The below will be found throughout this publication. It is important that the significance of each is thoroughly understood by those using this document. The definitions are as follows:
NOTE
Highlights an essential element of a procedure to assure correctness.
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, could result in
minor or moderate injury or equipment damage.
WARNING
INDICATES A POTENTIALLY HAZARDOUS SITUATION,
WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY
***DANGER*** INDICATES AN IMMINENTLY HAZARDOUS SITUA- TION, WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY.
I. GENERAL...................................................................................................................................... 4
II. FUNCTIONAL DESCRIPTION .................................................................................................. 4
A. Separator Vessels...................................................................................................................... 4 B. Instrumentation ........................................................................................................................ 6 C. Measurement Devices .............................................................................................................. 6 D. Other Devices........................................................................................................................... 7
III. INSTALLATION............................................................................................................................ 7
IV. COMMISSIONING AND STARTUP .......................................................................................... 8
V. OPERATION AND MAINTENANCE ........................................................................................ 8
The Fuel Gas Absolute Separator (MLI G015) is typically a duplex, vertical fuel gas filtering system con- sisting of two redundant skid mounted vessels. Each vessel is designed to operate with 100% of fuel gas flow and contains two stages of filtration. The Absolute Separator system is designed to protect the gas turbine against the entry of both liquids and particulate contaminants. The duplex arrangement allows for switching to the standby vessel without removing the gas turbine from service.
During operation, fuel gas enters the lower section of the vessel where large liquid and solid particles are removed by a multi-cyclone centrifugal separator and collected in a lower sump. The gas then flows to the upper section of the vessel through coalescing filter elements. These filter elements remove any remaining solid particles and entrained liquids. The remaining liquid removed from the fuel gas is then drained to an upper sump. Liquid Level Transmitters are provided in both the upper and lower sections and will continuously inform the Turbine Control Panel (TCP) the liquid level in their respective sections. The upper and lower sumps are equipped with a solenoid operated drain valve for Automatic Level Control. The automatic drain valve system will receive an open or close command from the TCP based upon the liquid level measured by its respective Level Transmitter.
Major components include:
• Absolute Separator Vessels
• Centrifugal Separators (First stage)
• Coalescing Filter Elements (Second stage)
• Instrumentation
• Isolation Valves
II. FUNCTIONAL DESCRIPTION
A. Separator Vessels
The Absolute Separator vessels are constructed of carbon steel. The skid consists of two 100% vessels, each with a separator section and a coalescing filter portion. The Absolute Separator vessel is divided into two sections by a tube sheet that supports the coalescing filter elements of the upper section.
The lower separation section (first stage) consists of a mechanical separator where a large percentage of the incoming liquids and solids are removed. The mechanical separator consists of a multi-cyclone centrifugal separator bundle. The main purpose of the first stage of filtration is to ensure that the major- ity of incoming liquid and solid particles are removed in order to prevent clogging of the second stage coalescing filters.
The upper separation section (second stage) of the vessel consists of multi-fiberglass or micro fiber syn- thetic material coalescing elements mounted vertically in parallel on support tubes. This arrangement will ensure that the elements remain above liquid level. Liquid droplets entering the filter elements are coalesced into larger particles and drain to the upper sump.
Maximum flange-to-flange pressure drop across the skid (clean condition): 5 psid
Each vessel is equipped with an automatic drain valve (VA85-20A/B in the lower section and VA85- 21A/B in the upper section) that are pneumatically operated and solenoid actuated (20AS-1A/B in the lower section and 20AS-2A/B in the upper section). Liquid level in the separator vessels is monitored by level transmitters (96AS-1A/B in the lower section; 96AS-2A/B in the upper section). Each level transmitter sends a 4-20 mA signal to the TCP based on the liquid level in the respective sump. When the liquid level inside the sump exceeds the predefined value, the TCP energizes the solenoids, which in turn actuates the drain valves. Should the drain system not operate properly, allowing the liquid level to exceed the automatic discharge level, the level transmitters will send a high level alarm signal to the TCP. High liquid level in the absolute separator does not initiate a turbine trip in the typical system configuration where there is a gas scrubber (MLI-G002) located downstream. The turbine is only tripped by a high liquid level in the final filtration vessel in the system (typically the gas scrubber). A Limit Switch is provided on the actuator of each drain valve. This will enable the operator to know when the drain valve is closed/not closed. In case of prolonged opening of the drain valve, the operator can take appropriate action and prevent the fuel gas from leaking into the drains tank.
Each vessel has a differential pressure switch (63GCF-A/B) to signal coalescing filter element contam- ination. The standard differential pressure switch set point is 10 psid, at which point the coalescing filter elements should be replaced. The Turbine Control Panel monitors this alarm signal. The duplex arrangement allows switching to the standby vessel when a high differential pressure is reached in the operating vessel.
C. Measurement Devices
Visual monitoring instrumentation includes:
• Flag style indicator, integral to the level transmitter chamber, for local liquid level indication.
• Differential pressure gauge (PDI-AS-1, 2), for local pressure drop across the filters
• Inlet pressure gauges (PI-AS-1, 2)
• Instrument air supply pressure gauge (PI-AS-3)
• Temperature Indicator (TI-AS-1)
D. Other Devices
Additional devices include:
• Pressure Regulator (VPR02-012) for pneumatic pressure (instrument air) supply.
• Thermal Overpressure Relief Valve (VR15-5, 6) to protect against an over pressure situation during periods of shutdown.
NOTE
A full flow pressure relief valve, supplied by others, must be installed in the fuel gas supply piping in order to protect the system against over pressure.
III. INSTALLATION
The following steps shall be taken:
• Ensure that the construction area is clear of unnecessary material and equipment.
• Ensure that all pipe work spool pieces and mating flanges are clean and free from foreign material and particles like pieces of welding rods, welding flux, nuts, bolts etc.
• Interconnecting piping should not be installed before installation of the Absolute Separator.
• Lift and position the Absolute Separator on its concrete foundation in the correct position.
• Level the Absolute Separator until the equipment is in a perfect horizontal position with the inlet and outlet nozzles at the correct elevation.
• Interconnect piping to be bolted to inlet and outlet flanges.
• Route drain line connection to drains tank (vented to safe area).
• Route vent line connections to safe area
NOTE
Isolation valves are not permitted in relief valve pipeline.
• Connect instrument air supply to skid
• Secure the skid base to the concrete foundation with anchor bolts, washers and nuts.
• Heat tracing / insulation for freeze protection to be provided to all liquid wetted portions of equipment if minimum ambient temperature is below 40ºF [4ºC].
• Field wiring from the TCP shall be terminated in the Absolute Separator junction box.
• The Absolute Separator shall be grounded and connected to the earth circuit according to the local code.
IV. COMMISSIONING AND STARTUP
• Electrical and Instrumentation functional testing shall be completed.
• Leak test shall be carried out in order to check for leakage from process and instrumentation connec- tions.
• Absolute Separator shall be purged with Nitrogen before startup.
CAUTION
Natural gas can lead to an explosive mixture of gas and air under pressure.
• Place all instrumentation, vent, drain and instrument air supply valve hand-levers in the normal position referring to P&ID Close all the main gas line valves.
• Gradually pressurize the main gas line by cracking open the inlet valve. This opening must be done with extreme caution to avoid damage to internal parts.
• When the Absolute Separator’s internal pressure has stabilized to the working pressure, the inlet valve can be completely opened.
• Visually check that all control valves are in normal position, referring to P&ID.
• At this point the Skid outlet ball valve can be opened. If the downstream piping is not under pressure, the outlet ball valve must be cracked open allowing a gradual pressurization of the line.
V. OPERATION AND MAINTENANCE
• Thermal Overpressure Relief valve shall be regularly tested.
• Fuel gas must be manually vented prior to inspection and maintenance.
• Periodically inspect all terminal connections and visible insulation for damage, looseness, fraying and defects as applicable. Retighten any loose terminal lugs and replace or repair damaged or deteriorated insulation. Sensors should be checked for accuracy and replaced if necessary.
• Check all cabling for visible damage and check tightness of termination nuts, fittings and glands.
PROHIBITED WITHIN THE HAZARDOUS AREA SURROUND- ING THE ABSOLUTE SEPARATOR SKID. THE ELECTRICAL EQUIPMENT MUST BE DE-ENERGIZED BEFORE MAINTE- NANCE TO AVOID ELECTRIC SHOCK.
• During annual shutdown periods or whenever convenient, inspect vessel and equipment to check that internal parts have been not damaged during operation.
• Check the vessel wall thickness of the Absolute Separator periodically according to local law or at least once per year.
• Refer to supplier manuals for instrument and equipment included in the Absolute Separator.
• Refer to supplier manual for recommended filter replacement interval.
