SUNCOR ENERGY Technical Standard No. FB-F-5624 FIREBAG PROGRAM HEAT RECOVERY STEAM GENERATOR (HRSG) SUNCOR ENERGY INC. CANADA 1_| 31-Jan-06_| Issued for Implementation ‘A. Deverider |A. Deverider| OTUs rt Rev | Date Document Status ‘Originator | Engineer _| Reviewer | Approver ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOGUMENT IN JPIEWR 100-206-001 —2-4-47 File Name: FB-F-5624 Rev__1_- Heat Recovery Steam Generator (HRSG).DOC Page 1 of 31Suncor) nor MUON ETT ENERGY TECHNICAL STANDARD Subject Number Rovio HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 REVISION HISTORY _— Rev [bate Description | SiJan-06 | Tesued Yor Implementation | “7.Nov.05 | Re-tssued for Exernal Squad Check - Updated = 8.1.47 added t Seaton 81 | —16.Jun-05 |" Issued for External Squad Check ‘A | 13-May-05 | Issuod for internal Squad Check ‘This specification is based on Suncor Energy no. Specification No. SPOt-F-1- Rev. 12 and has been developed specifically for use on Firebag Projects TABLE OF CONTENTS 1.0 SCOPE OF STANDARD 2.0 INTRODUCTION 3.0 SCOPE OF SUPPLY 3.1 General 32 Work by Seller 3.3 Optional Work 4.0 | WORK EXCLUDED 5.0 CODES, STANDARDS, AND REGULATORY REQUIREMENTS 6.0 PROJECT STANDARDS 7.0 OPERATING CONDITIONS 7.4 Site Data 72 Utility Data 8.0 | TECHNICAL REQUIREMENTS 8.1 General 8.2 Transition and Duct Burner Duct 83 Casing and Ductwork 84 Duct Burner 85 Heat Exchanger Modules 86 Stack 87 Instrumentation and Control Systems 88 Exceptions to Firebag Projects Standard FB-J-5406 8.9 General Requirements 8.10 Valves, Gauges, and Instrument Connections 8.11 Control Valves 8.12 Burner Management System (BMS) 8.13 Electrical Requirements UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-08) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 - 2.44.7 File Name: FE-F-5624 Rev_1_-. Heat Recovery. Steam_Gonerator (HRSG).DOC Page 2 0f31Suncor) TECHNICAL STANDARD ‘Subject Number: Revision: HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 9.0 PERFORMANCE REQUIREMENTS 10.0 INSPECTION AND TESTING 11.0 SURFACE PREPARATION AND PAINTING 12.0 INSULATION 13.0 SHIPPING, HANDLING AND STORAGE 14.0 SELLER DATA REQUIREMENTS APPENDICES Appendix 1 Gas Turbine Performance Data Appendix 2 Proposed Cogen Equipment Layout Appendix3 Boiler Feedwater Data Appendix 4 — Suncor Firebag Cogeneration Annual Gas Turbine Performance for HRSG Performance Calculations UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 -2-4-47 File Name: FB-F-6626 Rev_1_- Heat Racovory_ Steam Generator (HRSG}OOC Page 3 of 31Suncor) Ran CS NC PTT ENERGY TECHNICAL STANDARD Suet ‘Wamiber Raven HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 1.0 SCOPE OF STANDARD 1.0.1 This standard covers the minimum requirements for the design, supply, fabrication, installation and testing of once through type Heat Recovery Steam Generator (HRSG) unit(s). 2.0 INTRODUCTION 2.0.1 The HRSG will be a supplementary-fired unit, directly connected to the exhaust of a gas turbine (GT). The unit will be installed at the Suncor Energy Firebag facility located approximately 45 km NE of the Suncor Energy Upgrader Plant near Fort McMurray, Alberta, Canada. The HRSG will be installed outdoors with the control systems and attached piping located indoors, in a building attached to one wall of the HRSG. Burner control cubicles, control panels and other weather sensitive equipment will be installed indoors. 2.0.2 Any conflict between this document, codes, standards, regulatory requirements or other purchase order documents shall be brought to the attention of the Buyer for resolution before proceeding. 24 DEFINITIONS 2.4.1 “Seller” means vendor, supplier or manufacturer that supplies the materials and services. 2.1.2 “Buyer” means purchaser and is defined as Suncor Energy Inc., or its designated agent. 3.0 SCOPE OF SUPPLY 34 GENERAL 3.1.1 Seller's scope of supply shall include engineering, manufacturing, labor, materials, packaging and transportation, equipment and services required for installation, test supervision, and technical assistance for commissioning of one or more HRSG(s) with complete burner systems, and auxiliaries. The Seller shall supply all necessary materials and components, not herein specified, which makes the HRSG(s) a reliable working unit, in compliance with applicable Codes and Standards. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 2-44.7 File Name: FB.F.5624 Rev_ Hoat Recovery Sleam_Generator (HRSG) DOC Page 4 of 31"HERAG PROGANM = MECHAOUCAL DEPARTMENT SUN co TECHNICAL STANDARD ‘Subject ‘Number: Revision: HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 3.1.2 The HRSG(s) shall produce wet steam with a nominal steam quality of 75%. All calculations, 3.43 3.2 3.21 detail design, control system, and performance guarantee shall be based on the Seller's guaranteed average quality. Designs for steam quality higher than 80% are not practical because the quality of water treatment is sub-ASME quality. Close attention shall be paid to the susceptibility to scaling. Miscellaneous equipment, materials, controls/software, and services, not described in this, standard, but required for proper operation, control, monitoring and protection of the unit, shall be provided by the Seller. Each device's function and operational requirements shall be documented. The scope of materials and services shall be well defined in the Seller’s proposal. All proposed equipment and services, shall be listed in detail. These may include, among other items, full or partial transportation, equipment installation, commissioning, and testing. All terminal points and methods of performing services shall be indicated in the proposal. WORK BY SELLER The Seller's supply and related work shall include but not be limited to the following as a ‘minimum: a. Straight rectangular duct connecting the GT expansion joint (supplied by the GT Seller) to the divergent section of the HRSG transition duct that will clear the recessed location of that joint. b. Divergent transition duct to perforated plate. ¢. Firebox and mixing zone ducts to front row of heat exchangers. d. Duct burners complete with fuel delivery and regulating systems, logic and control strategies, panels, scanners, blowers, associated piping, and controls. @. Heat exchanger modules complete with appurtenances for transportation and field installation, and interconnecting piping between heat transfer modules. f. Insulated main casing, breeching, transition to stack, expansion joint, and stack, The main casing shall include connectors for attachment to a building where the pass control piping will be located. Stack shall include personnel protection insulation and provision for Continuous Emission Monitoring System (CEMS) equipment probes, stack damper, accesses and platforms. g. Trim required for operation, monitoring, control, safety, and operation of the fired HRSG including stop valves, outlet check and stop valves as a minimum. The outlet check valves shall be separate from the stop valves. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 — 24-47 Fille Name: FB-F-5624_ Rev_1 { Recovery. Steam_Generalor_(HRSG)DOC Page 5 of 31or) "FRERAG PROGRAM - MECHANICAL OEPARTINENT SUN TECHNICAL STANDARD Sabie Tambor Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 h. All necessary structural supports, accesses, and platforms. This will also include the framework for doghouse accesses and platforms. The doghouse will be supplied by the Buyer and located on top of burner area. i. Skid mounted wiring to a skid mounted terminal box for all the skids provided. j. Special interconnecting cables, such as for the BMS, igniters, or flame scanners. k. Start up and emergency blowdown pipe from steam line, including parallel slide type double block and bleed isolation valves. |. All pigging connections (separate connection for different size piping shall be supplied), m. Shop painting of all external surfaces and corrosion protection for transportation as required. n. Preparation for shipping, and shipping. Delivery location and method of transportation shall be included in Seller's proposal. ©. Chemical feed and pigging (Grayloc) connections. p. PSV's complete with drips and exhaust stacks. 3.3. OPTIONAL WORK 3.3.1. The Seller may quote the following optional work: a. a. Full transportation to site with unloading, installation and commissioning. The installation option should include stack insulation. Scissor lift for access to circuit equipment. Drain system (although the use of drains is not anticipated, the Seller may propose them if confident of the efficiency of its design). Additional stack height of 3m. In order to provide a fair bid comparison, these options should include estimated costing of the works. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 —2-4-4.7 File Name: FE-F-5624 Rev_1_- Heat Recovery Steam_Generaler_(HRSG)DOC Page 6 of 31Suncor) TECHNICAL STANDARD ‘Subject Number Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 4.0 WORK EXCLUDED 4.0.1 The following is excluded from Seller's Scope of Work. a. Site preparation. b. Concrete foundations with base plates for each column support, embedded pipe and conduit if required, grouting, and foundation bolts. ¢. Piping and wiring extemal to Seller's supply. d. Vents beyond Seller's supply, drains as applicable, chemical feed, chemical cleaning, water supply for hydrostatic testing, instrument air supply; and in general, piping, instrumentation, and materials beyond ASME Boiler and Pressure Vessel Code Section | classification. . Lightning protection, grounding, AC and DC electric power supply. f. Plant lighting, including stack lighting, g. Heat tracing, h. Pipe insulation. i, Emissions monitoring equipment. j. Basic Process Control System (BPCS), Safety instrumented System (SIS) and other instrumentation not in Seller’s scope, including all configuration and programming. k. Coordination of interfaces between HRSG and turbine. |. Building and Doghouse attached to HRSG. m. Stack insulation (under Optional Work, Section 3.3). ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 244-7 File Name: FE-F-S624 Rev__1_- Heat Recovery. Sleam_Generalor_(HRSG).DOC. Page 7 of 1,OR REBAG PROGRAI MECHANICAL DEPARTMENT Sun’ TECHNICAL STANDARD Subject Namiber: Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 5.0 CODES, STANDARDS, AND REGULATORY REQUIREMENTS 5.0.1 The HRSG and its auxiliaries and accessories, shall be designed, fabricated, tested and inspected in accordance with the latest applicable editions/addenda’s of the following: ABSA Alsi ANSI ASME ASTM AWS. cisc CsA EJMA, IEEE ISA Iso NBC NEC NEMA, NFPA OHSA ULC Alberta Boilers Safety Association American Iron and Steel Institute (for details not covered by CISC) ‘American National Standards Institute (B31.1, B31.3 and B16.5) American Society of Mechanical Engineers including Boiler and Pressure Vessel Code and Pressure Piping Codes ‘American Society for Testing and Materials (as applicable to materials used) American Welding Society Canadian Institute of Steel Construction Canadian Standards Association (including Canadian Electrical Code, B149.3 and W59 Welded Steel construction) Expansion Joint Manufacturers Association Institute of Electric and Electronic Engineers Instrument Society of America International Standards Organization National Building Codes of Canada National Electrical Code National Electric Manufacturers Association National Fire Protection Association (including NFPA 70 and NFPA 85 &% and Combustion Systems Hazard Code) Occupational Health and Safety Act, Province of Alberta Underwriters Laboratory of Canada, Inc ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-004 ~ 2.4.4.7 File Name: FB-F-5624 Rev__1_-. Heat Recovery. Steam. Generator_(HRSG).DOC Page 8 of 1oR) FREBAG PROORA - MECRICAL DEPARTIIENT SUNCOR TECHNICAL STANDARD SubeeE Number Revision: HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 5.0.2 Equipment and materials shall comply with applicable local and Canadian codes and standards, and governing local laws and regulations. 6.0 PROJECT STANDARDS 6.0.1 The equipment shall be designed, fabricated and tested in accordance with the following Firebag projects standards: Firebag Projects Standards: FB-A-5672 Plant Noise Level Control FB-A-5673 Equipment Protection During Transit and Storage at Jobsite FB-J-5403 Instrument and Control Panels FBJ-5404 Standard for Installation FB-J-5406 _ Instrumentation for Package Units Vendor Instructions FB-J-5419 Diaphragm Actuated Valves FB-L-5202 Piping Material Specifications (Note: This Piping Specification shall be lied to all work that is deemed non-ASME Section 1 Boiler External Piping) FB-L5203 Valves FB-L-5208 Thermal Insulation of Piping, Vessels & Equipment FB-L-5213 Positive Material Identification FB-L-5214 Painting FB-L-5217 Shop and Field Welding Requirements FB-M-5300 —_Civil/Structural Engineering Design FB.M-5301 Design of Steel Structures FB-M-5302 Furnishing of Steel Structures FB-M-5303 Erection of Steel Structures ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 2.44.7 File Name: FB-F-5624 Rev _1_- Heat Recovery. Steam_ Generator (HRSG).00C Page 9 of 31SUN cor) TECHNICAL STANDARD Subject ‘Nurmber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 FB-P-5502 _Basic Electrical Design FB-P-5506 General Electrical Installation Requirements FB-P-5552 _ Induction Motors 600 Volts and Below FB-P-5571 Package Equipment Electrical Requirements Engineering Standard Details: Drawing No. Title DD100D-M-1-1 Structural Steel General Notes Sheet 1 * DD100D-M-1-2 Structural Steel General Notes Sheet 2* DD100D-M-6-1 Structural Stee! Stairs * DD100D-M-7-1 Structural Stee! Handrail and Guardrail * DD100D-M-8-1 Structural Steel Ladders * DD100D-M-10-1 Structural Steel Floor * DD100D-M-11-1 Structural Steel Vertical Vessel Platforms * (*) Takes precedence in case of contradiction. 7.0 | OPERATING CONDITIONS 7A ‘SITE DATA 7.1.1 Refer to Site Conditions Data Sheet for additional information. 72 UTILITY DATA 7.2.1 Refer to Utility Data Sheet for additional information. Gas Turbine Data: See Appendix 1 — Performance Data See Appendix 2 ~ Proposed Cogen Equipment Layout Boiler Feedwater: See Appendix 3 — Boiler Feedwater Data 7.2.2 Seller shall specify minimum required feedwater pressure. UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 - 2-44-7 Filo Name: FB-F-5624 Rev_1_- Heat Recovery Steam Generator (HRSG).0OC Page 10 of 31[ OR FRAG PROGRAM WECHANTAL DEPARTMENT SUNCOR TECHNICAL STANDARD ‘SubecE Nomber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 8.0 TECHNICAL REQUIREMENTS 8.1 GENERAL 8.1.1 The HRSG shall be designed to the following requirements: a. Produce 75% quality steam at 11.03 MPa(a) downstream of HRSG isolation valve. b. Base design ambient temperature of 17°C at 60% relative humidity. c. Maximum duct firing temperature of 835°C at 17°C ambient. d. Exhaust approach temperature of 15°C or better at 835°C duct firing temperature and feed water temperature as defined on the data sheet. . Maximum gas side pressure loss at any fired condition of 340 mm HO, from GT exhaust to atmosphere (total to static) with no chimney effect. 8.1.2 The HRSG(s) shall be designed for constant steam production at any ambient temperature below 17°C. 8.1.3. The HRSG(s) shall be designed to operate, it continuously at gas turbine loads from 25% to 100%. supplementary fired or unfired modes, 8.1.4 Seller shall advise, in the submitted performance tables, the fouling factors considered in the performance calculations. 8.1.5 The duct bumer shall be designed for a NOx emissions guarantee of 38 g/GJ HHV or lower fired at all ambient and load conditions. 8.1.6 Near field noise level (1 m from any surface) shall not exceed a weighted average of 85 dBA at 1.5 m from grade. Exception to this requirement is allowed for the gas turbine exhaust connection area where the target maximum is 90 dBA. 8.1.7 The HRSG(s) shall be designed with adequate tube spacing, cavities and tube bank depth to allow for easy and proper cleaning, inspection, and maintenance access (including provision for scaffolding). Hand holes and manways shall be adequately provided. 8.1.8 The design shall be such that vibration is not detrimental to the integrity of tubes, piping, casing, and any other equipment. 8.1.9 The design shall permit boiler tubes to be mechanically and chemically cleaned. Pig connections (sending and receiving) and appurtenances to facilitate periodic pigging of all tube circuits shall be provided. Cleaning and draining shall be by pigging. A description of the connections for pigging shall be provided with bid. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 244-7 File Name: FB-F-5624, Rev_1_- Heal Recovery_Steam_Generator_(HRSG).DOC Page 11 of 31e FIREBAG PROGRAM ~ MECHANICAL DEPARTMENT INCOR Su! . TECHNICAL STANDARD ‘Sec ‘amber Revisor HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 41 8.1.10 Adequate margin shall be used in the support structure design to permit attachment of typical 81.411 8.1.12 8.1.13 8.1.14 8.1.15 8.1.16 8.4.47 82 8.24 8.22 8.23 piping connections to the HRSG(s). In addition, the casing shall be able to support the weight of a moderately heavy person with tools (120 kg) at any point. The Seller shall have the responsibility of choice of materials, however, materials to be used shall be submitted to Buyer for review and acceptance. Lifting and tailing lug designs shall be stamped by a registered professional engineer of Alberta in good standing indicating the safe working load. Lugs, their attachment welds and Parent metal shall be designed to carry their share of the applied load (minimum twice the equipment weight to account for dynamic effects) distributed in a reasonable manner and based on a minimum safety factor of 5 (based on ultimate tensile strength). In addition, lugs shall be designed for a minimum temperature of -45°C. Manufacturing design shall optimize size of parts and modules, in order to minimize site work and yet not compromise transportation requirements. Attention shall be paid to the site erection work, including equipment handling, termination types and locations. ‘Manufacturing methods shall be in accordance with applicable standards, using materials, welding procedures, correct for the application, and long-term component service life. The casing design pressure shall be a minimum of 1.5 times the maximum operating pressure (maximum GT exhaust flow operation with maximum firing). All valves, piping, fittings, and trim between boiler feed water main stop valve and the main steam stop valve shall be to ASME Boiler and Pressure Vessel Code Section |. Piping shall be to ASME B31.1. HRSG assembly and fabrication at site shall be carried out by an ASME accredited fabricator/contractor having the authorization to use ASME symbol stamp A. TRANSITION AND DUCT BURNER DUCT The duct from the gas turbine exhaust to the front of the heat exchanger tubes, shall include a straight duct section connecting the GT exhaust to the diffuser portion of the transition duct, diffuser duct with flow distribution perforated plate, duct burner firebox, and mixing duct. All parts of the duct shall be insulated and lined. The transition duct shall be of a shape best suited for making the flow as uniform as possible, asymmetrical shapes being allowed, as per experience and model testing optimization. The straight duct length will be defined for each case and its function is basically a distance piece to facilitate access to the gas turbine exhaust expansion joint, and or clearance of walls or equipment. UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 - 244-7 File Nome: FB.F-S624 Rev_1_-. Heat Recovery Steam_Generalor_(HRSG).DOC Pago 12 of 31INCOR Sur Y TECHNICAL STANDARD Subect Taambee Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 8.2.4 The duct system shall be designed to ensure the following: 8.25 827 8.28 8.3 8.3.1 8.3.2 83.3 8.3.4 ‘a. Acceptable flow distribution with minimal flow peaks, and no reverse flow areas downstream of the perforated plate, at all operating conditions. Straight flames from duct burner. Mixing zone with uniform outlet flow and temperature distribution. Liner design for long life operation with minimal deformation. ‘Adequate insulation and structural integrity. pans It is expected that the gas temperature distribution will not exceed 60°C just upstream of the front row of heat exchanger tubes. Assuming uniform steam distribution between passes, it is expected that tube wall temperature spread as measured on front row V-pads shall not ‘exceed 15°C with the unit in clean condition. The liner attachments shall be such that there will be no tearing or separation on any part of the liner plates. Particular attention shall be given to the attachments in the vicinity of the gas turbine exhaust, where turbulence is high. Long term liner deformation in the vicinity of the firebox shall be limited to 5mm at any point. Flow modeling shall be carried out by an experienced and reputable flow modeling company. The diffusion angles and perforated plate design shall be effective for different turbine operating conditions. The flow into the duct burner shall be as uniform as possible and the design of the firebox and mixing zone shall be supported by computational fluid dynamic (CFD) analysis by burner manufacturer. ‘The firebox design loading should not exceed 165 kW/m’ (approximately 16,000 Btu/ft*). The fire duct shall be provided with viewing windows to allow observation of the complete duct burner and firebox area. The duct walls downstream of the duct burner elements shall be essentially straight the only allowable area variation being for compensation of changes in gas density. CASING AND DUCTWORK The casing and ductwork system shall consist of gas tight outer casing, insulation and liner. The bottom of the casing shall be a minimum of 0.75 meters above grade for maintenance access. The Seller shall advise if a different value is required, for discussion. Outer, and inner casing design and materials shall be as per Seller's experience, and normal practice. The casing shall be sealed to be gas tight, including manways, and capable of withstanding 120 kg point load at any location. The liner shall be designed for long-term operation without damage or distortion. Expansion joints shall be provided where necessary, and these shall allow gas tight operation. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 2.44.7 File Name: FB-F-5624 Rev__1_- Heat Recovery. Steam Generator (HRSG).DOC Page 13 of 31OR ‘RERAG PROGRAM WECHINCAL OEPARTIENT SuNcoR TECHNICAL STANDARD Sabie amber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 41 84 DUCT BURNER 8.4.1. Acomplete duct firing system shall be supplied in accordance with NFPA 85. 8.4.2 _ Seller shall supply a duct firing system capable of burning any mixture of pipeline natural gas, rich fuel gas or produced gas. 8.4.3 The burner flow shall be modulated from 100% to 10%. There shall be no duct firing below 10% of burner maximum heat release. 8.4.4 Duct firing shall not exceed 835°C maximum under any operating condition. 8.4.5 Maximum burner heat release shall be 5% higher than heat release at duct burner design point, so that steam production can be constant at all ambient temperatures above 17°C, with the GT at full load. 8.4.6 Flame stability at all operating conditions, uniform fuel distribution, and freedom from vibration, are normal requisites for duct burner operation. Seller shall cooperate with the duct burner supplier to provide a reliable system, of burner and duct, with uniform flow and temperature at the outlet of the transition duct. It shall be the responsibility of the Seller to correct faulty operating characteristics of the burner / duct system. 8.4.7 The burner system manufacturer shall be a reputable company with extensive experience in ‘similar applications. 8.5 HEATEXCHANGER MODULES 8.5.1 The maximum heat flux shall not exceed 78 kW/m? (approximately 24,700 Btu/ft) at any point based on internal tube area, with design fouling factors included. The HRSG average heat flux shall be limited 51 kW/m? (approximately 16,000 Btu/ft’). Seller shall describe module configuration, tube location configuration (parallel or staggered), materials (tubes tube sheets, and fins), sizing, heat loads, etc with bid. 8.5.2 The front row tubes (bare tubes) shall be provided with thermocouples (V-pad type). There shall be two thermocouples per pass judiciously located so that metal temperature deviation monitoring is effective. 8.5.3 Fin type and spacing is left to the Seller's discretion and experience, however the following requirements shall apply as a minimum: Fin height and material shall be such that no excessive temperatures occur. Spacing shall be adequate to avoid fouling. Fins deformed during transportation shall be straightened. Fin thickness shall be adequate for any support stresses likely to occur. peace ‘UNCONTROLLED DOCUMENT WHEN PRINTED (91-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 — 2.4.4.7 Fle Name: FB-F-5624_ Rev_1_- Heat Recovery_Steam_ Generator (HRSG).0OC Page 14 of 31Suncor) TECHNICAL STANDARD Subjece 854 8.5.5 86 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 86.6 8.6.7 86.8 Nuanber Revision: HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 Seller shall provide with bid, information pertaining to tube support, vibration restraint, and tube end elbow design to avoid erosion. Tube diameters shall be such as to permit 45% turndown from maximum to minimum steam flows. STACK The stack shall be supported at grade. Stack height shall be 27 m from grade. The stack shall be designed as per intent of ASME STS-1-2000 Steel Stacks. A minimum of 3 mm corrosion allowance shall be incorporated into the stack design. The Seller shall furnish four environmental sampling ports in the exhaust stack at 90° intervals around the stack circumference. Each environmental sampling port shall be equipped with a stainless steel NPS 4 class150 ANSI raised face flange and blind flange. Buyer will advise ‘sampling port elevation. Additional CEMS sampling ports shall be provided for installation of Buyer supplied Continuous Emission Monitor. The Seller shall locate the sample ports in accordance with Alberta Environmental Protection (AEP) Stack Sampling Code, Method 1, and the AEP — Continuous Emission Monitoring System Code. Buyer will provide the information and details on the CEMS equipment. Ports shall be flanged (not screw caps). The stack sample port access platform shall encircle the stack over 360 degrees. It shall be designed to allow installation and maintenance of the emission analyzers and monitors, as well as the installation and removal of standard sampling probes. To do this, four platform wings shall be provided, one below each sampling port. Each wing. shall extend approximately 2.5 m radially from the stack wall. The platform assembly shall include access ladders and a davit for hoisting the sampling equipment. ‘Ateas requiring personnel protection include the area from grade to the damper, the area 2.5m above the stack sampling port platforms, and the ladder area to the platforms. Insulationfexpanded metal guard will be by Buyer. Seller shall provide clips for mounting insulation/expanded metal guards for personnel protection The stack shall include a non-modulating motor driven multi-bladed isolation damper system Open/Close hermetically sealed limit switches shall be included. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 — 2.44.7 File Name: FB-F-5624_ Rev_1_- Heat Recovery. Steamn_Gonerator_(HRSG).DOC Page 15 of 31Sun cor) TECHNICAL STANDARD ‘Subjeck Naber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 a7 8.7.1 87.2 87.3 87.4 87.5 88 8.8.1 8.8.2 INSTRUMENTATION AND CONTROL SYSTEMS Based on experience with scaling, the steam quality on any pass would never exceed 80%. Taking into account control deviations from one pass to another, the normal design shall be based on 75% quality with deviations of up to -3% and +5%. The control system shall be designed to insure that steam quality is kept at all times within these acceptable limits. The flow rate control system shall be based on an analytical thermodynamic heat balance basis. The Seller shall supply all field instrumentation, including control of firing and pass quality, and propose the control strategies that are mutually acceptable with the Buyer and Seller. The Seller is encouraged to use standard equipment and procedures to the maximum extent practical in order to supply the most economical equipment, which satisfies the requirements of this specification. Instrumentation shall be industrial quality of the latest proven design, and shall be selected to achieve the highest level of plant availability and ease of equipment maintenance. The following shall be made note of in conjunction with Firebag Projects Standard FB-J-5406 - Instrumentation for Packaged Units, Seller Instructions. EXCEPTIONS TO FIREBAG PROJECTS STANDARD FB-J-5406 The following standards noted in Firebag Projects Standard FB-J-5406 are not cons relevant to this standard: Suncor OSG 0112 Controlled Engineering Record Numbering Suncor OSG 0113 Equipment Numbering FB-L-5201 Plant Layout Standard FB-J-5401 Process Instrumentation and Control (Instrumentation) FB-J-5402 Instrument Identification and Numbering FB-J-5418 Design and Installation of Pressure Relieving Systems CSA C22.1 Canadian Electrical Code and ANSI B40.1 Indicating Pressure and Vacuum Gauges shall be complied with, ‘UNGONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JI EWR 100-2004-001 — 244.7 File Name: FB-F-5624 Rev_1_- Heal Recovery. Steam_Generator_(HRSG) DOC Pago 16 of 31SUNCOR TECHNICAL STANDARD Subject umber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 8.9 GENERAL REQUIREMENTS 8.9.1 The Buyer Basic Process Control System (BPCS) is Emerson Delta V. 8.9.2 The Buyer Safety instrumented System (SIS) is Triconex Tricon. 8.9.3 _Ingeneral, instruments interfacing the BPCS shall be Foundation Fieldbus compatible. Where this is not possible, they shall be 4 — 20 mA/ HART. Instruments interfacing the SIS shall be isolated 4 - 20 mA/ HART. 8.9.4 Drawings and equipment shall bear Buyer's project standard Instrument tagging conventions as assigned by Buyer. 8.9.5 Instrumentation supplied as part of the Seller package shall be consistent with Buyer's approved Seller List or be approved in writing by Buyer. 8.9.6 Electronic instruments and instrument systems shall be approved by CSA, ULC or cUL. Installation of electronic instrument systems shall comply with the requirements of the Canadian Electrical Code (CSA, Standard C22.1). Instruments shall be wired to terminal boxes located at the Package boundary. Instruments shall be capable of reliable operation at site conditions stated herein, preferably without winterization. Where winterization is required, electric heat tracing and insulation, enclosures, etc. shall be provided. 8.9.7 _ Inline instruments, including analytic without requiring a unit shut-down. |, shall normally be removable from the line for servicing 8.9.8 _ Individual Buyer instrument data sheets shall be completed by the Seller for each instrument provided within the HRSG package, including duplicated instruments. 8.9.9 Calculation sheets shall be provided for all relief valves, control valves and flow elements. All relief valve calculations shall be stamped by a Professional Engineer of Alberta in good standing. 8.9.10 Instruments shall not be made redundant unless otherwise required by code, or to achieve the stated project availability requirements, or operating objectives. Redundant instruments, where required shall be installed and wired as completely separate devices with individual sensing taps and isolation capabilities. 8.9.11 Seller shall be responsible for providing the control logic diagrams and control algorithms to meet all performance guarantees and warranties associated with the HRSG. Buyer will provide the control systems (BPCS & SIS) and configuration services to implement Seller's control requirements. Seller shall provide assistance and approval during implementation and testing of the control systems. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (51-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 ~ 2.4.4.7 Fle Name: FB-F-5624_Rev_1_- Heal Recovery_Steam_Generator_(HRSG).DOC Page 17 of 31Suncor) TECHNICAL STANDARD ‘Subject Tambor: Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 8.9.12 Buyer's BPCS and SIS will be utilized to implement the monitoring and control of the HRSG, including the initiation and shutdown of the duct firing by providing signals to the Seller supplied BMS. 8.9.13 All required temperature sensors shall be provided by the Seller. 8.9.14 Thermocouples (except those for tube metal temperature), RTDs and thermometers shall be furnished with thermowells to allow removal of the instrument during operation, 8.9.15 Thermowells shall be per Firebag Projects Standard FB-L-5202 for the piping class and material 8.9.16 RTD's shall be 3-wire, platinum type rated at 100 Ohms at 0°C. 8.9.17 The Seller shall provide sample ports and valved instrument connections for required instruments used in performance testing per ASME PTC 4.4 and Paragraph 5 of this specification. This shall include thermowells for monitoring gas temperature. 8.9.18 Pressure, differential pressure and flow devices shall be installed to permit maintenance calibration in place without removal of the instrument or disconnection of process tubing. 8.9.19 The Seller shall furnish individual instrument shut-off / isolation valves with means for maintenance calibration of the instrument. Differential pressure devices shall include 5-valve manifolds. 8.9.20 Instrument fittings shall be double compression type stainless steel with 316 stainless stee! tubing. The use of flare type tubing fittings is not acceptable. 8.9.21 The Seller shall attach permanent stainless steel tags with Buyer's tag numbers. Tags will be fastened with stainless steel wire. 8.10 VALVES, GAUGES, AND INSTRUMENT CONNECTIONS 8.10.1 The Seller shall provide all valves, gauges, and instruments within the Seller boundary. Instrument root valves and miscellaneous vent, drain and fill valves required for proper operation and maintenance of the boiler or required by the ASME boiler and pressure vessel code shall also be included. All valves shall be ANSI rated unless stated otherwise elsewhere in this specification. 8.10.2 Seller shall provide motor operated main steam block, boiler feed water block valve and steam blowdown vaives. 8.10.3 Full pressure double block and bleed isolation valves shall be supplied for each gage, instrument, drain, vent, sampling and blow-off 8.10.4 The safety relief valves clw drips, vent stacks and silencers shall be located within the Seller's boundaries. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JP! EWR 100-2004001 - 24.4.7 Fle Name: FE-F-5624_Rev_1_-. Heat Recovery. Steam Generator (HRSG).DOC Page 18 of 31SUN ) TECHNICAL STANDARD | Subjeat Tambor Revision: 8.10. 8.10. 8.11 8.11. 8.11. 8.11. att att att HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 5 Steam safety valve bodies, pipe spools, and nozzles shall be of compatible materials with the headers. Safety vaives shall be fumished with drain lines. Vent stacks will be by Buyer. 6 Control valves equipped with actuators (non-manual valves) shall be specified so that the valve will move to a safe position in the event of a failure of the actuator, or the loss of instrument air, electric power, or control signal as appropriate. CONTROL VALVES 1 Control valves shall be designed in accordance with the requirements of ANS! B31.1, ASME Section 2 or Section Vill, as applicable. .2 Motor-driven control valves shall have a motor drive compatible starter, with a 4 - 20mA analog output. Operators shall include end of travel limit switches and 4 - 20mA position feedback. 3 The Duct Burner fuel flow control valve shall be supplied with a mechanical stop for minimum firing position. 4 Control valves, which are smaller than the line size and employ reducers, shall not be used in horizontal runs, which are sloped for continuous draining. Drains shall be provided at additional low points created by the valves. 5 The required direction of flow shall be cast or stamped on the body of check and control valves. 6 Modulating control valves shall be equipped with pneumatic actuators. 812 BURNER MANAGEMENT SYSTEM (BMS) 8.12.1 The Seller shall provide a single local BMS control cabinet with all components required by NFPA 85 and in accordance with CSA B149.3. The local control cabinet will be located on or near the burner fuel gas skid and will be hard wired to Buyer supplied BPCS and SIS systems to allow for the supervisory start up and monitoring of OTHRSG purge, igniter starts, main burner start, igniter restart, main burner restarts, trips, and lamp test. In addition, a local Human Machine Interface (HMI) will be required to provide complete control and monitoring from the local control cabinet. Control cabinet shall be suitable for the area classification that itis located in ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004001 - 244-7 File Name: FB-F-5624 Rev _1_.. Heat Recovery Steam Generator (HRSG)0OC Page 19 of 31Suncor) TECHNICAL STANDARD ‘Subject HEAT RECOVERY STEAM GENERATOR (HRSG) Tanber Resision FB-F-5624 4 8.12.2 As a minimum, the following indicating lights and switches shall be furnished on the local panel or HMI: Lights Power On Limits Complete Purge In Progress Purge Complete Ready to Start Main Gas Shutdown Valves Energized Flame Detected (one per flame detector) First Out - Cause of Trip GTOn Low Scanner Cooling Air Minimum Fire Posit Pilot Block Valve #1 Open Pilot Block Valve #2 Open Pilot Vent Valve Closed n Burner Block Valve #1 Open Burner Block Valve #2 Open Burner Vent Valve Closed Pilot Burner On (one per flame detector) Pilot Ignition Unsuccessful Pilot / Burner Flame Failure Burner On (one per flame detector) Bumer Ignition Unsuccessful Burner Failure Fuel Gas Pressure Low ‘Amber Green Green Green Green Green Green Green Green Red Red Green Red Red Amber ‘UNGONTROLLED DOCUMENT WHEN PRINTED (41-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 2-4.4-7 File Name: FE-F-5624Rev__1_-. Heat Recovery. Stearn_Generalor_(HRSG).DOC Page 20 of 31Suncor) FREE RECA NECINEA CEPT EWERGY TECHNICAL STANDARD Subjeak Tamar vio HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 Lights Indicating Colour Fuel Gas Pressure Low Low Red Fuel Gas Pressure High Amber Fuel Gas Pressure High High Red Local Shutdown Red Remote Shutdown Red Hand Switches + Purge Start © Pilot Ignite Burner Ignite * Alarm Acknowledge * Alarm Reset © Shutdown «Lamp Test 8.12.3 The cabinet enclosure shall be NEMA 4X as a minimum. 8.12.4 The Burner Management System (BMS) shall be TUV approved for Safety Integrity Level (SIL) 2 application. 8.12.5 The BMS system control shall be capable of 10:1 turndown. 8.12.6 Accontrolled reduction of electrical load will result in a GT run-back to the full speed, reduced load condition. A control signal indicating the ‘loss of electrical load" condition will be generated in the GT and made available to BMS logic. 8.12.7 Specified data shall be provided to Buyer's balance of plant control system for monitoring and historisation. Buyer’s standard Modbus RTU serial communication protocol over RS-485 shall be used. 8.12.8 Seller shall verify communications compliance with the Delta V BPCS and shall take full responsibility for operability of the communications link to the BPCS. Full functional testing of ‘communications links shall be completed at the BPCS staging site prior to shipping the unit control systems to site. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 24.4.7 Fie Name: FBL-6624 Rev_1_-. Heat Recovery. Steam Generator (HRSG)DOC Page 21 of 31Y ) TECHNICAL STANDARD ‘Subject Naber Revision HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 4 8.12.9 8.12.10 8.12.11 8.12.12. 8.12.13 8.12.14 8.12.15 8.12.16 8.13 8.13.1 8.13.2 8.13.3 8.13.4 Panel-mounted scanner UV signal strength indicators shall be provided. The flame safety system logic shall include all applicable required safety interlocks recommended by NFPA 85 and CSA B149.3. All other required duct burner trips, shall be developed by independent switches. A manual shutoff panel switch shall be provided for emergency shutoff of the burners. BMS logic shalll generate all required alarms. Buyer's BPCS and/or SIS will monitor and trend NFPA 85 required analog process variables. Detectors shall include a vibration absorbing mount and be provided with a “self checking” feature which continuously checks all components from the ultraviolet detector to the output relay at least once every six seconds without affecting the response time of the detector. A three (3) second response time with a 1.25 V minimum is required. A failure of the gas valve limit switches shall alarm, but not trip, the duct burners. A Manual ‘Supervisory Valve complete with Limit Switches shall be included on the Duct Burner Supply. Reset from a shutdown condition shall not be automatic and shall be initiated locally. Control cabinets shall provide shielding to protect from electromagnetic interference. ELECTRICAL REQUIREMENTS All electrical equipment and systems fumished shall meet the requirements of the Codes, Standards, and Regulatory Requirements listed in Section 3.0 and in the attached Standards. All electrical equipment and systems furnished shall bear the label or listing of the Canadian Standards Association (CSA) or Underwriters’ Laboratories of Canada (ULC). Equipment or devices which must be located in high temperature areas shall be designed and rated for the service temperatures where located. Seller shall furnish grounding lugs or other provision for grounding all electrical equipment and metallic structures. All bonding and grounding conductors between equipment and ground grid will be supplied by Seller. UNCONTROLLED DOCUMENT WHEN PRINTED (31-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 - 244-7 cr FB-F-5624 Rev_1_- Heat Recovery. Steam _Generator_{HRSG)DOC Page 22 of 31Suncor) a ON NEUTER BST TECHNICAL STANDARD Subjeck Number Revision: HEAT RECOVERY STEAM GENERATOR (HRSG) FB-F-5624 1 8.13.5 Electrical cables shall reliably withstand normal and abnormal voltages, environmental effects, and have the required ampacity per CSA Code requirements. The following criteria shall be followed: a. Special consideration shall_be given to cables run in areas where the ambient temperature will exceed 40°C for cables installed in conduit. In general, cables shall be suitable for the temperature and environment where located. b. MI cable shall be utilized, if necessary, where located in hot environments exceeding 150°C or as per Seller’s recommendation. ¢. In multi-conductor cables with an overall jacket, AC and DC voltages shall not be mixed. d. Control cables shall have a minimum of 20% spare conductors. e. Control wiring shall be designed to minimize terminations. 8.13.6 Cable trays and conduits shall meet the requirements specified in Firebag Projects Standard FB-P-5502. 8.13.7 _In addition to Firebag Projects Standard FB-P-5502, separate cable trays will be provided for different voltage levels. Cable tray systems shall be divided, as a minimum, into distinct levels as follows: a. Low voltage power (including 208 V and 120 VAC) and control (including 120 VAC and 24 VDC digital circuits). b. Low level signal (instrumentation and communication). ¢. 600 V power. 8.13.8. All induction motors, including terminal boxes, supplied by Seller shall meet Firebag Projects Standard FB-P-5552, 575 V rated motors shall be supplied for motors from 3/4 hp up to and including 250 hp. 8.13.9 Electrical equipment mounted on the burner fuel gas skid and HRSG duct firing system shall be suitable for use in Class 1, Zone 2 hazardous area. The same requirement shall apply for the BMS control cabinet. 8.13.10 Each electric valve actuator shall be equipped with a motor operator (with motor starter built in) acceptable to Buyer. 8.13.11 The electric valve actuator shall be selected to start, accelerate, and stop the valve in either the opening or closing direction under maximum unbalanced pressure, within the travel time specified, with the lowest specified starting and running voltage. 8.13.12 Seller shall provide the actual speed of opening and closing for each actuator. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (61-Jan-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 —2-4-47 File Name: FB.F-5624 Rev_1_-_Heal_Recovery_Steam_Generator (HRSG).DOC Page 23 of 31