DHG PVE DD 3 ME SPC 005_Spec for Gas Turbine Compressor Package

8/10/2019 DHG PVE DD 3 ME SPC 005_Spec for Gas Turbine Compressor Package

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PETROVIETNAM DOMESTIC EXPLORATIONPRODUCTION OPERATING COMPANY LIMITED

PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS TURBINECOMPRESSOR PACKAGE

A 23/05/14 Issued for Review

Rev. Date Description PVE VSP ApprovalPVEP POC Approval

CA Approval

EpCI CONTRACTOR( VIETSOVPETRO JOINT VENTURE )

Document Number:

DHG-PVE-DD-3-ME-SPC-005

Number of pages: 56

(including the cover page)


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PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN


A 23/05/14 Issued forReview N.T.K.Ngoc V.T.Quan D.T.Dung V.V.Hung

Rev. Date Description Prepared

byChecked

by EM PM DisciplineTeam

Leader SPMBSub-Contractor EpCI Contractor

EpCI CONTRACTOR(VIETSOVPETRO JOINT VENTURE)

PV ENGINEERING J.S.C Document Number:

DHG-PVE-DD-3-ME-SPC-005


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DAI HUNG GAS GATHERING PROJECTDETAILED ENGINEERING DESIGN PHASE


Doc No: DHG-PVE-DD-3-ME-SPC-005 Rev. A Page 3/56

REVISION LOG

DateRevision

No. Section Revision Description

23/05/14 A All Issued For Review


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TABLE OF CONTENTS

1. INTRODUCTION ...................................................................................... 8

1.1 Project Overview .................................................................................... 8

1.2 Purpose of Document ............................................................................. 9

1.3 Definitions and Abbreviations .................................................................. 9

1.3.1 Definitions ................................................................................... 9

1.3.2 Abbreviations ............................................................................ 10

1.4 Codes and Standards ............................................................................ 11

1.5 References .......................................................................................... 13

2. GENERAL REQUIREMENTS ..................................................................... 13

2.1 CONTRACTORS Responsibility .............................................................. 13

2.2 Operation and Design Life ..................................................................... 14

2.3 CONTRACTORs Exceptions ................................................................... 14

2.4 Weight Control ..................................................................................... 15

3. LOCATION AND ENVIRONMENTAL CONDITIONS ..................................... 15

4. UTILITY DATA ...................................................................................... 16

4.1 Electrical ............................................................................................. 16

4.2 Instrument air: .................................................................................... 16

4.3 Fuel gas .............................................................................................. 16

4.4 Units ................................................................................................... 17

5. SCOPE OF WORK & SUPPLY ................................................................... 17


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6. DESIGN REQUIREMENTS ....................................................................... 19

6.1 General ............................................................................................... 19

6.2 Structural ............................................................................................ 21

6.3 Layout ................................................................................................. 23

6.4 Noise Level .......................................................................................... 24

7. GAS TURBINE ....................................................................................... 24

7.1 General ............................................................................................... 24

7.2 Turbine Air Inlet System ....................................................................... 25

7.3 Exhaust System ................................................................................... 26

7.4 Turbine Enclosure ................................................................................ 27

7.5 Fire Suppression Systems ..................................................................... 28

7.6 Turbine Wash Package ......................................................................... 29

7.7 Load Gear ........................................................................................... 29

7.8 Couplings and Coupling Guards ............................................................. 30

7.9 Lube Oil Systems ................................................................................. 30

7.10 Pressure Vessels .................................................................................. 31

7.11 Fuel Gas System Requirements ............................................................. 32

8. CENTRIFUGAL COMPRESSOR ................................................................. 32

8.1 General ............................................................................................... 32

8.2 Casing ................................................................................................. 33

8.3 Shaft and Impellers .............................................................................. 34

8.4 Bearings .............................................................................................. 35


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8.5 Shaft Seals .......................................................................................... 36

8.6 Rotor Dynamics ................................................................................... 39

9. TECHNICAL REQUIREMENTS FOR ELECTRICAL. ....................................... 40

10. TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL .... 42

10.1 General ............................................................................................... 42

10.2 Unit Control Panel ................................................................................ 43

10.3 Field Instruments ................................................................................. 44

10.4 Other Compressor Instruments ............................................................. 45

10.4.1 Vibration and Axial Displacement Monitoring .............................. 45

10.4.2 Bearing Temperature Monitoring ............................................... 45

10.4.3 Speed Instruments ................................................................... 45

10.4.4 Anti - Surge Control System ...................................................... 45

10.4.5 Peformance Control .................................................................. 46

10.5 Interface With Plant PCS/SSD/FGS ......................................................... 46

10.5.1 PCS ........................................................................................ 46

10.5.2 SSD ........................................................................................ 47

10.5.3 FGS ........................................................................................ 47

10.5.4 Alarms and Shutdowns ............................................................. 48

11. PIPING ................................................................................................. 48

12. UTILITIES & TIE-INS ............................................................................. 49

12.1 Utilities ................................................................................................ 49

12.2 Tie-Ins ................................................................................................ 49


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13. EQUIPMENT TAGGING AND NAMEPLATES ............................................... 50

14.

INSPECTION AND TESTING ................................................................... 50

14.1 General ............................................................................................... 50

14.2 Factory Acceptance Test (FAT) .............................................................. 51

14.3 Quality Assurance ................................................................................ 52

14.4 Certification ......................................................................................... 52

14.5 Site Acceptance Tests (SAT) ................................................................. 52

15. PROTECTIVE COATING .......................................................................... 53

16. SPECIAL TOOLS .................................................................................... 54

17. SPARE PARTS ....................................................................................... 54

17.1 Commissioning and start-up spare parts ................................................. 54

17.2 Two years operation Spare parts (option) .............................................. 54

17.3 Insurance Spare parts (option) .............................................................. 55

18. PREPARATION FOR SHIPMENT ............................................................... 55

19. DOCUMENTATION ................................................................................. 55

20. TRAINING (OPTION) ............................................................................. 56

21. GUARANTEES ........................................................................................ 56


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1. INTRODUCTION

1.1

Project OverviewDai Hung Field is located at Block 05-1a at North-West of Nam Con Son basinwithin South-East continental shelf, Viet Nam, 260km far from Vung Tauseashore. This field was discovered in 1988 by DH-1X.

In 2011, WHP-DH2 with existing system is operated to increase the capacityof associated gas up to 1 MMSCMD. Besides the associated gas there isconsiderable volume of natural gas located in bottom and middle of Mioxenlayer.

The overall Dai Hung Gas Gathering Project as show in figure 1 below:

Figure 1: Block Diagram Dai Hung Gas Gathering System

Modifying WHP-DH2 and installation pipeline between WHP-DH2 and BK-TNGis to gather and transport 1.9 BMSCM of associated gas at outlet of HHP Separator and Test Separator of WHP-DH2 to BK-TNG platform. Gas fromWHP-DH2 shall be transported to TEG skid on BK-TNG platform before beingrouted to NCS2 gas pipeline phase 1.


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Preliminary configuration of Dai Hung Gas Gathering Project is as follows:

On WHP-DH2: Gas Cooler, Gas Scrubber, Gas Engine Generator, CorrosionInhibitor Injection Skid, Electrical System, Instrumentation System, FuelGas System, Fire Fighting System, Telecommunication System and otherUtility Systems.

The 16 subsea gas pipeline (approximately 20 km) from existing 10 riserat WHP-DH2 to BK-TNG Platform and 16 Y-Tee for future connection.

On BK-TNG Platform: 16 Riser, Slug Catcher, DH Gas Custody MeteringSystem, DH Gas Compressor Suction Scrubber, DH Gas CompressorPackage, DH Gas Compressor After Cooler, Fuel Gas System, Piping

System, Instrumentation System, Telecommunication System, Open/Closed Drain System, and other Utility Systems.

1.2 Purpose of Document

This document, together with the project data sheets provided separately,defines the minimum requirements for supply, engineering, mechanicaldesign, performance guarantee (where specified), materials, fabrication,inspection, testing, certification, painting, preparation for shipment, packing,forwarding, transport and documentation for the Gas Turbine CompressorPackage to be installed as part of the Thien Ung Platform.

The CONTRACTOR shall ensure that all equipment and services supplied meetthe requirements of this specification, the project data sheets, codes andstandards and specifications specified herein, whether CONTRACTOR suppliesthe equipment and services directly. CONTRACTOR shall supply the equipmentin line with the scope of supply as indicated in this specification.

1.3 Definitions and Abbreviations

1.3.1 Definitions

PROJECT : Dai Hung Gas Gathering Project

CLIENT : PetroVietnam Domestic ExplorationProduction Operating Company Limited(PVEP POC)

EpCI CONTRACTOR : VIETSOVPETRO JOINT VENTURE (VSP)

ENGINEERING SUB-CONTRACTOR : PetroVietnam Engineering ConsultancyJoint Stock Company (PVE)


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CONTRACTOR : Party, which supplies material,equipment and services to perform theduties as specified by CLIENT in thescope of supply

1.3.2 Abbreviations

FPU-DH1 Dai Hung 1 Floating Production Unit Platform

WHP-DH2 Dai Hung 2 Wellhead Platform

BK-TNG Thien Ung Platform

MMSCMD Million Metric Standard Cubic Meter Per Day

BMSCM Billion Metric Standard Cubic Meter

GTC Gas Turbine Compressor Package

CCR Central Control Room

ESD Emergency Shut-Down

FGS Fire & Gas

HMI Human Machine Interface

HSE Health Safety and Environmental

ICSS Integrated Control and Safety system

IOM Installation Operation and Maintenance

ITP Inspection and Test Plan

LV Low Voltage

HV High Voltage

VFD Variable Frequency Drive

UPS Uninterruptible Power Supply

AC Alternating Current

DC Directing Current

SGR Switch Gear Room

RTD Resistance Temperature Detector

IEC International Electrical Commission

IP Ingress Protection


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MCC Motor Control Centre

MDR Manufacturers Data Report

MPI Magnetic Particle Inspection

NDT Non-Destructive Testing

PWHT Post Weld Heat Treatment

TBA To Be Advised

VDRL CONTRACTOR Data Requirements List

VDS CONTRACTOR Data Schedule

FAT Factory Acceptance Test

SAT Site Acceptance Test

SSD Safety Shut Down/ Safety Shut Down PLC

PPLC Process Programable Logic controller

SIS Safety Interated System

TEG Triethylene Glycol Dehydration

PCS Process Control System

APS Abandon Platform Shutdown

LCP Local Control Panel

UCP Unit Control Panel

1.4 Codes and Standards

In addition to the requirements of this specification and the referred orattached individual specification and data sheets together with the statutoryrequirements of the Vietnam Authorities, the general design, fabrication,assembling and testing of this package shall follow the indicated editions ofthe following API standards and the latest edition of international codes andstandards including any addenda published for the edition listed, which shallform part of this specification. These shall include but not be limited to thefollowing:

API 613 Special Purpose Gear Units for Petroleum, Chemical andGas Industry Services, Fifth Edition, February 2003.


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API 614 Lubrication, Shaft-Sealing and Control-Oil Systems and Auxiliaries for Petroleum, Chemical and Gas Industry

Services, Fifth Edition, April 2008. API 616 Gas Turbines for the Petroleum, Chemical and Gas

Industry Services, Fourth Edition, August 1998

API 617 Axial and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical and Gas IndustryServices, Seventh Edition, July 2002 or last edition.

API 670 Machinery Protection Systems, Fourth Edition, December2000

API 671 Special Purpose Couplings for Petroleum, Chemical andGas Industry Services, Fourth Edition, August 2007

API 676 Positive Displacement Pump Rotary, Second Edition,December 1994

API RP 686 Machinery Installation and Installation Design, December,2009

ASME B16.5 Pipe Flanges and Flange Fittings: NPS 1/2 through NPS 24Metric/Inch Standard, 2013

ASME B31.3 Process Piping, 2012

ASME B31.8 Gas Transmission and Distribution Piping System, 2012

ASME B36.19M Stainless Steel Pipe, 2004

ASME B36.10M Welded and Seamless Wrought Steel Pipe, 2004

ASME B16.34 Valves flanged, threaded and welding end, 2013

ASME B16.11 Forged fittings socket-welding and threaded, 2011

ASME PTC 1 Performance Test Code General Instructions

ASME PTC 10 Performance Test Code on Compressors and Exhausters

ASME PTC 22 Performance Test Code on Gas Turbines

ASME Sect. V Non-destructive Examination

ASME Sect. VIII ASME Boiler and Pressure Vessel Code

ASME Sect. IX ASME-Welding and Brazing Qualifications

AWS D1.1 Structural Welding Code


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EEMUA 140 Noise Procedure Specification

EN 10204 Metallic Materials Types of Inspection Documents

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

ISA International Society of Automation

ISO 9001 Quality system model for quality assurance in design,development, production, installation and servicing

ISO 9004 Quality management and quality system elementsguidelines

NEMA National Electrical Manufacturers Association

NFPA 70 National Electrical Code

UL Underwriters Laboratories

1.5 References

DHG-PVE-DD-3-ME-DAS-007 Datasheet for Centrifugal and AxialCompressor

DHG-PVE-DD-3-ME-DAS-008 Datasheet for Gas Turbine

1014-BKTNG-PR-PID-2023 PID DH Gas Compressor PackageIn case of any conflict between this specification and the requirements ofother CLIENT specifications, industry standards, codes, regulations, datasheets or drawings, the most stringent requirements shall apply with thewritten approval of CLIENT.

2. GENERAL REQUIREMENTS

2.1 CONTRACTORS Responsibility

The CONTRACTOR shall have full responsibility for design, selection of

materials, fabrication, Certification, testing, inspection and transportation ofGTC based on relevant project documents. Review and approval ofCONTRACTORs documents or inspection by the CLIENT shall not relieve theCONTRACTOR of any of these responsibilities.

The Overall GTC Responsibility shall be with the CONTRACTOR. Thatresponsibility shall include coordination of scope boundaries betweenCompressor, Driver and Other Components of the GTC. The CONTRACTOR


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has responsibility shall be liable for filling any scope gaps between thecompressor, Driver and Other Components of the GTC being supplied. The

responsibility includes, but not limited to, the following: Transmission to CONTRACTOR of all contractual requirements.

Compliance of CONTRACTORs item to the applicable specification andstandards

Basic design definition of CONTRACTOR equipment or works andtechnical coordination with CONTRACTOR.

Co-ordination and checking of CONTRACTORs drawings and documentsbefore submission to the CLIENT

Co-ordination with CONTRACTOR for inspection including notification tothe CLIENT

Co-ordination of expediting of all CONTRACTOR items such ascompressor, drive gas turbine, motors, gas seals panel, oil cooler,coupling, and etc.

Ensuring that the design of CONTRACTOR items are compatible witheach other equipment in all respects. In particular, they shall becompatible dimensionally, in performance, in control and in vibrationcharacteristics such that a fully integrated unit is achieved.

The CONTRACTOR shall be responsible for commissioning works of hisequipment and ensuring all performance guarantees as detailed in thisspecifications are met.

The CONTRACTOR shall give with the tender the list of expectedCONTRACTOR with referenced list.

2.2 Operation and Design Life

The equipment shall be designed for a minimum service life of 20 years withan uninterrupted operation of 4 years.

2.3 CONTRACTORs Exceptions

The CONTRACTOR Exceptions to this specification, project data sheets andother project documents including the codes and standards agreed upon andrecorded in the Bid Clarification Meeting Minutes which are part of thePurchase Order shall be applicable.


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2.4 Weight Control

The CONTRACTOR shall exercise an active weight control system throughoutthe design and fabrication.

The CONTRACTOR shall submit the weight data sheet attached with the datasheets, which shall contain the following details:

Dry weight Installed weight excluding operating fluids, spares, toolsand temporary packing.

Lift weight Dry weight + Packing weight

Operating weight Dry weight + Weight of operating fluids

Test weight - Dry weight + Weight of test medium Heaviest maintenance lifts weight

The location of the COG in the X, Y, and Z planes for each designatedweight Condition

Design calculations, lifting procedures and lift arrangement drawings shall bereviewed and approved by the CLIENT and CA. Final weighing shall beperformed prior to preparation of shipment. Final weighing shall achieve anoverall accuracy of +3%.

3. LOCATION AND ENVIRONMENTAL CONDITIONS

The equipment will be installed on an offshore platform in the south of thecoast of Vietnam.

Location: Out door, Zone 2, Gas Group IIA, Temperature Class T3 Hazardous Area.

The area in which the Gas Turbine Compressor Package is designated ashazardous Zone 2 Area. All equipment installed within the module shall besuitable for a Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area.

However, in order to permit interchange of instrument, a zone 1, gas groupIIB and temperature rating T6 certification shall be generally specified.

Electrical equipment supplied outdoors shall be protected to IP 56, while IP 42protection shall be specified for equipment installed indoors.

Ambient Temperature:

Extreme High Temperature 39.0 Deg C

Extreme Low Temperature 21.0 Deg C


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Average Annual Temperature 27.1 Deg C

Design Ambient Temperature 35 Deg C

Environment:

Salt Laden: Salinity 35%

Max. Relative Humidity 100%

Wind Speed:

Maximum 34.2 m/s (3 sec gust)

Design Wind Speed 34.2 m/s

The equipment will exposed to the weather without further protection.

4. UTILITY DATA

4.1 Electrical

The following electrical power supplies shall be made available for use by theCLIENT:

Normal Power supply: 400V10% AC, 3 phase, 4 wire, neutral solidlyearthed, 50 Hz 5%.

Non-UPS Power Supply: 230V 10%AC, 1 phase, 2 wire, neutral solidlyearthed, 50 Hz 5%.

UPS power supply: 230V 5%AC, 1 phase, 2 wire, neutral solidlyearthed, 50 Hz 2%.

Power supply: 24VDC 5% for Control system.

4.2 Instrument air:

7 barg (Norm), 5 barg (Min), 8 barg (Max) / 10 barg (Design).

4.3 Fuel gas

The fuel gas supply for operation of GTC is taken from Fuel Gas System,which is designed for high-pressure gaseous fuel of main Turbine generatoron platform. The system also supplies low-pressure fuel gas, purge gas,blanket gas, etc.

Fuel Gas System is designed to cater for the overall fuel requirement on BKTNG platform. The system consists of Pre-heater, Pressure Control Valve,Scrubber, Filter and Super heater. The normal fuel gas supply is dehydrated


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gas from TEG Contactor with back-up fuel gas supply tapped from theProduction Separator gas outlet.

4.4 Units

SI units shall be used for the project with certain exceptions where oil-fieldunits are to be adopted. Pressure shall be indicated in bar, kpa andtemperature in degrees Celsius.

5. SCOPE OF WORK & SUPPLY

The CONTRACTOR shall design and furnish all components and ancillaryequipment necessary to make compressor package complete, safe and readyfor trouble free operation. Equipment and services shall include but not belimited to the following for GTC:

Centrifugal Compressor unit

Dry Gas Seal conditioning Skid including Seal Gas Heater and Powercontrol;

Anti-surge recycle valves and associated controllers such as flow metersand other accessories...

Gas Turbine unit.

Gear box (if required). Base frame for gas turbine, compressors, gear box, gas seal skid, on-skid

auxiliaries equipment, lube-oil reservoir, run down tank (if required) andlube oil system, shims, mounting bolts.

Couplings with Non Sparking Coupling Guards

Fuel gas System.

Lube-Oil System.

Lube oil cooler (loosed item)

Inlet Air System (SS316L) with Manufacturers standard including Filters,Silencer and accessories.

Exhaust System with Manufacturers standard, including silencer,expansion joints and accessories.

Enclosure for Gas Turbine Unit (SS316), complete with ventilation systemand maintenance facilities.


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Fire and Gas Detection for Enclosure complete with field equipment andpackage cable system.

Carbon Dioxide Release Fire Suppression System for Enclosure

All instruments and control necessary for the control, monitoring andsafe operation whatever on GTC or loose supply included.

All installation material for pipe work, cabling, interconnecting wiring,terminals, instrument tubing and accessories for the control monitoringon GTC.

Electrical, Instrument and Control system for Gas Compressor Package

Motor control switchboard (MCC) for Gas Compressor Package (Optional)

Unit Control Panel (UCP) All required soft wares, fully validated.

Field Programmer/LAPTOP/DIVICES and software for PLC program andHMI monitoring, modifying.

Vibration detection and monitoring system.

Bearing Temperature Detection and Monitoring System

Turbine Starting System with AC Electric Motor.

Variable Frequency Drive (VFD) for Starting Motor complete with linereactor, (if required).

Back up DC Lube Oil Pump and Starter control;

Commissioning parts.

Inspection and Tests Plan

Third Party Certificate for entire GTC.

Documentation for project

Commissioning activities (Supervision).

Training courses (option).

Special Tools for turbine & compressor (Option).

Spares for 2 years operation for turbine & compressor (Option).

Anchor bolts for package frame.

Trolley cart -mounted gas turbine washing system.

The CONTRACTOR shall include in his supply:


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With the exception of process gas connections all piping and tubingconnections for interfacing with the CLIENT shall be brought to the edge

of each compressor flanges and terminated with a complete companion ANSI flange or Swage lock bulkhead fitting.

The CONTRACTOR shall take technical support to CLIENT in:

Mechanical Interface drawings between GTC package and CLIENTsequipments such as inlet/outlet piping.

Interface drawings of Inlet system, Exhaust system, lubrication oil coolersystem.

Provide drawings of Interconnecting electrical cables/instrument cables,

between the GTC and loosed items such as UCP, oil cooler, anti surge. Responsible for Technical support to CLIENT for GTC interface

engineering.

Interface and successful communication between CONTRACTORs UCPand CLIENTs DCS system shall be carried out.

Supply E&I cable list and interconnection for E&I wiring diagram.

EXCLUSION:

Interconnecting piping between GTC to oil cooler and field piping.

Interconnecting electrical cables/instrument cables, between the GTCand UCP/PCS/SIS/MCC.

UPS system for the UCP.

MCC.

Process Vessels.

Installation and Hook-up works for GTC in CLIENTs site.

6. DESIGN REQUIREMENTS

6.1 General

The CONTRACTOR shall minimize the points and locations of interface andlocate them at the unit skid edge. Piping interface with the off-skid pipingshall be provided with isolation valves and flanges as shown in the P&IDsattached. Common service piping such as drain, vent and utility piping shall bemanifold to interface with the off-skid piping where it is safe to do so. All


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6.2 Structural

The gas turbine, gear, and compressors shall be mounted on heavy-dutystructural steel skid. The structural skid may be split for logistic reasons.There shall be only one split line. The split line shall have accessible facility fordowelling after the compressor and gas turbine skids are aligned and boltedtogether.

All electrical motor driven pump mounting surfaces shall have 3-way(horizontal-2, vertical-1) 316 SS jacking/alignment provisions for the motors.The provisions shall use fine threads.

CONTRACTOR shall provide the necessary data required for structural dynamic

and static analysis of the deck support steel. This information shall include butnot be limited to the following:

Total weight of each skid, support points and center of gravity

Operating speed for all rotating pieces of equipment

Maximum allowable displacements along the skid

Operating rotational imbalance forces

Individual support point reaction forces

Support point locations with reaction forces for the inlet air filter andexhaust structures

Piping strain forces at each support point.

CONTRACTOR shall submit a set of preliminary General Arrangement (GA)drawing of his proposed skid with the bid. The GA shall display anticipatedskid dimension, weights, general layouts and interconnection orientations.

The skid shall be designed for multi-point mounting and shall be sufficientlyrigid to prevent misalignment of the drive train caused by platform movementor piping strains.

Skids shall have a solid plate top floor with non-skid painting and shall becontinuously seal welded around the perimeter. Gas turbine and inlet plenumstructural skid shall have a smooth surface metal floor in the bottom portion;i.e., no open skid from the bottom. The smooth metal floors shall becontinuously seal welded, and sloped towards a drain connection on theoutside of the skid. All drip pans shall be checked with water during the final,acceptance inspection to verify adequate slope.


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All areas of the skid shall be sealed. Areas that may contain spills or mayrequire draining shall have a drip pan built into the skid. The drip pans shall

have a 70 mm high lip or wall for containment and shall be sloped at 1:50 to alow point drain. The drain connection (min.2) shall be flanged.

(API-617, 3.3.1.2.2). Shim packs for compressor train and auxiliary rotatingequipment shall be made of 316 stainless steel. The minimum of one single9mm thick shim shall be provided for each mounting point. Laminated ortapered shims shall not be used. The shims shall be full face and thenumber of shims shall not exceed quantity of three per mounted point.

CONTRACTOR and CLIENT shall develop the mounting arrangements forcompressor / gear skid and gas turbine drive skid during detail design. Thedetails of skid mounting on the platform deck shall be included in theCONTRACTOR supplied equipment arrangement drawings.

(API-617, 3.3.1.).The hold down bolt holes on compressor equipment feetshall be sized at 1.25 times the bolt diameter.

The skid shall be assumed, for design purposes, to have simple supports atthe extreme ends and at the midpoint of the longitudinal base members. Allsub-skids shall be provided with jacking screws, anchor bolts and SS. shimblocks where required.

Skids shall have fully machined (top and bottom) mounting surfaces for thegas turbine, gear, and compressor. All surfaces for mounting the mainequipment shall be machined (milled) to within 0.08 mm per meter from oneside of the mounting plate to any other opposite side.

Machinery skid mounting surfaces or mounting pads shall be machined afterthe skid has been completely fabricated and welded.

Skid mounting pads shall be larger than the foot of the mounted machinery.

Floor/deck plate shall not be used as a mounting surface for rotating

equipment or piping/equipment braces.(API-617, 3.3.2.6).The bottom of the structural skid shall have machinedmounting pads.

All skids shall be blasted and painted in accordance with CLIENTSspecification.


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Each skid shall be provided with two 316L stainless steel grounding bossesfully welded to the structure complete with M10 studs, double washers and

nuts.Lifting point attachment welds and lifting point component welds shall besubjected to 100% RT/UT examination. Lifting point plate componentsexceeding 20mm thick shall be subjected to a UT check for laminations, thematerial to which the lifting point is welded shall be similarly checked over anominal area extending to 300 mm from the lug or trunnion extremities.Material certification for lifting points shall be 3.1b per EN 10204.

Packaged equipment shall be skid mounted with no part of equipmentprotruding beyond the skid edge.

Fabrication and welding of skid shall be in accordance with AISC Manual ofSteel Construction and AWS D1.1 codes. All fillet welds shall be continuous.

The skid shall be shown by calculations to be suitable for two primaryconditions: support of equipment during all conditions of operation (includingflushing and testing), and support of equipment (empty) during lifting andhandling in delivery /sea transport and at the fabrication site. In the operatingcondition, unless otherwise specified, the skid shall be assumed (for designpurposes) to have simple supports at the extreme ends and at the midpoint of

the longitudinal base members. Calculations for the design of the skid shall besubmitted for CLIENT approval.

The above 100 Year Return Period wind speed is at 10 meter above LAT andare omni directional. The wind velocity and the wind forces at each deckelevations shall be calculated in accordance with API RP 2A 21st Edition(WSD). The design wind speed shall be the 3 seconds gust wind speed.

6.3 Layout

Equipment shall be designed in order to keep the plot plan to a minimumwhilst ensuring operability and maintainability. It is intended to arrange theGTC in the limited area of module (see attached drawings), with sufficientmaintenance space in between the trains. The CONTRACTOR shall arrange theenclosure access doors accordingly.

The layout shall ensure access is available without the use of scaffolding orportable ladders.


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6.4 Noise Level

The location of the compressor package is regarded as a general work areaand to satisfy this environment; it is the CLIENTS objective to achieve soundpressure levels not exceeding 85 dB(A) measured at 1m from any package orindividual item of equipment measured in the free field condition. Noiseemissions from the package shall be guaranteed by the CONTRACTOR to meetthose levels specified on the noise data sheets included as part of therequisition.

For those items of equipment that emit high noise levels, suitable acoustictreatment shall be applied.

CONTRACTOR shall complete the noise data sheets, issued as part of therequisition including characteristic noise components such as narrow-band orimpulsive noise and the octave bands in which the narrow-band noise occurs.

7. GAS TURBINE

7.1 General

The Gas Turbine shall be designed per API-616 except as modified by thefollowing requirements.

The following curves shall be submitted during the design period.

Performance curves showing maximum power output against outputshaft speed.

Correction curves for the effect of inlet air temperature on maximumpower output, air flow and heat rate.

Curves showing the effect of inlet and exhaust pressure drop.

(API-616, 4.1.7) Total time from cold state required to reach rated poweroutput shall be stated in the proposal. Duration of the warm-up periods shallbe shown. Time limitations for immediate restart shall be clearly stated in the

respective design documents and in the operating manuals.

As a minimum, two of the speed sensors used for triggering of over-speed tripshall be separate from sensors used for normal turbine speed measurementand control.

The gas turbine shall be equipped with direct drive AC electric motor startsystem. CONTRACTOR shall furnish duly completed motor data sheet anddetails of the Variable Frequency Drive (VFD) with the Tender.


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All special tools required for overhaul removal and re-instatement of gasturbine shall be recommended. All special lifting gear inside enclosure shall be

included.The rotors shall be designed to withstand all stresses resulting to compressorrotor blades conversion from mechanical energy to gaseous energy withouttaking any permanent set or strain, and shall be designed to safely withstand120 per cent of rated speed.

Each bladed rotor shall be statically and dynamically balanced and over speedtested at the manufacturers works. The remaining unbalance shall be inaccordance with equivalent code and standard subject to the CLIENTsapproval. Relevant test records and certificates shall be provided by theCONTRACTOR.

Threaded, threaded and seal welded, or socket welded pipe connections infuel gas lines shall not be permitted.

The blade shall be designed to withstand all vibration, thermal shock, gas andmechanical loads that may be experienced during service. Materials employedshall be consistent with proven standards for long term operation, using thefuels specified, in the environmental conditions existing at the site. Where aproven coating to improve corrosion and erosion resistance is available, this

shall be provided and a technical description given. Each rotating blade shallbe weighed and numbered in such a way that the number will still be legibleat the end of the blades useful life. The record of each of the blade weightsshall be handed to the CLIENT and shall be included in the final MDR.

Turbine blades shall be designed to avoid the possibility of damage byvibration and to minimize the effect of any rubbing against the casing. Therotor design shall allow interchange of blade at site without need to rebalancethe rotor. Where variable geometry blade is proposed, the CONTRACTOR shallstate his method of ensuring that the blade cannot seize in a dangerous

position.For rotor blades in the first-stage, the material shall be heavy duty extrastrength for maximum tolerance to accidental intake of foreign materials.

7.2 Turbine Air Inlet System

The inlet air filter system shall be a three stage medium velocity filter, airintake silencer, plenum and expansion joints. The 4-Stage medium velocitytype air filter, left-hand side access shall consist of:


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First Stage: Marine vane separator/moisture eliminator.

Second Stage: Cleanable pre-filter.

Third Stage: High efficiency HEPA filters.

4th Stage - Vane Separator

The air filtration system shall be capable of removing 95% of dust. 99% airsuspended moisture and 99% of particles 2 m (microns) or larger.

The filter housing shall have an adequate drain system for the moistureseparators. All drains shall terminate in a common flanged manifold via anatmospheric seal suitable for a depression of 178 mm water. Drain system andpiping shall be 316L stainless steel.

Fabric Type expansion joints shall be used to connect the inlet filter housingand duct work to inlet Plenum.

Air inlet duct (inlet plenum), silencer shall be SS316L.

A316L stainless steel weather hood shall be provided by the CONTRACTORand shall be suitable for a rain angle of 45 degrees to the horizontal as aminimum.

The air inlet shall be fitted with 3mm stainless steel wire meshes screen(s).

CONTRACTOR shall provide access doors for inspection and maintenance ofthe inlet filter system. The access doors shall be instrumented to alarm uponopening.

CONTRACTOR shall provide 220 VAC lighting for internal inspection andmaintenance of the air inlet filter system. Switches for the lighting shall bemounted outside of each door to the inlet and shall be in enclosuresappropriate for the Area Classification.

The CONTRACTOR shall provide three Gas Detectors at the air intake. Thedetectors shall be wired to an external junction box in an easily accessible

location.

CONTRACTOR shall furnish design details for external support connections onthe inlet air filters.

7.3 Exhaust System

Manufacturers Standard exhaust system shall be supplied by theCONTRACTOR.


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CONTRACTOR shall furnish design details for exhaust system. The final heightof the stack above the platform main deck level shall be determined during

detail design.CONTRACTORs scope of supply for exhaust system shall include thefollowing:

Suitable expansion joint to avoid transmission of mechanical loads to gasturbine.

Exhaust silencer, in-line, vertical mount, shall be stainless steel SS409.The exhaust silencer shall be designed to meet the specified noise limitof 85 dBA @ 1m from the Package.

The design of the exhaust stack shall provide protection from rainwater,birds and other airborne debris.

Inspection opening with removable cover in ducting of exhaust silencer.

7.4 Turbine Enclosure

The gas turbine shall be housed in continuously vented, soundproof,weatherproof, fire & gas protected enclosure. The package and enclosuredesign shall ensure the daily operator checks can be completed effectivelywithout opening the enclosure doors.

The enclosure with SS316 material shall be designed such that the enclosurepanels can be removed (without cutting or hot work) allowing unfetteredaccess to the equipment inside.

A minimum of two access doors shall be installed in the enclosure walls topermit safe access to the interior for routine inspection and minormaintenance. The doors shall include hermetically sealed 300 mm x 300 mmor larger fire rated windows to allow viewing of the interior. Each access doorshall have at least three 316 stainless steel heavy duty hinges and a safeguardlatch to limit door travel upon over-pressurization of enclosure. A latching

device shall be installed on each door to allow locking in the open positionwhile a person is inside. All doors shall be able to be opened from the insideof the enclosure. The doors shall be instrumented to alarm upon opening.

CONTRACTOR to indicate the number of doors provided on each side of theenclosure in their proposal.

The enclosure shall be designed for positive pressurization. Each enclosureshall be provided with two x 100% ventilation fans to purge the enclosure


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prior to start-up, and the purge cycle shall be incorporated into the turbinestart-up sequence. As the area outside enclosure is hazardous and air is not

permitted to leak from outside to inside, the fans have to take suction from asafe area, i.e. from the gas turbine air inlet plenum after the filters.

The ventilation fans shall be selected for minimum of 200 air changes perhour. Air temperature inside the enclosure with the turbine running shall notexceed 60C.

All components shall be removable from the enclosure through one of thesides. Side panels for maintenance shall be hinged or easily removable.

Effort shall be made to provide a 500 mm wide walkway along the inside walls

of the gas turbine enclosures for access and maintenance.The outside enclosure skin temperature shall be limited to 60C. Personnelprotection measures shall be applied to all components that may present asafety hazard. This shall apply to components in-and outside the enclosurewhere surface temperature can exceed 60C and that are accessible topersonnel.

The enclosures shall be equipped with all necessary safety systems, includinggas detection, fire monitoring and extinguishing system using CO2. Operablelouvers with spring closures and pressure-driven trips shall be provided for

each enclosure opening other than doors. Enclosure penetrations shall beproperly flashed and sealed to prevent Carbon Dioxide leakage.

Each turbine enclosure shall be furnished with a minimum of three lightfixtures suitable for the area classification. Light switches and junction boxesshall be located outside the enclosure and shall be suitable for the areaclassification.

The enclosure shall be equipped with a CO2 fire suppression system asspecified in the next section below.

7.5

Fire Suppression SystemsUnless otherwise specified the enclosures shall have CO2 system installed perNFPA. Only pre-engineered systems utilizing certified components (UL listed)and that have been previously tested and approved for gas turbineenclosures, of equal or larger volume by an internationally recognized thirdparty fire system testing laboratory (e.g Factory Mutual) shall be acceptable.


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7.8 Couplings and Coupling Guards

Couplings shall be designed in accordance with API-671, Special PurposeCouplings For Refinery Services except as modified by this specification.

(API-671, 2.1.1.7)The maximum continuous coupling operating torque load atthe ISO gas turbine rating shall be limited to 80 percent of the couplingmanufacturers published rating.

CONTRACTOR shall supply a matched set of plug and ring gages for eachdifferent tapered bore for the hydraulically fated coupling hubs used.

For diaphragm couplings, the axial natural frequency of each coupling shall beat least 20 percent away from equipment system excitation frequencies.

If practical, the hydraulic tooling supplied for coupling hub installation andremoval shall also have the appropriate fittings to remove any hydraulic fittedthrust discs for the compressor, gear, or power turbine.

The coupling guards shall be sufficiently rigid to withstand application of 1500N force laterally at mid-span during compressor operation without causingcoupling rub and without permanent deformation. Material of constructionshall be brass.

7.9 Lube Oil Systems

Each lube oil system shall be designed per API-614, except as modified by thisspecification.

A lubricating oil system shall be provided complete with reservoir integral withthe skid such as pumps, dual filters, flame arresters for vent line, run downtank (if required), instrumentation and/or controls for turbine/ compressortrain.

Provisions for bypassing bearings for oil flush shall be provided. This includesall jumper pipes and/or temporary hoses. A document detailing therecommended system flushing configuration, flushing procedure andacceptance criteria shall be provided as part of the CONTRACTORsdocumentation.

With the exception of transmitter sensing lines, no portion of the oil systemshall contain stagnant oil during operation.

The main oil pump shall be equipment shaft driven; the stand-by lube oilpumps shall be A.C. motor driven. An emergency oil pump sufficient for


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equipment run-down to standstill and for bearing cool-down shall be provided.The back up DC oil pump and its control panel shall be provided.

A set of two oil filters with on-line change-over shall be provided. Filter drainand vent valves shall be connected to suitable disposal points. Valved oilsampling points shall be supplied downstream of the lube oil filters.

Lube oil air cooler be applicable to marine environment including Three-waytemperature control valve shall be provided.

All oil piping shall be butt-welded seamless 316L stainless steel and all fittingsshall be welded Screwed or socked welded connections shall not be permittedon the oil side. Seal welding shall not be permitted. Valve trim shall be 316L

stainless steel. As a minimum, all surfaces in contact with the lube oil shall have 316 stainlesssteel overlay.

Each mineral lube oil reservoir shall be fitted with a 500 mm wide top access.oil demister shall be provided.

Each system reservoir shall be provided with flanged vent connection(s) sizedper the requirements of API-614.

Each vent shall be provided with a flanged connection, and a properly sized oil

demister device attached to remove any traces of oil mist from the vent air.The oil reservoirs shall be equipped with electric tank heaters. Heaters shall bedesigned for heating oil from the specified minimum site ambient temperatureto required start-up temperature in 2 hours.

Stainless steel 316L weld neck flanges for the piping shall be mandatory. Alllube oil supply and drain piping shall be 316L stainless steel.

All lube oil piping shall be SS316L material. In pressurized service at or over60 C SS316 class steel cannot be used if exposed to atmosphere.

Tubing in pressurized service at or over 60 C shall be made of Alloy 28.7.10 Pressure Vessels

Pressure vessels shall be designed, fabricated, inspected, tested, and codestamped in accordance with Section VIII, Division 1, of the ASME Boiler andPressure Vessel Code, latest edition.

Pipe connections may be utilized for inspection of vessels less than 0.9 meterin diameter. For larger vessels, a 600 mm minimum diameter personal access


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opening shall be provided. All such access covers weighing over 25 kg shall beequipped with hinges or davits.

All connections to vessels shall be flanged. Minimum connection size shall be2-inch diameter.

CONTRACTOR shall furnish and install all internals required for the vessels.Internal steel materials shall be compatible with the shell steel.

Welding, quality control, inspection, and testing shall all be in accordance with ASME Boiler and Pressure Vessel Code, Section IX, latest edition,

CONTRACTOR shall furnish drawings of all vessels, including internal details,as well as vessel calculations and detailed specifications.

7.11 Fuel Gas System Requirements

A on skid natural gas ELECTRICAL FUEL MODULE shall be provided for the gasturbines. This system shall include fuel-gas filter and the fuel gas controlvalves, Flow meter... All components of the fuel systems shall be fullyaccessible for maintenance and shall be made from 316L SS material.

The system start-up sequence shall include automatic draining of anycondensate from skid fuel gas filter, which shall close after draining of theliquid if any.

8. CENTRIFUGAL COMPRESSOR

8.1 General

The compressor shall be designed per API-617 last edition except as modifiedby the following requirements:

High efficiency compressor to reduce required power and fuelconsumption.

Reduce space, footprint, number of dry gas seals.

Modular bundle concept for ease of maintenance includes the completecompressor internal assembly: rotor, statics, heads, gas seals, bearinghousings.

An off take for seal gas will be taken from discharge stream.

An Anti-surge Control System is required with a separate anti-surgevalves for each compressor stage.


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(API-617, 2.3.2.3.4) All auxiliary connections shall be flanged and not below1 NPS. The connections shall be butt welded and flanged or machined and

studded. All orifice plates shall be provided with the tag numbers and details engravedon their handles.

It is preferred that the compressed gas temperature of any compressor stageshall not exceed 150C. Temperatures exceeding 150C will be permitted ifthe CONTRACTOR can provide good reason for exceeding the limit and candemonstrate the adequacy of the equipment and seals supplied whenoperating at the higher temperature.

Orifice flanges with pressure tap shall be installed at a suitable point on thebalance line for a flow measuring device.

(API 617, 2.2.4.1) CONTRACTOR shall submit all the welding procedure forCLIENT review.

Auxiliary connection including instrumentation taps shall not be located on thecompressor nozzles.

The CONTRACTOR shall take precautions in the selection of materials,manufacturing procedures and heat treatment to prevent corrosion.

The cylinder casing maximum allowable working pressure shall exceed rateddischarge pressure by at least 15%. CONTRACTOR shall include considerablecorrosion allowance in the Tender.

The proposed material for compressor casings shall be suitable for the gascomposition and Operating conditions specified in the process gas data sheet.The inner casing (bundle) of barrel type compressors shall not be drilled fordraining or flushing connections.

8.3 Shaft and Impellers

(API 617, 2.5.10.1) The impellers shall be of closed type and shall beconstructed using forgings and shall be welded or milled and welded usingcontinuous full penetration welds.

Each impeller shall be statically and dynamically balanced and over speedtested at the manufacturers works before assembly. The remaining unbalanceshall be in accordance with equivalent code and standard subject to theCLIENTs approval. After the impeller is mounted to the shaft it shall be


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dynamically re-balance. All relevant test records shall be provided to theCLIENT.

Shaft sleeves for critical area (e.g. impeller seating area) shall be provided.The sleeves shall be stainless steel suitably hardened for wear resistance andsealed to the shaft.

(API-617, 2.5.5) Thrust disks shall be replaceable and mounted on the shaftwith a hydraulic fit.

(API-617, 2.6.8) Thrust disc shall be individually balanced.

Where applicable, the CONTRACTOR shall perform hardness check on at leastone heat affected zone and unaffected zone for each impeller after heat

treatment and the results shall be recorded.

The thrust balancing line shall be sized to handle balance piston labyrinth gasleakage with at least three times the initial labyrinth clearance withoutexceeding the load rating of the thrust bearing.

Impellers, diaphragms and guide vanes shall be selected to optimize efficiencyunder the full range of operating conditions. Riveted impellers are notacceptable. Provision shall be made for Baroscopic inspection of impellers.

Renewable shaft sleeves for critical area such as impeller bores shall be

provided. The sleeves shall be stainless steel suitably hardened for wearresistance and sealed to prevent leakage between the shaft and sleeve.

Impellers that can be used in a "restaged" rotor are easily salvaged anddowntime is minimized. Reusing old impellers, instead of purchasing new onesto match new operating conditions, enhances the economic feasibility ofrestaging to maintain optimum compressor performance and the lowestpossible operating costs.

8.4 Bearings

(API-617, 2.7.3.4) Thrust bearings shall be selected such that the maximumcompressor load does not exceed 50% of the bearing manufacturerspublished rating at the most adverse operating point, including start-up. Thedesign of thrust and journal bearings shall be in accordance with therequirements given in API 617. Thrust and journal bearings shall be of theleading edge groove (LEG), tilt pad type.


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(API-617, 2.7.4.1) Bearing housings shall be isolated from the seal chamberby an air space, and shall be fitted with a suitable sealing device to keep lube

oil from reaching the seal chamber.Thrust and journal bearings shall be fitted with RTDs to detect surfacetemperatures during compressor operation. Each journal bearing shall befitted with at least two embedded RTDs. Each thrust bearing shall be fittedwith at least two RTD's on the active side of the bearing and two RTD's on theinactive side of the bearing. RTDs shall be located in the area of minimum oilfilm thickness. They shall be embedded in the steel backing close to theBabbitt interface. Thrust proximity sensors shall be provided

The CONTRACTOR shall supply to the CLIENT a graphic display of speedagainst load capacity showing boundaries defined by the criteria below:

The minimum oil film thickness for continuous operation

The maximum bearing lining temperature for continuous operation

The fatigue or mechanical limit for the bearing or its lining material

Bearing metal temperature rise for hydrodynamic radial and thrust bearings(using RTDs) shall not exceed 100C at specified operating conditions with amaximum inlet oil temperature of 50C. CONTRACTOR shall provide bearingtemperature alarm and shutdown limits on the datasheets.

Bearing housings shall be non-pressurized, isolated from the seal chamber byan air space, and shall be fitted with aluminum alloy labyrinths or othersuitable seals to separate it from the seal chamber and keep lube oil fromreaching the seal chamber.

All bearing housings shall be provided with adequate oil seals to prevent lubeoil leakage into the coupling guards of non-lubricated couplings. Bearing oilseals shall be at least double labyrinth with a slinger and an oil return drainbetween labyrinth sections.

8.5 Shaft Seals

Terminology:

Seal gas: Gas injected immediately upstream of the PRIMARY seal(between the seal and inboard labyrinth).

Buffer gas: Gas injected immediately upstream of the SECONDARY seal(between the Secondary seal and intermediate labyrinth).


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Separation gas: Air injected between barrier seal.

The Dry Gas Sealing System shall comprise of tandem seal cartridges, a gasseal control panel including duplex coalescing filter, heater, control valve

The gas seal control system shall enable to control and monitoring dry gasseals, separation seal performance on site and in the control room. Alarm, tripsetting incorporated into PLC logic enable to protect compressors from sealsfailures. Design of the control panel shall have three main functions:

Filtration/heating and coalescing of seal gas as well as separation(buffer) air supply.

Regulation of seal gas pressure and differential pressure monitoring of

seal gas and Separation (buffer) air supply. Monitoring/protection of seal-gas leakage.

The seal gas supply shall be sized to provide sufficient flow to preventcontaminants from entering the primary seal chamber with an inner labyrinthclearance enlarged to at least three times its initial size. CONTRACTOR shallspecify seal gas flow rates at three times new labyrinth clearances.

A source selection system shall be incorporated into the module to switch theseal gas feed to the appropriate source during shut-down and start-up without

the need for operator interference. Apart from the internal supply from thecompressor discharge, seal gas shall be made available by the CLIENT asalternative seal gas sources.

The seal gas module shall be designed to remove all particles and liquids up to1 micron from the specified seal gas supply that could result in prematureseal failures. This shall include ensuring there is no potential for liquids tocondense at the seal faces during all operating conditions (including start-upand shutdown condition).

Piping for continuous seal gas injection shall include a single Y-type strainer

with 100 mesh screen upstream of the fine filters, the system shall alsoinclude an automatic differential pressure controller and low pressure alarmand seal gas pressure gauge.

Piping and components exposed to seal gas downstream of the strainer shallbe SS316L


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Pressurized Seal Gas piping not covered by an enclosure and at or over 60Cat any time of operation shall be duplex SS or other SS not prone to chloride

induced cracking. Tubing in such service shall be Alloy 28 Although the secondary (outboard) seal in the tandem set shall only be usedas an emergency backup to allow an orderly shutdown if the primary sealfails, it shall be identical to the primary seal in rating and design of theinternals.

(API 617, 2.8.4.1) The bearing separation seal shall be replaceable withouthaving to remove or disturb the dry gas seal cartridge.

(API-617, 2.8.4.1) The seal cartridge shall include a drain passage between

the separation seal and the secondary dry gas seal.CONTRACTOR to advise the minimum and maximum Instrument Air demandfor the separation seals

An alarm shall be initiated in case that:

The pressure downstream of the separation seal increases to a degreethat the differential pressure between the separation air supply and thedownstream vent reduces below a predetermined level as recommendedby the CONTRACTOR.

The separation air pressure is lost during operation.

The separation air pressure is lost when the compressor is in stand still,the lube oil flow to the bearings shall be stopped. A permissive to startshall be provided for starting the lube oil pump.

The dry gas seal rotating elements shall be component balanced andassembly checked. Balancing record shall be included in the compressordocumentation.

(API-617, 2.8.4.4) The seal assembly housings shall be clearly marked on theoutside of the cartridge with location description, or an arrow indicating thedirection of rotation of the seal elements.

The seals shall be suitable for operation without buffer gas.

The sealing components (o-rings, lip seals, etc.) belonging to the sealcartridges shall withstand unlimited depressurization rate.


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Electrical power will be provided by the CLIENT at 380V AC, 3-phase / 220V AC, 1-phase, 50Hz, neutral solidly earthed at source for lighting and small

power and 220V AC (UPS), 1-phase, 50Hz neutral earthed for UCP.Motor control switchboard (MCC) for Gas Compressor Package (Optional)

All AC electric motors, such as lube oil pumps, turbine enclosure ventilatingfans, etc., shall be rated 380 volts AC, 3-phase, 50 Hz. All motors shallconform to relevant IEC standards.

CONTRACTOR shall provide lighting fixtures for inside the gas turbineenclosure and inlet air filter. A battery pack that will allow the fixture tocontinue to operate after a power outage for approximately 90 minutes shall

be supplied in the fixture.Power and control wiring within the GTC package shall be in accordance withBS 7671 IEE Wiring regulations 17th edition, and Specification for ElectricalRequirement for Packaged Equipment.

Solenoid coils furnished by CONTRACTOR shall be rated 24 VDC unlessotherwise specified.

Motors, switches, etc. shall receive full tropical treatment for operation inhumid, salt-laden environment, including fungus-proofing for the interiorsurfaces.

Shutdown and alarm circuits shall be normally energized. Electrical power foralarm and shutdown purposes shall be connected to separate branch circuitsfor connection to CLIENTS SSD.

A maximum of two (2) conductors per terminal shall be permitted and shallnot violate the Ex requirement. 10% spare terminals must be allowed on allterminal strips.

Cable glands shall be dual certified explosion proof Exd and Exe typenickel plated brass with ISO threads, as manufactured by Hawke or

equivalent.

Grounding cables shall be installed from each skid mounted equipment to thepackage GTC steel frame unless it is directly welded to the GTC. Twogrounding bosses, M10, welded to the skid shall be provided.


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10. TECHNICAL REQUIREMENTS FOR INSTRUMENTATION ANDCONTROL

10.1 General

This section defines the minimum requirements for the design and integration,testing of the package instrumentation, control and automation system.

It shall be the responsibility of the package CONTRACTORs to advise theCLIENT should conflicts exist with the CLIENTS requirements and the safeand correct operation of the CONTRACTORs turbine/compressor package andCONTRACTOR provided auxiliary packages.

The packages controls systems which reside in the Unit Control Panel shall be

interfaced with the plant SSD, PCS, SCADA systems via Modbus or Ethernet IPnetwork.

The CONTRACTOR shall be responsible for interface and collaboration with theSCADA system existing to implement all necessary monitoring functionsassociated with the compressor package. The control functions for theproduction process and utilities should be achievable from the Control Room(CR) via the PCS, SSD system located in CR.

Direct operator interaction with the UCP located in CR shall be local start-up,control, maintenance and commissioning. All monitoring functions, includingalarm handling, shall be performed via the UCP and SCADA system.

The CONTRACTOR shall provide all the field devices on the GTC. These fielddevices shall be provided in accordance with the approved project data sheetsand specifications, which the CONTRACTOR shall prepare and submit forapproval by the CLIENT. The field devices shall be installed and wired to skid-edge junction boxes by the CONTRACTOR, ready to be connected to the CRby means of multi-core cables.

The CONTRACTOR shall be responsible to review selection of the special

cables used for machine protection system etc. between skid and UCP. TheCLIENT shall supply of all these skid-to-UCP special cables.

The Instrument Control & automation equipment and systems for the packageshall be designed and installed in accordance with the documents, drawings,standards. Field devices shall be selected in accordance with List of ApprovedInstrument CONTRACTORs & Equipment.

The CONTRACTOR shall participate in CLIENTS Hazop and Risk Assessment.


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CONTRACTOR shall provide SIL Classification, verification and Safetyrequirement specification (SRS).

10.2 Unit Control Panel

The UCP shall include PLC based, Anti-Surge system, Capacity Control systemand Machine Monitoring System complete with hardwired indicators,hardwired switches for starting, emergency s/d pushbutton, hardwired alarms,UCP-HMI etc.

The PLC based system functions shall include controls, sequential start-up/shutdown, safeguarding functions and protection and fire / gas detection andprotection. The PLC system hardware and software shall be SIL 2 certified (as

per IEC 61508/61511) or equal. It shall include dual redundant power supplymodules as a minimum.

The Control system shall include anti-surge control, capacity/performancecontrol. Any Diagnostic software shall be installed on a PC based system.

The UCP shall include Machinery Monitory System (MMS) and shall beintegrated into the PLC for machine condition monitoring and protection. TheMMS shall be supplied with interface facility.

The following spare capacity shall be provided as a minimum:

Networks and Communication Capacity: 40%

Installed I/O (per I/O type and per system): 20%

Processor Capacity for each part of the system: 30%

Operator Interface Capacity for each part of the system: 20%

Available physical space inside UCP (per system and per location): 20%

Power Supply Capacity: 30%

Field Cables, Junction Box size, UCP size, UCP termination spare, PLC I/Ocards, Channels and Rack Space: 20%

The CONTRACTOR shall be responsible for implementing all the control logicsin the PLC system. The CONTRACTOR shall furnish, to the CLIENT, detailedlogic diagrams with written descriptions for all turbine control functions. Inaddition, the CONTRACTOR shall provide detailed Cause and Effect Diagrams(CED) depicting the operation of the turbine/compressor control system.

The Fire and Gas control functions for the turbine enclosure shall be includedin CONTRACTORs scope. Appropriate logic within CONTRACTORs UCP PLCs


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shall be implemented to undertake necessary control and shutdown actions inthe event of fire or gas detection. Inputs into CONTRACTORs UCP PLC from

CLIENTS SSD/FGS system will be digital (voltage free contact). CONTRACTORshall specify his input requirements for SSD / FGS control.

CONTRACTOR should supply a Compressor Performance Monitoring andTurbine Performance Monitoring, each of these performances monitoringsystem shall be implemented on HMI in UCP.

The UCP HMI shall have graphics as required by the CONTRACTOR for thecontrol and monitoring of the compressor/turbine unit. The UCP HMIcommunicate with PLC via Ethernet or Control Net.

Remote access from Desktop computer to the UCP PLC via the Manufacturersdedicated card shall be provided by CONTRACTOR with respective softwareand license to allow the CLIENT staff remote troubleshoot and performanceoptimization activities. CONTRACTOR shall collaborate with The CLIENT toprovide this communications tie-in on the platform. This remote accessfeature will not be left active by the CLIENT on a regular basis. Passwordprotection is also required. Remote modifications to logic or system set pointswill not be allowed, these must be made on location and follow CLIENTmanagement of change procedures. A time based Auto log off facility shallalso be incorporated.

CONTRACTOR shall provide a laptop PC for programming and maintenance ofUCP, complete with all required software, hardware and all accessoriesinclusive of cables, adapters, carrying case, etc to permit up-loading anddown-loading of data and programs to the UCP PLC. The Laptop shall be ofultra-light weight, and be provided with Core 2 Duo Intel microprocessor asminimum, OS-Windows XP Professional latest version or later OS-Window, 15inch monitor, CD combo drive. All software shall be provided with evergreenlicenses.

10.3

Field InstrumentsField devices shall be sized, selected, tested and furnished by CONTRACTOR.CONTRACTOR furnished devices shall include: anti-surge control valve,temperature transmitter, pressure transmitter, flow transmitter...

Dedicated anti-surge systems shall be provided. The anti-surge valve(s) shallbe sized to meet the flow rate and opening speed to achieve surge protection.


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10.4 Other Compressor Instruments

10.4.1 Vibration and Axial Displacement Monitoring

Compression unit shall be equipped with a vibration monitoring system whichcomplies with API-670. The monitoring units shall be located on the packageUCP. The CONTRACTOR shall furnish all probes, conduit, and wiring to theskid mounted junction boxes. Attenuation for passing through critical speedson start-up/shutdown shall be provided if required.

Vibration probes, Proximitor probes and proximitor drivers shall be fullycompatible with Bently-Nevada Vibration monitoring system. Configurationsoftware licenses shall be provided to CLIENTS Document Control Manager as

part of CONTRACTOR documentation.10.4.2 Bearing Temperature Monitoring

In general, bearing temperature shall be measured at the points which areunder maximum loading.

Sensor shall be three wires RTD element of platinum having 100 ohmsresistance at 0 deg C.

Temperature Monitoring shall be on UCP-HMI.

10.4.3 Speed Instruments

All speed instruments shall be supplied as per CONTRACTORs standard.General philosophy is that key phasors are provided on each shaft that rotatesat different speed. Key phasor system shall be provided by CONTRACTOR forperforming analysis of vibration signals. CONTRACTOR shall provide necessaryreference on the shaft to determine one-per-turn occurrence.

10.4.4 Anti - Surge Control System

CONTRACTOR shall be fully responsible for the complete design of Antisurge/performance control system (ASC) including selection of type of flow

element and controller Algorithm. CONTRACTOR shall guarantee theperformance of machine with the offered ASC system. Wherever required,

ASC system shall be designed in such a way that it is capable of correcting thecompressor operating point so as to avoid surge while minimizingrecirculation.

Suitable anti-surge recycle valves and associated controllers shall be providedin line with the arrangement shown on the process flow diagrams. The valveselection shall be selected by the CONTRACTOR of the Anti-Surge System.


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The anti-surge control system shall include anti-surge and emergency anti-surge controllers for each recycle valve. The ASC shall be a dedicated single

loop controller on proprietary Hardware Platform or single/multi loopcontrollers of common hardware platform such as PLC.

Features of the anti-surge protection system shall include:

High integrity, fast acting system that provides accurate and rapid;

Opening of anti-surge control valves that fail in the fully open position;

Facility for adjusting the surge control line settings;

Anti-surge and emergency surge detection instrumentation.

The anti-surge control system shall be located within the UCP. Operator shallbe able to interface with the surge controller from UCP. A list of surgemonitoring and trending options shall be included in the bid submission.

CONTRACTOR of the Anti-Surge System shall issue the parameters andequations required to program the surge controllers. The programming andsurge control line equations shall initially be done on the expected surge linecurve issued and later reissued per the field test results.

All Anti surge controller connected transmitters shall provide the speed ofresponse necessary for anti-surge control function.

The CONTRACTOR shall establish the compressor recycle rate based on theperformance curves and size anti-surge valves to cater for surge control,startup, zero inlet flow, and any other operating conditions stated detailed inthe equipment datasheets.

10.4.5 Peformance Control

Master control function that will automatically control the speed.

10.5 Interface With Plant PCS/SSD/FGS

10.5.1 PCS

Signals required by the UCP for compressor control purposes shall be hardwired directly to the UCP by CLIENT.

CONTRACTOR shall provide interface of CONTRACTORs package PLC toSCADA via redundant Modbus protocol or Ether Net IP for remote statusmonitoring at SCADA console. CONTRACTOR shall provide PLC memory map,node address and other configuration details as required for configuration ofthis interface by CONTRACTOR.


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10.5.2 SSD

SSD will provide hardwired permissive signals for control ofsuction/discharge/Level shutdown valves, blow down valves and compressorstart-up. Signals which are used for compressor shutdown shall also behardwired directly to the UCP.

Suction/discharge/pressurization valves are controlled by both SSD and UCP.

CONTRACTORs package shall receive the hard wired signals as poweredDigital Outputs (24 VDC signals) from Platform SSD system. These signalsshall be identified during detail engineering.

CONTRACTOR shall install high reliability interposing relays in their cabinet to

isolate SSD power supply from its own power supply.

The CONTRACTOR shall ensure that the field devices selected and installed foreach loop fulfill the required Safety Integrity Level (SIL) in terms of the levelof certification carried by the device and the configuration. Furthermore, itshall be ensured that the classified SIL level can be met without requiringproof-testing more frequently than during planned maintenance shutdowns.

The CONTRACTOR shall also provide the necessary MTBF and reliabilitynumbers as per IEC 61508/61511 and shall include the same in theCONTRACTOR developed Safety Requirement Specification (SRS).

10.5.3 FGS

All areas outside the compressor skid will be monitored by CLIENTS FGS. Allareas within the compressor skid shall be protected by CONTRACTORS FGScontroller installed in UCP unit.

Minimum three IR hydrocarbon type detectors shall be provided byCONTRACTOR for each of the following locations:

Air Intake

Enclosure itself Enclosure Vent

Four flame (UV) and Four heat detectors inside the turbine enclosure

CONTRACTOR shall provide necessary warning audible and visual alarm.

The CONTRACTOR shall provide and install a fire and gas detection system

CONTRACTOR shall prepare and submit F&G field devices specifications and


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The fuel gas piping maximum design pressure shall be 45 barg at 150C.

All piping within Gas turbine CONTRACTORs scope shall be schedule 40 forsizes 2 and above and schedule 80 for sizes 1 and smaller. All pressurecontaining piping shall be hydro tested.

All small bore piping and tubing shall be sufficiently supported and protectedagainst damage when stepped on during maintenance and repair activities.

Tubing shall be ANSI 316L stainless steel material. For systems in pressurizedservice at or over 60C 316 class steel cannot be used if exposed toatmosphere and Alloy 28 shall be used instead.

12. UTILITIES & TIE-INS

12.1 Utilities

Cooling water is not available

DHG PVE DD 3 ME SPC 005_Spec for Gas Turbine Compressor Package

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