SUMMIT MEGHNAGHAT POWER COMPANY LTD.

337/305 MW CCPP
O&M By:KEPCO-KPS

PRESENTATION ON Natural Gas System from Plant

NG station to Gas Turbine NG skid

Presented By: Group-B

Shift in Charge Engineer: Md. Rokan Uddin
Control Room Engineer: Delwar Hossain
Power Block Engineer: Khairul Alam
BOPE Engineer: Ejaj-ul Ambia
Field Supervisor: Rashed Md. Yakub
 Topics

Overall Process Flow Diagram

Major Equipments from Gas inlet to

Compressor

Gas Compressor

GT side Filtration system

Gas Turbine NG skid & NG combustion

system
Overall Process Flow Diagram
 Major Equipments from Gas inlet to Compressor
1. Inlet Emergency Shutdown Valve-00EKA10AA002
- Instrument air operate
- on/off type; position switch send the open or close signal to the DCS.
- Auto shut off if there is any of the followings happen
a) A close command send by DCS.
b) Emergency close button is pressed in the local control room.
c) Instrument Air supply failure of actuator
d) The solenoid valves are de-energized.

2. Cyclone Separator
-The cyclone separator unit is designed for 100% of flow.
- separates solid particles and moisture droplets from the
supplied gas by centrifugal action.
Major Equipments from Gas inlet to Compressor

Main Inlet
Header
from Titas
RMS

lled
n e u m atic Contro
P ff
cy Shut o
Emergen e Main
Valv
Inlet
Manual
Isolation
Valve
Major Equipments from Gas inlet to Compressor
shu ain
val off
M

ve
t

Gas detector

Air line

Vent

N2 charging point
Measuring instrument
 Major Equipments from Gas inlet to Compressor
Manual
bypass
M isolation
iso anua valve of
la l
va tion cyclone
be lve separator
cy for
sep clon e
ara e
t or

con aining
Aut sate
Pressure relief

dr
d en
o
PI

Bypass valve
Cyclone
Level gauge separator
 Major Equipments from Gas inlet to Compressor

3. Filter Coalesce unit

- separate solid particles & liquid droplets from the natural gas.
- designed for 2X100% of flow. One in operation and another in standby
mode.The design gas flow of each filter is 88500Nm3/hr.
- Consists of two stages vertical chambers. At bottom chamber there is baffle
plate for churning action and the top chamber there is coalescer cardiges.

- Each filter contains 23no. DUOTOV-90/736 type of coalescer cardiges.

- A differential pressure transmitter is used to monitor differential pressure
across the filter.Normal value is 0.1~0.55 barg.The differential pressure
must not exceed 0.8 barg(filter cardiges will be damaged at high differential
pressure).
- Automatic condensate drain system is provided for both chambers. At High
level auto drain valve will open and at High High level auto drain valve will
be opened together with an Alarm annunciation in PLC. In that case manual
drain valve should be opened if actual level is high high.
Major Equipments from Gas inlet to Compressor

Inlet isolation valve of

filtration unit
Outlet isolation valve
after cyclone separator

Filter
 Major Equipments from Gas inlet to Compressor

4. Metering unit
- The metering system is used to measure the total gas consumption of Gas
Turbine.
- consists of pressure compensation transmitter, temperature compensation
sensor, ultrasonic flow meter,chromotograph & flow computer etc. The
pressure compensation transmitter is used to measure the gas absolute
pressure in working condition, the temperature sensor is used to measure
the gas temperature in working condition and flow meter measure the flow
rate of gas and Chromatograph takes the online real time measurement of
gas heating value,density & wobbe index .
- The Flow computer calculates the gas volumetric flow rate & mass flow rate
by receiving all the data i.e. flow rate from flow meter, gas components &
density from chromatrograph,temperature & pressure from transmitter.
[Wobbe Index= LHV/(SG of gas X T)]
Flow computer

PT TE AT
Ultrasonic Flow
meter
 Major Equipments from Gas inlet to Compressor
w
Flo ter
me pass
by alve
v

Flow
meter
inlet
valve
Sample line for
gas analyzer

Gas analyzer

Ultrasonic flow meter

 Gas Compressor
Fuel gas compressor is used to increase fuel gas pressure for the
requirement of gas turbine. There are three E35-6 model Gas
Compressors(3X50%) of which two will be in operation & one in standby
condition.
Main Components of Compressor:
• Six stage centrifugal compressor
• Gear Box
• Driving Motor
• Coupling
Auxiliary Systems of Compressor
• Lube oil System
• Overhead Oil system
• Natural Gas Cooler
• Automatic PLC control system
 Gas Compressor
Compressor Data: Driving Motor Data:
• No. of Stage: Six • Model: YBKS630-2
• Fluid: Natural Gas • Rated Power: 2240KW
• Inlet Flow rate: 44250 Nm3/hr • Rated Voltage: 6.6 KV
• Inlet Pressure: 10.713 bar (A) • Rated Current: 232 Amp
• Inlet Temperature: 200C. • Rated Speed: 2981 rpm
• Compressor outlet pressure: 27.513 • Type of Cooling: Upper cooling
bar(A) • Weight: 12000 kg.
• Compressor outlet Temperature: 1090C Gear Box data:
• Rated Speed: 13260 rpm • Model: HSG836-1
• First critical speed = 4900 rpm,2nd critical • Transfer power:2240 KW
speed = 17000 rpm. • Service Factor: 1.4
• Rated power: 1981 KW • Speed ratio: 13270/2981
• Rotation direction: Clock wise viewed • Oil consumption of Main gear box: 150
from suction side. L/min
• Weight: 11850 kg. • Weight: 110 kg
GasGasCompressor
Compressor

Cross sectional view of compressor

Gas Compressor
 Gas Compressor
Rated
speed
13260
rpm

Gas Booster
Compressor

GBC internal
structure
 Gas Compressor
Initially the opening of the
valve is 5-10 degree. The
opening of this control valve
shall be gradually opened to
30 degree for operation
without load for two hours
after the speed of machine
train reaches the working
Instrument speed and running steadily.
air line

Gas Inlet control

valve for gas
booster
compressor
 Gas Compressor

This anti surge control valve will

protect the compressor during
start up and shut down time by
m stru

relieving the drawback pressure.

Ai nt
In
e
r

This valve will be opened fully

during start up and shut down
time . The connection of the
control valve taken from the
delivery to suction line of gas
booster compressor .The
compressor shall be pressurized
by gradually closing the anti surge
valve ,but pressure shall be
controlled within the designed
value.

Anti surge control

valve
Gas Compressor

Compressor
Inlet

Compressor
outlet
 Gas Compressor

Inlet
line

To balance axial thrust there is balancing

piston at the discharge side of the
compressor. A small amount of gas flows
from this balancing piston to the suction
pipe to create a force opposite to axial
Balancing thrust direction. To absorb the residual
leak off thrust there are two thrust bearings at
line
the suction side of the compressor.
 Gas Compressor
Fuel Gas Compressor's parameters
Normal
SL No. Parameter Alarm value Trip Value Remarks  
Value
1 Compressor Shaft displacement(mm) <0.4  ≥ ±0.4 H ≥ ±0.8 HH    

2 Compressor Shaft vibration(µm) <30.6 ≥ 56 H ≥ 69 HH    

3 Compressor Journal Bearing Temp(°C) <95  ≥ 100 H ≥ 110 HH    

4 Compressor Thrust Bearing Temp(°C) <95 ≥ 100 H ≥ 110 HH    

5 Gear Box Bearing Temp(°C)  <95 ≥ 105 H ≥ 110 HH    

6 Gear Box Bearing vibration(µm) <30.6  ≥ 80 H ≥ 100 HH    

7 Motor Bearing Temp(°C)   ≥ 80 H ≥ 85 HH    

8 Motor Stator Temp(°C)   ≥ 140 H ≥ 145 HH    

Furthest Bearing Lube oil At 'L' alarm S/B pump

9 1.5 1.1 L 0.8 LL  
Pressure(barg) come into service

At 'L' alarm Heater ON

10 Lube oil tank Temp(°C) ≥ 25 ≤ 20 L     & at Normal value  
Heater OFF

  ≥45 H        
11 Temperature after Lube oil cooler (°C) 40
≤ 20 L        

12 Oil Filter Differential Pressure(barg)   1.5 H        

13 Lube oil tank Level(mm)   ≤525 L         

 Gas Compressor
Compressor Sealing
System
 Gas Compressor

s N2
li n g ga sealing
a
Se from
line essor line
pr Vent
com tlet line
ou
after
sealing
 Gas Compressor

Sealing lines

Flow meters & PI

for N2 & Gas
sealing

Oxygen content for nitrogen sealing

should be lower than 5%.During
normal operation, Nitrogen sealing
flow should be in the range of
45Nm3/h.
 Gas Compressor
Gas Cooler:
The specified shell and tube gas cooler is designed and applied that the cooling water
side pressure not higher than 1.0Mpa and inlet water temp not more than 32DegC.Shell
side design pressure less than 5Mpa and gas inlet design temp. less than or equal to
200degC.This service defines that cooling water cools and drops working high
temperature gas generated from multi units during operation
 Gas Compressor
Cooling
water
out

Gas
in

Gas Cooling
out water in

Gas Cooler Design Data:

Temperature(degC): Tube side 120 degC &
Shell side 80 degC
Pressure(barg): Tube side 30 barg &
Shell side 10 barg
 Gas Compressor
Lube Oil System: Lube Oil System Parameters:
• Oil tank capacity: 4500L
The lube oil system consist of lube oil
station, overhead oil tank and oil pipe • Flow rate of electric pump: 509L/min
line beside the compressor. This • Pump pressure: 1.0Mpa
system provides oil for all the • Power of electric pump
lubricating points of this machine motor:15KW*2(One working one
train. Double electric pumps are standby)
provided for the oil station, and they • Consumption of cooling water: 35t/h
are standby to each other. Both the • Inlet temperature of cooling water:32ᵒC
oil cooler and filter for the oil station
• Filtering precision for lube oil: 20um
are duplex, One working and one
standby respectively. The pressure of • Lube oil supply pressure: 0.25Mpa
lube oil is adjusted by the self • Supply temperature 42±3ᵒC
powered pressure control valve to • Power of electric heater: 4KW*3
guarantee the operating • Power of mist fan: 1.1KW
requirements.
 Gas Compressor
LO System P & ID:
LO supply pressure
Lube oil filter
Lube oil cooler control valve

Over pressure control

valve
Vapor extractor

Lube oil
supply

Lube oil return

Lube oil pump Level gauge

 Gas Compressor

Return
Lo tank
Lube Oil Skid Capacity 4500L
tor
x trac
o re
Local MCC Vap
Lube oil
pump

Suction

Delivery

Lo
Self cooler
pressure
control
valve Lo Filter
 Gas Compressor
There are two screw pumps for
supplying oil to the compressor
bearings, motor bearings & gear box.
One pump is running & another one
in standby condition. When the
supply oil pressure drops below 0.11
MPa the standby oil pump come into
service automatically; after the
pressure returns to normal the spare
pump stops automatically.
If pressure dropped ≤0.08Mpa unit
will be tripped.

Lube oil pump

Suction strainer
 Gas Compressor
Bypass manual
valve
These heaters will maintain
the lube oil tank
temperature from 20ᵒC-
25ᵒC.If tank temperature
goes down to 20ᵒC heater
vvee

will be on and at 25ᵒC heater

vvaall

will be off.Alarm will be

ooll
nnttrr

initiated when tank oil level

ccoo

will be 525mm below the oil

rree
ssssuu

tank surface.
PPrree

ers
aters
eerr
OOvv

ctric
Electr
Ele heat
ic he
 Gas Compressor
Lube oil is cooled in the
er coolers.The oil
Ov sure e
es in temperature at outlet of
Lube pr ch l
Oil dis the cooler is regulated by
in controlling the cooling
water flow.It alarms when
oil temperature is above
45deg C. .Consumption of
cooling water is
35t/h*2(One working one
standby).Inlet cooling
water temperature is
32deg C.
Lube
oil
out

Cooling
water
Outlet

Cooling
Lube oil cooler water
inlet
 Gas Compressor
Lube oil then runs into filter after
Lube oil filter
cooling. Filtering precession for lube oil
is 20μ. when the DP is more than
0.15Mpa, service filter should be
changed over. A self power pressure
Vent control valve is provided at the supply
header after the filter which will control
the supply header pressure.

Filter Filter
outlet inlet

Drain
Self
pressure
control
valve

Common
Com
m lube oil
lube on supply
o
retur il header
n
head
er
 Gas Compressor
Emergency/Overhead lube oil tank:

An overhead lube oil tank is

provided for emergency
purpose . If emergency like
blackout happens that time
Overhead the check valve will allow
tank return
the oil flow to the
compressor for safe
shutdown. The manual valve
is used for tank filling.

Check valve
Bypass
Fil manual
De ling & valve
liv
lin ery
e

Common
lube oil
supply
header
 Gas Compressor
Gearbox Parameters:
• Model: HSG836-1
• Transmitted power:
2240KW
• Service factor: 1.4
• Speed ratio: 13270/2981
• Oil Consumption: 150L/min
• Weight: 1100kg
 Gas Compressor
Motor Parameters:
• Model: YBKS630-2
• Rated power: 2240KW
• Rated voltage: 6600V
• Rated current: 232A
• Rated speed: 2981r/min
• Cooling mode: Water cooling
• Weight:12000Kg
 Gas Compressor
Cooling
water
Motor winding outlet
cooling

Cooling
water
outlet

Cooling
water
inlet

Cooling
water
inlet
 Standby Gas Compressor
These are the
interconnection valves
after cooler of GBC-3 to
supply gas for both GBC-1
and GBC-2 delivery header.
By operating those valves
gas can be supplied at both
GBC’s delivery header. This
valves should be kept open
always for standby
To GBC -2
delivery operation.
header

To GBC-1
delivery
header
 Gas Compressor
PLC System:
• PLC system is used to start/stop & control the Gas compressors & associated items.
• SMPCL GBC PLC system is provided by GE.
• Location: GBC MCC room.
Gas Compressor
Gas Compressor
Gas Compressor
Gas Compressor
Gas Compressor
Gas Compressor
 Gas Compressor
Start up Interlock:
 Gas Compressor
Compressor Trip logic:
 Gas Compressor
Lube Oil Heater on/Off
Logic:
 Gas Compressor
LO pump Logic:
 Gas Compressor
Normal Operation: The suction adjusting valve of
compressor E-35 shall be gradually opened and the anti surge
valve shall be gradually closed so as to increase the gas volume
for pressurizing of the process system. The anti surge valve shall
be switched to automatic mode when the process system will
running steadily.
Normal shutdown: The load of compressor shall be firstly
reduced and the anti surge valve shall be opened and the
machine train shall be disconnected with the process system
before shutdown.
 Condensate Tank & Vent Stack

Condensate
pump

Condensate
drain

Common vent for all vent point Condensate tank for all condensate
and pressure relief valve drain.
 Gas Turbine Inlet Filtration & Heating System

Electric heater and final skid before GT

A 110KW
electric
heater
To vent

Bypass
of heater
 Gas Turbine Inlet Filtration & Heating System
Electric
heater

Inlet from
gas
conditioni
ng unit
Heater
control
panel

Heater parameters
Capacity:110KW
Design pressure:35bar
Design temperature:60DegC
Operating temperature:50-55DegC
Volume:0.25m3
Valve
before
entering
heater
Heater
bypass valve
 Gas Turbine Inlet Filtration & Heating System
Gas fuel forwarding supply system:
Equipment Specifications
• Gas forwarding filter FLT101/102
• Gas pneumatic stop valve VS4-4
• Gas flow meter VM-1
• Gas total bleeding valve VA13-18
• Pressure switch of gas VSR stop valve 63FG-1/2
• Pressure transmitter of gas VSR stop valve 96FG-1
• Gas VSR stop valve VSR-1
• Pressure transmitter of gas VSR stop valve 96FG-2A/2B/2C
• Gas regulating control valve VGC-1
• Gas inter-valve bleeding solenoid valve 20VG-1
• Gas valve control hydraulic oil accumulator AH1-3
Gas Turbine Inlet Filtration & Heating System

Gas forwarding
filter

Vent
Manual v/v line
before entering
filter

Level
Condensate
gauges
drain
 Gas Turbine Inlet Filtration & Heating System

Gas
pneumatic
stop valve Gas total
VS4-4 bleeding
valve VA-13-
18

Gas flow meter

VM-1
 Gas Turbine NG Skid
e
es sur s of
Pr ucer
nd FG
tra SR 96 2C
V 2 B/
sure / Gas
Pres h of 2A
c manifold
swit FG-1
63
VSR FG-2
& 63

Pressure
transmitter
of VSR 96FG1
Gas
regulating
Gas int control
er valve
valve
bleedin VGC-1
Gas g
solenoi
VSR d
valve
stop 20VG-1
valve
VSR1

Hydraulic
Hydraulic oil in oil
accumulat
or AH1-3 P & ID of the gas
module
Hydraulic oil out
 Gas Turbine NG Skid

Stop/Speed Ratio Valve(VSR)

The gas stop/speed ratio valve has two functions. It provides a positive fuel shutoff
when required by either normal or emergency conditions and it acts as a pressure
regulating valve. The ratio function of the stop/speed ratio valve provides a regulated
fuel pressure at the inlet of the control valve. The pressure is regulated as a function of
turbine speed. At low turbine speeds, such as during startup, the required pressure is
low; as the turbine gains speed, the pressure requirement increases. In this manner,
the gas stop/speed ratio valve aids the control valve control manifold pressures ranging
from 1.5 to 150 psig (0.07-10.34bar). The plug of the stop/speed ratio valve has a steep
taper to provide the high gain necessary to maintain good pressure control.
 Gas Turbine NG Skid

Hydrau
Return lic oil in
hydraulic
oil

Pressure
switch
63FG-1 &
2

The gas stop/speed ratio valve VSR-1

Pressure
transmitter
96FG-1
 Gas Turbine NG Skid
Control Valve.
The function of the fuel gas control valve
is to admit the proper amount of fuel
required by the turbine for a given load
or speed.
Control
valve
VGC-1

Hydrauli
c oil

Gas valve control

hydraulic
accumulator AH1-3
 Gas Turbine NG Skid

Low gas pressure switch 63FG–1 & 63FG-2, installed in the gas piping
ahead of the gas stop/speed ratio and control valve assembly, provides
alarm protection and, on a dual–fuel unit, initiates a transfer to liquid fuel
should the supply gas pressure drop below the switch setting. An alarm will
be initiated and displayed on the turbine panel in the control center.
 Gas Turbine NG Skid
Solenoid–operated valve 20VG–1 is installed in
the vent piping from the casing of the
combination gas stop/speed ratio and gas
control valve. When the turbine is at rest, any
20VG-1 fuel gas that might accumulate in the area
between the stop/speed ratio and control valve
vents to atmosphere through this valve.

Fuel gas vent valve

Pressure transducers 96FG–2A, 2B, and 2C are

installed in the system between the
stop/speed ratio valve and the control valve. It
Pressure transducers
provides the operational pressure feedback
96FG-2A,2B,2C signal to the pressure control loop of the
SPEEDTRONIC control system. This is used to
control the stop/speed ratio valve.Before firing
the gas turbine software proceeds to
automatic gas valve leak test controlling gas
pressure between gas ratio valve and control
valve.
 Gas Turbine NG Skid

Servo valve 65GC-1

Servo valve 90SR1 of of VGC-1
VSR1

Hydraulic
trip
Hydraulic relayVH5-2
trip
relayVH5-1

When trip oil pressure is normal, gas fuel trip relay VH5 is held in a position that allows hydraulic oil to flow
between control servo valve 90SR and hydraulic cylinder of VSR.In this condition, normal control of the
stop/speed ratio valve is allowed. In the event of a loss of trip oil pressure, the spring in the trip relay shifts the
spool to interrupt the flow path of hydraulic oil between the control servo valve and the hydraulic
cylinder.Simultaneously,the hydraulic oil in the VSR is dumped to drain and the stop/speed ratio valve
closes,shutting off fuel gas flow to the turbine.
 Thank
You All!!