249A5939 Design Manual
249A5939 Design Manual
249A5939 Design Manual
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24-Jan-2012-10:37
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24/05/2011
BUNOD LUDOVIC
FERRARIS ALAN
CHEVALIER STEPHANE
BUNOD LUDOVIC
FERRARIS ALAN
VALIDE
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24/05/2011
CHEVALIER STEPHANE
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24/05/2011
249A5939
DT-7C
GRD X
MARIOTTO EVELYNE
DESIGN MANUAL
CONTENTS
1. PURPOSE ..........................................................................................................3
2. DESCRIPTION ...................................................................................................3
3. FUNCTION .........................................................................................................7
4. DESCRIPTION OF THE INSTRUMENTATION AND CONTROLS...................10
5. ANALYSIS OF FAILURE IN SERVICE .............................................................12
6. INTERFACE OF SYSTEMS ...............................................................................13
7. HEALTH AND SAFETY .....................................................................................13
8. REFERENCED DOCUMENTS ..........................................................................13
Reference : 249A5939
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DESIGN MANUAL
STATE OF MODIFICATIONS
INDEX
DATE
24/05/2011
Reference : 249A5939
Rev. :
DESCRIPTION
First issue
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DESIGN MANUAL
1. PURPOSE
The Distillate fuel oil feeding system of the GT is constituted of 2 pre-assembled modules :
These modules condition the liquid fuel to obtain the required characteristics at GT inlet in flow, pressure, filtration
and viscosity.
Customer to supply fuel with viscosity between 1.8 and 50cSt at the forwarding skid inlet.
Between filtering skid and the GT the pipe is made of stainless steel schedule 10. All pipes between modules will
be fitted with vents and drain valves for each high and low point.
All piping supplied by customer.
Tank: supplied by customer
In general GE ask an alarm a low low level fuel oil tank in order to have:
2. DESCRIPTION
This specification concerns only the off-base distillate fuel system (refer to Off Base Fuel system P& I D -Chapter
8 referenced documents).
The GT on-base fuel equipment is described in separate documents.
2.1. CONSTITUTION
1st Module : Distillate Fuel Oil Forwarding Skid
This Distillate Fuel Oil module forwards the liquid fuel from the tank to the GT inlet, with a sufficient pressure
to overcome the pressure drop of the various components and to provide the required pressure at the GT
inlet.
NOTA 1 : Pumps dont operate during the gas system operation. Pumps operate during crude oil
operation.
2nd Module : heater skid (supplied by customer)
3rd Module : Distillate Filtering Skid
This skid allows the distillate fuel oil filtration and pressure regulation at GT inlet.
The liquid fuel pressure at GT inlet must be between 2.75 bar(g) to 5.17 bar(g) (36 to 75 PSI)
Electrical heat tracing
A self-regulating electrical heat tracing system and insulating are installed on all fuel direct piping and
equipment between hot fuel source (heater skid or fuel tank) and the GT inlet if fuel oil viscosity is higher than
10 cSt at minimum temperature.
The fuel temperature will be maintained at +16C during stand-by periods, to secure the good fuel viscosity
value (<10 cSt), necessary for the GT fuel combustion system at ignition time.
Upstream the hot fuel source, the fuel temperature will be maintained at +0C during stand-by periods.
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DESIGN MANUAL
If during the GT stop, a heat tracing supply fault is detected, the operator has to solve this failure quickly to
allow an eventual immediate GT start with fuel oil.
2.2. DISTILLATE FUEL OIL FORWARDING SKID
P&ID
See Chapter 8 for Distillate fuel oil forwarding & filtering skid P& I D references.
2.2.1.Mechanical equipment
Two pump units parallel connected (201PO/M and 202PO, one in operation, the other in stand-by.)
3
Flow maxi: 39 m /h.
3
Minimum required flow: 3 m /h
NPSH required (MCL): 8
Inlet Max pressure: 2 bar
Viscosity maxi : . 50 cSt
Pumps shall be gravity flooded: minimum fuel level in the upstream tank will be never lower than
pump axis.
Four valves (HV 201, HV 202, HV 204 and HV 205) to isolate the strainers and the pumps
(manoeuvring to be carried out only for intervention on the pumps or on the strainers).
One check valve at each pump discharge (NV 201, NV 202) to avoid re-circulation through the standby pump.
Two strainer filters (FLT 201 and FLT 202) protects the pumps.
Filtration threshold : 1.5 mm
The frame is fitted with a sloped bottom steel plate to collect all the drains and possible leaks and to
evacuate these (by gravity flow).
2.2.2.Electrical equipment
Two motor-pump units parallel connected (M [88 FD-1] and M [88 FD-2], one in operation, the other in
stand-by.
Each motor 400 V TRI 50 Hz 22 kW at 2950 rpm - anti-condensation heater 230 V MONO.
2.2.3.Instrumentation
One safety valve (PSV 251) protects the pipe upstream the forwarding skid against an eventual overpressure due to the fuel thermal expansion (in case of the fuel temperature increases when isolating
valves are closed).
Adjustment : 3 bar(g).
One safety valve (PSV 254) protects the circuit downstream the forwarding skid against an eventual
over pressure if isolating valves on filtering skid are closed at the same moment and the fuel
temperature increases ; adjustment : 12 bar(g).
An equipment including, a valve 5 ways (HV252B), an isolating valve (HV252A) and a pressure gauge
(PI252) checks the pressure:
Reference : 249A5939
skid inlet
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DESIGN MANUAL
One temperature sensor (PT100) on each pump TE255 & TE256 gives a signal fuel oil high
temperature at 85C (probably due to a null fuel oi l flow) for automatic AC motor pump changeover
and fuel oil high temperature alarm display.
At the discharge of the pumps ( on the common outlet): a pressure gauge (PI253) to check the
pressure, an isolating valve (HV253A) and a bleed valve (HV253B).
Range: 0 to 16-bar(g) (0 to 232 psi)
One pressure switch (PSL [63FD-1]) gives a low-pressure signal for automatic AC motor-pump
changeover and low pressure alarm display.
One SPDT contact open on decreasing pressure at 6 bar(g) (+/-0.2 bar)
According to light distillate fuel oil contractual analysis, heating temperature shall be 16C minimum .
2.4. DISTILLATE OIL FILTERING SKID
2.4.1.Mechanical equipment
Two filters ( FLT 301 and FLT 302), one in operation and the other in stand-by.
One regulating system to control the distillate fuel oil pressure at GT inlet.
It is constituted of one main regulating valve (PCV 355 piloted by air pressure reference), one needle
valve (HV 355), two reverse mounted spring loaded check valves (NV355A, NV355B).
Isolating valves and bleed valves (HV 313, HV 315, HV 356, HV 305, HV 301 and HV 352).
The frame is fitted with a sloped bottom steel plate to collect all the drains and possible leaks and to
evacuate these to the sump tank (by gravity flow).
2.4.2.Electrical equipment
Not Applicable
2.4.3.Instrumentation
One safety valve (PSV 351) protects the upstream circuit against an eventual over pressure if isolating
valves are closed at the same moment and the fuel temperature increases.
Adjustment : 12 bar(g)
Two filters (FLT 301 and FLT 302), one in operation and the other in stand-by, equipped with :
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DESIGN MANUAL
one drain valve for each body (HV 308 and HV 310)
one vent valve for each body (HV 307 and HV 309)
One safety valve for each body (PSV 361 and PSV 362) ; adjustment: 10 bar(g).
One differential pressure gauge (PDI 356) indicates the pressure drop generated by the selected filter
and then the filter clogging state.
Range : 0 to 1.75 bar
One differential pressure switch (PDSH [63LF-2]) displays an alarm when clogging maximum value of
selected filter is reached.
One changeover, contact open on increasing differential pressure at 1.5 bar +/- 0.1bar
One pressure gauge (PI 354) to check the GT inlet fuel pressure.
Range : 0 to 10 bar(g)
One pressure switch (PSH [63FD-2]) displays an alarm if liquid fuel pressure at GT inlet is too high.
One changeover, contact open on increasing pressure at 6 bar(g).
One liquid fuel metering by-pass valve (HV 314) and two isolating valves (HV 316 and HV 317).
One oval wheel metering (accuracy better than +/- 0.3 %) with local indication (FQI 358) totalises the
GT liquid fuel consumption and a pulses transmitter (FT [77FL-1]) generating 1pulse per litre.
One pressure accumulator isolating valve (HV 318).
One pressure accumulator (301 AQ) absorbs sudden fuel pressure variations at GT inlet.
Inflating pressure: 2.5 bar(g)
One solenoid valve (FY/20FD-2 ), normally open, is necessary to insure a minimum flow for pump
pressure regulating valve, heater if any, and fuel pressure regulating valve. When GT consumption
ensures this minimum flow, the return is closed to avoid over sizing of liquid fuel line.
One solenoid valve (FY/20FD-6), normally close, is necessary to pilot regulating valve PCV 355. It
should energize just before starting distillate forwarding pumps (PCV355 should be open status when
pumps start). Solenoid valve stay energized open status when pumps are running . solenoid valve
FY/20FD-6 will de-energized only when fuel pumps stopped.
One pneumatic valve FV359, normally closed, authorizes or cuts the GT fuel supply. FV359 is piloted
by solenoid valve (FY [20FD-1]).
One solenoid valve 3 ways (FY/20FD-1), normally closed to air instrumentation inlet, authorizes or cuts
air to the actuator of the pneumatic valve.
Electrical supply : 125 V DC, consumption 12W
A air pressure regulating valve AFRG359 with filter automatic drain and PI gives a pilot pressure on
pneumatic valve FV359.
Setting: 6 bar(g)
A air pressure regulating valve AFRG355 with filter automatic drain and PI gives a pilot pressure on
regulation valve PCV355.
Setting: 5 bar(g)
One air instrumentation isolating valve (HV 359).
A temperature gauge TI360 to check the fuel oil temperature.
Scale: 0 to 160C
A temperature element (TE [FT-HS-5]) gives an alarm:
o
if the temperature is lower than fuel oil temperature +16C (fuel oil viscosity > 10 cSt).
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DESIGN MANUAL
3. FUNCTION
3.1. STEADY STATE OPERATION AND START-UP
As soon as the valves are positioned as indicated on the P&ID (NC for closed), the following is fully automatic.
When the start order is given to the "Speedtronic", the "4 FD" signal is activated and then :
Solenoid valve FY / 20 FD-6 is energized (open for the air instrumentation), so the pressure regulation
valve PCV355 can operate)
starting of the selected motor-pump unit (201/202 PO).
solenoid valve FY / 20 FD-1 is energized ( open to the air instrumentation).
Wait 30 seconds for fuel temperature and pressure stabilization ("preliminary preparation")
GT can start.
Solenoid valve FY / 20FD-2 is energized (closed) when 14HS =1and 4FD = 1. The operating of the
distillate fuel oil system is automatic (except the filter permutations) and it is entirely controlled by the
"Speedtronic".
3.1.1.Description : Distillate Fuel Oil Pressure Regulating System
The system can be cut in three parts:
The regulating valve PCV 355 which adjusts the fuel pressure at the GT inlet. When this pressure
increases, PCV 355 closes, and when this pressure decreases, PCV 355 opens.
The "reference pressure (setting point : 5 bar(g)) is made by air pressure coming from 20FD-6 when GT
is burning fuel oil.
The system constituted of two spring-loaded check valves reverse mounted NV 355 A and NV 355 B and
the needle valve HV 355; it treats the "actual pressure" to have a good stability (or speed, when
necessary) of the regulating system.
3.1.2.Operating Distillate fuel Oil Pressure Regulating System
When the selected motor-pump unit starts, the "reference pressure is made by air pressure coming from
20FD-1 when GT is burning fuel oil (setting point: 5 bar(g)). above PCV 355 diaphragm.
The fuel pressure at skid outlet arrives under PCV 355 diaphragm via HV 315 and HV 355; the PCV 355
regulating valve then moves to the right position until obtaining the same pressure under and above the
actuator diaphragm, and then a regulated fuel pressure at skid outlet equal to the reference pressure,
independently of flow through PCV 355 and of upstream pressure value.
In normal working, an eventual "pumping" of the regulating system is dampened by the needle valve HV
355 which imposes a low speed and then a good stability of the system.
However, when the system must operate immediately (for example when the GT load is quickly and
largely varying), the orifice diameter of HV 355 is too small to allow that.
When the difference between the "reference pressure" and the "actual pressure" exceeds the check valve
(NV 355 A or NV 355 B) setting value (+/-10 PSI), the main regulating valve PCV 355 can be quickly
operated via one of these two check valves.
3.1.3.Distillate Fuel Motor-Pump Units
Note: It is forbidden to start 2 pumps simultaneously. If one pump is running in automatic mode, it should
be impossible to start the other pump, even manually.
NORMAL OPERATION:
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DESIGN MANUAL
A 201 PO-M [88 FD-1 ]/ 202 PO- M [88 FD-2] with safety changeover pressure switch (PSL [63
FD-1])
3.1.3.2. Manual selection between 201 PO and 202 PO: (Speedtronic facility)
Selected pump stop when "4FD" is de-activated (without electrical heater supplied by GE)
Time delay when "4FD" is de-activated after a trip or a normal GT stop, running of the selected
pump is maintained during 3 minutes to keep a fuel recirculation for heater cooling
201 PO / 202 PO or 202 PO / 201 PO safety changeover : the sensor used is the pressure switch
(PSL [63 FD-1]).
If at the end of delay, following the starting of the selected pump, the pressure switch is still not
satisfied:
o
Locked stop of the selected pump, to avoid the restarting of this pump.
If after the same time delay following the starting of the stand-by pump, the pressure switch is not
satisfied, the 2nd pump is locked stop.
If after the permutation, the pressure switch or fuel oil high temperature of the second pump is
not satisfied, the second pump is locked stop.
In case of crude oil trip, GT will run with distillate fuel oil.
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DESIGN MANUAL
When FQML becomes lower then 2.6 lb/s, then de energizing of solenoid valve FY / 20 FD-2.
GAS FUEL
This transfer lasts 30 seconds for the smoothly transfer: fuel oil and gas fuel are progressively mixed. The
initial fuel passes from 100% to 0% and the final fuel passes from 0% to 100%
When FQML becomes lower then 2.6 lb/s, then de energizing of solenoid valve FY / 20 FD-2.
When the transfer is finished (100% gas; 0% liquid fuel) ; then continue normal stop
This transfer lasts 1 minute: 30 seconds to prepare the fuel to be used ("preliminary preparation") ; 30
seconds for the smoothly transfer: fuel oil and gas fuel are progressively mixed. The initial fuel passes
from 100% to 0% and the final fuel passes from 0% to 100%
o
Solenoid valve FY / 20FD-2 is energized (closed) when FQML exceeds 3.6 lb/s.
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DESIGN MANUAL
Start the fuel system as describe in 3.1 without the 30s delay time
Solenoid valve FY / 20FD-2 is energized (closed) when FQML exceeds 3.6 lb/s.
During gas fuel operation, solenoid valve FY / 20 FD-2 is not energized (open). During gas fuel
liquid fuel transfer, solenoid valve FY / 20 FD-2 is energized (closed) when FSR1 signal exceeds
20%.
During liquid fuel operation, solenoid valve FY / 20 FD-2 is energized (closed). During liquid fuel
transfer, solenoid valve FY / 20 FD-2 is de energized (open) when FRS1 becomes lower then
15%.
When GT consumes the second liquid the return line on diesel forwarding skid should be opened.
So FY/20FD-2 is open when "33TU=1".
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DESIGN MANUAL
When fuel oil start order is recorded: if fuel oil temperature is lower than +16C (fuel oil viscosity > 10 cSt),
its forbidden to start the GT with fuel oil
When GT operates with fuel oil:
If fuel oil temperature is decreasing and becomes lower than +16C (fuel oil viscosity > 10 cSt) durin g
more than 1 minute (time adjustable from 0 to 5 minutes):
Automatic stop of GT after 15 minutes if the temperature is always below 16C (fuel oil viscosity >
10 cSt).
If fuel oil temperature higher than 85C (fuel oil viscosity < 1.8 cSt):
Automatic stop of GT after 15 minutes if the temperature is always higher than 85C (fuel oil
viscosity < 1.8 cSt).
PSL (63FD-1)
PSH (63FD-2)
Liquid fuel pressure increases above High liquid fuel oil pressure at GT
6 bar(g).( +/- 0.2 bar )
inlet .
PDSH (63LF-2)
Liquid fuel oil temperature is higher Liquid fuel oil high temperature
than 85C for automatic AC motor inside pump
pump changeover and
TE / FT-HS-7
TE / (FT-HS-7)
Not Applicable
Not Applicable
Not Applicable
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DESIGN MANUAL
GT trip condition
Not Applicable
Not Applicable
Not Applicable
(see GT documentation)
Loss of 125 V DC
o
Note: for a good process value, all the sensor switches are closed. 125 V DC loss will have the same
effect than switch opening.
o
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DESIGN MANUAL
6. INTERFACE OF SYSTEMS
6.1. MECHANICAL INTERFACE
Distillate fuel supply in required flow, pressure and viscosity ranges (see Interface Table E0878 000 --- FD
002).
Instrumentation air supply in required flow, pressure (see Interface table E0878 000 --- FD 002).
Distillate fuel oil quality in accordance with GEEPE specification GEI 41047.
Frequency: 50 Hz
8. REFERENCED DOCUMENTS
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