36-samss-001

Previous Issue: 31 August, 2002 Next Planned Update: 1 September 2007 Revised paragraphs are indicated in the right margin of 78 Primary contact: Basel A. Ishwait on 966-3-8745133

Copyright©Saudi Aramco 2002. All rights reserved.

Materials System Specification

36-SAMSS-001 30 September, 2002 Co-Generation Train

Energy Optimization and Co-Generation Standards Committee Members Soliman NourEldin Mahmoud Bahy Mahmoud, Chairman Mahfoudhi, Refaat, Vice Chairman Al-Anizi, Salamah Salem Al-Beshri, Ali Husain Al-Ghamdi, Khalid Saleh Al-Khadra, Nizar Adnan Al-Khunaizi, Ghassan, Abduladim Rikhaimi, Nabeel Abdulaziz

Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 Conflicts and Deviations................................ 3 3 References..................................................... 3 4 Qualification................................................... 5 5 Guarantee and Warranty............................... 9 6 Combustion Gas Turbine Requirements...... 10 7 Generator Requirements.............................. 17 8 Fire Protection Systems............................... 23 9 Fuels and Auxiliaries.................................... 24 10 Gas Turbine Generator and HRSG Control

and Monitoring System......................... 25 11 Generator Step-Up Transformer Unit

(GSU) if Applicable............................... 32 12 Heat Recovery Steam Generator (HRSG)... 40 13 Inspection..................................................... 55

14 Combustion Gas Turbine/Generator Factory Tests........................................ 55

15 Field Performance Test................................ 57 16 HRSG Inspection and Equipment Testing... 58 17 GSU Performance Testing........................... 62

Document Responsibility: Energy Optimization and Co-Generation 36-SAMSS-001 Issue Date: 30 September 2002 Next Planned Update: 1 September 2007 Co-Generation Train

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Table of Contents (Cont"d)

Co-Generation Train Generator Data Sheet...... 63 Co-Generation Train Generator Step-Up Transformer Unit (GSU) Data Sheet............ 66

Co-Generation Train Heat Recovery Steam Generator (HRSG) Data Sheet Attachment 1............................. 72 Co-Generation Train Heat Recovery Steam Generator (HRSG) Data Sheet.................... 76

1 Scope

1.1 This Standard defines the mandatory minimum requirements for design, and selection of Co-Generation train unit. The bid document will specify the Minimum Power Output, Minimum Steam Demand and Minimum Number of Units required for the plant, Suppliers my exceed the minimum specified power, steam and number of units in the tender offering. This entire standard may be attached to and made as part of purchase orders or contract document.

1.2 A Co-Generation Train consists of four Major components, these being a Combustion Gas Turbine (CGT), Generator, Generator Step-Up Transformer (GSU), (if applicable) and a Heat Recovery Steam Generator (HRSG). In addition, the Co-generation Train unit includes other systems and subsystems such as turbine base frame, turbine inlet air system, lubrication system, turbine control system, fire protection and gas detection system, generator gear box (if applicable), generator line/neutral side cubicles, generator excitation system, and other accessories and auxiliary systems for starting, operating, stopping, protecting and monitoring the entire train unit.

1.3 The Supplier shall provide all the required data as stated in the submittal section with bid documents.

1.4 This Standard intended in its entirety, for use on Saudi Aramco Power Generation and Co-Generation Projects to select the Train components. For all other applications and selections, other Saudi Aramco Specifications should be used.

1.5 This Standard intended to be a stand-alone document. The train unit specifications and selections are in accordance with the general power industries' guidelines and similar industrial applications.


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2 Conflicts and Deviations

2.1 Use of alternate codes and standards that deviate from those listed herein will not be allowed without the written approval of the manager of consulting department (CSD).

The proper stamps shall be affixed to denote conformance to the appropriate codes. The date for establishing code requirements shall be the contract date.

All data reports and inspection certificates required by the codes shall be submitted. Any conflicts between this Standard and other codes and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department, Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this Standard in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department, Saudi Aramco, Dhahran.

3 References

The equipment shall be designed and constructed at a minimum in accordance with the latest applicable requirements of the codes and standards listed below and all the applicable electrical and general specifications, except where modified or supplemented by these specifications; and in accordance with the applicable requirements of the US Federal "Occupational Safety and Health Standards".

Referenced standards and specifications shall be the latest edition, revision or addendum in effect on the date of the purchase order, unless stated otherwise.

3.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Form and Data Sheet

8002-M-ENG Combustion Gas Turbine Data Sheet

3.2 Industry Codes and Standards

American Institute of Steel Construction

American Iron and Steel Institute

http://standards/docs/Saep/PDF/SAEP-302.PDF

http://standards/docs/Saep/PDF/SAEP-302.PDF


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American National Standards Institute

ANSI C50.10 Rotating Electrical Machinery - Synchronous Machines

ANSI C50.13 Rotating Electrical Machinery - Cylindrical- Rotor Synchronous Generators

ANSI C50.14 Requirements for Combustion Gas Turbine Driven Cylindrical Rotor Synchronous Generators

ANSI C57.12.00 Standard General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers

ANSI C57.12.10 Transformers Safety Requirements

ANSI/IEEE C57.12.90 Standard Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers

American Society of Mechanical Engineers

ASME SEC I Rules for Construction of Power Boilers

ASME SEC V Non-destructive Examination

ASME PTC 4.1 Steam Generating Units

ASME PTC 22 Performance Test Code for Gas Turbine Power Plants

American Society for Testing and Materials

ASTM D1066 Standard Practice for Sampling Steam

American Welding Society

Factory Mutual

Hydraulic Institute

International Electrotechnical Commission

IEC 34-4 Rotating Electrical Machines, Part 4: Methods for Determining Synchronous Machine Quantities from Tests

IEC 60076 Power Transformers

IEC 60227 Polyvinyl Chloride Insulated Cables of Rated Voltages


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IEC 60332 Tests on Electric Cables under Fire Conditions

IEC 60502 Extruded Solid Dielectric Insulated Power Cables for Rated Voltages from 1 kV up to 30 kV

Institute of Electrical and Electronics Engineers, Inc.

IEEE 115 Test Procedures for Synchronous Machines

IEEE 421.1 Standard Definitions for Excitation Systems for Synchronous Machines

IEEE 522 Guide for Testing Turn-to-Turn Insulation on Form-Wound Stator Coils for AC Rotating Electric Machines

IEEE C37.101 Guide for Generator Ground Protection

IEEE C57.91 Guide for Loading Mineral-Oil-Immersed Transformers

Instrument Society of America

International Organization for Standardization

ISO 9001 Quality Management Systems

National Electrical Manufacturers Association

NEMA MG 1 Motors and Generators

NEMA ICS 6 Industrial Control and Systems Enclosures

NEMA TR 1 Transformers Regulators and Reactors

NEMA Standard Combustion Gas Turbine Sound and its Reduction Publication #SM33-1464

National Fire Protection Association

NFPA 70 National Electrical Code

NFPA 72 National Fire Alarm Code

NFPA 85C Standard for the Prevention of Furnace Explosion

Tubular Exchanger Manufacturers Association

4 Qualification

4.1 The Co-Generation Train Unit components shall be supplied by Suppliers complying with ISO 9001 quality standards and qualified by experience in manufacturing the units proposed. To qualify, the Supplier or his licensee must


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have manufactured at the proposed location of manufacture at least 2 units with identical or equivalent performance characteristics (Heat Rate, Efficiency, Output). These Units must have been in service for at least 2 years and must be performing satisfactorily. Details and location of operation shall be provided to Saudi Aramco upon request. In addition, the Supplier shall disclose each proposed design, manufacturing procedure, component, or assembly that does not have at least 2 years satisfactory field operating experience in similar service.

4.2 The Supplier shall supply, with the bid, an installation list for equipment of a similar rating and duty to the equipment quoted. The list shall indicate user company name, installation location, date of installation, and site rating of the Train Unit. During bid evaluation, the Supplier shall be prepared to provide contact names and telephone numbers for installations selected by the Buyer.

4.3 Performance Curves and Data Submittal

Full performance data on the combustion turbine generators and associated equipment, including the following curves and data shall be submitted. Items marked 4.3.1 – 4.3.12 shall be submitted as part of the Tender offering for inclusion in the Contract documents, and 4.3.13 – 4.3.26 upon receiving purchase order:

4.3.1 Combustion turbine generator performance curves

4.3.2 Combustion turbine generator heat rate, exhaust flow, and exhaust temperature curves versus load, showing the effect of Inlet Guide Vane (IGV) control.

4.3.3 Compressor inlet temperature correction curves for heat rate, capacity, exhaust temperature, and mass flow.

4.3.4 NOx generated correction curves and their effects on heat rate, capacity, exhaust temperature and mass flow.

4.3.5 If it is applicable, NOx control water or steam injection requirements versus combustion turbine load curve for each fuel at various compressor inlet temperatures.

4.3.6 If it is applicable NOx and CO emission levels versus load for each fuel at the expected water or steam injection rate

4.3.7 Inlet pressure loss correction data

4.3.8 Exhaust pressure loss correction data


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4.3.9 Ambient pressure (or altitude) correction curves

4.3.10 Estimated output, heat rate, inlet airflow, and exhaust temperature degradation versus equivalent fired hours curves from initial startup through second major overhaul. Equivalent fired hours shall be clearly defined and expressed as a formula incorporating the effects of base load and peak load operating hours, and the number of normal and fast cycle starts.

4.3.11 Generator reactive capability versus kilowatt load curves

4.3.12 Generator efficiency versus load curves at power factors from 0.8 to 1.0.

4.3.13 Thermal damage curve illustrating volts/hertz versus time for the generator.

4.3.14 Generator "V" curves - plots of per unit kVA versus field amps, at fixed levels of excitation voltage.

4.3.15 Generator decrement curves for a 3-phase and a single-phase fault current in amperes versus time in seconds.

4.3.16 Generator frequency capability versus time curve

4.3.17 Zero power factor saturation curve

4.3.18 No-load saturation curve

4.3.19 Synchronous impedance curve

4.3.20 Current transformer ratio correction factor and excitation curves

4.3.21 Generator voltage decay curve with loss of exciter

4.3.22 Voltage versus time and frequency versus time curves showing the voltage and frequency applied to the generator for combustion turbines provided with static start systems.

4.3.23 All turbine, generator, exciter, and regulator data required completing a mathematical model study of system stability.

4.3.24 Block diagrams of significant transfer functions representing the turbine, generator, exciter and regulator, satisfactory for computer studies of system stability.


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4.3.25 Manufacturer shall supply the following gas turbine component repairs and replacement intervals including inspection, borescope, major overhaul and replacement parts.

4.3.26 Manufacturer shall supply the following information related to the HRSG as part of the Tender offering for inclusion in the Contract documents:

a) A completed DATA SHEET.

b) A curve of superheat temperature versus steam load for each fuel or combination of fuels specified.

c) Circulation design criteria, including: all flows, temperatures, pressures, and pressure drops, for each circuit of the HRSG offered, complete with a circuit diagram.

d) A list of users operating HRSG's of the same design and under similar operating conditions.

e) Tubular surface corrosion/erosion allowances.

f) Design criteria for determining the number and sizing of supply and riser tubes and headers.

g) Sizes of observation ports.

h) Anticipated maximum tube metal temperatures for each stage of super heaters along with procedures for determining those temperatures.

i) The pressure and flow rate required for superheated spray water if applicable.

j) Tube cleaning procedures.

k) Technical description of vibration restraints and their predicted metal temperatures.

l) Dimensional drawing(s) showing internals of drums, materials of drums and headers, inside diameters, drum and header thicknesses, water and steam circuit arrangements, casing, casing structure and flue and duct arrangements.

m) A cross-sectional sketch of steam drums showing the location of internals, all water levels, and the highest downcomer. The


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sketch shall also show the useful water volume in the steam drum below the Normal Water Level (NWL), Low Water Level (LWL), and Low Level Cut-Off (LLCO).

n) Locations of access doors, observation ports, platforms, stairways, and ladders on a general arrangement type drawing.

o) Acid dew point temperature and a justification of material selection and the provisions for protecting external surfaces of tube sheets and tube bends in header boxes against acid dew point corrosion.

p) Steam and water quantities, water temperature requirements, and a description of water washing procedures.

q) Turndown ratio from maximum to minimum operating range.

r) Minimum load obtainable with different CGTG firing schemes.

s) A completed noise data with a detailed description of acoustical design.

t) Location and sizes of openings required for water washing.

u) Materials of all pressure components, heat transfer components and heat transfer supports.

4.3.27 HRSG Manufacturer shall furnish the flue gas ductwork from the outlet to the stack, with all the necessary appurtenances. The system shall include supports, expansion joints, hangers, access doors, dampers, isolation plates, flue gas sample connections, and connections for the measurement of flue gas, temperature, and pressure.

4.4 Unit component manufactured under a license agreement shall carry the licensor's written guarantee.

5 Guarantee and Warranty

5.1. Should field tests as specified show that the equipment fails to meet guarantees as to heat rate and output, Saudi Aramco may select alternatives Payment, in settlement thereof, an amount of money as stated in the contract document.

5.2 Performance Guarantees

5.2.1 Performance shall be guaranteed at the site conditions specified when burning any of the specified fuels.


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5.2.2 For the purpose of evaluating guarantee compliance, the unit shall be demeed "new and clean" for any or all tests.

5.2.3 The combustion turbine generator shall be guaranteed to perform as specified herein and as stated in the BID DOCUMENTS; all guarantees shall be met simultaneously.

5.2.4 The combustion turbine generator shall be guaranteed to operate satisfactorily, and without structural damage to the unit, in a daily load swings value and rate of load changed as defined in the Data Sheet.

5.2.5 The noise emanating from each combustion turbine generator at all capacity levels shall be guaranteed not to exceed the limits specified in DATA SHEET.

5.2.6 All emission guarantees shall be met simultaneously at all loads for each fuel over the full range of ambient conditions specified in DATA SHEET.

5.2.7 Combustion turbine exhaust temperature, mass flow (operating on each fuel specified) measured at the combustion turbine exhaust connection shall be guaranteed to be not less than that stated in vendor proposal offering.

5.2.8 The value of the synchronous, transient, sub transient, negative sequence, and zero sequence reactance values of the generator shall be in accordance with NEMA MG 1.

6 Combustion Gas Turbine Requirements

6.1 General

Combustion gas turbine/generating unit shall be of proven standard design. The Supplier or his licensee shall have at least 2 units with identical or equivalent performance characteristics (Heat Rate, Efficiency, Output) operating on similar fuel specification. These Units shall be in service for at least 2 years and must be performing satisfactorily. As a minimum the package, including all auxiliaries, controls and instruments supplied by the Supplier shall be capable of maintaining annual system availability in excess of 95% as defined per IEEE.

The combustion gas turbine and generator shall be factory assembled in shippable pre-engineered modules for convenient field erection. Accessories for both the turbine and generator shall also be factory assembled in pre-engineered modules for field installation and shall be suitable for outdoor exposure in a coastal environment. Lifting devices and monorails shall be provided inside


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each module compartment as required for normal maintenance. Equipment arrangements shall be optimized to carry out routine maintenance functions with a minimum disassembly. All wiring and piping shall be complete within each module. Where possible, electrical cables between modules shall be supplied with factory installed connectors. The Supplier shall include all equipment grounding for the modules.

6.2 Basic Design

6.2.1 The continuous base load capability of the combustion turbine generator at site design conditions in co-generation operation shall be as required to meet the plant output criteria. No corrections will be allowed for losses associated with equipment provided by the Supplier with the combustion turbine including, but not limited to, duct losses and air filtration losses.

6.2.2 Combustion turbine generator performance shall be based on the combustion turbine being in new and clean condition.

6.2.3 The combustion turbine generator shall be capable of normal cycle starts with minimal performance degradation. The unit shall be capable of hot restart.

6.2.4 The combustion turbine generator shall be capable of operating across the full range of ambient conditions specified in site design conditions per BID DOCUMENTS.

6.2.5 The combustion gas turbine shall be of the heavy duty industrial, suitable for continuous service, with a direct or gear driven generator designed to withstand quick starting in rapid load changes.

6.2.6 The Supplier shall perform a lateral and torsional critical speed analysis of the combined driver and driven equipment system. No critical speeds shall be within 10% of the first or second harmonic of the rotational frequency in the operating speed range.

Shaft vibration amplitudes shall be measured at each bearing cap during factory acceptance. The control system shall provide high vibration alarm at an RMS value of 12.7 mm per second (0.5 in/sec) and trip the unit at an RMS value of 25.4 mm per second (1.0 in/sec).

6.2.7 The combustion turbine generator unit shall be designed for firing either natural gas or No. 2 diesel fuel. The unit shall be furnished with a noise attenuation enclosure and silencers as required.


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6.2.8 Sound attenuation shall be accomplished by means of inlet, exhaust and generator silencers and sound attenuation equipment. Combustion gas turbine silencers shall conform with Part 4 of NEMA Standard Publication #SM33-1464 "Combustion Gas Turbine Sound and its Reduction."

6.2.9 Noise levels for control valves and other field instrumentation shall not exceed 85 dbA at one meter from the source. Noise levels in the control room shall not exceed 40 dbA.

6.2.10 The combustion gas turbine will be arranged for unit operation with HRSG. The exhaust gases from the turbine shall either pass through the associated HRSG or be exhausted through the combustion gas turbine's stack to atmosphere.

6.2.11 A coupling duct including flange shall be furnished to permit quick Turbine/HRSG connection. Thermal expansion of the duct shall be controlled so that the connection to the HRSG shall have zero movement under maximum operating conditions.

(If applicable) BID DOCUMENT shall specify a guillotine or a diverter valve to be provided between the combustion gas turbine and the HRSG. Stack guillotine / diverter valve leakage shall not exceed one percent (1%). Supplier's design shall include provision for dampers used to shift operating mode between simple-cycle to waste-heat boiler cycle (co-generation). Coupling and duct system including bypass stack damper with pneumatic drive equipment with positioner, position transmitter and I/P connection, and a guillotine isolation gate with motor drive shall be furnished.

6.2.12 If applicable, BID DOCUMENTS will specify the combustion gas turbine to be provided with dual fuel combustors with automatic changeover under load from natural gas to No. 2 diesel fuel or from No. 2 diesel fuel to natural gas.

6.2.13 The combustion chamber design and materials shall be suitable for burning the fuel specified above and shall be complete with necessary burning equipment and accessories.

6.2.14 The combustion chamber shall be designed to prevent direct flame impingement of any metal components. Compressor and turbine internal components shall be coated with anti corrosion coating; circulating hot air system activated during turbine shutdown is not an acceptable alternative.


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6.3 Lagging and Enclosure

6.3.1 The combustion gas turbine generator package shall be designed to give a neat and smooth appearance. The lagging and enclosures shall be arranged for operation and maintenance easy access. The package insulation shall limit sound isolation to 85 dba at one meter, and enclosure surface temperature not to exceed 60°C at 50°C ambient.

6.3.2 The lagging or enclosures shall be lightweight and neatly constructed with pleasing contours and weather-tight. Where walk-in enclosures are furnished heat and noise-insulating materials shall be fastened to the lagging or enclosure. Ventilation shall be provided.

6.3.3 The turbine exhaust hood shall be thermally insulated and provided with removable heavy gauge steel lagging having smooth contours and neat appearance. Sufficient thermal insulation shall be provided so that casing surface temperature under full load shall not exceed 60°C under 50°C ambient temperature conditions.

6.3.4 All lighting within the local control compartments and walk-in type enclosures shall be furnished and installed. Conveniently located light switches shall be furnished adjacent to outside doors. Installation shall be in accordance with NEC.

6.3.5 Removable sections shall be furnished to facilitate removal of compressor upper half casing, combustors and the turbine section casing.

6.4 Automatic Governor

6.4.1 The Manufacturer shall supply the combustion gas turbine generator unit with a speed-governing device capable of controlling and regulating the speed of the turbine with stability at all power outputs between zero and the maximum power output, inclusive, when the generator is operating isolated from the system.

6.4.2 The turbine governing system offered shall be of the Supplier's standard design.

6.4.3 The governor shall be equipped with a speed changer by means of which the speed or power output of the turbine may be changed within limits when the turbine is in operation. The speed sensor shall be of magnetic pick-up type. The speed changer shall be equipped with a means for manual adjustment, located at or near the speed governor system and also for remote control. Speed shall be adjustable through


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a range from 5% below to 7% above synchronous speed before synchronization.

6.4.4 The turbine shall be equipped with a load limit device arranged for manual setting at the turbine and remotely from the control room for limiting the fuel consumption while turbine is in operation.

6.4.5 The proposal shall contain a statement of the permissible maximum value of the steady state speed regulation for which the speed governing system may be adjusted.

6.4.6 In case of a sudden loss of load while the turbine is operating with the maximum turbine power output, the speed governing system shall be capable of controlling the speed to a value that is less than the setting of the emergency over speed trip.

6.4.7 When the generator is operated isolated and is under load, the governor shall regulate the speed within plus or minus 2-½% when going from half load to full load.

6.4.8 The Supplier shall furnish starting equipment, including automatic engaging and disengaging clutch and auxiliary equipment, accessories and controls as required for startup of the combustion gas turbine-generator unit.

6.4.9 The bearings, combustors and any components with a limited service life shall be easily accessible and removable for inspection and maintenance.

6.4.10 Thermocouples shall be furnished along with protection wells, as required for measuring the temperatures of the turbine wheel spaces, compressor inlet and discharge and turbine exhaust, as required for controlled starting and supervision of operation. Thermocouples shall be provided in all main bearing drains, thrust-bearing drains and the lube oil supply header.

6.5 Emergency Trip Devices

6.5.1 Two independent over speed devices shall be provided. The over speed trip devices shall be set to trip starting at 10% above normal synchronous speed, in addition the automatic speed governor shall be programmed for emergency over speed trip.

6.5.2 The package fire protection system shall trip the turbine and de-energize all fans, close enclosure dampers, discharge CO2, and energize audible and visual alarms panel.


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6.5.3 Vibration protection system shall trip the turbine package and energize audible and visual alarms panel.

6.5.4 Low lubrication oil pressure device shall be provided to trip the turbine on extreme low pressure in the lubricating oil system. A low oil pressure switch for starting auxiliary lube oil pumps and alarm purposes shall be furnished.

6.5.5 All bearings shall be furnished with a dual lube oil drain temperature detector to provide alarm. All bearing shall be equipped with RTDs located at the loaded section; control system shall annunciate temperature alarms.

6.5.6 Double block and bleed valves arrangement shall be provided on the fuel gas piping for each combustion gas turbine unit. This is in addition to the safety shutdown valve. The two block valves have to be of the fast acting type with the automatic bleed valve located in between. The first block valve shall be installed downstream of the unit's knockout drum. The second block valve shall be physically located/installed as close as possible to the combustion gas turbine unit. This will ensure that fuel gas is immediately cut-off from the combustion gas turbine unit once a shutdown signal is initiated and the fuel gas trapped in between the block valves is immediately bled/vented to the flare.

6.5.7 The turbine generator unit shall be designed to withstand the stresses due to an over speed of 15% above normal synchronous speed. Contractor shall perform fifteen percent (15%) over speed test for the generator rotor and a 10% over speed test for the turbine unit.

6.5.8 Two 125 VDC solenoid trip coils activated by electrical protective devices shall be arranged in two redundant trip circuits and a remote turbine trip push button shall be provided as a part of the automatic fuel stop valve mechanism. The push button shall operate one solenoid only.

6.6 Turning Gear (if applicable)

6.6.1 An AC motor operated rotor-turning gear including controls and instruments for local and remote manual starting, and indication shall be furnished. Necessary oil piping and appurtenances shall be included. This system shall be a part of the lubrication system and shall be complete with all necessary pressure switches or other interlocks to prevent unsafe operation of the turning gear.


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6.6.2 The turning gear shall be equipped with a zero rotor speed indicator for showing the turbine rotor speed as the rotor approaches rest. The speed sensor shall transmit its signal to an indicator or alarm to be mounted in the control room and shall also initiate the automatic engagement of the rotor turning gear when the shaft has reached speed below turning gear speed. A zero speed switch shall be included in the interlock circuit to prevent engagement while the rotor is in motion.

6.6.3 Suitable housings and safety guards shall be provided for all moving parts of the turning gear.

6.6.4 A provision for manual control of the turning gear shall be included.

6.7 Blades

6.7.1 Blades shall be of a design, which has operated successfully in commercial service at 3600 rpm. The natural frequency of all rows of power turbine blades shall be such as to avoid resonant vibration at or near the normal operating speeds, including off-frequency operations. The natural frequencies of the blades and blade groups shall have been determined by calculation and checked by rotation of a complete row of finished blades through a speed range sufficient to verify that resonance will not occur when the turbine is in normal service.

6.7.2 The Proposal shall describe in detail the methods used for full-scale testing of blade harmonics, and for varying the natural frequency of the blade groups.

6.8 Inlet Air Filters

6.8.1 Supplier shall supply a two-stage high efficiency, first stage shall be a pulsejet self-cleaning filter and the second stage shall be a barrier filter type. Saudi Aramco will provide the pulsation air for the filter. Supplier shall specify quantity, quality and the required air pressure.

6.8.2 Inlet system shall be elevated a minimum of 15 feet above turbine foundation.

6.8.3 The filter shall undergo one complete pulsation prior to a normal CGT shutdown.

6.8.4 A manual push button to activate pulsation cycle shall be provided. The pulsation cycle control shall include a timer to allow periodic activation of the pulse cleaning system, independent of the differential pressure auto-pulse control.


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7 Generator Requirements

7.1 General

The generator shall be an alternating current generator, meeting the performance requirements specified for the combustion turbine generator unit, a cylindrical rotor, synchronous machine 3600 rpm, wye connected. The generator construction shall conform to ANSI/IEEE and NEMA standards for turbine driven synchronous generators or IEC corresponding equivalent.

7.1.1 The generator shall be designed to operate satisfactorily in parallel with other generating units.

7.1.2 The generator windings shall be made of high conductivity copper alloy.

7.1.3 The stator core laminations shall be low loss silicon steel sheet insulated with C5 or better coating, and shall be oriented grain type optimizing the total losses in the teeth and the yoke.

7.1.4 End winding support system shall be designed to withstand 180 degrees out of phase synchronizing with no major damage.

7.1.5 End turns shall be braced two-by-two and the surge rings to withstand 3-phase short-circuit forces.

7.1.6 Winding wedges shall provide a positive radial force, the stator slot wedging shall include the closing wedge, a ripple spring and slot top fillers. All these materials shall be class F.

7.1.7 Rotor shall be one-piece steel forging with integral shaft ends and radial slots machined for field winding.

7.1.8 The turbine generator shall have continuous short-time and cumulative short-time under frequency capability to allow under frequency load shedding.

7.1.9 The generator Class B rise kVA rating at 0.85 power factor lagging shall match or exceed the combustion turbine drive output at the manufacturer's defined base rating over the full ambient design range described in site design conditions.

7.2 Generator Rating

The minimum rating of the generator at specified site conditions, with the combustion gas turbine exhausting to a waste-heat boiler with 254 mm water


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gauge (10" H2O) design back pressure, shall be in accordance with the following requirements:

MVA DATA SHEET

MW @ 0.85 PF DATA SHEET

Phases 3-phase

Terminal voltage DATA SHEET

Frequency 60 Hz

Short circuit ratio 0.5-0.6

Design over speed 120% of rated speed

Minimum sub transient 10% Reactance X"d, at rated Voltage

7.3 Electrical Insulation

7.3.1 The insulation of the armature and field windings of the generator shall be capable of satisfactorily withstanding the temperatures and high voltage tests specified by ANSI C50.10.

7.3.2 Insulation of the armature windings, field windings, and collectors shall be Class F with Class B rise design conditions. The operating temperature rise shall not exceed class B limit for both the stator and rotor windings

7.3.3 All conductors shall be copper. Class "F" insulation, or better, and shall be used throughout the stator and rotor windings with total temperatures rise not to exceed those specified in ANSI Standard for Class B insulation, i.e., when operating continuously at Base Load Rating in the simple cycle mode at site conditions of 50°C ambient air temperature. Total temperatures may be slightly higher than the foregoing values when operating at peak rating but shall be within the Class "F" insulation rating. Windings shall be insulated for full voltage to ground.

7.4 Telephone Influence Factor

The telephone influence factor shall be as defined by ANSI C50.13 and ANSI C50.14 and shall not exceed the values specified in ANSI C50.14.

7.5 Generator Voltage Wave Form

The generator line-to-line voltage waveform deviation shall comply with ANSI C50.10.


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7.6 Short-Circuit Requirements

7.6.1 The generator short time thermal capabilities shall be in accordance with ANSI C50.13.

7.6.2 The generator shall be able to withstand 3-phase, phase-to-phase-to-ground, phase-to-phase, and phase-to-ground fault both internal and external to the machine.

7.6.3 The generator shall be able to withstand a multiple pole slip condition.

7.7 Temperature Rise

7.7.1 The generator shall be capable of operating continuously at base site rated load with the design range of ambient temperatures specified without exceeding Class B rise.

7.7.2 The temperature rises as determined by any of the methods given in the standards of ANSI for the stator field windings and collector rings shall not exceed that listed for Class B insulation.

7.7.3 The construction of the generator shall be such that the average temperature rise of the various parts of the machine above the average temperature of the cooling media shall not exceed the values specified in the latest revision of ANSI C50, for this type and size machine. The temperature of the cooling media shall be the average temperature of the media leaving the coolers as specified in the latest revision of ANSI C50 for the various air pressures.

7.8 Windings and Grounding

7.8.1 Stator winding shall be wye-connected with six armature leads brought out for application of differential and other relaying protection.

7.8.2 Generator neutral side connection shall include the current transformers specifies to be mounted on the phase leads forming the neutral.

7.8.3 Generator phase leads shall include the current transformers specifies to be mounted on the phase leads also shall include line and surge apparatus. The line side shall be ready for bus connection.

7.8.4 Grounding pads shall be furnished at four locations on the Generator frame. The pad shall be drilled and tapped for connection to station ground grid. The tap shall be Ml2 thread 25 mm long.


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7.9 Temperature Detectors and Thermocouples

7.9.1 The stator slots shall be equipped with resistance temperature detectors (RTDs) for determining the generator stator winding operating temperatures. The RTD's shall be 100 ohms, three-lead and covered by a semi-conductive paint.

7.9.2 The detectors shall be built into the generator windings (at least two per circuit per phase), fully protected from the cooling medium, distributed around the circumference, and embedded in the slots in positions normally having the highest temperature.

7.9.3 Detectors shall be provided for indicating the inlet and outlet air temperatures to the generator and inlet and outlet of the supplied cooling system.

7.9.4 Thermocouples shall be provided in the generator and exciter journal bearing if applicable.

7.10 Synchronizing Equipment

Automatic and manual synchronizing equipment package shall be supplied with the combustion turbine generator unit and shall include, but not be limited to, the following:

7.10.1 Automatic synchronizing (with DCS control provision) with separately adjusted phase angle window and closing time advance for automatic synchronizing.

7.10.2 Synchronizing check or synch-acceptor to supervise both automatic and manual synchronizing (must be separate relay).

7.10.3 Hot bus-dead line bypass.

7.10.4 Manual synchronizing will bypass the automatic synchronizing relay, for local manual synchronizing.

7.10.5 Manual synchronizing with bus and line voltmeters, frequency meters, synchroscope, synchronizing lights, and synchronizing supervisory relay shall be supplied.

7.10.6 The generator unit shall be provided with a tachometer or other suitable speed indicator, with digital readout mounted on the local control panel for use in manual synchronizing.

7.11 Generator Protection


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7.11.1 The generator protection shall consist of a dual multifunction microprocessor based relays and two 86 lockout relays. The dual multifunction relays, shall be fed from independent and separate current transformers CT's.

7.11.2 The Supplier shall furnish all control equipment, meters, relays, or similar devices not specifically listed, but that are required for the operation of the unit from the local control cabinet.

7.11.3 The Supplier shall provide recommended protective relay settings for all generator protection relays.

7.11.4 The above relays and automatic synchronizing equipment shall be furnished complete with all wiring and adjustments made and ready for operation.

7.12 Generator Monitoring

7.12.1 A partial discharge monitor/recorder shall be furnished and installed to detect and alarm generator's winding fault in its incipient stage. The system shall be per generator manufacturer recommendations.

7.12.2 The control system shall include metering and equipment to monitor generator frequency, voltage, current, watts, Vars, kWh, speed of turbine, temperatures, vibration, and pressures.

7.12.3 A system shall be provided to monitor the vibration of the winding end turns. This system may be combined with the turbine vibration monitoring system. The system shall alarm if excessive vibration occurs.

7.12.4 A system shall be provided to monitor and display the temperature of the generator rotor. The system shall alarm high temperature. The system shall be supplied with the generator.

7.12.5 A system shall be provided to monitor and control the shaft voltage relative to the generator bearings. The system shall control this voltage to eliminate radio noise and damage to the bearings and seals. The system shall alarm on high shaft voltage. The system shall be supplied with the generator. The excitation system output shall be designed to minimize the voltage induced in the shaft and the output current spikes.

7.13 Generator Cooling

A complete generator cooling system shall be furnished for the generator supplied. The Supplier shall complete cooling section in Data Sheet. The


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cooling system shall be reliable trouble free and with sufficient capacity enabling the generator to meet the specified output, as stated per Bid package.

7.14 Excitation System

7.14.1 The generator manufacturer shall be the provider of the excitation system and shall coordinate all design parameters and take full responsibility for the excitation control system.

7.14.2 A automatic, solid state voltage regulator with a manual standby regulator control. The automatic voltage regulator supplied shall be capable of power generation and Var control modes.

7.14.3 The excitation system nominal response, as defined by IEEE 421.1, shall be 0.50 second.

7.14.4 The Rectifier assembly shall have sufficient redundancy to allow for device failure replacement without compromising the required generator availability.

7.14.5 The continuous current rating shall be larger than the maximum required by the synchronous machine field under all continuous operating conditions and shall allow the machine to operate at full rated MVA and within ± 5% of rated terminal voltage. The continuous rating shall apply with the redundant parts out of service.

7.14.6 The ceiling voltage shall be determined by the manufacturer to match the response requirements.

7.15 Generator Terminals

7.15.1 All six terminals shall be brought out of the machine and shall be available for external connections.

7.15.2 Line terminals shall be available to accept bus or cable connection (isolated bus duct or cable duct) to generator circuit breaker or step-up transformer, Data Sheet.

7.15.3 Neutral terminals shall be connected together with bus extending to the generator neutral grounding transformer.

7.16 Space Heaters

7.16.1 Generator shall be supplied with low power density space heaters with a nameplate voltage rating twice the supply voltage given the Synchronous Generator Equipment Data Sheet. The heaters shall be sized to protect


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the generator, and control components from condensing moisture. The heaters shall be automatically controlled so that they are energized when the generator is at rest.

7.16.2 Space heaters shall be arranged so that all live parts are covered and heat is radiated from both sides to provide uniform heating of stator windings. The heaters shall maintain windings temperature at approximately 9°F (5°C) above the ambient temperature. The surface temperature of the heater elements shall not be grater than 400°F (204°C).

7.17 Generator Neutral Grounding

7.17.1 A generator neutral grounding system shall be supplied in accordance with the requirements of this section and the latest applicable IEEE.

7.17.2 The generator neutral grounding shall be high resistance grounding as defined by IEEE C37.101, table 1, method I (Distribution Transformer grounded - High Resistance).

7.17.3 The high resistance grounding system shall consist of a low-ohmic value resistor connected to the secondary of a distribution transformer with the primary winding of the transformer connected from the generator neutral to ground.

7.17.4 Current through the primary of the grounding transformer for a single phase to ground fault shall be limited to between 5 and 15 amperes dependent on generator size and zero-sequence capacitance to ground in the circuit operating at generator voltage.

8 Fire Protection Systems

8.1 Two fire protection systems shall be furnished in accordance with NFPA 72 as follows:

8.1.1 The first system to be actuated is a low pressure CO2 gas flooding system at the turbine and all auxiliary package enclosures. This system shall be automatic and shall include temperature or products of combustion sensors, gas bottles, and wired local control panel. Each sensor shall be capable of initiating a gas discharge.

8.1.2 The second system to be actuated shall be a dry chemical type for the turbine exhaust bearing area only. This shall be an automatic system and shall include temperature sensing devices, spray nozzles, dry chemical and nitrogen cylinder, wired local control panel for a continuously monitoring system with visual indication of actuation.


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8.2 An emergency DC power supply shall be provided to operate alarm circuits.

8.3 Either protective system shall shut the turbine down and de-energize all fans, and energize audible and visual alarms. Manual initiators shall be located at each protected zone. In addition, two relay contacts (trouble and alarm) shall be wired to the fire alarm system control panel.

8.4 Fire alarm and trouble signals provision from both systems shall be provided to hard wired to existing system and also to be transmitted via RS-232 to the main fire alarm panel in central control room (if applicable).

9 Fuels and Auxiliaries

9.1 General

The primary fuel for the combustion turbine shall be natural gas. No. 2 diesel fuel shall be the backup fuel (if needed). The combustion turbine generator shall be designed to operate satisfactorily when firing either of the fuels specified and shall be capable of transferring, on-line, from one fuel to the other.

9.2 No. 2 Diesel Fuel System (if applicable):

9.2.1 A diesel fuel system shall be furnished with all necessary equipment, devices and instrumentation to provide reliable metering of No. 2 diesel fuel at the combustion gas turbine unit. This system shall include, as minimum, stop fuel valves, pressure gauges, fuel pumps, diesel fuel filters, integral piping and valves and air atomization.

9.2.2 The diesel fuel shall be given a final filtering before entering the combustor. A full size parallel system of duplex diesel fuel filters and two-way transfer valves with manual switchover shall be provided for the unit. Alarms for high filters differential pressure shall be provided. The Supplier shall indicate the number, size and type of filter element and removal efficiency.

9.2.3 The diesel fuel system shall have one supply and one return connection to the plant fuel system. Supplier shall furnish shut off valves.

9.2.4 The combustion gas turbine shall be provided with a diesel fuel meter totalizer capable of measuring fuel flow and recording total consumed fuel over the range of 20-100% of full flow.

9.3 Fuel Gas


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The unit shall have its own fuel meter connection to the plant fuel header. Each connection shall have double shutoff valves. The fuel system shall be provided with the followings as minimum:

9.3.1 Fuel control valve assembly.

9.3.2 Inlet strainer with an isolation valve.

9.3.3 Gas pressure control valve with alarm on excessive low or high pressure.

9.3.4 Manual test vent valve.

9.3.5 Fuel meter and ring manifold.

9.3.6 Double block and bleed valves arrangement shall be provided in the gas supply line upstream of main control valve and downstream of the fuel gas isolation valve. The two block valves shall be of the fast acting type with an automatic bleed valve to plant flare system, located between the two block valves.

9.3.7 The fuel meter shall be capable of measuring of fuel flow rate and total consumed fuel over the range of 20-100% of full flow.

9.3.8 All piping shall be of stainless steel material AISI type316. Leak test of pipe and fittings shall be provided with Contractor's test report. All circumferential butt welds in the piping shall be 100% radio graphed.

9.3.9 Contractor shall verify if the available pressure satisfies the minimum gas pressure required by the combustion gas turbine for guaranteed load as provided in the DATA SHEETS.

9.3.10 All necessary means shall be provided to assume safe and reliable operation of the fuel gas handling system and combustion gas turbine unit to meet requirements of all applicable codes and standards.

10 Gas Turbine Generator and HRSG Control and Monitoring System

10.1 General Control System Requirements

10.1.1 The co-generation train controls system shall be an integrated architecture, utilizing a dual or triple modular redundant (DMR or TMR) control platform. This redundancy is essential to provide the reliability function needed for the co-generation components, and for interfacing with equipment auxiliary systems such as lubrication and seal fluid systems, vibration monitoring, fire protection, emergency


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shutdown, etc. Whichever platform is selected however, the control/emergency shutdown systems must be capable of executing all control and protection algorithms within the manufacturer's minimum prescribed process (or dynamic, rotating equipment) time constants consistent with safe operation, control, protection and emergency shutdown.

10.1.2 Control system functionality shall permit automatic startup, slow roll, variable speed ramp rate, and automatic synchronization of generator to the output electrical bus, as well as startup, shutdown and load-control of the HRSG and its burner management and safeguard system. Automatic, failsafe alarm and protective systems shall be provided, as well as provision for manual operator intervention during startup or shutdown of the turbine-generator. It shall not be possible to bypass or compromise the integrity of emergency shutdown systems or equipment protection functions.

10.1.3 The control system shall be designed for local and remote operation with the provision that a single component failure shall not prevent the normal startup, operation, and shutdown of the rotating or HRSG equipment in the event of an emergency.

10.1.4 Interlock systems shall be provided to block selective local operation when remote selection is made, and visa-versa. Failure of the remote control systems interfaces shall have no impact on local control/auxiliary systems or the safe startup and operation of the unit. Local – Remote – Local control transfer shall be possible while the unit is in operation.

10.1.5 Sensor, transmitter, controller and auxiliary system redundancy shall be provided as necessary for regulatory control and systems safety to avoid nuisance trips, and to ensure continuous, reliable train operation. Transmitters shall be used to measure and communicate process and auxiliary system variables, except where proven to be unsuitable for the measurement application or its ambient environment. Separate, voted, dual or triple sensors and logic shall be provided for ESD and protective systems to prevent a dangerous operating situation or potential equipment damage in the event of a single component failure in either the control or safety systems. Sensors shall be voted as per the manufacturer's standard, except for thrust measurement, where 1oo2 voting shall be used.

10.2 Gas-Turbine-Generator and HRSG Control Consoles and Local Instrument Panels


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10.2.1 The Gas Turbine Generator unit shall be controlled and monitored from the local control console, located in the control compartment, which can be used either as the primary operator interface or as a maintenance workstation.

10.2.2 Gas turbine-generator operator interface controls and display consoles shall provide for automatic, sequenced startup and shutdown. All permissive run conditions, sequential steps, or protective/emergency shutdown (ESD) functions, shall be graphically and interactively displayed on the operators console. Equipment protection, alarm, and ESD events shall be alarmed, displayed, logged and time-tagged according to actual sequence of events (SOE). Automated controls shall be provided for generator synchronizing; generator breaker control, automatic loading and unloading; voltage and speed control; base to peak load selector speed/load set point and governor and generator excitation set points stop. Manual controls shall permit manual start, stop, manual check synchronizing; manual loading, unloading, provided the associated permissive conditions are met. The above control functions shall be available from a remote operators console.

10.2.3 Local instrumentation for rotating equipment systems and train equipment shall be provided on an instrumentation rack/panel located in the Turbine Auxiliary Compartment and shall include all necessary transducers and gauges. The following sensors/ transducers/ indicators shall be provided as a minimum:

a) Air inlet vacuum gauge and bimetallic thermometer, installed within a thermowell

b) Inlet/Discharge pressure gauge

c) Instrument air header pressure gauge

d) Bearing oil pressure gauge and bimetallic thermometer

e) Main oil pump(s) discharge pressure gauge

f) Emergency oil pump discharge pressure gauge

g) Fuel pump discharge pressure

h) Fuel filter differential pressure

i) Fuel gas pressure

j) Fuel gas filter differential pressure

k) AC seal oil pump discharge pressure

l) DC seal oil pump discharge pressure


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m) Inlet air filter differential pressure gauge

n) Main atomizing compressor inlet pressure and temperature

o) Main atomizing compressor discharge temperature

p) Inlet oil pressure to each fuel nozzle

q) Purge air header pressure and temperature

r) Atomizing air and hydraulic oil system pressure gauges and differential pressure gauges

10.3 Turbine-Generator Control Systems

10.3.1 Control, sequencing and protective systems for the gas turbine – generator, synchronizing, load controller, bus/breaker controller and auxiliary control systems shall be performed within an integrated DMR or TMR control platform (note: TMR architectures are preferred over DMR architectures). DMR or TMR platforms shall have a proven track record of at least 6 months of operation on a similar frame size of rotating equipment. The system shall be capable of manipulating either fuel, liquid or gas fuel sources, in accordance with the generator speed/loading control requirements, from startup to full load, to minimum load turndown conditions.

10.3.2 Controller set points, tuning parameters and performance parameters shall be accessible and adjustable during train operation utilizing a multi-level, security password system. It shall be possible to make modifications to the sequencing and/or control algorithms/logic when the rotating machinery is not operating.

10.3.3 Control, auxiliary system and shutdown system interfaces, if implemented on different platform equipment or systems shall be performed in a hard-wired manner.

10.3.4 Extensive built-in diagnostics shall be provided for fault identification purposes enabling personnel to pinpoint controller, sensor/transmitter or subsystems faults down to device and I/O channel levels. Systems configuration shall enable the on-line replacement of system modules/boards without having to shutdown equipment. Similarly those sensors where physical access and system isolation are possible shall be capable of on-line replacement.

10.3.5 Local operator interface consoles shall be configured for a redundant, minimum 14" color graphic CRT display driven by graphics/control/communications processors, to provide a train operating. Operator inputs shall be accomplished by means of


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trackball or mouse cursor control or via a sealed membrane type keyboard.

10.4 Turbine - Generator Local Control Panel

10.4.1 Turbine control, display, alarm and protection equipment/system shall be enclosed in an indoor, NEMA 12 (or equivalent) turbine control panel/enclosure.

10.4.2 CGTG control, sequencing and protection shall include the following automatic control features as a minimum:

a) Permissive startup, control and sequencing

b) Speed/load set point and governor

c) Exhaust gas temperature (EGT) control

d) Guide vane control

e) Fuel control

f) Generator exciter set point control

g) Automatic synchronization and control (speed/voltage matching)

h) Emissions control

i) Control of turbine exhaust shut-off and bypass dampers

10.4.3 Interlock shall be provided within the startup and shutdown sequence that will prevent an operator from making an inappropriate action that could be detrimental to operation or safety of the CGTG and/or its auxiliary systems. Sequential interlocked steps/functions shall be provided for:

a) GT auxiliary systems (MCC starters)

b) Startup, running and shutdown

c) Purge and ignition

d) Fuel changeover

e) Alarm management

f) Generator synchronizing

g) Maintain counters/timer for starts, trips and run time (hours), Fired time

h) Sequence of Event logging

i) Manually initiated starts


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j) Fired starts

k) Fast load starts

l) Emergency trips

10.4.4 The Gas Turbine protection system shall be designed to be fail-safe and fault-tolerant. Redundant sensors/transducers, I/O channels, processors and auxiliary systems shall be as necessary to accomplish this and to protect against:

a) Turbine Over speed

b) Over temperature (both EGT and compensated generator winding temperature)

c) Excess shaft vibration and thrust movement for turbine, generator, gear boxes

d) Loss of flame

e) Low fuel pressure

f) Fire detection sensors - carbon dioxide fire protection

g) Low lube oil pressure

h) High lube oil temperature

i) Emergency trip (pushbutton)

j) Generator, step-up transformer and circuit breaker trips

k) Loss of cooling fluids

l) Manual equipment trips

10.4.5 The following alarms and alarm messages shall be provided as a minimum to alert the operator of an equipment problem or malfunction.

a) Check Diagnostic Alarms

b) Auxiliary Lube Oil Pump – Run/Stop

c) Lube Oil – Low Level - Turbine

d) Lube Pressure Low

e) Lube Oil Temperature Low - Turbine

f) Lube Oil Temperature High - Turbine

g) Lube Oil Temp. Low - Generator

h) Lube Oil Temp. High - Generator


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i) Loss of Flame

j) Failure to Ignite

k) Flame Detector Trouble

l) Turbine Air Inlet Low Flow

m) Turbine Inlet Air Filters - High Differential Pressure

n) Turbine Incomplete Start Sequence

o) CGTG sequential Holts, Lockout and Progress steps.

p) Failure to Start

q) Fire Detector System Trouble

r) Fire in Turbine Area

s) Turbine Compartment High Ambient Temperature

t) Fire Protection System Inoperative

u) Vibration/Thrust Transducer or Detector Faults or failures

v) High Vibration Alarm Level

w) Master Protective Startup Lockout Relay

x) 20% Speed and No Flame

y) Motor Control Center Under voltage

z) Battery Charger AC Under voltage

aa) Battery Bus Under voltage

bb) Battery Bus Grounded

cc) Bus Under voltage

dd) Auto Synchronizing Lockout

ee) Failure to Synchronize

ff) Generator Stator High Temperature

gg) Generator Field Ground

hh) Exciter Over voltage

ii) Exciter Rectifier Bridge High Temperature

jj) Bus or Generator PT's Failure

kk) Bleed Valve Position or IGV Position Trouble

ll) Exhaust Gas Temperature High

mm) Exhaust Gas Temperature - Element Failure


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nn) Exhaust Gas Pressure High

oo) Turning Gear Failure (If Applicable)

pp) By-pass Damper Failure

qq) Seal Oil System Abnormal

rr) Start up Atomizing Air Compressor Running

ss) Control System Self-diagnostic Check OK

tt) Fuel Gas Control Fault

uu) Fuel Oil Pressure Low

vv) Fuel Gas Pressure High

ww) Lube Oil Temperature Trouble

xx) Ventilation system failure alarm

11 Generator Step-Up Transformer Unit (GSU) if Applicable

11.1 General

The Generator Step-up transformer unit (GSU) furnished shall be complete with all accessories ready for installation, connection, and immediate service. The generator transformer shall be sized to carry the maximum generator output as shown on the generator capability curves and site conditions for all possible tap positions. The contractor shall provide the generator capability curves during detail design. The transformer configuration and rating shall be per DATA SHEET and equipped with standard accessories according to ANSI C57.12.00, Section 4.1.

The transformer shall be rated based on the actual installed conditions. Under no circumstances shall the transformer be a limiting factor to turbine generator output. The transformer shall be a standard 65°C rise transformer and shall be de-rated fifteen percent (15%) to allow for the site rating ambient

The GSU shall be capable of withstanding without damage, the stresses caused by tripping the turbine generator fully loaded and simultaneously shedding all loads connected to the transformer.

The transformer shall also be capable of absorbing without damage an energy amount equal in value and time to the energy dissipated in a fault at the generator terminals during the entire time the generator is coasting to a standstill after tripping the turbine generator fully loaded at maximum generator output.

11.2 Design and Accessories


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11.2.1 The transformer shall be equipped with internal oil rate of pressure rise devices.

11.2.2 The transformers is subject to sand and dust storms, salt laden winds and fog, and airborn chemical contaminants from industrial process plants. The airborn salt levels of NaC1 may be 300 ppm and of MgC1 50 ppm.

11.2.3 The temperature of metal surfaces exposed to direct solar radiation can reach 75°C. The interiors of unventilated metal cabinets (exclusive of internal heat-producing sources) can reach 56°C. The transformer and its accessories, including cabinets and junction boxes, shall be designed accordingly. Sun shields shall not be fitted, unless specified in DATA SHEET.

11.2.4 The transformers shall be designed such that the actual OA and FA derating factors do not exceed the ANSI Loading Guidelines for continuous operation at unusual ambient temperatures without reducing normal life expectancy.

11.2.5 The attachments and accessories such as bushings, instrument transformers, tap changers, and surge arresters shall be compatible with the ANSI/IEEE C57.91 loading guidelines and shall not limit the transformer kVA rating at unusual ambient temperatures.

11.2.6 The minimum winding BIL insulation levels shall be as specified in the ANSI tables, unless specified otherwise in the DATA SHEET.

11.2.7 No-Load tap changer for de-energized changing operation shall be as specified on DATA SHEET.

11.2.8 A magnetic liquid level gauge shall be provided for the transformer. The alarm contacts shall be rated and wired in accordance with Section 9.7 of this ANSI Standard.

11.2.9 A liquid temperature indicator shall be provided for the transformer. A two electrically separate sets of contacts shall be rated and wired in accordance with Section 9.7 of this ANSI Standard.

11.2.10 A pressure vacuum gauge shall be provided for the transformer equipped with a sealed tank oil preservation system. The two electrically separate alarm contacts shall be rated in accordance with Section 7 of this ANSI Standard.


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11.2.11 Valves shall be provided on a transformer equipped with detachable radiators to enable these radiators to be removed without affecting the liquid in the tank. The tank drain valves shall be padlockable.

11.2.12 The number of transformer windings and winding connections shall be as specified on DATA SHEET.

11.2.13 A pressure relief device shall be provided for the transformer.

11.2.14 Transformer construction shall permit to remove any cover-mounted bushing without removing the main tank cover.

11.2.15 A winding temperature simulator shall be provided for the transformer with forced-air cooling, and shall control the fans and give visual indication of winding temperature.

11.2.16 The Supplier shall supply a disconnect device in the control cabinet for each power supply.

11.2.17 The enclosures shall be raintight and dust-tight, National Electrical Manufacturers Association, NEMA ICS 6 Type 3. Undrilled gland plates are not acceptable. For transport prior to erection, conduit hubs shall be sealed with threaded steel plugs; bus-duct and pothead entrances shall be sealed with steel plates.

11.2.18 A throat connection(s) shall be provided for windings of 350 kV BIL (69 kV nominal system voltage) or less when specified on the DATA SHEET.

11.2.19 Current transformers shall be provided as specified on the DATA SHEET.

11.2.20 A conservator or expansion-tank system, when provided, shall include a diaphragm or bladder in the auxiliary tank to prevent oil-to-air contact. Externally mounted expansion bladders are not acceptable.

11.2.21 A conservator or expansion-tank system, when provided, shall have a Buchholz-type relay.

11.2.22 Transformer noise levels shall not exceed NEMA TR 1 Standards for OA, FA, or FOA operation.

11.2.23 The paint color shall be per DATA SHEET. All painted surfaces shall have the Supplier's standard finish with a minimum thickness or 5-mil dry thickness.


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11.3 Mechanical Construction

11.3.1 The tank including covers, handholes, and manholes shall be in accordance with ANSI C57.12.10.

11.3.2 Ground pads shall be furnished on transformer tank in accordance with the requirements of ANSI C57.12.10, Article 9.2.8.

11.3.3 The transformer tank design shall be such that ventilation is provided between the concrete supporting slab and the bottom of the transformer tank. Only supporting steel beneath the bottom of the transformer tank may touch the concrete slab. Design of the steel supporting the transformer tank bottom shall be such that the bottom is accessible for inspection after installation.

11.4 Cores and Coils

11.4.1 Cores and coils shall be in accordance with ANSI C57 standards except as otherwise specified, and shall be braced to withstand short-circuit forces as determined in ANSI/IEEE C57.12.00, Article 7.1, and as limited only by the transformer impedance without damage or displacement of the coil on the core and to withstand normal moving and handling without the use of special shipping braces.

11.4.2 The minimum basic insulation impulse level (BIL) for the transformer winding shall be in accordance with ANSI C57.12 standard unless specified otherwise in the DATA SHEET.

11.4.3 The core ground connection shall be made by means of a copper ground strap, brought to an externally located terminal box accessible without making entry into the main tank. The core ground shall be connected to the grounding bus.

11.5 Bushings

11.5.1 All bushings for outdoor application shall be made from wet process glazed porcelain and shall have a threaded stud.

11.5.2 All bushings of the same voltage class shall be interchangeable.

11.5.3 All outdoor bushings for nominal system voltages of 69 kV and above shall have a capacitor tap for testing.

11.5.4 The minimum BIL levels of winding bushings shall be as shown in Table 1 of this specification, unless specified otherwise in DATA SHEET:


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Table 1 – Bushing BIL Level

Nominal

Voltage (kV) Minimum

BIL Level (kV) 2.4 60

4.16 75

13.8 110

34.5 200

69 350

115 650

230 1050

11.5.5 Outdoor bushings shall have minimum creepage of 40 mm per kV line-to-line of nominal system voltage.

11.5.6 Type and location of bushings shall be as specified on DATA SHEET.

11.6 Fans and Power Supply

11.6.1 The voltage for the forced-cooling fans or pump motors shall be as specified on DATA SHEET.

11.6.2 Fan motors shall be totally enclosed, 60 Hz, squirrel cage, induction-type, and shall be suitable for continuous operation in 50°C ambient temperature. Motors shall conform to the requirements of NEMA MG 1.

11.6.3 Three phase motors and motors with other voltages under 600 V are acceptable if specified on DATA SHEET.

11.6.4 Fans and accessories for forced-air cooling shall be supplied on all transformers rated 2500 kVA OA or larger, and shall not be supplied on transformers rated less than 2500 kVA, unless specified on DATA SHEET. All fans shall be fitted with fan guards.

11.6.5 All fans shall be fitted with fan guards. The fan guards shall have wires spaced to limit openings to less than 12.7 mm.

11.6.6 The power supply shall be as specified on the DATA SHEET.

11.7 Control Cabinet

11.7.1 Control cabinet(s) shall be tank-mounted, shall be accessible from grade, and shall house all terminal connections for transformer


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accessories and all control equipment and other devices. All wiring requiring Buyer's interconnection shall be terminated to suitable terminal blocks. Terminal blocks shall be one-piece, phenolic, barrier type, rated 20 A, 600 V minimum with pre-numbered marking strips and suitable for two terminations per point. A maximum or 2 wires per point is permitted. Shorting terminal blocks shall be provided for current transformer circuits and shall be capable of receiving 10 mm² (8 AWG) wire.

11.7.2 Control cabinet(s) shall be outdoor, raintight, dust-tight, NEMA ICS 6 Type 3, suitable for bottom entry. Cable or conduit top entry is not acceptable. Doors shall be double or full-length hinged, capable of opening not less than 120 degrees, and equipped with stainless steel hardware, including locking devices.

11.7.3 Control cabinets shall be provided with a 240 V rated space heater with thermostat, a 120 V convenience outlet to NEMA 5-20R configuration, and a 120 V overhead light. All three devices shall be connected for 120 V AC. A door-mounted ammeter shall be provided to indicate that the space heater is in service. A disconnecting means shall be provided for each power supply. A wiring diagram indicating the control cabinet circuits and fuse or circuit breaker ratings, shall be affixed inside the cabinet door.

11.7.4 All relays, switches, terminal blocks, and other devices shall be identified by engraved nameplate(s), which shall be securely attached without the use of adhesives.

11.7.5 Wiring shall be run in hot dipped galvanized rigid steel conduit. Where flexibility is required, liquid-tight flexible metal conduit may be used in lengths not to exceed 500 mm. Alternatively, metal clad cable or armored cable per IEC 60502 may be used without conduit.

11.7.6 All wiring and cables shall comply with the requirements of the National Electrical Code, ANSI/NFPA 70, (latest edition). Acceptable cable types are THHN and XHHW; XHHW insulation shall be XLPE. Alternatively, IEC 60227 wires or IEC 60502 cables, with minimum temperature rating of 85°C, fire retardant per IEC 60332, may be used.

11.7.7 All wiring shall be a minimum of 2.5 mm² (14 AWG) 600-V stranded copper.

11.7.8 Each wire shall be identified with a thermoplastic, slip-on wire marker with permanently printed characters. Snap-on or adhesive type markers are prohibited.


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11.7.9 Insulated, ring or forked tongue, compression (crimped) terminals shall be provided for all control wiring. A maximum of two conductors may be terminated on a single terminal.

11.7.10 Manually operable switch and fan control relay shall be located in the control cabinet.

11.8 Surge Arrestors

11.8.1 Surge arresters shall be as specified on DATA SHEET, including all terminating accessories, and shall have the minimum creepage of 40 mm per kV line-to-line of nominal system voltage. Gapless metal-oxide type surge arresters shall be rated for 60°C peak ambient temperature.

11.8.2 The surge arrester voltage rating, class, and type shall be per Table 2 of this specification, unless specified otherwise in DATA SHEET.

Table 2 – Surge Arrester

Nominal System Voltage (kV rms)

Arrester Class & Type

Voltage Rating (kV rms)

13.8 Intermediate/Station (1) 15

34.5 Station, Metal-oxide (2) 39

69 Station, Metal-oxide (2) 60



Notes: (1) Use Station Class for 5000 kVA OA or more. (2) Use gapless metal-oxide non-linear resistor type.

11.8.3 An individual ground pad shall be provided for each surge arrester. The material required for connecting each surge arrester ground pad to tank ground pads shall be provided and installed by the Supplier. The ground wires shall be stranded bare copper.

11.9 GSU Guarantee

11.9.1 The Supplier shall provide in DATA SHEET as part of his Bid the guaranteed values of load and no-load losses in accordance with ANSI C57.12.00. The load losses shall be based on the OA self-cooled rating with a winding temperature of 85°C. The no-load losses shall be based at rated nominal voltage at nominal tap position and 20°C winding temperature.


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When Loss Evaluation Constants A and B are provided in DATA SHEET, the bids will be evaluated by capitalizing the losses. The Supplier shall supply a transformer designed to minimize the total present value price C in the following equation:

C = P + (A * Li) + (B * Lc) (1)

where

C = total evaluated present-value price used for bid comparison purposes;

P = transformer quoted price, including delivery to site;

A = cost/kW of no-load loss from DATA SHEET;

Li = guaranteed no-load loss in kW at rated voltage;

B = cost/kW of load loss from DATA SHEET;

Lc = guaranteed load loss in kW at the OA self-cooled rating at winding temperature of 85°C.

11.9.2 In addition to the guarantee and warranty specified in contract or purchase order documents, the No-load and Load Losses shall be guaranteed and measured in accordance with ANSI/IEEE C57.12.90. If the losses, when measured, are found to be higher than the guaranteed losses, the cost of the transformer shall be reduced by an amount equal to the difference between the actual losses and the guaranteed losses in kilowatts as specified above multiplied by the evaluation factor $/kW given in the DATA SHEET.

12 Heat Recovery Steam Generator (HRSG)

12.1 General

This specification covers the minimum mandatory requirements of manufacturing a new fired or unfired Heat Recovery Steam Generator (HRSG). The HRSG primary function is to provide the transfer of heat from the exhaust of the combustion turbine and or by supplement firing to the feed water in order to supply the required plant process steam. The HRSG system shall be suitable for operation at all loads from startup to the maximum steam generating capability of the HRSG. The rate of load change of the HRSG shall be compatible with the rate of load change of the associated combustion turbine and process steam demand. The HRSG system shall be designed for safe and reliable operation under the following conditions:

12.1.1 Capable of continuous operation at maximum steam generation.


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12.1.2 Capable of providing a 10% per minute load rate change at the maximum design steam capacity.

12.1.3 The heat recovery steam generator operating conditions and auxiliary systems design shall be determined by the manufacturer. A safety margin shall also be included to allow the Heat Recovery Steam Generator System to operate safely and reliably during peak operating conditions. These peak-operating conditions shall be determined based on the peak process steam demand.

12.1.4 The Supplier shall design and provide a reliable Control of the Heat Recovery Steam Generator System. Supplier shall provide for a remote control interface to plant DCS system

12.1.5 The HRSG Manufacturer is responsible for the thermal design, mechanical design, (Code and structural calculations), and supply of all materials, fabrication, inspection, testing, and preparation for shipment, in accordance with the Code.

12.1.6 The Manufacturer shall supply the balance of HRSG instrumentation in accordance with the industry standard requirements and Data Sheets for both field and control room instruments; and it shall include feed water regulatory controls, steam drum level indication and shutdown instruments, flue gas and waterside analyzers.

12.1.7 The HRSG Manufacturer's proposal shall include a detailed description of any exception to the requirements of this specification.

12.2 Design

12.2.1 The design of HRSGs, HRSG piping, and associated equipment shall conform to the ASME Codes, and the completed DATA SHEET.

12.2.2 The design and construction of HRSGs and all auxiliary equipment shall be of a proven and commercially demonstrated design and performed satisfactorily for a minimum of five years.

12.2.3 HRSGs shall be designed to operate continuously in the automatic control mode, but with manual control override capabilities; under all conditions specified in the RFP document.

12.2.4 The HRSGs shall be designed for outdoors location in coastal environment and suitable for continuous operation at the summer design temperature for a particular site.


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12.2.5 Regardless of climatic conditions, all external surfaces shall be self-draining and protected against corrosion. Open covers (roof and sides only) shall be provided with over firing aisles.

12.2.6 HRSGs and auxiliaries, including control instrumentation, shall be designed for continuous operation during electrical power outages through an uninterrupted power supply system. The HRSG Manufacturer shall submit an estimate of the electrical power required.

12.2.7 HRSGs and auxiliaries shall be capable of sustained operation in automatic control mode between 25% and 100% Maximum Continuous Rate (MCR) for a minimum period of two years between shutdowns required for the complete testing and inspection of the HRSG.

12.2.8 HRSGs shall be capable of accommodating a rate of change of 10% MCR per minute over the control range of the HRSG, for both increasing and decreasing steam demand, without causing a level shutdown or water carryover during the transient condition.

12.2.9 Circulation calculations at 50% MCR, 70% MCR and 100% MCR shall be prepared and submitted by the HRSG Manufacturer for review in the Bid submittal.

12.2.10 Gas paths through HRSG casing, super heaters and heat transfer surfaces, as well as flue gas ducts, shall be designed and arranged to prevent vibrations from vortex shedding, impact loadings, and turbulence. HRSG Manufacturer shall submit vibration calculations.

12.2.11 All water and steam piping shall extend 1.0 m beyond the battery limits of the HRSG; the Design Engineer shall specify exact locations.

12.2.12 Space and access shall be provided for the inspection, cleaning, removal, and maintenance of tube bundles, headers and valves. The HRSG floor casing shall be a minimum of 1 m above grade.

12.2.13 Guards or personal protection type insulation shall be provided around operating areas where exposed surfaces are hotter than 65°C.

12.2.14 Facilities shall be provided to completely allow for units water drainage from the fireside of HRSG after wash. Drains openings shall be a minimum of 75 mm diameter and be sealed against overheating and escape of flue gases.

12.2.15 Enclosures for instrumentation and electrical equipment shall be selected for the area classification as specified in Bid package.


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12.3 Corrosion Allowances

12.3.1 The minimum corrosion allowance for tubes shall be 2.5 mm.

12.3.2 For all other pressure components the minimum corrosion allowance shall be 1.5 mm.

12.4 Structure and Casing

12.4.1 The gas path enclosure casing plate shall be an internal casing rectangular box open in both ends for entry and exit of the gas stream. Transition ducts shall be provided at the inlet and exit of the HRSG for connection to the gas source and to a duct or stack exhausting to the atmosphere.

12.4.2 Tubes, headers and drums shall be supported with an external structural framework integral to the casing plate.

12.5 Steam Generating and Super Heater Tubes

12.5.1 All tubes shall be seamless steel or Electric Resistance Welded (ERW) steel. ERW shall not be used for super heaters tubes.

12.5.2 All tubes shall have a minimum outside diameter of 50 mm.

12.5.3 Tube material shall be selected based on the highest anticipated metal temperatures and flue gas composition.

12.5.4 Tube configurations shall allow the free natural circulation of water and steam, in the proper direction, at all loads, and installed to allow complete draining of each tube.

12.5.5 All tubes shall be arranged to avoid soot buildup. Provision shall be made to allow removal of soot from the top of lower drums.

12.5.6 Tubes to HRSG drums shall be attached by rolling for drums with design pressures up to 8.27 MPa (1200 psig) as shown in Table 1.

12.5.7 Vertical tubes shall be supported or guided, or both, to prevent sagging and vibration, and also to permit expansion.

12.5.8 The minimum wall thicknesses of tubes shall be: 5 mm, for carbon steel and 3 mm for alloy steels.

12.6 Drums and Headers


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12.6.1 The maximum allowable working pressure, per the ASME Code shall be at least 7% or 100 KPa (15 psig), whichever is the greater above maximum operating drum pressure.

12.6.2 Downcomers and internals shall be designed to ensure positive circulation under all loads.

12.6.3 Steam drum sizing shall satisfy the following criteria:

a) The inside diameter shall be not less than 1220 mm with a ratio of length (tangent to tangent) to diameter no greater than 6:1.

b) The steam space shall be adequately sized to contain steam separation equipment necessary to attain the guaranteed steam purity specified throughout the control range.

c) The water holding capacity between the LWL and LLCO shall be sufficient to sustain one-minute evaporation at MCR with no feed water flow.

d) The LLCO shall be located not less than 50 mm above the top of the highest downcomer.

e) A rise in water level (swell) above the NWL resulting from the requirements specified in paragraph 12.2.8 shall not cause a carryover or actuation of the High Level Cut-Off (HLCO).

f) A fall in water level (shrinkage) below the NWL resulting from the requirements specified in paragraph 12.2.9 shall not cause the actuation of the LLCO.

12.6.4 When intermediate headers are required within a circulating circuit, restrictions to HRSG circulation caused by headers shall be considered. Headers shall be protected from flue gases heat.

12.6.5 Drum connections shall be a minimum of ¾ inch normal pipe size (NPS).

12.6.6 The wall thickness of connections up to and including 2 inch NPS shall be schedule 160 minimum.

12.6.7 Pipe sizes of 1¼ inch, 5 inch, and 7 inch NPS shall not be used.

12.6.8 A man way shall be provided at both ends of steam and water drums and provided with hinged covers.


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12.6.9 Header hand holes shall be provided with bolt-on type covers.

12.6.10 Drum connections shall be in accordance with Table 3.

Table 3 – Drum Connections

Service Description

Design Pressure

Type of End-Connection

Steam outlets All Welded

Safety valves All Flanged

Chemical feed with thermal sleeve All Flanged

Feed water inlet with thermal sleeve All Flanged Water columns, lower connection with thermal sleeve

Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

Test connections Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

Steam pressure gages Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

Vents Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

Sampling connections Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

Downcomer Tubes Under 8.27 MPa (1200 psig) 8.27 MPa (1200 psig) and above

Flanged Welded

Riser Tubes Under 8.27 MPa (1200 psig) 8.27 MPa (1200 psig) and above

Flanged Welded

Continuous and intermittent blow down

Under 4.48 MPa (650 psig) 4.48 MPa (650 psi) and above

Flanged Welded

12.6.11 The facings of flanged connections shall be either the raised face or ring joint types.

12.6.12 Steam and water drums shall be welded, post weld heat-treated, and 100% radio graphically tested in accordance with the ASME Code.

12.6.13 Headers shall be constructed of seamless steel pipe. Where needed to facilitate safety, operation, maintenance, and inspection, headers shall be provided with inlet nozzles, outlet nozzles, inspection openings, drains, vents, and connections for blow down, and chemical cleaning.

12.6.14 Drums with wall thicknesses 50 mm and thicker shall have nozzle connections as follows:

a) Connections 6 inch NPS and larger per Figures PW-9.1 (q-1), (q-2), (q-3), or (q-4) of ASME SEC I.

b) Connections 4 inch and less as per (1) above or Figure PW-9.1 (a), (b), (c), (g), or (h) of ASME SEC I.


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12.7 Steam Drum Internals

12.7.1 Steam drum internals shall consist of equipment for steam separation, feed water distribution, chemical feed distribution, and blow down.

12.7.2 Steam separation equipment shall consist of centrifugal separators, followed by primary and secondary chevron sections designed to meet the purity of steam specified in the Bid Package.

12.7.3 Proposals for other types of steam separation equipment must be included in the HRSG Manufacturer's proposal and must be substantiated with test results from a commercial units, that the steam purity entering the super heater will not exceed those specified in the Bid Package.

12.7.4 All internals shall be designed such that they can be removed without cutting.

12.7.5 The design of chemical feed distribution piping shall comply with the following:

a) Be extended through steam drums and be of sufficient length to ensure proper mixing of chemicals.

b) Be perforated

c) Closed at the far end with a threaded cap

d) Provided with a thermal sleeve.

e) Located in the steam drum to avoid short-circuiting of chemicals into the continuous blow down collection system.

12.7.6 HRSG feed water distribution piping shall be provided with a thermal sleeve and be extended through the steam drum to assure proper mixing of the feed water with the saturated recirculated water so that thermal shock is avoided.

12.7.7 The design of continuous blow down internal piping shall comply with the following:

a) Located in the area with the highest concentration of HRSG water impurities

b) Be extended as far as possible

c) Be perforated with holes not smaller than 9.5 mm or V-notched on the top

12.8 Water Drum Intermittent Blow Down


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12.8.1 Intermittent blow down nozzles shall be located on the lowest point of water drums. The size shall be based on water quality and operation, but shall not be less than 1½ inch nor greater than 2 inch NPS.

12.8.2 Separate drain valves shall be provided at the lowest point of water drums as a means for the draining of HRSGs.

12.9 Materials

12.9.1 All materials shall be in accordance with the ASME Code and the selection criteria in this specification for individual components.

12.9.2 The maximum tensile strength of tube materials shall be 775 MPa (112 Ksi).

12.9.3 Copper-bearing and aluminum alloys component materials are not permitted.

12.9.4 Cast iron, or cast steel fittings are not permitted.

12.9.5 When tube support design temperatures exceed 600°C and fuels contain a vanadium/sodium ratio between 3:1 and 18:1, tube supports shall be fabricated from high alloy materials: 60% Chromium-40% Nickel or 50% Chromium-50% Nickel materials. High alloy components shall not be welded to carbon steel components.

12.10 Valves

12.10.1 The selection of gate, globe and check valves shall be in accordance with the Code and Bid Package requirements.

12.10.2 Position indicator handles shall be supplied for all ball and plug type valves.

12.11 Super Heaters

12.11.1 Super heaters shall be located such that inlet tubes are not located in regions of highest flue gas temperatures.

12.11.2 Super heaters shall be -welded drainable type.

12.11.3 Flow equalization through super heater tubes shall be achieved by the sizing of tubes, inlet header, and outlet headers. Tube inlet restrictions, including swaging, are not permitted.

12.11.4 Super heater steam flow should not be less than 0.95 of the average steam mass flow.


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12.11.5 Super heater elements shall be located and supported to prevent vibration, sagging, and misalignment.

12.11.6 Super heater headers and supports shall be located outside gas spaces. All headers shall be provided with drain and vent connections. Intermediate and outlet headers shall be provided with thermo well, test gage, pressure transmitter, and pressure gage connections. The outlet header shall be provided with connections for safety valves and startup vent. All outlet header connections shall be located upstream of the startup vent.

12.11.7 The startup vent and its discharge stack shall be sized for not less than 35% MCR steam flow, and shall be provided with a silencer. Silencers shall be provided with suitable drains for condensate removal, and piped to sewer.

12.12 Desuper Heaters

12.12.1 Desuper heaters shall be of the water-spray design.

12.12.2 Oil-free condensate or demineralized HRSG feed water shall be used as spray medium.

12.12.3 A spray-type desuper heater mixing chamber with an alloy steel liner shall be provided.

12.13 Economizers

12.13.1 Economizers shall be designed for upward water flow. The water outlet connection shall be located below the LLCO of the steam drum.

12.13.2 The selection of economizer materials shall be based on the flue gas composition and the maximum metal temperature developed during minimum load operation.

12.13.3 A full-size water bypass with double block valves shall be provided for the startup and maintenance of economizers susceptible to acid dew point corrosion. Economizer shall be provided with a block valve and a safety valve.

12.13.4 Tubes shall be arranged in staggered rows for clean flue gas service and in straight (in-line) rows for fouling service and liquid fuel services.


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12.13.5 Economizer tubes subjected to acid dew point corrosion attack at any load under clean HRSG operating conditions, shall be of the in-line tube arrangement.

12.13.5 Finned tubes, with a maximum of five fins per 25 mm, may be used where the products of combustion are considered to be clean. The fins shall be attached by high-frequency continuous resistance welding. The fin thickness shall be a minimum of 1.25 mm and the fin height shall not exceed 25 mm.

12.13.6 Finned tubes are not acceptable for heavy liquid fuel firing, but may be used for light distillate fuel firing where tube metal temperatures are greater than those determined in paragraph 12.13.17, with a maximum of three fins per 25 mm.

12.13.7 The materials of construction of tubes and tube sheets shall be selected based on the Acid Dewpoint Corrosion Temperature (ADCT) plus 28°C. The value of the ADCT shall be calculated on the basis of a 5% conversion of sulfur dioxide to sulfur trioxide.

12.14 Ductwork

12.14.1 Ducts shall be designed, arranged, and installed in a manner to prevent vibration, distortion, and undue noise.

12.14.2 Ducts shall be gastight. The maximum velocity of flue gas shall not exceed 8.24 m/s.

12.14.3 Ducts shall be capable of withstanding an internal transient pressure of 14 KPa (2 psi).

12.14.4 The minimum thickness of flue gas ducts shall be 4.8 mm.

12.14.5 Where more than one HRSG exhausts to a common stack, an isolating plate, complete with davits, and flange spreaders, shall be provided in the discharge ducting of each HRSG. Isolation plates shall be designed for tight shut-off and maximum fan discharge pressure.

12.14.6 Flanged connections shall be complete with flanges, erection bolts, and nuts. Flanges shall be seal welded in the field.

12.14.7 Ductwork shall be shop-fabricated for field assembly, including the installation of supports required for external insulation or internal refractory lining.


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12.14.8 An expansion joint manufactured from a suitable fabric shall be provided between force draft fans and the discharge ducting to HRSG.

12.14.9 Internal lining shall be provided where the metal temperature is less than the calculated value for ADCT.

12.15 Stacks

12.15.1 Unless otherwise specified per DATA SHEET, stacks shall be furnished by the HRSG Manufacturer. The minimum stack height above grade shall be 45 m

12.15.2 HRSGs shall be designed to operate in compliance with local environmental regulations.

12.15.3 The HRSG Manufacturer shall calculate and guarantee emission rates of nitrogen oxides and sulfur oxides. The emission rates shall be expressed in Lb/MM BTU's when the HRSG is operated at its design rate firing the fuels specified. Flue gas emissions (NOx, CO, particulates, hydrocarbons, etc.) shall not exceed the specified levels.

12.15.4 Where the stack metal temperature at any operating load can be less than the calculated value for ADCT a 50-mm castable refractory lining shall be provided.

12.15.5 All external attachments to the shell shall be continuously welded.

12.16 Insulation and Refractories

12.16.1 Headers, drums, air heaters, economizer casings, wind boxes, external super heater headers, exposed tubes, hot gas ducts, hot air ducts, steam turbines, and other heated and exposed surfaces shall be insulated in accordance with Saudi Aramco Requirements.

12.16.2 The design and installation of refractory systems shall be design not to exceed a cold face temperature of 65°C at 50°C ambient.

12.16.3 Corners of insulation on ductwork shall be protected with metal corner beading. Insulation on ducts shall be properly supported and securely fastened.

12.16.4 Clips or welding studs for holding wires and bands shall be spaced a maximum of 450 mm on center. Exposed supports, duct doors, and other parts that project through the insulated surfaces shall be insulated for protection of personnel.


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12.16.5 Where the metal temperature of a duct, at any operating load, is less than the calculated value of the ADCT a 50 mm castable refractory lining shall be provided.

12.17 Noise Attenuation

12.17.1 The Sound Pressure Levels (SPL) and Sound Power Levels (PWL) at the designated locations shall be per Data Sheets.

12.17.2 The HRSG Manufacturer shall ensure that the required limits as specified for SPL and PWL can be achieved by supplying test results of a representative HRSG.

12.17.3 HRSGs shall be designed and provided with the acoustical treatment necessary to meet the specified noise levels. This shall include burner mufflers and acoustical lining for plenums, ducts, and stacks, vent silencer as required.

12.18 Connections, HRSG Trim, and Instruments

12.18.1 The HRSG Manufacturer shall supply all connections and equipment in accordance with this specification.

12.18.2 All instrument connections, except thermo wells, shall be provided with separate block valves to permit removal of devices without affecting other active devices.

12.18.3 Steam drum connections shall be provided with level instrumentations.

12.18.4 Connections shall be provided for the chemical cleaning of HRSGs, super heaters, and economizers.

12.18.5 Drain connections shall be provided for draining all water after shutdown or boil out. Valves shall be 2 inch NPS minimum and located at the lowest point on the water drum to allow complete drainage of HRSGs in one hour or less at a pressure of 35 KPa g (5 psig).

12.18.6 Connections shall be provided for the quick draining of all accumulated water in areas of furnaces, super heaters, HRSG banks, and economizers following water washing of external tube surfaces.

12.18.7 The minimum HRSG trim requirements to be provided by the HRSG Manufacturer, shall be as follows:


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a) Safety valves for drums, super heater outlets, and economizers in accordance with the requirements of the ASME Code. Valves shall be complete with discharge piping to a point 3 m above the nearest platform. Safety valves shall be equipped with lifting levers.

b) A steam outlet stop valve and a screw-down nonreturn valve, each with a pressure-sealed bonnet and of approved HRSG quality. A pressure-equalizing warm-up line of not less than 2 inch NPS shall be provided around stop valve.

c) Intermittent blow down valves, using two valves in series at each blow down nozzle. The outside valve shall be quick opening, except at water wall headers.

d) HRSG feed water shutoff and check valves.

e) HRSG vent valves, using two valves in series at each location.

f) Valves for obtaining representative saturated steam samples, using two valves in series (double block) at each takeoff from the steam drum. If the HRSG design includes a series of small-diameter tubes between the steam drum and super heater header, the sample points shall be spaced no more than 1.5 m apart. Sample connections shall be in accordance with ASTM D1066.

g) Continuous blow down valves, using two valves in series. The downstream control valve shall be a hand-operated, V-port valve with a micrometer indicator or a V-port valve with TDS/conductivity control.

h) Chemical feed valves, using two block valves in series and a check valve.

i) Super heater drain and vent valves, using two valves in series at each location.

j) Lower header drain valves, using two valves in series for each connection.

A sample connection with two valves in series for obtaining representative water samples. The sample connection shall be located upstream of the continuous blow down control valve.

k) Lower drum drain valves, using two valves in series at each location.


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l) Valves for obtaining representative final steam samples, using two valves in series at each takeoff point on the super heater discharge piping. Sample points shall be in accordance with ASTM D1066.

m) Three sample coolers (in accordance with ASTM D1066), each with a rack, valving and drainage through. The sample piping and valving shall be arranged such that HRSG water, saturated steam, and final steam each have a dedicated cooler.

n) Desuper heater water shutoff and check valves.

o) Economizer outlet stop valve and screw down no return valve, where a water bypass is included.

p) Economizer water bypass stop valve and a screw-down non-return valve, if a bypass is included.

q) Economizer safety valve (in accordance with the Code) if a bypass is included.

12.18.8 The minimum piping to be supplied by the HRSG Manufacturer shall be as follows:

a) Steam piping from the super heater outlet header to the main stop valve

b) Interconnecting steam piping between super heater stages and the desuper heater

c) Saturated steam piping from the steam drum to the super heater inlet header

d) Interconnecting piping from the economizer to the steam drum

e) HRSG feed water piping from the check valve to the economizer inlet header

f) Complete piping for the sealing air system, from the FD fan to all users

g) Complete piping for the aspirating air system from a single point supply connection to all users

h) All drain piping from the source to 1 m above grade

12.18.9 Instrumentation and Safety Relief shall be provided in accordance NFPA 85C and the following:


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a) Sample connections for oxygen and combustible analyzers at HRSG outlet.

b) Connections for the measurement of opacity, particulate matter, sulfur dioxide, nitrogen oxides, oxygen, and carbon monoxide.

c) Connections for draft gauges at HRSG inlet and outlet.

d) A minimum of four knife-edge thermocouple devices mounted on selected super heater tubes to measure tube metal temperatures.

e) Thermocouple wells for measuring the steam temperature after each stage of super heaters, including the steam temperature before and after the desuper heater. Thermo wells shall also be provided for measuring the temperature of the feed water to and from the economizer.

12.19 Painting

12.19.1 Exposed surfaces shall be prepared and painted per specifications DATA SHEET.

12.19.2 Gasket contact surfaces shall not be painted.

12.20 Fabrication

12.20.1 The layout of shell plates, heads, and head plates shall be made in such a manner that manways, nozzles and their reinforcement are not located within any weld seams. Manways, nozzles and their reinforcement shall not be located within 50 mm of any weld seam.

12.20.2 All nozzles and manways shall be ground flush to the inside curvature of the drums and headers, and inside diameters shall be radiuses smooth.

12.20.3 Where a split-reinforcing pad is required, the weld joining the pad sections shall be oriented with the circumferential direction of the shell. Tapped tell-tale holes ¼ inch NPT shall be provided as follows:

a) One hole in all single piece-reinforcing pads.

b) Where a pad is split, each segment shall have at least one tapped hole.

12.20.4 Internal and external non-pressure-welded attachments shall be fully seal welded and shall have radiuses corners.


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12.20.5 External non-pressure attachments shall be vented through a ¼ inch NPT telltale hole.

12.20.6 Welding shall be in accordance with ASME 1.

12.21 Nameplates and Stampings

12.21.1 HRSGs manufactured both in Saudi Arabia and outside Saudi Arabia shall be ASME Code stamped.

12.21.2 Nameplates and nameplate mounting bracket shall be located such that they will not be covered by insulation and are easily readable from grade or a platform.

12.22 Drawings, Calculations and Data

12.22.1 The HRSG manufacturer shall prepare and submit for approval and review the preliminary and certified drawings and data.

12.22.2 Drawings and calculations, which are provided in Data Sheets, shall not relieve the HRSG Manufacturer from any responsibilities to comply with the ASME Code, and this specification.

13 Inspection

Saudi Aramco reserves the right to inspect parts during manufacturing, review manufacturing procedures, check dimensions against drawings and review materials, repairs, castings, etc. Saudi Aramco also reserves the right to monitor the Suppliers subcontractors where desired.

14 Combustion Gas Turbine/Generator Factory Tests

14.1 Combustion Gas Turbine factory tests shall include but not be limited to:

a) All pumps tested for capacity, head and efficiency

b) Dynamic balancing of compressor and turbine rotors

c) Turning gear assembly

d) Rotor over speed

e) Thermal stability

f) Complete assembly with rotor to establish operating clearance

g) Starting system

h) Tests specified for electrical equipment as detailed in the electrical specifications


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i) Interlock and control system test

14.2 The generator shall be subject to standard factory tests in accordance with ANSI C50.13 or IEC 34-4, which shall include the following:

a) Mechanical inspection (including air gap measurement)

b) Mechanical balance

c) Over speed run.

d) Measurement of cold resistance of armature and field windings

e) Insulation resistance measurement of armature and field windings using a 500 volt megger

f) Polarization index

g) Dielectric test of armature and field windings

i) Stator - The standard test voltage shall be an effective value of 1000 volts plus twice the rated voltage of the generator. This test shall be applied for 60 seconds duration prior to shipment of the generator stator.

ii) Field - The standard test voltage shall be an alternating voltage with an effective value of 10 times the rated excitation voltage, but not less than 1500 volts. This test shall be applied for 60 seconds duration prior to shipment to the generator rotor.

h. Resistance temperature detector

i. Voltage balance and phase sequence

j. Open circuit saturation curve

k. Rotor impedance

l. Short circuit saturation curve

m. Harmonic analysis and measurement TIF

n. Heat run test

o. Short circuit tests at reduced voltage to determine reactance and time constants

p. Measurement of segregated losses

q. Measurement of bearing insulation resistance

14.3 The static excitation components shall receive standard factory tests as follows:


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14.3.1 Current Transformers and Power Potential Transformers shall receive the following tests if type test is not available:

a. DC resistance of all windings

b. Voltage ratio test

c. Polarity check

d. Exciting current

e. High potential tests on windings at 60 Hz

f. Induced potential tests at twice operating voltage for 400 cycles

14.3.2 Excitation Cubicle:

a. High potential tests on all circuits to ground

b. Device operational checks

c. Rectifier voltage drop at reduced current through rectifier

d. Reverse leakage test for all rectifiers in generator field circuits

e. Regulator gain test

14.3.3 Rotating Alternator Exciter:

a. Balancing of rotor.

b. Over speed run.

c. Measurement of cold resistance of windings

d. Measurement regulation of saturation and voltage

e. Measurement of insulation resistance using a 500 Volt mugger.

f. Polarization index.

g. Dielectric tests.

14.3.4 All running tests for turbine, generator and exciter shall be conducted at the voltage, phase, cycles, rpm, etc., at which the equipment will operate at the site.

15 Field Performance Test

15.1 The combustion gas turbine generator unit shall be tested by the Contractor in accordance with the ASME PTC 22.

15.2 The Contractor shall submit, for Saudi Aramco approval, detailed procedures and programs for all tests to be performed. The Contractor shall also submit, for Saudi Aramco approval, detailed procedures for extrapolation of test results to


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prove guarantees at site conditions. Preliminary test procedures, test program and extrapolation of test results and procedures shall be included in the proposal. The performance test shall be performed on a complete assembled unit.

15.3 The unit instrumentation and monitoring system shall be the primary source for test data, if additional instrumentation is required Supplier shall supply.

15.4 Prior to the performance test the unit shall be adjusted and operated under load to demonstrate reliable commercial operation.

15.5 Saudi Aramco will witness the performance tests and the data collection. The test shall include the following load points:

a. 25% rated load b. 50% rated load c. 75% rated load d. 100% rated load e. Peak load f Duration of startup from cold and warm conditions

15.6 Performance test shall also demonstrate all local and remote control operations.

15.7 Functional and operational test of the turbine generator and all accessories systems. Shall include but not limited to the followings:

15.7.1 Continuity and insulation resistance check and correctness of all power and control wiring

15.7.2 Insulation resistance and polarization index of main generator and exciter windings

15.7.3 DC high potential tests (at 85% of factory test potential) on main and field windings and on main power connections

15.7.4 Preliminary operational tests of complete assembly, including checking of performance, temperatures, noise and vibration

15.7.5 Contractor shall submit fifteen (15) copies of certified field performance tests to Saudi Aramco for record

16 HRSG Inspection and Equipment Testing

16.1 Inspection


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16.1.1 All materials and fabrication shall be subject to inspection by the Saudi Aramco Inspector in accordance with Saudi Aramco Inspection Requirements.

16.1.2 Written reports and evaluations of all inspections performed by the HRSG Manufacturer shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector.

16.1.3 Written reports and evaluations of all inspections performed by the Vessel Manufacturer shall be made and submitted to the Saudi Aramco Inspector, at a frequency to be determined by the Saudi Aramco Inspector.

16.1.4 Prior to final inspection and pressure testing, the inside and outside of HRSGs shall be thoroughly cleaned of all slag, scale, dirt, grit, weld spatter, paint, oil, etc.

16.1.5 The Saudi Aramco Inspector shall have free access to the work at all times.

16.1.6 All materials, except carbon steels, shall be alloy verified in accordance with Saudi Aramco Requirements.

16.1.7 Refractory linings and materials shall be inspected in accordance with Saudi Aramco Requirements.

16.2 Nondestructive Testing

16.2.1 All Nondestructive Testing (NDT) shall be performed in accordance with the HRSG Manufacturer's written procedure prepared in accordance with ASME SEC V with the scope of NDT and acceptance/rejection criteria as defined by the Code and this specification.

16.2.2 All NDT on HRSG drums, which are to be post weld and heat-treated, shall be made after post weld heat treatment.

16.2.3 All pressure and non-pressure welds shall be visually inspected.

16.2.4 If any of the tube casting go a liquid penetrate inspection test failed to meet the minimum requirements of ASME SEC I, PG-25, then all tubes shall go a radiographic test.

16.2.5 Areas of stress concentration in corners of castings, especially at support lugs, shall be radio graphically inspected. At least two spot


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radiographs shall be taken of the lower flanges of each cast tube support section.

16.2.6 One random spot radiograph shall be made for each girth weld and one random radiograph for each two vertical welds of a stack shell. In addition, each vertical and circumferential welds intersection shall be radio graphed in the circumferential direction.

16.2.7 All butt-welds on HRSG piping, 32-mm wall thickness and thicker shall be ultrasonically tested. Ultrasonic examination and interpretation shall be in accordance with ASME SEC VIII.

16.2.8 Tube sheets and forgings 50 mm and thicker shall be ultrasonically tested in accordance with A435.

16.2.9 Beveled edges of carbon steel plates with thickness 25 mm and thicker and all ferrous alloy plates shall be magnetic particle examined for linear discontinuities. Defects shall not exceed limits as per A12.

16.2.10 All internal and external welds for all services made using the submerge metal arc weld (SMAW) welding process when the nominal thickness of pressured components is 25 mm and thicker shall be magnetic particle tested.

16.2.11 Weld hardness testing shall be in accordance with the requirements of Saudi Aramco Requirements.

16.3 Post Weld Heat Treatment

16.3.1 Code exemptions from ASME requirements for post weld heat treatment of ferritic materials based on the use of austenitic or nickel-based electrodes are not permitted.

16.3.2 The maximum post weld heat treating soaking temperature for carbon steel and C-½ Mo materials shall not exceed the temperature at which the test pieces were heat treated, as shown on the Mill Test Certificates or 650°C for carbon steel and 690°C for C-½ Mo.

16.3.3 The maximum post weld heat treating soaking temperature for low-chrome alloy steels shall not exceed the tempering temperature at which test pieces and components were heat treated as shown on Mill Test Certificates, but shall be not less than 700°C.

16.3.4 Post weld heat treatment shall follow all welding and repairs but shall be performed prior to any hydro test or other load test.


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16.3.5 Post weld heat-treating shall be in accordance with ASME 1.

16.4 Performance Testing

16.4.1 A performance test, shall demonstrate complete and smokeless combustion without flame impingement on the furnace heating surface or flame penetration through the furnace exit screen, at all loads within the burner turndown range, and with any fuel or combination of fuels available at the time of the test on each of HRSG.

16.4.2 A test procedure shall be provided by the HRSG Manufacturer, which shall be approved by the Saudi Aramco Inspector including the criteria by which the onsite test results shall be judged for conformance.

16.4.3 Test connections shall be provided by the HRSG Manufacturer to verify combustion air, fuel balances between burners, and combustion airflow during commissioning and normal operation.

16.4.4 If the results of a performance test do not conform with the acceptance criteria, the HRSG Manufacturer shall immediately correct the deficiencies so that the HRSG meets the guaranteed performance.

16.4.5 HRSG efficiency shall be based on the higher heating value of the fuel, and the tests shall be made in accordance with ASME PTC 4.1, Performance Test Code (Abbreviated Method).

16.4.6 Unless otherwise specified, the acceptance test shall be performed by the HRSG Manufacturer's representative after commissioning.

16.4.7 Hydrostatic test of all pre-assembled pressure-containing sections shall be preformed in accordance with the ASME Code.

16.4.8 A smoke or soap test of all pre-assembled sections shall be preformed.

16.5 HRSG Performance Guarantees

The followings shall be guaranteed for the length of the warranty period specified in the purchase order or contract documents:

16.5.1 Super heater outlet pressure and temperature at non-return valve downstream as specified on the DATA SHEET operating between 25% and 100% of maximum continuous rating (MCR).

16.5.2 Efficiency at 50%, 70% and 100% MCR with steam conditions and CGTG fuels fired as specified.


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16.5.3 Unless otherwise specified on the DATA SHEET, a maximum concentration of 100 ppb (parts per billion) total dissolved solids (TDS) and 20 ppb each of sodium and silica in saturated steam at any load within a HRSGs controlled range.

17 GSU Performance Testing

Factory Tests - All routine tests specified in ANSI C57.12.00, Article 8.2.1, plus Impulse Tests, Switching Surge Test, Partial Discharge Test, power factor test, insulation resistance test, ratio test, additional tests as specified herein, shall be performed on each transformer. In addition, all routine tests specified in ANSI C57.12.00, Article 8.3, shall be performed on each transformer.

Revision Summary 31 August, 2002 New Saudi Aramco Materials System Specification. 30 September, 2002 Editorial revision to add IEC 34-4 and delete ANSI B133.1-12, ANSI C37.13 & UL 489

under Section 3 References.


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Co-Generation Train - Generator

Data Sheet

*Denotes information to be furnished with the proposal **Denotes information to be furnished upon receipt of purchase order Information not marked should be provided by the purchases, marked as not applicable by the purchases, or marked for generator or drive vendor to provide. ITEM NO. DESCRIPTION DETAILS 1 Buyer's Purchase Order/Quotation Request ____________ Buyer's Budget Item/Job Order Number ____________ Buyer's Line Item Number ____________ 2 SAMSS Attachments & Supplements 36-SAMSS-001 4 BASIC DATA Number of Phases (Three) Three Kva Base at Rated Voltage and 25°C KVA ____________ Frequency (Hz) 60 Power Factor (P.F.) ____________ Synchronous RPM RPM ____________ Minimum Power Requirements ____________ Minimum Number of Units ____________ 5 DESIGN SITE DATA: Elevation Ft ____________ Site Maximum Ambient Temperature °F ____________ Site Minimum Ambient Temperature °F ____________ Site DESIGN Ambient Temperature °F ____________ Relative Humidity @ Site DESIGN Temperature % ____________ Average Rainfall / Year Inches ____________ 6 EQUIPMENT REQUIREMENT: a) ENCLOSURE TEFC (Yes/No) ____________ TEAAC (Yes/No) ____________ TEWAC (Yes/No) ____________ Special Notes: ____________

7 ELECTRICAL SYSTEM CONDITIONS: 1) Short Circuit Design at Generator Bus kAIC ____________ X/R Ratio ____________

2) Type System Grounding: DISTRIBUTION TRANSFORMER (Yes/No) ____________ RESISTOR (Yes/No) ____________ Combination Transformer / Resistor (Yes/No) ____________ Maximum Ground Fault Amperes ____________

3) Parallel Operation Requirements (Yes/No) ____________ a) Utility ____________ b) Other Generators (Yes/No) ____________ (Yes/No) ____________


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ITEM NO. DESCRIPTION DETAILS

8 GENERATOR TO COMPLY WITH IEEE : 1) Generator Parameters (State Per Unit Values, Generator) ____________ Amature Leakage Reactance (Saturated) X1 ____________ Amature Leakage Reactance (Non-Saturated) X1 ____________ Direct Axis Synchronous Reactance (Saturated) X2 ____________ Direct Axis Synchronous Reactance (Non-Saturated) X2 ____________ Potier Reactance (Saturated) Xp ____________ Potier Reactance (Non-Saturated) Xp ____________ Field Resistance (Without FDRs) Rf ____________ Field Resistance (With FDRs) Rfr ____________ Direct Axis Transient Reactance (Saturated) X'd ____________ Direct Axis Transient Reactance (Non-Saturated) X'd ____________ Direct Axis Subtransient Reactance (Saturated) X"d ____________ Direct Axis Subtransient Reactance (Non-Saturated) X"d ____________ Quadrature Axis Synchronous Reactance (Saturated) Xq ____________ Quadrature Axis Synchronous Reactance (No-Saturated) Xq ____________ Quadrature Axis Transient Reactance (Saturated) X'q ____________ Quadrature Axis Transient Reactance (Non-Saturated) X'q ____________ Quadrature Axis Subtransient Reactance (Saturated) X"q ____________ Quadrature Axis Subtransient Reactance (Non-Saturated) X"q ____________ Zero Sequence Reactance X0 ____________ Stator Armature Resistance Ra ____________ Zero Sequence Resistance R0 ____________ Positive Sequence Resistance R1 ____________ Negative Sequence Resistance R2 ____________ Direct Axis Transient Open-Circuit Time Conatant T'do sec ____________ Quadrature Axis Transient Open-Circuit Time Conatant T'qo sec ____________ Direct Axis Subtransient Open-Circuit Time Conatant T"do sec ____________ Quadrature Axis Subtransient Open-Circuit Time Conatant T"qo sec ____________ Direct Axis Transient Short-Circuit Time Conatant T'd sec ____________ Direct Axis Subtransient Short-Circuit Time Conatant T" sec ____________ 2) * Calculated Expected Data at the Following Loads: Amperes ½ LOAD ____________ Amperes ¾ LOAD ____________ Amperes Full LOAD ____________ Efficiency ½ LOAD ____________ Efficiency ¾ LOAD ____________ Efficiency Full LOAD ____________ Guaranteed Efficiency at PF ____________

Daily Swing Range Max value ____________

Daily Swing Range Min value ____________ Rate of Load change ____________

3) * Rated Generator Field: Amps ____________ Volts ____________ 4) * Rated Exciter Field: Amps ____________ Volts ____________


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ITEM NO. DESCRIPTION DETAILS

9 Line Side Termination

a) Type: Junction Box/Throat ____________ Position (Top / Side) ____________ Take-off Angle (Vert/Hor/Angle) ____________

b) Junction Box Type Cable Size (mm²) ____________ Conductor Size and Type Stranded mm² ____________ Tube IPS-in. ____________ Conductor Material (Copper/Aluminum) ____________ Number of Conductors per Phase ____________

c) Throat Connection (Buyer will supply full details after award of contract)

d) Accessories Surge Capacitor Required (Yes/No) ____________ Surge Arresters Required (Yes/No) ____________ 10 Current Transformers

a) Line Side Relaying | Metering Number Required per Phase ______ _____ Accuracy Class (C-/100/200/400/800 or 0.3/0.6/1.2) ______ _____ Standard Burden (B-1/2/4/8, or B-0.1/0.2/0.5/0.9/1.8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ Cont. Thermal Current Rating Factor 1.33 1.33

b) Neutral Side Relaying | Metering Number Required per Phase ______ _____ Accuracy Class (C-/100/200/400/800 or 0.3/0.6/1.2) ______ _____ Standard Burden (B-1/2/4/8, or B-0.1/0.2/0.5/0.9/1.8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ 11 Potential Transformers

a) Line Side Relaying | Metering Quantity ______ _____ Accuracy Class ( ) ______ _____ Standard Burden ( ) ______ _____ Primary Voltage (Volts) ______ _____ Secondary Voltage (Volts) ______ _____ Ratio ______ _____


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ITEM NO. DESCRIPTION DETAILS 12 Terminal Box Space Heaters Required:

a) Line Side Cubical Quantity ____________ Voltage Volts ____________ Number of Phases Phase ____________ Wattage kW ____________

b) Neutral Side Cubical Quantity ____________ Voltage Volts ____________ Number of Phases Phase ____________ Wattage kW ____________

c) Generator & Windings Quantity ____________ Voltage Volts ____________ Number of Phases Phase ____________ Wattage kW ____________


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Co-Generation Train

Generator Step-Up Transformer Unit (GSU) Data Sheet

ITEM NO. DESCRIPTION DETAILS 1 Buyer's Purchase Order/Quotation Request ____________ Buyer's Budget Item/Job Order Number ____________ Buyer's Line Item Number ____________ 2 SAMSS Attachments & Supplements 36-SAMSS-001 4 Number of Phases (Three) Three Temperature Rise (C) 65°C Frequency (Hz) 60 Transformer Type (2 or 3 winding) ____________ Coolant (Mineral Oil-Immersed) Oil-Immersed Operation (Step-up) ____________ Angular Displacement (ANSI or IEC 60076) ____________ Impedance (% at 85°C on OA Base) ANSI: Other: Forced Cooling & Controls (Yes/No) ____________ Fan or Pump Motor Voltage & Phases V / Ph 5 Loss Evaluation Constants

a) Currency of Evaluation Symbol ____________ b) No-load Loss Constant A Cost/Kw ____________ c) Load Loss Constant B Cost/Kw ____________ 6 High Voltage Winding

Continuous OA/FA/FOA Ratings (kVA) ____________ Voltage Rating (kV) ____________ Winding Connection (Delta, Wye) ____________ Neutral Grounding (Solid, Ungrounded) ____________ Winding BIL Level (kV) ____________ Neutral BIL Level (kV) ____________ Surge Arresters

a) Mounted Complete (Yes/No) ____________ b) Provisions only for - Manufacturer: ____________ Catalog Number: ____________ c) Voltage Rating (kV) ____________ d) Ground Plugs (Yes/No) ____________ e) Neutral Terminal (kV) ____________


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ITEM NO. DESCRIPTION DETAILS 7 Low-Voltage Winding

Continuous OA/FA/FOA Ratings (kVA) ____________ Voltage Rating (kV) ____________ Winding Connection (Delta, Wye) ____________ Neutral Grounding (Solid, Ungrounded) ____________ Winding BIL Level (kV) ____________ Neutral Grounding (Solid, Ungrounded) ____________ Winding BIL Level (kV) ____________ Neutral BIL Level (kV) ____________ Surge Arresters

a) Mounted Complete (Yes/No) ____________ b) Provisions only for - Manufacturer: ____________ Catalog Number: ____________ c) Voltage Rating (kV) ____________ d) Ground Pads (Yes/No) ____________ e) Neutral Terminal (kV) ____________ 8 High Voltage Winding Termination

Type: Bushings/Junction Box/Throat Position (Top Cover/Tank Side) ____________ a) Outdoor Bushings Line-end BIL (kV) ____________ Neutral-end Bil (kV) ____________ Color (Brown/Grey) ____________ Terminal Type (Stud/NEMA Pad) ____________ Take-off Angle (Vert/Hor/Angle) ____________ Conductor Size and Type Stranded mm² ____________ Tube IPS-in. ____________ Conductor Material (Copper/Aluminum) ____________

b) Junction Box Type (Cable, Conduit, Separable Connectors) ____________

1) Cable Junction Box Cable Size (mm²) ____________ Cable Type ____________ Number of Cables ____________ Number of Potheads ____________ Number of Conductors per Phase ____________

2) Conduit Junction Box Conduit Size (inch) ____________ Number of Hubs ____________ Entry Location (Top/Bottom) ____________ Conductor Size (mm²) ____________ Conductor Material (Cu/Al) ____________

3) Separable Connectors (Yes/No) ____________

c) Throat Connection (Buyer will supply full details after award of contract)


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ITEM NO. DESCRIPTION DETAILS 9 Low-Voltage Winding Termination

Type: Bushings/Junction Box/Throat Position (Top Cover/Tank Side) ____________ a) Outdoor Bushings Line-end BIL (kV) ____________ Neutral-end Bil (kV) ____________ Color (Brown/Grey) Brown Terminal Type (Stud/NEMA Pad) ____________ Take-off Angle (Vert/Hor/Angle) ____________ Conductor Size and Type Stranded mm² ____________ Tube IPS-in. ____________ Conductor Material (Copper/Aluminum) ____________

b) Junction Box Type (Cable, Conduit, Separable Connectors) ____________



3) Separable Connectors (Yes/No) ____________

c) Throat Connection (Buyer will supply full details after award of contract) 10 Tap Changer Type

Type: (De-energized/Load) ____________ Tap kVA Ratings (Full/Reduced-Capacity) ____________ Location (High Voltage/Low Voltage) ____________ Number of Steps Above: ____________ Below: ____________ Step Size (Percent) ____________ Mechanical Key Interlock (Yes/No) ____________ Compartment Pressure-Rise Relay (Yes/No) ____________ Load Tap Changer Control (If applicable) ____________ Local Control (Yes/No) ____________ Remote Control (Yes/No) ____________ Manual Control (Yes/No) ____________ Supervisory Control (Yes/No) ____________ Position Telemetering (Yes/No) ____________ Automatic Voltage Control (Yes/No) ____________ AC Reference Voltage (RMS Nominal) ____________ Parallel Operation Required (Yes/No) ____________ Line Drop Compensator (Yes/No) ____________ Motor Supply Voltage, Phase (AC RMS) ____________


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ITEM NO. DESCRIPTION DETAILS 11 Current Transformers

a) High-Voltage Windings/Bushings Relaying | Metering Number Required per Phase ______ _____ Accuracy Class (C-/100/200/400/800 or 0.3/0.6/1.2) ______ _____ Standard Burden (B-1/2/4/8, or B-0.1/0.2/0.5/0.9/1.8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ Cont. Thermal Current Rating Factor 1.33 1.33

b) Low-Voltage Windings/Bushings Relaying | Metering Number Required per Phase ______ _____ Accuracy Class (C-/100/200/400/800 or 0.3/0.6/1.2) ______ _____ Standard Burden (B-1/2/4/8, or B-0.1/0.2/0.5/0.9/1.8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ Cont. Thermal Current Rating Factor 1.33 1.33

c) Winding Neutral End/Bushing HV LV Number Required ______ _____ Location (Bushing/External) ______ _____ Accuracy Class (C-50/100/200/400/800) ______ _____ Standard Burden (B-1/2/4/8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ Cont. Thermal Current Rating Factor 1.33 1.33 12 Additional ANSI Test Requirements

Zero Sequence Impedance (Yes/No) ____________ 13 Miscellaneous & Accessories

Combustible Gas Detector (Buchholz relay) (Yes/No) ____________ Padlockable Drain Valve (Yes/No) ____________


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ITEM NO. DESCRIPTION DETAILS 1 Tertiary-Voltage Winding (if applicable) (Third Winding)

Continuous OA/FA/FOA Ratings (kVA) ____________ Voltage Rating (kV) ____________ Winding Connection (Delta, Wye) ____________ Neutral Grounding (Solid, Ungrounded) ____________ Winding BIL Level (kV) ____________ Neutral BIL Level (kV) ____________ Simultaneous Loading of Tertiary (kVA) ____________ 2 Impedance (% at 85°C on Tertiary OA base) High Voltage to Tertiary ____________ Low Voltage to Tertiary ____________ 3 Tertiary-Voltage Winding Termination

Type: (Bushings/Junction Box/Throat) ____________ Position (Top Cover/Tank Side) ____________ a) Outdoor Bushings Line-end BIL (kV) ____________ Neutral-end Bil (kV) ____________ Color (Brown/Grey) Brown Terminal Type (Stud/NEMA Pad) ____________ Take-off Angle (Vert/Hor/Angle) ____________ Conductor Size and Type Stranded mm2 ____________ Tube IPS-in. ____________ Conductor Material (Copper/Aluminum) ____________ b) Junction Box Type (Cable, Conduit, Separable Connectors) ____________



3) Separable Connectors (Yes/No) ____________ c) Throat Connection (Buyer will supply full details after award of contract)


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ITEM NO. DESCRIPTION DETAILS 4 Surge Arresters

a) Mounted Complete (Yes/No) ____________ b) Provisions only for - Manufacturer: ____________ Catalog Number: ____________ c) Voltage Rating (kV) ____________ d) Ground Plugs (Yes/No) ____________ e) Neutral Terminal (kV) ____________ 5 Current Transformers Relaying | Metering

a) Bushings Number Required per Phase ______ _____ Accuracy Class (C-/100/200/400/800 or 0.3/0.6/1.2) ______ _____ Standard Burden (B-1/2/4/8, or B-0.1/0.2/0.5/0.9/1.8) ______ _____ Primary Current Rating (Amperes) ______ _____ Secondary Current Rating (Amperes) 5 5 Number of Ratios (Single/Dual/Multi) ______ _____ Cont. Thermal Current Rating Factor 1.33 1.33 b) Inside Delta (Polarizing) Relaying | Metering Number Required per Phase ____________ Accuracy Class (C-100/200/400/800) ____________ Standard Burden (B-1/2/4/8) ____________ Primary Current Rating (Amperes) ____________ Secondary Current Rating (Amperes) 5 Number of Ratios (Single/Dual/Multi) ____________ Cont. Thermal Current Rating Factor 1.33


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Co-Generation Train Heat Recovery Steam Generator (HRSG) Data Sheet

Attachment 1

Performance Guarantees

The following guarantees shall be made for HRSG at both the maximum unfired output condition and the maximum fired output condition.

Maximum Unfired Output Condition

HP IP LP Steam Pressure, psig Steam Flow, lb/hr Steam Temperature, °F (±10) Steam Pressure Drop, psi Steam Purity Superheat Temperature Control Range, % Maximum Continuous Unfired Rating

Gas Side Pressure Drop, iwc Minimum Exhaust Temperature, F Availability Deaerator Outlet O2 and CO2 Concentration SCR Catalyst Life, years (if applicable) Pressure Part Weld Count, Type, Size

Maximum Fired Output Condition HP IP LP

Steam Pressure, psig Steam Flow, lb/hr Steam Temperature, F (±10) Steam Pressure Drop, psi Steam Purity Superheat Temperature Control Range, % Maximum Continuous Unfired Rating

Gas Side Pressure Drop, iwc Minimum Exhaust Temperature, °F Deaerator Outlet O2 and CO2 Concentration


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Physical Data: Units HP Drum Diameter IN. HP Drum Length FT. HP Drum Purity PPM IP Drum Diameter IN. IP Drum Length FT. IP Drum Purity PPM LP Drum Diameter IN. LP Drum Length FT. LP Drum Purity PPM Materials Material HP Superheater Material HP Evaporator Material HP Economizer Material IP Superheater Material IP Evaporator Material IP Economizer Material LP Superheater Material LP Evaporator Material LP Economizer Material HP Drum Material IP Drum Material LP Drum Material

SCR: (if applicable) Manufacturer Quantity Guaranteed Life, yr.

CO Catalyst (if applicable) Manufacturer Quantity Guaranteed Life, yr.

Unit Guarantees HRSG Availability Hrs/Yr HRSG Pressure Part Weld Count Number HRSG Pressure Part Weld Length Total Feet


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Project Name: Project Location Date: Project Concept: Revision Number:

ITEM SCOPE OF SUPPLY BY HRSG VENDOR OPTION NOT

INCLUDED 1 Turbine Outlet Expansion Joint 2 Ducting from Turbine to HRSG 3 Turning Vanes 4 Flow Distributor 5 Duct Burner 6 Piping from Duct Burner to Skid 7 Duct Burner Controls 8 HP Superheater #3 9 HP Superheater #2 10 HP Interstage De-Superheater 11 HP Superheater #1 12 HP Evaporator 13 HP Economizer #3 14 HP Economizer #2 15 HP Economizer #1 16 IP Superheater #3 17 IP Superheater #2 18 IP Interstage De-Superheater 19 IP Superheater #1 20 IP Evaporator 21 IP Economizer #3 22 IP Economizer #2 23 IP Economizer #1 24 IP Superheater #3 25 IP Superheater #2 26 IP Interstage De-Superheater 27 IP Superheater #1 28 IP Evaporator 29 IP Economizer #3 30 IP Economizer #2 31 IP Economizer #1 32 HP Drum 33 IP Drum 34 LP Drum 35 Integral Deaerator, Horizontal 36 Pressurized Blow Down Tank 37 Atmospheric Blow Down Tank 38 All Valves and Trim (ASME)


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39 All Temp., Press., and Level Transmitters 40 Control Valves (within ASME piping) 41 All Piping within ASME Code Limits 42 Electromatic Relief Valve 43 Relief Valve Silencers 44 Startup Relief Valve Silencers 45 Expansion Joint, HRSG/Stack Transition 46 HRSG/Stack Transition 47 Expansion Joint, Stack Transition/Stack 48 Stack 49 EPA Connections and Access Platform 50 FAA Lighting and Access Platform 51 Walkways 52 Ladders and Stairs 53 Space for Stalk Silencer 54 Stack Outlet Damper 55 Space for CO Catalyst Modules (if applicable) 56 CO Catalyst Modules (if applicable) 57 CO Catalyst Support Structures (if applicable) 58 CO Catalyst Casing (if applicable) 59 Ammonia Injection Grid (if applicable) 60 Ammonia Mixing Skid (if applicable) 61 Ammonia Injection Controls (if applicable) 62 SCR Modules (if applicable) 63 SCR Modules (if applicable) 64 SCR Supports (if applicable) 65 SCR Loading Rails (if applicable) 66 SCR Loading Hoist (if applicable) 67 Electrical Wiring 68 Instrument Tubing 69 Internal SS Liner 70 Internal Insulation 71 External Insulation 72 Internal Module Coating 73 Drum Surface Primer 74 Piping Surface Primer 75 Module Ext. Surface Primer 76 Drum Insulation & Flat Lagging 77 Piping Insulation & Jacketing 78 Flow Model Test 79 Erection Supervision 80 Erection 81 Freight 82 FWPH Re-Circulation Pumps and Motors 83 Startup Spare Parts 84 Spare Parts for One Year Operation


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HP

NRV HP SH

3 HP SH

2 HP

DESUP HP SH

1 HP

EVAP 1

HP ECON

3

HP ECON

2

HP ECON

1 Heating Side Data

Fluid Fouling Factor

Flow Rate lb/hr Design Pressure iwc

Design Temperature F Inlet Pressure iwc

Outlet Pressure iwc Pressure Drop iwc

Inlet Temperature F Outlet Temperature F

Temperature Drop (Rise) F Heat Released mmbtu/hr

Supplement Fuel Heat Input mmbtu/hr Effeciency

Cooling Side Data Fluid

Fouling Factor Flow Rate lb/hr

Design Pressure Psia Design Temperature F

Inlet Pressure psia Outlet Pressure psia Pressure Drop psia


Temperature Drop (Rise) F Heat Absorbed mmbtu/hr

Blowdown % Equipment Data

Heating Surface ft² Tube Diameter in. Wall Thickness in.

Calculated minimum wall thickness in. Tube Length feet

Tube Material Tube Metal temperature F

No. Transverse Tubes No. Rows Deep

St in. Sl in.

Fin Density fins/in. Fin Height in.

Fin Thickness in. Fin Material

Fin Temperature F Drum Diameter in

Drum Length feet Drum Thickness in

Drum Material Drum Retention Time minutes

Drum Volume ft³ Module Weight lbs.

Field Weld Count Field Weld Size


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IP SH 3 IP SH 2 IP

DESUP IP SH 1 IP

EVAP 1 IP

ECON 3 IP

ECON 2 IP

ECON 1 Heating Side Data



Design Temperature F Inlet Pressure lwc

Outlet Pressure lwc Pressure Drop lwc


Temperature Drop (Rise) F Heat Released mmbtu/hr

Supplement Fuel Heat Input mmbtu/hr Effeciency



Design Pressure psia Design Temperature F

Inlet Pressure psia Outlet Pressure psia Pressure Drop psi


Temperature Drop (Rise) F Heat Absorbed mmbtu/hr



Calculated minimum wall thickness in. Tube Length Feet

Tube Material Tube Metal temperature-outer F


St in. Sl in.



Fin Temperature F Drum Diameter in.

Drum Length feet Drum Thickness in.





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LP SH 3 LP SH 2 LP

DESUP LP SH 1 LP

EVAP 1 LP

ECON 3 LP

ECON 2 LP

ECON 1 Heating Side Data



Design Temperature F Inlet Pressure iwc

Outlet Pressure iwc Pressure Drop iwc


Temperature Drop (Rise) F Heat Released mmBtu/hr

Supplement Fuel Heat Input mmBtu/hr Effeciency



Design Pressure psia Design Temperature F

Inlet Pressure psia Outlet Pressure psia Pressure Drop psi


Temperature Drop (Rise) F Heat Absorbed mmBtu/hr



Calculated minimum wall thickness in. Tube Length feet

Tube Material Tube Metal temperature- outer F


St in. Sl in.



Fin Temperature F Drum Diameter in

Drum Length Feet Drum Thickness in




36-samss-001

Documents

cogeneration train unit

gas turbine generator

generator requirements

generation train page

generator gea

turbine control system

minimum steam demand

hrsg control