SPANISH POWER PLANTS DEI Compliance

Transcription

1 Work Order Synthesis ENGINEERING AND Sheet 1 of 11 PROJECT SPANISH POWER PLANTS DEI Compliance Security Index Internal Use / P TITLE CLIENT ENEL GLOBAL GENERATION JOB no. Document no. CLIENT SUBMITTAL [X] FOR APPROVAL [] FOR INFORMATION ONLY [] NOT REQUESTED SYSTEM APPL. TO UNIT DOC. TYPE RG DISCIPLINE G FILE 00 REV DESCRIPTION OF REVISIONS 00 First issue TR PE GP COS AVV QUA AUT PEM PE/PEM REV Date Scope Prepared by Co-operations Approved by Issued by partially, and to provide any related information to others without previous written consent

2 Sheet 2 of 11 INDEX 1. SUBJECT DEI FRAMEWORK SCOPE OF WORK EXCLUSIONS CONTRACT PRICE PAYMENTS LIQUIDATED DAMAGES WARRANTY TECHNICL STANDARDS QUALITY SYSTEM WORK ORDER PARTITION AND SCHEDULE REQUIREMENTS FOR QUALIFICATION... 7

3 Sheet 3 of SUBJECT Enel Engineering and Construction (hereinafter named also E&C) is looking for a specialized EPC Contractor (hereinafter named EPC) for engineering, design, procurement, fabrication, erection, commissioning and project management of the Balance of Plant (hereinafter named also BoP) relevant to the retrofit of flue gas line into power plants greater than 200 MW in Spain in order to comply to the emission limits defined by the Directive 2010/75/EU (hereinafter named also DEI). For these projects the EPC Contractor shall act as a Main Contractor with a leading role in the execution of activities defined by the BoP scope of work. 1.1 DEI FRAMEWORK Directive 2010/75/EU was Published in the Official Journal of European Union (OJ) on December 17th 2010, entered into force on January 6th Transposed into Spanish legislation by means of: Real Decreto 815/2013 on October 18th Applies to existing combustion facilities setting pollutants emission limits of sulphur dioxide (SO2), nitrogen oxide (NOx) and dust (particles): 200 mg/nm3 for SO2 and NOx, and 20 mg/nm3 for particles (values on dry basis and at 6%O2). For domestic coal power plants which cannot comply with the SO2 limit values due to the characteristics of this fuel, the DEI fix a minimum rate of desulphurization (DI) according to the prescribed rules.. These values should be reached before January 2016, but the Directive for some plants considers flexibility mechanisms to allow a progressive adaptation for the existing facilities: Transitional National Plan (PNT) and Life limit (maximum 17,500 operation hours). Basically, DEI states these two ways to proceed: Retrofitting of Plants during a period (PNT) from 01/01/2016 to 30/06/2020, adding and sharing pollutant mass emissions as a whole, inside a emission bubble. Limit values for 2016 are according directive 2001/80/EC and ceilings for years 2017 and 2018 shall be set providing a linear decrease of the ceilings 2016 and Operate the Plants for a limited number of hours (17,500h), limited life derogation (Jan-16 to Dec-23).

4 Sheet 4 of SCOPE OF WORK EPC for BoP Contract includes, but not limited to, the following main items: a) Detail design, purchasing, fabrication, erection and commissioning of BoP for: Gypsum handling system and temporary storage (silo) Process and temporary tanks with pumps New ducting in DeSOx area including dampers, expansion joints by-pass and steel structures New GGH Ljungstroem types with relevant ancillaries and supporting structures New booster fans variable pitch axial type including electrical motors and auxiliaries Existing ESP revamping for performance improvement for BREF purpose consisting in revamping of current T/R sets and improvement of the flow distribution with deflectors New air compressor Steel structures for SCR and ducts including associated civil works New gas ducts from boiler outlet to SCR inlet and from SCR outlet to air heaters, including modifications of existing flue gas ducting Due to the low design pressure of flue gases path and new pressure losses for SCR, reinforcement of flue gases ducts and precipitators Ammonia waste water treatment plant Replacement of secondary air preheater baskets and sealing improvement Replacement of ID fan electrical motors due to power increase Additional steam coil air heater on primary air to mill Refurbishment of Existing MgO powder or new Alkali (Ca(OH)2 or MgO) powder addition system to GGH due to high SO2/SO3 conversion with pet coke firing Fly ash removal system from bottom of DeNOx Replacement of primary air preheaters (PAP/PAS) with new one Ljungstroem type Modification of existing parts (ducts, piping, switchboards, etc.) for connection of new supply Interference solution Interconnecting piping including valves, supports, fittings Instrumentation and Control systems for new equipment Electrical works: electrical plants (lighting, earthing, etc.), electrical equipment & systems, switchboards and panels, cable and cableways Civil works relevant to new installation (including new buildings) Demolition and safeguards relevant to new installation New MV MOTORS b) Erection and commissioning of: New DeSOx systems and equipment (Absorber, Gypsum dewatering system, limestone storage and preparation system, DeSOx WWT) supplied by Other (according to law requirements) New Selective Catalytic Reduction systems and auxiliaries (NH3 or urea storage etc.)

5 Sheet 5 of 11 New Selective Not-Catalytic Reduction systems and auxiliaries (UREA ammonia storage, etc.) c) EPC General Services: Project management Project coordination Civil detail design for DeSOx and DeNOx systems/equipment supplied by Other (according to law requirements) Civil detail design for BoP (according to law requirements) Mechanical, piping and ducts detail design Electrical detail design I&C detail design Machinery detail design Process detail design Topography and geotechnical surveys and studies Reverse engineering, georadar and laser scanning Independent verifications of main structures Specialized services of engineering: fuel & combustion characteristics, studies, FF, etc. OM boiler detail engineering for ECO modification, PAP and PAS and special calculations OM ESP detail engineering for reinforcement OM ID Fan detail engineering for shaft line study Verification and Design of ducts and ESP reinforcement Fluid-dynamic studies of air-flue gas path Document management Training course HAZOP risk analysis Noise measurement Certification according to CE Directive (PED, machinery, LV, EMC, ATEX, etc. ) by Notified Body ad NDC for existing equipment to be modified Dirección Facultativa (including Legalization services for Puesta en marcha, etc.) Topography follow-up during construction Inspecciones reglamentarias (ATEX, DPEX, Luxometría, Lugares de Trabajo, REBT,1215, ) Site facilities (healt&safety, mobilitation, office services, infrastructures, consumptios) Implementation of a QMS, ensuring its application during Project lifetime HSEQ quality inspection on manufacturing HSEQ site environmental and permitting HSEQ site health and safety supervision HSEQ site quality supervision Permitting services (according to law requirements)

6 Sheet 6 of EXCLUSIONS Detail design and supply of the new DeSOX systems (Absorber, Gypsum dewatering system, limestone storage and preparation system, DeSOx WWT) Detail design and supply of the new DeNOX systems (Catalytic Reactor, Selective Not- Catalytic Reduction, NH3 ammonia/urea storage) 4. CONTRACT PRICE Activities will be compensated on lump sum basis. 5. PAYMENTS Payments shall be settled on the basis of working progress of the relevant activity at defined milestones on the basis of neutral cash flow at tender stage. 6. LIQUIDATED DAMAGES The Liquidated Damages will be defined in the contractual documents at Tender stage. 7. WARRANTY The Warranties will be defined in the contractual documents at Tender stage. 8. TECHNICL STANDARDS The Supply (including design, procurement, fabrication and erection) shall be in full compliance with Spanish laws, Spanish and EU standards and codes, Enel E&C technical specifications and relevant attachments as well as international standards previously agreed with Enel E&C. Where required by laws in forces, the detail design shall be stamped and signed by qualified engineers recognized and registered accordingly as well as certified by Third Parties (as for example Notified Bodies). 9. QUALITY SYSTEM Quality Management System in compliance with ISO 9001:2008. For the software products relevant to automation/control/protection systems concerning people safety, equipment protection, environmental protection, plant reliability and availability, the last ISO 9001 requirements shall be applied as per the interpretation given by last ISO Standard. 10. WORK ORDER PARTITION AND SCHEDULE The Schedule and work order partitions will be defined at Tender stage.

7 Sheet 7 of REQUIREMENTS FOR QUALIFICATION The Bidding entity shall demonstrate (providing suitable documentation) to fulfill all the requirements hereinafter listed. The Bidding entity A) Bidding entity shall demonstrate to have all technical and economical requirements for the management and execution of similar job in Power Plants, for which the Bidding entity have realized or under completion not less than three (3) projects as EPC with leading role (no subcontractor role or equivalent subordinate positions) during last eight (8) years in Power Plants with an installed power greater than 200 MW for each Power Plant, and for a total amount greater than 100M for each project. At least one of the three (3) projects has to be a flue gas line retrofit of Power Plant. For one (1) of the three (3) above mentioned projects the Bidding entity shall prove the successful completion of the project. B) Bidding entity shall demonstrate to have realized at least one (1) project as EPC with leading role (no subcontractor role or equivalent subordinate positions) during last ten (10) years in for a total amount greater than 50 M for each project. MANDATORY DOCUMENTS TO BE SUBMITTED AS EVIDENCE OF POINTS A AND B: Reference table (see Engineering Supplier Assessment Questionnaire, chapter 4) fulfilled including as a minimum the following Project key data: - Project name and location - Client and Final client/owner - Year of contract awards and of commercial operation - Manhours - Type of contract - Role - Value of contract - Type of project (short description) Letters of reference Certification or equivalent official auditable document from Client. C) Bidding entity shall demonstrate to have an adequate and properly sized organization able to develop large projects requiring a comprehensive capability in the management of all the aspects of a project (i.e. Project Management, Engineering, Procurement, Planning, Expediting, Quality Control, Construction and Commissioning management). The Engineering, Project Management, Procurement/Quality, construction and commissioning organization shall be staffed for key roles with resources experienced in Power Plants Project. Moreover Bidding entity shall have a consistent number of employees working in engineering department. In order to fulfill the above requirement the Bidder has to demonstrate to be able to develop internally engineering at least

8 Sheet 8 of 11 manhours/years and out of which at least manhours/years in Power Plant Projects. MANDATORY DOCUMENTS TO BE SUBMITTED AS EVIDENCE OF POINT C: Company organization charts Divisional organization charts with detail about project management, engineering, procurement, erection and commissioning units For each department, human resources information: - Number of employees - Years of experience - Specialization Typical Project Execution Plan for EPC projects in Power Sector CV s of permanent payroll key figures here below listed: PROJECT COORDINATION FIGURES (with at least 2 persons of at least 5 years of experience in that role in power plant / large projects): - Project Managers - Senior Project Engineers - Procurement managers with experience in large project for large machinery and bulk material purchasing - Contracts administrators - Project Controllers - Project Planners - Senior Quality Engineer - QA/QC supervisors (for fabrication and erection) - Safety managers - Site managers - Construction managers - Commissioning managers PURE ENGINEERING (with at least 4 persons of at least 5 years of experience in that role in power plant projects) - Senior Process Engineers, including at least one senior chemical engineer - Senior Electrical Engineers - Senior Civil Engineers, including at least one senior structural engineer with experience on design of large steel structures and large ducts - Senior Mechanical Engineers with experience in large rotary machine, static equipment and pressure parts, handling systems - Senior Instrumentation & Control Engineers - Senior Piping & Layout Engineers

9 Sheet 9 of 11 D) Bidding entity shall demonstrate experience in managing with internal resources procurement and subcontracts/subvendor follow-up activities with contract values greater than 3 M each, providing a list of at least three (3) orders for Services & Works greater than 3 M and at least three (3) orders for Supplies greater than 3 M issued in the last seven (7) years for Project where the Bidding entity was EPC or EPCM. Reference table of orders with at least, for each of them, the following key data shall be indicated: - project name - year of order award - description of Service/Work scope or description of Supplies - type of contract - level of economical value (i.e. >3M, >5 M, >10 M, >15 M, >20 M, >25 M ). E) The Bidding entity shall demonstrate to have implemented a Quality Systems complying with module D of the UNI EN ISO 9001:2008 standard and an Environmental Management System complying with UNI ISO 14001:2008; any certification of the Quality System by an accredited body shall constitute sufficient proof of the suitability of this QS. However, even in this case, Enel shall reserve the right to carry out an audit of the Quality System, if it deems this necessary. Collection of certification (compliant with ISO 9001:2008, OHSAS 18001:2008, ISO 14001:2008, any others relevant to the scope of work) F) The Bidding entity shall demonstrate to adopted quality policy and procedures in the execution of projects as EPC or EPCM as well as experience in the permitting in Spain and in the Certification according to EU CE Directives - List of all internal procedures applicable for EPC/EPCM projects - Reference list of previous experience for authorization process of power/ industrial plants and Declaration of reference in the permitting for Spain projects G) The Bidding entity shall have and adequate IT structure and related tools in terms of hardware and software required for the development and management of the projects. In particular the Bidding entity shall demonstrate proven experience (more than five years) of implementation in design activities of following SW tools: - 3D modeling software (industrial software)

10 Sheet 10 of 11 - Engineering software to perform specific activities, at least for steel structural design (industrial software) - Planning (industrial software) - Management of bulk materials quantity for erection works (in house or industrial software) - Document management (in house or industrial software) Declaration of experience about the use of the above mentioned Software and list of Hardware and Software H) The Bidding entity shall demonstrate adequate experience on management of site erection works. Moreover the Bidding entity shall demonstrate adequate direct experiences or, in case Bidding entity will act as Main Contractor, shall provide adequate references of the Erection Company selected (i.e. subcontract) for at least five (5) erection works for international Power Projects for an amount of > 15M for each erection work. At least two (2) erection works shall be executed in Spain. Reference list of erection works, which includes for each at least the following Project key data: - Project name and location - Client and Final client/owner - Year of contract awards and of commercial operation - Manhours - Type of contract - Role - Value of contract - Type of project (short description) Letters of reference Certification or equivalent official auditable document from Client I) The Bidding entity shall demonstrate adequate experience on management of commissioning works. Moreover the Bidding entity shall demonstrate adequate direct experiences in commissioning or, in case Bidding entity will act as Main Contractor, shall provide adequate references of the Commissioning Company selected (i.e. subcontract) for at least five (5) years of experience in commissioning works for international Power Plant Projects. At least two (2) years of commissioning works shall be executed in Spain. Reference list of previous experience in commissioning of power plant shall include as a minimum the following Project key data:

11 Sheet 11 of 11 - Project name and location - Client and Final client/owner - Year of contract awards and of commercial operation - Manhours - Type of contract - Role - Value of contract - Type of project (short description) Letters of reference Certification or equivalent official auditable document from Client J) The Bidding entity shall demonstrate adequate experience on safety management. In particular: a. The Bidding entity shall demonstrate to have implemented a safety management system according to international standard b. Keeping the accident log/master file updated, along with the procedures for detailed accident analyses and corrective actions and accident statistics (last 2 years, number, frequency and severity) - Certification of safety management system or equivalent auditable document - Industrial accident trend for its own workers calculated on the basis of the previous year, with a frequency index [FI = (Number of accidents/ Number of worked hours) x 106] and severity index [SI = (Days lost for injuries/ Number of worked hours) x 103]