Materials System Specification

32-SAMSS-100 Combustion Gas Turbines Gas Turbines & Diesel Engines Standards Committee Members
Sabri, Hasan Abdulrahman, Chairman Sabban, Mahmoud Abdulrahim, Vice Chairman Beckenbach, Joseph William Fagihi, Ali Saoud Hussain, Khaleel Ma'Atug Issa, Mohammad Abdallah Jamea, Khalid Hamad Khalifah, Khalifah Sa'Ad Khowaiter, Abdul Rahman Othman Odan, Nabeel Mohammad Saeed, Mustafa Taher Saffar, Adel Abdullah

1 December 2007

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 General..4 Design............................................................ 8 Inspection..................................................... 31 Testing.......................................................... 31

Appendix I Definitions...................................... 34

Previous Issue: 25 January 2006

Next Planned Update: 30 November 2012 Page 1 of 35

Primary contact: Sabban, Mahmoud Abdulrahim on 966-3-8760124

CopyrightSaudi Aramco 2007. All rights reserved.

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

Scope 1.1 This Specification defines the mandatory minimum requirements for design, manufacture and installation of gas turbine packages for the applications of mechanical and power generation drives. This entire Specification may be attached to and made a part of purchase orders. The gas turbine package includes a base frame or a plate, accessory and auxiliary systems for starting, stopping, protecting, controlling and monitoring the gas turbine.

1.2

Conflicts and Deviations 2.1 Any conflicts between this Specification and other applicable Materials System Specifications (SAMSSs), Standard Drawings (SASDs) or industry standards, codes and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department, Saudi Aramco, Dhahran. Direct all requests to deviate from this Specification in writing to the Company or Buyer Representative to be forwarded to the Manager, Consulting Services Department, Saudi Aramco, Dhahran.

2.2

References The selection of material and equipment and the design, construction, and repair of equipment and facilities covered by this Specification shall comply with the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Materials System Specifications 32-SAMSS-008 34-SAMSS-625 34-SAMSS-831 Inlet Air Filtration Systems for Combustion Gas Turbines Machinery Protection Systems Instrumentations for Packaged Units

Saudi Aramco Standard Drawing AB-036322 Sht. 001 Anchor Bolt Details Inch and Metric Sizes

Saudi Aramco Forms and Data Sheets 7305-ENG Equipment Noise Data Sheet
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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

8002-ENG & 8002-M-ENG

Combustion Gas Turbine Data Sheets

Saudi Aramco Inspection Requirements Form 175-325501 thru 325519 Combustion Gas Turbine Package

Saudi Aramco Product Specification A-888 3.2 Industry Codes and Standards American Concrete Institute ACI 318 Building Code Requirements for Structural Concrete Diesel

American Institute of Steel Construction AISC Code of Standard Practice for Steel Buildings and Bridges

American National Standards Institute ANSI MC96.1 American Petroleum Institute API STD 614 API STD 616 Lubrication, Shaft Sealing and Control Oil Systems for Special Purpose Applications Gas Turbines for Refinery Services Temperature Measurement Thermocouples

American Society of Mechanical Engineers ASME B1.21.1 ASME B16.5 ASME B31.1 ASME PTC 1 ASME PTC 4.4 ASME PTC 22 ASME SEC VIII ASME SEC IX Pipe Threads, General Purpose Pipe Flanges and Flanged Fittings Power Piping General Instructions (Performance Test Code) Performance Testing of Heat Recovery Steam Generation Performance Test Code on Gas Turbines Boiler and Pressure Vessel Code/Pressure Vessels Standard for Welding and Brazing Procedures

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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

International Electrotechnical Commission IEC 60502-1 Power Cables with Extruded Insulation and theirAccessories for Rated Voltages from 1 kV up to 30 kV - Part 1: Cables for Rated Voltages of 1 kV and 3 kV

NACE International NACE MR0175 2002 Edition Materials for use in H2S-containing Environments in Oil and Gas Production

US Environmental Protection Agency USEPA Method 1, Section 2.5, Gas Flow Angles and Sampling Procedure 40 CFR 60, Appendix A National Fire Protection Association NFPA 12 NFPA 70 NFPA 72 Process Industry Practices STF05501 STF05511 STF05520 STF05521 STF05530 4 General 4.1 Gas turbine units shall be supplied by Vendors qualified by experience. To qualify, the Vendor must have manufactured at least two turbines of identical or greater speed, firing temperature and power rating for operation on fuels of similar specification. These turbines must have been in continuous service for at least two (2) years and must be performing satisfactorily. Both the gas turbine and inlet air filter element vendors shall be selected from Saudi Aramco Regulated Vendor List (RVL). Fixed Ladders and Cages Fixed Industrial Stairs Pipe Railing for Walking and Working Surface Details Details for Angle Railing for Walking and Working Surfaces Grating Details Carbon Dioxide Extinguishing Systems National Electric Code National Fire Alarm Code

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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

Alternatively, the Vendor may satisfy this experience requirement based on an individual component life in comparable or more severe service conditions. Experience need not be concentrated in a single turbine unit but may be spread through separate operating turbine components such as gas generators and power turbines. To qualify, however, each of the referenced turbines must have been in continuous service for at least Two (2) years and must be performing satisfactorily. For vendors new to Saudi Aramco, documentation substantiating the Vendor's prior experience and existing resources and capabilities shall be submitted through the Company or Buyer Representative to be reviewed for compliance by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department prior to order placement. The Vendor shall provide contact names of other Users and locations of shipped units to enable verification of satisfactory field operation of referenced turbines. Also, the vendor shall provide a list of all approved repair shops. When other fuels such as natural gas liquids, liquefied petroleum gas, crude oil, residual fuel oils and heavy distillate fuels are used, the Vendor shall provide, as part of the experience qualifications, documented evidence of prior successful experience of burning the contract defined fuels in the proposed turbine and the effect on turbine rating, availability, reliability, parts life and frequency of inspections and overhauls. 4.2 ISO Rating 4.2.1 The Vendor shall identify location of inlet and exhaust conditions used in determining the unit's performance. Typically, the inlet conditions are measured at the compressor inlet flange and the exhaust conditions are measured at the turbine exhaust flange. When required, the power is measured at the output shaft for mechanical drive units. For generator trains, the power is measured in MWe at the generator output terminals.

4.2.2

4.3

Life Requirements 4.3.1 The life requirements for major components shall be based on a base load operation, burning natural gas fuel, and a minimum of 90 annual starts (or more), with an average of 100 hours between starts. For both the aero-derivate and heavy duty industrial combustion gas turbine (CGT) units, the Vendor shall submit the following in the proposal to be used in the Life Cycle Cost (LCC) analysis:

4.3.2

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a)

A detailed breakdown of the unit required inspection intervals for dry natural gas fuel at base load operation condition, and for other fuels when specified in the data sheets. The information shall include manhours to perform typical inspections, outage times, and correction factors for inspection intervals for different loads and number of starts. A detailed maintenance plan, including parts replacement schedule for a 20 years period and a certified current cost of spare parts. The fleet reliability and availability figures.

b)

c) 4.4

Performance, Power, Speed and Emission Requirements 4.4.1 The Vendor shall account for and provide all performance correction factors (from ISO conditions) including the effects of temperature, elevation, humidity (maximum humidity at site maximum temperature), and gearbox, transmission, and other losses, if any. Packages used for mechanical drive or power generation, which are not connected to the national electric grid, shall have a guaranteed available power (hp, kW), at the site rated conditions, of 10% or greater above the required load. The following information shall be also included in the Vendor's proposal and in the operating and maintenance manual (O&M): a) Performance curves (or correction factors) of the following parameters versus compressor inlet or ambient temperature; b) Power output and heat rate. Inlet and exhaust airflow rates. Heat rate versus load. Exhaust temperature versus load. Exhaust flow rate versus load. Maximum and Minimum continuous speed.

4.4.2

4.4.3

The following curves shall also be submitted by the Vendor: For Mechanical drive units, the output shaft power and heat rate versus output shaft speed for the specified speed range (e.g., 50% to 105 %) at the site rated conditions.

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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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Inlet and exhaust pressure drop effects (including inlet filters, inlet and exhaust silencers and inlet and exhaust ducts) on the unit output shaft power and heat rate. Expected performance degradation curve versus time (e.g., power output & efficiency (performance loss) versus number of equivalent operating hours). Output power and heat rate curves versus ambient humidity.

c)

Output Shaft Speeds (for mechanical drive units): Output shaft speed(s), at design and at rated conditions. The maximum continuous speed; this shall be at least equal to 105% of the highest speed required by the driven equipment. The minimum operating speeds. The shaft(s) critical speeds.

d) e) f) g)

Minimum and maximum generator power output. Load factors for power generation units. Load-gear load limits, if applicable. Emissions (i.e., NOx & CO) curves across the proposed unit's full operating range and emission correction curves of all impacting parameters. Reference list of similar engines to include contacts of current users.

h) 4.5

Unless otherwise specified, the turbine Vendor is assigned the responsibility for the complete train (including driven equipment and related auxiliaries). This responsibility means trouble-free startup and operation for the specified operating hours of the entire train of equipment comprising gas turbine, power transmission, driven equipment and accessory and auxiliary equipment. This responsibility shall include the following: Common control system; Power transmission components; Equipment layout and baseplate design, if applicable; All vendor supplied accessory and auxiliary equipment, including the supplied fuel and lube oil systems; Monitoring and protection systems;
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4.6

GT compressor washing systems; GT turbine washing system if ash forming fuels are specified; Performance and guarantee of the complete train; Lateral and torsional dynamic analyses; Noise attenuation.

The Vendor shall provide parts lists as follows: Spare parts and consumables for the first two years of operation. Parts and consumables for a combustion inspection. Parts and consumables for a hot gas path inspection. Parts and consumables for a major inspection. Major components with a life expectancy less than 20 years. [i.e., turbine nozzles (if applicable), blades, combustion liners and transition pieces (if applicable), rotors (if applicable), compressor blades, inlet guide vanes, inlet and exhaust ducts, expansion gaskets, inlet and exhaust silencers, lube oil coolers, motors, pumps, gears, etc.]

4.7 5

The Vendor shall provide a list of the equipment requiring emergency power.

Design 5.1 General 5.1.1 Mechanical drive gas turbine packages shall comply with API STD 616, fourth edition. Manufacturer's standard design is acceptable provided that it complies with this engineering specification's requirements, and a list of exceptions to API STD 616 is provided for review by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. If applicable, the auxiliary gearbox shall be of the manufacturer's standard design which has been proven in either an identical or at minimum in a similarly loaded and operated unit. The proposed gas turbine unit auxiliary systems shall be suitable for both the lowest and highest site ambient temperatures.

5.1.2

5.1.3 5.2

Enclosures 5.2.1 For outdoor operation, the gas turbine shall be packaged in an enclosure. For indoor operation, the gas turbine shall be either in an
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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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enclosure or free standing. The Vendor shall provide, on the Data Sheet, the heat rejection rate from the unit to the building. 5.2.2 Maintenance provisions and equipment for lifting the heaviest gas turbine components shall be provided (e.g., overhead cranes lifting beams and cranes inside accessory compartments). Removable sections in the lagging shall be furnished to facilitate access and removal of compressor upper half casing, combustors and the turbine section casing. All lighting within the local control compartments and walk-in type enclosures shall be furnished and installed. Installation shall be in accordance with NEC or IEC. A ventilating purge air system shall be provided for the accessory compartment, gas turbine compartment and purged exhaust stack, where applicable. This ventilation air shall be taken from the clean air plenum of the inlet air filter housing. The system shall have an installed spare motor driven fan. All doors shall be equipped with panic bars.

5.2.3

5.2.4

5.2.5

5.2.6 5.3

Compressor 5.3.1 When possible, the Vendor shall provide the option for coated compressor stage if the coating is not standard. This information shall be submitted through the Company or Buyer Representative for review by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. The unit shall be equipped with a compressor off-line and on-line washing systems. The manufacturer shall provide instructions for both off-line and on-line washing and shall list allowable cleaning detergents/chemical and recommended washing frequencies and instrumentation to be disconnected during the wash cycle. A manual drain valve shall be provided at the lowest point of the compressor casing. The drain line shall be piped and flanged to skid edge. 5.3.3 5.3.4 The starting device shall be used to crank the compressor rotor for offline washing. The unit control shall include a drying cycle which can be selected by the operator to start the unit after off-line washing.
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5.3.2

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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5.4

Combustor 5.4.1 5.4.2 The Manufacturer shall provide allowable variation of the Wobbe Index for the gaseous fuel(s) specified in the data sheet. An automatic drain valve shall be provided at the lowest point of the combustion casing to drain any liquid that may enter the combustion casing when the unit is shut down. A manual valve shall also be provided in the drain line, downstream of the automatic valve, at an easily accessible location. The drain line shall piped and flanged to skid edge.

5.5

Turbine 5.5.1 The turbine shall be capable of a hot restart at any time after a trip. If this cannot be achieved, the Vendor shall specify the pre-cooling interval between start attempts required by the turbine under any operating conditions, and shall be supplied for review and approval by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. This pre-cooling interval should be part of the re-start logic of the control system. When crude oil is used as fuel, the unit turbine section shall be equipped with off-line washing system. The manufacturer shall provide complete washing instructions and recommended washing frequencies. If heat exchangers are used to cool the turbine cooling air, then an installed spare shall be provided (e.g., 2x100%,1x100% with 3x50% fans). The heat exchanger design shall comply to section 5.9 of this SAMSS.

5.5.2

5.5.3

5.6

Inlet Air System 5.6.1 The inlet air system, up to and including the inlet plenum, shall be in accordance with 32-SAMSS-008. The filtration system shall be a self cleaning type. A manometer or pressure sensor readout shall be provided at the turbine inlet flange, with connection to the turbine control. The inlet silencers shall be corrosion resistant Manufacturer's standard design. If coating is used, it shall be zinc free. A bulkhead double lock type gasket-sealed access panel or bolted manhole shall be provided to access the interior of the plenum
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5.6.2 5.6.3 5.6.4

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

5.6.5

Two safety glass viewing window, one on each side of the inlet plenum, shall be provided as per manufacturer's standard design. The height of the viewing window shall not exceed 1.6m above grade, platform, or walkway. The inlet plenum and the inlet duct shall have drain pipes installed in all low points. The bottom of the inlet plenum shall slope away from the compressor inlet flange towards the drains. A slope of 3/1000 to 5/1000 is acceptable. The drain pipe diameter shall be 25 mm (1 in) minimum, and 50 mm (2 in) minimum for units with evaporative coolers. The drains shall slope downwards continuously and shall be connected to a common trap fitted with an automatic drain valve. Failure of the automatic drain valve shall be indicated by an alarm. The drain system shall be configured such that the maximum liquid level shall not be less than 250 mm (10 in) below the bottom of the inlet plenum. The drain system shall be air tight. In areas where rain can enter the inlet air system, a water droplet catcher shall be installed.

5.6.6

5.6.7 5.7

Drain holes open to atmosphere in the plenum low points are not acceptable.

Exhaust System 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 The discharge of the gas turbine exhaust gases shall be outside of a three-dimensional fire hazardous zone. The exhaust stack discharge shall be at least 3 m higher than any platform or access within a horizontal distance of 7.5 m. The exhaust stack shall discharge outside any classified electrical area. The turbine exhaust stack external surface temperature shall not exceed 230C to a height of ten (10) feet above grade and platforms. Where personnel protection and/or reduction of heat rejection are required, external insulation shall be installed on any surface up to ten (10) feet above grade, walkways, and platforms. The exposed surface temperature shall not exceed 70C. The exhaust duct and expansion joints shall be provided by the Vendor. A pressure indicator shall be provided at the turbine exhaust plenum.

5.7.6 5.7.7

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5.7.8

The exhaust plenum and the exhaust silencers shall be Manufacturer's standard. The exhaust plenum shall be provided with an access manhole (i.e., between the exhaust diffuser and silencers) at grade level or access platform if located above grade. The turbine Manufacturer shall also supply any required extensions to the supporting structure and safety provisions for personnel protection. Emission sampling ports shall be according to referenced USEPA Method 1, Section 2.5, 40 CFR 60. Emissions sampling ports are also possible after the diffuser in the vertical plane.

5.7.9

5.8

Couplings 5.8.1 All couplings shall be of the dry, flexible diaphragm or disc type. If the load is higher than the capability of flexible couplings, solid couplings may be provided. For mechanical drive units, the Vendor shall offer, as optional, a torque metering load coupling designed for continuous operation. The coupling monitor display shall include torque, speed and power. Strain gauge type couplings are not acceptable.

5.8.2

5.9

Fuel System 5.9.1 5.9.2 The proposed gas turbine unit shall be designed to operate on the primary and backup fuels. For gaseous fuels, the proposed unit shall be capable of handling the fuels specified in the data sheets without requiring any hardware or software modifications. The on-skid fuel gas piping shall be SS 316L and of the manufacturer's proven standard design. In addition, all fuel piping welds shall be subjected to 100% inspection (radiography, magnetic particle, dyepenetrate). If sour gas is used as fuel, then fuel gas piping shall be in compliance with NACE MR0175, 2002 Edition. Strainer A fuel gas strainer with a differential pressure gauge shall be provided loose to be installed upstream of the gas supply connection to the turbine fuel delivery interface flange. The internals of this strainer shall be corrosion resistant stainless steel. 5.9.5 For liquid fuel burning unit, the extent and method of liquid fuel treatment shall be determined for each project individually and shall
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5.9.3

5.9.4

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

depend on the fuel quality (grade) and the requirements of individual turbine make and type. Proposals by the Vendor for burning liquid fuel shall detail the fuel specification treatment required. Proposals shall be submitted through the Company or Buyer Representative for review and approval by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. 5.10 Lube Oil and Hydraulic Oil Systems 5.10.1 General 5.10.1.1 The lube oil system shall comply with API STD 614 latest revision, for mechanical drive, and with ASME B31.1 for power generation units. The system shall also comply with the requirements noted in this specification. The list of deviations, where applicable, to this Specification shall be submitted for review by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. If the lube oil system is custom designed (not the Manufacturer's standard construction), it shall be sized to handle both the turbine and the driven equipment. Also, when space limitation exists, as may be the case on an offshore production facility, a combined lube oil system shall be specified. The custom design lube oil system shall comply with Chapter 1 & 2 of API STD 614, Fourth Edition, and the requirements noted in this specification. Provisions shall be made for bypassing the bearings of the unit and driven equipment during lube oil system flushing. The hydraulic oil system, if applicable, shall be of the manufacturer's proven standard design.

5.10.1.2

5.10.1.3 5.10.1.4 5.10.2

Lube Oil Reservoir 5.10.2.1 The location of the lube oil reservoir shall be in accordance with the Manufacturer's standard construction. If the lube oil system is to be custom designed, the reservoir shall be separate from the turbine baseplate. The reservoir retention time shall be in accordance with the Manufacturers standard design, but not less than 5 minutes, based on normal flow and retention capacity.
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5.10.2.2

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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5.10.2.3

The reservoir shall be either stainless steel or internally coated carbon steel. However, welding to the oil tank is not permitted if the tank has already been coated. Lube oil return flow may enter the oil tank below the nominal oil level, provided that no foaming takes place and it is the Manufacturer's standard method, and is supported by extensive field experience with satisfactorily continuous service of at least one year. Features to minimize the potential of oil foaming shall be part of such set up. Information pertaining to oil tank material, coating and oil return flow setup shall be submitted by the Manufacturer through the Buyer or Company Representative for information to the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department.

5.10.2.4

5.10.3

Lube Oil Coolers Lube oil coolers shall be of the manufacturer's proven standard design for the site condition (e.g., marine, desert, etc.), with the following exceptions and additions: 5.10.3.1 5.10.3.2 5.10.3.3 An installed spare shall be provided (e.g., 2x100%,1x100% with 3x50% fans). Oil-to-water coolers shall be provided with air venting feature on water side. Fin fan coolers shall be provided with 316L stainless steel material tubes and heads. All other coolers material of construction shall be submitted for approval to the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. Brush (wire mesh) type turbulators for cooler internals are not acceptable. The minimum cooler design airside fouling resistance shall be 0.000352 m K/W (0.002 ft h F/Btu). The minimum cooler design inlet air temperature shall be the summer dry bulb temperature at 1.0% plus 4.4C (8F). U-bends in air coolers are not allowed
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5.10.3.4 5.10.3.5 5.10.3.6 5.10.3.7

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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5.10.3.7

The vendor shall advise the Buyer of the cooled oil temperature achievable under specified maximum ambient temperature conditions. In no case shall the lube or seal oil temperature downstream of the cooler exceed 60C (140F). The lube oil cooler fan motors shall be equipped with siezmic vibration probs.

5.10.3.8 5.10.4

Lube Oil Filters 5.10.4.1 5.10.4.2 Dual lube oil filters shall be provided. The filter elements shall be of the disposable cartridge type. Lube oil filter switchover valves shall be provided, and shall only switchover between the filters. Valves removal/reinstallation for maintenance shall not require cutting/welding. Lube oil filter switchover during operation shall not affect the unit operation. Differential pressure device across the filter shall be provided with an alarm.

5.10.4.3 5.10.4.4 5.10.5

Lube Oil System Piping The lube oil system supply piping, downstream of and including the lube oil filters, shall be 316L Stainless Steel or better. Carbon steel valves with stainless steel trim are acceptable.

5.11

Piping and Tubing (General) 5.11.1 5.11.2 5.11.3 All threaded process connections shall be tapered per ASME B1.21.1. All flanged process connections shall conform to ASME B16.5. Flexible hoses/piping shall be with integral connectors.

5.12

Starting System 5.12.1 5.12.2 The type of starting system shall be as specified in the datasheets. Starting system associated diesel engines, electric motors, and steam turbines shall be of the manufacturer's proven standard design. The starter steam turbine shall be equipped with its own overspeed protection system.

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5.12.3

The starting system shall be of the manufacturer's proven design, but capable of a minimum of three consecutive start attempts. The Vendor shall specify waiting periods required between starts for recovery of the starting system for various operating conditions. For mechanical drives, the torque curve of the driven equipment shall be obtained from its supplier. As a minimum, the torque curve shall be provided from zero speed to self-sustaining speed of the train. If black start capability is specified, the starting device shall be a diesel engine or an electric motor fed from a dedicated diesel generator supplied by Buyer.

5.12.4

5.12.5

5.13

Controls and Instrumentation 5.13.1 Gas Turbine Control System (TCS) shall be of the manufacturer's standard design. Third party control systems may be allowed only if the gas turbine manufacturer does not offer its own control system. The control system shall be electronic, microprocessor based, and fully redundant. Wherever feasible, a single control system for both the CGT and driven equipment is desired. The turbine control function shall include starting, operating, stopping, protecting, monitoring and cleaning (on-line and off-line) of the gas turbine unit. The control system shall be installed in an air conditioned cabin located in the vicinity of the unit. The control cabin shall be as per paragraph 5.18 of this SAMSS. The starting cycle sequence shall be automatic, unless otherwise specified. The operator shall be able to pause the start up cycle at certain safe steps (e.g., system check, purging, idle) and return to a previous step in the start up cycle (one at a time) without subjecting the unit to any damage or unsafe operation. The operator shall also be able to abort the start up at any point during the start up cycle. The control system shall provide a purge period to displace three to five times the entire volume of the gas turbine and the inlet and exhaust systems, before firing the unit. The control system shall have an independent Uninterrupted Power Supply (UPS) capable of supplying power sufficient to achieve a safe and orderly unit shutdown. The UPS shall be of manufacturer's standard on-line type.
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5.13.2

5.13.3

5.13.4

5.13.5

5.13.6

5.13.7

Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

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5.13.8

Radio Frequency Interference (RFI), from sources such as hand-held radio transceivers operating at 5 watts within the frequency ranges , 50-174 MHz, 406-470 MHz, and 800-870 MHz, and held at a distance of 1.0 meter from the control equipment shall not cause any malfunction, data corruption or damage to the turbine control equipment. For generator drive gas turbines, the speed governor system shall be capable of adjusting through a range of plus/minus 4% of synchronous speed before synchronization.

5.13.9

5.13.10 For generator drive gas turbines operating in an isolated island mode and are under load, the governor shall regulate the speed within plus/minus 4% droop when going from half load to full load. 5.13.11 The proposal shall contain a statement of the permissible maximum value of the steady state speed regulation for which the speed governing system may be adjusted. 5.13.12 Power generating units shall be capable of maintaining the load despite a sudden loss of the parallel or back up power supply (e.g., supplied from a national electric power grid). The units shall also have the capability and facility to synchronize back with the grid power supply while it is carrying the connected load.
Commentary Note: The intent of 5.13.12 is to assure that the GT will be able to supply the required power if the main grid power supply is disconnected for whatever reason, without any limitations imposed on plant's operation.

5.13.13 For heavy industrial units, vibration measurement and monitoring shall be provided on all bearings. The following instrumentation shall be provided: One event per revolution sensor (key phasor) on each shaft. Journal bearings shall have radial shaft relative displacement sensors (X-Y probes) mounted at 45 from the vertical centerline. Bearing housings shall have a piezo-velocity seismic transducer displaying vertical velocity in RMS. The thrust bearings shall have dual probes with voting logic monitoring the axial position. For probes requiring cooling, the Vendor shall specify the cooling air quantity and quality.
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Installation and calibration shall be in accordance with 34-SAMSS-625. 5.13.14 For aero-derivative engines, vibration measurement and monitoring shall be per the Vendor's standard. A minimum of two transducers are required, one on the compressor casing and one on the turbine casing. Both transducers shall be used for alarm and emergency shutdown. Installation shall be in accordance with 34-SAMSS-625. The driven equipment shall be equipped with a minimum of a keyphasor, and proximity probes measuring radial and axial directions on each bearing housing, as applicable. 5.13.15 For heavy industrial units, bearing lube oil drain thermocouples or RTD shall be provided for every bearing. One common thermocouple in a combined drain is not acceptable, except for bearings with common cavities. Hydrodynamic thrust and radial bearings shall each have either an RTD or a thermocouple installed in a pad that is expected to read the highest temperature. Lube oil drain thermocouples shall be utilized for alarm and emergency shutdown. Installation shall be in accordance with 34-SAMSS-625. 5.13.16 The speed sensor shall be either of magnetic or inductive pick-up type. 5.13.17 For turbines equipped with rolling element bearings, on-line metal chip detection instrumentation shall be provided in each bearing lube oil drain line. Annunciation of detected chips or debris shall be provided in the plant control room. 5.13.18 The instrumentation system shall comply with the electrical area classification requirements designated in the Purchase Order or on the approved electrical area classification drawing. 5.13.19 The arrangement, grouping and number of panels for instrumentation shall be in accordance with the Manufacturer's standard. 5.13.20 The control system shall have a redundant connection, MODBUS or Ethernet, with the Human Machine Interfacte (HMI) and with the plant Distributed Control System (DCS). 5.13.21 Alarm and shutdown systems shall be of fail-safe design. 5.13.22 Control system cabinets shall be rigid, self-supporting and made of metal. 5.13.23 Cabinets requiring heat dissipation shall be convection-ventilated and provided with readily accessible, removable filter screens inserted
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behind slotted louver inlets. Louvers and filters installed within cabinet doors are acceptable. If fans are used to assist in heat removal and are required to dissipate heat when the HVAC is running, redundant fans shall be provided. 5.13.24 Interiors of floor-mounted digital cabinets containing power supplies shall be monitored by an addressable high-sensitivity air sampling or point-type smoke detection system. The detection systems shall have at least two adjustable set points. All sensing devices shall be addressable to the local fire panel. Each cabinet requires an individually identifiable smoke detection end device so that the fire panel will identify which specific cabinet is generating the alarm. Air sampling tubes or pipes for high sensitivity smoke detection systems shall be steel or otherwise have a flame spread rating not over 25 without evidence of continued progressive combustion and a smoke developed rating no higher than 50 or otherwise be UL listed specifically for air sampling smoke detector service. Use of unrated PVC pipe or tubing is not allowed. 5.13.25 The instrument piping and tubing materials and installation shall ensure the reliable and accurate operation in the working environment of the instrument(s) involved, and allow sufficient access for maintenance, calibration and testing. 5.13.26 Instrument tubing shall be adequately supported to eliminate any vibration transmission to the instruments or excessive load to the piping connection. 5.13.27 Each instruments tubing shall be equipped with block valve (root valve) for isolation and maintenance of the associated instrument only. 5.13.28 instrument enclosures shall be stainless steel or copper free aluminum and shall be rated as NEMA 4X or IEC Type IP 65. 5.13.29 all shutdown initiating devices shall be redundant. 5.13.30 Emergency shutdown buttons shall be provided on both sides outside of the gas turbine enclosure. Buttons shall be of the pull type not push type. 5.14 Wiring 5.14.1 General power wiring, for circuits up to 600V to ground and a maximum current rating of 15A, shall be stranded copper; flame retardant PVC, XLPE or XLPO insulated; size 14 AWG minimum;
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have an insulation minimum temperature rating of 90C and shall comply with NFPA 70 or IEC 60502-1. 5.14.2 Instrumentation signal wiring shall be stranded copper; flame retardant PVC, XLPE or XLPO insulated. The minimum wire size shall be: a) 16 AWG single twisted pair/triad from instruments to the nearest skid mounted junction box. Cables carrying analog signals shall also be shielded. Smaller wire size may be accepted if substantiated by field experience and a written approval is obtained from the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. 18 AWG for multi-twisted pair/triad cables from junction boxes to other junction boxes, marshalling cabinets, or control system. 22 AWG for multi-conductor cable inter-cabinet wiring.

b) c) 5.14.3 5.14.4

Pair/triads of multi-twisted pair/triad control cables shall be numbered. Except for thermocouple wiring, a) Power and signal wiring shall be color coded as follows:
AC Supply: Phase Black DC Supply Signal Pair Signal Triad

Positive Red or red sleeve over any Positive Black Positive Black color except green Negative Black or black sleeve over Neutral White Negative White Negative White any color except green Ground Green or green with Third Wire Red yellow trace

b) c) 5.14.5 5.14.6

Thermocouples shall be as per ANSI MC96.1. Blue color insulation or jacket shall only be used for intrinsically safe installation.

Splices are not permitted in wiring. When wiring must be extended, connections shall be made via terminal blocks. Wiring connections shall be made to channel (rail) mounted terminal blocks. These terminal blocks shall have tubular box clamp connector and compression bar or yoke for wire termination. More than two connections per terminal point are not allowed.
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5.14.7 5.14.8

Fused terminals shall be used for power distribution, alarm, and shutdown systems. Double Block and bleed arrangement for each one of the instruments, grouped in the 2 out of 3 shutdown logic, shall be provided to enable maintenance while the unit is in operation Different instruments signals shall be segregated from each other and from power wiring.

5.14.9

5.14.10 Cables may be routed utilizing one of two methods: 5.14.10.1 Instrument cables may be routed in conduits. The conduit installation shall be in accordance with NFPA 70. 5.14.10.2 Armored cables may be routed on trays. For this option, the following guidelines shall be followed: a) The armored cable shall be suitable for the area classification where the packaged unit is installed (e.g., ITC, PLTC, MC, etc.). The armored cables shall be routed on aluminum or stainless channel trays. Galvanized steel trays are not acceptable. The cable armor shall be either steel wire armor or interlocked metallic armor. The trays shall be elevated and shall not be mounted to the skid base plate unless protected by grating. Tray ends are bent to avoid having sharp edges. The glands at both ends of the armored cable shall be certified flameproof (EExd) gland. Where sealing is required by NFPA 70, the gland shall be certified (EExd) with a compound barrier seal (e.g., CMP Protex 2000 - PX2K).

b)

c) d) e) f)

5.14.11 JB shall be 316 series SS and be IEC 60529 type IP66 or NEMA 250/NEMA ICS type 4X and shall meet the segregation requirements of paragraph 5.18.9. 5.14.12 Instruments and JBs shall have permanently attached engraved phoenolic / laminate or plastic nameplates, showing tag numbers. Phoenolic nameplates shall be installed with two stainless steel screws.

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5.14.13 All packaged unit wiring, intended for interface with plant wiring and/or control package, shall be terminated in junction boxes. 5.14.14 Interconnecting wires between skid mounted components, between skid mounted instruments and the skid termination panel, and between skid termination panels and control system panels shall be tagged. Each tag shall identify the device to which the opposite end of the wire is connected. Heat shrink or ferrule type wire tags with permanently embossed identification markings shall be used. 5.15 Electrical System 5.15.1 The electrical equipment shall comply with the electrical area classification requirements designated in the Purchase Order or on the approved electrical area classification drawing. Batteries 5.15.2.1 Batteries supplying power for the DC auxiliary system and turbine control power shall be located in a separate ventilated building or compartment, adjacent to the turbine control compartment in accordance to paragraph 5.18.7. Batteries shall be suitable for site conditions and sized by the GT Vendor to ensure proper operation and safe GT unit shutdown. The batteries shall be of the industrial type and capable of supplying the required stand by power for at least ten (10) continuous hours. Vendor provided batteries and battery chargers shall be of the manufacturer's proven standard design. Valve regulated batteries are subject to pre-approval by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. The vendor shall demonstrate prior experience.

5.15.2

5.15.2.2

5.15.2.3

5.15.2.4

5.15.3

Provision for grounding the skid structure shall be made at diagonally opposite corners. The skid structure shall be designed to accommodate two-hole compression connector, for (2/0 AWG) copper conductor, at each corner. Motors

5.15.4

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5.12.4.1 5.12.4.2

Name plate rating for 480V and 4160V power supply shall be 460V and 4000V respectively. Motors shall meet the criteria for class F insulation, with an allowable temperature rise, above ambient temperature of 50C (122F), to not exceed that listed for Class B.

5.16

Protection Systems The combustion gas turbine unit shall be provided with the following protection systems. 5.16.1 Overspeed Protection 5.16.1.1 The overspeed system shall have redundancy. A minimum of one electric (electronic) and one mechanical trip devices per shaft shall be provided. A totally electronic system may be accepted, however, a fully redundant system with three shaft probes and two out of three voting logic shall be provided. For multiple shaft units, each shaft shall have its own overspeed trip protection. The trip system shall allow on-line testing without overspeeding the turbine (simulation). A load coupling failure shall not result in a turbine speed increase beyond the specified overspeed limit. Alarm and trip speeds shall be specified by the Manufacturer.

5.16.1.2

5.16.1.3 5.16.1.4 5.16.1.5 5.16.1.6 5.16.2

Over-Temperature Protection 5.16.2.1 A minimum of six thermocouples shall be placed circumferentially in the turbine exhaust gas stream to measure exhaust gas temperatures. Alarm and trip temperature settings for the average and spread exhaust temperatures from the thermocouples shall be provided by the Vendor. Over temperature protection may use the same thermocouples instrumentation used for the turbine temperature control.

5.16.2.2

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5.16.2.3

Heavy industrial turbines shall have a minimum of two thermocouples for each turbine disk cavity, where feasible. Alarm settings for the maximum allowable disk cavity temperatures shall be provided by the Vendor. Aero-derivative engines shall have, as a minimum, two disk cavity thermocouples downstream of the last turbine wheel.

5.16.2.4 5.16.3

Fire Protection 5.16.3.1 The fire detection and fighting systems shall be in accordance to NFPA 72 and NFPA 12, respectively. Additional means of detection, such as optical, are acceptable. The fire protection system shall provide coverage to the gas turbine and the driven load enclosures (e.g., the generator enclosure, if Vendor's standard). The protection system shall consist of a fire detection system, fire suppression system, and for gas fueled units, a gas detection system. The fire extinguishing medium shall be Carbon Dioxide (CO2). Carbon dioxide cylinders shall be stored in a separate cabinet for outdoor applications, close to the turbine. A device to determine if the cylinders are full shall be supplied. A common one 100% uninstalled spare agent cylinders shall be provided per site. Audible and visual warning devices shall be installed inside and outside, two each side of the GT walk-in enclosure, to be activated 30 seconds prior to any discharge of CO2 into the area. The color-coding for the CO2 pre-discharge visual alarms or beacons shall have a different distinctive color than that for gas detection. Lock-out devices to disarm the CO2 system when personnel are present shall be installed unless the omission is approved by the Chief Fire Prevention Engineer. The control system shall display an alarm indicating a disabled firefighting system when it is locked out. Air-moving power and fire dampers in the ventilation system shall shutdown upon system actuation.

5.16.3.2

5.16.3.3

5.16.3.4

5.16.3.5

5.16.3.6

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5.16.3.7

Appropriate warning signs shall be affixed in noticeable locations inside/outside all protected CGT's compartments and outside each entrance to CO2 cylinders storage room in accordance with NFPA 12.

5.16.4

Gas and Hydrogen Sulfide Detection System: 5.16.4.1 Gas detection system inside the gas turbine compartment shall be provided. Manufacturer's standard detectors are acceptable with the exception of electrochemical detectors. Set points shall be per the Manufacturers' standard, but in no case shall be higher than the following levels: 50% Lower Explosive Limit (LEL) 25% Lower Explosive Limit (LEL)

Critical (High-high) alarm Warning (High) alarm 5.16.4.2

If sour gas is used as the primary or the alternate fuel, H2S detectors shall be installed in addition to the combustible gas detectors. Set points shall be per manufacturers' standard, but in no case shall be higher than the following levels: 50 PPM Hydrogen Sulfide 20 PPM Hydrogen Sulfide

Critical (High-high) alarm Warning (High) alarm 5.16.4.3

The gas and hydrogen sulfide detection system shall be capable of initiating a gas turbine unit trip using a two out of two voting system logic. When heavy fuel gas is used, proper ventilation and gas detectors shall be installed to facilitate gas detection and discharge in case of a leak. Audible and visual gas and Hydrogen Sulfide, when applicable, detection alarms shall be installed outside of the turbine compartment on each side. The length of the complete train shall be considered to define the number and locations of the alarms to ensure proper area coverage. H2S and LEL beacon colors shall be blue and red respectively.

5.16.4.4

5.16.4.5

5.16.4.5

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5.17

Emissions 5.17.1 Equipment noise levels shall be less than 85 dB(A) at a distance of one meter from the unit at 1.5 meter height above ground. The Vendor shall advise whether acoustic treatment will be required to meet this noise requirement. The need for acoustic treatment shall be determined after review of the plant requirements. Acceptable exceptions to noise limits in 5.17.1 include those emitting from the unit inlet filtration air-pulse system, by-pass operations, bleed-valves, unit trips, start/shut down, transitory conditions, fuel switch-over, no load condition, areas within enclosures, emergency sirens, alarms, and loudspeakers. Exhaust Emission levels for the full expected operating range shall be provided for the proposed gas turbine units. Emission levels shall not exceed the limits specified in the table below across the full operating range identified in the data sheets or the Purchase Order. Combustion Gas Turbines (CGTs) Emission Requirements for Proposed Unit Primary Fuel
Within The Royal Commission Areas Outside The Royal Commission Areas

5.17.2

5.17.3

Refer to the Royal Commission environmental standards Nitrogen Oxides (NOx) @ 15% O2 Sulfur Dioxide (SO2) <60 ppmvd Any emission control will be based on Ambient Air Quality Surveillance (AAQS) compliance

5.17.4

The proposed gas turbine low emission system shall have been performing satisfactorily in continuous service for a minimum of two (2) years in at least two units similar to the proposed one. The vendor shall be responsible for final tuning to the agreed emission levels, start up, and commissioning of the emission controlled systems for the total operating range of the unit. Steam or water injection for emission control is not acceptable.

5.17.5

5.17.6 5.18

Control Cab 5.18.1 The cab shall be positively pressurized and equipped with 2x100% fully segregated HVAC and pressurizing systems.

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5.18.2 5.18.3 5.18.4 5.18.5 5.18.6 5.18.7 5.18.8

False ceilings shall not be used in the control cab. All requirements stated in this SAMSS shall apply on the control cab (e.g., electrical installation, wiring). The control cab shall be made of non-combustible contruction and finishing. Smoke detectors, two below the floor and two to the ceiling, shall be installed per NFPA requirements. The control cab shall be grounded. All doors shall be equipped with panic bars.. Battery Rooms 5.18.8.1 Flooded type batteries shall be installed in concrete construction room in accordance with Saudi Aramco Engineering Standards (SAES) and requirements (e.g., eye wash, safety equipments, etc.). Regulated Valve Batteries (VRLA) shall be placed in a separate room. It shall be in accordance with the control cab requirements of this SAMSS and the following: 5.18.8.2.1 Battery room floor shall be covered with an electrolyte (acid or alkali) resistant, durable, antistatic and slip-resistant surface overall, to a height 100 mm on each wall. 5.18.8.2.2 Battery rooms shall be provided with an addressable spot-type smoke detection system. 5.18.8.2.3 Battery rooms shall be vented to the outside air by forced ventilation to prevent accumulation of hydrogen. The ventilation system is determined such that the hydrogen concentration shall be limited to less than 1% of the total air volume of the battery room. 5.18.8.2.4 The ventilation system shall be 100% redundant and based on one complete air change every three (3) hours. Only direct driven exhaust fans shall be used.

5.18.8.2

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5.18.8.2.5 Air-pressure measuring device, such that ventilation insufficient to the 1% hydrogen limit will cause the high-rate charge to stop and alarm is displayed in the control system. 5.18.8.2.6 Doors shall open outward toward the outside of the cab and fitted with door closers. Doors between battery room and other rooms are not permitted. 5.18.8.2.7 Inlets of air-conditioning shall be no higher than the top of the battery cell and the outlets (exhaust) at the highest level in the room. Return air-conditioning ducts from battery rooms shall be prohibited. 5.18.8.2.8 Working space of at least 1 meter shall be provided in front of each battery rack. 5.18.8.2.9 Lighting fixtures shall be vapor tight and installed at least 300 mm below the finished ceiling to allow hydrogen dispersion past the fixture. 5.19 Baseplates 5.19.1 A baseplate shall be required on all packaged units. A single baseplate to accommodate the turbine, accessory and auxiliary equipment, driven equipment, gear unit, lube oil system, and instrumentation panels is preferred. However, baseplates over 12 m (40 ft) long may be split into bolted and doweled sections to be assembled at the site. Soleplates are acceptable only for very large gas turbine units which must be shipped in sections for site assembly. The Vendor shall provide the necessary features or material for equipment leveling, including leveling shims if required. The leveling material shall be 316L Stainless Steel. If shims are required, the Vendor shall provide packs 3 mm to 13 mm (0.125 in to 0.5 in) thick. Vent and drain piping and valves, manifolded and brought to a skid edge flange RF type in accordance with ASME B16.5 specification.

5.19.2

5.19.3 5.20

Access Structure

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5.20.1

Grating shall be in accordance with PIP STF05530. Railings shall be in accordance with PIP STF05520 and STF05521. Stairs shall be in accordance with PIP STF05511. Ladders and cages shall be in accordance with PIP STF05501. However, fixed ladders shall be of the side step design, except on tanks under 3 meters high where step-through ladders may be used. The above mentioned PIPs may give solutions to certain types, if such a case is encountered, the type and its solution shall be followed.

5.20.2

5.20.3 5.21

Structures 5.21.1 All structural and supporting materials, except ASTM A193, ASTM A194, ASTM A490 or ASTM A490M bolts, and crane rails, shall be galvanized, unless painting is specified in the Contract Documents. Steel embedded in concrete (including ASTM A36, ASTM A307 and ASTM F1554 anchor bolts) shall be hot-dip galvanized. Zinc plating is not acceptable. Galvanizing of steel shapes, washers, plates and hardware shall be in accordance with the following ASTM specifications: a) b) Steel shapes and plates - ASTM A123 ASTM A325 Type 1 or ASTM A325M Type 1 bolts and corresponding nuts and washers -ASTM B695 (or ASTM A153 / ASTM A153M when approved by the Buyer) ASTM A36 / ASTM A36M threaded bar or ASTM A307 bolts and corresponding nuts and washers - ASTM A153 / ASTM A153M or ASTM B695 All bolts, nuts, and washers shall meet required mechanical properties after galvanizing.

5.21.2

c)

d) 5.22 Anchor Bolts 5.22.1

Anchor bolts shall be in compliance with Standard Drawing AB-036322 (The AB-036322 requirement of SAES-Q-005 shall be considered inapplicable for anchor bolts). It is the responsibility of the foundation design engineer to verify the capacity of any vendor furnished or detailed anchor bolts. Equipment shall be installed on mounting plate(s), and the direct attachment of equipment feet to the foundation using the anchor bolts

5.22.2

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shall not be permitted. Mounting plates shall be of sufficient strength and rigidity to transfer the applied forces to the foundation. 5.22.3 Anchor bolts and embedded items shall be set accurately, using templates provided by the equipment manufacturer within the tolerances specified in the AISC Section 7.5, Code of Standard Practice, unless specified otherwise on the vendor drawings. The design of anchor bolts shall be in accordance with the requirements of Appendix D of ACI 318. The minimum anchor bolt diameter shall be 20 mm ("), except when specified otherwise by the vendor for small equipment or for the anchorage of small miscellaneous steel items such as; ladder supports, small piping supports, handrail anchorage, stair stringers, small platforms, etc. Anchor bolts subject to uplift or vibration shall be equipped with an additional nut to serve as a lock nut, to ensure against loosening. Minimum clear distance from anchor bolts or anchor bolt sleeves to edge of concrete shall be 100 mm. Metallic sleeves are not allowed and anchor bolts shall not be in contact with reinforcing steel. Anchor bolts shall have 3 mm as a corrosion allowance in addition to the coating required by the Standard Drawing AB-036322. Post-installed anchor bolts shall not be used for new construction without prior written approval. Approval request will only be considered for chemical anchor bolts that are less than 20 mm (") which are for use as indicted in paragraph 5.22.5. These requests shall be submitted through the Company or Buyer Representative for review and approval by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. When approved for use, the post-installed bolts shall be designed per ACI 318, Appendix D and in strict compliance with the manufacturer's recommendations.

5.22.4 5.22.5

5.22.6 5.22.7

5.22.8 5.22.9

5.22.10 Unless otherwise specified in the PO, anchor bolts and templates shall be made available for delivery six months before the first portion of the first equipment delivery date. 5.23 Dynamics The turbine Manufacturer shall be responsible for providing a lateral critical speed and unbalance response analysis for each of the train components, and a
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torsional analysis for the complete train. The analysis shall be submitted through the Company or Buyer Representative for information to the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. 5.24 Materials Materials of construction of the gas turbine unit shall be Manufacturer's standard for the specified operating conditions, except as required by this SAMSS, the Data Sheets or specified in the Purchase Order. 6 Inspection Inspection during manufacturing shall be in accordance with the Vendor's procedures with the exception of components required to satisfy special material requirements and safety procedures detailed in this Specification, the Purchase Order and the minutes of bid clarification and pre-award meetings. Buyer's inspection of the equipment shall be in accordance with the Form 175-325501 through 325519, Inspection Requirements, corresponding to the particular equipment and as specified in the Purchase Order. 7 Testing 7.1 Hydrostatic Tests The Vendor shall identify in the proposal which components are tested hydrostatically. Testing, when identified, shall be in accordance with test procedures and acceptance criteria of API STD 616. 7.2 Mechanical Running Test 7.2.1 The gas turbine unit mechanical running test is required to verify mechanical integrity, and shall be performed, at the manufacturer's shop, unless otherwise approved by the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. Test procedures and acceptance criteria shall be based on API STD 616 for mechanical drive units, and on Manufacturer standard's for power generating units. The test shall be conducted at full speed and no load for a minimum of 4 hours total duration, and it should include testing of the shaft overspeed trip functionality. The final testing procedure, including Vendor's proposed standard test procedures and acceptance criteria shall be mutually agreed upon by Vendor and Buyer and approved by the Chairman, Gas Turbines &
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7.2.2

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Diesel Engines Standards Committee, Consulting Services Department. 7.2.3 The Vendor shall provide the results of the mechanical running test. Dismantling of the unit is required only in the event of an unsatisfactory test results.

7.3

Electric/Electronic instruments and Control System Tests 7.3.1 Functional test of all electronic instruments after testing for short circuit, cable continuity, ground insulation with a megger, and ground faults. Functional test of all electronic control loop verifying a proper response to simulated input signals. The functional test shall also include, but not limited to, wiring point to point check, insulation and dielectric test, earthing check, power destribution check, I/O signals check and cross signal check, communcation links, sub-system check, and softwear validation test.

7.3.2

7.4

Emission Test Source emission testing or stack testing shall be performed on site within 180 days from the date of initial startup. To demonstrate compliance with applicable source emission requirements, stack tests shall be conducted as per U.S. EPA recommended methods. Other methods may also be acceptable; however, approval must be obtained from EPD prior to commencement of the test(s). A written test report shall be provided to EPD within 60 days thereafter summarizing the results of the stack test.

7.5

Fire Extinguishing System Test The CO2 Extinguishing System shall be required to pass a total flooding performance field test, witnessed by the Chief Fire Prevention Engineer and the General Supervisor, P&TS Div., Fire Protection Department or their representatives, prior to mechanical acceptance sign-off. The test shall demonstrate a full discharge of entire design quantity of CO2 through system piping to verify that CO2 is discharged into the protected equipment and that the CO2/O2 concentration is achieved and maintained for the period of time required by the design specifications, and that all pressure operated devices function as intended. The commissioning and testing procedures shall be submitted to the Chief Fire Prevention Engineer or his representative prior to the time of request to inspect for mechanical completion.

7.6

Sound Level Test

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The noise level test shall be performed on site to meet the requirements of paragraphs 5.17.1 and 5.17.2. The proponent shall contact EPD to request noise level testing during the commissioning process, prior to approval of the Mechanical Completion Certificate (MCC). 7.7 Additional Optional Test The vendor shall include a proposal for an optional gas turbine performance test to be considered for inclusion in the Purchase Order per the following criteria: The machine shall be performance tested on site in accordance with the ASME PTC 1, ASME PTC 22 (or ASME modified), and ASME PTC 4.4 (COGEN units). The test procedure shall be agreed upon by the Manufacturer and the Chairman, Gas Turbines & Diesel Engines Standards Committee, Consulting Services Department. Test shall demonstrate the guaranteed power and heat rate for simple cycle units. The test shall also demonstrate the guaranteed exhaust temperature and flow for cogeneration units. The turbine manufacturer shall submit a report on the unit site performance arrangement with all the required details. This report shall include all protective settings and the necessary curves to define actual site performance. 7.8 Upon the completion of all required tests, the gas turbine rotor(s) shall be axially and radially locked for shipment. Such arrangement will help in minimizing the chance of any impact damage on bearings that may result during the on-road transportation of the gas turbine unit(s).

1 December 2007

Revision Summary Major revision.

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Appendix I Definitions
Base Load: The Vendor's defined output load that the gas turbine is required to produce at site rated conditions while achieving an operating life of over 20 years and the OEM recommended Time Between Overhaul (TBO). Design Condition: The point at which usual operation is expected and optimum efficiency is desired. This point is usually the point at which the vendor certifies that the heat rate is within the tolerances stated in this specification. Parameters used to determine the normal operating point including speed, site conditions, emissions, and fuel composition. Island Mode Operation: When the gas turbine driven generator(s) is operating alone disconnected from the main utility grid (SEC). Life Cycle Cost (LCC): LCC is the equipment Life Cycle Cost analysis to determine cost of equipment acquisition and operation for a 20 years basis and it typically include: initial equipment cost, maintenance, and operational costs. Minimum allowable Temperature: The lowest temperature for which the manufacturer has designed the equipment (or any part to which the term is referred). Minimum Site Temperature: The minimum recorded site ambient temperature as identified in the data sheets. Operating Range: The load and/or speed ranges that the unit is expected to be operated within, at the site expected conditions. Overspeed limit: The maximum speed limit that the shaft are permitted to reach safely.

Peak Load: The power output when firing at a temperature above base load firing temperature as specified by the Manufacturer. Peak load operation capability is intended only for limited or emergency use. Summer Dry Bulb Temperature at 1.0% : A dry bulb temperature that has been equaled or exceeded by 1% (30 hours) of the total hours during the months of June through September.
Site Rated Power: The output shaft power developed by the gas turbine when it is operated at site rated: firing temperature, speed, inlet air temperature, minimum inlet pressure, auxiliary system losses including inlet and exhaust duct losses, exhaust pressure, and normal fuel composition. [Net shaft horsepower (HP) for mechanical drive units, or net generator output in MW for power generation units]. Site Rated Inlet Temperature: The site's ambient temperature as identified in the data sheets, and used for determining the site rated power. Site Rated Speed: The rotational speed required by the unit to achieve the Site Rated Power. This speed should be equal to or close to the normal design speed corresponding to the maximum efficiency point specified by the Manufacturer. Site Rated Firing Temperature: The turbine inlet total temperature, measured at a location immediately upstream of the first-stage turbine nozzles, required to meet site rated power conditions.

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Document Responsibility: Gas Turbines & Diesel Engines Issue Date: 1 December 2007 Next Planned Update: 30 November 2012

32-SAMSS-100 Combustion Gas Turbines

Wobbe (gas) Index: The Wobbe index is a gauge of the OEM allowable range of change in heating value. It is the ratio of the Lower Heating Value (LHV) of the fuel gas divided by the square root of the product of relative density (with respect to air at ISO conditions) and the absolute temperature, T, of the fuel gas:

LHV (G T ) 0.5

G is gas specific gravity

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