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Table of Contents ...............................................................................................................................3
4.0 METHODOLOGY....................................................................................................................9
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
9.0 RECOMMENDATIONS........................................................................................................30
10.0 CONCLUSIONS....................................................................................................................31
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Company plans to develop the Gendalo and Gehem Hubs located in the Makassar
Strait, offshore East Kalimantan, Indonesia.
Gendalo Hub comprises of reserves from Gendalo field (Gendalo 1020 and Gendalo
1130), Maha field (Maha 3130), and Gandang field (Gandang 1200). Water depth in the
Gendalo Hub location ranges from 600 m to 1800 m, with a water depth of 1170 m at the
FPU location.
Gehem Hub comprises of reserves from the two primary reservoirs in the Gehem field,
i.e. Gehem 1520 and 1580 reservoirs, plus secondary targets in the 1400 Series and
1018 reservoirs. Water depth in the Gehem Hub location ranges from 1750 m to 1800 m,
with a water depth of 1771 m at the FPU location.
The Gehem Hub is located approximately 100 km north of Gendalo Hub. Gehem Hub is
located approximately 80 km offshore east of Santan Terminal while Gendalo is located
approximately 150 km offshore southeast of Santan Terminal. Santan Terminal is an
onshore terminal currently operated by Company, located approximately 150 km north of
Balikpapan, East Kalimantan, Indonesia.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Each of these primary reservoirs will be developed with clustered subsea wells,
connected in a dual-flow line configuration and controlled from the respective manned
Floating Production Unit (FPU) in a deepwater location near the respective fields.
Gendalo, Maha and Gandang fields will be tied to the Gendalo FPU while the production
from Gehem fields will be delivered to Gehem FPU.
Gas and condensate from each hub will be exported via separate single phase export
pipelines to a shore tie-in location at Company operated Santan Terminal.
Onshore facilities will consist of pressure control and gas metering; condensate storage,
metering, and offloading; and other processing and utility systems as required. The
natural gas will then be transported to the existing Bontang LNG plant via the POMA gas
pipe-line infrastructure.
2.0 OBJECTIVES
To identify the sources and supplies of fuel gas for system design based on fuel
gas specification/ requirements of the users
To calculate the fuel gas consumption/ demand for several cases of operation
(i.e. black start, re-start up, normal operation and compressors change-over
operation)
To develop fuel gas system configuration for Gendalo FPU facility.
The document also explains description of fuel gas system, the demand and supplies of
fuel gas users and fuel gas simulation including its basis. The selected configuration of
fuel gas system and its technical requirement/ recommendation shall be incorporated in
P&ID. The fuel gas system shall be reliable and safe in operation. In addition, the fuel
gas quality shall meet specification for all users, especially to meet manufacture
specification for gas turbines.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
3.1 ABBREVIATIONS
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
4.0 METHODOLOGY
The purpose of fuel gas system study is to develop the optimum fuel gas system
configuration to be installed at Gendalo FPU facility. In order to generate the study, the
steps below are followed:
1) Determine the basis for fuel gas system design. The following points are the
sequences to determine the basis for fuel gas system design.
a) Identify HP and LP fuel gas users and its demand/ consumption based on heat
duty rating of each user
b) Define HP and LP fuel gas user specification/ requirement; specifically for gas
turbine where it shall refer to the manufacturer
c) Identify, determine and analyze of selected gas to be used as fuel gas sources
d) Define fuel gas system requirement as per COMPANY Standard
2) Identify fuel gas system operating scenario
3) Calculate maximum fuel gas system capacity based on the demand/ consumption
4) Simulate fuel gas system based on the operating scenarios
5) Determine basis for fuel gas system sizing
In this study, ASPEN HYSYS ver. 7.1 is used as a process simulator for fuel gas system
simulation. The components and fluid package used in the study is as per Process
Simulation Report [Ref. 1, 2].
The following sections present basis for the design of fuel gas system. The basis
includes fuel gas user identification, fuel gas specification, fuel gas sources review and
fuel gas system requirements.
For the basis of fuel gas system study, the simulation cases considered for each
production phase are Early Life-1, Early Life-2, Mid Life and Late Life as per Process
Simulation Report for Gendalo FPU [Ref. 2].
Fuel gas specification used for this study is not only derived based on the compressor
drivers and gas turbine generators manufacturers, but also based on low pressure
users specification. The fuel gas specification will be reviewed based on Solar and GE
(General Electric) manufacturers [Ref. 3, 4]. As the fuel gas specification is considered
based on several manufacturers, it will develop optimum fuel gas system in Gendalo
FPU.
Fuel gas system shall be designed to cover the requirements of Gendalo FPU facility
operation scenarios such as: black start, re-start up, normal operation, compressors
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
change-over and loss of primary supply. Based on the operating scenarios, fuel gas
users in Gendalo FPU facility will consist of the followings:
As per electrical load list study, main power generators are operated in 3 x 50%
philosophy. Two of GTGs shall be in operation supplying Gendalo FPU electricity
demand and the third shall be on standby. Solar Turbine Mars 100 or equivalent
matches the requirement of gas turbine generation. In line with Solar Turbine fuel
specification, minimum fuel gas supply pressure required for gas turbine
generator is 22.75 Barg (330 psig) at 15.56C ambient temperature. The
maximum pressure is also 34.47 Barg (500 psig) (see Attachment-8 page 2)
[Ref. 3, 22].
The fuel gas consumption for seal gas compressor is not taken into account in
the fuel gas system since the required pressure is higher than fuel gas system
pressure. The required pressure of seal gas compressor is 150 psig above the
Export Gas Compressor (EGC) settle-out pressure. The source of the seal gas
shall be dew-pointed gas. It shall be liquid-free and filtered to remove 100% of 10
micron and larger particles [Ref. 5]. Thus, a dedicated seal gas treatment
package shall be provided in Gendalo FPU. As per process simulation, the
preliminary assumption capacity of seal gas treatment skid is 2.0 MMscfd which
shall be confirmed based on data from final vendor for gas compressors [Ref.2].
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
The fuel gas for supplemental firing is required since the total required heating
duty is larger than heat duty available from exhaust gas of GTGs. The following
table 5.1-1 presents the required heating duty for each production life (the data
will be updated based on heating system study) [Ref. 6].
Table 5.1-1: Required Heating Duty for Supplemental Firing in WHRU [Ref. 6]
DUTY (kW)
HEATING MEDIUM USERS Early Early
Mid Life Late Life Design Turndown
Life-1 Life-2
Liquid Heater - - 100 714 2 990 714
Condensate Reboiler 2 106 1 845 1 511 839 1 597 839
Fuel Gas Heater 640 659 387 208 387 208
Operational Drain Drum Heater 66 66 66 66 66 66
Hull Tank Heating 1 000 1 000 1 000 500 1 000 500
Rich MEG Recycle Heaters 519 1 024 1 534 519 1 730 519
MEG Reboilers A/B 9 120 17 990 26 952 9 120 30 400 9 120
MEG Flash Separator Heaters 1 350 2 663 3 990 1 350 4 500 1 350
TOTAL 14 801 25 248 35 540 13 316 42 671 13 316
Notes:
1. The duty data are taken from Heating System Study Report [Ref. 6].
2. The design case data reflects the duty data during reprocessing in MEG Recovery Unit.
3. Liquid Heater is not required during Early Life-1 and 2. The maximum data of Liquid Heater
duty is based on maximum water case.
c) Pilot Gas
As a preliminary basis, a typical fuel gas demand of 2.68 Nm3/h (100 scfh) per
pilot is considered. The value is taken from Technips previous projects
experiences. A minimum of three (3) pilot burners shall be furnished for each
flare tip [Ref. 8].
d) Blanketing Gas
The blanketing gas is supplied for On-spec, Off-spec condensate storage, Slop
Oil tanks, Condensate Surge Drum, Rich MEG Surge Drum, Rich MEG
Pretreatment Vessel, Reclaimed MEG Vacuum Receiver (in MRU Package),
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Floatation Cell and Operational Drain Drum. For the other tanks, such as Heating
Medium Expansion Vessel, Lean MEG Surge Drum, Lean/ Rich MEG Tanks, the
blanketing gas will be Nitrogen gas [Ref . 9, 10]. The calculation follows the
tables in API Std. 2000 [Ref. 11].
To accommodate the fuel gas supply pressure of minimum at 26 Barg (377 psig) and
maximum at 30 Barg (435 psig), the Fuel Gas system will supply a fuel gas at 27.6 Barg
(400 psig) for HP users and 5.5 Barg (80 psig) for LP users. However, the fuel gas
source from outlet DPCU has pressure larger than maximum pressure of fuel gas user.
In addition to supply pressure as mentioned in the above section 6.1, fuel gas system
shall fulfill the following criteria as per turbine manufacturer and low pressure fuel gas
specification [Ref. 3, 4]:
1) Fuel Volume Ratio (45456 / Wobbe Index) is in the range of 0.9 to 1.1. The Wobbe
Index is kJ/m.
2) Fuel Mass Ratio (50125 / LHV) shall be lower than 5. The LHV is in kJ/kg.
3) Modified Wobbe Index (LHV / (SG gas x T gas)) is in the range of 54 40.
4) Methane is in the range of 85 100 %mole of reactant species.
5) Ethane is in the range of 0 15 %mole of reactant species.
6) Propane is in the range of 0 15 %mole of reactant species.
7) C4+ is in the range of 0 5 %mole of reactant species.
8) Total Inerts is in the range of 0 15 %mole of total (reactant + inerts).
9) Hydrogen content shall be less than 4% by volume.
10) Carbon Monoxide content shall be less than 12.5% by volume.
11) Hydrogen Sulfide shall be less than 3000 ppmw.
12) Filtration level should be 99.5% removal of 5 micron particle.
13) Supply temperature shall be in the range of 93.3C (200F) and -40C (-40F) at
operating/ supply pressure.
14) Supply temperature at inlet flange of gas turbine package shall be the higher value
between dew point temperature plus 27.8C (50F) for hydrocarbon and dew point
temperature plus 16.7C (30F) for water.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
15) BTEX content shall be less than 5000 ppm. Refer to the e-mail under Attachment-8.
16) Gas quality to LP users is in superheat condition.
Considering Gendalo FPU facility, there are some locations in process facility that can
be used as fuel gas sources. In order to select the fuel gas sources, process gas shall
be reviewed for all operating scenarios to obtain a reliable fuel gas system. In terms of
further treatment process, the fuel gas sources shall require a minimum treatment before
it is utilized.
In general, fuel gas sources can be divided into three categories: primary sources,
secondary sources and tertiary sources. The description of each fuel gas sources are
presented below.
Primary Source is used continuously during normal operation. There are three source
options that can be utilized as primary source:
Of the three (3) primary gas source options, the review of its quality and quantity are
made. The review of its using in fuel gas system will also be made, which will investigate
the heating duty requirement and design condition of the system.
Secondary Source is used for any re-start/ start up purpose. It is also used as back up
supply. The fuel gas source can be from gas export pipeline.
In case fuel gas pressure drops at fuel gas scrubber below low/ low set point level in
normal operation, critical alarm is activated in control room. Operators shall manually
switch over secondary source to keep fuel gas system under control.
Tertiary Source is used as initial/ black start gas in the event of non-availability of
secondary supply.
The tertiary fuel gas source is taken from gas outlet of Inlet Separator/ HP gas header
instead of upstream of Inlet Separator since gas from upstream of Inlet Separator
contain more liquids (wet gas). To accommodate black start scenario, protection and
control system of Inlet Separator shall be included in black start up essential load [Ref.
13].
The summary of fuel gas source review for different operating scenario is presented in
Table 5.3-1. The detailed results are presented in Attachment-4.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit FEED Services GLO-T800-PRO-EVA-TEC-000-00001-00
Mixed HP and LP Flash Gas NO NO NO NO - The selected secondary fuel gas source is from gas
(Note-3) (Note-4) (Note-4) (Note-4) (Note-4) export pipeline.
- For the flash gas, the available capacity is not sufficient
and the quality does not meet its specification (Note-4).
Gendalo-1020 YES YES YES YES The optimization shall be considered to utilize this gas
SECONDARY as fuel gas source.
NO NO - All the gases from Inlet separator are also suitable to be
Gendalo-1130 YES YES
(Note-5) (Note-5) used as fuel gas source. But, it is preferable to use as
tertiary source since it will be available during black
Maha-3130 YES YES YES YES start.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Notes:
1. The fuel gas sources are reviewed under HP fuel gas supply pressure of 400 psig.
2. The fuel gas sources are reviewed based on fuel gas specification (mentioned in section 5.2).
3. Mixed HP and LP flash gas is flash gas from flash gas compressors discharge.
4. The flash gas does not meet the fuel volume ratio, wobbe index and minimum required
methane quantity.
5. Dew point of gas from Gendalo-1130 is high, thus supply Temperature to generator gas
turbine exceeds the criteria (>200F).
6. The detailed review is presented in Attachment-4.
The wet gas quality from Inlet Separator gas outlet meets fuel gas specification, except
for gas from Gendalo-1130 field. During black start, only wet gas from Gendalo-1020
and Maha-3130 field can be used as fuel source. Hence, the FPU shall be started (Black
Start) with either Gendalo-1020 or Maha-3130 [Ref. 13]. With this review, requirement to
install fuel gas start-up skid in Fuel Gas System package can be eliminated in order to
limit the space, weight and number of equipment in Gendalo FPU.
The fuel gas source selection shall also consider the flash gas source since it can
increase the plant efficiency in term of fuel requirement. The following section 5.4
describes the utilization of flash gas for fuel gas system.
The observations and findings are made to address the utilization of flash gas for fuel
gas system. With respect to the fuel gas sources review, the flash gas can not be the
only source of primary fuel gas because of its quantity and quality (fuel volume ratio,
wobbe index and minimum methane quantity, see Attachment-4 for detail quality
review). If the flash gas is to be used as fuel gas, it shall be combined or blended with
the primary fuel gas from Dew Point Control Unit outlet. Blending with dew-pointed gas,
flash can be utilized as a fuel gas during normal operating scenario only.
Considering that the Flash Gas Compression Unit shall be available in Gendalo FPU, it
will present flexibility whether flash gas is used as fuel gas source or routed to the
suction booster compressors. If the flash gas is utilized as fuel gas source, it will be
routed to the upstream of Fuel Gas Scrubber (170-MBF-1705). The simplified process
schemes are presented in the figure 5.4-1.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
CONDENSATE
TREATMENT/
STABILIZATION HP USERS
UNIT FG FILTER-
LP FLASH GAS
SEPARATORS
(2x100%)
TERTIARY &
FG
SECONDARY
HEATERS
SOURCE
LP FG
SCRUBBER
LP USERS
Refer to Attachment 4 and 6, flash gas after gas compression can be utilized as fuel gas
by blending with dew-pointed gas (gas from DPCU outlet) at the ratio of 1 : 1.1 (Flash
gas : Dew-pointed gas) as a minimum requirement. Since fuel gas demand is higher
rather than generated flash gas, during all production life, all flash gases can be used as
fuel gas source by blending with dew-pointed gas.
In case flash gas can not be utilized as fuel gas source due to any reasons, i.e. BTEX
content, flash gas shall be routed to suction header of Booster Compressor.
Based on fuel gas source review and flash gas utilization review, the recommended fuel
gas sources are listed as follows:
Primary source is dew-pointed gas from downstream of Dew Point Control Unit
or blended gas (dew-pointed gas with flash gas).
Secondary source is dew-pointed gas from gas export pipeline.
Tertiary source is wet gas from Inlet Separators gas outlet.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
The fuel gas system is a gas treatment package to treat process gas before it is utilized
as fuel gas. After being treated and meeting the specification/ criteria specified by
equipment users, the gas can be utilized as a fuel gas.
Fuel gas system configuration is designed appropriate with Gendalo FPU facility. Fuel
gas system design shall comply with company standard requirement as stated in
COMPANY standard PAK-SU-17.22 (Fuel Gas System Equipment) and PAK-SU-17.23
(Fuel Gas Filter Package) [Ref. 14, 15].
As stated in COMPANY standards, the fuel gas system package shall consist of the
following components as minimum:
The scrubber as first stage separation shall contain vane type mist eliminator or internal
device recommended by vendor [TBD]. The second stage for the filter-separator shall
contain replaceable resin impregnated molded fiberglass elements. The separators shall
have maximum pressure loss of 0.28 bar (4 psi) (for clean service) and 1.72 bar (25 psi)
(for dirty service) [Ref. 15].
The fuel gas filter separator shall remove 99.5% of 5-micron and larger contaminants
and entrained liquids as per turbine vendor specification [Ref. 4]. Carry-over of free liquid
in the exit gas of the filter separator shall be less than 0.01 gallon per MMscfd [Ref. 15].
The Fuel Gas Heater shall be electric or circulating heating medium [Ref. 14]. The
selection of Fuel Gas Heater type describes in the section 8.4 (Optimization of Fuel Gas
System).
As per process philosophy, there are four (4) operating scenarios that shall be
considered for designing the fuel gas system at Gendalo FPU. The operating scenarios
are as follows:
Normal operation
Initial/ black start
Re-start up /start up
Compressor change-over
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Loss of primary supply of fuel gas and use of secondary source as back-up fuel
gas.
The description of fuel gas users in each operating scenarios is listed as per following:
During this operation scenario, the fuel gas is sourced from primary source which is
process gas at downstream of Dew Point Control Unit or blended gas. The fuel gas
users are booster compressor gas tur bines, export compressor gas turbines, gas
turbine generators and LP users such as: fuel gas for supplemental firing in WHRU,
purge / pilot gas, blanketing gas and gas for polishing unit. The maximum numbers
of gas turbines that are running during this operating scenario are as per following:
The governing case for fuel gas consumption is in Mid Life [Ref. 2]. The number of
compressors running is the largest compared to other production life.
This operating scenario happens when Gendalo FPU facility is shut down due to
emergency shutdown. Due to FPU total blowdown process, there is no gas available
from process facilities. To re-start up the facility, pipeline gas is utilized. The
operating condition of fuel gas is at gas export pipeline settle-out condition.
The wet gas from subsea is introduced to BGC and then it is processed in the DPCU
before entering the EGC. In the beginning, the gas from DPCU still does not meet its
specification, thus primary source should not be used as fuel gas source. Once the
dew-pointed gas meets export gas specification (The gas processing facility is in
stable condition), the fuel gas source will be taken from primary source.
During this operating scenario, at first, one Power Generator is run with diesel fuel.
Once fuel gas system is started up, the diesel fuel is switched over to fuel gas for
running the Power Generator. Then, the fuel gas will supply to gas compressor for
one train only [Ref. 13].
Thus, during start up operation, the fuel gas consumption will be provided for one
train compressor (booster compressor gas turbine and export compressor gas
turbine), power generator and LP users such as: fuel gas for supplemental firing in
WHRU, purge / pilot gas, blanketing gas and gas for polishing unit. The maximum
numbers of gas turbines that are running during this operating scenario are as per
following:
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
This scenario is similar with re-start up scenario, but the fuel gas is sourced from
tertiary source which is wet gas fr om the gas outlet of Inlet Separators. Once the
dew-pointed gas is achieved at DPCU outlet, then tertiary gas is substituted by
primary gas.
Thus, the fuel gas users are booster compressor gas turbine, export compressor gas
turbine, power generator and LP users such as: fuel gas for supplemental firing in
WHRU, purge / pilot gas, blanketing gas and gas for polishing unit [Ref. 13]. The
maximum numbers of gas turbines that are running during this operating scenario
are as per following:
The incident is that off-spec gas occurs at DPCU discharge. To avoid off-spec gas is
sent to the EGC unit, the DPCU train producing off-spec gas shall be isolated by
manual intervention. The other DPCU unit can still keep working based on maximum
production of 50%. In this case, fuel gas can be still taken from DPCU discharge
header.
In case both DPCU trains producing off-spec gas, both trains discharge shall be
isolated leading to EGC and BGC unit to work under recycle mode and flaring DPCU
incoming gas through pressure control valve. However, in order to minimize loss of
gas through flaring, FPU inlet shall be throttled by choke valve to minimum possible
turndown.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
In this scenario, fuel gas shall be provided from export pipeline as primary fuel gas
back-up. This process shall be operated by manual intervention from control room.
When off-spec export gas still occurs in the system, the compressors will be running
in recycle mode [Ref. 16, 18]. During this condition, the primary source cannot supply
fuel gas to the fuel gas system, and then, immediate restoration of fuel gas source is
required. The primary fuel source is manually substituted by using secondary source,
once low/ low pressure alarm at fuel gas system is indicated in control room.
Considering Gendalo FPU facility operating scenarios, summary fuel gas consumption
for governing operating cases are presented in the following table. The detailed
calculation and relevant references are provided in Attachment-3.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
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FEED Services
Date: 27-Dec-11 Rev. H01
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
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FEED Services
Date: 27-Dec-11 Rev. H01
b) Change-over: 2 BGCs and 2 EGCs at 100% load each + additional consumption for
change-over compressor + 2 GTGs at 50 % load each + LP Consumption. The number
of running compressor will be based on respective production life.
c) Normal Operation: 2 BGCs and 2 EGCs at 100% load each + 2 GTGs at 50 % loads
each + LP Consumption. The number of running compressor will be based on
respective production life.
d) Re-start up: 1 BGC at 100% load + 1 EGC at 100% load + 1 GTG at 50% load + LP
Consumption.
e) Loss of primary supply: BGCs and EGCs at 50% load each + 2 GTGs at 50 % loads
each + LP Consumption. Compressors are in recycle mode. The number of running
compressors is based on respective production life.
2. The tertiary sources are as follows:
a) Tertiary 1 = GENDALO-1020
b) Tertiary 2 = MAHA-3130
3. No flowrate margin is applied for all of the cases
4. During Early Life Phase-1, GANDANG-1200 is not online. Gendalo-1130 is not considered
since it is not recommended to be used during black start operation.
The hydrate formation is investigated by using Hysys simulation for all operation cases
and various fuel gas sources. In this investigation, the gas is let down to the required fuel
gas system pressure of 31.0 Barg (450 psig). The result of hydrate formation verification
in fuel gas system is summarized in the table 8.2-1. This table studies hydrate formation
without any heating in fuel gas system.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
2. The upstream pressure is the stream operating pressure, whereas the downstream pressure
is the fuel gas system operating pressure of 31.0 Barg (450 psig).
3. During Early Life Phase-1, GANDANG-1200 is not online. Gendalo-1130 is not considered
since it is not recommended to be used during black start operation.
4. Depression temperature (T) is difference temperature between operating temperature and
hydrate temperature of the fluid. If the difference temperature between operating and hydrate
temperature is less than 5C (10F), then hydrate is considered to form.
5. Refer to Attachment-5 for detail results.
The results show that the hydrate tends to form when the secondary and tertiary fuel gas
sources are utilized. The high pressure of secondary/tertiary fuel gas supply gives a
large differential pressure across control valve. Consequently, the gas temperature will
drop down to below its hydrate temperature. The detailed results are presented in
Attachment-5. Therefore, in order to prevent hydrate formation, heating of fuel gas
source is required before letting down the pressure across the pressure control valves
(the configuration as shown in Attachment-1). With this configuration, the operating
temperature is able to be maintained at 5C (10F) above hydrate temperature.
In this study, HYSYS process simulations for fuel gas system design are carried out. The
following assumptions are used for generating process simulation:
The pressure drop across heater is 10 psi for heating medium heater and 5 psi
for electric heater
The pressure drop of scrubber and filter/ separator is 1 psi and 4 psi respectively.
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Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit FEED Services GLO-T800-PRO-EVA-TEC-000-00001-00
Tertiary (Gendalo-1020) 2 12.10 1300.0 89.6 9.9 88.9 71.1 69.8 61.2 635.9 NOTE-5
Black Start up
Tertiary (Gendalo-1020) 3 12.43 1300.0 89.6 9.9 88.9 71.1 69.8 61.2 653.4 NOTE-5
Tertiary (Maha-3130) 4 14.12 500.0 34.5 10.0 41.9 40.6 39.1 29.0 251.4
Normal operation Primary 5 22.43 1080.0 74.5 20.0 60.0 43.4 41.8 31.3 584.6
Loss of Primary Supply Secondary 6 16.05 2990.0 206.2 48.8 88.9 43.4 41.8 31.3 487.2
Re-start up Secondary settle out 7 13.69 2015.8 139.0 29.4 77.3 43.4 41.8 31.3 481.0
EARLY LIFE-2 PHASE
Normal operation Primary 1 22.53 1080.0 74.5 17.6 58.7 42.1 40.5 30.0 602.1
Change over operation Primary 2 24.66 1080.0 74.5 17.6 58.7 42.1 40.5 30.0 659.2
Loss of Primary Supply Secondary 3 16.12 2990.0 206.2 48.8 87.6 42.1 40.5 30.0 470.9
Re-start up Secondary settle out 4 14.30 2007.7 138.4 29.4 75.9 42.1 40.5 30.0 484.7
Change over operation Primary 2 28.87 970.0 66.9 39.9 61.1 47.6 46.1 35.9 387.3
Loss of Primary Supply Secondary 3 18.21 2665.0 183.7 48.8 88.8 47.6 46.1 35.9 542.3
Re-start up Secondary settle out 4 14.82 1796.9 123.9 29.4 77.3 47.6 46.1 35.9 506.9
Loss of Primary Supply Secondary 2 8.78 1525.0 105.1 48.7 75.8 51.6 50.2 40.4 159.5
Re-start up Secondary settle out 3 11.65 1118.7 77.1 29.4 67.9 51.6 50.2 40.4 287.3
Notes:
1. The fuel gas consumption is for 100% load of BGC, 100% load of EGC, 50% load of GTG and LP Users.
2. The fuel gas consumption is for 80% load of BGC, 80% load of EGC, 50% load of GTG and LP Users.
3. The fuel gas consumption is for 100% load of BGC, 100% load of EGC and LP Users. GTG is driven by diesel fuel.
Page 24 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit FEED Services GLO-T800-PRO-EVA-TEC-000-00001-00
Table 8.3-2: Fuel gas System Simulation Result with Blended Gas
Temperature HC dew
Fuel Wobbe Fuel Gas Temperature Temperature Temperature Heater
Phase Operating Case Upstream Fuel point /
Gas Index Consumption Outlet Heater to HP Users to LP Users Duty Remarks
of Life Scenario 3 Gas Scrubber Water dew
Source (kJ/m ) (MMscfd) (C) (C) (C) (kW)
(C) point (C)
Change- Maximum
Max Blended
over 1 48386 21.92 82.7 56.2 26.7 / 26.7 54.5 42.9 468.5 Temperature
Cond. Gas
operation outlet Heater
Change-
Early Blended Maximum
over 2 47553 22.68 73.0 53.1 23.7 / 23.5 51.5 40.2 526.0
Life-1 Gas Duty
operation
Change-
Early Blended
over 3 46689 23.52 58.7 43.1 20.1 / 13.6 41.4 30.1 502.1
Life-2 Gas
operation
Change-
Mid Blended Maximum
over 4 46041 28.42 62.8 49.4 4.7 / 19.8 47.7 37.3 387.7
Life Gas Capacity
operation
Notes:
1. Blended gas is dew-pointed gas with flash gas from flash gas compressor.
2. The flash gas to dew-pointed gas ratio is 1:1.1 as a minimum requirement.
Page 25 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
From table 8.3.1 & 8.3-2 and Attachment-4 & 7, the following observations are made:
All fuel gas sources (primary, secondary and tertiary) meet the requirement of
fuel gas specification.
The secondary source or gas inside pipeline is considered sufficient to provide
fuel gas for re-start up purpose. The available buffer time is 4.5 days. This buffer
time is based on Late Life wherein the settle-out pressure is the lowest. During
Early Life and Mid Life, the settle-out pressure is considered higher than that of
Late Life, so the buffer time available must be larger than 4.5 days. The detailed
calculation is provided in Attachment-7.
The compressor change-over operation determines the fuel gas system design
capacity. During Mid Life, required fuel gas flowrate is 28.9 MMscfd. Therefore,
Fuel gas system shall be designed for 28.9 MMscfd.
Fuel gas heating is required for all operating scenarios. Without heating, the fuel
gas supply temperature will be less than the HP users required temperature. The
maximum required duty for normal operation is 659.2 kW (case-2) during Early
Life-2. As a minimum, the standby heater will be designed for this duty of 659.2
kW.
In case for black start purpose, the fuel gas heater is utilized to treat fuel gas for
100% load of BGC, 100% load of EGC, 50% load of GTG and LP users, the
heating duty will be 726.6 kW (case-1, Early Life-1).
When blended gas is utilized as primary fuel gas source, fuel gas heating is
required for all production life. The maximum heating duty is 526 kW (case-3,
Early Life-2).
Gas from Inlet Separators is not selected as the primary sources because it
requires more heating duty compared to gas from outlet DPCU at the same
flowrate.
The heater outlet temperature reaches up to 88.9C (192F). The heater design
temperature including its piping system shall be able to cover this maximum
operating temperature.
Page 26 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
The fuel gas system needs to be optimized in order to achieve reliable system in
Gendalo FPU. The observations are made for optimization of fuel gas heater and control
valve configuration. As indicated in section 8.3 Fuel Gas Simulation Results, the
required heating duty for normal and start up operation is presented in the table 8.4-1.
The fuel gas system is a critical service for the gas processing facility. During initial/
black start up, the fuel gas system is required to supply fuel gas for compressor gas
turbines. In order to reduce operational difficulty during start up, the start-up fuel gas
heater is designed as an electric heater instead of using a heating medium.
In the other hand, to reduce electrical load during normal operation, it is proposed to use
heater with heating medium to obtain the required superheat of fuel gas for normal
operation. A separate 1 x 100% electric heater, called Start-up Fuel Gas Heater will be
used for black start up/ re-start up purpose.
In order to optimize the fuel gas heater design, the electric fuel gas heater is designed
for 660 kW, considering the following factors:
This heating duty can handle the heating requirement for 80% load of BGC, 80%
load of EGC, 50% load of GTG and LP Users, which is sufficient for black start
up purpose.
This heating duty is capable to accommodate the heating load for fuel gas
system during normal operation (back up heater).
With this duty design, it will provide lower cost due to less electrical element
required.
Page 27 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Based on the above analysis, therefore, the design of fuel gas system will consist of the
following heaters:
Control Valve
The fuel gas entering to the fuel gas system has various operating conditions with
different ranges of pressure drop. The optimization shall be made in order to get
optimum size of the control valve. Two fuel gas heaters are provided for normal
operation and start up purpose. The primary source line is connected to the both of fuel
gas heaters, while all the source lines are connected to the electric fuel gas heater.
Therefore, two (2) sets of control valves are provided for each downstream line of
heater.
The table 8.4-2 is presented for the optimization of control valve configuration.
Page 28 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Two (2) sets of control valves are proposed, namely, main and back-up control valves.
In order to adequately control the range of fuel gas demand with varying pressure drops,
multiples valves of different sizes are arranged in parallel configuration for back-up
control valves. One (1) control valve is also provided at back-up control valves for start-
up purpose. These control valves should be sized based on table 8.4-2.
The control valve configuration is presented in the proposed fuel gas system
configuration (Attachment-1).
The MEG injection is only required during start-up. When starting up the fuel gas electric
heater, the heater may not be ready to heat up the gas at desired temperature so that
hydrate is possible to occur in the fuel gas system. Therefore, MEG injection line is
provided at the upstream of control pressure let down valve in fuel gas system.
The simulation is carried out to obtain required MEG injection in Fuel Gas system. The
results are presented in the following table 8.4-3. The MEG injection is only simulated for
re-start up and black start during Early Life-1 since the depression temperature is the
lowest during this period as indicated in table 8.2-1.
Table 8.4-3: MEG Injection in Fuel Gas System for Start-up Operation
MEG Injecion
Fuel Gas Source Mass Rate
(kg/h)
Secondary Settle-out condition 1
Tertiary Gendalo-1020 12.5
Notes:
1. Margin 50% is added to the required MEG Injection mass rate.
2. The simulation is presented in Attachment-5.
The sizing basis for the fuel gas system is established as follows:
1) As mentioned in section 8.2, the design capacity of fuel gas scrubber and filter-
separators is 28.9 MMscfd. This capacity is required during compressor change-over
operation. While estimating the fuel gas consumption, the power of gas turbines has
considered in normal and site condition. But, the fuel gas system is only designed
based on site-condition power as this the maximum power limit that will be utilized for
gas compression. Flowrate design margin is not applied in calculation as the design
capacity is based on the compressor change-over scenario. Therefore, the fuel gas
scrubber and fuel gas filter-separators will be designed for 28.9 MMscfd of gas at
pressure of 31.0 Barg (450 psig).
Page 29 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
2) The equipment, instrumentation and pipework rating of fuel gas system are as
follows:
a) The high pressure gas stream of 206.2 Barg (2990 psig) (from gas export
pipeline) exposes the electric fuel gas heater along with the piping system
upstream control valve. This section will be rated for 1500# rating.
b) The heating medium fuel gas heater will be rated only for 900# since the gas
passes to this equipment is gas from outlet DPCU.
c) All the equipment, instrumentation and piping system at downstream of control
valve are only operated at about 31 Barg (450 psig). Thus, its design will be rated
for 300# rating.
d) For LP users, the gas pressure is reduced down to 5.5 Barg (80 psig). Thus, in
order to accommodate LP fuel gas users, all equipment, instrumentation and
piping system for LP section will only be rated for 150# rating.
3) The following list is used for the basis to design and size the equipment in the fuel
gas system.
a) The electric fuel gas heater design duty is 660 kW. This duty is designed similar
with the fuel gas heater for normal operation, since its function as standby
heater. For the gas capacity, it will be sized for 28.9 MMscfd. Maximum gas
flowrate is based on compressor change over scenario during Mid Life.
b) The heating medium fuel gas heater design duty is 660 kW. This duty is based
on compressor change over scenario during Early Life-2. For the gas capacity, it
will be sized for 28.9 MMscfd. Maximum gas flowrate is based on compressor
change over scenario during Mid Life.
c) HP gas scrubber shall be designed for gas capacity of 28.9 MMscfd at pressure
of 31.0 Barg (450 psig).
d) HP fuel gas filter shall be designed for gas capacity of 28.9 MMscfd at pressure
of 31.0 Barg (450 psig).
e) LP fuel gas scrubber shall be sized for gas capacity of 7.0 MMscfd at pressure of
5.5 Barg (80 psig).
4) The basis for control valve sizing is as per the table 8.4-2.
9.0 RECOMMENDATIONS
1) As per section 8.4, two (2) sets of control valves are proposed for both fuel gas lines
with electrical heater and heating medium. The configuration of 2 x 100% of pressure
control valves with staggered set point for normal operation. The pressure set point
of the standby control valve will be slightly lower than that of main control valve. The
2 x 100% pressure control valves (with staggered set point) on the both fuel gas
trains inlet line to the HP fuel gas scrubber will maintain the required supply pressure
to all users especially for the gas turbines. If main pressure control valves are not
able to maintain the pressure in scrubber properly, then the second (back up)
pressure control valves will start to open and keep maintaining the fuel gas supply
pressure.
Page 30 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
2) As per the requirement of providing 2 x 100% of heaters [Ref. 3], two (2) fuel gas
heaters are provided, which are electric fuel gas heater for start up & normal
operation and heating medium fuel gas heater for normal operation only. During
normal operation, both electric heater and the heater with heating medium are
sharing the load by 50% in order to ensure system reliability since the heaters must
always be in-service.
3) Similar to 2 x 100% fuel gas heater requirement, the two numbers of filter-separator
are required for the fuel gas system. As per COMPANY standard requirements, the
filter-separators shall contain replaceable resin impregnated molded fiberglass
elements. During normal operation, there is a probability of replacing the dirty
cartridge element. In order to avoid the fuel gas system shutdown, the spare 100%
filter-separator is required in the system design. Thus, the fuel gas system shall be
provided with the 2 x 100% filter-separators (one as a spare).
4) The flash gas from flash gas compressor is recommended to be routed to the fuel
gas system. The blended gas of primary gas (dew-pointed gas) and flash gas meets
the fuel gas specification.
5) Considering Gandang-1200 is not online during Early Life, black start fuel gas for
Early Life can be taken from Gendalo-1020 and Maha-3130 only. In case Gandang-
1200 is online during other production period, gas from Gandang-1200 can also be
used as a black start fuel gas source.
6) Start up sequence shall consider Start up Fuel Gas Heater (170-HAP-1705) heating
capacity equivalent to 80% load of BGC, 80% load of EGC, 50% load of GTG and LP
Users.
10.0 CONCLUSIONS
1) Fuel gas system is designed appropriate with Gendalo FPU for all cases of operation
scenarios. Start up fuel gas skid is not required for initial/ black start up and re-start
up case since the selected wet gases (from Gendalo-1020 and Maha-3130) meet the
specification.
2) The fuel gas system in Gendalo FPU consists of:
Page 31 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
11.0 REFERENCES
Page 32 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
16) External Interface Request. Settle-out Pressure of Gendalo Gas Export Pipeline.
GLO-P000-INT-IRF-TEC-WPI-00001.
17) Electrical Design Basis, GGC-T800-ELE-BOD-TEC-000-00001-00-E02.
18) Off-spec Product Handling and Processing Study Report for Gendalo FPU, GLO-
T000-PRO-RPT-TEC-000-00007-00-E02.
19) Produced Water Treating Study Report for Gendalo FPU, GLO-T600-PRO-RPT-
TEC-000-00001-H01.
20) Gendalo Fluid Characterizations, GLO-G000-SFA-RPT-CHV-000-00001-00
21) Gas Turbine Compressor Specification sheets.
22) Gas Turbine Generator Specification sheets.
23) Export Pipeline Basis of Design, GGC-G000-PPL-BOD-CHV-000-00001-00.
24) Process Configuration Study for Gendalo FPU, GLO-T000-PRO-EVA-TEC-000-
00002-00-E02.
25) Utility Consumption List Gendalo MEG Recovery Unit Package, GLO-V000-PRO-
LST-TEC-T01-00002-00-E01.
12.0 ATTACHMENTS
Page 33 of 44
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 34 of 44
Flash Gas
from Gas Outlet of
Flash Gas Compressors PC
NOTE 7
NOTE 4 NO
NOTE 6 170-HAP-1705 HP USERS
START UP/ STANDBY
FUEL GAS
HEATER
NOTE 2
1500#
NC
900#
NOTE 1 170-MAJ-1702
NOTE 3 NOTE 2 HP FUEL GAS
Primary Gas HH HH
FILTER/
PC TC TT LL PT LL NC
(from DPCU) SEPARATOR B
MAIN LINE
NOTE 4 NOTE 5
Secondary Gas NOTE 5
(from Gas Export Pipeline) 170-MBF-1705
900# 300# HP FUEL GAS
SCRUBBER
FI
LP USERS
170-HBG-1705
Dew Point Export Gas Export Gas FUEL GAS
HEATER PC
Control Unit Compression Metering
170-MBF-1710
LP FUEL GAS
300# 150# SCRUBBER
Notes:
1. Two sets of control valve are provided, namely, main and back-up control valves.
2. During normal operation, both electric heater and the heater with heating medium are sharing the load by 50% in order to ensure system reliability since the heaters must always be in-service.
3. Two shutdown valves are provided to reduce the possibility of fuel gas system failure. If SDV in main line unintentionally stucks closed, then, the fuel gas will flow to back-up line to cater the user's demands and simultaneously
the electric fuel gas heater will operate at 100% load duty.
4. Any heater failure is detected by TAHH/LL at downstream of each control pressure let down valve. It will initiate to shut down the heater and close the SDV at the same line.
5. In case of loss of primary supply due to any process reason, it will be detected by PALL at upstream scrubber. On low-low fuel gas pressure, the SDV on the secondary supply gas line can only be opened with manual
intervention by the operators.
6. Connection from tertiary sources, Gendalo-1020, Maha-3130, and Gandang-1200. Gas from Gendalo-1130 is not utilized since its quality does not meet specfication.
7. Provision is made to utilize flash gas from flash gas compressor as fuel gas source. It will be blended with dew-pointed gas. Pressure of flash gas is reduced to 450 psig. As minimum requirement, the flash gas to dew-pointed
gas ratio is 1:1.1 only.
Page 35 of 44
Attachment-2
ATTACHMENT-2: FUEL GAS SIMULATION RESULTS
Tertiary (Gendalo-1020) 2 12.10 1300.0 89.6 9.9 88.9 71.1 69.8 61.2 635.9 NOTE-5
Black Start up
Tertiary (Gendalo-1020) 3 12.43 1300.0 89.6 9.9 88.9 71.1 69.8 61.2 653.4 NOTE-5
Tertiary (Maha-3130) 4 14.12 500.0 34.5 10.0 41.9 40.6 39.1 29.0 251.4
Normal operation Primary 5 22.43 1080.0 74.5 20.0 60.0 43.4 41.8 31.3 584.6
Loss of Primary Supply Secondary 6 16.05 2990.0 206.2 48.8 88.9 43.4 41.8 31.3 487.2
Re-start up Secondary settle out 7 13.69 2015.8 139.0 29.4 77.3 43.4 41.8 31.3 481.0
EARLY LIFE-2 PHASE
Normal operation Primary 1 22.53 1080.0 74.5 17.6 58.7 42.1 40.5 30.0 602.1
Change over operation Primary 2 24.66 1080.0 74.5 17.6 58.7 42.1 40.5 30.0 659.2
Loss of Primary Supply Secondary 3 16.12 2990.0 206.2 48.8 87.6 42.1 40.5 30.0 470.9
Re-start up Secondary settle out 4 14.30 2007.7 138.4 29.4 75.9 42.1 40.5 30.0 484.7
MID LIFE PHASE
Normal operation Primary 1 26.73 970.0 66.9 39.9 61.1 47.6 46.1 35.9 358.6
Change over operation Primary 2 28.87 970.0 66.9 39.9 61.1 47.6 46.1 35.9 387.3
Loss of Primary Supply Secondary 3 18.21 2665.0 183.7 48.8 88.8 47.6 46.1 35.9 542.3
Re-start up Secondary settle out 4 14.82 1796.9 123.9 29.4 77.3 47.6 46.1 35.9 506.9
LATE LIFE PHASE
Normal operation Primary 1 13.09 970.0 66.9 39.2 64.6 51.6 50.2 40.4 207.8
Loss of Primary Supply Secondary 2 8.78 1525.0 105.1 48.7 75.8 51.6 50.2 40.4 159.5
Re-start up Secondary settle out 3 11.65 1118.7 77.1 29.4 67.9 51.6 50.2 40.4 287.3
SHEET 1 OF 11
Attachment-2
ATTACHMENT-2: FUEL GAS SIMULATION RESULTS BY UTILIZING BLENDED GAS
Early Life-1 Change-over operation Blended Gas 2 47553 22.68 73.0 53.1 23.7 / 23.5 51.5 40.2 526.0 Maximum Duty
Early Life-2 Change-over operation Blended Gas 3 46689 23.52 58.7 43.1 20.1 / 13.6 41.4 30.1 502.1
Mid Life Change-over operation Blended Gas 4 46041 28.42 62.8 49.4 4.7 / 19.8 47.7 37.3 387.7 Maximum Capacity
Late Life Normal Operation Blended Gas 5 45618 13.01 65.3 52.3 1.8 / 23 50.8 41.0 206.3
Table 2.0-2: Fuel Gas System Simulation Result by Utilizing Blended Gas
Notes:
1. Blended gas is gas from outlet DPCU and flash gas from Flash Gas Compressor.
2. The observations are made to utilize the flash gas. It is found that Flash Gas Compression Unit shall be provided. It will present flexibility whether the gas is used as fuel gas source or routed to the suction booster compressors.
3. The blended gas quality is presented in Attachment-6 (table 6.0-2).
4. The flash gas to primary gas ratio is 1:1.1 as a minimum requirement.
5. The operating scenario is compressor change over scenario. It is simulated in order to obtain maximum required flowrate and heater duty. Except for Late Life, the normal operation scenario is to obtain turndown case.
SHEET 2 OF 11
Scenario: Black/ Initial Start
Phase: Early Life-1
Source: Tertiary from Gendalo-1020
801 Remarks:
817a
Temperature 9.958 C 1 EGC and 1 BGC at 80% load
1 GTG at 50% load Temperature 69.82 C
Pressure 89.63 bar_g LP Consumption
Pressure 27.58 bar_g
Molar Flow 12.10 MMSCFD
Molar Flow 3.449 MMSCFD
170-HAP-1705 (Start up/ Stand by Heater)
DUTY 635.9 kW
A
op-107
Feed Temperature 9.958 C ADJ-1 817
817a LHV 3.495e+004
Product Temperature 88.91 C VLV-123
801 Q-100 TEE-104 HCDew 42.01 C
FuelGas
-
WaterDew -1.887 C
818 GP
TEE-102-2 811
810 op-107
802 804 170-MAJ-1705 TEE-103
806 819
170-HAP-1705 VLV-100 (Fuel Gas --
(Start up/ 809 Filter/Separator) 821
Stand by
Heater)
TEE-105
Q-110 822 823
812
VLV-122 Temperature 61.20 C
804 806
828
Case:
Wed Dec
N:\6310\2000-ENG\2100-PROCESS\Process
28 10:42:51 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Early Life-1\FG IFD-Black start 1 (2)[GENDALO - Option 1 Case 1 (Early
Flowsheet:
Life-1)Case
090811].hsc
(Main)
Scenario: Black/ Initial Start
Phase: Early Life-1
Source: Tertiary from Gendalo-1020
Remarks:
1 EGC and 1 BGC at 100% load
LP Consumption
817a
801 170-HAP-1705 (Start up/ Stand by Heater) Temperature 69.82 C
Temperature 9.958 C DUTY 653.4 kW Pressure 27.58 bar_g
Pressure 89.63 bar_g Feed Temperature 9.958 C Molar Flow 4.311 MMSCFD
Molar Flow 12.43 MMSCFD Product Temperature 88.91 C
op-107
A 817
817a LHV 937.9
ADJ-1 VLV-123
801 Q-100 TEE-104 HCDew 42.01 C
FuelGas
-
WaterDew -1.887 C
818 GP
TEE-102-2 811
810 op-107
802 804 170-MAJ-1705 TEE-103
806 819
170-HAP-1705 VLV-100 (Fuel Gas --
(Start up/ 809 Filter/Separator) 821
Stand by
Heater) 823
TEE-105
Q-110 822 Temperature 61.20 C
812
VLV-122 Pressure 5.516 bar_g
823 Molar Flow 0.1230 MMSCFD
--842
824
170-MBF-1705
(HP FG 815 816
803-2 805 807 Scrubber) TEE-106 825
170-HBG-1705 VLV-100-2-2
(FG Heater)
170-MBF-1710 826
(LP FG
804 806 Scrubber)
828
Case:
Wed Dec
N:\6310\2000-ENG\2100-PROCESS\Process
28 10:43:25 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Early Life-1\FG IFD-Black start 1 (3)[GENDALO - Option 1 Case 1 (Early
Flowsheet:
Life-1)Case
090811].hsc
(Main)
Scenario: Compressor Change-Over
Phase: Mid Life
Source: Primary from gas outlet DPCU
Remarks:
2 EGC and 2 BGC at 100% load
2 GTG at 50% load 817a
LP Consumption Temperature 46.07 C
Pressure 27.58 bar_g
S Molar Flow 10.65 MMSCFD
803-2 SET-8
Temperature 39.93 C
A
Pressure 66.88 bar_g 817 817a
Q-100 ADJ-1 VLV-123
Molar Flow 28.87 MMSCFD
FuelGas
TEE-104 818
GP
802 804 -
170-HAP-1705 VLV-100 op-107
811
(Start up/ --
Stand by 810 TEE-103 op-107
819
2 Heater) 170-MAJ-1705 (Fuel
TEE-102-2
Gas Filter/Separator) LHV 949.0
806 809 821
TEE-105 HCDew 18.27 C
822 WaterDew -1.465 C
807
Q-110
Temperature 47.55 C 812
TEE-107 VLV-122 823 823
Pressure 31.03 bar_g
824 Temperature 35.85 C
Molar Flow 14.43 MMSCFD 815
31 Pressure 5.516 bar_g
3
825 Molar Flow 3.249 MMSCFD
170-MBF-1705 816
803-2 805 807 4 (HP FG Scrubber)
TEE-106
170-HBG-1705 VLV-100-2-2 826
(FG Heater) MIX-104
170-MBF-1710 827
170-HBG-1705 (FG Heater) 805 (LP FG
Scrubber)
DUTY 193.6 kW Temperature 61.02 C
Feed Temperature 39.93 C Pressure 66.19 bar_g
Product Temperature 61.02 C Molar Flow 14.43 MMSCFD
840
841
WedCase:
Dec 28
N:\6310\2000-ENG\2100-PROCESS\Process
10:51:52 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Mid Life\FG IFD-Change Over[GENDALO - Option 1 Case 3 (Mid
Flowsheet:
Life) 090811].hsc
Case (Main)
Q-104 Scenario: Compressor Change-Over
Phase: Early Life-2
Source: Primary from gas outlet
DPCU 817a
Remarks: Temperature 40.53 C
2 EGC and 1 BGC at 100% load
Pressure 27.58 bar_g
2 3 1 EGC at 50% load (Change-over)
E-100 2 GTG at 50% load Molar Flow 4.274 MMSCFD
LP Consumption
817a
FuelGas
A
14 817
ADJ-1 VLV-123
S TEE-104 818
801 Q-101
Q-101 SET-5 Heat Flow 329.6 kW - GP
819
-- op-107
811 TEE-103
802 804 806 810
VLV-100 op-107
170-HAP-1705 170-MAJ-1705 (Fuel 821
TEE-102-2
(Start up/ 809 Gas Filter/Separator) LHV 946.2
Stand by TEE-105
Heater) HCDew 12.73 C
822
. WaterDew 5.321 C
Q-110 807
812
Temperature 42.06 C VLV-122
823
Pressure 31.03 bar_g 823
803-2 815
Molar Flow 12.33 MMSCFD 31 824 Temperature 29.95 C
TEE-107
Pressure 5.516 bar_g
170-MBF-1705 825
.. (HP FG 816 Molar Flow 3.259 MMSCFD
805 807 ---- Scrubber)
170-HBG-1705 VLV-100-2-2 TEE-106 826
(FG Heater) MIX-104
7 170-MBF-1710
803-2 (LP FG 827
Scrubber)
Temperature 17.60 C
170-HBG-1705 (FG Heater)
Pressure 74.46 bar_g
DUTY 329.6 kW
Molar Flow 24.66 MMSCFD
Feed Temperature 17.60 C 840
Product Temperature 58.54 C 841
805
Temperature 58.54 C
Pressure 73.77 bar_g
828
Molar Flow 12.33 MMSCFD
19
Wed
Case:
Dec
N:\6310\2000-ENG\2100-PROCESS\Process
28 10:49:03 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Early Life-2\FG IFD-Change over[GENDALO - Option 1 Case 2 (Early
Flowsheet:
Life-2) 090811].hsc
Case (Main)
A
ADJ-1 817a
ash
as 817 Temperature 50.08 C
808 808 VLV-123
VLV-101
Pressure 27.58 bar_g
Temperature 46.27 C TEE-104
818 Molar Flow 3.715 MMSCFD
S Pressure 31.03 bar_g
SET-5 Molar Flow 10.37 MMSCFD
Q-100
170-MAJ-1705 (Fuel Gas 817a
Heat Flow 202.8 kW Filter/Separator)
801 Q-100 Blending 819 FuelGas
Scenario 813
TEE-105
GP op-107
TEE-102-2 811
810 821
814 op-107 HCDew 22.28 C
802 804 806 TEE-103
170-HAP-1705 (Start-up/ Standby Heater) VLV-100 822 WaterDew 26.73 C
809
LHV 1089
2
Q-110 823
812 823
VLV-122
Q-110 824 Temperature 38.11 C
TEE-107 170-MBF-1705 (HP Pressure 5.516 bar_g
Heat Flow 202.8 kW FG Scrubber) --842
-
Molar Flow 2.929 MMSCFD
3 MIX-104 825
815 816
803 805 807 TEE-106
170-HBG-1705 (FG VLV-100-2-2 826
Heater)
841
828
Q-700
622
506
se: N:\6310\2000-ENG\2100-PROCESS\Process
Wed Dec 28 10:56:12 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Flash Gas Utilization\Flash Gas IFD-[GENDALO - Option 1 Design Case 1 (Max
Flowsheet:
Cond) Case
090811
(Main)
mod01].h
--811
Temperature 50.17 C
Pressure 27.58 bar_g
Scenario: Loss of Primary Supply Molar Flow 2.155 MMSCFD
Phase: Late Life
Source: Secondary - settle out condition
Remarks:
1 EGC and 1 BGC at 50% load
2 GTG at 50% load --811
VLV-123 FuelGas
LP Consumption
817
A GP
818
ADJ-1 - op-107
170-HAP-1705 (Start up/ Stand by Heater) TEE-106
802
DUTY 159.5 kW
Temperature 48.68 C TEE-103 op-107
Feed Temperature 48.68 C
Pressure 105.1 bar_g Q-100 LHV 938.0
Product Temperature 75.76 C 819
Molar Flow 8.776 MMSCFD HCDew 22.37 C
811
810 -- WaterDew -0.2363 C
821
170-MAJ-1705 (Fuel
TEE-102-2
809 Gas Filter/Separator)
806 TEE-104
802 804 VLV-112
170-HAP-1705
(Start up/ 822
Q-110
Stand by 812
Heater) VLV-122
823
823
815 Temperature 40.38 C
31 824 Pressure 5.516 bar_g
Molar Flow 8.400e-002 MMSCFD
170-MBF-1705 (HP FG 816 825
803-2 805 807 Scrubber)
VLV-100-2-2 TEE-105
170-HBG-1705 (FG
Heater) 826
170-MBF-1710
806 (LP FG 827
804 Scrubber)
Temperature 51.59 C
Temperature 75.76 C
Pressure 31.03 bar_g
Pressure 104.8 bar_g
Molar Flow 8.776 MMSCFD
Molar Flow 8.776 MMSCFD
840
841
828
Case:
Wed Dec
N:\6310\2000-ENG\2100-PROCESS\Process
28 10:57:11 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Late Life\FG IFD-Loss primary[GENDALO - Option 1 Case 4 (Late Life)
Flowsheet:
090811Case
mod01].hsc
(Main)
817a
Temperature 41.84 C
Re-start up Scenario
Fuel Source: Secondary Pressure 27.58 bar_g
Molar Flow 4.252 MMSCFD
A
op-107
ADJ-1 817
817a LHV 950.9
VLV-123
801 Q-100 Q-100 TEE-104 HCDew 14.04 C
FuelGas
Heat Flow 481.0 kW -
WaterDew 5.382 C
818 GP
TEE-102-2 811
810 op-107
802 804 170-MAJ-1705 TEE-103
806 819
170-HAP-1705 VLV-100 (Fuel Gas --
(Start up/ 809 Filter/Separator) 821
Stand by
Heater)
TEE-105
Q-110 822
812
VLV-122
823
--842
824
170-MBF-1705
(HP FG 815 816
803-2 805 807 Scrubber) TEE-106 825
170-HBG-1705 VLV-100-2-2
(FG Heater)
170-MBF-1710 826
(LP FG
Scrubber)
827
840
841
828
Wed
Case:
DecN:\6310\2000-ENG\2100-PROCESS\Process
28 10:44:54 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\Early Life-1\FG IFD-Re-start up[GENDALO - Option 1 Case 1 (Early
Flowsheet:
Life-1) 090811].hsc
Case (Main)
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 36 of 44
ATTACHMENT 3
SHEET 1 OF 9
ATTACHMENT 3
SHEET 2 OF 9
ATTACHMENT 3
SHEET 3 OF 9
ATTACHMENT 3
SHEET 4 OF 9
ATTACHMENT 3
SHEET NO. 5 OF 10
CALCULATION SHEET
CONTRACT NO. C-690163
Total Required Venting for On-spec and Off-spec Tank 2387.00 SCMH
2.02 MMSCFD
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 10.5761 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
PROCESS CALCULATION
Project No. Doc. Doc. No. Rev No.
6310 EVA GLO-T800-PRO-EVA-TEC-000-00001-00 H01
Total Required Venting for 2 x 100% Slop Oil Tanks 1029.13 SCMH
0.87 MMSCFD
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 3.6285 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
PROCESS CALCULATION
Project No. Doc. Doc. No. Rev No.
6310 EVA GLO-T800-PRO-EVA-TEC-000-00001-00 H01
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 17.5718 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
PROCESS CALCULATION
Project No. Doc. Doc. No. Rev No.
6310 EVA GLO-T800-PRO-EVA-TEC-000-00001-00 H01
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 10.5761 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
PROCESS CALCULATION
Project No. Doc. Doc. No. Rev No.
6310 EVA GLO-T800-PRO-EVA-TEC-000-00001-00 H01
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 5.1084 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
PROCESS CALCULATION
Project No. Doc. Doc. No. Rev No.
6310 EVA GLO-T800-PRO-EVA-TEC-000-00001-00 H01
(P2/P1) = 0.9902
2/k = 1.4286
k+1/k = 1.7143
k/MTZ(k-1) = 0.0004
A = 2.9533 cm2
Based on GS EP ECP, the piping minimum sizes shall be 2" and because the vent line is complete with flame arrestor, the vent line will take one size bigger
because of pressure drop
so size of vent line is 3"
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 37 of 44
ATTACHMENT 4
PHASE: EARLY LIFE-1
FUEL GAS SOURCES
Fuel Volume Ratio (45456 / Wobbe Index ) % 90 - 110 99.9 96.1 101.1 99.4 99.4 88.9 X Note 2
Modified Wobbe Index 54 - 40 49.2 O 49.0 O 51.0 O 51.6 O 51.6 O 55.8 X Note 2, 12
Fuel Mass Ratio (50125/ LHV Btu/lb) 5 1.04 1.05 1.03 1.04 1.04 1.09 Note 2
Methane %mole 100 - 85 97.3 90.4 99.5 96.3 96.3 75.0 X Note 2, 11
Propane %mole 0 -15 0.6 2.9 0.1 1.1 1.1 9.5 Note 2, 11
C4+ %mole 0-5 0.6 2.4 0.2 0.8 0.8 6.9 Note 2, 11
Inerts (N2+CO2+Ar) %mole 0 - 15 1.1 1.4 1.1 0.0 0.0 1.1 Note 2, 11
BTEX content ppm 5000 0.0 636.0 0.0 65.1 65.1 320.4 Note 2
Table 4.0-1: Fuel Gas Sources Review for all Operating Scenarios during Early Life-1
Notes:
1. Criteria Flag: = Comply with Requirement, X = NOT Comply with Requirement
2. The criteria are based on Turbine vendor specification. The fuel specification criteria is presented in Attachment-8.
3. The BTEX content limitation is 5000 ppm based Solar Turbine's correspondence.
4. The available capacity for secondary source fuel gas will be confirmed based flow assurance study.
5. Based on production profile P50, Gas from Gandang field is not online during Early life-1 phase.
6. All fuel gas sources except Tertiary and Flash gas can be utilized as fuel gas. If flash gas is used as fuel gas, further treatment such as: blending with primary source shall be carry out.
7. Mixed flash gas is flash gas from outlet flash gas compressor.
8. Mixed Flash gas is not fulfill fuel gas specification due to its fuel volume ratio, Wobbe Index and minimum methane quantity. Gas from Gendalo 1130 is not fulfill fuel gas specification due to its temperature exceeds 93.3C.
9. Refer to Attachment-2: Fuel Gas Simulation Result, Gas from Inlet Separators is not selected as the primary sources because it requires more heating duty compared to gas from outlet DPCU at the same flowrate.
10. The above fuel gas sources is at 400 psig.
11. For methane, ethene, propane, C4+, it is percentage mole of reactant species, whereas, for Inerts, it is percentage of total (inerts + reactants).
12. The MWI variability has allowable limit for within +/-5% from the criteria range of 54 - 40.
SHEET 1 OF 4
ATTACHMENT 4
PHASE: EARLY LIFE-2
FUEL GAS SOURCES
Gas Outlet HP Gas Outlet HP Gas Outlet HP Gas Outlet HP Mixed HP and LP
CRITERIA Gas Outlet DPCU Gas Export Pipeline
PARAMETER UNIT Separator GLO 1020 Separator GLO 1130 Separator Maha Separator Gandang Flash Gas (Note 6) REMARKS
(Note 2)
Supply Supply Supply Supply Supply Supply Supply
Status Status Status Status Status Status Status
Condition Condition Condition Condition Condition Condition Condition
barg 89.6 89.6 34.5 89.6 74.5 206.2 34.5
Source supply Pressure
(psig) 1300 1300 500 1300 1080 2990 500
Source supply Temperature C 9.9 49 10 9.9 17.6 48.8 49.9
Water Dew Point @ HP user supply pressure C -1.9 35.0 6.8 -2.0 5.321 5.321 37.4
HC Dew Point @ HP user supply pressure C 41.7 73.1 11.2 34.9 12.73 12.73 37.5
Available capacity MMscfd 314.0 126.0 109.0 151.0 702.3 NOTE 4 4.7
kJ/m3 34970.0 38900.0 33970.0 34330.0 35250.0 35250.0 45390.0
LHV
(Btu/scf) 938.6 1044.0 911.7 921.4 946.1 946.1 1218.2
Gas M.W. 17.0 19.3 16.5 16.6 17.2 17.2 23.2
Wobbe Index 45503.9 47555.2 44969.3 45196.6 45656.9 45656.9 50630.4
Std. Density kg/m3 0.722 0.819 0.698 0.706 0.729 0.729 0.985
Temperature to Gas Turbine Users C 93.3 69.5 100.9 X 39.0 62.7 40.5 40.5 65.3 Note 2
Fuel Volume Ratio (45456 / Wobbe Index ) % 90 - 110 99.9 95.6 101.1 100.6 99.6 99.6 89.8 X Note 2
Modified Wobbe Index 54 - 40 49.3 49.3 51.0 49.4 51.7 51.7 55.1 X Note 2, 11
Fuel Mass Ratio (50125/ LHV Btu/lb) 5 1.04 1.06 1.03 1.03 1.04 1.04 1.09 Note 2
Methane %mole 100 - 85 97.3 89.8 99.5 99.1 96.8 96.8 77.0 X Note 2, 10
Ethane %mole 0 - 15 1.5 4.4 0.2 0.3 1.6 1.6 7.4 Note 2, 10
Propane %mole 0 -15 0.6 3.1 0.1 0.2 0.9 0.9 8.6 Note 2, 10
C4+ %mole 0-5 0.6 2.7 0.2 0.4 0.7 0.7 6.8 Note 2, 10
Inerts (N2+CO2+Ar) %mole 0 - 15 1.1 1.4 1.0 1.0 1.1 1.1 2.3 Note 2, 10
BTEX content ppm 5000 0.0 684.6 0.0 0.0 60.9 60.9 311.9 Note 2
Table 4.0-2: Fuel Gas Sources Review for all Operating Scenarios during Early Life-2
Notes:
1. Criteria Flag: = Comply with Requirement, X = NOT Comply with Requirement
2. The criteria are based on Turbine vendor specification. The fuel specification criteria is presented in Attachment-8.
3. The BTEX content limitation is 5000 ppm based Solar Turbine's correspondence.
4. The available capacity for secondary source fuel gas will be confirmed based flow assurance study.
5. All fuel gas sources except Tertiary and Flash gas can be utilized as fuel gas. If Flash gas is used as fuel gas, further treatment such as: blending with primary source shall be carry out.
6. Mixed flash gas is flash gas from outlet flash gas compressor.
7. Mixed Flash gas is not fulfill fuel gas specification due to its fuel volume ratio, Wobbe Index and minimum methane quantity. Gas from Gendalo 1130 is not fulfill fuel gas specification due to its temperature exceeds 93.3C.
8. Refer to Attachment-2: Fuel Gas Simulation Result, Gas from Inlet Separators is not selected as the primary sources because it requires more heating duty compared to gas from outlet DPCU at the same flowrate.
9. The above fuel gas sources is at 400 psig.
10. For methane, ethene, propane, C4+, it is percentage mole of reactant species, whereas, for Inerts, it is percentage of total (inerts + reactants).
11. The MWI variability has allowable limit for within +/-5% from the criteria range of 54 - 40.
SHEET 2 OF 4
ATTACHMENT 4
PHASE: MID LIFE
FUEL GAS SOURCES
Gas Outlet HP Gas Outlet HP Gas Outlet HP Gas Outlet HP Mixed HP and LP
CRITERIA Gas Outlet DPCU Gas Export Pipeline
PARAMETER UNIT Separator GLO 1020 Separator GLO 1130 Separator Maha Separator Gandang Flash Gas (Note 6) REMARKS
(Note 2)
Supply Supply Supply Supply Supply Supply Supply
Status Status Status Status Status Status Status
Condition Condition Condition Condition Condition Condition Condition
barg 34.5 34.5 34.5 34.5 66.9 183.7 34.5
Source supply Pressure
(psig) 500 500 500 500 970 2665 500
Source supply Temperature C 9.9 49 10 10 39.9 48.8 49.8
Water Dew Point @ HP user supply pressure C 6.5 45.7 7.0 6.7 -1.465 -1.465 38.0
HC Dew Point @ HP user supply pressure C 10.5 48.3 11.0 10.7 18.27 18.27 37.9
Available capacity MMscfd 255.0 122.9 115.0 123.0 615.1 NOTE 4 1.6
kJ/m3 34900.0 39480.0 33990.0 34240.0 35360.0 35360.0 46590.0
LHV
(Btu/scf) 936.7 1059.6 912.3 919.0 949.0 949.0 1250.4
Gas M.W. 17.0 19.6 16.5 16.6 17.3 17.3 23.9
Wobbe Index 45456.7 47843.6 44983.2 45133.8 45722.7 45722.7 51186.7
Std. Density kg/m3 0.721 0.834 0.698 0.704 0.731 0.731 1.016
Temperature to Gas Turbine Users C 93.3 38.3 76.1 O 38.8 38.5 46.1 46.1 65.7 Note 2
Fuel Volume Ratio (45456 / Wobbe Index ) % 90 - 110 100.0 95.0 101.1 100.7 99.4 99.4 88.8 X Note 2
Modified Wobbe Index 54 - 40 51.6 51.3 51.0 51.2 51.3 51.3 55.7 X Note 2, 11
Fuel Mass Ratio (50125/ LHV Btu/lb) 5 1.04 1.06 1.03 1.03 1.04 1.04 1.09 Note 2
Methane %mole 100 - 85 97.3 88.6 99.5 99.1 96.6 96.6 75.3 X Note 2, 10
Ethane %mole 0 - 15 1.5 4.5 0.2 0.3 1.6 1.6 7.0 Note 2, 10
Propane %mole 0 -15 0.6 3.4 0.1 0.2 1.0 1.0 9.6 Note 2, 10
C4+ %mole 0-5 0.6 3.3 0.2 0.4 0.8 0.8 7.9 Note 2, 10
Inerts (N2+CO2+Ar) %mole 0 - 15 1.1 1.4 1.0 1.0 1.1 1.1 2.5 Note 2, 10
BTEX content ppm 5000 0.0 746.4 0.0 0.0 71.3 71.3 281.2 Note 2
Table 4.0-2: Fuel Gas Sources Review for all Operating Scenarios during Early Life-2
Notes:
1. Criteria Flag: = Comply with Requirement, X = NOT Comply with Requirement
2. The criteria are based on Turbine vendor specification. The fuel specification criteria is presented in Attachment-8.
3. The BTEX content limitation is 5000 ppm based Solar Turbine's correspondence.
4. The available capacity for secondary source fuel gas will be confirmed based flow assurance study.
5. All fuel gas sources except Tertiary and Flash gas can be utilized as fuel gas. If Flash gas is used as fuel gas, further treatment such as: blending with primary source shall be carry out.
6. Mixed flash gas is flash gas from outlet flash gas compressor.
7. Mixed Flash gas is not fulfill fuel gas specification due to its fuel volume ratio, Wobbe Index and minimum methane quantity.
8. Refer to Attachment-2: Fuel Gas Simulation Result, Gas from Inlet Separators is not selected as the primary sources because it requires more heating duty compared to gas from outlet DPCU at the same flowrate.
9. The above fuel gas sources is at 400 psig.
10. For methane, ethene, propane, C4+, it is percentage mole of reactant species, whereas, for Inerts, it is percentage of total (inerts + reactants).
11. The MWI variability has allowable limit for within +/-5% from the criteria range of 54 - 40.
SHEET 3 OF 4
ATTACHMENT 4
PHASE: LATE LIFE
FUEL GAS SOURCES
Gas Outlet HP Gas Outlet HP Gas Outlet HP Gas Outlet HP Mixed HP and LP
CRITERIA Gas Outlet DPCU Gas Export Pipeline
PARAMETER UNIT Separator GLO 1020 Separator GLO 1130 Separator Maha Separator Gandang Flash Gas (Note 6) REMARKS
(Note 2)
Supply Supply Supply Supply Supply Supply Supply
Status Status Status Status Status Status Status
Condition Condition Condition Condition Condition Condition Condition
barg 34.5 34.5 34.5 34.5 66.9 105.1 34.5
Source supply Pressure
(psig) 500 500 500 500 970 1525 500
Source supply Temperature C 9.9 48.1 10 10 39.2 48.7 52.2
Water Dew Point @ HP user supply pressure C 6.5 44.7 7.1 6.8 -0.2363 -0.2363 40.0
HC Dew Point @ HP user supply pressure C 10.3 47.2 11.0 10.6 22.37 22.37 40.2
Available capacity MMscfd 133.0 31.0 72.0 68.0 303.7 NOTE 4 0.4
kJ/m3 34930.0 39550.0 33990.0 34240.0 34950.0 34950.0 43670.0
LHV
(Btu/scf) 937.5 1061.5 912.3 919.0 938.0 938.0 1172.1
Gas M.W. 17.0 19.7 16.5 16.6 17.0 17.0 22.5
Wobbe Index 45475.6 47893.9 44980.0 45131.1 45506.6 45506.6 49495.9
Std. Density kg/m3 0.722 0.835 0.698 0.704 0.721 0.721 0.954
Temperature to Gas Turbine Users C 93.3 38.1 75.0 O 38.8 38.4 50.2 50.2 68.0 Note 2
Fuel Volume Ratio (45456 / Wobbe Index ) % 90 - 110 100.0 94.9 101.1 100.7 99.9 99.9 91.8 O Note 2
Modified Wobbe Index 54 - 40 51.6 51.4 51.0 51.2 50.7 50.7 53.7 Note 2, 11
Fuel Mass Ratio (50125/ LHV Btu/lb) 5 1.04 1.06 1.03 1.03 1.03 1.03 1.09 Note 2
Methane %mole 100 - 85 97.3 88.6 99.5 99.1 97.5 97.5 81.0 X Note 2, 10
Ethane %mole 0 - 15 1.5 4.5 0.2 0.3 1.2 1.2 5.6 Note 2, 10
Propane %mole 0 -15 0.6 3.4 0.1 0.2 0.7 0.7 6.6 Note 2, 10
C4+ %mole 0-5 0.6 3.4 0.2 0.4 0.6 0.6 6.6 Note 2, 10
Inerts (N2+CO2+Ar) %mole 0 - 15 1.1 1.4 1.0 1.0 1.1 1.1 2.7 Note 2, 10
BTEX content ppm 5000 0.0 757.4 0.0 0.0 49.5 49.5 308.4 Note 2
Table 4.0-2: Fuel Gas Sources Review for all Operating Scenarios during Early Life-2
Notes:
1. Criteria Flag: = Comply with Requirement, X = NOT Comply with Requirement
2. The criteria are based on Turbine vendor specification. The fuel specification criteria is presented in Attachment-8.
3. The BTEX content limitation is 5000 ppm based Solar Turbine's correspondence.
4. The available capacity for secondary source fuel gas will be confirmed based flow assurance study.
5. All fuel gas sources except Tertiary and Flash gas can be utilized as fuel gas. If Flash gas is used as fuel gas, further treatment such as: blending with primary source shall be carry out.
6. Mixed flash gas is flash gas from outlet flash gas compressor.
7. Mixed Flash gas is not fulfill fuel gas specification due to minimum methane quantity.
8. Refer to Attachment-2: Fuel Gas Simulation Result, Gas from Inlet Separators is not selected as the primary sources because it requires more heating duty compared to gas from outlet DPCU at the same flowrate.
9. The above fuel gas sources is at 400 psig.
10. For methane, ethene, propane, C4+, it is percentage mole of reactant species, whereas, for Inerts, it is percentage of total (inerts + reactants).
11. The MWI variability has allowable limit for within +/-5% from the criteria range of 54 - 40.
SHEET 4 OF 4
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Attachment-5: Hydrate Mitigation Results and MEG Injection Simulation for Start-up
Page 38 of 44
ATTACHMENT 5
Pressure (barg) Temperature (C) Hydrate Difference Required
Phase Fuel Gas Sources Upstream Downstream Upstream Downstream Temperature Temperature Temperature to avoid Result
Valve Valve Valve Valve (C) (C) Hydrate (C)
Primary Normal Operation 74.5 31.0 20.1 -2.1 -21.6 19.5 -16.6 Will NOT Form
Settle-out Condition 140.0 31.0 29.4 -17.5 -21.6 4.0 -16.6 Will Form
Secondary
Export Condition 206.2 31.0 48.8 -9.3 -21.6 12.3 -16.6 Will NOT Form
Early Life-1
Gendalo-1020 Well 89.6 31.0 10.0 -20.3 7.8 -28.1 12.8 Will Form
Tertiary Gendalo-1130 Well 89.6 31.0 49.0 24.3 10.1 14.3 15.1 Will NOT Form
Maha Well 34.5 31.0 10.0 8.2 4.1 4.1 9.1 Will Form
Primary Outlet DPCU 74.5 31.0 17.6 -4.7 -21.6 16.9 -16.6 Will NOT Form
Settle-out Condition 139.4 31.0 29.4 -17.0 -21.6 4.6 -16.6 Will Form
Secondary
Export Condition 206.2 0.0 48.8 -9.3 -21.6 12.3 -16.6 Will NOT Form
Early Life-2 Gendalo-1020 Well 89.6 31.0 9.9 -20.3 7.8 -28.1 12.8 Will Form
Gendalo-1130 Well 89.6 31.0 49.0 24.3 10.3 14.0 15.3 Will NOT Form
Tertiary
Maha Well 34.5 31.0 10.0 8.2 4.2 4.0 9.2 Will Form
Gandang Well 89.6 31.0 10.0 -19.3 5.7 -24.9 10.7 Will Form
Primary Outlet DPCU 66.9 31.0 39.9 24.0 -21.2 45.2 -16.2 Will NOT Form
Settle-out Condition 124.9 31.0 29.4 -12.2 -21.2 8.9 -16.2 Will NOT Form
Secondary
Export Condition 183.7 31.0 48.8 -4.5 -21.2 16.6 -16.2 Will NOT Form
Mid Life Gendalo-1020 Well 34.5 31.0 9.9 8.0 6.0 1.9 11.0 Will Form
Gendalo-1130 Well 34.5 31.0 49.0 47.5 10.8 36.7 15.8 Will NOT Form
Tertiary
Maha Well 34.5 31.0 10.0 8.2 4.3 3.9 9.3 Will Form
Gandang Well 34.5 31.0 10.0 8.2 5.0 3.2 10.0 Will Form
Primary Normal Operation 66.9 31.0 39.2 23.5 -21.6 45.1 -16.6 Will NOT Form
Settle-out Condition 78.1 31.0 29.4 7.5 -21.6 29.1 -16.6 Will NOT Form
Secondary
Export Condition 105.1 31.0 48.7 19.4 -21.6 41.0 -16.6 Will NOT Form
Late Life Gendalo-1020 Well 34.5 31.0 9.8 7.9 6.2 1.7 11.2 Will Form
Gendalo-1130 Well 34.5 31.0 48.1 46.4 10.9 35.6 15.9 Will NOT Form
Tertiary
Maha Well 34.5 31.0 10.0 8.2 4.4 3.8 9.4 Will Form
Gandang Well 34.5 31.0 10.0 8.2 5.1 3.1 10.1 Will Form
6 7
Gendalo-1020 VLV-119
MIX-107
Gendalo-1020
Temperature 9.958 C
Pressure 89.63 bar_g MEG-1
Molar Flow 13.82 MMSCFD Temperature 43.33 C
Pressure 140.0 bar_g 3
MEG-1 Mass Flow 0.2000 kg/h Temperature -17.20 C
Pressure 31.03 bar_g
Molar Flow 13.69 MMSCFD
2 3
VLV-109
Secondary
MIX-104
Secondary
Temperature 29.44 C
Pressure 139.0 bar_g
Molar Flow 13.69 MMSCFD
Fri Dec
Case:
23N:\6310\2000-ENG\2100-PROCESS\Process
16:43:24 2011 Studies\GLO\Fuel Gas System Study\IFD\Hysys\hydrate\FG IFD-Re-start up[GENDALO - Option 1 Case 1 (EarlyFlowsheet:
Life-1) 090811].hsc
Case (Main)
1
Case Name: FG IFD-Re-start up[GENDALO - Option 1 Case 1 (Early Life-1) 090811].h
2 TECHNIPNET
3 Burlington, MA Unit Set: CICo GLO SI (1)1
4 USA
Date/Time: Fri Dec 23 16:54:45 2011
5
6
7 Stream: 7 Hydrate Formation Utility: Hydrate (Black Start)
8
9
HYDRATE FORMATION
10
11 Hydrate Formation at Formation Temperature at Formation Pressure at
12 Stream Conditions: Stream Pressure: Stream Temperature:
13 Will NOT Form -25.89 C 91.72 bar_g
14 Hydrate Type Formed: No Types Type II Type II
15 Calculation Mode Use 3-Phase Model Use 3-Phase Model Use 3-Phase Model
16
PROPERTIES
17
18 Overall Vapour Phase Liquid Phase Aqueous Phase
19 Vapour/Phase Fraction 0.9974 0.9974 0.0022 0.0004
20 Temperature: (C) -20.24 -20.24 -20.24 -20.24
21 Pressure: (bar_g) 31.03 * 31.03 31.03 31.03
22 Molar Flow (MMSCFD) 13.82 13.79 2.990e-002 5.640e-003
23 Mass Flow (kg/h) 1.173e+004 1.161e+004 107.4 10.07
24 Std Ideal Liq Vol Flow (barrel/day) 5670 5644 24.84 1.417
25 Molar Enthalpy (kcal/kgmole) -1.946e+004 -1.938e+004 -4.337e+004 -8.555e+004
26 Mass Enthalpy (kJ/kg) -4780 -4797 -2517 -9984
27 Molar Entropy (kJ/kgmole-C) 148.0 148.2 122.1 -45.08
28 Mass Entropy (kJ/kg-K) 8.690 8.763 1.694 -1.257
29 Heat Flow (kW) -1.557e+004 -1.547e+004 -75.07 -27.93
30 Molar Density (kgmole/m3) 1.749 1.745 9.702 31.42
31 Mass Density (kg/m3) 29.79 29.51 699.5 1126
32 Std Ideal Liq Mass Density (kg/m3) 312.2 310.6 652.5 1073
33 Liq Mass Density @Std Cond (kg/m3) --- --- 660.9 1097
34 Molar Heat Capacity (kJ/kgmole-K) 41.63 41.39 141.1 102.2
35 Mass Heat Capacity (kJ/kg-K) 2.444 2.448 1.958 2.851
36 Thermal Conductivity (W/m-K) --- 3.014e-002 0.1127 0.3038
37 Viscosity (cP) --- 1.056e-002 0.4275 20.80
38 Surface Tension (dyne/cm) --- --- 17.44 59.28
39 Molecular Weight 17.03 16.91 72.09 35.85
40 Z Factor --- 0.8731 0.1570 4.850e-002
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Licensed to: TECHNIPNET * Specified by user.
1
Case Name: FG IFD-Re-start up[GENDALO - Option 1 Case 1 (Early Life-1) 090811].h
2 TECHNIPNET
3 Burlington, MA Unit Set: CICo GLO SI (1)1
4 USA
Date/Time: Fri Dec 23 16:55:23 2011
5
6
7 Stream: 3 Hydrate Formation Utility: Hydrate (Re-start up)
8
9
HYDRATE FORMATION
10
11 Hydrate Formation at Formation Temperature at Formation Pressure at
12 Stream Conditions: Stream Pressure: Stream Temperature:
13 Will NOT Form -22.99 C ---
14 Hydrate Type Formed: No Types Type II Type II
15 Calculation Mode Use 3-Phase Model Use 3-Phase Model Use 3-Phase Model
16
PROPERTIES
17
18 Overall Vapour Phase Liquid Phase Liquid Phase
19 Vapour/Phase Fraction 0.9983 0.9983 0.0017 0.0000
20 Temperature: (C) -17.20 -17.20 -17.20 -17.20
21 Pressure: (bar_g) 31.03 * 31.03 31.03 31.03
22 Molar Flow (MMSCFD) 13.69 13.66 2.329e-002 2.183e-004
23 Mass Flow (kg/h) 1.180e+004 1.172e+004 76.51 0.4469
24 Std Ideal Liq Vol Flow (barrel/day) 5652 5634 18.34 6.225e-002
25 Molar Enthalpy (kcal/kgmole) -1.952e+004 -1.949e+004 -3.926e+004 -9.030e+004
26 Mass Enthalpy (kJ/kg) -4720 -4735 -2491 -9194
27 Molar Entropy (kJ/kgmole-C) 148.8 148.8 113.9 -71.01
28 Mass Entropy (kJ/kg-K) 8.597 8.642 1.726 -1.728
29 Heat Flow (kW) -1.547e+004 -1.541e+004 -52.94 -1.141
30 Molar Density (kgmole/m3) 1.726 1.724 10.21 27.54
31 Mass Density (kg/m3) 29.88 29.69 673.6 1132
32 Std Ideal Liq Mass Density (kg/m3) 315.0 314.0 629.8 1084
33 Liq Mass Density @Std Cond (kg/m3) --- --- 637.1 1105
34 Molar Heat Capacity (kJ/kgmole-K) 41.99 41.83 132.8 109.2
35 Mass Heat Capacity (kJ/kg-K) 2.426 2.429 2.014 2.658
36 Thermal Conductivity (W/m-K) --- 3.031e-002 0.1099 0.2829
37 Viscosity (cP) --- 1.066e-002 0.3349 26.11
38 Surface Tension (dyne/cm) 16.28 --- 16.28 56.62
39 Molecular Weight 17.31 17.22 65.95 41.09
40 Z Factor --- 0.8733 0.1474 5.467e-002
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Licensed to: TECHNIPNET * Specified by user.
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 39 of 44
ATTACHMENT 6
ATTACHMENT-6: FLASH GAS UTILIZATION
Fuel Volume Ratio (45456 / Wobbe Index ) % 90 - 110 93.9 95.6 97.4 98.7 99.6 Note 2
Fuel Mass Ratio (50125/ LHV Btu/lb) 5 1.06 1.06 1.05 1.04 1.04 Note 2
BTEX content ppm 5000 187.1 148.2 111.5 83.2 56.6 Note 2
Total Required Rate (NOTE 7) MMscfd 21.9 22.7 23.5 28.4 13.0
Table 4.0-2: Fuel Gas Sources Review for all Operating Scenarios during Early Life-2
Notes:
1. Criteria Flag: = Comply with Requirement, X = NOT Comply with Requirement
2. The criteria are based on Turbine vendor specification. The fuel specification criteria is presented in Attachment-8
3. The BTEX content limitation is 5000 ppm based Solar Turbine's correspondence.
4. The gas is reviewed at HP supply operating pressure of 400 psig.
5. The flash gas to primary gas ratio is 1 : 1.1 as a minimum requirement.
6. For methane, ethene, propane, C4+, it is percentage mole of reactant species, whereas, for Inerts, it is percentage of total (inerts + reactants).
7. The MWI variability has allowable limit for within +/-5% from the criteria range of 54 - 40.
8. The blended gas total flowrate is to supply fuel gas for change over scenario. Except for Late Life, the required flowrate is based on normal operation for turndown scenario.
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 40 of 44
ATTACHMENT 7
SHEET NO. 1 OF 1
CALCULATION SHEET
CONTRACT NO. C-690163
Page 41 of 44
Specification No. ES 9-98U
The contaminants found in COG must be controlled to levels listed in Tables 1 and 5. Contact Solar
Turbines for recommendations on Balance of Plant equipment to remove or reduce the
contaminants to levels acceptable for gas turbine operation.
The superheat level specified in Table 5 is also required for COG to ensure remaining naphthalene
and heavy hydrocarbons do not precipitate out in the fuel system.
**If carbon monoxide is present in the fuel gas, precautions must be taken to
detect leaks
***Flammability limits at 1 atm and 25C as defined by M.G. Zabetakis, US
Bureau of Mines Bulletin 627.
Note:
FOR INFORMATION
Page 1 of 3 Page 2 of 3
{In Archive} RE: MARS 100 Output Power Cleaning Fluids fro Solar Gas Turbine Engines ?
Trenady Pramudya Currently we are having ES9-98 Rev L Date 28/8/06.
to:
'Ricko Sjarief'
04/15/2011 11:59 AM Best Regards
Cc:
"'Iskandar ZulkarnaenMulia'", "'JawaharlalK Reddy'", "'GB Singh'", "'Veeraraghavan
Ricko SJARIEF
Vasudevan'"
Process Engineering and Technology Department
Show Details _____________________________________________________________________
PT. Technip Indonesia 18th Floor, Menara Bank Danamon Jl. Prof. Dr. Satrio Blok E4 No. 6 - Mega Kuningan Jakarta
12950 Indonesia www.technip.com
History: This message has been replied to. Tel (Direct): +62 21 5799 0616 Switchboard: +62 21 5799 0888 Fax: +62 21 5799 1818
Regards,
The current ISO rating for Mars 100 is 16000 HP and our average compressor turn down is 40%.
From: Ricko Sjarief [mailto:rickos@technip.com]
Sent: 15 April 2011 10:16
Best regards,
To: pramudya@indoturbinept.com
Cc: Iskandar ZulkarnaenMulia; JawaharlalK Reddy; GB Singh; Veeraraghavan Vasudevan
Subject: Re: MARS 100 Output Power Pram
Pram,
From: Ricko Sjarief <rickos@technip.com>
Thanks for the response. Date: Thu, 14 Apr 2011 10:51:03 +0700
To: <pramudya@indoturbinept.com>
In addition to the previous information query, kindly inform us the following information. Cc: Veeraraghavan Vasudevan<veeraraghavanv@technip.com>; Iskandar
ZulkarnaenMulia<iskandarzm@technip.com>; JawaharlalK Reddy<jkreddy@technip.com>
1. A Common Site Rated Power for Mars 100 and Titan 130 considering the operation will be in Kalimantan Subject: MARS 100 Output Power
Offshore Area .
For your information : Dear Pramudya,
Air temperature Min.18.9 C Max.39.4 and Average. 27.8 C
Following our communication on MARS 100 output power. Could you inform us formally the correct value of
Rel. Humidity Min 77 % Max. 91% and Average 78% MARS 100 output power since we have different data between Data Sheet from Website and Previous Data
Elevation is approximately 30 meters above the sea level. that we have from Solar Turbine name card ?
2. In our processing facility, there is a possibility that fuel gas source has BTX (Benzene Toluene Xylene) For your info, Solar Turbine website said 16000 HP but data from name card is 15000 HP.
contaminants approximately 400 ppm
Could you inform us whether it is acceptable for Solar Turbine ? In addition to this, Could you inform us the common turn down ratio for this MARS 100 turbine ?
3. Could you give us the latest version of ES9-98 : Specification Fuel, Air, Water (or. Steam) & Compressor
file://C:\Documents and Settings\rickos\Local Settings\Temp\notes162488\~web4435.h... 6/10/2011 file://C:\Documents and Settings\rickos\Local Settings\Temp\notes162488\~web4435.h... 6/10/2011
Page 3 of 3
Best Regards
Ricko SJARIEF
Process Engineering and Technology Department
_____________________________________________________________________
PT. Technip Indonesia 18th Floor, Menara Bank Danamon Jl. Prof. Dr. Satrio Blok E4 No. 6 - Mega Kuningan Jakarta
12950 Indonesia www.technip.com
Tel (Direct): +62 21 5799 0616 Switchboard: +62 21 5799 0888 Fax: +62 21 5799 1818
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This email and any attached files ("Message") may contain confidential and/or priv
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therefore the authorized recipients shall protect this confidential information disclosed pursuant to
provisions of PT.Indoturbine's policy.
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The below will be found throughout this publication. It is important that the significance of
GE Energy each is thoroughly understood by those using this document. The definitions are as follows:
NOTE
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or equipment damage.
WARNING
***DANGER***
Specification for Fuel Gases for Combustion in Heavy-Duty Gas
Turbines INDICATES AN IMMINENTLY HAZARDOUS SITUATION,
WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR
SERIOUS INJURY.
These instructions do not purport to cover all details or variations in equipment nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further
information be desired or should particular problems arise which are not covered sufficiently for the purchaser's
purposes the matter should be referred to the GE Company.
LIST OF FIGURES
LIST OF TABLES
3 4
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
General Electric heavy-duty gas turbines have the ability to burn a wide classification of gaseous fuels as
FUEL PROPERTIES MAX MIN NOTES
shown in Table 1. The properties of these gases can vary significantly due to the relative concentrations
of the reactant and inert constituents. In order to protect the gas turbine and to burn these fuels in an Gas Fuel Pressure Varies with Varies with See note 3
efficient and trouble free manner, allowable ranges are defined in this specification for physical unit and unit and
properties, constituents and contaminants. combustor type combustor type
Gas Fuel Temperature, F see note 4 Varies with gas See note 4
Table 2a specif ies the allowable limits for the fuel properties and constituents and Table 2b lists the
pressure
limitation on contaminants. These tables provide a screen for fuels that are acceptable for all frame sizes
and combustor types. Fuels that fall outside of these limits may be acceptable for specific applications Lower Heating Value, Btu/scft None 100-300 See note 5
e.g. a high hydrogen fuel can be used with standard combustors in most cases. Contact GE for further
evaluation of these fuels. Modified Wobbe Index (MWI) See note 6
- Absolute Limits 54 40 See note 7
Table 3 identifies the acceptable test methods to be used for determining gas fuel properties shown in
- Range Within Limits +5% -5% See note 8
Tables 2a and 2b.
Flammability Ratio See note 9 2.2:1 Rich: Lean Fuel/Air
Table 1. Fuel Gas Classification Ratio volume basis.
See note 10
FUEL LHV Btu/scft MAJOR COMPONENTS
Constituent Limits, mole %
Natural Gas and Liquefied Natural 800-1200 Methane Methane 100 85 % of reactant species
Gas
Ethane 15 0 % of reactant species
Liquefied Petroleum Gas 2300-3200 Propane, Butane Propane 15 0 % of reactant species
Gasification Gases Carbon Monoxide, Butane + higher paraffins (C4+) 5 0 % of reactant species
-Air Blown 100-150 Hydrogen, Nitrogen, Water Vapor Hydrogen Trace 0 % of reactant species
-Oxygen Blown 200-400 Carbon Monoxide, Hydrogen, Water Vapor Carbon Monoxide Trace 0 % of reactant species
Process Gases 300-1000 Methane, Hydrogen, Carbon Monoxide, Oxygen Trace 0 % of reactant species
Carbon Dioxide
Total Inerts (N2 +CO2 +Ar) 15 0 % of total (reactants +
inerts).
Aromatics (Benzene, Toluene etc.) Report 0 See note 11
Sulfur Report 0 See note 12
5 6
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
11. When fuel heating for thermal efficiency improvements is utilized (e.g. Tgas > 300F) there is a
possibility of gum formation if excess aromatics are present. Contact GE for further information.
12. The quantity of sulfur in gas fuels is not limited by this specification. Experience has shown that fuel
sulfur levels up to 1% by volume do not significantly affect oxidation/corrosion rates. Hot corrosion
of hot gas path parts is controlled by the specified trace metal limits. Sulfur levels shall be
considered when addressing HRSG Corrosion, Selective Catalytic Reduction (SCR) Deposition,
Exhaust Emissions, System Material Requirements, Elemental Sulfur Deposition and Iron Sulfide.
(see section IV, D)
13. The contamination limits identified represent the total allowable limit at the inlet to the turbine
section. These limits will be reduced if comparable contaminants are present in the compressor inlet
air and combustion steam/water injection. Consult with GE for limits for specific applications.
14. Sodium and potassium, from salt water, are the only corrosive trace metal contaminants normally
found in natural gases. Na/K =28 is nominal sea salt ratio. Other trace metal contaminants may be
found in Gasification and Process Gases. GE will review these on a case-by-case basis.
7 8
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
15. The fuel gas delivery system shall be designed to prevent the generation or the admittance of solid II. FUEL GAS CLASSIFICATION
particulate to the gas turbine gas fuel system. This shall include but not be limited to particulate
A. Natural Gas, Liquefied Natural Gas (LNG) And Liquefied Petroleum Gas (LPG)
filtration and non-corrosive (i.e. stainless steel) piping from the particulate filtration to the inlet of
the gas turbine equipment. Fuel gas piping systems shall be properly cleaned/flushed and maintained Natural gases are predominantly methane with much smaller quantities of the slightly heavier
prior to gas turbine operation. (see section IV, A) hydrocarbons such as ethane, propane and butane. Liquefied petroleum gas is propane and/or butane
with traces of heavier hydrocarbons.
16. The fuel gas supply shall be 100% free of liquids. Admission of liquids can result in combustion
and/or hot gas path component damage. (see section III, C) GE will require an input signal from the 1. Natural Gas
conditioning system liquid level indication closest to the GE Speed Ratio Valve or Gas Control
Valve. This liquid level indication will be brought into the turbine controller and used as a signal to Natural gases normally fall within the calorific heating value range of 800 to 1200 Btu per
stop Gas Turbine operation when the liquid level reaches a fault level. It is highly recommended that standard cubic foot. Actual calorific heating values are dependent on the percentages of
this device have redundancy. The supplier of the gas conditioning system should provide this signal. hydrocarbons and inert gases contained in the gas. Natural gases are found in and extracted from
underground reservoirs. These raw gases may contain varying degrees of nitrogen, carbon
Table 3. Test Methods For Gaseous Fuels dioxide, hydrogen sulfide, and contain contaminants such as salt water, sand and dirt. Processing
by the gas supplier normally reduces and/or removes these constituents and contaminants prior to
PROPERTY METHOD distribution. A gas analysis must be performed to ensure that the fuel supply to the gas turbine
Gas Sampling Procedure GPA 2166(3) meets the requirements of this specification.
Compressibility Factor ASTM D 3588 The hydrocarbon dew point is typically less than -10F at 500 psia but, depending on the
Dew Point (see Test Method ASTM D 1142 processing steps and tank size, the dew point may increase if the boil-off is continuously
note 1) extracted between deliveries. Cooling and recompression of the boil-off will avoid this potential
problem. The expected range in component concentrations should be obtained from the gas
Sulfur (see Test Method note 2) ASTM D 3246 supplier to determine the potential change in dew point.
1. Hydrocarbon and water dew points shall be determined by direct dew point measurement (chilled The heating values of Liquefied Petroleum Gases (LPGs) normally fall between 2300 and 3200
mirror device). If dew point cannot be measured, an extended gas analysis, which identifies Btu/scft (LHV). Based on their high commercial value, these fuels are normally utilized as a
hydrocarbon components from C1 through C14, shall be performed. This analysis must provide an back-up fuel to the primary gas fuel for gas turbines. Since LPGs are normally stored in a liquid
accuracy of greater than 10 ppmv. A standard gas analysis to C6+ is normally not acceptable for dew state, it is critical that the vaporization process and gas supply system maintains the fuel at a
point calculation unless it is known that heavier hydrocarbons are not present, as is most often the temperature above the minimum required superheat value. Fuel heating and heat tracing are
case with liquefied natural gases. required to meet these requirements.
2. This test method will not detect the presence of condensable sulfur vapor. Specialized filtration B. Gasification Fuels
equipment is required to measure sulfur at concentrations present in vapor form. Contact GE for Gasification fuels are produced by either an oxygen blown or air blown gasification process and are
more information. formed using coal, petroleum coke or heavy liquids as a feedstock. In general, the heating values of
gasification fuel are substantially lower than other fuel gases. The reduced heating value of
gasification fuels result in the effective areas of the fuel nozzles being larger than those utilized for
natural gas fuels.
9 10
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
The heating values of gases produced by oxygen blown gasification fall in the range of 200 to COREX gases are similar to oxygen blown gasified fuels, and may be treated as such. They are
400 Btu/scft. The hydrogen (H2 ) content of these fuels are normally above 30% by volume and usually lower in H2 content and have heating values lower than oxygen blown gasified fuels.
have H2 /CO mole ratio between 0.5 to 0.8. Oxygen blown gasification fuels are often mixed with Further combustion related guidelines may be found in Bureau of Mines Circulars 503(5) and
steam for thermal NOx control, cycle efficiency improvement and/or power augmentation. When 622(6).
utilized, the steam is injected into the combustor by an independent passage. Due to the high
hydrogen con-tent of these fuels, oxygen blown gasification fuels are normally not suitable for III. FUEL PROPERTIES
Dry Low NOx (DLN) applications (see Table 2a). The high flame speeds resulting from high
A. Heating Values
hydrogen fuels can result in flashback or primary zone re-ignition on DLN pre-mixed
combustion systems. Utilization of these fuels requires evaluation by GE. The heat of combustion, heating value or calorific value of a fuel is the amount of energy generated
by the complete combustion of a unit mass of fuel. The US system of measurement uses British
2. Air Blown Gasification thermal units (Btu) per pound or Btu per standard cubic foot when expressed on a volume basis. The
heating value of a gas fuel may be determined experimentally using a calorimeter in which fuel is
Gases produced by air blown gasification normally have heating values between 100 and 150 burned in the presence of air at constant pressure. The products are allowed to cool to the initial
Btu/ scft. The H2 content of these fuels can range from 8% to 20% by volume and have a H2 /CO temperature and a measurement is made of the energy released during complete combustion. All fuels
mole ratio 0.3 to 3:1. The use and treatment of these fuels is similar to that identified for oxygen that contain hydrogen release water vapor as a product of combustion, which is subsequently
blown gasification. condensed in the calorimeter. The resulting measurement of the heat released is the higher heating
value (HHV), also known as the gross heating value, and includes the heat of vaporization of water.
Gasification fuels provide a significant fraction of the total turbine mass flow rate. With oxygen The lower heating value (LHV), also known as the net heating value, is calculated by subtracting the
blown fuels the diluents addition (typically nitrogen) also assists with NOx control. Careful heat of vaporization of water from the measured HHV and assumes that all products of combustion
integration of the gas turbine with the gasification plant is required to assure an operable system. including water remain in the gaseous phase. Both the HHV and LHV may also be calculated from
Due to the low volumetric heating value of both oxygen an air blown gases, a special fuel system the gas compositional analysis using the procedure described in ASTM D 3588. For most gas fuels, a
and fuel nozzles are required. standard gas analysis to C6+ is adequate for determination of heating value, but an extended C14
analysis (4) may also be used if available. Gas turbines do not operate with condensing exhaust
C. Process Gases systems and it is common gas turbine industry practice to utilize the LHV when calculating the
Many chemical processes generate surplus gases that may be utilized as fuel for gas turbines. (e.g. tail overall cycle thermal efficiency.
or refinery gases). These gases often consist of methane, hydrogen, carbon monoxide, and carbon
dioxide that are normally byproducts of petrochemical processes. The hydrogen and carbon B. Modified Wobbe Index (MWI)
monoxide content, these fuels result in a high rich-to-lean flammability limit. These types of fuels Gas turbines can operate with fuel gases having a very wide range of heating values, but the amount
often require inerting and purging of the gas turbine gas fuel system upon unit shutdown or a transfer of variation that a specific fuel system design can accommodate is limited. The fuel nozzles are
to a more conventional fuel. When process gas fuels have extreme flammability limits such that the designed to operate within a fixed range of pressure ratios and changes in heating value are
fuel will auto ignite at turbine exhaust conditions, a more conventional start-up fuel is required. accommodated for by increasing or decreasing the fuel nozzle area or gas temperature. A measure of
Additional process gases that are utilized as gas turbine fuels are byproducts of steel production. the interchangeability of gas fuels for a given system design is the MWI(7). This term is used as a
These are: relative measure of the energy injected to the combustor at a fixed pressure ratio and is calculated
using the fuel lower heating value, the specific gravity with respect to air and the fuel temperature.
1. Blast Furnace Gases The mathematical definition is as follows:
Blast Furnace Gases (BFGs), alone, have heating values below the minimal allowable limits. LHV
These gases must be blended with other fuels such as coke oven gas, natural gas or hydrocarbons Modified Wobbe Index = (1)
such as propane or butane to raise the heating value above the required lower limit. SGgas x Tgas
Coke oven gases are high in hydrogen and methane and may be used as fuel for non-DLN LHV
combustion systems. These fuels often contain trace amounts of heavy hydrocarbons, which may Modified Wobbe Index = ( 2)
MWgas
lead to carbon buildup on the fuel nozzles. The heavy hydrocarbons must be scrubbed or x Tgas
removed from the fuel prior to delivery to the gas turbine. 28.96
11 12
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
LHV = Lower Heating Value of the Gas Fuel (Btu/scf) To avoid hydrocarbon condensation the superheat requirement is:
SGgas = Specific Gravity of the Gas Fuel relative to Air
MWgas = Molecular Weight of the Gas Fuel 2
T sh = 2.33 x (3)
Tgas= Absolute Temperature of the Gas Fuel (Rankine) (Pgas
100
) - 2.8 x (Pgas
100
)
28.96 = Molecular Weight of Dry Air where:
The allowable MWI range is established to ensure that required fuel nozzle pressure ratios are Tsh is the hydrocarbon superheat requirement in F (incremental temperature above the
maintained during all combustion/turbine modes of operation. When multiple gas fuels are supplied hydrocarbon dew point)
and/or if variable fuel temperatures result in a MWI that exceed the 5% limitation, independent fuel P gas is the gas fuel delivery pressure at the inlet to the gas turbine control system, psia
gas trains, which could include control valves, manifolds and fuel nozzles, may be required for
standard combustion systems. For DLN systems, an alternate control method may be required to To avoid moisture and hydrate formation the superheat requirements is:
ensure that the required fuel nozzle pressure ratios are met. An accurate analysis of all gas fuels,
along with fuel gas temperature- time profiles shall be submitted to GE for proper evaluation.
T sm = 5.15 x Pgas - 7
( ) (4)
100
MWI Variability Within the +/-5% Range
where:
This gas fuel specification is written to provide customers with the allowable limits of gas fuel
properties that can be tolerated with a specific set of hardware and permit the turbine to operate Tsm is the moisture superheat requirement in F (incremental temperature above the moisture dew
within the normal limits for emissions and combustor dynamics. It was not written with the intent of point)
addressing fuel variability within the stated limits. The gas turbine can operate successfully within the
stated limits without the need for outages or for combustion system hardware modification such as The superheat requirements are shown graphically on Figure 1 for moisture and hydrocarbons. Both
fuel nozzle changes. It is expected that as the fuel properties vary from one extreme limit to the next, should be determined and added to the respective dew points (moisture and hydrocarbon) at the gas
some controls adjustments to change combustor operation may be required to operate the combustion turbine fuel delivery pressure. The higher of the two values, superheat plus dew point, will determine
system with optimum dynamics and emissions performance. Currently, these controls changes are the preliminary minimum gas fuel temperature that is required in order to meet the superheat
performed manually, on-line and without the need for an outage. Accordingly, if the variability requirements. In some cases, the hydrocarbon dew point may be low enough, that the requirement for
described above is encountered on a frequent (daily, weekly) basis, then an automatic compensation meeting the moisture superheat will dominate. However, if the hydrocarbon dew point is close to the
system may be preferable to constant monitoring with manual intervention. moisture dew point, and the hydrocarbon dew point varies sufficiently, the moisture and hydrocarbon
superheat requirements may flip-flop on which one dominates. In order to avoid this situation, GE
Exceptions to the fuel specif ication must be evaluated on a case-by-case basis. has developed a breakpoint strategy. The breakpoints that will be used are based on gas supply
pressure, as seen in the table below:
C. Superheat Requirement
The superheat requirement is establish to ensure that the fuel gas supply to the gas turbine is 100% Gas Supply Pressure Hydrocarbon Dew Point Breakpoint
free of liquids. Superheat is the temperature difference between the gas temperature and the
respective dew point. The requirement is independent of the hydrocarbon and moisture concentration. 500 psia or less -25F
501 psia to 600 psia -35F
Depending on its constituents, gas entrained liquids could cause degradation of gas fuel nozzles, and
for DLN applications, premixed flame flashbacks or re-ignitions. Condensation of moisture must be 601 psia to 700 psia -50F
avoided to prevent the formation of gas hydrates and collection of water in low points of the gas fuel
system. The superheat requirement is specified to provide enough margin to compensate for the Maximum Hydrocarbon Dew Point less than Breakpoint
temperature reduction as the gas expands across the gas fuel control valves. The requirements are
applicable at all operating conditions and apply to all units including those installed with either If the maximum hydrocarbon dew point, calculated during the Order to Requisition process, is below
standard or DLN combustion systems. Exceptions are units burning coal derived low Btu fuels, the the breakpoint level, then GE will assume that the hydrocarbon superheat requirements are less than
requirements for which must be determined on a case-by-case basis. The superheat requirements take the moisture superheat requirements. Therefore, the minimum gas temperature will be determined by
into account the gas temperature drop and the relationship of the moisture and hydrocarbon dew point the moisture dew point plus the moisture superheat.
lines to the gas fuel pressure. Because of differences between the dew point line characteristics in the
region of interest (less than 700 psia), the opportunity for moisture condensation as the gas expands is Maximum Hydrocarbon Dew Point greater than Breakpoint
less than that for hydrocarbons. Advantage has been taken of this physical property to provide users
with two separate requirements in order to minimize the cost of superheating. In addition, the However, if the maximum hydrocarbon dew point, calculated during the Order to Requisition
superheat requirements depend on the expansion ratio across the control valves and are therefore be process, is above a breakpoint, then GE will assume the unconditioned gas is saturated. This will
expressed as a function of the incoming gas pressure at the inlet to the gas fuel control system. require the full hydrocarbon superheat to be applied to the unconditioned gas. The resulting gas
13 14
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
temperature may be higher than just adding the hydrocarbon dew point and hydrocarbon superheat. (ASTM D 1142). If a direct measurement cannot be performed, the dew point may be calculated from
See Appendix 4 for a sample calculation. the extended C14 gas fuel analysis (4). Use of a C6+ analysis for dew point determination may result
in an under-estimation of 30F to 40F or more. Exceptions are fuels that do not contain heavy
Continuous Hydrocarbon Dew Point Measurement hydrocarbons such as liquefied natural gas.
An alternate approach, to the use of a breakpoint, is to provide instrumentation to measure the E. Moisture Dew Point
hydrocarbon dew point continuously, and provide that signal to GE through the gas turbine
The gas fuel moisture dew point is dependent upon the moisture concentration and the gas fuel
controller. The turbine controller will then use the hydrocarbon dew point, along with the moisture
pressure. When expressed in units of lbs/mmscft (pounds per million standard cubic feet), the
dew point, provided during the Order to Requisition process, to determine if sufficient superheat has
resulting dew point is practically independent of the gas fuel composition (other than moisture).
been provided.
Typically, many pipeline tariffs limit the maximum allowable moisture content to 7 lbs/mmscft while
Non-superheated Gas Temperature Signal the actual value may be significantly less. It is the maximum allowable value, however, that
determines the design requirements for superheat. Figure 2 is included to provide a guide for
GE will require an input signal, into the turbine controller, of the gas fuel temperature upstream of determining the expected moisture dew point from the moisture concentration and gas fuel pressure
any performance or superheating system. The turbine controller will take action if sufficient of a typical natural gas. The actual dew point will vary slightly with gas composition changes.
superheat is not supplied.
Figure 2. Moisture Dew Point as a Function of Concentration and Gas Pressure for a Typical Natural
Figure 1. Hydrocarbon and Moisture Superheat Requirements Gas Fuel
D. Hydrocarbon Dew Point
The hydrocarbon dew point is the temperature at which the first droplet of hydrocarbon forms as the
gas temperature is reduced at a given pressure and is analogous to the moisture dew point. The
hydrocarbon dew point is very sensitive to small concentrations of heavy hydrocarbons (C6+) and
contamination of the gas sample during sampling can be an issue. The use of a sample probe and
following the sampling procedure described in GPA 2166(3), particularly with respect to sample
cylinder purging, can avoid these problems. For this reason the recommended method for
hydrocarbon dew point determination is by direct measurement using a chilled mirror instrument
15 16
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
17 18
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
in the compressor inlet air may result in cracking of ANSI 300 series stainless steels in the hot B. Liquids
gas path.
Gas at the wellhead is typically produced in a wet saturated condition and is treated to remove water
and heavy hydrocarbon liquids. Depending on the degree of treatment and the supply pressure, the
4. Exhaust Emissions
gas may be delivered in a dry condition. After pressure reduction it is possible for condensates to
Sulfur burns mostly to sulfur dioxide, but 5%-10% oxidizes to sulfur trioxide. The latter can form as the gas cools during expansion. The condensates may be either water or hydrocarbons or
result in sulfate formation, and may be counted as particulate matter in some jurisdictions. The both. Carry over of lubricating oil from compressor stations is another source of liquids.
remainder will be discharged as sulfur dioxide. To limit the discharge of acid gas, some localities
may restrict the allowable concentration of sulfur in the fuel. C. Sulfur
Sulfur is usually combined with either hydrogen as H2 S or carbon as COS. It is produced with the
5. System Material Requirements natural gas. Typically the gas supplier will limit H2 S to a concentration of less than approximately 20
ppmv by removing sulfur in a treatment system. Sulfur may also be present in very low
When considering fuel gases containing H2S (sour gas fuels) material selection for system concentrations (< 100 ppbv) in the form of elemental sulfur vapor.
piping and components shall comply with NACE Standard, MR0175(9).
D. Trace Metals
6. Elemental Sulfur Deposition
The details of various sources of alkali contaminants in the following text apply to MS 3000, MS
Solid elemental sulfur deposits can occur in gas fuel systems downstream of pressure reducing 5000, B, E and F class machines. The sources of contaminants for 6C, FB and H-class machines are
stations or gas control valves under certain conditions. These conditions may be present if the discussed in GEK 107230(1).
gas fuel contains elemental sulfur vapor, even when the concentration of the vapor is a few parts
per billion by weight. Concentrations of this magnitude cannot be measured by commercially Contributions to the alkali content of the combustion gases can come from any of the material
streams supplied to the combustor; fuel, air, water or steam. The basic parameter which can be used
available instrumentation and deposition cannot therefore be anticipated based on a standard gas
analysis. Should deposition take place, fuel heating will be required to maintain the sulfur in to define the allowable alkali metal content admitted to the turbine is Xt, the combined sodium and
vapor phase and avoid deposition. A gas temperature of 130F or higher may be required at the potassium con-tent of the combustion gas at the entry to the first stage nozzle. This concentration
inlet to the gas control valves to avoid deposition, depending on the sulfur vapor concentration. must not exceed the values stated in Table 2b. Since there is no simple test method for measuring Xt
The sulfur vapor concentration can be measured by specialized filtering equipment. Contact GE in an operating turbine, it must be calculated from the alkali metal contents of the fuel, air, water and
for further information on this subject. steam flows.
19 20
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
E. Air APPENDIX 1
There are four sources of alkali metal contained in the compressor discharge air, (a) Inlet filter carry
over of sodium chloride in ambient air (b) carry over of sodium dissolved in water used for I. DEFINITIONS
evaporative cooling (c) carry over of sodium dissolved in water used for inlet fogging and (d) carry
over of sodium from water used for on-line water washing. Dew Point
This is the temperature at which the first liquid droplet will form as the gas temperature is reduced.
When concentrations of trace metals in fuel, water or steam are not precisely known, a value of 0.005 Common liquids found in gas fuel are hydrocarbons, water and glycol. Each has a separate and
ppmw, GER 3419 (10), can be used for systems with or without evaporative coolers. This value, based measurable dew point. The dew point varies considerably with pressure and both temperature and
on experience, would cause an insignificant contribution to the overall contamination level and have pressure must be stated to properly define the gas property. Typically, the hydrocarbon dew point
a minor impact on parts lives. will peak in the 300 to 600 psia range.
Dry Saturated Conditions
For systems with inlet foggers, the water carry over is 100% compared with approximately 0.003%
for evaporative coolers and the potential sodium carry over is therefore proportionally higher. The The gas temperature is at, but not below or above, the dew point temperature. No fee liquids are
maximum inlet fogging water flow rate is approximately 1/3 of the natural gas flow rate and, present.
depending on the sodium concentration, could use up a significant portion of the total allowed at the Gas Hydrates
turbine inlet. Refer to GEK 101944(11) for information on water purity requirements. If it is
anticipated that the specification could be exceeded, General Electric should be consulted for Gas hydrates are semi-solid materials that can cause deposits that plug instrumentation lines, control
recommendations on the selection of the water source and use of proper air filtration equipment. valves and filters. They are formed when free water combines with one or more of the C1 through C4
hydrocarbons. Typically the formation will take place downstream of a pressure reducing station
F. Steam where the temperature drop is sufficient to cause moisture condensation in a region of high
turbulence. Because hydrates can cause major problems in the gas distribution network, the moisture
Steam for gas turbine injection is typically taken from a suitable extraction point on a steam turbine content is usually con-trolled upstream at a dehydration process station.
or HRSG. The limiting purity requirements for this steam are those for the steam turbine. These
limits are defined in GEK 72281(12). Gas Hydrate Formation Line
This is similar to the dew point line. A potential for hydrate formation exists if free water is present.
G. Water Calculations performed using the commercial software Hysys (15) show that the hydrate formation line
The maximum alkali meta l (sodium plus potassium) content of water to be used for injection is is approximately 10F above the moisture dew point line. Maintaining the required degree of
discussed in GEK 101944(11). The maximum water injection rate is approximately equal to the fuel superheat above the moisture dew point will eliminate hydrate formation problems. (see section III, C
injection rate. If the alkali content approaches the maximum allowable value stated in GEK Superheat Requirement)
101944(11), it may use all of the allowable margin at the turbine inlet, leaving none available for the Glycol
fuel. If it is anticipated that the specification could be exceeded, GE should be consulted for
recommendations on the selection of the water source. Glycol is not a natural constituent of natural gas but is introduced during the dehydration process.
Various forms of glycol are used, di-ethylene and tri-ethylene glycol being two most common. In
NOTE some cases glycol is injected into the pipeline as a preservative. In most cases, glycol may only be a
problem during commissioning of a new pipeline or if an upset has taken place at an upstream
The concentration of sodium in steam and water, at the levels specified, can be dehydration station.
measured directly using an on-line sodium analyzer or, in the laboratory, with an Odorant
ion or pH meter fitted with a sodium specific electrode or by an atomic
absorption spectrometer fitted with a graphite furnace. Odorants are injected into natural and LP gas to make leaks readily detectable. The oderant
commonly used for natural gas is tertiary butyl mercaptan, while ethyl mercaptan is used for LP gas.
H. Fuel
Superheat
The final source of contamination to be considered is the fuel. Most cases of alkali metal
contamination and corrosion of hot gas path components are related to liquid fuel contamination. It is This is defined as the difference between the gas temperature minus the liquid dew point. The
rare that natural gas will contain trace metals but gasification fuels may contain alkalis carried over difference is always positive or zero. A negative value implies that the value is being measured at two
from the gas clean up system. The issues and requirements with gas fuels are discussed separately in differing states of pressure and temperature and is not valid. A measured gas temperature below the
the prior sections. theoretical dew point means that the gas is in a wet saturated state with free liquids present.
21 22
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
APPENDIX 2
Saturation Line
This is the same as the dew point line. I. PARTICLE SIZE LIMITATIONS
Wet (Saturated) Conditions The effective particle size for erosion considerations is determined by a particles terminal settling
A mixture consisting of both vapor and liquids. velocity. The size and density distribution of the solid particles must be such that not more than 1.0
percent by weight of the particles shall have a terminal settling velocity in air (70F) and 30 inches
Hg, absolute) greater than 14 inches per minute, and not more than 0.1 percent shall have a terminal
settling velocity in excess of 23 inches per minute. For a solid spherical particle, Stokes Law of
settling permits calculating the terminal settling velocity if the particle size and shape and particle
specific gravity are known. The following tabulation gives the spherical particle diameters equivalent
to the limiting terminal settling velocities for particles of specific gravity 2.0 and 4.
23 24
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
APPENDIX 3 APPENDIX 4
I. EQUIVALENT CONTAMINANT RELATIONSHIPS (ALL MACHINES EXCEPT FB, H- I. MINIMUM GAS FUEL TEMPERATURE REQUIREMENT CALCULATIONS
CLASS)
The gas fuel pressure at the purchasers connection FG1 should first be determined. The hydrocarbon
The following relationships can be used to determine turbine inlet contaminant and fuel equivalent and moisture superheat can then be calculated from the equations shown on Figure 1. For example, at
contaminant concentrations to compare to limits given in Table 2b. In general, for mass balances on a gas fuel pressure of 490 psia, the moisture and hydrocarbon superheat requirements are 18F and
the flows and on the contaminants from fuel, air and steam/water at the turbine inlet. 42F respectively.
E=F+A=S (5) For a typical pipeline gas the maximum allowable moisture content is 7 lbs/mmscft. At 490 psia the
moisture dew point can be determined from Figure 2 and is equal to 23F. The minimum gas
(XE)E = (XF)F + (XA)A + (XS)S (6) temperature to avoid moisture condensation is equal to the moisture dew point plus the required
superheat, or 23+ 18 = 41F.
where:
For hydrocarbons, the maximum expected hydrocarbon dew point should be determined by
A, F, S and E are the mass flows of air, fuel, injected steam/water and combustion gases at the turbine consultation with the gas supplier and a review of historical data if available. The hydrocarbon dew
inlet, respectively point will be dependent on the source of the gas, the degree of gas processing and may vary
seasonally with overall gas demand and the economics associated with liquids removal and recovery.
XA, XF, XS, and XE are the contaminant concentrations (ppm by weig ht) in the inlet air, in the fuel, For a fuel with a maximum hydrocarbon dew point of, for example, 35F at 490 psia, the theoretical
in the injected steam/water, and in the combustion gases at the turbine inlet, respectively. minimum gas fuel temperature is 42+ 35= 77F. The temperature, in this example, is higher than the
minimum required to avoid moisture condensation, therefore it establishes the minimum gas
The fuel equivalent concentration of contaminants (XFe) is (dividing (5) and (6) by F) temperature to avoid both hydrocarbon and moisture condensation. However, the actual minimum
gas fuel temperature will be based on the hydrocarbon dew point breakpoint. (see section III, C) In
XFe = XE(1 = A/F + S/F) = XF + XA(A/F) + XS(S/F) (7) the example above, the assumed hydrocarbon dew point was 35F. (at 490 ps ia) The hydrocarbon
dew point for this case is higher than the breakpoint. (-25F) Therefore, GE will assume that the gas
entering the superheating system is saturated, and will require the full hydrocarbon superheat be
For example for a natural gas contaminated with salt at a sodium concentration of 0.1 ppm, an air applied. For example, if the gas entering the superheating system is at a temperature of 55F, then the
sodium contamination of 5 ppb, and a steam contamination of 5 ppb, the equivalent sodium in the minimum gas temperature would be 97F. (55F + 42F) The 97F temperature is what the turbine
fuel for A/F =50 and S/F=1 is from equation (7) controller will begin to take protective action on. The use of the 97F temperature, instead of the
77F temperature is based on GEs experience of gas fuel dew point variation on sites.
XFe = 0.1 + 0.005(50) + 0.005(1) = 0.355ppm (8)
For another example, if the hydrocarbon dew point is calculated as -30F, (at 490 psia) then the
hydrocarbon dew point would be less than the breakpoint. (-25F) Therefore, the minimum gas fuel
This is the amount of sodium considered to come from a fuel source only, which gives the same temperature would be based on the moisture dew point and superheat. Assuming a 7 lbs/mmscft, the
sodium concentration at the turbine inlet as from the combined three sources. dew point is 23F and superheat required is 18F, resulting in a theoretical and actual minimum gas
temperature of 41F. (23F + 18F)
The turbine inlet concentration, XE, is found by rearranging (7)
These values are well within the sodium specification values of 1 ppm on a fuel basis (XFe), and 20
ppb for the turbine inlet concentration (XE). XE and XFe values for all contaminants are given in
Table 2b.
For equivalent contaminant relationships in 6C, FB, and H-Class machines, refer GEK 107230(1).
25 26
Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040j GEI 41040j Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
APPENDIX 5 14. ASME Handbook Water Technology for Thermal Power Systems, chapter 12
I. RELATED SPECIFICATION DOCUMENTS 15. Hysys, a gas process simulation program, Aspen Technology, Inc., Cambridge, Massachusetts
GER 101944(11) Includes water and steam purity requirements in gas turbines
GEK 106669(13) Includes cooling steam purity requirements for H class gas turbines
GEK 107230(1) Includes allowable alkali metal concentrations for 6C, FB and H class gas fuels
REFERENCES
1. GEK 107230 Specification for Alkali Metal Contamination in Fuels for the 6C, FB and H Model
Gas Turbines
3. Obtaining Natural Gas Samples for Analysis by Gas Chromatography, GPA Standard 2166, Gas
Producers association, 6526 East 60th Street, Tulsa, Oklahoma
4. Tentative Method of Extended Analysis for Natural Gas and Similar Gaseous Mixtures by
Temperature Programmed Gas Chromatography, GPA Standard GPA 2286, Gas Producers
association, 6526 East 60th Street, Tulsa, Oklahoma 74145
5. Bureau of Mines Bulletin 503, Flammability Characteristics of Combustible Gases and Vapors,
1950
6. Bureau of Mines Bulletin 622, Flammability Characteristics of Combustible Gases and Vapors,
1965
8. GER 3942 Gas Fuel Clean-up System Design Considerations for GE Heavy-Duty Gas Turbines
9. MR0175, NACE Standard, Sulfide Stress Cracking Resistant Metallic Material for Oilfield
Equipment
12. GEK 72281 Steam Purity Recommendations for Utility Steam Turbines GE Energy
General Electric Company
13. GEK 106669 Specification for Cooling Steam Purity for Closed Circuit Steam Cooled Gas
Turbine
www.gepower.com
27 28
CLIENTE - CUSTOMER
PRELIMINARY UTILITY
CONSUMPTION LIST
For:
PGT 25 SAC GAS TURBINE
AND
BCL509 CENTRIFUGAL COMPRESSOR
TYPICAL
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FUEL
FLOW PRESSURE TEMPERATURE
TYPE CONDITION QUALITY
[ kg/hr ] [ Bar g ] [ C ]
min: <28C above dew point refer
min: 26
Fuel Gas Rated HOLD (Note 1) MID-TD-0000-1
max: 30 max: 140C (Note 2)
NITROGEN
FLOW PRESSURE TEMPERATURE
SERVICE
[ Stdl/min ] [ Bar g ] [ C ]
Tertiary labyrinth dry gas
80 6 35
seal
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Page 42 of 44
Transient Analysis Shutdown/Cooldown GLO
X S ttl outt conditions
Settle diti upon shutdown
h td
3500 120 1600 90
1400 80
3000
100
70
1200
2500
80 60
1000
2000 50
60 800
1500 40
mperature (F)
mperature (F)
Pressure (psia)
Pressure (psia)
600
Tem
Tem
40 30
1000
400
20
Design Rate = 700 MMscfd 20 Late Life Rate = 236 MMscfd
500 200 10
0 0 0 0
0 25000 50000 75000 100000 125000 150000 175000 0 25000 50000 75000 100000 125000 150000 175000
Pipeline length (m) Pipeline length (m)
Pressure profile pipeline - before shutdown Pressure profile pipeline - before shutdown
Pressure profile pipeline - after 8 hours shutdown/cooldown Pressure profile pipeline - after 8 hours shutdown/cooldown
Temperature profile pipeline - before shutdown Temperature profile pipeline - before shutdown
Temperature profile pipeline - after 8 hours shutdown/cooldown Temperature profile pipeline - after 8 hours shutdown/cooldown
Flowrate Settle out P @ FPU Settle out P @ riser base Settle out T @ FPU after Settle out T @ riser base
Case #
(MMscfd) after shutdown (psia) after shutdown (psia) shutdown (F) after shutdown (F)
1 700 2063.7 2281.1 85 40
2 616 1879.1 2076.5 85 40
3 491 1588.4 1752.1 85 40
4 236 1018.7 1114.9 85 40
Chevron 2011 Settle out time varies from 2 to 2.3 hours after shutdown
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
Page 43 of 44
Mechanical Drive (ISO conditions - natural gas - shaft output)
ISO RATED HEAT RATE EFFIC. PRESSURE EXHAUST TURBINE EXHAUST
POWER RATIO FLOW SPEED TEMPERATURE
kW shp kJ/kWh btu/shp-h % kg/sec Ibs/sec RPM C F
GE10-2 11,982 16,068 10,822 7,651 33.3 15.5 46.7 103.0 7,900 480 896
PGT16 14,240 19,096 9,924 7,016 36.3 20.2 47.3 104.3 7,900 491 916
PGT20 18,121 24,300 9,867 6,975 36.5 15.7 62.6 137.9 6,500 475 887
PGT25 23,266 31,200 9,548 6,750 37.7 17.9 68.9 151.9 6,500 525 976
PGT25+ 31,372 42,070 8,751 6,187 41.1 21.5 84.3 185.8 6,100 500 932
PGT25+G4 34,302 46,000 8,719 6,162 41.2 23.8 89.6 197.7 6,100 510 950
LM6000* 43,854 58,809 8,468 5,985 43.0 28.0 125.0 275.0 3,600 455 851
LMS100* 100,200 8,160 44.1 40.0 206.9 456.0 3,600 417 782
MS5002C 28,340 38,005 12,467 8,814 28.8 8.8 124.3 274.1 4,670 517 963
MS5002E* 32,000 42,912 10,000 7,070 36.0 17.0 102.0 225.0 5,714 511 952
MS5002D 32,580 43,690 12,235 8,650 29.4 10.8 141.4 311.7 4,670 509 948
MS6001B 43,530 58,380 10,820 7,650 33.3 12.2 140.0 309.0 5,111 544 1,011
MS7001EA 86,226 115,630 10,920 7,720 33.0 12.6 296.0 652.5 3,600 535 995
MS9001E 130,140 174,520 10,397 7,350 34.6 12.7 410.0 901.0 3,000 540 1,004
(*) DLE Combustion
29 GE Gas Turbines
Indonesia Deepwater Development Fuel Gas System Study Report for Gendalo FPU
Gendalo Gehem Floating Production Unit GLO-T800-PRO-EVA-TEC-000-00001-00
FEED Services
Date: 27-Dec-11 Rev. H01
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