40-A-00030_E_Tech spec GAS MODULE3.pdf

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DOC. ID: 40-A-00030 REV/STATUS: E / Approved

DATE: 17 Dec 2013 MADE/APPROVED: SIVAKOMA / TUUKAHON

PAGE: 1(20)

NAME: Technical Specification

SUBJECT: Gas Pressure Control Module

CITEC OY ABP.O. Box 109, FI-65101 VAASA, FINLAND, Tel. +358 6 3240 700 • Fax +358 6 3240 850

www.citec.com

FUEL GAS PRESSURE

CONTROL MODULE

(GAS MODULE 3)

TECHNICAL SPECIFICATION

Revision history

Revision Made by Approved by Reason for revision

ARamaswamyNeelakantan

Jonas Nylund Original revision

BRamaswamyNeelakantan

Tuukka Ahonen Process Updations

CSivakumar

KomarasamyTuukka Ahonen

Fuel gas compositionupdated. Material

requirements updated.

D Tuukka Ahonen Jonas Nylund Process Updations

ESivakumar

Komarasamy

Tuukka Ahonen Gas flowrate updated



DOC. ID: 40-A-00030

DATE: 17 Dec 2013

PAGE: 2(20)

TABLE OF CONTENTS

1.

DESIGN BASIS .......................................................................................................... 3

2.

CODES AND STANDARDS ...................................................................................... 5

3.

DESIGN INPUTS ....................................................................................................... 6

4.

SYSTEM DESCRIPTION .......................................................................................... 7

5.

SCOPE OF WORK ...................................................................................................... 9

6.

TECHNICAL SPECIFICATIONS ............................................................................ 12

7.

TERMINAL POINTS ................................................................................................ 13

8.

DATASHEET ............................................................................................................. 15

9.

PERFORMANCE GUARANTEE .............................................................................. 20



DOC. ID: 40-A-00030

DATE: 17 Dec 2013

PAGE: 3(20)

1. DESIGN BASIS

FUEL GAS ANALYSIS - NATURAL GAS

Natural gas will be used as preliminary fuel and Jet A1 fuel is used as back up fuel.

Components Volume % Weight% Mol. Wt g/Mol

C1 (Methane) 97.83 94.98 16.04C2 (Ethane) 1.22 2.22 30.07C3 (Propane) 0.01 0.03 44.10i-C4 (i-Butane) 0.07 0.21 58.12n-C4 (n-Butane) 0.07 0.24 58.12

i-C5 (i-Pentane) 0.02 0.09 72.15n-C5 (n-Pentane) 0.01 0.04 72.15C6+ (Hexane +) 0.01 0.05 84.0Mcyclo-C5 0.00 0.02 84.16Benzene 0.00 0.00 78.11Cyclo C6 0.00 0.01 84.16C7 Heptane 0.072 0.43 96.0Mcyclo – C6 0.00 0.01 98.19Toluene 0.00 0.00 92.14C8 0.0078 0.05 107.00C2-Benzene 0.00 0.00 106.17mp-Xylene 0.00 0.00 106.17O-Xylene 0.00 0.00 106.17C9 0.00 0.01 121.0C10 0.00 0.00 134.0C11 0.00 0.00 147.0C12 0.00 0.00 161.0C13 0.00 0.00 175.0C14 0.00 0.00 190.0C15 0.00 0.00 206.0H2O 0.0006 0.00 18

Nitrogen 0.20 0.34 28.01CO2 0.26 0.68 44.01H2S ( Refer Note) 0.00 0.00 34.08C7+ 0.01 0.09 102.7C12+ 0.00 0.00 210.0Total 100% 100%



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For design, ±5% on composition is considered. Fuel gas temperature will be vary

depends on ambient conditions from 15°C to 38°C.

Design ambient temperature for gas system 26°CMin. Ambient temperature for gas system 14°CMax. Ambient temperature for gas system 38°C

GENERAL FUEL GAS PROPERTIES

Description Unit Value

Molecular weight g/Mol 16.53Molar Density Kg mole/m3 4.503Mass Density Kg/m3 74.41Mass heat capacity kJ/kg °C 2.947Specific heat kJ/kg mole °C 48.70Thermal conductivity W/m °K 4.305E-002 Viscosity cP 1.400E-002HC dew point °C -27.07

Note: The above given general fuel gas property is based on 23.71°C and 92 bar pressure.

For all basic information about project, site details and requirements, please refer to

the general specifications that are attached (Doc Id: 40-0000520).

Components Unit Values

Specific Gravity 0.567C7+ Density g/cc 0.750C12+ Density g/cc 0.834Dry Gross Cal. Value BTU/SCF 1022.0Wet Gross Cal. Value BTU/SCF 1004.0Water dew point °C -25@90bar



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PAGE: 5(20)

2. CODES AND STANDARDS

The module components shall comply with the latest editions of relevant standardsissued by EN standards unless otherwise specified. Here some of them mentioned,but this is not an exhaustive/full list:

PED 97/23/EC The European Pressure Equipment Directive

EN 1776 Requirements for the design, construction, commissioning,operation and maintenance of new gas measuring stations

EN 12186 Gas supply systems, gas pressure regulating stations fortransmission and distribution. Functional requirements

EN 1594:2009 Gas supply systems. Pipelines for maximum operating pressureover 16 bar. Functional requirements.

EN 14382 Safety devices for gas pressure regulating stations andinstallations. Gas safety shut-off devices for operating pressureup to 100 bar

EN 12732:2000 Gas supply systems. Welding steel pipework. Functionalrequirements

EN 10204:2004 Metallic materials. Types of inspection documents

EN 10208-2:2009 Steel pipes for pipelines for combustible fluids. Technicaldelivery conditions. Pipes of requirement class B

EN 12068:1999 Cathodic protection. External organic coatings for the corrosionprotection of buried or immersed steel pipelines used inconjunction with cathodic protection. Tapes and shrinkablematerials

EN 12327:2000 Gas supply systems. Pressure testing, commissioning and

decommissioning procedures. Functional requirements

EN 12954:2001 Cathodic protection of buried or immersed metallic structures.General principles and application for pipelines

EN 13445:2009 Unfired pressure vessels.

EN 13480 Metallic industrial piping

EN 14141:2003 Valves for natural gas transportation in pipelines. Performancerequirements and tests

http://shop.bsigroup.com/en/ProductDetail/?pid=000000000030003462


















DOC. ID: 40-A-00030

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EN 15001-1:2009 Gas infrastructure. Gas installation pipework with an operating

pressure greater than 0,5 bar for industrial installations andgreater than 5 bar for industrial and non-industrial installations.Detailed functional requirements for design, materials,construction, inspection and testing

3. DESIGN INPUTS

Fuel gas supply pressure & temperature at Gas pressure control Module battery limit

PressureNormal Fuel gas inlet pressure = 54 Bar (g)Fuel gas pressure required at outlet ofpressure control module = 48.0 barg

(in order to Maintain 46.5±1.4barg at GT inlet consideringpressure drop in valves & pipingtowards GTs.)

TemperatureMinimum fuel gas inlet temp = 15 °CNormal Fuel gas inlet temperature = 40…70 °CMax Fuel gas inlet temperature = 90 °CMechanical Design temperature = 125°C

(Max temperature at GT inlet = 121 °C)

FlowMinimum * = [GE to specify later, will be from zero] kg/hr x 1 GT runningNormal ** = 7904 kg/hr x 4 GT = 31616 kg/hr (GT at base load & Chiller ON)

OR

Maximum = 10272.73 kg/hr x 4 GT = 41090.92 kg/hr

* GT at ambient temperature of 35 °C, GT at base load & Chiller Off** GT at ambient temperature of 15 °C, GT at base load & Chiller ON (463 kBtu/hr)

For all information about mechanical design values and conditions, please refer to

the general specifications that are attached (Doc Id: 40-0000520).

Design shall be according to EN codes & Standards.

E





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4. SYSTEM DESCRIPTION

The Fuel Gas System for the plant conveys natural gas from the terminal point ofplant at 54 Bar(g) & operating temperature of 15-38 °C at proper conditions to thefuel gas Module. Maximum supply pressure will be 86 bar(g).

The gas fuel supply system consists of following Modules Common for 4 Gas turbines

Gas Receiving & Metering & ESD Module #1

Gas Conditioning Module #2 (Indirect gas fired bath heater with auxillaries)

Pressure Control Module #3

This specification covers the scope of work for Gas pressure control Module 3.

The gas from the Gas conditioning Module will pass through the Pressure Control

Module #3 consisting of Three (3) Pressure reduction/control stations (PRCS) and

will be forwarded to a common header and further distributed to individual Gas

turbines.

The PRCS shall have two (2) numbers 30 - 100% streams, one (1) number 0 - 30%

start-up line. The two full flow PRCS are each for total fuel gas requirement of 4 gas

turbines. Third PRCS is for the start-up requirement.

The pressure control module is installed downstream of the gas conditioning module.This allows keeping the upstream vessels as small as possible and will prevent thegas temperature dropping below the dew point, with the possibility of hydrateformation. The pressure reduction and control valves shall be of pneumatic typecontrolled by downstream pressure using pressure transmitters.

The gas control valve allow fuel flow when the turbine starts and runs, control thefuel flow, and provide protective fuel isolation when the turbine is shut down. Thefuel manifold connects to the header, which distributes the gas fuel into the gasfilter module before GTs.

The Gas Turbine requires fuel gas pressure to be maintained at constant pressurefor its proper operation. When the gas turbine load alters, the fuel gas flow changesresulting in variation of header pressure. The pressure control/reduction valve willreduce and maintain the set pressure at the outlet of gas pressure control modulebased on the pressure measurement or/and the pilot valve sensing line. It consists oftwo regulating valves of which one will be normally open taking 100 % of the flow,the other one closed in stand-by.

The gas pressure at the gas turbine inlet shall be controlled by activecontrol/reduction valve. In case of failure of this valve the monitor valve shall takeover the function of the active valve in a fast and stable response. The active controlvalve closed loop control function shall be integrated in the local PLC and shall havea possibility of signal exchange into DCS.



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Dual redundant pressure transmitters shall be provided and dedicated to the control

monitoring and high/low pressure alarming function. Additional one pressuretransmitter shall be provided and dedicated for indication and high/low pressurealarms, at the inlet and outlet of pressure reduction facility to measure the gassupply pressure. Temperature measurements shall be provided at inlet and outlet ofthe pressure reduction facility integrated in the local PLC and shall have apossibility of signal exchange into DCS.

Also one start-up pressure control/reduction valve is provided to cater low-lowcondition during first gas turbine start up. The automatic switch over between thestart-up valve and the 100% control/reduction valves shall be “bumpless”.

Fuel gas supply to the gas turbines shall be safeguarded by an automatic safety

shut-off system.

Regarding all modules

A pipeline vent connection will be provided near gas turbine inlet to vent outentrapped gases during cold start-up of the plant to vent stack. Module vendor toprovide equipment and pipeline vent connections at module border. Normally, for allequipment, one vent line will contain manually operated ball valves for initialpurging. All vents on natural gas lines shall be connected to vent stack. Thepressure safety system shall be ensured by providing suitable pressure safety valvesand the system vents will be connected to vent stack (vent stack excluded from

module scope).

Natural Gas lines shall be carbon steel piping.

Vendor is responsible for the module engineering. Customer has the right to review

and require changes to the vendor engineering documents. Vendor is allowed

optionally to propose gas fuel supply system in a different amount of modules. I.e.

the total system can be divided into modules in a different way than presented here

and there can be fewer modules than presented here. However the functionality &

performance must fulfil the requirements in these specifi cations.

The fuel gas modules shall be designed for outdoor installation and shall be suitablysized to meet the fuel gas requirement of 4 gas turbine’s for the site design

conditions and the purity of gas as per gas turbine manufacturer’s requirement /

specification.



DOC. ID: 40-A-00030

DATE: 17 Dec 2013

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5.

SCOPE OF WORK

The scope of supply of the vendor under this specification and associated data sheetis intended to cover design, engineering, manufacture, assembly, testing and supplyof the skid with all accessories, site installation supervision, commissioningsupervision, performance guarantee testing, operator training and training materialand handing over of items related to Gas Module 3 as defined in Scope of work,Technical Specification or elsewhere in this specification.

All supplied materials/equipment shall be new and unused. The vendor shall acceptfull responsibility for his work including documentation, manufacture, preparationfor shipment, inspection, warranty provisions, compliance with the applicable codesand standards and the requirements of this Specification. The scope of supply andservices shall include all necessary work and supply of equipment and materialwhether mentioned in these specifications or not, but which are necessary for thesatisfactory, reliable and safe operation and maintenance of the plant and requiredfor achieving guaranteed performance of the plant. Any equipment, device ormaterial even if not included in the original bid but found necessary for the safe andsatisfactory functioning of the units under the bid shall be supplied by the vendor atno extra cost. The module should be delivered in a properly packed condition asspecified here in under but not limited to:

The skid details proposed in this specification and P&ID (Doc No 40-A-00027- Gas

pressure control Module # 3) are indicative only. Vendor can also suggest better systemthan specified. Complete gas Module #3 shall be designed to meet the main fuelrequirements of 4 Gas turbines and comprises of:

2 X 100% streams, each stream will include an isolating type pressure controlvalve with isolation valves.

1 X 30% stream (start-up) including isolation type pressure control valve withisolation valves

Instrumentation and valves for the safe and efficient operation of the skid

mounted equipment, including manual inlet and outlet isolating valves oneach stream

Only one external nitrogen connection for each module will be provided to thevendor. Vendor to tap off as per module requirements from externalconnection.

Nitrogen purging line with check valve and double isolating manual ball valveto be provided inside the skid area to purge the pipeline & skid equipment,before charging with fuel gas and also to purge the entrapped gas in pipeline& skid equipment while taking-up maintenance jobs/long shutdown.

Internal nitrogen purging connections and internal piping inside the module



DOC. ID: 40-A-00030

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as required based on the system design shall be taken care by the vendor (only

one external connection is allowed). Bidder shall provide requisite number oftapings for nitrogen purging as the standard practices, the number indicated

in the P&ID attached shall be treated as minimum.

Drain lines with double isolation valve

Two numbers of portable gas detectors (totally 2 numbers for all three gas

modules together) of the flame ionization metering type, capable of detecting

fuel gas in concentration of one part per million. All necessary detector

accessories shall be included.

Manual depressurisation line with double isolation valves

Relief valves required for protection

All the vents / drains to connected to a common header & terminated at

module terminal

Insulation (example rock wool) with aluminium cladding shall be provided

for all the pipes/equipments/surfaces having surface temperature more than

50°C, the insulation thickness shall be designed based on media andambient temperature.

Thermal insulation shall be provided in order to maintain the temperature in

the main gas line and hot water lines. In other locations mainly for personnel

protection. Insulation for personnel protection shall be provided such that the

temperature of protective cladding is not higher than 50 C.

All interconnecting piping, valves, specialities, supports within Module

mounted equipment as shown in the P&ID as minimum. It is Supplier’s

responsibility to provide all piping components as necessary for the safeoperation of the system

All equipment, C&I devices shall be suitable for E Ex _ II A T1 for Natural

gas systems (normally T class, however, T3 or higher T4 is ok). Ex class

normally E Ex d. Instruments normally other type depending on the zone and

if barriers are used or not.

Modules/skids for Natural gas are located at Ex zone 2.

All instrumentation shall have double isolation valves .



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All instrumentation shall have double isolation valves .

It shall be possible to provide all analogue and digital signals to plant DCS.

Also it shall be possible to change the pressure control set point from plant

DCS.



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6. TECHNICAL SPECIFICATIONS

S.NO PARTICULARS UNIT DESIGN VALUES

1. ModuleFUEL GAS PRESSURECONTROL MODULE –

2. Capacity for all 4 GT’s 2 x 100% & 1 X 30%(Start-up)

3. Mode of Operation Continuous

4. Medium Handled Fuel Gas ( Natural Gas)

5. Fuel LHV KJ/Kg 48772

6. Flow at the module batterylimit

430 MMBTU Each GT( 4.54 x 10^8 KJ/HR)

Minimum flow for each GT Kg/hr LATER (from Zero)Normal flow for each GT Kg/hr 7904

Design Flow for 4 GT Kg/hr 10272.73 x 4 = 41090.92

Design Flow for the module Kg/hr 41091

7. Fuel gas pressurerequired at module outlet

Barg 48

8. Allowable pressure pulses Bar 0.9 max

9. Fuel gas pressure at inletof Pressure control Module Barg

86 Max54 Normal

10. Temperature of fuel gas atinlet of pressure controlModule Battery Limit

°C90 Max~40…70 Normal15 Min

11. Temperature of fuel gas atoutlet of pressure controlModule Battery Limit

°CMin temp to be 28°Cabove dew point.

12. Design pressure of fuel gassystem up to Module Inlet

Barg 86

13. Design pressure of fuel gassystem at Module Outlet

Barg 65

14. Noise Level75dB(A) for a singleequipment @ 1m.

15. Piping material

Material

denominationto be givenacc to EN

To be of carbon steel

E

E



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7. TERMINAL POINTS

S.NO DESCRIPTION SCOPE

A. MECHANICAL

1. Fuel Gas

Inlet of the pressure controlModule terminal with counterflanges

Outlet of the pressure controlModule terminal with counterflanges

2. Drains

All drains connected to a commonheader & terminated at Outlet ofModule with counter flange/stubconnection.

3. Vents

Gas vents / safety valve dischargeto be connected individually to acommon header. The header to be

terminated at the module terminalpoint.

4. Nitrogen Connection at module terminal

5. Instrument air7 barg, dryness +3 deg C(flange connection at moduleterminal)

B. ELECTRICAL

1. EarthingTwo earthing terminals atdiagonally opposite locations of theskid.

Notes

1. Flange connections shall be provided with its counter flange, bolts, nuts andgaskets.



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EXCLUSIONS

1. Foundations of Gas pressure control Module2. Civil construction work like building, equipment foundation etc3. Erection of Module and its accessories4. Fire fighting system5. Nitrogen piping up to supply point at module border6. Instrument piping up to supply point at module border7. Supply of Cables from local JB to Control room



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8. DATASHEET

The given below datasheet to be filled in by the Vendor.

S. No PARTICULARS UNITS To Be Indicated By Bidder

1.0

General

Gas pressure control moduledesignationName of manufacturer

Model Number

Design standard

Testing standard

Equipment shall be designed forseismic loads (Yes/No)

2.0 Fuel Gas Supply Conditions Max. Norm. Min.

Gas Flow in supply line Nm3/hr

Gas Pressure required at GT Bar (g) 47.9 46.5 45.2

Gas temperature required at GT

(Min temp to be 28°C above dewpoint.)

C

121 - -

Gas Supply Pressure at inlet ofModule

Bar (g)

Gas Supply Temperature at inlet ofModule

C

Pressure control module (100%)Outlet Pressure

Bar (g)

Pressure control module (0-30%)Outlet Pressure

Bar (g)

Gas Supply Temperature at outlet ofModule

C

Design pressure of fuel gas systemup to Pressure control module inlet

Bar (g)

Design pressure from Pressurecontrol module outlet to GasTurbine battery limit

Bar (g)

Percentage opening of Controlvalve during full load & Min loadoperation

%

3.0 Design & Performance Requirement

A

General

Terminal point pressure at alloperating gas supply condition (max /

Bar (g)



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min )

Terminal point temperature at alloperating gas supply condition (max /min )

C

Maximum Gas Velocity insidepipeline under maximum operatingconditions.

m/sec 20 unfiltered35 filtered

Design pressure of fuel gas systemup to and including the Pressurereduction/control module

Bar (g)

Design pressure of fuel gas systemfor downstream of the Pressurereduction/control module

Bar (g)

Gas pressure at outlet of Pressurecontrol module (minimum)

Bar (g)

Temperature drop across Pressurecontrol module

C

Max. Pressure drop across thecontrol valve

kPa

4.0 Other equipment

Material denomination to be givenacc to EN

A Actuator/Control Valves

Type

Manufacturer

Quantity

Size, In/Out connection ends (DN)

PN-class

Material (Body/Trim)

Pressure Class

Leakage class

B Relief Valve

Type

E



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Manufacturer

Quantity

Size, In/Out connection ends

PN-class

Set Point

Material

Rating

Location

Leakage class

C

Manual Valves (Isolation/drain

valves)

Manufacturer

Quantity

Type

Size

PN-class

Connection ends

Material (Body/Trim)

Leakage class

D Insulation

Insulation Material & Density Rock wool / Mineral wool

Insulation Type and Thickness(Will be different for Thermalinsulation and for Personalprotection)

Insulation Class



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Metal Jacketing/Cladding

Securement Wire

Surface Temperature 60 Deg.C

Material standard

E Instruments

Type

Make

Model

Range

Accuracy / Accuracy class

F External signals

Name

Type

G Accessories

Bolts

Nuts

Orifice/ nozzles/ splash cups5.0 Utilities

A Instrument Air

Quantity Nm3/hr

Quality

Pressure Bar(g)

B Nitrogen

Quantity Nm3/hr



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Quality

Pressure Bar(g)

6.0

Gas pressure control Module

(Bidder to furnish the following details per

pedestal/foundation)

Empty weight

Operating weight

Test weight

Dynamic load (if any)

Live load of platforms

Minimum depth of foundation (if anyspecific requirement)

Empty weight

Operating weight

Test weight

Dynamic load (if any)

Minimum depth of foundation (if anyspecific requirement)Note : Vendor to Submit complete details of all items (if additional from this

data sheet) as suitable required for this Skid



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9. PERFORMANCE GUARANTEE

S. No. Description Unit Guarantee

1

Fuel gas temperature at the outlet ofpressure control module

Maximum flow

Minimum flow

°C

2

Fuel gas Pressure at the outlet ofpressure control module

Maximum flow

Minimum flow

Pressure pulses maximum size (bar)

Bar(g)

3

Pressure Drop across the Controlvalve

Maximum flow

Minimum flow

kPa

4Noise level during control valveoperation dBA

5Noise level during safety valveoperation

dBA

Documents

40-A-00030_E_Tech spec GAS MODULE3.pdf