56) OR Seawater Pump 4 NOT OFF Force (00PAS14AP001:XB56) OR Seawater Group NOT OFF command (00PAR01EE100:XA92)]



3 Actuators Required



Seawater Group ON Command (00PAR01EE100:XA91) AND Seawater Pump Group 3 actuator required (00PAS10EE200:XA73) AND [Seawater Pump 1 NOT OFF Force (00PAS11AP001:XB56) OR Seawater Pump 2 NOT OFF Force (00PAS12AP001:XB56) OR Seawater Pump 3 NOT OFF Force (00PAS13AP001:XB56) OR Seawater Pump 4 NOT OFF Force (00PAS14AP001:XB56) OR



2 Actuators Required



Seawater Group NOT OFF command (00PAR01EE100:XA92)] Seawater Group ON Command (00PAR01EE100:XA91) AND Seawater Pump Group 2 actuator required (00PAS10EE200:XA72) AND



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION 00PAS10EE200



Seawater Pumps Manager (00PAS10EE200) [Seawater Pump 1 NOT OFF Force (00PAS11AP001:XB56) OR Seawater Pump 2 NOT OFF Force (00PAS12AP001:XB56) OR Seawater Pump 3 NOT OFF Force (00PAS13AP001:XB56) OR Seawater Pump 4 NOT OFF Force (00PAS14AP001:XB56) OR



1 Actuators Required



Seawater Group NOT OFF command (00PAR01EE100:XA92)] Seawater Group ON Command (00PAR01EE100:XA91) AND Seawater Pump Group 1 actuator required (00PAS10EE200:XA71) AND [Seawater Pump 1 NOT OFF Force (00PAS11AP001:XB56) OR Seawater Pump 2 NOT OFF Force (00PAS12AP001:XB56) OR Seawater Pump 3 NOT OFF Force (00PAS13AP001:XB56) OR Seawater Pump 4 NOT OFF Force (00PAS14AP001:XB56) OR Seawater Group NOT OFF command (00PAR01EE100:XA92)]



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SEA WATER INTAKE SYSTEM DESCRIPTION 00PAS10EE200



Seawater Pumps Manager (00PAS10EE200)



0 Actuators Required



[Seawater Pump 1 NOT OFF Force (00PAS11AP001:XB56) OR Seawater Pump 2 NOT OFF Force (00PAS12AP001:XB56) OR Seawater Pump 3 NOT OFF Force (00PAS13AP001:XB56) OR Seawater Pump 4 OFF Force (00PAS14AP001:XB56) OR Seawater Group OFF command (00PAR01EE100:XA92)]



Fault



Seawater Pump 1/2/3/4 NOT in AUTO (00PAS11/12/13/14AP001:XB20) OR Seawater Pump 1/2/3/4 Discharge MOV NOT in AUTO (00PAS11/12/13/14AA101:XB20) OR Seawater Pump 1/2/3/4 In Fault (00PAS11/12/13/14AP001:XB64) OR Seawater Pump 1/2/3/4 Discharge MOV In Fault (00PAS11/12/13/14AA101:XB64) OR Seawater Pump 1/2/3/4 NOT on permit (00PAS11/12/13/14AP001:XB35) OR Seawater Pump 1/2/3/4 OFF force (00PAS11/12/13/14AP001:XB56) OR Seawater Pump 1/2/3/4 OVR Trip



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SEA WATER INTAKE SYSTEM DESCRIPTION 00PAS10EE200



Seawater Pumps Manager (00PAS10EE200) (00PAS11/12/13/14AP001:XB31)



ON Feedback



Seawater Pump 1/2/3 Running (00PAS11/12/13/14AA101:XB81)



5.2.3. PB seawater pumps (00PAS11/12/13/14AP001) The system includes four 4x33% seawater vertical wet pit pumps. The number of PB seawater pumps to be on duty is set as per the following criteria: -



When two out of three (3x50%) CCWS pumps are on duty, three out four (4x33 %) PB seawater pumps shall work simultaneously



-



When one out of three (3x50%) CCWS pumps are on duty, two out of four (4x33 %) PB seawater pumps shall work simultaneously



In both cases, there will be at least one pump in stand-by mode, ready to start in case of main pump failure, maintenance, etc. For further details on CCWS see document AD2-C1-00-PG_-PSD-IDM-00763 Closed Auxiliary Cooling Water System Description. Each pump is provided with one isolating valve (ON-OFF motorized) (00PAR11/12/13/14AA101) with slow opening rate actuators, this type of valve allows an automatic and smooth start-up, and an automatic changeover maneuver.



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SEA WATER INTAKE SYSTEM DESCRIPTION 00PAS11AP001 00PAS12AP001 00PAS13AP001 00PAS14AP001



Seawater Pumps 1/2/3/4



Manual reject



N/A



Auto permitted



Always Permitted



Auto selection



Auto Sel. order from Seawater System functional Group (00PAR10EE100: XA93)



On permitted



Seawater Pump 1/2/3/4 reverse rotation detector NOT activated (00PAS11/12/13/14CG301:XH12) AND Seawater Pump 1/2/3/4 mtr wdg temp U NOT high high (00PAS11/12/13/14CT210:XH03) AND Seawater Pump 1/2/3/4 mtr wdg temp V NOT high high (00PAS11/12/13/14CT211:XH03) AND Seawater Pump 1/2/3/4 mtr wdg temp W NOT high high (00PAS11/12/13/14CT211:XH03) AND Seawater Pump 1/2/3/4 DE brg temp NOT high high (00PAS11/12/13/14CT201:XH03) AND Seawater Pump 1/2/3/4 mtr NDE brg temp high high (00PAS11/12/13/14CT203:XH03) AND Seawater Pump 1/2/3/4 pump thrust brg temp high high (00PAS11/12/13/14CT209:XH03) AND Seawater Pump 1/2/3/4 Discharge MOV closed (00PAR11/12/13/14AA103:XB62) AND Seawater Level NOT Low Low (00PAA10CL901:XH54)



Force OFF



Seawater level Low Low Low (00PAA10CP901:XH56)



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SEA WATER INTAKE SYSTEM DESCRIPTION OR Seawater level Bad quality (00PAA10CP901:XM26)] Force ON



N/A



Trip



[ Seawater Pump 1/2/3/4 U wdg temp High High High (00PAS11/12/13/14CT210:XH05) OR Seawater Pump 1/2/3/4 V wdg temp High High High (00PAS11/12/13/14CT211:XH05) OR Seawater Pump 1/2/3/4 W wdg temp High High High (00PAS11/12/13/14CT212:XH05) OR Seawater Pump 1/2/3/4 mtr DE brg temp High High High (00PAS11/12/13/14CT201:XH05) OR Seawater Pump 1/2/3/4 mtr NDE brg temp High High High (00PAS11/12/13/14CT203:XH05) OR Seawater Pump 1/2/3/4 pump thrust brg temp High High High (00PAS11/12/13/14CT209:XH05) OR Seawater Pump 1/2/3/4 Discharge MOV closed (00PAR11/12/13/14AA103:XB62/64/66) OR Seawater Pump 1/2/3/4 Discharge Pressure Low Low Low (00PAR11/12/13/14CP901:XH56) OR Seawater Pump 1/2/3/4 Discharge Pressure Bad quality (00PAR11/12/13/14CP901:XM26)] AND Seawater Pump 1/2/3/4 Running (After a certain time delay) (00PAS11/12/13/14AP001:XB81)



Auto-ON



Seawater Pump 1/2/3/4 (00PAS11EE201:XA61/63/65)



ON



command



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SEA WATER INTAKE SYSTEM DESCRIPTION Auto-OFF



Seawater Pump 1/2/3/4 OFF command (00PAS11EE201:XA62/64/66)



5.2.4. Seawater pump discharge motorized valves (00PAR11/12/13/14AA101) Seawater Pump discharge valves open when pump starts and close when pump is stopped. 00PAR11/12/13/14AA101



Seawater Pump 1/2/3/4 Discharge MOV



Manual Reject



N/A



Auto permitted



Always Permitted



Open permitted



Always Permitted



Close permitted



Always Permitted



Auto Selection



Auto Sel. order from Seawater System functional Group (00PAR10EE100: XA93)



Auto Open command



Seawater Group ON command (00PAR01EE100:XA91) AND Seawater Pump1/2/3/4 Running (00PAS11/12/13/14AP001:XB81) AND Seawater Pump1/2/3/4 Discharge Pressure NOT Low (00PAR11/12/13/14CP901:XH52)



Auto Close command



Seawater Group OFF command (00PAR01EE100:XA92) OR Seawater Pump1/2/3/4 Stopped (00PAS11/12/13/14AP001:XB82)



Force Open



N/A



Force Close



N/A



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SEA WATER INTAKE SYSTEM DESCRIPTION



5.2.5. PB seawater pumps recirculation valve (00PAR20AA101) Downstream the common discharge header, there is a recirculation line with a control valve that keeps the pressure below the pumps minimum recirculation point by means of a control valve (motorized – modulating type). This valve is part of a control loop with the following characteristics: 



Process variable: pressure at the common header to consumers (00PAR20CP001/002)







Final control element: PB pumps recirculation valve 00PAR20AA101







Set point: refer to the system settings given in annex 1



00PAR20AA101 Manual reject



Seawater Pumps Minimum Recirculation MOV Seawater Pumps Discharge Pressure Bad Quality (00PAR20CP901:XM26)



Auto permitted



Always permitted



Modulate permitted



[Either of the Pumps Running (00PAS11/12/13/14AP001:XB81) OR Seawater Group ON Command (00PAR01EE100:XA91)



Auto selection



Auto Sel. order from Seawater System functional Group (00PAR10EE100: XA93)



Remote setpoint



SP(XXXX)



Process value



Seawater Pumps Discharge Pressure (00PAR20CP901:XQ01)



Force open



N/A



Force Close



N/A



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SEA WATER INTAKE SYSTEM DESCRIPTION



5.2.6. CTs bypass valve (00PAR50AA101) The direct discharge to seawater outfall is made by means of the control valve placed in the CT bypass line. When the plant is operating in open cycle mode, or CTs make-up needs are lower than the CCWS cooling needs, the CT bypass control valve increases the flow conveyed as needed based on the flow measurement of the flowmeters placed at PB seawater pumps discharge (common header). In all cases, the flow to be running thru the common discharge header shall be equal to the number of PB seawater pumps required to be on duty (see previous chapter) by the normal operating flow of each one. This valve is part of a control loop with the following characteristics: 



Process



variable:



flow



at



the



common



header



to



consumers



(00PAR30CF001/002) 



Final control element: CTs bypass valve 00PAR50AA101







Set point: refer to the system settings given in annex 1



00PAR50AA101



Seawater to Water Outfall MOV



Manual reject



Seawater Pumps Discharge Pressure Bad Quality (00PAR20CP901:XM26)



Auto permitted



Always permitted



Modulate permitted



[Either of the Pumps Running (00PAS11/12/13/14AP001:XB81) OR Seawater Group ON Command (00PAR01EE100:XA91)



Auto selection



Auto Sel. order from Seawater System functional Group (00PAR10EE100: XA93)



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SEA WATER INTAKE SYSTEM DESCRIPTION No. of Pump running selected



Remote setpoint



(00PAS11/12/13/14AP001:XB81) Seawater Pumps Discharge Flow



Process value



(00PAR30CF901:XQ01) Force open



Seawater Pumps Discharge Pressure High High High (00PAR20CP901:XH05)



Force Close



N/A



5.2.7. Self-cleaning filters package This is a package supply with its own controller. Between package local controller and DCS there is a basic signal exchange to allow coordinated operation. This unit removes dirt from the seawater before it reaches the plant consumers, when the filtering elements reaches the clogged level set for the differential pressure transmitter to command the cleaning process, motor drives the scraper blades to remove the impurity attached on the inner surface of the filtering elements, opening the automatic drain valve to remove that dirt form the filter and discharging it into an existing trash collection point. For further details see vendor’s documentation. 00PAR20EE200



Seawater Self Cleaning Filter 1 2 ACT (00PAR20EE200)



Change Over Required



N/A



2 Actuators Required



N/A



1 Actuators Required



Always Required



0 Actuators Required



N/A



Fault



Seawater Self-cleaning filter 1/2 NOT ready to start



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION (00PAR21/22GH001:XH84) OR Seawater Self-cleaning filter 1/2 General Alarm (00PAR21/22GH001:XH48) OR Seawater Self-cleaning filter 1/2 DP High High High (00PAR21/22GH001:XH05) OR Seawater Self-cleaning filter 1/2 inlet MOV NOT Opened (00PAR21/22AA101:XB61) AND Seawater Self-cleaning filter 1/2 inlet MOV NOT in Auto (00PAR21/22AA101:XB20) OR Seawater Self-cleaning filter 1/2 outlet MOV NOT Opened (00PAR21/22AA102:XB61) AND Seawater Self-cleaning filter 1/2 outlet MOV NOT in Auto (00PAR21/22AA102:XB20)



ON Feedback



Seawater Self-cleaning filter 1/ 2 Inlet MOV Opened (00PAR21/22AA101:XB61) AND Seawater Self-cleaning filter 1/ 2 Outlet MOV Opened (00PAR21/22AA102:XB61)



5.2.8. Self-cleaning filters isolation valves 00PAR21/22AA101/102 There are 2x100% self-cleaning filters, each unit is provided with isolation valves (ON-OFF motorized) at the inlet and outlet, to allow a remote changeover maneuver, if needed.



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SEA WATER INTAKE SYSTEM DESCRIPTION 00PAR21/22AA101



Seawater Self-cleaning filter 1/ 2 Inlet MOV



Manual Reject



N/A



Auto permitted



Always Permitted



Open permitted



Always Permitted



Close permitted



Seawater Self-cleaning filter 2/ 1 Inlet MOV Opened (00PAR21/22AA101:XB61) AND Seawater Self-cleaning filter 2/ 1 Outlet MOV Opened (00PAR21/22AA102:XB61)



Auto Selection



Auto Sel. order from Seawater System functional Group (00PAR10EE100: XA93)



Auto Open command



2ACT Seawater Self-cleaning filter 1/ 2 Open Command (00PAR20EE200:XA61/63)



Auto Close command



2ACT Seawater Self-cleaning filter 1/ 2 Close Command (00PAR20EE200:XA62/64)



Force Open



N/A



Force Close



N/A



00PAR21/22AA102



Seawater Self-cleaning filter 1/ 2 Outlet MOV



Manual Reject



N/A



Auto permitted



Always Permitted



Open permitted



Always Permitted



Close permitted



Seawater Self-cleaning filter 2/ 1 Inlet MOV Opened (00PAR21/22AA101:XB61) AND Seawater Self-cleaning filter 2/ 1 Outlet MOV Opened (00PAR21/22AA102:XB61)



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SEA WATER INTAKE SYSTEM DESCRIPTION Auto Sel. order from Seawater System



Auto Selection



functional Group (00PAR10EE100: XA93) 2ACT Seawater Self-cleaning filter 1/ 2 Open



Auto Open command



Command (00PAR20EE200:XA61/63) 2ACT Seawater Self-cleaning filter 1/ 2 Close



Auto Close command



Command (00PAR20EE200:XA62/64) N/A



Force Open



5.2.9. Seawater screening facilities package This is a package supply with its own controller. Between package local controller and DCS there is a basic signal exchange to allow coordinated operation. This unit is composed of two identical channels (2x100%) and removes all type of debris and marine biomass (e.g. jelly fish) before the seawater reaches the PB pumps intake. The first stage is a bar screen with a racking beam for filtering/separation of heavy and big size solid materials, an automatic cleaning mechanism removes the solids into a tray. The second stage is a travelling band screen for a fine screening that protects the PB pumps, and discharges into a tray all marine biomass removed from the system. A pumping station (2x100%) provides water for an easy removal of all collected solids in the abovementioned trays, up to an existing trash basket. For further details see vendor’s documentation. 00PAA10GH001



Sea Water Band Screen System Group



Manual Reject



N/A



Auto permitted



Always permitted



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION On permitted



Always permitted



Off permitted



Always permitted



Auto Selection



Band Screen System Group ON Command from Automatic Plant Sequencer (00PAA10EE100: XA61, as pulse) Band Screen System Group ON Command from Automatic Plant Sequencer (00GMA30EE100: XA61, as pulse) (for certain time delay)



Auto On command



Auto Off command



N/A



Force On



N/A



Force Off



N/A



No Discrepancy



Bar Screen NOT fault (00PAA10GH01:XB29) AND Bar Screen NOT fault (00PAA10GH02:XB29) AND Washer



System



in



remote



mode



(00PAA10GH003:XB57) AND Washer Pump 1 NOT trip (00PAA21AP001:XB81) AND Washer Pump 2 NOT trip (00PAA22AP001:XB81) AND Band 4 NOT General alarm (00PAA10AT007:XB48) AND Band 4 in Remote mode (00PAA10AT007:XB57) AND Band 3 NOT General Alarm (00PAA10AT005:XB57) AND Band 3 in Remote mode (00PAA10AT005:XB57) AND Band 2 NOT General Alarm (00PAA10AT003:XB57) AND Band 2 in Remote mode (00PAA10AT003:XB57) AND Band 1 NOT General Alarm (00PAA10AT001:XB57)



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SEA WATER INTAKE SYSTEM DESCRIPTION AND Band 1 in Remote mode (00PAA10AT001:XB57)



00PAA10AT001/3/5/7



Seawater Band Screen 1/2/3/4



Start Command



[Band Different Level High High High (00PAA10AT001/3/5/7:XG55) OR Band Different Level High High (00PAA10AT001/3/5/7:XG55)] AND Band Screen System Start Command (00PAA10GH001:XA91)



Stop Command



5.2.10.



Or by a pushbutton from operator workstation No start command Or by a pushbutton from operator workstation



Electro-chlorination plant package



This is a package supply with its own controller. Between package local controller and DCS there is a basic signal exchange to allow coordinated operation. This plant produces chlorine by means of two (2x100%) electro-chlorination devices that are fed by a pumping station (2x100%), stores it in two tanks (2x100%), being dosed in the common intake by means of continuous /chock dosing pumps (2x100%) for the PB facilities, and shock dosing pumps (2x100%) for DP facilities. The plant is fitted with a chemical cleaning system for the electrolyze units. For further details see vendor’s documentation. 00PBN11EE100



Chlorination Plant System Functional Group



Manual Reject



N/A



Auto permitted



Always permitted



On permitted



Always permitted



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION Off permitted



Always permitted



Auto Selection Auto On command



Chlorination Plant Group ON Command from Automatic Plant Sequencer (00PBN11EE100: XA61) Chlorination Plant Group ON Command from Automatic Plant Sequencer (00PBN11EE100: XA61, as pulse) (for certain time delay)



Auto Off command



N/A



Force On



N/A



Force Off



N/A



No Discrepancy



Chlorination Plant System (00PBN11GH001:XA57)



00PBN11GH001



Chlorination Plant System



Start command



[Chlorination Plant System Group ON Command (00PBN11EE100:XA91) AND Chlorination Plant System Ready to Start (00PBN11GH001:XB84) Chlorination Plant System Group OFF Command (00PBN11EE100:XA92)



Stop command



in



remote



mode



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION 6.



REFERENCE DOCUMENTS



Main system documents AD2-C1-00-GA_-PDW-IDM-00671 Seawater intake system P&ID AD2-C1-00-GA_-PCR-IDM-00672 Seawater intake system Design Calculation Note Other related documents AD2-C1-00-PG_-PSD-IDM-00763 Closed Auxiliary Cooling Water System Description TA-M-01-050-002/003 Seawater intake pump station GA Control documents AD2-C1-00-GA_-IDW-IDM-06758 Sea Water Intake System Logic Diagrams AD2-C1-00-YDS-IDW-IDM-06740 Logic Control Diagrams Symbology AD2-C1-00-YYD-ILS-IDM-06130 Alarms and Set Points List Other related P&IDs AD2-C1-00-PG_-PDW-IDM-00761 Closed Auxiliary Cooling Water System P&ID AD2-C1-00-PA_-PDW-IDM-00731 Circulating Water System P&ID AD2-C1-00-GMA-PDW-IDM-00791 Plant Drainage System P&ID Electro-chlorination plant AD2-C1-00-PBN-MDS-QSR-00500 Equipment’s datasheet AD2-C1-00-PBN-MDW-QSR-00500 P&ID



AD2-C1-00-PBN-MDW-QSR-00501 GA drawing AD2-C1-00-PBN-GMN-QSR-00004 System description AD2-C1-00-PBN-MLS-QSR-06000 Instrument list AD2-C1-00-PBN-ILS-QSR-06000 Set value & alarm list Seawater screening facilities AD2-C1-00-PAA-MDW-SYD-04000 P&ID AD2-C3-00-Y-MGP-SEPM-03000 Travelling band screen assembly AD2-C3-00-Y-MGP-SEPM-03001 Bar screen and raking beam assembly AD2-C3-00-Y-MGP-SEPM-03005 Channel stop gate assembly AD2-C3-00-Y-MGP-SEPM-03007 Pit stop gate assembly



Rev.: 2



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SEA WATER INTAKE SYSTEM DESCRIPTION AD2-C1-00-PGB-MDS-SED-00004 Datasheet AD2-C1-00-PAA-EGP-SYD-05011 Instrument list AD2-C1-00-PAA-EDW-SYD-05014 DCS communicated signal list Seawater self-cleaning filters AD2-C1-00-PAR-MDW-SDF-03001 GA drawing AD2-C1-00-PAR-MDS-SDF-03003 Datasheet AD2-C1-00-PAR-ISD-SDF-06001 Functional description AD2-C1-00-PAR-IDW-SDF-06002 Control logic diagram PB seawater pumps AD2-C1-00-GAF-MDW-FLS-03009 Pump GA drawing AD2-C1-00-GAF-MDS-FLS-03015 Pump datasheet AD2-C1-00-GAF-MDW-FLS-03011 P&ID CCW PHX documentation AD2-C1-00-PGB-MDW-TRT-03000 PHX GA drawing AD2-C1-00-HAN-MDS-TRT-03002 PHX datasheet



Rev.: 2



PROJECT



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DATE



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SEA WATER INTAKE SYSTEM DESCRIPTION 7.



ANNEXES







Annex 1 – Seawater intake system settings







Annex 2 - Seawater intake system functional Diagram



Rev.: 2