DOC.

ID:

40-A-00030

REV/STATUS:

E / Approved

DATE:

17 Dec 2013

MADE/APPROVED:

SIVAKOMA / TUUKAHON

PAGE:

1(20)

NAME:

Technical Specification

SUBJECT:

Gas Pressure Control Module

FUEL GAS PRESSURE

CONTROL MODULE
(GAS MODULE #3)
TECHNICAL SPECIFICATION

Revision history
Revision

Approved by

Reason for revision

Jonas Nylund

Original revision

Tuukka Ahonen

Process Updations

Sivakumar
Komarasamy

Tuukka Ahonen

Fuel gas composition

updated. Material
requirements updated.

Tuukka Ahonen

Jonas Nylund

Process Updations

Sivakumar
Komarasamy

Tuukka Ahonen

Gas flowrate updated

A
B

Made by
Ramaswamy
Neelakantan
Ramaswamy
Neelakantan

CITEC OY AB
P.O. Box 109, FI-65101 VAASA, FINLAND, Tel. +358 6 3240 700 Fax +358 6 3240 850
www.citec.com

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TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.

DESIGN BASIS .......................................................................................................... 3

CODES AND STANDARDS ....................................................................................... 5
DESIGN INPUTS ....................................................................................................... 6
SYSTEM DESCRIPTION .......................................................................................... 7
SCOPE OF WORK ...................................................................................................... 9
TECHNICAL SPECIFICATIONS ............................................................................12
TERMINAL POINTS .................................................................................................13
DATASHEET .............................................................................................................15
PERFORMANCE GUARANTEE ..............................................................................20

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1. DESIGN BASIS
FUEL GAS ANALYSIS - NATURAL GAS
Natural gas will be used as preliminary fuel and Jet A1 fuel is used as back up fuel.
Components
C 1 (Methane)
C 2 (Ethane)
C 3 (Propane)
i-C 4 (i-Butane)
n-C 4 (n-Butane)
i-C 5 (i-Pentane)
n-C 5 (n-Pentane)
C 6 + (Hexane +)
Mcyclo-C 5
Benzene
Cyclo C 6
C 7 Heptane
Mcyclo C 6
Toluene
C8
C 2 -Benzene
mp-Xylene
O-Xylene
C9
C 10
C 11
C 12
C 13
C 14
C 15
H2O
Nitrogen
CO 2
H 2 S ( Refer Note)
C7+
C 12 +
Total

Volume %
97.83
1.22
0.01
0.07
0.07
0.02
0.01
0.01
0.00
0.00
0.00
0.072
0.00
0.00
0.0078
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.0006
0.20
0.26
0.00
0.01
0.00
100%

Weight%
94.98
2.22
0.03
0.21
0.24
0.09
0.04
0.05
0.02
0.00
0.01
0.43
0.01
0.00
0.05
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.34
0.68
0.00
0.09
0.00
100%

Mol. Wt g/Mol
16.04
30.07
44.10
58.12
58.12
72.15
72.15
84.0
84.16
78.11
84.16
96.0
98.19
92.14
107.00
106.17
106.17
106.17
121.0
134.0
147.0
161.0
175.0
190.0
206.0
18
28.01
44.01
34.08
102.7
210.0

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Components
Specific Gravity
C7+ Density
C12+ Density
Dry Gross Cal. Value
Wet Gross Cal. Value
Water dew point

Unit

Values
0.567
0.750
0.834
1022.0
1004.0
-25@90bar

g/cc
g/cc
BTU/SCF
BTU/SCF
C

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

depends on ambient conditions from 15C to 38C.
Design ambient temperature for gas system
Min. Ambient temperature for gas system
Max. Ambient temperature for gas system

26C
14C
38C

GENERAL FUEL GAS PROPERTIES

Description
Molecular weight
Molar Density
Mass Density
Mass heat capacity
Specific heat
Thermal conductivity
Viscosity
HC dew point

Unit
g/Mol
Kg mole/m3
Kg/m3
kJ/kg C
kJ/kg mole C
W/m K
cP
C

Value
16.53
4.503
74.41
2.947
48.70
4.305E-002
1.400E-002
-27.07

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

For all basic information about project, site details and requirements, please refer to
the general specifications that are attached (Doc Id: 40 -0000520).

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2. CODES AND STANDARDS

The module components shall comply with the latest editions of relevant standards
issued by EN standards unless otherwise specified. Here some of them mentioned,
but this is not an exhaustive/full list:
PED 97/23/EC

The European Pressure Equipment Directive

EN 1776

Requirements for the design, construction, commissioning,

operation and maintenance of new gas measuring stations

EN 12186

Gas supply systems, gas pressure regulating stations

transmission and distribution. Functional requirements

EN 1594:2009

Gas supply systems. Pipelines for maximum operating pressure

over 16 bar. Functional requirements.

EN 14382

Safety devices for gas pressure regulating stations and

installations. Gas safety shut-off devices for operating pressure
up to 100 bar

EN 12732:2000

Gas supply
requirements

EN 10204:2004

Metallic materials. Types of inspection documents

EN 10208-2:2009

Steel pipes for pipelines for combustible fluids. Technical

delivery conditions. Pipes of requirement class B

EN 12068:1999

Cathodic protection. External organic coatings for the corrosion

protection of buried or immersed steel pipelines used in
conjunction with cathodic protection. Tapes and shrinkable
materials

EN 12327:2000

Gas supply systems. Pressure testing, commissioning

decommissioning procedures. Functional requirements

EN 12954:2001

Cathodic protection of buried or immersed metallic structures.

General principles and application for pipelines

EN 13445:2009

systems.

Welding

steel

pipework.

for

Functional

and

Unfired pressure vessels.

EN 13480

Metallic industrial piping

EN 14141:2003

Valves for natural gas transportation in pipelines. Performance

requirements and tests

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EN 15001-1:2009

Gas infrastructure. Gas installation pipework with an operating

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

3. DESIGN INPUTS
Fuel gas supply pressure & temperature at Gas pressure control Module battery limit
Pressure
Normal Fuel gas inlet pressure
Fuel gas pressure required at outlet of
pressure control module

Temperature
Minimum fuel gas inlet temp
Normal Fuel gas inlet temperature
Max Fuel gas inlet temperature
Mechanical Design temperature
(Max temperature at GT inlet
Flow
Minimum *
Normal **

=
=

54 Bar (g)

48.0 barg
(in order to Maintain 46.51.4
barg at GT inlet considering
pressure drop in valves & piping
towards GTs.)

=
=
=
=
=

15 C
4070 C
90 C
125C
121 C)

[GE to specify later, will be from zero] kg/hr x 1 GT running

7904 kg/hr x 4 GT = 31616 kg/hr (GT at base load & Chiller ON)
OR

Maximum

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

* GT at ambient temperature of 35 C, GT at base load & Chiller Off

** GT at ambient temperature of 15 C, GT at base load & Chiller ON (463 kBtu/hr)
For all information about mechanical design values and conditions, please refer to
the general specifications that are attached (Doc Id: 40-0000520).
Design shall be according to EN codes & Standards.

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4. SYSTEM DESCRIPTION
The Fuel Gas System for the plant conveys natural gas from the terminal point of
plant at 54 Bar(g) & operating temperature of 15-38 C at proper conditions to the
fuel gas Module. Maximum supply pressure will be 86 bar(g).
The gas fuel supply system consists of following Modules Common for 4 Gas turbines

Gas Receiving & Metering & ESD Module #1

Gas Conditioning Module #2 (Indirect gas fired bath heater with auxillaries)
Pressure Control Module #3

This specification covers the scope of work for Gas pressure control Module # 3.
The gas from the Gas conditioning Module will pass through the Pressure Control
Module #3 consisting of Three (3) Pressure reduction/control stations (PRCS) and
will be forwarded to a common header and further distributed to individual Gas
turbines.
The PRCS shall have two (2) numbers 30 - 100% streams, one (1) number 0 - 30%
start-up line. The two full flow PRCS are each for total fuel gas requirement of 4 gas
turbines. Third PRCS is for the start-up requirement.
The pressure control module is installed downstream of the gas conditioning module.
This allows keeping the upstream vessels as small as possible and will prevent the
gas temperature dropping below the dew point, with the possibility of hydrate
formation. The pressure reduction and control valves shall be of pneumatic type
controlled by downstream pressure using pressure transmitters.
The gas control valve allow fuel flow when the turbine starts and runs, control the
fuel flow, and provide protective fuel isolation when the turbine is shut down. The
fuel manifold connects to the header, which distributes the gas fuel into the gas
filter module before GTs.
The Gas Turbine requires fuel gas pressure to be maintained at constant pressure
for its proper operation. When the gas turbine load alters, the fuel gas flow changes
resulting in variation of header pressure. The pressure control/reduction valve will
reduce and maintain the set pressure at the outlet of gas pressure control module
based on the pressure measurement or/and the pilot valve sensing line. It consists of
two regulating valves of which one will be normally open taking 100 % of the flow,
the other one closed in stand-by.
The gas pressure at the gas turbine inlet shall be controlled by active
control/reduction valve. In case of failure of this valve the monitor valve shall take
over the function of the active valve in a fast and stable response. The active control
valve closed loop control function shall be integrated in the local PLC and shall have
a possibility of signal exchange into DCS.

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Dual redundant pressure transmitters shall be provided and dedicated to the control
monitoring and high/low pressure alarming function. Additional one pressure
transmitter shall be provided and dedicated for indication and high/low pressure
alarms, at the inlet and outlet of pressure reduction facility to measure the gas
supply pressure. Temperature measurements shall be provided at inlet and outlet of
the pressure reduction facility integrated in the local PLC an d shall have a
possibility of signal exchange into DCS.
Also one start-up pressure control/reduction valve is provided to cater low -low
condition during first gas turbine start up. The automatic switch over between the
start-up valve and the 100% control/reduction valves shall be bumpless.
Fuel gas supply to the gas turbines shall be safeguarded by an automatic safety
shut-off system.
Regarding all modules
A pipeline vent connection will be provided near gas turbine inlet to vent out
entrapped gases during cold start-up of the plant to vent stack. Module vendor to
provide equipment and pipeline vent connections at module border. Normally, for all
equipment, one vent line will contain manually operated ball valves for initial
purging. All vents on natural gas lines shall be connected to vent stack. The
pressure safety system shall be ensured by providing suitable pressure safety valves
and the system vents will be connected to vent stack (vent stack excluded from
module scope).
Natural Gas lines shall be carbon steel piping.
Vendor is responsible for the module engineering. Customer has the right to review
and require changes to the vendor engineering documents. Vendor is allowed
optionally to propose gas fuel supply system in a different amount of modules. I.e.
the total system can be divided into modules in a different way than presented here
and there can be fewer modules than presented here. However the functionality &
performance must fulfil the requirements in these specifi cations.
The fuel gas modules shall be designed for outdoor installation and shall be suitably
sized to meet the fuel gas requirement of 4 gas turbines for the site design
conditions and the purity of gas as per gas turbine manufacturers requirement /
specification.

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5. SCOPE OF WORK
The scope of supply of the vendor under this specification and associated data sheet
is intended to cover design, engineering, manufacture, assembly, testing and supply
of the skid with all accessories, site installation supervision, commissioning
supervision, performance guarantee testing, operator training and training material
and handing over of items related to Gas Module#3 as defined in Scope of work,
Technical Specification or elsewhere in this specification.
All supplied materials/equipment shall be new and unused. The vendor shall accept
full responsibility for his work including documentation, manufacture, preparation
for shipment, inspection, warranty provisions, compliance with the applicable codes
and standards and the requirements of this Specification. The scope of supply and
services shall include all necessary work and supply of equipment and material
whether mentioned in these specifications or not, but which are necessary for the
satisfactory, reliable and safe operation and maintenanc e of the plant and required
for achieving guaranteed performance of the plant. Any equipment, device or
material even if not included in the original bid but found necessary for the safe and
satisfactory functioning of the units under the bid shall be supp lied by the vendor at
no extra cost. The module should be delivered in a properly packed condition as
specified here in under but not limited to:
The skid details proposed in this specification and P&ID (Doc No 40-A-00027- Gas
pressure control Module # 3) are indicative only. Vendor can also suggest better system
than specified. Complete gas Module #3 shall be designed to meet the main fuel
requirements of 4 Gas turbines and comprises of:

2 X 100% streams, each stream will include an isolating type press ure control
valve with isolation valves.

1 X 30% stream (start-up) including isolation type pressure control valve with
isolation valves

Instrumentation and valves for the safe and efficient operation of the skid
mounted equipment, including manual inlet and outlet isolating valves on
each stream

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

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

Internal nitrogen purging connections and internal piping inside the module

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as required based on the system design shall be taken care by the vendor (only
one external connection is allowed). Bidder shall provide requisite number of
tapings for nitrogen purging as the standard practices, the number indicated
in the P&ID attached shall be treated as minimum.

Drain lines with double isolation valve

Two numbers of portable gas detectors (totally 2 numbers for all three gas
modules together) of the flame ionization metering type, capable of detecting
fuel gas in concentration of one part per million. All necessary detector
accessories shall be included.

Manual depressurisation line with double isolation valves

Relief valves required for protection

All the vents / drains to connected to a common header & terminated at

module terminal

Insulation (example rock wool) with aluminium cladding shall be provided

for all the pipes/equipments/surfaces having surface temperature more than
50C, the insulation thickness shall be designed based on media and
ambient temperature.

Thermal insulation shall be provided in order to maintain the temperature in

the main gas line and hot water lines. In other locations mainly for personnel
protection. Insulation for personnel protection shall be provided such that the
temperature of protective cladding is not higher than 50 C.

All interconnecting piping, valves, specialities, supports within Module

mounted equipment as shown in the P&ID as minimum. It is Suppliers
responsibility to provide all piping components as necessary for the safe
operation of the system

All equipment, C&I devices shall be suitable for E Ex _ II A T1 for Natural

gas systems (normally T class, however, T3 or higher T4 is ok). Ex class
normally E Ex d. Instruments normally other type depending on the zone and
if barriers are used or not.

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

All instrumentation shall have double isolation valves .

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All instrumentation shall have double isolation valves .

It shall be possible to provide all analogue and digital signals to plant DCS.
Also it shall be possible to change the pressure control set point from plant
DCS.

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6. TECHNICAL SPECIFICATIONS
S.NO
1.

Module

2.

Capacity for all 4 GTs

3.
4.
5.

Mode of Operation
Medium Handled
Fuel LHV
Flow at the module battery
limit
Minimum flow for each GT
Normal flow for each GT
Design Flow for 4 GT
Design Flow for the module
Fuel
gas
pressure
required at module outlet
Allowable pressure pulses
Fuel gas pressure at inlet
of Pressure control Module
Temperature of fuel gas at
inlet of pressure control
Module Battery Limit
Temperature of fuel gas at
outlet of pressure control
Module Battery Limit
Design pressure of fuel gas
system up to Module Inlet
Design pressure of fuel gas
system at Module Outlet

6.

7.
8.
9.
10.
11.
12.
13.
E

PARTICULARS

14.
15.

UNIT

Kg/hr
Kg/hr
Kg/hr
Kg/hr

DESIGN VALUES
FUEL GAS PRESSURE
CONTROL MODULE
2 x 100% & 1 X 30%
(Start-up)
Continuous
Fuel Gas ( Natural Gas)
48772
430 MMBTU Each GT
( 4.54 x 10^8 KJ/HR)
LATER (from Zero)
7904
10272.73 x 4 = 41090.92
41091

Barg

48

Bar

0.9 max
86 Max
54 Normal
90 Max
~4070 Normal
15 Min

KJ/Kg

Barg
C
C
Barg

86

Barg

65
75dB(A) for a
equipment @ 1m.

Noise Level
Piping material

Min temp to be
above dew point.

Material
denomination
to be given
acc to EN

28C

single

To be of carbon steel

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7. TERMINAL POINTS

S.NO
A.

DESCRIPTION

SCOPE

MECHANICAL
Inlet of the pressure
Module terminal with
flanges

1.

control
counter

Fuel Gas
Outlet of the pressure control
Module terminal with counter
flanges

2.

Drains

3.

Vents

4.

Nitrogen

5.

Instrument air

B.

ELECTRICAL

1.

Earthing

All drains connected to a common

header & terminated at Outlet of
Module with counter flange/stub
connection.
Gas vents / safety valve discharge
to be connected individually to a
common header. The header to be
terminated at the module terminal
point.
Connection at module terminal

7 barg, dryness +3 deg C

(flange
connection
at
terminal)

module

Two
earthing
terminals
at
diagonally opposite locations of the
skid.

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

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EXCLUSIONS
1.
2.
3.
4.
5.
6.
7.

Foundations of Gas pressure control Module

Civil construction work like building, equipment foundation etc
Erection of Module and its accessories
Fire fighting system
Nitrogen piping up to supply point at module border
Instrument piping up to supply point at module border
Supply of Cables from local JB to Control room

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8. DATASHEET
The given below datasheet to be filled in by the Vendor.
S. No
1.0

PARTICULARS

UNITS

To Be Indicated By Bidder

General
Gas pressure control module
designation
Name of manufacturer
Model Number
Design standard

2.0

Testing standard
Equipment shall be designed for
seismic loads (Yes/No)
Fuel Gas Supply Conditions
Gas Flow in supply line

Nm3/hr

Gas Pressure required at GT

Bar (g)

Gas temperature required at GT

3.0
A

(Min temp to be 28C above dew

point.)
Gas Supply Pressure at inlet of
Module
Gas Supply Temperature at inlet of
Module
Pressure control module (100%)
Outlet Pressure
Pressure control module (0-30%)
Outlet Pressure
Gas Supply Temperature at outlet of
Module
Design pressure of fuel gas system
up to Pressure control module inlet
Design pressure from Pressure
control module outlet to Gas
Turbine battery limit
Percentage opening of Control
valve during full load & Min load
operation
Design & Performance Requirement

Norm.

Min.

47.9

46.5

45.2

121

Bar (g)
C
Bar (g)
Bar (g)
C
Bar (g)
Bar (g)
%

General
Terminal point pressure at all
operating gas supply condition (max /

Max.

Bar (g)

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S. No

PARTICULARS

UNITS

Terminal point temperature at all

operating gas supply condition (max /
min )
Maximum Gas Velocity inside
pipeline under maximum operating
conditions.
Design pressure of fuel gas system
up to and including the Pressure
reduction/control module

To Be Indicated By Bidder

min )

4.0
A

Bar (g)

Temperature drop across Pressure

control module
Max. Pressure drop across the
control valve

Other equipment
Actuator/Control Valves

Manufacturer
Quantity
Size, In/Out connection ends (DN)
PN-class
Material (Body/Trim)
Pressure Class
Leakage class
Relief Valve
Type

20 unfiltered
35 filtered

Bar (g)

Design pressure of fuel gas system

for downstream of the Pressure
reduction/control module
Gas pressure at outlet of Pressure
control module (minimum)

Type

m/sec

Bar (g)

kPa
Material denomination to be given
acc to EN

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S. No

PARTICULARS

UNITS

To Be Indicated By Bidder

Manufacturer
Quantity
Size, In/Out connection ends
PN-class
Set Point
Material
Rating
Location
Leakage class
C

Manual Valves (Isolation/drain

valves)
Manufacturer
Quantity
Type
Size
PN-class
Connection ends
Material (Body/Trim)
Leakage class

Insulation
Insulation Material & Density

Rock wool / Mineral wool

Insulation Type and Thickness

(Will be different for Thermal

insulation and for Personal
protection)

Insulation Class

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S. No

PARTICULARS

UNITS

Metal Jacketing/Cladding
Securement Wire
Surface Temperature

60 Deg.C

Material standard
E

Instruments
Type
Make
Model
Range
Accuracy / Accuracy class

External signals
Name
Type

Accessories
Bolts
Nuts
Orifice/ nozzles/ splash cups

5.0
A

Utilities
Instrument Air
Quantity

Nm3/hr

Quality
Pressure
B

Bar(g)

Nitrogen
Quantity

Nm3/hr

To Be Indicated By Bidder

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Quality
Pressure
6.0

Bar(g)

Gas pressure control Module

(Bidder to furnish the following details per
pedestal/foundation)
Empty weight
Operating weight
Test weight
Dynamic load (if any)
Live load of platforms
Minimum depth of foundation (if any
specific requirement)
Empty weight
Operating weight
Test weight
Dynamic load (if any)

Minimum depth of foundation (if any

specific requirement)
Note : Vendor to Submit complete details of all items (if additional from this
data sheet) as suitable required for this Skid

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9. PERFORMANCE GUARANTEE

S. No.

Description
Fuel gas temperature at the outlet of
pressure control module

Unit
C

Maximum flow
Minimum flow
Fuel gas Pressure at the outlet of
pressure control module

Bar(g)

Maximum flow
2
Minimum flow
Pressure pulses maximum size (bar)
Pressure Drop across the Control
valve
3

4
5

kPa

Maximum flow
Minimum flow
Noise level during control valve
operation
Noise level during safety valve
operation

dBA
dBA

Guarantee