BOOKIII

Part 4 Technical Requirements

Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

TABLE OF CONTENT
) BOOK 111

PART 4 TECHNICAL REQUIREMENTS

SECTION 4.6 MECHANICAL WORKS

SUB-SECTION 4.6.11 FUEL GAS SYSTEM

4.6.11 FUEL GAS SYSTEM ...................................................................................... 1

4.6.11 .1 SCOPE OF WORK ...................................................... .. ......... .. ... .. .. 1

4.6.11.2 DESIGN AND OPERATING CONDITIONS ..... ......................... ....... 2

4.6.11.3 DETAILED REQUIREMENTS ....... ........... ........ ........ .... ..... ..... ...... ... 2
4.6.11.3.1 GENERAL ...................................... ....... ....... .. ............ . 2
4.6.11.3.2 FILTER-SEPARATORS ....... .. ............ .......... ........ ....... 4
4.6.11.3.3 FLOW METERING .... ....... ....... .. ......... ......... .. ............. . 4
4.6.11.3.4 GAS PRESSURE REGULATING VALVE ................... 5
4.6.11 .3.5 FUEL GAS HEAT EXCHANGER ................... ..... ... .. .. . 5
-) 4.6.11.3.6 FUEL GAS PIPING .. .... .. .......................................... ... 6
4.6.11.3.7 FUEL GAS BOOSTING SYSTEM (IF REQUIRED) .. ... 8
4.6.11.3.8 PAINTING AND PROTECTIVE COATING .. .. ... .. .. ... .. .. 9
4.6.11.3.9 CONDENSATE DRAIN TANK ................... ............. ..... 9
4.6.11.3.10 CONDENSATE DRAIN PUMP ......... ........................... 9
4.6.11.3.11 ONLINE H2S ANALYZER, SPECIFIC GRAFITY
METER AND GAS CHROMATOGRAPH ... ........ .. .... .... ...... ......... .. ... 9

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

4.6.11 FUEL GAS SYSTEM

The fuel gas supply system will be provided by Gas Supplier. The fuel
gas supply system will be provided by others and it is not included in
the scope of work of the Bidder. The fuel gas system will be scope of
work of the Bidder.

The fuel gas system connection point will be at the Power Plant
boundary.

4.6.11.1 SCOPE OF WORK

The fuel gas system shall be completed in every respect and suitable
for safe, reliable and continuous operation. All materials and equipment
shall be provided as are required to make a complete, properly
functioning installation and shall confirm to the highest standards of
engineering design and workmanship.

Scope of fuel gas system shall include the design, manufacture,

construction, factory testing, packing for transport, delivery to site,
unloading at site, storing, complete erection, testing at site, painting,
commissioning, putting into normal operation, tie-in with fuel gas supply
system from Gas Supplier facilities, reliability and performance testing
of fuel gas system and associated equipment including but not limited
to:
• Connection pipeline to interface point.
• Three (3) x 50 % gas pressure regulating valve
• Three (3) x 50 % fuel gas boosting system (gas compressor) if gas
turbine needs pressure higher than discharge pressure from Gas
Supplier (if Required)
• Two (2) x 100 % fuel gas heat exchanger
• Two (2) x 100 % gas filter separators
• One (1) Condensate Drain Tank
• Two (2) x 100 % Condensate Drain Pumps
• One ( 1) gas metering station at connecting pipe
• All necessary piping, control valves, manual valves with support;
spring hangers; root valves for tapping points; valves and piping for
J drains and vents, etc.
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 BOOKIIJ
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

• Monitoring and Control Equipment

• Electrical equipment
• All other items which are necessary for the proper performance of
the fuel gas system.
• Fixed access ladders and platforms with galvanized hand rails
• Painting and corrosion protection
• Two safety shutoff valves (Emergency shutdown valve) in series
on the main fuel line
• Venting system (including cold stack flare)
• Gas analyzer, specific gravity meter and gas chromatograph
• Gas detector for measuring gas leakage at Gas Turbine Enclosure
• Portable gas detector for measuring gas leakage at gas skid and
along gas pipeline .
• One ( 1) x 100% final gas filters for each Gas Turbine
• One (1) x 100% gas metering on each Gas turbine

4.6.11.2 DESIGN AND OPERATING CONDITIONS

The expected analysis and condition of the gas is as specified inSub-

Section 4.3.17.

All equipment will be in compliance with hazardous area requirements

of IEC 79. The fuel gas system shall be suitable for continuous
unattended operation . The fuel gas flow for Gas Turbines shall be
controlled manually and automatically from the operators console. The
status of the fuel systems shall be shown on Panel in Local Control
Compartment for gas turbine. Interlocks for protection against mal-
operation shall be provided.

All gas turbines governing and protection systems shall remain fully
operative at any condition.

4.6.11.3 DETAILED REQUIREMENTS

4.6.11.3.1 GENERAL

The Bidder shall provide the complete fuel gas system within the Power
Plant. This shall include fuel gas supply piping to the ending at gas
turbines control valve.
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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

) All the equipment shall be fitted with isolating valves to permit repair
and maintenance without interrupting the gas supply.

All isolating valves shall be ball type with double block and bleed
function .

All gas vessel nozzles shall be flanged.

The equipment provided shall be capable of removing contaminants

from the fuel gas to achieve the required quality and of supplying the
required quantity of gas at the required dry and clean conditions.

Emergency shut-down valves shall be "fire safe" in accordance with

API - 607 or BS-5146 and of anti-static design in accordance with BS-
5351 .

The bidder shall design, supply and erect the fuel gas system as
required by the gas turbine operations.

)
Equipment for controlling the gas supply pressure within the specified
limits in the event of an emergency shutdown from the Power Plant
shall be provided.

The Bidder shall provide all equipment necessary in such an event to

protect the equipment supplied under this Contract.

Materials for the fuel gas system shall be selected to avoid sulphide
stress cracking and/or corrosion resulting from impurities in the fuel
gas.

A gas detection system shall be provided in the necessary places to

continuously monitor and for raise an alarm in the event of fuel gas
leakage.

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

4.6.11.3.2 FILTER-SEPARATORS

A filter-separator shall be a horizontal or vertical pressure vessel

separated into two stages. The first stage is the filter compartment and
the second is a high efficiency liquid separator or mist eliminator.
The filter-separator and its auxiliaries shall be designed for the design
pressure of the fuel gas treatment system and the material selection
based on the use of the specified fuel.

The filter separator shall be fitted with drain valves, a lockable vent
valve connection leading to the vent system, a pressure safety valve
and a vessel purge connection.

The design of the filter-separators such that they provide proper

reduction of Hydro-carbon liquid droplets in the gas stream to make it
suitable for bidder's gas turbine fuel gas nozzles, and other gas
handling/burning equipment the filter separator efficiency shall not be
less than 99.95 % per particle size of 0.3 micron in diameter.

4.6.11.3.3 FLOW METERING

The function of flow metering is to measure and record the total gas
consumption of the unit The line metering shall have independent
pressure and temperature measuring tapping used for converting gas
quantity from actual pressure to standard pressure and temperature
quantity.

Specific gravity of the fuel gas shall be considered for the above
conversion .

The flow meters shall be provided with isolating valves to facilitate

maintenance.

The flow metering shall have a tariff metering accuracy (within 0.5%
from minimum to maximum) and shall comply with API Chapter 14,
section 3 (AGA Report #3, Gas producers association 8185-90)
specification.

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

Calibration certificates shall be issued by an approved and recognized

authority and shall be submitted by the bidder.

The main flow meter (common) shall be suitable with Gas Turbines
with necessary inspection facility.

The flow meters shall be installed for each Gas turbine.

4.6.11.3.4 GAS PRESSURE REGULATING VALVE

Three (3) x 50 % Gas Pressure Regulating Valve shall be provided to

regulate the pressure to the required pressure of the gas turbine .

The pressure control valves and isolating valves shall be in accordance

with the requirements stated in the specifications of Sub-Section 4.6.1.

It shall be possible to select any one of the 3 x 50% Gas Pressure

Reducing Station streams as a stand-by stream or as back-up stream.

The individual lines should be protected from high pressure by a relief

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valve and each line shall have a hand operated valve to relieve the
pressure of a line in case of maintenance, etc.

The gas velocity through the valves shall be such that the noise level
shall not exceed 85 dBA measured at a distance of 1 meter.

A position indicator graduated 0 to 100% valve travel in 10%

increments shall be provided.

4.6.11.3.5 FUEL GAS HEAT EXCHANGER

A fuel gas heating system shall be installed to ensure the necessary

fuel gas temperature required by the Gas Turbine. This will also
prevent formation of hydrates which might have an adverse effect on
gas combustion equipment.

The single pass heat exchangers shall be located downstream of the

pressure control and reducing equipment.

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

The heat exchangers shall contain stainless steel tube bundles and
) tube sheets through which the gas will flow.

Bidder shall design furnish complete gas heater suitable for Fuel gas
heating before burning in the combustion chamber of Gas Turbine.

4.6.11.3.6 FUEL GAS PIPING

The piping work shall be designed and supplied in accordance with the
requirements of the specification Sub-Section 4.6.1.

All the gas pipes shall be designed, constructed and tested in

accordance with ANSI B31.1 or ANSI B31.8 Gas Transmission and
Distribution Piping System, as appropriate.

All pipes downstream the final filter up to Gas Turbines inlet shall be of
stainless steel.

All butt welds of the fuel gas supply system shall be subject to 100%
radiography test and all other welds shall be subject to 100% non
destructive testing .

All pipe work shall be tested hydraulically to at least 1.5 times the
design pressure for at least 1 hours, or a leak test with air to 1.1 times
the design pressure for at least 2 hours shall be performed.

The hydrostatic test of the pipe work shall be carried out with skids
isolated from the pipe work. Skids shall be tested separately before
installation and connection to pipe work.

The internal surface of all pipes in this system shall be cleaned and
dried after hydraulic testing to the satisfaction of the Owner.

After reconnection of the pipe work, all joints (particularly those not
previously tested on site or in the factory) on the pipe work and skids
shall be air leak tested at full maximum working pressure. After this test
the pipe work shall be dried with dry compressed air and on completion
the system shall be pressurized with nitrogen.

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

All the gas lines shall be sloped to drain to a series of drain valves
) located at suitable points. These drain valves shall be lockable.

Flanges in fuel gas pipe work shall be kept to a minimum.

Isolating valves shall be of the ball type with double block and bleed
function .

All isolation valves shall be designed to withstand the differential

pressure across them when closed.

Vents and thennal reliefs shall discharge to the vent system.

Below ground pipes shall be protected by an approved insulation

system and additional protected by sacrificial anode cathodic protection
and monitoring system. The design of cathodic protection shall be
made by an authorized company. The system shall consist of different
circuits and shall be complete in every respect. Insulation flanges shall
be provided to disconnect the above ground from the below ground
system.

Flanges shall be electrically bridged over for grounding.

Purging and Testing

Sufficient permanent valve connections and vents shall be provided to

permit the gas system to be purged with inert gas, the location and
quantity shall be in accordance with the start-up, shutdown and
maintenance procedure requirements. However, sectionwise system
isolation and purging shall be possible without the need of systems
shutdown (eg. filter, heater, compressor, ESD maintenance). NRV's
shall be installed on the inert gas lines.
Tapping points with isolation valves for testing shall also be provided.

Pressure Vessels

All pressure vessels shall be designed in accordance with ASME Boiler

and Pressure Vessel, Section VIII Unfired Pressure Vessels. All butt
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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

welds shall be subject to 100 % radiography test and all other welds
shall be subject to 100 % non-destructive testing.

The quality requirements of the welds are given in Sub-Section 4.6.1 .

4.6.11.3.7 FUEL GAS BOOSTING SYSTEM (IF REQUIRED)

In case that the fuel gas supply pressure is inadequate for the
operation of the gas turbine, gas booster compressors shall be
provided to compress the available fuel gas.

Rotary compressors with AC drive motors and fabrication frames with

vibration dampers shall be installed. The compressors shall be within
noise compartments with forced draught ventilation or HVAC if
required.

The gas compressors shall be designed according to API standard 618

and shall comply additionally with the German UW regulations.

The drive motors and all other E-motors shall be of explosion proof
design, as far as required by the hazardous zone classification.

Preferably compressors with continuous flow and pressure control shall

be provided.

The lubricating pumps shall be of spindle type and provided with

separate driver motors.

The compressor coolers shall be preferably of the air cooler type.

The gas compressor stations shall comply with the Gas Turbines
demand at all defined load conditions from start up to full load
operation.

The fuel gas boosting systems must be able to satisfy the max. Gas
Turbines demand at worst compressor inlet conditions.

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

4.6.11.3.8 PAINTING AND PROTECTIVE COATING

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Before shipment, all parts of the equipment shall be thoroughly cleaned
of all mill scale, rust, grease and other foreign matter and shall be
painted as specified below.

All parts of the equipment, except the instruments apparatus, shall be

given one "shop coat" of manufacturer's standard primer and finish
paint suitable for the service.

Instrument apparatus shall be prime coated and painted in accordance

with Bidder's standard practice for the equipment.

Before shipment all exposed machined ferrous metal swfaces shall be

coated with a suitable anti-rust compound. Inlet, outlet and all other
orifices shall be blanked off or, plugged.

Interior surfaces of casing shall be coated by Bidder to prevent

corrosion .

) 4.6.11.3.9 CONDENSATE DRAIN TANK

The tank shall be of carbon steel and shall be of horizontal, cylindrical

underground type for atmospheric pressure for the storage of
condensate from the gas fuel. The design and construction shall be in
accordance with ASTM standards.

4.6.11.3.10 CONDENSATE DRAIN PUMP

The contractor shall supply the Condensate Drain Pump to transfer

condensate gas from Condensate Drain Tank to temporary drum
storage. The pump shall be of the horizontal centrifugal type.

4.6.11.3.11 ONLINE H2S ANALYZER, SPECIFIC GRAFITY METER AND GAS

CHROMATOGRAPH

The Contractor shall provide the necessary equipment to monitor H2S

content (H2S Analyzer), specific gravity and caloric value computed by

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 BOOKIII
Part 4 Technical Requirements
Section 4.6 Mechanical Works
Sub-Section 4.6.11 Fuel Gas System

a gas chromatograph meter. The caloric value is to be computed based

on the composition of individual constituent of the gas.

(Last Page of Sub-Section 4.6.11)

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