CONFIDENTIAL Description (Z) Fuel gas system Process description Wartsila project ID: Wartsild Doc ID: /13033 DBAC745638 a WARTSILA _ | Wartsilé supplier: Source Doc 1D: owner & PT PLN @ersero) UNIT INDUK PEMBANGUNAN Ix Consultant: ' ™ [eouano oI ERIRNORING | RC ooo S16 Loy APPROVEDTRS NOTED Contractor: a Ba ony | So nronmarion warTsiA SEA [nce pom gerne! ‘Consortium Watsiis PP ne SPONSIBILITY FOR ERROR O eur | rar Project: _ PLTMG BANGKANAI PROJECT (155MW}- PLN No. TM.23.2013-00-M-NK-0001-09 10-Sep-2013 Pontus Strand | arko Kojo Lars Snare a | sep0c2003 | ist isue Pontusstrand | Anuolia | Lars snire Rev Date - Reason/Explanation for change Made ‘Checked ApprovedDocument ID: DBAC745638 a 219) TM.23.2013-00-M-NK-0001-09 (Z) Fuel gas system _ Contents. 1 Scope and related documents. Abbreviations 2 3 Overview: 4 Main shut-off valves, vent valves, pressure measurements BA Funeton sn 42 Control 4.2.1 Normal operation. sesh 4.2.2. Failure operation and plant emergency shut down... aaa 5 5 Compact gas ramp ZAC 011-161 with engine specific flow metering 5.1 Function 5.2 Control 5.2.1 Normal operation.. 5.2.2 Failure operation... 5.23 StartDocument ID: OBAC74S638 a 30) TM.23.2013-00-M-NK-0001-09 1 Scope and related documents This document describes the basic control and functionality of the fuel gas system. It is to be read in conjunction with the latest revision of fuel oil system related main flow diagrams, see Table 1 ‘The description covers primarily control functions. and operations of equipment that is in ‘Wartsila scope of supply, except for the equipment integrated on the engine. Table 1 Reference documents Document number Title DBACE91582 (@) Fuel gas system - Main flow diagram DBAB653347 ‘Compact gas ramp — Main flow diagram 2 Abbreviations CGR Compact gas ramp ESD Emergency shut down PLC Programmable Logic Controller PoC Pre-Combustion Chamber McC. Main Combustion Chamber SOGAV Solenoid operated gas admission valve wols ‘Wartsila operator interface system 3 Overview The fuel gas system provides the engine with an uninterrupted and reliable supply of clean fuel gas at the desired pressure (which depends on the engine load). Fuel gas is led into the engines through fuel gas header pipes which contain main shut-off valves and vent valves and engine specific compact gas ramps (CGR). Pressure control, as well as opening and closing of the fuel gas supply as well as engine specific flow metering are done in the CGR. To ensure a reliable operation of the engines a clean fuel gas supply is required. Particles and other impurities have to be removed from fuel gas before the engine. The maximum allowed particle size is 5 ym and the maximum amount of particles in the fuel gas is 50 mgim? determined in base conditions of 0°C and 1.013 bar(a)..Document ID: DBAC745638 a 4 (9) ‘TM.23.2013-00-M-NK-0001-09 ‘The main components and modules in the fuel gas system are Equipment Code Function Manual main shut-off valve ZAA 900 VO01 Gas isolation (engines 01-04) Manual main shut-off valve. ZAA 900 VO02 Gas isolation (engines 05-08) Manual main shut-off valve ZAA 900 V003 Gas isolation (engines 09-12) Manual main shut-off valve ZAA 900 V014 Gas isolation (engines 13-16) Automatic main shut-off valve ZAA 900 V004 Gas isolation, ESD (engine 01- 04) Automatic main shut-off valve ZAA 900 VO06 Gas isolation, ESD (engine 05- 08) Automatic main shut-off valve ZAA 900 VO08 Gas isolation, ESD (engine 09- 12) Automatic main shut-off valve ZAA 900 VO16 Gas isolation, ESD (engine 13- 16) Automatic vent valve ZAA 900 VO05 ESD venting (engine 01-04) Automatic vent valve ZAA 900 VO007 ESD venting (engine 05-08) Automatic vent valve ZAA 900 VO09 ESD venting (engine 09-12) Automatic vent valve ZAA 900 VO017 ESD venting (engine 13-16) Compact gas ramps ZAC 011-161 Fuel gas flow and pressure control 4 Main shut-off valves, vent valves, pressure measurements 4.1 Function The engine specific gas supply to the engine hall A and B is controlled by manual shut-off valves, automatic main shut off valves and automatic vent valves. The valves are located as near the building as possible but outside the power house, with easy access for the operators. This is required in order to be able to isolate the gas system from the gas grid outside the building, The gas supply may be cut-off by closing the manual main shut-off valve if necessary, ie during maintenance or in emergency situations. The automatic shut-off valve is equipped with an electro-pneumatic actuator of fail CLOSE type. The automatic vent valve is equipped with an electro-pneumatic actuator of fail OPEN type. Both of the automatic valves are equipped with Ex-classified solenoid valve to control the instrument air flow to the actuator oylinder. The automatic valve assemblies include an Ex-classified limit switch for remote position indication and position alarm to control system. Inlet fuel gas pressure is measured with an Ex-classtfied pressure transmitter. 4.2 Control 4.2.1 Normal operation During normal operation the manual and automatic main shut-off valves are open allowing fuel gas supply to the CGRs and further to the engines. The automatic vent valve is closed. The solenoid valve of the fail CLOSE shut-off valve is open towards the actuator enabling the actuator cylinder be pressurised with control air. Thus the spring actuator can not close the valve, The solenoid valve of the fail OPEN vent valve is open towards the actuator enabling the actuator cylinder be pressurised with control air. Thus the spring actuator can not open theDocument ID: DBAC745638 a 5 (9) ‘TM.23.2013-00-M-NK-0001-09 valve. Pressure transmitter is used for pressure monitoring. The inlet pressure shall be visible in the control system also when all plant is in stand-by and CGRs are closed in which case 002 in CGR does not sense pressure. 4.2.2 Failure operation and plant emergency shut down A plant emergency shut down is activated in the case of a gas leak (20% of LEL sensed by a gas detector) or when ESD button is pressed on the common control panel. As an option, it is also initiated by a fire ESD. Alternatively, fire panel gives an alarm and the operator acts as needed, ESD valve control is the following ‘© The solenoid valve in the main shut-off valve assembly is de-energized and control air from the actuator is released to enable closing of the main shut-off valve. ‘+ The solenoid in the vent valve assembly is de-energized and control air from the actuator is released to enable opening of the vent valve. There is a position error alarm if the valve position differs from the normal position. 5 Compact gas ramp ZAC 011-161 with engine specific flow metering 5.1 Function The compact gas ramp (CGR) controls the gas admission to the engine by delivering the fuel gas at a correct feed pressure to the engine depending on the engine load. In addition, a leakage test and a leakage check of the main shut-off valves of the CGR is performed after engine stop (normal stop) or shut down. The engine specific CGR is of double line type since the W20V34SG engine requires different fuel gas pressure for the main combustion chamber (MCC) than for the pre- combustion chamber (PCC). PCC gas has its own pressure control since injection time (duration) cannot be adjusted for the oylinder specific mechanically operated PCC gas admission valves. Thus, fuel gas mass flow can only be controlled by pressure control for the PCC line. ‘The main functions of the compact gas ramp are: + To filter the fuel gas and measures its flow before feeding to the engine NOTE: the flow meter is delivered as loose supply with the CGR + To supply the engine with a constant fuel gas flow in a correct pressure depending on the engine load (MCC and PCC lines have individual pressure control valves ~ ‘voos and V006) * To control the gas admission to the engine together with the main gas admission valves at the engine © To perform a leakage test and/or leakage check after engine stop or shut down to ensure that the shut-off valves V003 and V004 are working properly Opening of the valves V003 and VO04 in engine start mode Closing of the fuel gas feed to the engine at engine stop, shut down and emergency shut down modes with valves VOO3 and VO04 © Venting of fuel gas at the engine stop, shut down and emergency shut down modes with vent valves VO08 and VOOS ‘The shut-off valves and the vent valves are automatically controlled by the PLC (programmable logic controller). There are two venting connections for the CGR ‘The compact gas ramp is protected against overpressure with aDocument ID: DBAC745638 a 6 (9) TM.23.2013-00-M-NK-0001-09 safety relief valve, the outlet of which is combined with the manual vent valve and 1* automatic vent valve outlets. 5.2 Contre 5.2. Normnal operation 5.2.1.1 Pressure control Correct fuel gas flow and subsequent suitable air-fuel ratio is adjusted by controlling the fuel gas pressure in the CGR and duration (opening time) of the cylinder specific main gas admission valves (SOGAV). The gas pressure is controlled by the engine control system based on the charge air pressure. The fuel gas pressure is higher than the charge air pressure, The engine control system gives a 4...20 mA control signal that corresponds to a valve position. The digital valve controller included in the pressure control valves VOOS and VOO6 adjusts the desired outlet pressure depending on the engine load. 2 Pressure monitoring and alarm and shut down limits The inlet pressure is monitored by a pressure transmitter P002, Ifthe inlet pressure is too HIGH or LOW, an alarm is given. The HIGH alarm limit is set at 8.0 bar(g) and the LOW alarm limit is set at default set value of 1.5 bar(g). In case the pressure increases to a HIGH shut down limit of 8.5 bar(g), CGR is closed. The safety relief valve set point is at 9.5 bar(g), The outlet pressure is monitored by pressure transmitters PO03 (located in the MCC gas line) and P004 (located in the PCC gas line). These pressure signals are connected to engine control system, They act as back-up for engine pressure measurements (P901 for MCC gas and P91 for PCC gas). 5.2.1.3 Temperature monitoring and alarm limits The temperature is monitored with a resistance thermometer T001. HIGH alarm is at 50 °C and LOW alarm is at § °C. 5.2.1.4 Flow monitoring The engine specific fuel gas flow is monitored with a flow meter F001. Momentary and cumulative mass flows are measured. The flow meter is located at the inlet of the CGR. On. electrical side it is connected via junction box of the CGR to the control system. Failure operation ‘An alarm is given to the control system and is visible in WOIS (Wartsila operator interface system) when the pressure or the temperature alarm limits are exceeded or any of the pressure or the temperature sensors have failed (sensor fault) In case of engine shut down the compact gas ramp is closed. In case of an emergency shutdown, the 24 VDC power supply for the compact gas ramp is. disconnected and the valves will go to the fail safe position (hardwired ESD), which is shown in Table 6. The shut-off valves VO03 and V004 are closed fast by de-energising the solenoid valve and opening the quick release valve located in the actuator to enable rapid air release from the actuator, The vent valves VO08 and VO09 are opened and the pressure control valves VO05 and V006 are closed due to air release from the actuator by the solenoid valve. If the leakage test after the engine stop or shut down is passed successfully and also all gas. leak checks are passed, the engine is allowed to start immediately after start command provided no other start blocks are active.Document ID: DBAC745638 a 7(9) ‘TM.23.2013-00-M-NK-0001-09 A failed leakage test or alternatively leakage check will activate a start block for the engine, The start block can be reset either through a manual leakage test initiated from the WOIS by the operator or through an automatic leakage test before engine restart. If a gas leakage check is in progress when a start command is given the test will be terminated and the valves will go to their initial positions before the start sequence can progress. When the engine enters a stop mode, a longer leakage test is performed to ensure that the shut-off valves do not leak during the engine stop mode. The test is made when the engine is completely stopped and the exhaust gas ventilation fan is in operation. When the engine is in stop mode for a longer time the leakage check is made every 23 hours to ensure the performance of the shut-off valves and to be able to detect possible leakage. Before the engine is started, the shut-off valves V003 and VO04 are opened and the vent valves V008 and V009 are closed. Table 2: Start seqence of the compact gas ramp 0 ‘Command to open the compact gas ramp is active, gas leakage test failure is not active and the gas leakage test is successfully passed. The vent valve VOO8 and the pressure control valves VOOS and O06 are closed and the first shut-off valve VOO3 is opened. The sequence goes to step 1. 4 [After two seconds from step 0, VO04 is opened giving fuel gas to the pressure control valves VOOS ‘and VO06, which control the fuel gas pressure sultable for the engine according to mA signal from the control system, Stop Table 3: Stop sequence of the compact gas ramp Step Control action ° ‘Command o close the compact gas ramp is active, then the sequence goesto step 3. 1 ‘V003 and V004 are closed. Vent valves VOO8 and VO009 are opened. After the stop the leakage test is carried out as per the following sequence. Table 4: Gas leakage test sequence of the compact gas ramp Step Control action ° Taal state. The shut-off valves O03 and VOO4 are in closed position and the vent valve VOO8 in between the shut-off valves isin open position. The engine is in stop mode. 1 ‘The shutoff valves VO03 and VO04 are in closed position and the vent valve VO08 in between is closed. The pressure transmitter P002 monitors the fuel gas pressure in between the main shut-off valves for 1 minute. Ifthe transmitter indicates an Increase of over 0.2 bar between the main shut- off valves, the first shut-off valve V003 is leaking and the sequence goes to step 5. Otherwise the sequence goes to step 2.Document ID: DBAC745638 a 8 (9) ‘TM.23.2013-00-M-NK-0001-09 2 First shut-off valve VOO3 is opened and fuel gas is admitted into the space between the main shut- off valves V003 and VOOs. Ifthe pressure does not increase, indicated by the pressure transmitter 002, the transmitter is broken or the first shut-off valve is malfunctioning and the sequence goes to step 6. Otherwise the sequence goes to step 3 First shut-off valve is closed again. Ifthe pressure between the two main shut-off valves decreases 3 ‘more than 0.2 bar within 1 minute, the second shut-off valve is leaking and contro is transferred to step 7. Otherwise the sequence continues to step 4 Shut-off valves VO03 and VOD4 are in closed position and the vent valve VOO8 in between is opened. 4 ‘The CGR isin initial state. The signal that gas leakage test successfully passed Is activated, The gas leakage test sequence is ended. 5 ‘An alarm, leaking first shut-off vaive VO03, is set and the sequence goes to step 8. 6 An alarm, first shut-off valve VO03 stuck or pressure transmitter P002 broken, is set and the sequence goes to step 8. ? {An alarm, leaking second shut-off valve VO04, is et and both shut-off valves are closed, vent valves are opened and the sequence goes to step 8. 8 Gas leakage test failure alarm is activated, The gas leakage testis ended, The leakage check is performed 23 hours after a successful leakage test and in sequence every 23 hours during the time the engine is in stand-by mode. The tightness of the first shut-off valve is checked in the leakage check during the engine stand-by mode. Table 5. Gas leakage check of the compact gas ramp Step Control action 0 Initial state. Shut-off valves VOO3 and OOS are in closed position and the vent valve VOO8 in between the two shut-off valves i in open position. Engine ts in stand-by. 1 ‘Shut-off valves VO03 and V004 are in closed position and the vent valve VO08 in between is closed. ‘The pressure transmitter POO2 monitors the fuel gas pressure in between the two shut-off valves for 1 minute. Ifthe transmitter indicates an increase of over 0.2 bar between the two shut-off valves, the first shut-off valve is leaking and the sequence goes to step 3. Otherwise the sequence goes to step 2. Both shut-off valves are in closed position and the vent valve in between is opened. The CGR isin 2 initial state. The signal that gas leakage check successfully passed is activated. The gas leakage check sequence is ended.Document ID: DBAC745638.a 919) ‘TM,23.2013-00-M-NK-0001-09 3 ‘An alarm, leaking frst shut-off valve, is set and the sequence goes to step 4 4 Gas leakage check fallure alarm is activated. The gas leakage check is ended. If the gas leakage test or leakage check fails a start block is activated until a successful leakage test is passed Table 6 Emergency shut down mode, which shows the contro! action for the valves in the compact gas ramp. Valve Code Position Shut-off valves 003 and Vos Fall CLOSE Vent valves voo8 and voos Fall OPEN Pressure control valves Voos and VO06 Fail CLOSE