Joint Venture: Requisition S60133-0504 (gas Turbine Generator Package)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

REQUISITION S60133-0504 (Gas Turbine Generator Package)

1

0

16/01/2019

C. W. Lee

J. H. Kim

J. Y. Park

Rev.

DATE:

PREPARED BY

REVIEWD BY

SECTION CHIEF

PROJ. ENG.

PROC. COORD.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

INDEX 1.0

GENERAL...................................................................................................................................................5

2.0

SCOPE OF SUPPLY..................................................................................................................................7

3.0

UNIT RESPONSIBILITY...........................................................................................................................16

4.0

GUARANTEE AND WARRANTY.............................................................................................................17

5.0

APPLICABLE DOCUMENTS, CERTIFICATIONS, SAFETY REQUIREMENTS.....................................19

6.0

GENERAL PROJECT REQUIREMENTS.................................................................................................26

7.0

MECHANICAL REQUIREMENTS............................................................................................................34

8.0

ELECTRICAL REQUIREMENTS.............................................................................................................35

9.0

INSTRUMENTATION AND CONTROLS REQUIREMENTS...................................................................49

10.0

GENERAL DRAWING..............................................................................................................................52

11.0

BID DOCUMENT LIST.............................................................................................................................53

12.0

JOB FORMAT..........................................................................................................................................54

13.0

EXCEPTION, DEVIATION AND CLARIFICATION..................................................................................55

14.0

APPROVED VENDOR LIST.....................................................................................................................56

15.0

INSTRUCTION OF LARGE PACKAGE ITEM PACKING...………………………………………………....57

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

APPENDICES Number APPENDIX 1

Rev.

Description

File name

F00

GT Performance Data - Full Load & Part Load Cases

BD0933H-1383A_01-AP01.xlsm

APPENDIX 2

F00

Gas Turbine Data Sheet

BD0933H-1383A_01-AP02.xlsm

APPENDIX 3

F00

Synchronous Generator Data Sheet

BD0933H-1383A_01-AP03.xlsx

APPENDIX 4

F00

Gearbox Data Sheet

BD0933H-1383A_01-AP04.xlsm

APPENDIX 5

F00

Air Intake Filter Data Sheet

BD0933H-1383A_01-AP05.xlsm

APPENDIX 6

F00

Documents and Data Requirements

BD0933H-1383A_01-AP06.xlsm

APPENDIX 7

F00

P&ID

BD0933H-0550-50-001_AP07-1.pdf BD0933H-0550-50-002_AP07-2.pdf BD0933H-0550-50-003_AP07-3.pdf

APPENDIX 8

F00

Plot Plan

BD0933H-0550-01-001_AP08-1.pdf BD0933H-0550-01-002_AP08-2.pdf

APPENDIX 9

-

APPENDIX 10

C00

Job Format Basic Engineering Design Data

Job Format_AP09.zip BD0933T-01A1_AP10.pdf

APPENDIX 11

C00

Welded Unfired Pressure Vessels

APPENDIX 12

C00

Tubular Heat Exchanger

APPENDIX 13

C00

Double Pipe and Multiple Heat Exchangers

APPENDIX 14

C00

Air Cooled Heat Exchangers

APPENDIX 15

F01

Centrifugal Pumps – Heavy Duty

BD0933T-10A1 Welded unfired pressure vessel_AP11.pdf BD0933T-21A1 Tubular Hex_AP12.pdf BD0933T-22A2 Double Pipe Hex_AP13.pdf BD0933T-23A1 Air cooled Hex_AP14.pdf BD0933T-31A1 Centrifugal Pump for Heavy duty pump_AP15.pdf

APPENDIX 16

F01

Rotary Positive Displacement Pump

BD0933T-31A6 Rotary pump.pdf

APPENDIX 171/2/3

C00/ F01/ F01

Induction Motors

BD0933T-38A1 INDUCTION MOTOS_AP17-1.pdf BD0933T-38A1_APP17-2.xls BD0933T-38A1_APP17-3.xls

APPENDIX 20

C00

GENERAL NOTES AND VENDOR DOCUMENTS FOR MECHANICAL EQUIPMENT LUBRIFICATION, SHAFT SEALING AND CONTROL OIL SYSTEMS AND AUXILIARY INDUSTRIAL GAS TURBINES

APPENDIX 21

C00

SPECIAL PURPOSE GEARS

BD0933T-38A4_AP21.pdf

APPENDIX 22

F01

CIVIL DESIGN LOADS

BD0933T-40A2_AP22.pdf

APPENDIX 23

F01

Instrumentation

BD0933T-60A1.10_AP23

APPENDIX 18 F01 APPENDIX 19 C00

BD0933T-39B9_AP18.pdf

BD0933T-39A2_AP19.pdf BD0933T-38A14_AP20.pdf

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

APPENDIX 24

C00

Instrumentation Connections on Vessel and Piping

APPENDIX 25

C00

Local Control Panels

APPENDIX 26

F01

APPENDIX 27

C00

APPENDIX 28

C00

APPENDIX 29

F01

APPENDIX 30

F00

APPENDIX 31 F01

APPENDIX 32 APPENDIX 33 APPENDIX 34

0 1

1

Instrumentation Symbols and Identification Instrumentation on Package Unit Electrical Material supplied with Package Units Painting GAS TURBINE 550-GT-001A/G DUTY SPECIFICATION BASIC PROCESS AND EQUIPMENT DESIGN REQUIREMENTS AND CRITERIA LIST OF VENDORS FOR EQUIPMENT AND MATERIALS Instruction of Large Package Item Packing Rev.1 Attachment - SECL Packing List(Large Package item)

INSTRUMENTATION.pdf BD0933T-60A1.13_1_AP24 INSTRUMENTS CONNECTIONS ON VESSEL AND PIPING.pdf BD0933T-60A1.40_AP25 Local Control Panel.pdf BD0933T-60A3.pdf BD0933T-60A7.02_AP27.pdf BD0933T-72A23_AP28.pdf BD0933T-83A1_AP29 Painting spec.pdf BD0933H-PR-0550-DS-GT001 rev0_AP30.pdf BD0933T-PR-0000-PH-004 Equipment Design Sizing Criteria_AP31.pdf SONATRACH Nouvelles Refineries (1-BD-933A)_AP32.pdf SPR0058ENN_Instruction of Large Package Item Packing_Rev.1_AP17.docx Attachment - SECL Packing List(Large Package item) Rev.1_AP18.xls

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 1.0

GENERAL

1.1

This Material requisition covers the supply of two, natural gas-fuelled gas Turbine Generator unit to be part of the new Sonatrach refineries located in Hassi Messaoud (Algérie) as part of “Projet Nouvelles Raffineries”. Each plant location will be completed with two identical GTG units, as described in the present technical requisition.

1.2

This Material Requisition contains the requirements of two (Nominal electric power output 32 MWe at ISO conditions) industrial gas turbine generator sets, hereafter known as GTG, to be furnished by the equipment manufacturer, hereafter known as Vendor, and installed by the Owner or Owner's agent, hereafter known as Purchaser. The Owner requires nominal performances as outlined in Appendix 1 of the present document.

1.3

The table below gives an overview of the requirements and process conditions. 550-GT-001A/B Tag Number Process Service Description Cogeneration Gas Turbine Generator Set Type of Equipment Combustion Gas Turbine Service Class Critical, spared Continuous, Intended for Baseload Duty Operation Location Hassi Messaoud (Algérie) Estimated Power, at ISO conditions 32 MWe Area Classification Non-hazardous Fuel Supply - Normal Operation & Natural Gas Starting

1.4

The proposal preparation and bidding shall follow the criteria listed below.

1.4.1

Vendor Qualification The gas turbine shall be similar in design features and control set-up to at least two machines having been in baseload operation for 16000 hours with satisfactory performance and having suffered no major damage to the compressor/turbine rotors or stationary parts in the combustion & hot gas path. Specifically, the following similarity criteria between the proposed machine and the two reference units shall apply:

1.4.2

a.

Identical design and materials of the turbine/compressor rotor, combustion chambers and hot gas path parts.

b.

Inlet temperature to the first stage turbine buckets (TRIT) equal to or higher than that of the proposed machine.

c.

Controls, protective and auxiliary systems of similar design and same set-up as regards critical controls (combustion, DLN staging, IGV).

d.

Same fuel control and distribution hardware and same design burners.

Generator shall be supplied by Vendor qualified by experience in manufacturing the unit proposed. To qualify, Vendor must have manufactured, at the proposed point of manufacture, at least two generators of similar design and comparable output, speed, and

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) voltage rating. These generators must have been in service at least one year and must be performing satisfactorily. Vendor shall submit a list of operating units. 1.5

The Gas Turbine Vendor shall supply, and assume full responsibility for all the equipment covered by this Material Requisition, and for their satisfactory operation and performance.

1.6

Terminology Throughout this material Requisition, the following specific wordings are used: a.

On-base - Refers to all systems, equipment, components, etc. installed within the sound enclosure(s) covered by the fire extinguishing system.

b.

Off-base - Refers to everything not falling under the definition of on-base.

c.

Off-base critical – Refers to off-base systems, equipment and components handling fuel gas and therefore regarded as safety critical.

d.

On-skid - Refers to any system, piece of equipment, component, instrument, etc. mounted on a skid or baseplate that is shipped to site as a completely pre-assembled and wired unit. It may be either on-base or off-base.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 2.0

SCOPE OF SUPPLY Vendor's scope of supply shall include, but shall not be necessarily limited to, the items listed below. To the maximum extent practical, the main equipment and ancillary skids shall be assembled, wired and tested prior to shipment to site.

2.1

Main Mechanical Equipment

2.1.1

Heavy duty gas turbine engine for operation on natural gas, as specified on the GT data sheet under Appendix 2 of this Material requisition, with DLN combustion system (if selected by Vendor). Features for maintenance interval enhancement shall be included.

2.1.2

Load gearbox (speed reducer), per API 613

2.1.3

Special purpose flexible coupling between GT and gearbox

2.1.4

Base plates for the complete package, consisting mainly of: a.

gas turbine base

b.

load gearbox and generator base

c.

accessory base

d.

base plates for all other equipment supplied (“off-base” units)

2.1.5

Starting system with MV electrical motor, hydraulic torque converter and ancillaries

2.1.6

Oil system, as follows: a.

Complete lube and control oil system for gas turbine and generator, including reservoir, pumps (gearbox shaft driven main pump, AC motor driven auxiliary pump, DC motor driven emergency pump), dual water-cooled heat exchangers, dual filters.

b.

Oil mist eliminator system provided with 100% redundant fans, to allow on line maintenance (no redundancy on filter/coalescer unit, no major maintenance allowed on the run).

2.1.7

Fuel gas system, including gas valve module, gas strainer and related piping

2.1.8

GTG train turning gear

2.1.9

Personnel protection shall be provided for any accessible surfaces 60°C or hotter outside the GT enclosure

2.1.10

Painting for very aggressive environment (industrial, refinery)

2.1.11

Anti-icing system, if deemed necessary due to sites environmental conditions

2.2

Ancillary Equipment

2.2.1

Complete air intake system including: a.

Stainless steel filter house and ducting equipped with silencers, flexible joint and supports where applicable. The air intake system support structure, complete with access walkways, ladders, lifting appliances, etc., shall be also supplied by Vendor.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) b.

Mechanical cooling system inside suction filter to enhance GT performance under most strict conditions, as outlined in appendix 1 (GT operating cases). Cost of the option shall also include re-rating of the generator as required.

2.2.2

Exhaust plenum with the duct connection in axial direction. The outlet flange of the latter shall be the Vendor-to-Purchaser battery limit and shall connect to the HRSG inlet expansion joint and duct.

2.2.3

Fuel gas conditioning system, including: a.

Gas cleaning skid, including simplex knockout/filter/coalescer, with isolation valves, PSV’s, level transmitter and manual drain valves on each compartment, all necessary appurtenances. Vents and drains shall have double-block-and-bleed arrangement. filter/coalesce shall be provided with purge and vent connections.

Each

b.

Skid-mounted, electric natural gas start-up heater unit; heater shall be fitted with isolation and valves appropriate piping arrangement to by-pass the gas flow around it on completion of the unit start-up procedure. Temperature monitoring system shall be included

c.

Gas scrubber, to be located downstream of the Purchaser-supplied performance heater (2.9.9) aimed at protecting the gas turbine from an exchanger tube leak.

d.

Gas flow meter sufficient for machine monitoring and control.

e.

If feasible, Vendor to propose alternative cost-effective design based on filter/coalescer unit located downstream of the gas heaters, thus eliminating the gas scrubber.

2.2.4

Off-base skid mounted wash water unit and injection nozzles for on-line and off-line washing of the gas turbine compressor. All wetted components to be manufactured from 304L stainless steel.

2.2.5

Off-base mounted, walk-in type, weatherproof enclosures for the GT and generator package, designed to limit noise sound pressure. Noise limits to be set during detailed engineering phase. The enclosures for the gas turbine package shall include as a minimum: a.

Complete ventilation system for gas turbine, gas module, accessory compartment and generator compartment, consisting of: 1. air inlet from appropriate location 2. ducting between compartments and fans 3. 100% redundant electric motor driven fans 4. appropriately routed exhaust ducting 5. instrumentation, controls, shut-off dampers actuated by the fire extinguishing system

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) b.

Internal manual hoist, to lift and remove all maintenance items, in the accessory compartment and trolley beam with hoist in the GT compartment, above the combustion area,

c.

Fire detection system and fire extinguishing system for all compartments excluding the generator enclosure, consisting of water-mist fire suppression system supplied in accordance with NFPA 750, complete with water tank, pressurization system, release valves, distribution piping and nozzles. If the vendor has not applied or tested their enclosures with water mist, then a CO2 system shall be proposed, including weather-protected, high-pressure CO2 bottle rack, CO2 release valves, distribution piping and nozzles. In either case the following requirements apply:

2.2.6

•

Adequate personnel safety measures shall be provided; for a CO2 system safety measures shall typically include a combination of key-locks to positively prevent personnel entry into the enclosure(s) unless the fire suppression system has been locked-out. System lock-out condition to trigger an alarm on the control system HMI.

•

The system design shall allow full on-line testing of the operation of the fire protection system up to and including the release solenoid, but without release of extinguishing medium.

d.

Gas detection system

e.

Internal lighting (normal and emergency) and heating for maintenance operations.

Electrical and instrument/automation packaged compartment (ELE/I&A compartment from now on), complete with: a.

Weatherproof enclosure suitable for unprotected outdoor installation, complete with access steps and platforms, ladders to rooftop, lightning protection, etc.

b.

100% redundant HVAC system

c.

normal and emergency lighting

d.

convenience outlets (power supply sockets)

e.

fire/smoke detection and alarming system

f.

Badge reader and door lock on each door

The ELE/I&A compartment shall house the equipment listed under 2.4.1 and 2.4.4. Equipment shall be completely installed, wired and tested prior to ELE/I&A compartment shipment. 2.2.7

Bleed heat system. If bleed heat is required to guarantee the emissions criteria across the entire power range as defined in para 4.4, then this should be quoted as an option. Scope of supply shall include all interconnect piping, valving and control logic.

2.3

Electrical Equipment

2.3.1

Electrical generator (see data sheet under Appendix 3 and section 8.0 of this Material Requisition), including:

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

2.3.2

2.3.3

2.3.4

a.

Closed-circuit air-water cooling system.

b.

Excitation system Brushless type with AVR

Generator terminal box and star point grounding cubicle, including: a.

connections to generator and relevant supporting structures as required;

b.

current transformers;

c.

grounding resistor.

Equipment installed within the ELE/I&A compartment: a.

LV switchgears (MCC and sub-distribution boards to supply all AC auxiliaries of the GTG unit)

b.

Local DC board complete with battery pack, rectifier, battery charger and relevant distribution panel for all GTG DC auxiliaries including the turbine control system

c.

Local UPS complete with battery pack and relevant distribution panel for users included in the GTG package that should need uninterruptible power supply, if any

All cables within the gas turbine/generator package, including: a.

Standard cable system (i.e. on-base wiring)

b.

Terminal boxes

c.

All power and control cables interconnecting equipment included in Vendor scope of supply (i.e. on-base and off-base items to ELE/I&A compartment, cables from LV switchgear to users), with relevant cable trays/ladders, conduits, terminal and junction boxes, etc.

2.4

Instrumentation, Controls and Protective Systems

2.4.1

The equipment and systems listed below shall be installed in the Vendor-supplied ELE/I&A compartment (2.2.6 above), to be located inside turbine building. a.

Gas turbine and Generator control and protection system (in a Triple Modular Redundant –TMR- fault tolerant configuration) with synchronising system

b.

GTG (and gearbox) vibration monitoring and protection system

c.

GTG (and gearbox) temperature monitoring and protection system

d.

Generator and step-up transformer protection and metering system

e.

Rotor earth fault monitoring system

f.

Generator control including power and control of excitation system

g.

Option – Generator Partial Discharge Measurement system (capacitive pick-ups shall be however included in the base supply): 1. Option 2.4.1.g.1 Continuous monitoring system 2. Option 2.4.1.g.2 Periodic monitoring system

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) h.

HMI workstation as Operator interface and system maintenance station for each GTG, to be installed in Main Control Room

i.

Rack mounted 19” screen operator and engineering workstation complete of keyboard, mouse and laser colour printer for each GTG, to be installed on control system cabinet inside the turbine building

j.

Option - Additional HMI station (to be installed inside turbine building)

k.

All necessary equipment (hardware and software) to realize a redundant Modbus TCP/IP communication link with plant DCS (refer to paragraph 9.1 here below)

l.

Colour laser printer

m.

Fire & gas panel

2.4.2

Hydraulic / pneumatic control systems, as necessary

2.5

All field instrumentation; transmitters shall be used as far as possible in-lieu of switches for pressure, temperature and flow measurement

2.5.1

Fire and gas systems, incorporating gas detection, fire detection, alarming and fire extinguishing release facilities

2.5.2

All cables within the gas turbine/generator package, including: a.

Vendor Standard instrumentation cables for on-base/on-skid wiring and interconnecting all Vendor-supplied items within the ELE/I&A COMPARTMENT.

b.

Cable trays/conduits and supporting system for all on-base and on-skid cabling.

c.

Terminal boxes and junction boxes at base/skid edge, located so as not to obstruct quick removal of any enclosure panels.

d.

All instrumentation interconnecting cables (i.e. all Vendor-supplied items to ELE/I&A compartment), following a routing not obstructing the quick removal of any enclosure panels.

e.

Fibre optic communication interface modules, including fibre optic/electrical converters necessary to interface the GTG Operator Workstation(s) in control Room with the GTG control system in the turbine building. Optical Fibre cables will be supplied by Customer based on Contractor specification

2.5.3

Time synchronization system (refer to paragraph 9.1).

2.5.4

Factory Acceptance Test, witnessed by the Owner, of all supplied control and safety systems (100% of hardware, software and communication data links to 3rd party systems).

2.5.5

Integrated Test between the control systems and the DCS to verify the communication and the functionality of the exchanged signals, to be performed at the DCS Vendor workshop by means of a portable GTG control system configured for the project.

2.6

General

2.6.1

Piping and fittings, as follows (refer to Appendix 8 for a conceptual schematic of main interconnections and interfaces): a.

All on-base and on-skid piping, installed, tested and cleaned

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) b.

All interconnecting piping between the following off-base units and the GTG unit, including valves, controls, pipe supports/steel structure (where applicable), etc.: 1. Washing water skid 2. Fire extinguishing skid 3. SSOV skid (Safety Shut-Off Valves)

c.

Piping necessary to bring all Purchaser’s connections immediately outside any enclosure; all such connections shall be flanged.

d.

Temperature control valve(s) on cooling water, if necessary.

2.6.2

All steel supports, walkways, stairs, ladders, handrails, safety gates, etc. for gas turbine generator units and off-base units.

2.6.3

Utility connections for maintenance and inspection tools located within enclosures.

2.6.4

Set of special tools for installation and maintenance, including as a minimum: a.

Templates covering GT, Generator & Load gear and Accessory Baseplate (to assist in locating foundation anchor bolts and embedded parts)

b.

GT and Generator rotor removal equipment

c.

Additional tools, as required (Vendor to provide list).

2.6.5

All foundation-embedded steel parts, and anchor bolts, washers and shims for main base plates (GT, generator & load gear and accessory compartments).

2.6.6

Recommended spare parts for erection, commissioning and start-up of above scope of supply.

2.7.

Services

2.7.1

Engineering a.

Process, mechanical, electrical, and structural design of the equipment, including engineering documents (cable block diagrams and layout of end users) necessary for the design of cable ways and supporting structures

b.

Design engineering and full responsibility for GT-Gearbox-Generator coupling

c.

Engineering assistance to Purchaser for the proper integration of the GTG train into the process unit

d.

Engineering assistance to Purchaser and plant DCS supplier for proper integration of GTG systems into DCS network (assistance for configuration of communication datalink with DCS, for design of HMI graphic displays)

e.

Coordination with sub-Vendors and within the Vendor’s organisation

2.7.2

Documents, drawings, APPENDIX 6.

and

maintenance/operation

manuals

as

specified

under

2.7.3

Copy of the 3D model of the whole Vendor scope of supply (including off-base skids and outsourced units). The model shall be supplied for Owner’s/Purchaser’s review at least three times during the engineering phase, as mutually agreed between Purchaser and Vendor.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 2.7.4

Shop inspection and testing, including Vendor’s standard Full Speed/No Load factory acceptance test.

2.7.5

Site Technical Advisory services, covering as a minimum

2.8

a.

Inspection and supervision consulting of site erection, alignment, pre-commissioning and commissioning of the entire GTG package.

b.

Preparation of commissioning checklists and procedures for Owner’s approval.

c.

Witnessing of site performance test of the unit.

d.

Training of Owner’s personnel; Vendor to propose their standard training package for Owner’s review.

Exclusions Purchaser will provide the following:

2.8.1

Concrete foundations and grouting

2.9

Surrounding GTG building

2.9.1

Step-up transformer and Generator terminal box-to-transformer bus duct

2.9.2

Generator circuit breaker

2.9.3

MV switchgear

2.9.4

MV/LV transformers

2.9.5

External power supplies to ELE/I&A compartment-installed equipment

2.9.6

Instrumentation cabling between the ELE/I&A compartment and RIB (Remote Instrument Building)

2.9.7

Cooling water piping to GT and generator, fittings and block valves (excluding however temperature control valves)

2.9.8

Natural gas supply to gas cleaning skid

2.9.9

Natural gas performance heater (by hot boiler water, with pressure higher than NG pressure).

2.9.10

Gas interconnecting piping between gas cleaning skid, electrical heater & scrubber skid and gas valve module

2.9.11

Heat Recovery Steam generator (HRSG) downstream of GT exhaust plenum

2.9.12

Lighting outside all enclosures

2.9.13

Utility stations in the area, outside enclosures

2.9.14

Heat insulation and heat tracing, except for on-base and on-skid piping and equipment

2.9.15

First filling of all lubricants, hydraulic fluids, detergents and additives (except CO2 bottles)

2.9.16

Cable ways and supporting structures for cables and equipment not included in the scope of supply

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 2.10

BATTERY LIMITS (refer to Appendix 8 for a conceptual schematic)

2.10.1

Mechanical battery limits:

2.10.2

a.

Combustion Air:

b.

Fuel (natural gas): 1. Gas supply

2. 3.

Out of gas skid Into electrical gas heater

4.

Out of gas scrubber

5.

Into valve skid

Air intake filter face Outlet flange of the manual block valve upstream of gas cleaning skid edge (inlet flange to skid) Outlet flange of gas cleaning skid Inlet flange to electrical heater / scrubber skid Outlet flange from electrical heater / scrubber skid Inlet flange to gas valves skid

c.

Exhaust gas:

Exhaust adapter expansion joint outlet flange

d.

Machinery cooling water:

Inlet/Outlet flange of each user. Where practical, these inlet/outlet flanges shall be located at the edge of skid.

e.

Utilities:

Inlet/Outlet flanges of each user. Where practical, these inlet/outlet flanges shall be located at the edge of skid.

f.

Vents to atmosphere:

Safe location

g.

Vents to flare:

Outlet flange of each vent valve. Where practical, these inlet/outlet flanges shall be located at the edge of skid.

h.

Drains:

Outlet flange of each liquid drain connection. Where practical, these inlet/outlet flanges shall be located at the edge of skid.

Electrical battery limits: a.

Generator:

Line terminals for connection to bus duct toward the step-up transformer.

b.

Starting motor:

Incoming terminals

c.

Excitation transformer

Incoming terminals

d.

LV Switchgears:

Incoming terminals for 400 V power supply

e.

Protection & measurement system:

Incoming terminal strips from CT’s and VT’s (when not included in Vendor scope of supply); outgoing signal terminal strips

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) (only toward equipment not included in Vendor scope of supply) f.

2.10.3

GTG control & protection panel:

Outgoing signal terminal strips (only toward equipment not included in Vendor scope of supply)

Instrumentation & control: a.

GT/Gen control & protection panel:

marshalling cabinets (and not the individual panels) within the ELE/I&A compartment

b.

Instruments:

Junction terminal boxes for incoming and outgoing instrumentation (all instrumentation should be cabled to onbase and on-skid junction boxes)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 3.0

UNIT RESPONSIBILITY

3.1

The Vendor shall be responsible for the design, engineering coordination, supply, delivery, testing final check-out and satisfactory operation of the whole unit including Gas Turbine, Generator, ancillaries, electrical equipment, instrumentation and controls. Engineering coordination also covers responsibility for handling, expediting and delivering documents & drawings, including those pertaining to outsourced equipment.

3.2

The Vendor shall be responsible for equipment and materials supplied by its sub-Vendors.

3.3

The Vendor shall be responsible for ensuring that all applicable information and documentation is passed-on to its sub-Vendors, since all the information pertaining to outsourced equipment or components may not be necessarily repeated in the pertinent section of the material requisition.

3.4

Compliance with Standards, Codes and Specifications does not relieve the Vendor or the manufacturer(s) from the responsibility for furnishing equipment, materials and accessories of proper design and construction, fully suitable for all specified duties, operating conditions and performance guarantees.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 4.0

GUARANTEE AND WARRANTY

4.1

Mechanical Guarantees These are minimum guarantee terms. Possible additional guarantee terms stated in the Purchase Order and associated documents shall also be considered, and will prevail in case of conflict. It is understood that the Vendor guarantees and agrees to the following:

4.1.1

The equipment shall be guaranteed for satisfactory performance per item 4.2 below.

4.1.2

The Vendor shall guarantee the equipment and component parts against design faults, defective or improper materials, poor workmanship and failure due to normal usage. If any defects or performance deficiencies occur during the guaranteed period, the Vendor shall make all necessary make-goods repairs, replacements, or alterations, as applicable.

4.2

Performance guarantees

4.2.1

Vendor shall guarantee the Net Power Output at Generator Terminals and the relevant Equipment Heat Rate at the specified conditions.

4.2.2

Vendor shall guarantee the exhaust emissions over the entire operating envelope, from 40% to 100% of load and throughout the temperature range. Exhaust emission guarantees shall be as listed in table 4.4 below.

4.2.3

Guarantees on noise level of the unit shall be set during detailed engineering phase.

4.3

Correction Curves Vendor shall provide guaranteed correction curves in order to evaluate Gas Turbine and Generator performance at operating conditions different from the reference, including correction curves for gas analysis and degradation curves. Performance Guarantees are based on new and clean conditions of the Equipment. Net Equipment Output and Net Equipment Heat Rate will be corrected for degradation after 200 fired hours. Performance curves are used during the site performance test to correct performance readings back to the site conditions at which the performance guarantee was provided

4.4

Summary of Performance Guarantees Reference conditions for design case Ambient temperature °C Atmospheric pressure mbar a Relative humidity % Power factor @ generator terminals Cooling water supply temperature °C Cooling water return temperature °C Gas turbine load % Turbine exhaust backpressure (static) mm w.c. Fuel characteristics Fuel gas temperature °C Guaranteed figures

25 980 63% 0.8 lagging 32 42 100% 250 Refer to paragraph. 0

185 Note 5

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Power output (see Note 1 below) Auxiliaries power consumption (see Note 2 below) Equipment Heat rate (see Note 3 below) Emissions (see Note 4 below) - NOx (reference 15% O2, dry) - CO (reference 15% O2, dry) - Particulate (reference 15% O2, dry)

kW kW kJ/kW*h mg/Nm³ mg/Nm³ mg/Nm³

≤ 20 ≤ 30 ≤8

- Noise (see Note 6 below)

dB(A)

Noise limits to be set during detailed engineering phase.

Reliability @ full load

-

Refer to paragraph 6.3.5

Note:

1) 2) 3) 4) 5) 6)

By Vendor By Vendor By Vendor

Power Output = power measured @ generator terminals Maximum total power of normally running auxiliaries Equipment Heat rate = Fuel power [LHV] / Power Output Emissions limits to be guaranteed over the whole range of ambient conditions and between 40% and 100% load. Vendor to advise temperature to be maintained during start-up. Noise emission guaranteed values shall apply across the load range 40% to 100%, over the entire range of ambient conditions specified.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 5.0

APPLICABLE DOCUMENTS, CERTIFICATIONS, SAFETY REQUIREMENTS

5.1

The GTG unit and all components thereof shall be designed, manufactured, built and installed in accordance with the documents listed here below.

5.1.1

The technical documents hierarchy, in order of decreasing authority, shall be as follows: a.

Laws and regulations

b.

This Material Requisition

c.

Job Specifications

d.

Codes and Standards referred to in this Material Requisition and in the Job Specifications.

5.1.2

Vendor shall notify Purchaser in writing of any conflicts among the above listed documents for resolution prior to commitment.

5.2

Local, National and EU Laws, Regulations and Requirements The following general requirements apply: a.

The gas turbine/generator package shall be designed, fabricated, inspected and tested in accordance with all applicable laws, rules and authority regulations in Algérie; EU directives shall be also taken in due consideration for the package design.

b.

The installation shall be designed to comply with all local codes, standards and regulations. Local laws and all codes, standards and practices enforced by law must be complied with.

c.

The responsibility for any authority applications, permitting, etc. remains with the Owner, who will pass on to Vendor all necessary related requirements. Vendor will provide the necessary assistance (supply data, information, etc.) to Owner to successfully complete the approval/permitting procedure

5.3

Compliance with European Community Directives

5.3.1

Machinery Directive a. The “Machinery”, as per the definition of art.2 para. (a) of Directive 2006/42/EC, shall fully comply with the Directive, and shall be CE marked as one entire package by Vendor.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

Vendor’s equipment boundary for which Vendor shall provide ATEX certification

5.3.2

b.

The Vendor shall supply the following documents: 1. Declaration of conformity of the entire package, as per Annex IIA of the Directive 2. An adequate comprehensive safety instruction manual for installation, operation and maintenance, written in the language of the country where the apparatus shall be installed and in English language 3. The Technical file of the Machinery as per Annex VII A of the Directive (as a minimum the documents listed in following Appendix D shall be supplied)

c.

Vendor shall anyway supply the Technical file as mentioned before and shall specifically declare which ESR (essential health and safety requirements) have been complied with (refer to Directive Annex II.1.B.4).

Pressure Equipment Directive (PED) a.

All the “Pressure equipment” as per definition of Art. 1 of the Directive 2014/68/EU, shall fully conform to the Pressure Equipment Directive and its essential safety requirements.

b.

The package that contains pressure equipment shall be subjected to a conformity assessment (by a Notified Body, where requested) according to one procedure among those specified in Attach. III of the Directive, at Vendor’s choice and responsibility.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

Boundary of Vendor’s package for which Vendor = PED manufacturer and Vendor provides PED declaration

5.3.3

c.

Vendor shall supply one single declaration of conformity and CE marking for the entire package intended as a whole. The sketch above depicts conceptually the intended package boundaries; Purchaser will provide to Vendor all the necessary certification of Purchaser-supplied portions for incorporation into the Vendor’s certification.

d.

Design and fabrication shall be carried out by Vendor according to National or International Code amended or approved as required by the selected Notified Body to fulfil PED requirements and in particular but not limited to: 1. The Notified Body from which Vendor has to obtain the conformity assessment and CE mark, shall be selected by Vendor itself, unless otherwise required in the Material Requisition. 2. Costs and timing to obtain CE mark from Notified Body shall be under Vendor’s duty and responsibility. 3. Moreover, vendor shall supply the safety instruction manuals written both in French and in English according to Directive Annex 1, para. 3.3 and 3.4. The instruction manuals shall include, as a minimum, in addition to erection, operating and maintenance procedures, the following information: i. Inspection procedures specifying inspection intervals or the extent of inspection after the equipment have been commissioned into service by the owner ii. Residual Hazards iii. Hazards arising from misuse 4. Vendor to advise FWI about package PED category and selected conformity Module and Notified Body.

Equipment in Potentially Explosive Atmosphere (ATEX) a.

Electrical equipment to be used in hazardous classified areas shall be fully compliant to ATEX Directive and bear the ATEX identification code. It shall be also

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) in accordance with relevant IEC/EN standards, thus bearing the code therein specified (EEx, type of protection, explosion group and temperature class of the gas). All the necessary certificates and documentation shall be included in Vendor scope.

5.4

b.

Area Classification 1. The unit will be installed indoor. GTG building is located within a refinery area classified as Non-hazardous. Should the GT package itself include sources of hazard, it shall be Vendor’s responsibility to limit the hazardous area classification inside the package hence avoiding impacts on external building classification. Whereas this cannot be satisfied, Vendor to provide the related area classification drawing, with size and calculation notes. 2. Vendor shall determine the area classification based on sources of release and ventilation conditions existing within its scope of supply and determine the appropriate design and installation requirements for both electrical and non-electrical equipment within its scope.

c.

For non-electrical equipment vendor shall specify the maximum allowed surface temperatures; the necessary provisions to ensure such temperatures are not exceeded shall also be engineered and supplied by vendor.

d.

Where required by the area classification, field instrumentation will use the following methods of protection (according to ATEX 2014/34/EU Directive). The field instrumentation shall be in Exe or d or n execution (according to ATEX 2014/34/EU Directive), where required by area classification (Exi – intrinsically safe – is requested only in Zone 0).

Job Specifications Number BD0933T-01A1

Rev. C00

Description Basic Engineering Design Data

BD0933T-10A1

C00

Welded Unfired Pressure Vessels

BD0933T-21A1

C00

Tubular Heat Exchanger

BD0933T-22A2

C00

Double Pipe and Multiple Heat Exchangers

BD0933T-23A1

C00

Air Cooled Heat Exchangers

BD0933T-31A1

F01

Centrifugal Pumps – Heavy Duty

BD0933T-31A6

F01

Rotary Positive Displacement Pump

BD0933T-38A1

C00/ F01/ F01

Induction Motors

BD0933T-39B9

F01

GENERAL NOTES AND VENDOR DOCUMENTS FOR MECHANICAL

File name BD0933T-01A1_AP10.pdf BD0933T-10A1 Welded unfired pressure vessel_AP11.pdf BD0933T-21A1 Tubular Hex_AP12.pdf BD0933T-22A2 Double Pipe Hex_AP13.pdf BD0933T-23A1 Air cooled Hex_AP14.pdf BD0933T-31A1 Centrifugal Pump for Heavy duty pump_AP15.pdf BD0933T-31A6 Rotary pump.pdf BD0933T-38A1 INDUCTION MOTOS_AP17-1.pdf BD0933T-38A1_APP17-2.xls BD0933T-38A1_APP17-3.xls BD0933T-39B9_AP18.pdf

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

BD0933T-39A2

C00

BD0933T-38A14 BD0933T-38A4 BD0933T-40A2 BD0933T60A1.10

C00 C00 F01

EQUIPMENT LUBRIFICATION, SHAFT SEALING AND CONTROL OIL SYSTEMS AND AUXILIARY INDUSTRIAL GAS TURBINES SPECIAL PURPOSE GEARS CIVIL DESIGN LOADS

F01

Instrumentation

C00

Instrumentation Connections on Vessel and Piping

C00

Local Control Panels

F01

Instrumentation Symbols and Identification

BD0933T-38A14_AP20.pdf BD0933T-38A4_AP21.pdf BD0933T-40A2_AP22.pdf BD0933T-60A1.10_AP23 INSTRUMENTATION.pdf BD0933T-60A1.13_1_AP24 INSTRUMENTS CONNECTIONS ON VESSEL AND PIPING.pdf BD0933T-60A1.40_AP25 Local Control Panel.pdf BD0933T-60A3.pdf

C00

Instrumentation on Package Unit

BD0933T-60A7.02_AP27.pdf

BD0933T-72A23

C00

Electrical Material supplied with Package Units

BD0933T-83A1

F01

Painting

BD0933H-PR0550-DS-GT001

F00

BD0933T-PR0000-PH-004

F01

SONATRACH Nouvelles Refineries (1-BD933A)_

0

LIST OF VENDORS FOR EQUIPMENT AND MATERIALS

SPR0058ENN

1

Instruction of Large Package Item Packing Rev.1

SPR0058ENN

1

Attachment - SECL Packing List(Large Package item)

BD0933T60A1.13_1 BD0933T60A1.40 BD0933T-60A3 BD0933T60A7.02

5.5

GAS TURBINE 550-GT-001A/G DUTY SPECIFICATION BASIC PROCESS AND EQUIPMENT DESIGN REQUIREMENTS AND CRITERIA

BD0933T-39A2_AP19.pdf

BD0933T-72A23_AP28.pdf BD0933T-83A1_AP29 Painting spec.pdf BD0933H-PR-0550-DSGT001 rev0_AP30.pdf BD0933T-PR-0000-PH-004 Equipment Design Sizing Criteria_AP31.pdf SONATRACH Nouvelles Refineries (1-BD933A)_AP32.pdf SPR0058ENN_Instruction of Large Package Item Packing_Rev.1_AP17.docx Attachment - SECL Packing List(Large Package item) Rev.1_AP18.xls

International Codes and Standards Standard

Edition th

Gas Turbines For Petroleum, Chemical and Gas Industry Services

th

Special Purpose Gear Units for Petroleum, Gas Industry Services Lubrication, Shaft-Sealing, And Control-Oil Auxiliaries For Petroleum, Chemical And Services Vibration, Axial Position And Bearing Monitoring Systems Gas turbines - Acceptance tests Carbon Dioxide Extinguishing Systems

API 616

5 , 2011

API 613

5 , 2003

API 614

5 , 2008

API 670

4 , 2000

ISO 2314 NFPA 12

Title

th

th

nd

2 , 1989 Feb. 2005

Chemical and Systems And Gas Industry Temperature

Applicability Full, except as amended in this Mat Req Full Full Full Full Full

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Standard

IEC 60034-1 IEC 60034-3 IEC 60034-16 IEC 61869 IEC 60079 IEC 62271200 IEC 60332 IEC 61439 IEC/TR 61641 5.6

Edition Latest rev. Latest rev. Latest rev.

Applicability

Rotating electrical machines. Part 1: Rating and performance Rotating electrical machines. Part 3: Specific requirements for synchronous generators driven by steam turbines or combustion gas turbines Rotating electrical machines - Part 16: Excitation systems for synchronous machines

Full Full Full

Latest rev.

Instrument transformers

Full

Latest rev.

Electrical apparatus for explosive gas atmosphere

Full

Latest rev.

High-voltage switchgear and controlgear - Part 200: A.C. metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV

Full

Latest rev.

Test on electric and optical fibre cables under fire conditions

Full

Latest rev. Latest rev.

Low-Voltage Switchgear and Controlgear Assemblies Part 1: General rules Enclosed Low-Voltage Switchgear and Controlgear Assemblies – Guide for Testing under Conditions of Arcing Due to Internal Fault

Full Full

Directives Directive

2006/42/CE 2014/35/EU 2014/30/EU 2014/68/EU 2014/34/EU 5.7 5.7.1

Title

Title MACHINERY DIRECTIVE LOW VOLTAGE DIRECTIVE EMC DIRECTIVE PRESSURE EQUIPMENT DIRECTIVE (PED) EQUIPMENT IN POTENTIAL EXPLOSIVE ATMOSPHERES (ATEX)

Safety Vendor is responsible for the package safety. Vendor shall therefore: a. Execute all applicable safety-related analysis and studies, in order to guarantee that package can be commissioned, operated, maintained and de-commissioned in a safe way by plant operators. Vendor shall use methodologies like HAZOP and SIL analysis applying codes above indicated, or equivalent studies, at his discretion; the method adopted shall be indicated in the Vendor’s proposal. b. Implement, at its own care and cost, all necessary safety systems and devices related to the package scope, in order to remove risks or, when it is not possible, to reduce them at an “as low as reasonably practicable” level, according to the risk analysis and acceptability evaluation study performed by Vendor. Vendor, in its safety analysis, shall consider the uninterrupted service required by gas turbine. Vendor shall clearly highlight in its proposal any situation where technical constraints result in the need for more restrictive intervals.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) It is highlighted that Purchaser can require, at its own discretion, to receive safety reviews and risk analysis documentation. 5.7.2

Purchaser will arrange and lead a HAZOP review, conducted applying Purchaser methodology, with Client and package Vendor participation, with the sole scope of: a. Jointly analyse the interfaces between the package and the rest of the plant, in order to identify and evaluate all risks (including fire hazard originated inside the package) resulting from or originating interactions between the unit and any system or equipment not supplied by Vendor. b. Define adequate prevention and mitigation measures for the identified risks. c. Identify the subject (Vendor, Client or Purchaser) that will be responsible for the implementation of the above-mentioned prevention and mitigation measures. In conjunction with the HAZOP review, Vendor shall be responsible for: - Providing all necessary information required during the review. - Providing information related to instruments in Vendor supply but part of an “interfaced” Safety Function (Failure rate, SIL certificate, configuration, etc.) - Indicating the suggested active and passive fire protection strategies, in case they are to be applied outside its scope of supply - Implementing all prevention and mitigation measures that the review indicates to fall under its responsibility. - Giving evidence to Purchaser of such implementation

5.7.3

As far as EU directives are concerned, refer to specific requirements in Section 5.6 and in the Job Specification BD0933T-39B9 “General notes and vendor documents for machinery equipment”.

5.8

Applicability extent and compliance with applicable standards and practices: Vendor’s scope of supply should be fully in accordance with this Material Requisition and all applicable Standards, Specification and Codes listed in the present material requisition. It is recognised that the Gas Turbine core engine and many of the items included in the GTG package are part of a long established, proven Vendor design, such that modifications to it should be kept to a minimum. For this reason, Vendor shall carefully review all the listed standards and practices and identify any applicable requirement or feature that cannot be reasonably accommodated into its equipment design. The Vendor will then prepare “non-compliance lists” identifying all deviations, exceptions and comments to each of the above standards and practices. Full compliance with applicable documents is assumed where no exception or deviations are recorded in tender documents

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 6

GENERAL PROJECT REQUIREMENTS

6.1

SITE INFORMATION

6.1.1

Meteorological and Site Data Refer to job specification BD0933T-01A1. Vendor to take into proper consideration site elevation for equipment design.

6.1.2

Utilities

6.1.2.1

Cooling water: Refer to job specification BD0933T-01A1 for characteristics of utilities required for equipment operation. For easy reference, here below are reported the characteristics of cooling water available at GTG boundaries:

CW Supply CW Return

Pressure [barg] Min. Norm. Max. 6.5 3.5 -

Design 12 12

Min. -

Temperature [°C] Norm. Max. Design 32 70 42 45 (1) 70

(1) Max individual user return temperature

Chemical composition of cooling water is shown in the following table: Element Na content [mg/l] Ca content [mg/l] Mg content [mg/l] K content [mg/l] Sr content [mg/l] Ba content [mg/l] NH4 content [mg/l] Fe(II) content [mg/l] Mn content [mg/l] Cl content [mg/l] SO4 content [mg/l] CO3 content [mg/l] HCO3 content [mg/l] NO3 content [mg/l] F content [mg/l] SiO2 content [mg/l] B content [mg/l] PO4 content [mg/l] CO2 content [mg/l] TDS [ppm] Conductivity [µS/cm]

Content 35,777 21,43 7,84 0,692 0,053 0 0 0 0 51,574 69,142 0,048 20,173 2,079 0 1,113 0 0 8,457 211,72 303,772

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Fouling resistance for cooling water can be considered equal to 0.0004 m2*h*°C/kcal 6.1.2.2

Boiler Feed Water: Boiler feed water is available at GTG battery limit for NOx emission abatement purposes.

BFW supply

Pressure [barg] Min. Norm. Max. 152.3 -

Design 185

Min. -

Temperature [°C] Norm. Max. Design 132 162

Chemical composition of boiler feed water is shown in the following table: Parameter pH at 20 °C Total hardness as CaCO3 [ppm] Total Alkalinity as CaCO3 [ppm] Calcium as Ca [mg/l] Hydrocarbons [ppm] Free Chlorine [ppm] Copper as Cu [ppm] Iron as Fe [ppm] Total Diss. Solids [ppm] Suspended solid [ppm] Conductivity [µS/cm] Silica [mg/l] Hydrazine [mg/l] Sodium and Potassium as Na+K [mg/l] Oxygen [ppb] 6.1.2.3

BFW 9.5 0 0 Absent 0 < 0.003 < 0.01 < 0.1 Nil < 0.2 < 0.02 < 0.01 4 ppb

Steam: As well as BFW, there’s availability of steam at GTG battery limit for NOx emission abatement purposes. Quality of the steam is the following: Parameter Conductivity Silica (SiO2) Sodium + Potassium (Na + K) Total Iron (Fe) Total Copper (Cu) ClSulphates/Sulphites Suspended Solids Moisture content

U.M. µS/cm ppb ppb

Reference Value < 0.2 < 20 < 10

ppb ppb ppb ppb ppm %

< 20 <3 < 10 < 20 <1 < 0.05

Conditions of the steam available at battery limit is indicated in the table here below. Whereas let-down station or attemperator is required by Vendor in order to match the

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) adequate steam condition for the GTG, this is intended to be included in Vendor’s scope of supply. Vendor to inform in the proposal whereas this need is envisaged.

Service HHP Steam HP Steam MP Steam LP Steam 6.2

Conditions at process units battery limit Pressure, bar g Temperature, °C Max. Norm. Min. Design Max. Norm. Min. Design 117.0 113.0 112.0 130.0 515 500 490 545 44.5 42.0 40.0 49.5 400 370 340 425 13.0 12.0 9.5 15.0 320 260 240 350 5.5 4.5 3.5 7.3 240 190 170 270

BASES OF DESIGN The Gas Turbine and all associated equipment shall be supplied in accordance with the following bases of design.

6.2.1

Fuel a. Gas Turbine shall be able to operate on Natural Gas. Composition and properties of four different sampling taken from distribution networks, as well as average values of the natural gas entering the refinery, are reported in the following table: Sample 1

Sample 2

Sample 3

Sample 4

Average

Helium [%mol]

0,07

0

0,1

0,19

0,09

Nitrogen [%mol]

1,18

0,2

5,53

4,78

2,92

Methane [%mol]

84,2

83,62

85,87

84,61

84,58

Ethane [%mol]

10,19

12

6

7,54

8,93

Propane [%mol]

2

2,73

0,5

1,86

1,77

i-Butane [%mol]

0,14

0,3

0

0,27

0,18

n-Butane [%mol]

0,19

0,51

0

0,37

0,27

i-Pentane [%mol]

0,02

0,11

0

0,06

0,05

n-Pentane [%mol]

0,01

0,12

0

0,06

0,05

C6+ [%mol]

0

0,11

0

0,04

0,04

CO2 [%mol]

2

0,3

2

0,22

1,13

H2O (ppm)

50

50

50

50

50

Total

100

100

100

100

100

MW [kg/kmol]

18,88

19,14

18,23

18,6

18,72

LHV [kJ/kg]

46203

48682

43077

45579

45922

WI [kJ/Nm3]

48201

51143

44163

47192

47703

CO2 content in the natural gas can be up to 2% b.

Natural gas, during operational conditions, will contain no traces of the following components: 1. water and hydrocarbons in liquid state

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 2. 3. c.

solid particulate in such quantities that would damage the materials used for gas transportation other gases which may affect the safety or integrity of the transportation system

Natural gas conditions at GT battery limit are indicated in the following table: Min. HP Natural Gas

Pressure [barg] Norm. Max.

33

38

60

Design

Min.

70

15

Temperature [°C] Norm. Max. 30

45

Design

80

Further natural gas details are available in specification BD0933T-01A1 “Basic engineering design data”. Vendor shall inform about the following value downstream natural gas battery limit. Value Parameter Unit Operating Design (1) (1) Pressure at GTG filter/coalescer inlet bar g (1) (1) Temperature at GTG filter/coalescer inlet °C (2) (1) Pressure at GTG scrubber inlet bar g (1) (1) Temperature at GTG scrubber inlet °C Notes:

6.2.2

6.2.3

1) To be indicated by GTG Vendor 2) GTG Vendor to provide the minimum acceptable Natural Gas pressure required for GTG operation over the entire range of ambient conditions and load cases.

NOx Abatement a.

Vendor is free to provide DLN combustors on gas turbine to attain the required NOx emission level.

b.

If an alternative technology is available to attain a lower NOx emission level, it should be proposed as option provided that its application meets the following criteria: 1. It is adequately proven in service, in accordance with the requirements of paragraph 1.4.1 2. It does not reduce or impair the dynamic response capability of the unit (capability to ride through a full load rejection and/or the very rapid load changes associated with unplanned automatic islanding)

c.

Steam and boiler feed water are anyway available at GTG battery limit for emissions reduction up to acceptable level as specified at point 4.4 above.

Battery Limit Conditions Air intake filter pressure drop:

mbar

by Vendor

Exhaust pressure drop, static (ISO condition):

mm w.c.

250 (1)

Voltage at generator terminals:

kV

by Vendor

Electrical auxiliaries power supply: 1. Supply to Vendor’s LV switchgear: 2. Motors rated above 200 kW:

V V

400 ± 5% 6000 ± 5%

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Other utilities: Notes:

6.2.4

Refer to 0

1) Vendor to indicate the maximum permissible exhaust pressure drop & the trip setting

Gaseous Emission Limits Refer to guarantee conditions, paragraph 4.4.

6.2.5

Operating Philosophy a.

The GT will operate on natural gas only. The Plant operating philosophy shall be based on a continuous operation of the gas turbine for the maximum uninterrupted operation. Vendor shall design the Gas Turbine, Electrical Generator and all auxiliary equipment to accommodate this operating regime.

b.

The unit will normally be operated from the plant DCS operator workstations (after putting them in “remote mode” from a selector switch in the Power Train control system). The commands available will be the ones related to the shutdown (normal and emergency) sequences and load control.

c.

Detailed operations will only be available on Power Train operator workstations (located in the ELE/I&A compartment). Specifically, GTG unit start-up and shut down will only be done from the GTG HMI.

6.3

PROCESS AND DESIGN DATA

6.3.1

Performance Data Gas Turbine performances at different operating conditions shall be given by filling in the performance data format enclosed to Appendix 1. Vendor shall provide also the Gas Turbine performances on Natural Gas in the cases “Full Speed No Load” and “Spinning Reserve (minimum technical load)”. It is highlighted that gas turbine could be requested to operate continuously at partial load as highlighted in appendix 1. Vendor shall confirm the availability of proposed equipment to meet the requested performances on continuous operation basis both in terms of load and gaseous emissions (please refer to point 4.4 of this material requisition).

6.3.2

Utilities Consumption Vendor shall indicate the normal and peak consumption of the below listed utilities whose characteristics are shown in the document ‘Ambient Conditions and Utility Requirements’ (see 5.2). a.

Instrument Air:

Nm³/h

by Vendor

b.

Auxiliaries’ electric power:

kW

by Vendor

c.

Cooling Water: Cooling Water Δt: Cooling water fouling factor:

m³/h °C m²▪°K/W

by Vendor by Vendor 0.0002

d.

Demi water (for compressor washing):

m³/cycle

by Vendor

e.

Nitrogen:

Nm³/h

by Vendor

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) f.

In regards to electric auxiliaries, a complete load list shall be provided for the different operating conditions (normal, start-up, shutdown) defining operating and stand-by load. DC load list shall be included.

Vendor shall advise the necessity and the consumption of other utilities, not mentioned above, or specify limitations (low/high temperature, etc…) if any. 6.3.3.

Chemicals Requirements

6.3.4

Vendor shall advise the necessity and relevant consumption of chemicals, if any (compressor washing, etc.)

6.3.5

Reliability/Availability Information a.

The vendor shall provide the following estimated data covering the whole GT and Generator package: 1. Over a 6 year cycle the typical number of days required for planned maintenance (Boroscope, Combustion, Hot Gas Path, Major inspections, Generator, etc.) 2. A typical number of outage days per year for unplanned maintenance (as a result of faults within the Vendor scope of supply) 3. Typical number of trips and trips to FSNL per year (as a result of faults within the Vendor scope of supply) as well as automatically initiated normal shutdown events

b.

Moreover, Vendor shall indicate the planned maintenance schedule of the supplied equipment showing the following: 1. Frequency of the maintenance operation; 2. Maintenance operation description; 3. Man-hours/personnel required for maintenance operation; 4. Maintenance estimated cost.

c.

Vendor shall indicate the GT life expenditure, in terms of equivalent hours of operation, associated to each GT start-up/shutdown.

d.

Vendor shall advise the typical delay in obtaining emergency hot parts (fuel nozzles, combustor liners, buckets, nozzles, shrouds etc.) in the event that the refinery does not have spares in stock.

e.

Vendor shall provide all information necessary for the evaluation of the Equivalent Availability Factor (EAF) of the supplied equipment/package, using the following formula: EAF = (PH-FOH-EDOH)/PH where: •

PH or Period Hours is the number of hours in a year, equal to 8760 hours.

•

FOH or Full Outage Hours is the number of Outage Hours in a period when the equipment is not capable of producing electric power due to Unplanned Maintenance and Planned Maintenance.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) •

6.3.6

EDOH or Equivalent Derated Outage Hours is the number of Outage Hours in a period when the output of the equipment is derated due to Unplanned Maintenance.

Gaseous Emissions Vendor shall provide NOx, CO, TOC and particulate emissions for all ambient conditions and GT loads indicated in Appendix 1.

6.3.7

Exhaust duct Vendor is to provide the flue gas velocity distribution at exhaust interface. Vendor is to advise the recommended flue gas duct length, downstream of the exhaust interface, required to achieve acceptable flow distribution (about ± 10% rms) in front of the first heat exchanger coil.

6.3.8

Gas Turbine and Generator Cooling System The Purchaser shall provide a dedicated closed-loop cooling water system to cover all GTG unit cooling loads: Vendor is to indicate the actual loads associated with the GT and the Generator as well as the water return temperatures and required flow rates.

6.3.9

Vents Vendor is to provide flow rate and characteristics of vents to atmosphere and of vents to flare. Vents to atmosphere shall be minimised; where vents to atmosphere are adopted, double blocks shall be provided. In those instances where double block valves cannot be used on vents to atmosphere, then 2oo3 limit switches on single block valves are required as a minimum, however a specific review with Purchaser is also required.

6.4

OPERATING MODES

6.4.1

Normal Operation The Gas Turbine and coupled Generator shall be designed for continuous operation at partial or maximum load as required by the electrical power demand of refinery, according to the Power Generation Plant load sharing philosophy.

6.4.2

Load Rejection (Idle Condition) The Gas Turbine and coupled Generator shall be able to withstand a full load rejection maintaining the “full speed no load” condition for indefinite period.

6.4.3

Island Condition The Gas Turbine and coupled Generator shall be able to work in island conditions, feeding the Refinery loads, as a consequence of the loss of the external grid connection, whichever the reason, in particular following a short circuit or abnormal transient condition in the external grid. The Gas Turbine controller shall prevent overspeed by modifying the Gas Turbine power output, if necessary, according to the load demand of the refinery and in accordance with the set point sent by the concerned Control System (DCS or EMS) acting as power management and load sharing system.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) When in island, the Gas Turbine Controller shall operate in isochronous mode, to regulate the system frequency, or droop mode in accordance with the operating requirements and load sharing strategy imposed by the power management and load sharing system (DCS, or EMS); when the initial conditions will be restored, the generator will be manually reconnected to the external grid and the turbine shall take load with an adequate ramp. 6.4.4

Operating Flexibility The Gas Turbine shall be able to operate continuously on Natural Gas. Vendor shall advise the load operating range corresponding to the full control capability of the unit. Vendor to inform about the regulating capability throughout the entire operating range of the GTG, showing relevant relationship with IGVs position, turbine outlet temperature, flue gas mass flow and overall GT efficiency. Furthermore, Vendor shall provide the ramps that GTG can bear during cold and hot start-ups (from 0% to 100% of load) and during normal load operation (from 40% to 100%) expressed as MWe/min.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 7.0

MECHANICAL REQUIREMENTS

7.1

For all details pertaining to technical details of gas turbine to be supplied by Vendor, please refer to attached specification BD0933T-38A14.

7.2

BASIC DESIGN

7.2.1

General Gas turbine, together with generator and all auxiliary equipment, will be installed indoor into a dedicate building. Ventilation system shall be designed in order to prevent significant accumulation of potentially explosive mixture inside the building. Anti-icing system shall be foreseen if requested by start-up of equipment, taking in consideration the sites meteorological data as per specification BD0933T-01A1.

7.2.2

Lubrication system Oil system shall conform to API614 and applicable job specification BD0933T-39A2.

7.2.3

Piping And Appurtenances All on-base auxiliary piping shall be according to Vendor’s standard.

7.2.4

Cooling system Special considerations shall be given to chlorides content to cooling water available in the plant. Whereas plate type heat exchangers are expected to be used, material of construction shall be selected in accordance.

7.2.5

Noise limits Noise constraints shall be set during detailed engineering phase.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 8.0

ELECTRICAL REQUIREMENTS

8.1

GENERALS The following design data shall be applied to the electrical synchronous generator, its auxiliary services and to the electrical distribution system of Vendor’s package.

8.2

a.

All electrical equipment shall be rated for continuous operation at ambient temperature of +40°C.

b.

Electrical equipment shall have the appropriate degree of mechanical protection IP in accordance to the ambient conditions, as detailed in the subsequent paragraphs.

c.

Vendor shall design the generator in accordance to IEC 60034-3, taking into account the Gas Turbine performance versus ambient temperature as per table in Appendix 3.

d.

Generator performance, characteristics and protection & metering schemes shall comply with the requirements of the Algerian Grid Operator rules (Grid Code) for generation groups: though the main requirements are preliminarily included in this Material Requisition, the Vendor have the responsibility of complying with the Grid Operator requirements.

e.

The sizing of the generator and other parts carrying generator current continuously shall not limit the mechanical power at Gas Turbine shaft whichever the ambient temperature and at the rated power factor.

GENERATOR MAIN CHARACTERISTICS AND OPERATING CONDITIONS The generator shall be synchronous type, three-phase, round rotor type, with air to water heat exchanger. a.

The generator shall be sized to deliver the maximum continuous power at rated power factor with class B winding temperature rise. Generator ratings (power, reactances etc.) shall be referred to 40°C primary coolant temperature [IEC 60034-3, 4.2].

b.

The main data and capability of the synchronous generator shall be as per annexed data sheet under Appendix 3.

c.

The generator shall be capable to operate in parallel with the external grid at any active power between the efficient power and the technical minimum and reactive power, according to generator capability curve, over ranges of generator terminals voltage and frequency according to IEC 60034-3, Figure 1: i. Without time limitation for frequency between 49Hz and 51Hz (patterned area) ii. For single periods not exceeding 15 minutes time between 47.5Hz and 49Hz and 51Hz and 51.5Hz (no filled area).

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

d.

The regulator shall guarantee the stable operation of the group for an indefinite period of time, for any frequency between 47.5 Hz and 51.5 Hz and with any load up to the maximum power generable by the group. Furthermore, it must guarantee proper operation in a wider frequency range for limited period of time (typically down to 47 Hz and up to 52 Hz for few seconds); specific requirements for these conditions shall be agreed with the Grid Operator during EPC project phase.

e.

The generator shall tolerate, without disconnecting, the inverse sequence current caused by dissymmetric faults cleared by NTG backup protection within 2 seconds.

f.

The generator shall withstand without tripping single-phase faults in the 220kV external grid cleared within 500 ms by means of auto-reclosure systems and a permanent 10% load unbalance.

g.

The generator shall be able to withstand erroneous coupling in out-of-phase conditions with phase difference of 120° and 180°, without suffering any mechanical or electrical damages.

h.

Generator and its auxiliaries shall be capable of ridding through voltage dips close to zero for 250ms.

8.3

GENERATOR DESIGN

8.3.1

Conductors and Insulation All generator windings shall have copper conductors. Stator and field insulation systems shall be Class F with Class B temperature rise.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 8.3.2

8.3.3

8.3.4

8.3.5

8.3.6

Stator Winding Connection and Leads a.

Generator stator windings shall be arranged for WYE-connection. Phase and neutral leads shall be brought out and terminated in metal enclosed cubicles. Neutral leads shall be provided with the necessary number of current transformers.

b.

Generator parts carrying current continuously shall be rated for the maximum generator capability or higher. All equipment and materials shall have thermal and mechanical capability to withstand effects of short circuit currents for the times stated in the applicable specified standards.

Winding Temperature Detectors a.

Generators shall have six dual resistance type temperature detectors (RTDs) in their stator windings, spaced equally around the circumference of the stator.

b.

RTDs shall be wired to a dedicated terminal box.

c.

RTDs shall be connected to the Turbine Control System.

Generator Cooling System a.

The cooling system shall be of the closed-circuit air-water cooling type of sufficient capacity to maintain temperatures of the various parts of the generator within values as specified by IEC 60034 when operating at rated power, voltage, power factor and frequency with all coolers in service.

b.

Coolers shall be preferably mounted on the side or bottom of the generator enclosure. The design of the generator enclosure shall prevent water from cooler leaks from directly striking the generator windings.

c.

The system shall provide two or more independent cooler sections. Coolers shall be sized so that, if one section is out of service, the unit can carry at least 67% of rated load continuously, without the permissible temperatures of the active parts of the generator being exceeded.

d.

Cooling water pipes entering from the bottom are preferred.

e.

The air-water cooling systems shall be equipped with proper instrumentation for alarm and trip.

Space Heaters a.

Space heaters shall be provided inside generator and exciter to prevent condensation when the generator is not operating.

b.

Heaters shall be wired to a dedicated terminal box.

Generator and Exciter Bearing All bearings shall be lubricated from the common lubricating system provided for the turbine. Generator and rotating exciter bearings shall be insulated to prevent the flow of shaft current through any bearing.

8.3.7

Vibration and Balance

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) a.

Generator rotor shall be dynamically balanced before generator assembly. Rotor shall be final-balanced after the overspeed test.

b.

Rotating components for shaft-driven excitation systems shall be dynamically balanced.

c.

After final balancing, vibration shall be measured on the generator rotor.

8.4

EXCITATION SYSTEM

8.4.1

Main Characteristics a.

The generator shall be provided with a brushless exciter system for DC excitation (main exciter) complete with diode bridge and with pilot exciter constituted by Permanent Magnet Generator (PMG) single phase type.

b.

Vendor shall guarantee that all the performances requested by the National Grid Code are met under all operating conditions.

c.

The main data and capability of the excitation system shall be as per annexed data sheet under Appendix 3.

d.

The rotating rectifier system shall be: - Capable of providing full excitation power with only 80 percent (or less) of the diodes per phase in operation. - Protected against diode failure by series-connected fuses. - Provided with visual indication for operation of any diode fuse.

8.4.2

e.

An automatic detection system shall be provided to actuate an alarm circuit whenever any diode fuse operates.

f.

The excitation system shall be able to provide an adequate range of excitation to guarantee a sufficient margin of stability under all steady and transient load conditions and to guarantee that the control will keep the generator running within the acceptable limits of temperature rise and voltage.

g.

Temperature, voltage and current of the excitation system shall be monitored according to Vendor standard.

Voltage Regulator Facilities a.

The excitation system shall include two Automatic Voltage Regulators (AVR), electronic type, each made of two regulation channels, automatic and manual, with automatic bumpless changeover device.

b.

The AVR systems shall include the following facilities: • Voltage control • Reactive power control • Power factor control • Voltage drop compensation up to 80% of the transformer voltage drop • Reactive current compensation

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) • • • • • • • • • •

8.5

Logic system digital type Volt/Hertz limiter Over excitation limiter(1) Under excitation limiter(1) Field circuit breaker Fast de-excitation system Signalling and monitoring system (alarm and measurement) Local and remote control Boosting Stator Overcurrent Limiter

c.

The excitation system shall be able to provide the following performances according to the National Grid Code (the below requirements are typical and subject to confirmation from the Grid Operator): • Automatic control range 80-110% Vn • Manual control range 0-120% Vn • Error ± 0.2% of setting value • Settable dead-band including zero as a setting value • Positive ceiling voltage ≥ 160% - 2s (2) • Rotor over current ≥ 150% - 30s

d.

When the generator is subjected to a sudden load rejection at maximum output and rated power factor, the excitation system shall be capable to limit the momentary over voltage to less than 120% of the rated voltage and shall restore the voltage within 2% of the pre-set value before 3 s.

SPEED REGULATOR

(1)

(2)

a.

The speed regulator shall have proper characteristics in accordance with the National Grid Code requirements, in the following preliminary typical values which shall be subject to Grid Operator confirmation : • Speed regulator accuracy 0.02% or better • Speed regulator insensitivity not greater than ±10mHz • Dead band not greater than ±20mHz • Droop settable from 2% to 8%

b.

The load set point can be changed from 0% to 100% of the rated value in a time not higher than 50s.

Over/under excitation limits shall allow automatic voltage regulation within the margin of the capability curve. The limit curves shall be as close as possible to the capability curve to avoid reduction of the generator operation range. It shall be possible to temporarily overcome the over excitation limit in case of fault. Under excitation and over excitation limits shall vary with voltage to adapt to the generator capability curve. The excitation system shall be capable to force the exciter ceiling voltage for at least 2s in case of three-phase short circuit at high voltage side of step-up transformer (rated power = generator MVA; xcc = 11%)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) c.

The regulator shall allow a stable operation of the generator in the range between 47.5÷51.5 Hz, whichever the load. Moreover it shall allow a correct operation down to 47 Hz and up to 52 Hz for few seconds.

d.

The speed regulator shall include a Frequency Local Integral function, to face major perturbations in the network, with the following characteristics: • Automatic activation Frequency error greater than ±0.3Hz • Automatic inhibition Frequency error lower than ±0.1Hz

8.6

GENERATOR ANCILLARIES

8.7

Generator Control System The generator control system shall be interfaced with turbine control system and shall include control (automatic and manual) functions described in this document. The generator control system shall be arranged for local and remote control via the Turbine Control System.

8.6.1

8.6.3

Synchronization System a.

An automatic synchronizing system, digital type, shall be provided for each Gas Turbine Generator; it shall be designed to allow the synchronization at the circuit breaker on the 35kV switchgear.

b.

Synchronizing automatic sequence start/stop shall be possible both via Turbine Control System and via Electrical Management System (EMS). The following facilities shall be provided to avoid wrong synchronization: • Synchro-check relay in series with auto-synchronizer • Watch-dog relay to continuously monitor synchro-check and auto-synchronizer • Comparison among upstream and downstream voltages.

b.

Facilities to allow manual synchronizing shall be included in Turbine Control System.

Protection System a.

Redundant protections shall be foreseen for any type of faults. Main protections and their back up shall be provided in different relays (channels), fed by different DC circuits.

b.

Different channels shall act on different lock-out relays.

c.

Protective relays shall be of multifunction microprocessor design, PC programmable type, with facilities for being synchronized from external clock and IEC 61850 communication. Lock-out and auxiliary relays shall be high-speed type.

d.

Protective relays shall be connected to the Plant EMS through an IEC 61850 link to exchange commands and information.

e.

Relays shall have internal continuous supervision of the operating condition with dedicated output alarm relay (watchdog).

f.

Each relay shall have Sequence Of Event (SOE) recording function.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) g.

All tripping releases shall operate at least down to 70% of the nominal DC supply voltage.

h.

In case of fault within step-up transformer or generator, protections shall trip the relevant lock-out relay, which opens the 35kVgenerator.

i.

In case of fault in the external grid the generator shall promptly separate from the grid by tripping the incoming 35kV circuit breakers in order to allow operation on refinery load island. Protections setting shall be agreed with the National Grid Operator.

j.

It shall be possible to test the protective relays by secondary or primary injection. Secondary injection shall not trip the generator during relay testing. Each relay shall have dedicated test plug(s) on front of the equipment with easy access.

k.

The following protection functions shall be provided, as a minimum: CHANNEL A 87G: generator differential relay 21: under impedance relay 46: reverse phase sequence relay 24: over-excitation relay 78: out of step relay 40: loss of excitation relay 32: reverse power relay 64S: stator earth fault relay (100%) 64S: stator earth fault relay (95%) 59: stator over voltage relay 27: stator under voltage relay 59N: neutral overvoltage relay (MV side) 81U: under frequency relay 81O: over frequency relay 64R: rotor earth fault relay 60: voltage balance relay 50BF: breaker failure over-current relay 51V: voltage restrained overcurrent relay 86G: lockout relay 80: auxiliary supply bistable relay

CHANNEL B 87G: generator differential relay 21: under impedance relay 46: reverse phase sequence relay 24: over-excitation relay 78: out of step relay 40: loss of excitation relay 32: reverse power relay 64S: stator earth fault relay (100%) 64S: stator earth fault relay (95%) 59: stator over voltage relay 27: stator under voltage relay 59N: neutral overvoltage relay (MV side) 81U: under frequency relay 81O: over frequency relay 64R: rotor earth fault relay 60: voltage balance relay 50BF: breaker failure over-current relay 51V: voltage restrained overcurrent relay 86G: lockout relay 80: auxiliary supply bistable relay

CHANNEL A CHANNEL B 87T: step-up transf. differential relay 87O: overall differential relay 87N: step-up transf. earth fault relay (HV side) 50/51: step-up transf. overcurrent relay 50N/51N: step-up transf. ground overc. relay (HV side)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 86T: lockout relay 80: auxiliary supply bistable relay

8.6.4

86T: lockout relay 80: auxiliary supply bistable relay

l.

Transient recording function shall be integrated in protective relays. The analogue signals shall be recorded with a bandwidth not less than 250Hz. The digital signals shall be recorded with a resolution time of 1 ms. The recording time shall be adjustable so that: • the pre-fault time is not less than 500 ms; • the post-fault time is not less than 5000 ms

m.

Relays trips shall be recorded. The analogue signals to be recorded shall include at least generator: • line voltage phase R • line voltage phase S • line voltage phase T • zero sequence voltage • line current phase R • line current phase S • line current phase T • zero sequence current

n.

Protection system shall be part of generator control, protection and metering cubicle (IP31).

Metering System a.

The following transducers, 4-20mA, 1 or 2 accuracy class shall be provided at generator terminals: • Phase currents (Ia, Ib, Ic) • Phase voltages (Va, Vb, Vc) • Frequency • Active power • Reactive power • Power factor

b.

Energy meters shall comply with IEC 62053-22 and IEC 62053-23.

c.

The following energy meters, static type with output pulses shall be provided at generator terminals: • Active energy (0.2 accuracy class) • Reactive energy (0.5 accuracy class)

d.

The following energy meters, static type with output pulses, shall be provided at a.c. switchgears incoming terminals: • Active energy (0.5 accuracy class). • Reactive energy (1 accuracy class).

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

8.7

8.8

e.

Each energy meter shall have suitable IEC 61850 interface (or other available serial interface) to be connected to the EMS for accounting purposes.

f.

Metering system shall be part of generator control, protection and metering cubicle (IP31).

CURRENT AND VOLTAGE TRANSFORMERS a.

Current and voltage transformer ratings shall be in accordance with IEC 61869 standards. CTs’ shall be selected in order not to limit the generator performance in the whole ambient temperature range. The short-time thermal and mechanical rating shall be specified to withstand the available short-circuit current.

b.

Particular attention shall be paid to CTs’ transient behaviour. Calculation sheets shall be produced to demonstrate the correct sizing.

c.

CTs’ secondary current shall be preferably 1 A. VT’s secondary voltage shall be preferably 100 V.

d.

For generator/transformer bay, accuracy class for measuring shall be 0.2.

e.

Voltage and current transformers shall be readily accessible for maintenance purposes. Primary side of voltage transformers shall be protected by fuses and secondary side shall be equipped with miniature circuit breakers (MCBs).

EMC REQUIREMENTS a.

All the electronic device of the package shall comply with the emission and immunity levels prescribed by the specific standard applicable to the component.

b.

In the absence of a specific standard, reference shall be made to the following IEC standards. REFERENCE STANDARDS

TEST or MEASUREMENTS

CLASS/TEST LEVEL

EMISSION IEC 61000-3-4

Emission of harmonic currents

by Vendor

IEC 61000-3-5

Flicker

by Vendor

IMMUNITY IEC 61000-4-2

Electrostatic discharge immunity

6 kV contact 8 kV air

ENV 50204 IEC 61000-4-3

Radio frequency electromagnetic field Immunity

10 V/m

IEC 60801-4 IEC 61000-4-4

Electrical fast transient/burst immunity

Power supply: 2 kV control lines: 2 kV signal lines: 1 kV

ENV 50142 IEC 61000-4-5

Surge immunity

2 kV line/ground 1 kV line/line

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package)

8.9

REFERENCE STANDARDS

TEST or MEASUREMENTS

CLASS/TEST LEVEL

IEC 61000-4-6

Conducted disturbances induced by radio-frequency fields immunity

IEC 61000-4-8

Power frequency magnetic field immunity

30 A/m

IEC 61000-4-9

Pulse magnetic field immunity

100 A/m

IEC 61000-4-10

Damped oscillatory magnetic field

by Vendor

IEC 61000-4-11

Voltage dips short interruption

to be defined by Vendor

IEC 61000-4-12

Oscillatory waves immunity

2 kV (CM) 1 kV (DM)

10 V

STARTING MOTOR The starting motor shall comply with the requirements of the following chapter 8.13 and shall be complete of any device necessary for the correct operation. Vendor shall point out the minimum short circuit power required on 6 kV busbars. The starting motor shall be sized not to limit starting attempts. Vendor shall point out the maximum number of restarts and the required time interval between two consecutive starting attempts. This equipment will be controlled and monitored by the turbine control system.

8.10

LV SWITCHGEARS LV switchgears shall be metal clad type, arc resistant, free standing, dead-front, steel structure, for indoor installation, protection degree IP41, minimum form 4-a (IEC 61439-1). The switchgear shall have two incoming feeders, one from normal power source and the other one from emergency power source (diesel generator) equipped with withdrawable circuit breakers. Suitable interlocks shall be provided between the breakers. Automatic change-over between the two incoming feeders shall be provided. Motor feeders shall be equipped with withdrawable circuit-breaker, contactor and thermal relay. Static load outgoing cubicles shall be equipped with withdrawable automatic circuit breaker, moulded case type; Appropriate spare cubicles not equipped shall be provided (not less than 20%).

8.11

DC SYSTEM

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) The DC system shall supply the GTG package DC loads for the time required for the safe management (shut down) of the Package during the emergency, anyway not less than one hour. The DC System voltage level shall be as per Vendor standard (e.g. 110 Vdc or 125 Vdc). AC/DC rectifiers-battery chargers and battery banks shall be 100% redundant; DC distribution board shall be formed of one section supplied from one rectifier and battery branch, the second rectifier being in stand-by. The batteries shall be Nickel Cadmium type valve regulated. The batteries shall be installed in dedicated cubicle of the DC system or in the battery room of the electrical and control module, with direct access from outside. The room shall be equipped with hydrogen gas detector and ventilation fans. The distribution boards shall be equipped with fixed automatic circuit breakers, two poles type, with auxiliary contacts for alarming. 8.12

UNINTERRUPTIBLE POWER SUPPLY (AC) The UPS system shall supply GTG package loads which require uninterruptible power supply (to be defined by Vendor). The UPS System voltage level shall be 230 V single phase. AC/DC rectifiers-battery chargers, inverters and battery banks shall be 100% redundant; AC distribution board shall be formed of one section supplied from one rectifier and battery branch, the second rectifier being in stand-by. The batteries shall be Nickel Cadmium type valve regulated. The batteries shall be installed in dedicated cubicle of the UPS system or in the battery room of the electrical and control module, with direct access from outside. The room shall be equipped with hydrogen gas detector and ventilation fans. The distribution boards shall be equipped with fixed automatic circuit breakers, two poles type, or the combination of switches and fuses, with auxiliary contacts for alarming.

8.13

INDUCTION MOTORS a.

The induction motors included in the scope of supply shall be in accordance to IEC 60034 series.

b.

Induction motors shall have the main following characteristics: − Motor type asynchronous − Efficiency class IE3 (IEC 60034-30) − Cooling type air cooled − Protection degree motor ≥ IP 54 − Thermal insulation/temperature rise F/B − Voltage and frequency variation: Normal condition: zone A (as per IEC 60034-1 fig. 12)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Exceptional conditions: zone B (1) (as per IEC 60034-1 fig. 12)

8.1.4

c.

Motors shall be designed for direct starting at full voltage and for re-acceleration with 100% residual voltage, and for two consecutive starting at 80% of rated voltage (from hot condition).

d.

In addition they shall keep in service their mechanical loads when the supply voltage at their terminals is 70% of rated voltage.

e.

All DC motors shall be supplied complete of starting resistors.

f.

Motor control circuit shall include a local control station (included in the scope of supply) near the motor on the side opposite the cable entry. The control circuit shall include the following: • For motors controlled by an automatic device, the local control station shall include a selector switch with three maintained positions labelled MAN-OFFAUTO, and a start button that can operate only when the selector switch is in the MAN position. There shall be provision for padlocking the selector switch in the OFF position. • For other motors, the local control station shall be START-STOP type and lockable in the STOP position.

g.

All motors will be provided with local emergency stop buttons (included in the scope of supply).

CABLING a.

LV power cables shall have the following characteristics: annealed stranded copper conductor, XLPE insulated, concentric type ground return copper conductor, PVC over sheathed, fire retardant type according to IEC 60332-3A Standard.

b.

Control, signal, protection and in board cables shall be flame propagation restraining and not emitting corrosive and toxic gases, according to IEC 60754-1 and IEC 60754-2. Control and signal cables shall be shielded type, to prevent EMC interference. A single shield for each couple of 4-20 mA and RTD signal shall be foreseen.

c.

Safety circuit control cables (including safety lighting cables and emergency electrical shut-down cables) shall be fire resistant according to IEC 60331.

d.

Cables installed in classified area shall be armoured.

e.

Above ground instrument cables shall be steel armoured, PVC cover, run in cable trays. Power cable section shall be selected according to the following criteria: • load current, with minimal voltages in normal operation (proper de-rating factors shall be applied considering the worst laying condition);

(1)

In this condition windings’ temperature shall not exceed 10°C over the temperature rise class B indication

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) •

•

fault current withstand (the maximum short circuit level of the supply and the fault clearing time of the last back-up upstream feeder protective device shall be used); voltage drop (feeders and sub-feeders = 2%, motor feeders = 5% at rated output and 10% at motor terminals during start-up).

f.

Minimum cross sections per electric cables shall be: • Power cables: 2.5 mm2 • CTs’ cables: 4 mm2 • VTs’ cables: 2.5 mm2 • Electric control cables: 1.5 mm2

g.

Colour of cables’ conductors shall be selected in accordance with the standard IEC 60445. Conductors of control cables will be black identified by numerals.

h.

For cables installation, cable trays and ladders shall be used on-skid and on-base. For off-base connections underground installation shall be considered with cables installed in PVC duct bank.

i.

Different cable typologies shall be separated by appropriate. Where necessary, segregation with appropriate barriers shall be arranged to avoid the risk of fire propagation to near cables.

8.1.5

TESTING

8.15.1

Generator and excitation system a.

The generator and its excitation system shall be fully assembled, tested and inspected in Manufacturer’s plant. The tests shall consist of Manufacturer's standard factory tests and shall include at least the following: • Measurement of insulation resistance of generator stator and rotor windings. • Measurement of cold resistance of generator stator and rotor windings. • High potential test of generator stator and rotor windings. • Measurement of polarization index of generator stator winding. • Mechanical balancing and measuring vibration of the generator rotor. • Overspeed test of generator rotor at not less than 120 percent of normal operating speed. • Hydrostatic test on generator air-water coolers at 1.5 times the rated pressure by the Cooler Vendor. • Polarity of field coils • Measurement of air gap • No load saturation test • Heat run test (temperature rise test) • Short circuit characteristic • No-load losses (PF=1)

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) •

b.

8.15.2

Determination of efficiency, including the determination of armature and field I2R losses, core losses, friction and windage losses, and stray load losses (testing methods per IEEE C50.13, and IEEE 115). • Complete performance curves and data shall be verified by factory tests using the test methods of IEEE 115 for the parameters listed on the Data Sheet. • Insulation dissipation factor test (measurement of tan δ). • During the tests, at least the following measurements and checks shall be provided: iii. Field current measurement at normal voltage and frequency iv. Measurement of shaft voltages and currents v. Stator current balance measurement vi. Waveform and harmonic content measurement vii. Inspection of bearings and mechanical operation viii. Test of bearing temperature rise The following tests shall be performed on the brushless exciters: • Measurement of insulation resistance of rotating exciter stator and rotor windings, and of pilot exciter (if any) stator winding. • Measurement of cold resistance of rotating exciter stator and rotor windings, and of pilot exciter (if any) stator winding. • High potential tests of rotating exciter stator and rotor windings, of pilot exciter (if any) stator winding and rectifier assembly, and of pilot exciter (if any) rotor.

c.

Additional test requirements for generator auxiliaries compartment and generator excitation compartment shall be carried out as follows: • check all wires for continuity point-to-point. • functional check by simulating operation of each relay and checking for proper response. • operational check of all meters, transducers, relays, and controls to confirm proper response.

d.

Additional on-site tests that may be necessary to demonstrate the compliance of the generating unit to the National Grid Code requirements (to be confirmed during EPC project phase) shall be included. Details for test execution will be agreed with the Purchaser and the National Grid Operator during the EPC phase.

Generator auxiliaries, ancillaries and other electrical equipment For all the other equipment included in this MR, tests shall be made in accordance with the referenced applicable Job Specifications and the applicable IEC standards.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 9.0

INSTRUMENTATION AND CONTROLS REQUIREMENTS

9.1

Control and Protection System in ELE/I&A compartment The GTG control and protection systems for the Power Train shall be provided in a Triple Modular Redundant (TMR) fault tolerant configuration. The protection system and associated instrumentation, such as sensors and final elements, shall be designed such that all Vendor safety trips meet a Safety Availability Target (AT) of 98%. The vendor shall provide SIL (Safety Integrity Level) documentation to demonstrate that this 98% will be achieved in accordance with IEC 61508 & 61511. The testing frequency for these Safety Instrumented Functions (SIF's) shall be clearly documented in the SIL calculations provided. The Reliability of the Control and Protection System shall be considered within the overall reliability requirements for the total GT and Generator package (see section 6.3.5). The gas turbine generator (GTG) control system includes all the control, regulation and protection devices needed for reliable and economic operation of the GTG set within the limits of supply. This includes all the necessary switchgear and control cabinets for the complete generator set, including all the associated measuring devices and actuators. The GTG control and protection system must be interconnected, via hardwired signals and Modbus TCP communication datalink, with the central Plant DCS, to allow to operate and monitor the GTG from the Plant DCS. Interface point will be the DCS cabinets inside Remote Instrument Building RIB 550. The GTG control System shall contain all hardware necessary to realize a redundant Modbus TCP/IP link with DCS to provide all needed information to the Plant DCS. Hardwired (Inputs/Outputs) for each GTG control system are required. The Plant DCS, ESD and the HRSG BMS will have a limited set of key-commands (i.e. load selection, trip request, start-up permissives, etc) transferred to the GTG via hardwired connections. The Vendor battery limits are the marshalling cabinets in the ELE/I&A compartment. The GTG HMI workstations, one for each GTG, provided by GTG Supplier with 21 inch monitor, connected to the GTG control system and located in Main Control Room, will be the primary interface with GTG control and protection system. From this station it shall be possible to start-up, synchronize and shut-down the Power Train (GT, Generator, auxiliary systems etc). In addition it shall be used to perform the detailed diagnostic and maintenance of the GTG systems. A rack mounted 19” screen operator and engineering workstation complete of keyboard, mouse and laser colour printer shall be also be provided for each GTG, installed on control system cabinet inside the turbine building. An additional desk mounted workstation shall be quoted in option for each GTG, with 21 inch screen minimum, keyboard and mouse, to be located in the turbine building. The Vendor shall submit during the detailed design phase a proposed I/O list for the supervisory monitoring of the Power Train from the Plant DCS consoles. The loops interfaced to the Plant DCS shall be double tagged in the final revision of Vendor P&ID’s and Instrument List etc so that they show both the Vendor tag number and the Refinery standard tag number.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) Each GTG HMI schematic engineered by the Vendor, with the associated I/O’s, shall be provided in an official document by the Vendor during detailed engineering. As an OPTION the Vendor shall quote all necessary hardware and software to allow the Vendor remote access to the system. The communication will be realized by means of a dedicated phone line provided by others (Vendor shall include the modem and provide the requirements of the phone line). This station will not be used as a standard HMI station. The Vendor shall work with Client on the security details for this remote connection. It shall be possible to synchronize the time in the control and protection system by an external master clock signal made available on the GTG data link. The Mark VIe system shall be sized in order to provide 15% spare I/O capability upon completion of the unit commissioning and start-up. 9.2

Vibration and Bearing Temperature Monitoring System A Machine Monitoring System shall be supplied for each GTG train for the vibration monitoring of gas turbine, gearbox, generator, etc., in accordance with API670. For each GTG instrumentation shall include the following: 2 proximity probes per radial bearing for the entire turbine train including load gearbox and generator. 2 proximity probes on all thrust bearings 2 thermocouples on all radial and thrust bearings. On the gearbox radial bearings, the thermocouples shall be located on the loaded pads or segment of each bearing. Separate JB’s shall be provided for vibration and temperature probes / transmitters. The rotor shaft sensing areas to be observed by radial-vibration probes shall be concentric with the bearing journals. All shaft sensing areas (both radial vibration and axial position) shall be free from stencil and scribe marks or any other surface discontinuity, such as an oil hole or keyway, for a minimum of one probe-tip diameter on each side of the probe. These areas shall not be metalized, sleeved, or plated. The final surface finish shall be a maximum of 39 µin. (1.0 µm) Ra, preferably obtained by honing or burnishing. These areas shall be properly demagnetized or otherwise treated so that the combined total electrical and mechanical runout does not exceed 25 percent of the maximum allowed peak-to-peak vibration amplitude or the following value, whichever is greater: • For areas to be observed by radial-vibration probes, 0.25 mil (5 µm). •

For areas to be observed by axial-position probes, 0.5 mil (10 µm).

GTG supplier shall include in the quotation the hardware and software needed to interface the Machine Monitoring System with the Central Plant Machine Monitoring System (supplied by Others). 9.3

Field Instrumentation Analogue transmitters, not switches, shall be used for all process alarm and shutdown input devices, e.g. for Pressure, Flow and Level etc. All trips that cause a reduction in the power production (including ancillary devices such as enclosure door limit switches) and

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) that impact the plant reliability factor shall be implemented with ”two out of three (2oo3)” sensors. Other fault tolerant voting strategies (e.g. exhaust temperature) shall be proposed by Vendor. During the bidding phase the Vendor shall submit a preliminary list of the trip initiators and voting strategies for review. Minimum degree of environmental protection for instruments is IP65. All process-connected measurements such as pressure transmitters shall have isolation valves to facilitate maintenance. If the Site Performance Tests require field instrumentation with technical characteristics & performances different from those normally used for the operation of the unit, the provision of such instruments (on a temporary basis) shall be included in the scope of supply. The installation activities will also be included and will consist in the removal of the existing instrumentation, installation of the instruments for the tests, electrical connection to the control systems, removal of the instrumentation after the tests, installation of the original instruments and electrical connection to the control systems. 9.4

Wiring Vendor shall avoid the routing of wiring through or within areas that may be exposed to temperatures that could jeopardize the functionality of the cables. If this cannot be avoided in all situations, the Vendor shall include in the design details to protect this wiring from heat related damage.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 10.0

GENERAL DRAWINGS

10.1

P&ID and Plot Plan See Appendix 7 for P&ID and Appendix 8 for Plot plan.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 11.0

BID DOCUMENT LIST No.

Description

Remark

1

Completed Purchaser’s Datasheet

Note 1

2

General Arrangement Drawing

Note 2

3

Electric Load List

4

P&ID including Scope of Supply indication

5

Specific statement of vendor’s scope of supply

6

Inspection & Test plan

7

Instrument list with short specification

8

Technical description for instrumentation and control system

9

Deviation List

10

Typical sectional drawing with part list including material

11

Foundation plan drawing with loading data

12

Sub Vendor List

13

Utility consumption list

14

Consumable list

15

Reference list

16

Spare Part List for Commissioning & Start-up

17

Spare Part List for 2 Year separately (as option)

Note 3

18

Spare Part list for Mandatory spare, if any

Note 3

19

Latest Technical Brochure

20

Completed SECL Packing List (Large Package Item)

Note 1. Design data for Waste heat recovery unit shall be provided. 2. Detail DWG with dimension and load for maintenance, erection and total shall be shown. 3. Separate price with quantity for each part to be specified.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 12.0

JOB FORMAT

Vendor information shall be submitted using attached Job Format in Appendix 9.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 13.0

EXCEPTION, DEVIATION AND CLARIFICATION

In principle, vendor shall prepare his proposal in full compliance with the stipulations, conditions and requirements stated in this requisition. Vendor’s exceptions and deviations from the Purchaser’s documents shall clearly be listed in the format (attached as Appendix); otherwise vendor’s quotation shall be regarded to be fully conforming to the Purchaser’s requirements. Even if there is no Exception, Deviation and Clarifications, Vendor shall submit Appendix to declare Vendor’s full compliance.

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 14.0

APPROVED VENDOR LIST

See Appendix 32

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SONATRACH - Projet Nouvelles Raffineries Argelia S60133-0504 (Gas Turbine Generator Package) 15.0

INSTRUCTION OF LARGE PACKAGE ITEM PACKING

See Appendix 33 and 34. Completed SECL Packing List (Large Package item) to be provided by Vendor.

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