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Technical description of GT6 HRSG project
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00 08-01-2018 Issued for proposal N.R AAQ AAQ

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

JOB DESCRIPTION:

QAPCO POWER PLANT

EPCC OF GT6 HEAT RECOVERY STEAM GENERATOR PROJECT

TITLE:

Technical description of GT6 HRSG project

FORM
JOB NUMBER SECT AREA UNIT SYSTEM COMP DISC ACT TYPE NUMBER SHEETS REV
SIZE

A 4 G 0 0 1 3 0 0 0 0 M B V 0 A A A 2 0 5 0 1 4 0 0

SADELMI POWER reserve all rights on this document and on the information contained therein. Reproduction, use or disclosure to
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QAPCO Power Plant - GT#6 HRSG Tender
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Date : 17-12-2017

Technical description of GT6 HRSG project

9.1 Project Description


9.1.1 Project Description
9.1.2 Design Basis
9.1.3 Process Description, Main Systems & Design Parameters
9.1.4 Main Equipment/Sized Equipment List
9.1.5 Interfaces & Tie-Ins for Process (P streams) and Non-process (N streams)
9.1.6 HSE Design Considerations

9.2 WORK Scope


9.2.1 Work Package 1: Management, Project Control and Administration &
QHSE
9.2.2 Work Package 2: Engineering
9.2.3 Work Package 3: Procurement of itemized Equipment
9.2.4 Work Package 4: Procurement of Bulk Material
9.2.5 Work Package 5 Construction & Installation
9.2.6 Work Package 6 Commissioning including Assistance
9.2.7 Work Package 7 Mobilization & Demobilization

9.3 Process Diagrams


9.3.1 Block Flow Diagram,
9.3.2 Process Flow Diagram

9.4 Location and Layouts


9.4.1 Plot Plan
9.4.2 Electrical Layout – Single Line Diagram
9.4.3 Control Architecture

9.5 Table of Performance Guarantees


9.5.1 Performance Guarantee Test Procedure
9.5.2 Utilities, Chemicals & Auxiliary Material consumptions
9.5.3 List of Performance Guarantees

9.6 Proposed Spare Parts and Auxiliary Material


9.6.1 List of Capital Spare
9.6.2 List of Two Years Spare Parts
9.6.3 List of Spare Auxiliary (Absorbents, Adsorbents, Catalysts, Ion Exchange
Resins, Desiccants)
9.6.4 List of Special Tools

SADELMI POWER reserve all rights on this document and on the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
REV.: 00
Date : 17-12-2017

Technical description of GT6 HRSG project

Project Description

Qatar Petrochemical Company (QAPCO) presently has six (6) Gas Turbines (GT-1 and GT-2
turbines with boilers and GT-3, 4, 5 & 6 without boilers). QAPCO intends to expand its high
pressure steam generation facilities by adding a fired Heat Recovery Steam Generator (140 TPH
, Single pressure 45 Barg , 400 Deg C With Fuel Gas Supplementary fire) and the associated
facilities to be integrated with the recently installed Gas Turbine Generator Unit # 6 (GT6).

Terms and Definitions


Term and definition are reported herein below:
Sadelmi Power - Sadelmi
QAPCO - Qatar Petrochemical Company
HRSG - Heat Recovery Steam Generator

The present document includes the technical description of new GT#6 - Heat Recovery Steam
Generator (HRSG) to be built inside the QAPCO premised in Mesaieed Industrial City, Qatar as
offered by SADELMI
The proposal developed by SADELMI for the preparation of the present offer has been intended
to produce the optimum solution for delivering reliable and lowest life cycle cost Electricity, burning
the design natural gas in standard and well proven HRSG, in line with the QAPCO Request for
Proposal (RFQ– P04-01-007) and the relevant Tender Bulletin No.1 to 4.
Furthermore, the arrangement proposed by SADELMI combines all the above advantages with the
customized solutions studied to optimize the use of the available space in order to simplify the
maintenance activities on the HRSG

The Sadelmi’s scope of work for this Project includes Engineering, procurement, installation,
commissioning, start-up and performance test of following systems
 Heat recovery team generator (HRSG)
 Heat recovery team generator Auxiliaries
 Feed water system
 Condense system
 Chemical dosing system
 sampling system
 Low Pressure and High pressure steam system
 Fuel gas system

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third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
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Technical description of GT6 HRSG project

 Gaseous nitrogen
 Cooling water system
 Raw water system
 Fire Protection System
 Mechanical tie-ins from the HRSG to the existing plant
 Piping and valves
 Painting and insulation

Design Basis

Mechanical design basis

The following parameters are followed for design of mechanical systems

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QAPCO Power Plant - GT#6 HRSG Tender
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Date : 17-12-2017

Technical description of GT6 HRSG project

1. INTRODUCTION.

This specification is intended to cover the system description and design criteria of Fuel
Gas Stream Tracing System For GTG# 1 To 6 for the QAPCO Expansion Project, Qatar for
the duty and services as specified herein and as required for efficient, safe and trouble free
operation.

It is the intention of this specification to cover the basic requirements for the
Equipment/System. The work to be carried out as per scope of work specified under
Technical Requirement shall be all in accordance with the requirements, conditions,
appendices etc. stated in specification as if bound herewith.

2. PROJECT INFORMATION

2.1 Purchaser

SADELMI POWER

2.2 Owner

QATAR PETROCHEMICAL COMPANY (QAPCO)

2.3 Project Name

QAPCO EXPANSION PROJECT (Replacement of GT-1, GT-2, Supply of GT-6 and


Refurbishment of GT-3, GT-4 & GT-5)

2.4 Project Brief

Qatar Petrochemical Company (QAPCO) Q.S.C presently has five (5) Gas Turbines (GT-
1 and GT-2 turbines with boilers and GT-3, 4 & 5 without boilers). QAPCO intend to
modify and increase the capacity of its power generation system to cover the future
demand of electrical power by

a) Installation of a new Gas Turbine GT-6

b) Installation of two new Gas Turbines (GT1 & GT2) including the bypass stack,
diverting damper and their integration with the existing boilers.

c) Refurbishment of three existing Gas Turbines (GT3, GT4 and GT5) for turbine
control system, generator control / protection, AVR system, vibration monitoring
system & fire / gas system

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third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
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Technical description of GT6 HRSG project

Sadelmi Power is retained as EPC Contractor to execute the above said QAPCO
expansion project.

2.5 Project and Site Information

For Project Site information, refer Attachment # 1.

3. CODES AND STANDARDS

The steam heat tracing system will be designed/supplied according to ASME Code and
European codes will be also applied where identified in this document.

ASME B 31.1 Codes for power piping

ASME B 36.10 Code for Welded and Seamless Wrought Steel Pipe

ASME B 16.5 Code of steel flanges and pipe fittings

ASME B 16.9 Code of Factory made Wrought Steel Butt Welding Fittings

ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves

ASME B 16.11 Forged Steel Fittings; Socket Welding & Threaded

ASME B 16.21 Flat Ring Gaskets

ASME B 16.34 Steel Valves; Flanged, Threaded & Butt welding Ends

4. DESIGN INPUTS AND ASSUMPTIONS

4.1 The Fuel Composition (Attachment#2) to the Gas turbines considered in the steam
heat tracing system (QAPCO Email Ref : G0013-QAP-SP-E-118 dated 05-Aug-2015)

4.2 As per revised fuel gas composition (500ppm H2O scenario), The minimum fuel gas
temperature of 37°C at TP100 (GE battery limit ) is required as per (SP Email Ref :
G0013-SP-QAP-E-0149 dated 26-Aug-2016)

4.3 Fuel gas minimum temperature to Existing Fuel gas Heater inlet is 10 Deg C (QAPCO
Email Ref : G0013-QAP-SP-E-126 dated 30-Aug-2015)

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third parties without express authority is strictly forbidden
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Date : 17-12-2017

Technical description of GT6 HRSG project

4.4 Expected Fuel gas temperature to Existing Fuel gas Heater outlet is 30 Deg C (To be
Confirmed by QAPCO)

4.5 The system shall be designed for Maximum Gas flow of 34 Ton /hr as per QAPCO
input without any liability to SP.

4.6 The heat tracing will increase the temperature by 10 degree (for the maximum fuel
gas flow of Ton/hr) from the fuel gas heater outlet. QAPCO shall confirm that the
outlet fuel gas heater temperature from the existing fuel has Heater , shall not be
less than 30 degree , in any of operating condition.

4.7 Design and operating conditions of Heating Steam (Refer atatchement#3) shall be
available at control trace supply point.

 Operating pressure : 4 Bar (g)

 Operating temperature: 220 Deg C

 Design Pressure : 6 Bar(g)

 Design Temperate : 260 Deg C

4.8 Condensate drain from the steam tracing system will be connected to nearest plant
drains.

4.9 One (1) No. Temperate indicator (TI) and One (1) No. Temperature transmitter (TT)
will be provided in the Gas Main Header Upstream and downstream of the Heat
tracing System to control the steam flow for the system

4.10 The heat tracing shall work independently ( input/output and control)

4.11 The heat tracing will be supplied and installed only for the straight pipe runs, for
elbows, Valves fittings, Insulation to be provided only, and steam and Heat Insulation
looping will be done by vendor

4.12 As per the fuel gas steam hear tracing system, The Design Fuel gas temperature at
TP 100 (GTG#6 battery limit) is considered as 37 Deg C (During 10 Deg C ambient
condition)

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third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
REV.: 00
Date : 17-12-2017

Technical description of GT6 HRSG project

4.13 The Maximum acceptable Fuel gas temperature is 60 Deg C (at Fuel gas Heater
outlet)

4.14 We have assumed fuel gas process parameters @39 Deg C are

 Density : 0.69 Kg/M3

 Thermal Conductivity : 0.032W/m/K

 Specific Heat : 2.2 KJ/Kg/K

 Viscosity : 0.0107cP

4.15 As per Atatchement#4, Pipe size from Heater outlet is 10” or 250 NB and Pipe
material considered as A106 Gr.B (Sch 40)

4.16 Total Length of the fuel gas Pipe from Existing Fuel gas heater to TP100 (GT#6 battery
limit) is 400mtrs.

4.17 Type of Insulation used for fuel gas piping is considered as 40mm (1.5 Inch) thick
mineral Wool on all fuel gas Piping.

4.18 We have considered Worst Case winter Ambient condition 10 Deg C and Worst Case
Summer Ambient condition 48 Deg C with a velocity speed of 40kph

4.19 Painting and colour code for the Steam heat tracing system is as per manufacture
standard.

4.20 As per QAPCO piping specification (D03), Pipe material for Steam piping shall be A
106 Gr.B . Sch 80 Pipe will be used for pipe size up to 40 NB and Sch 40 Pipes will be
used for size 65 NB and above as per ASME B36.10.

4.21 All the Isolation valve shall be globe type and As per QAPCO piping specification
(D03), Valve Material for Steam piping shall be Body ( A 105) ,SW End connection, for
size up to 50 NB. Valve Material for Steam piping shall be Body (A 216 WCB) ,BW End
connection for size 65 NB and above .

Several design assumptions were made by SP for the fuel gas steam hear tracing system and
The QAPCO needs to confirm all of the design assumption before fabrication.

SADELMI POWER reserve all rights on this document and on the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
REV.: 00
Date : 17-12-2017

Technical description of GT6 HRSG project

5. SYSTEM DESCRIPTION

The main purpose of this fuel gas steam heat tracing in system is to maintain the
minimum fuel gas temperature of 37 Deg C at TP 100 (GT#6 Battery Limit). This
requirement is as per revised fuel gas composition (500ppm H2O scenario) for the
good and safe operation of the machine

As per Existing QAPCO operation philosophy, Fuel gas from Fuel gas treatment send
to fuel gas heater in order to increase the temperature and further it is send to existing
gas turbines and Heat Recovery Boiler (Supplementary firing) through 10” common
Header.

The heat tracing shall increase the temperature by 10 degree for the Design fuel gas
flow of 34 ton and QAPCO shall confirm that the outlet temperature from the existing
fuel gas Heater shall not be less than 30 Deg C, in any of operating condition

As per proposed fuel gas heat tracing system, Please note the following

Design Summery
Design fuel
Ambient Steam Temp Temp Temp
Pipe Size Pipe gas Flow
Temperature Pressure (A) (B) (C)
(Inch) material rate
(Deg C) (barg) Deg C Deg C Deg C
(Tons/Hr)
A 106 Gr.B
Mim 10 10" 34 4 30 40 37
sch40

A 106 Gr.B
Max 48 10" 34 4 30 40 37
sch40

A : Existing Fuel gas Heater outlet and Control Trace Heating section starting point
B: Control Trace Heating section Ending point
C : TP 100 (GTG#6 Battery limit)

Control Trace Heating with insulation will be provided for Fuel gas piping and the main
purpose is to heat the fuel gas from Heater outlet ( Point A) to (Point B) by 10 Deg C .

SADELMI POWER reserve all rights on this document and on the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden
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QAPCO Power Plant - GT#6 HRSG Tender
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Date : 17-12-2017

Technical description of GT6 HRSG project

The Design Temperate at Point B will 40 Deg C (Considering 30 Deg C at Fuel gas heater
out which is to be confirmed by QAPCO) .

The remaining area of Fuel gas piping from (point B) to Point C ( TP 100 -GTG#6 Battery
limit C below) will be well insulated, but unheated and purpose of this section is to
main the temperature up to TP 100 (GTG#6 Battery limit) and the Design Temperate
at Point C will 37 Deg C (considering 3 Deg C for heat loss due to insulation)

Based on the assumptions above, under worst case winter conditions the flowing
process will Not fall below 37 Deg C before the end of the 400m line.

One (1) No. Temperate indicator (TI) and One (1) No. Temperature transmitter (TT) will
be provided in the Gas Main Header Upstream and downstream of the Heat tracing
System to control the steam flow for the system

6. PIPING AND VALVES

Pipe material for Steam piping shall be A 106 Gr.B . Sch 80 Pipe will be used for pipe
size up to 40 NB and Sch 40 Pipes will be used for size 65 NB and above as per ASME
B36.10.

All the Isolation valve shall be globe type and As per QAPCO piping specification (D03),
Valve Material for Steam piping shall be Body ( A 105) ,SW End connection, for size up
to 50 NB. Valve Material for Steam piping shall be Body (A 216 WCB) ,BW End
connection for size 65 NB and above . Valve Class shall be As per ASME B16.34.

7. PERFORMANCE GUARANTEE FOR HEAT TRACING SYSTEM

Heat Tracing System Will Increase The Temperature by 10 Deg C

SADELMI POWER reserve all rights on this document and on the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden

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