40-a-00022_e_tech spec gas module2.pdf

8/9/2019 40-A-00022_E_Tech spec GAS MODULE2.pdf

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DOC. ID: 40-A-00022 REV/STATUS: E / Approved

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

PAGE: 1(21)

NAME: Technical Specification

SUBJECT: Gas Conditioning Module

CUST. DOC. ID:

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

www.citec.com

FUEL GAS CONDITIONING

MODULE

(GAS MODULE 2)

TECHNICAL SPECIFICATION

Revision history

Revision Made by Approved by Reason for revision

ARamaswamyNeelakantan

Jonas Nylund Original revision

BRamaswamyNeelakantan

Tuukka Ahonen Process Updations

C SivakumarKomarasamy

Tuukka Ahonen Fuel gas compositionupdated. Material

requirements updatedD Ramaswamy

NeelakantanTuukka Ahonen Updated Module Scheme

E SivakumarKomarasamy Tuukka Ahonen Fuel gas flow updated


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TABLE OF CONTENTS

1. DESIGN BASIS .......................................................................................................... 32. CODES AND STANDARDS ...................................................................................... 5

3.

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

4. SYSTEM DESCRIPTION .......................................................................................... 65. SCOPE OF WORK ...................................................................................................... 86. TECHNICAL SPECIFICATIONS ............................................................................ 117. TERMINAL POINTS ................................................................................................ 128. DATASHEET ............................................................................................................. 14


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1. DESIGN BASIS

FUEL GAS ANALYSIS - NATURAL GAS

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

Components Volume % Weight% Mol. Wt g/Mol

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

i-C5(i-Pentane) 0.02 0.09 72.15n-C5(n-Pentane) 0.01 0.04 72.15C6+ (Hexane +) 0.01 0.05 84.0Mcyclo-C5 0.00 0.02 84.16Benzene 0.00 0.00 78.11Cyclo C6 0.00 0.01 84.16C7Heptane 0.072 0.43 96.0McycloC6 0.00 0.01 98.19Toluene 0.00 0.00 92.14C8 0.0078 0.05 107.00C2-Benzene 0.00 0.00 106.17mp-Xylene 0.00 0.00 106.17O-Xylene 0.00 0.00 106.17C9 0.00 0.01 121.0C10 0.00 0.00 134.0C11 0.00 0.00 147.0C12 0.00 0.00 161.0C13 0.00 0.00 175.0C14 0.00 0.00 190.0C15 0.00 0.00 206.0H2O 0.0006 0.00 18

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


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

ambient conditions from 15C to 38C.

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

Max. Ambient temperature for gas system 38C

GENERAL FUEL GAS PROPERTIES

Description Unit Value

Molecular weight g/Mol 16.53Molar Density Kg mole/m3 4.503Mass Density Kg/m3 74.41Mass heat capacity kJ/kg C 2.947Specific heat kJ/kg mole C 48.70

Thermal conductivity W/m K 4.305E-002Viscosity cP 1.400E-002HC dew point C -27.07

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

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

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

Components Unit Values

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


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2.

CODES AND STANDARDS

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

PED 97/23/EC The European Pressure Equipment Directive

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

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

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

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

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

EN 10204:2004 Metallic materials. Types of inspection documents

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

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

EN 12327:2000 Gas supply systems. Pressure testing, commissioning anddecommissioning procedures. Functional requirements

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

EN 13445:2009 Unfired pressure vessels.

EN 13480 Metallic industrial piping

EN 14141:2003 Valves for natural gas transportation in pipelines. Performance

requirements and tests
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EN 15001-1:2009 Gas infrastructure. Gas installation pipe work with an operating

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

3. DESIGN INPUTS

Fuel gas supply pressure & temperature at Gas Receiving & Metering module inlet batterylimit

PressureNormal Fuel gas supply pressure = 54 Bar (g)Mechanical Design pressure = 86 Bar (g)

TemperatureMinimum Fuel gas supply temperature = 15 CNormal Fuel gas supply temperature = 25 CMaximum temperature = 38CMechanical Design temperature = 50 C

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

OR

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

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

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

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

Design shall be according to EN codes & Standards.

4.

SYSTEM DESCRIPTION

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

Gas Receiving & Metering & ESD Module #1

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

Pressure Control Module #3

Natural gas will be used as primary fuel for gas turbines. This gas shall be processed in Gasconditioning skid to meet the requirement of Gas Turbine.

E
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The Gas conditioning Module consist of

1 x 100 % indirect gas fired water bath heater with gas burner & Chimney

Fuel gas Scrubber/filter for burners

The fuel gas from the Gas Receiving & Metering with ESD Modules will be directed to 1 x100% indirect bath heater with gas burner.

Indirect water bath gas heater (1 x100%) is provided to compensate the temperature dropdue to the heat loss to the ambient from the pipeline and to increase/control the Fuel gastemperature required by the Gas Turbine. Fuel gas heating is done indirectly through waterbath heater by means of firing gas in the burner & fuel gas is finally heated to an operatingtemperature of 70 C. After heating the gas to higher temperature, gas will pass through thePressure Control Module #3.

The gas is generally heated to prevent the formation of liquids and hydrates in the flowstream due to gas temperature drop resulting from the Joule-Thompson throttling effect.Removal of liquids is required prior to heating the gas, since fuel gas heater is designed toheat dry (superheated) gas and do not evaporate entrained liquids.

Heater is used to maintain gas 28C above dew point at the gas turbine inlet. The degree ofsuperheat at the outlet of the heater provides enough margins to account for the change indew point temperature that corresponds to pressure reduction across the fuel gas

downstream piping.

The heated and moisture free natural gas will be forwarded to a common header and furtherdistributed to gas turbines.

Regarding all modules

A pipeline vent connection will be provided near gas turbine inlet to vent out entrappedgases during cold start-up of the plant to vent stack. Module vendor to provide equipmentand pipeline vent connections at module border. Normally, for all equipment, one vent linewill contain manually operated ball valves for initial purging. All vents on natural gas lines

shall be connected to vent stack. The pressure safety system shall be ensured by providingsuitable pressure safety valves and the system vents will be connected to vent stack (ventstack excluded from module scope).

Natural Gas lines shall be of carbon steel piping.

Vendor is responsible for the module engineering. Customer has the right to review andrequire changes to the vendor engineering documents. Vendor is allowed optionally topropose gas fuel supply system in a different amount of modules. I.e. the total system can bedivided into modules in a different way than presented here and there can be fewer modulesthan presented here. However the functionality & performance must fulfil the requirements

in these specifications.


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The fuel gas modules shall be designed for outdoor installation and shall be suitably sized to

meet the fuel gas requirement of 4 gas turbines for the site design conditions and the purityof gas as per gas turbine manufacturers requirement / specification.

This specification covers the scope of work for GasConditioning Module 2 (Indirect bathheater with gas burner 1 x 100 %)

5.

SCOPE OF WORK

The scope of supply of the vendor under this specification and associated data sheetis intended to cover design, engineering, manufacture, assembly, testing and supplyof the skid with all accessories, site installation supervision, commissioningsupervision, performance guarantee testing, operator training and training materialand handing over of items related to GasConditioning Module 2 as defined in Scopeof work, Technical Specification or elsewhere in this specification.

All supplied materials/equipment shall be new and unused. The vendor shall acceptfull responsibility for his work including documentation, manufacture, preparationfor shipment, inspection, warranty provisions, compliance with the applicable codesand standards and the requirements of this Specification. The scope of supply andservices shall include all necessary work and supply of equipment and materialwhether mentioned in these specifications or not, but which are necessary for thesatisfactory, reliable and safe operation and maintenance of the plant and required

for achieving guaranteed performance of the plant. Any equipment, device ormaterial even if not included in the original bid but found necessary for the safe andsatisfactory functioning of the units under the bid shall be supplied by the vendor atno extra cost. The module should be delivered in a properly packed condition asspecified here in under but not limited to:

Gas Conditioning Module 2 is comprised of 1 x100% Stream. The skid details proposedin this specification and P&ID (Doc No 40-A-00023) are indicative only. Vendor canalso suggest better system than specified. Complete Gas Module #2 shall bedesigned to meet the main fuel requirements of 4 Gas turbines and comprises of:

o

One (1) number 100% capacity indirect gas fired water bath heater .Theheater shall be sized to cater gas flow requirement of four (4) gas turbines at100% load. Water will be used as the heating medium in to raise the fuel gastemperature to 70 C (max) at Gas conditioning module outlet.

o Gas heater to be provided with gas burners for firing fuel gas & blowers forsupplying combustion air, main body, the coil or tube bundle, water expansiontank, fuel feeding line, the fire-tube, chimney, burner management system,skid frame and service platform and insulation. Temperature Control to bedone internally inside module. Set point to be set at local control panel withpossibility for doing it from DCS. Set point can be chosen by operator between

40...70C.o The gas fuel heating system shall be designed to support specified gas fuel


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temperature set point required by the gas turbine, including high and low

temperature alarms.

o Burner control, bath temperature control, gas outlet temperature control andwater level control shall be automatic. DM water connection is provided at themodule border.

o Chemical dosing system and chemicals for water bath shall be included.

o Fuel gas for the burners shall be filtered through the fuel gas scrubber/filterin order to protect the burners.

o Insulation (example Rockwool) with aluminium cladding shall be providedfor all the pipes/equipments/surfaces having surface temperature more than50C, the insulation thickness shall be designed based on media andambient temperature.

o Thermal insulation shall be provided in order to maintain the temperature inthe main gas line. In other locations, insulation is mainly for personnelprotection. Insulation for personnel protection shall be provided such that thetemperature of protective cladding is not higher than 50 C.

o Standard instrumentation and valves for the safe and efficient operation ofthe Module mounted equipment

o All instrumentation shall have double isolation valves

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

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

o Internal nitrogen purging connections and internal piping inside the moduleas required based on the system design shall be taken care by the vendor (onlyone external connection is allowed). Bidder shall provide requisite number oftapings for nitrogen purging as the standard practices, the number indicatedin the P&ID attached shall be treated as minimum.

o Drain lines with double isolation valve

o Two numbers of portable gas detectors (totally 2 numbers for all three gasmodules together) of the flame ionization metering type, capable of detecting

fuel gas in concentration of one part per million. All necessary detectoraccessories shall be included.


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o

Manual depressurisation line with double isolation valves

o Relief valves required for protection

o All the vents / drains to be connected to a common header & terminated atmodule terminal

o All interconnecting piping, valves, specialities, supports within Modulemounted equipment as shown in the P&ID as minimum. It is Suppliers

responsibility to provide all design and piping components as necessary forthe safe operation of the system

o

Regarding instrumentation / sensors / transmitters etc bidder shall note thatP&ID Dwg No 40-A-00023 submitted along with specification is indicativeonly.

o All equipment, C&I devices shall be suitable for E Ex _ II A T1 for Naturalgas systems (normally T class, however, T3 or higher T4, ... is ok). Ex classnormally E Ex d. Instruments normally other type depending on the zone andif barriers are used or not.

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

o

Instrument air is available at 7 bar (g), dryness + 3 C.

o All foundation bolts/ anchor bolts, insert plates, pipe sleeves, embedment, etcrequired for any equipment/ foundation/ concrete under the package.(Foundations are excluded from scope.)

o Local control station/Local Push Button Station (Flame proof) shall beprovided for each skid.

o It shall be possible to provide all analogue and digital signals to plant DCS. Itshall be also possible to operate and start/stop the unit from the plant DCS.

o All required documentation from vendor is presented in attachedRequirements for Documentation, document number 40-A-00175.


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6.

TECHNICAL SPECIFICATIONS

S.NO PARTICULARS UNIT DESIGN VALUES

1. Module FUEL GASCONDITIONINGMODULE

2. Capacity Streams 1 x 100% for all 4 GTs

3. Mode of Operation Continuous

4. Medium Handled Fuel Gas ( Natural Gas)

5. Density at 15C kg/m3 42

6. Density at 26C kg/m3 37

7.

Fuel LHV KJ/Kg 487728. Flow at the module battery

limit430 MMBTU Each GT( 4.54 x 10^8 KJ/HR)

Minimum flow for each GT Kg/hr LATERNormal flow for each GT Kg/hr 7904

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

41091

9. Fuel gas pressure at powerplant inlet battery limit

Barg 54

10. Fuel gas maximum pressure at

inlet battery limit. Mechanicaldesign value.

Barg 86

11. Temperature of fuel gas atmodule inlet

C 15...38, Normal 25

12. Temperature of fuel gasrequired at module outlet

C Normally 4070C atmodule outlet

Min gas temp shall be28C above dew point.

13. Design pressure of fuel gassystem up to Module Outlet.Mechanical design value.

Barg 86

14.

Noise Level 75dB(A) for a singleequipment @ 1m.

E

E


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7. TERMINAL POINTS

S.NO DESCRIPTION SCOPE

A. MECHANICAL

1. Fuel Gas

Inlet of the Module terminal withcounter flanges

Outlet of the Module terminal withcounter flanges

2. Drains

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

3. Vents

Gas vents / safety valve discharge

to be connected individually to acommon header. The header to beterminated at the module terminalpoint.

4. Nitrogen At one point in inlet of module.

5. Instrument air At one point in inlet of module.

6. DM water (make up) At one point in inlet of module.

Combustion airNo terminal point. Complete

system in vendor scope


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S.NO DESCRIPTION SCOPE

Exhaust gas outletNo terminal point. Complete


Chemical DosingNo terminal point. Complete


B. ELECTRICAL

1. Earthing

Two earthing terminals atdiagonally opposite locations of theskid

Notes

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

gaskets.

EXCLUSIONS

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


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8.

DATASHEET

The given below datasheet to be filled in by the Vendor

S.NO PARTICULARS UNIT VALUES

1.0 General

Design Standard EN

Module nameGas conditioningModule

Equipment shall be designedfor seismic loads

Fuel Gas Supply Conditions

Gas Flow at inlet of Module

Gas Supply Pressure atinlet of moduleGas Supply Temperature atinlet of module

2.0

Design & Performance

Requirement

GeneralMaximum Gas Velocity insidepipeline under maximumoperating conditions

m/sec20 unfiltered

35 filtered

Gas Pressure at outlet ofModuleGas Temperature at outlet ofModuleMax. Pressure drop across theModule

3.0 Fuel gas Heater

Fuel gas

Design fuel gas flow In Kg/Hr andNm3/hr (0C

and1.013bara)

Inlet temperature C 15-38, Normal 25

Outlet temperature C 70

Maximum operating pressureBar (g) Gas side =86 Barg

E


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Design pressureBar (g) Gas side = 86 Barg

Maximum operatingtemperature

C Gas side = 90 C

Mechanical Designtemperature C Gas side = 125 C

6.0 Materials of construction

Gas lines to

be Carbon

steel.

Materials to

be given acc

to EN

denomination.

A Gas heater

Shell

Tubes

Tube Supports/Baffles

Expansion joint of both shell

Vapour belt

B Insulation

Insulation Material &Density

Rock wool /Mineral wool

Insulation Type andThickness

(Will bedifferent forThermalinsulationand forPersonalprotection)

Insulation Class

Metal Jacketing/Cladding

Securement Wire Temperature/Material/Size

Surface Temperature 50C

Material standard

Note : Vendor to provide all details of the Heater inside the module not limited to this datasheet.


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7 Design & Performance Requirement

7.1 General

Terminal point pressure at all operatingnatural gas supply conditions (max /min )

Bar(g)

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

C

Maximum Gas Velocity inside pipeline m/sec

Design pressure of fuel gas system up toand including the Module

Bar(g)

Indirect Gas Fired Water Heater

A General

Manufacturer

Equipment Type

Model

Quantity

B Performance Parameters

Gas Flow ( Max)

M3/hr @temp,

pressureAnd

In kg/hr

Gas Design Flow

M3/hr @temp,

pressureAnd

In kg/hrTurn Down Ratio

Gas Design Pressure Bar(g)

Gas Design Temperature C

Gas Side Pressure Drop flange to flange@ design

Bar

Fuel gas flow to burners inlet

M3/hr @temp,

pressureAnd

In kg/hr


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Fuel gas pressure required at burners

inlet

Bar(g)

Fuel gas temperature required atburners inlet

C

Fuel gas purity required at burners inlet

Design heat load kJ/sec

C Design & Construction Features

Design Code

Shell OD mm

Shell Wall Thickness mm

Shell Material

Shell Channel / Cover Material

Gas Flange Inlet/Outlet, Size, Rating

Gas Side Flange(s) Material

1 Expansion Joint (if any)

a. Manufacturer

b. Model No.

c. Quantity

c. Material

d. Maximum Axial Movement

e. Maximum Radial Movement

f. Maximum Off-set

g. Can all maximum movement beapplied simultaneously

Yes/No

2 Corrosion Allowance mm

3 Thermocouples Type & location

4 Insulation

Insulation Material & Density

Insulation Type and Thickness

Insulation Class

Metal Jacketing/Cladding

Securement Wire Temperature/Material/Size

Surface Temperature C


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Material standard

8 Paint Specification

9 Weight Empty Kg

10

Accessories (Generally all other

equipment in the module)

10.1 Vent Valves

Manufacturer

Quantity

Type

Size, In/Out connection ends

PN-class

Material

Leakage class

10.2 Relief Valves

Manufacturer

Quantity

Type

Size, In/Out connection ends

PN-class

Set Point Bar(g)

Material

Rating

Location

Leakage class10.3 Manual Drain Valves

Manufacturer

Quantity

Type

Size DN

PN-class

Connection ends

Material (Body/Trim)


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Leakage class

10.4 Actuator Valve

Type of valve

Manufacturer

Type of operation

Actuator

Quantity

Size DN

PN-class PN

Leakage class

Operation time (fully open-close) sec

Control Accuracy

Material (Body/trim)

10.5 Instruments

Type

MakeModel

Range

Accuracy / Accuracy class

10.6 External signals

Name

Type

10.7 Utilities required

Instrument Air

Quantity Nm3/hr

Quality

Pressure Bar(a)

Nitrogen

Quantity Nm3/hr

Quality

Pressure Bar(a)


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11 FOUNDATION DATA

A

Gas conditioning Module

(Bidder to furnish the following

details per foundation)

Empty weight kg

Operating weight kg

Test weight kg

Dynamic load (if any) kg

Live load of platforms kg

Minimum depth of foundation (if anyspecific requirement)

12 ACCESSORIES(Indicate whether the following

accessories and services are offered )Companion flanges with nuts, bolt &gaskets

Foundation bolts

Base plate with Anchor bolts andshimsIntegral instruments piping andvalves as required for all systems.

Safety Relief Valve

Drain & Vent Arrangement

Mandatory spares

Spares for five years of operation

Special tools and tackles

Painting and protective coating

Insulation

5.0 INSPECTION TEST

Material test

Pneumatic test pressure andduration

6.0 PERFORMANCE TEST AT SHOP

7.0 WEIGHT SCHEDULE

Weight of the complete module withall accessories

Kg

All tests & inspections as perspecification shall be done


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8.0 SHIPPING DIMENSIONS

COMPLETE MODULE WITH ALL

ACCESSORIES

Note : Vendor to Submit complete details of all items (if additional from this data

sheet) as suitable required for this Skid

PERFORMANCE GUARANTEE

S. No. Description Unit Guarantee

1

Pressure drop across the Heater(flange to flange) at

Design FlowNormal Flow

kPa

2Gas Heater

a)

Gas temperature at the module outlet @Minimum gas FlowNormal gas FlowDesign gas Flow

oC

b) Max. pressure drop across gas side Bar

c) Heat Duty kJ/sec

3Noise level

a) Normal operationb) Pressure Relief valve in

operation

dBA

4Auxiliary Power consumption(Bidder to furnish complete break-up ofauxiliary power consumption)

kW

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