Suez Oil Company Intercompany Memo Ret: 944/22 To :C.8T. Board From : O-1 CC: 0-10/0-40/0-70/ C-1 Date : 26/12/2022 Subj. : ZB turbines control & excitation systems upgrade SUCO operates 4EA T8500 gas turbines generators & other GEA units in service for gas plant production facilities at Zeit Bay field. During lst few years, we experienced difficulties to obtain spare parts or to repair defective parts of control system; as most of parts are obsolete or no longer supported, to maintain our turbines operation. So we plan to upgrade turbines control system, upgrading job has been already performed successfully for four units “3 in power generation units & 1 in gas production”. Upgrading the control system package based on the similar Allen Bradley control logix, vibration, fire & gas system of the already upgraded units to achieve reduction & unify in spare parts stock. Based on the attached scope of work and TRF (include the recommended bidders) your kind approval to issue a tender to proceed with the subject as soon as possible for a lump sum offer (supply materials, installation, commissioning and start-up) to upgrade the following:- - Ruston TB5000 gas turbine driven generator (GT-10010) with estimated funds $900,000. - Ruston TBS000 gas turbine driven compressor (GT-2502 HPI) with estimated funds $500,000. - Generator control panels (4 panels) for power generators with estimated funds $200,000. Suco standard’ terms and conditions for such services are to be applied. Attachments: -Tender request form to C. &T. Board ~ Suco’ Scope of work. ~ Copy of the approved requisitions. “Ahmed Farid Operations General Manager And Board Member PagetTENDER REQUEST FORM (TRF) / FOR SERVICES PART (A) - INFORMATION TENDER SUBJECT: ZB turbines control & excitation systems Upgrade - REQUESTED STARTING DATE OF CONTRACT: 15.1. 2022. - TYPE OF CONTRACT (LUMP SUM - UNIT RATE ~ etc...): | - PROPOSED CURRENCY OF PAYMENT ( IF NOT INCLUDED IN E.GP.C LIST): uu 8% - IF ABACK UP CONTRACTOR IS REQUIRED: YES ~ -NO--- (IF YES PLS. JUSTIFY) - IF A PERFORMANCE GUARANTEE IS REQUIRED: YES~—--- NO-- JUSTIFY) ~ (IF NO PLS. | - IF ATECHNICAL EVALUATION IS REQUIRED: YES-----—- NO— - EST COST OF THE TENDER: $ 1,600,000 PART (B) - SCOPE OF WORK AND SCHEDULE OF PRICES (BRIEF DESCRIPTION OF THE | WORK AND / OR SERVICES TO BE UNDERTAKEN) DETAILED SCOPE OF WORK AND SCHEDULE OF PRICES IS ATTACHED (TO BE PREPARED AS AN ANNEX WHICH COULD BE USED AS AN INTEGRATED PART OF | | THE CONTRACT) } i ee a ie g ge aePART (C) - PROPOSED TENDERERS (FULL AND EXACT NAME) 4- Name: Siemens 2 Fax No.: 02 26143399 PART (D) - TENDER EVALUATION PLANE FOR TECHNICAL OFFERS — (IF ANY) DETAILED PLAN IS ATTACHED (IF ANY) PART (E) - SIGNATURES weT Deparment] OPERATIONS Dion, ‘ >. | Engineering Oepartmem 2B turbine control & excitation systems Upgrade [aaaaon Tp Page: | Page 10f 13 Scope Of Work ss ge? [Date ZB turbines control & excitation systems Upgrade Part |: GT-1001D Control system Upgrade Part Il: Manual Excitation replacement Part Ill: GT-2502HPI Control system Upgrade see Beer Page 1 of 137a T Department] OPERATIONS Dion oo inerraDesormens | 2B turbine control & excitation systems Upgrade - a | Revision: | 0 Page: | Page 20f32 Scope Of Work prose: _} Page? ane : Date 3 1. Introduction Suez oil company (SUCO) has a generating plant consists of four TB5000 Gas Turbines tagged “ GT-1001A/8/C/D" that drive a 3.3KV Generators at Zeit Bay field on the Red sea in Egypt “as shown in Figure 1”. 0 Oo ETL Figure 1: 2/8 Power Station simplified Single Line Diagram Three of those units have an upgraded control using Allen Bradley Control Logix PLC. Unit O still has the original control from Ruston. All units have old manual excitation systems. The automatic excitation system of each unit was upgraded to use CGCM device from Allen Bradley. ‘The PMS system was upgraded to use Allen Bradley PLC Control Logix as the PMS controller. Please note that the power station has two sections bus bar (bus A and bus 8) with a bus coupler. The power station works with the bus coupler closed that is one bus bar system. However, depends on the operator's discretion, the power station can work with open bus coupler, that is two bus bars operation. The CGCM devices are controlled and accessed by the PMS PLC via Control Net. The Redundant Control Net cables were connected in daisy chain that is from the control room to unit A, to unit B, to unit C then as|ast node unit D. as shown in Figure 2. sie Page 2 0f13Separmang| PRIOR Dn i - | egussy eect 2B turbine control & excitation systems Upgrade Taovaons te Page: | Page3 of 13 Scope Of Work sg - PLE RACK Control Room Unit € Excitation Unit D Excitation Compartment Compartment lerA0016 jort001D Unit A Excitation Compartment or-s0018 or-t0018 Figure 2: old Control Net Now, the philosophy is changed and CGCM is controlled directly through Turbine PLC , otherwise turbine “D” is controlled by temporary Allen Bradly plc chassis installed in generator panel until execution of the turbine Upgrade to add the logic to turbine controller, and the PMS controller and turbines’ PLC is communicating through Ethernet network. On other hand , six TBS000 Gas Turbines that drive centrifugal compressors are existing at the same site “ Zeit Bay field” for gas injection & LPG production facilities , the turbine control upgrade for one of these turbine units GT-2502 HPI “ high pressure compression unit “ is a part of this scope of work 2. System Description 2.1. Power Management System “PMS” The old PMS, microprocessor-based system, was upgraded couple of years ago to PLC-based system. ‘The upgraded PMS is using Control Logix PLC to execute the PMS algorithms to manage & monitor the operating of four generation ¢ Ee Page 3 of 13] - Department rneing Deparment 28 turbine control & excitation systems Upgrade [Revisions [0 P | Page of 3 Scope Of Work a = = [Date 2.2. Power Generation Turbine Control The unit sequence, starting, accelerating, loading and unloading, engine control, fuel control, unit protection, etc. are managed by the Control Logix PLC in each unit (A, B and C). Unit D still has the original control system from Ruston “the subject of upgrade”. Each unit (A, 8 and C) has HMI located inside its control compartment. Each PLC and HMI has a dedicated IP address, 2.3. Excitation System ‘The excitation system has two main parts, the automatic excitation part and the manual excitation part. The automatic excitation part of the system was upgraded to Combined Generator Control Module (CGCM) from Allen Bradley. The manual excitation part of the system still using the old components. The excitation supply is a single-phase PMG that supplies both the Automatic Excitation and the Manual excitation systems. Figure 3 shows the schematic of the current excitation system. ge Page 4 0f 13‘OPERATIONS Division nginering Deparment oO Page § of 13 Department] ZB turbine control & excitation systems Upgrade Scope Of Work 2.3.1 Manual Excitation System The old manual excitation system is still in work. Its main function is to provide a back up to the automatic excitation system in case of CGCM failure or if required by the operator (during system maintenance and/or testing for example). The manual excitation system is tracking the automatic excitation system so in case of losing the automatic excitation system, in this case the CGCM device, the manual excitation system will keep the excitation at the last value. The transition from the automatic to the manual is 2 bumpless. The operator can control the excitation manually after the transfer to manual mode. 2.3.2 Automatic Excitation System The excitation systems of all units were upgraded years ago to use Allen Bradley Combined Generator Control Module (GCM) ‘The CGCM device is connected to the turbine PLC via a Control Net. All the operations of, reading from and writing to the CGCM devices are controlled by the turbine’s PLC vie the Control Net. Figure3 Shows how the automatic part and the manual part are interfaced to each other, to the generator and the control system. Both parts (manual and automatic) are supplied from a single-phase PMG. 2.4 Gas Compression Turbine Control GT-2502 HPI unit the subject of upgrade is one of eight units for gas injection & LPG facilities at Zeit Bay field, It is the same model of the generation set "TB-5000” but drive two stage dresser centrifugal compressors, the turbine package has the original Rustronic control system, which control & monitoring the turbine in addition to monitoring the parameters of compressor like vibration & temperature levels but the surge control of compressor is not included. 3. Scope of Work The required scope of work has three parts as described below. Part |: Unit D Control Upgrade Upgrade the turbine control of unit 0 will be like other units. The new control must be Allen Bradley Control Logix based system. Other types will not be accepted. Allen bradely HMI must also be provided. “The following points summarize the required upgrade of unit-D upgrade’ 1) The required system will be similar to pervious upgraded units, as in control system components guide in the end of the scope of work so Ow Page 5 of 13‘OPERATIONS Dion Engineering Department 0 = | Department 2B turbine control & excitation systems Upgrade Revisioi Page: | Page 6 of 13 Scope Of Work ae | 2) To guarantee the continuity and technical support of system hardware, the following will be taken in consideration : ~The newest model of processor card will be accepted. - The communication between PLC & I\Os Flex modules through Ethernet DLR instead of ControiNet - The ControlNet module will kept for CGCM module, any other communication topology will be subject of approval by SUCO and Rockwell. = Any new offered component will be subject of contractor justification and SUCO acceptance & approval. 3) The required upgrade system will replace the chassis from 1 through 6, A through C and the DC Contactor Cabinet. 4) PLC software will be Allen Bradley RSLogix V20, HMI software is Factory-Talk View Studio V8 5) A new vibration system using Bentley Nevada 3500 system will replace the existing old vibration system “Rochester system’. In addition to new barriers, sensors and new wiring might if required. 6) HMI Panel from Allen Bradley with Factory Talk Site edition is required for the Human Machine Interface Project. 7) HMI screens will have two levels authorization for operating & maintenance and will be similar to unit A\B. 8) A replacement of the old fire and gas system, including the gas and UV detectors through LON network. SUCO requires the updated versions of the Detronics System. 9} To replace skid equipment and wiring as required to accommodate the new control system. 10) The new system must be of the same panel architecture as of units A through C. 11) A laptop must be supplied with all software packages and the final versions of the application programs. 12) To Supply & install the required system (materials and software). The installation of the next part will start after successfully completing the above part with satisfactory operating performance. Part ll: Manual Excitation Upgrade of All Units Upgrade the manual excitation system. The following are the main required steps; 1) Provide a new design using up to date component “Basler Electric component is recommended “. 2) Demolition of the old excitation part. 3) Installation of the new manual excitation system. 4) All old components will be replaced including panel switches , Gauges, and pushbuttons , any old component will be kept in the new design is subject of Contractor justification and SUCO approval 5) Interface the new manual excitation component to the automatic excitation component by doing a complete wiring of the different component. Qn Page 60f 13.re Department] OPERATIONS Dion ; Ensietig Depimens 2B turbine control & excitation systems Upgrade “Taaaao. Te Page: | Page? ofi3 Scope Of Work & z 2 a eke : a Date 6) Check the wiring before powering up the system. 7), Power up the complete excitation system to check the voltages at different points. 8) Start up the generator and control its excitation manually. 9} Test the complete operation of the unit according to the approved test procedures. The start-up & Commissioning of Part | & Il of scope are completed after achieving the following: ~ Running GT-1001D upgraded control system is running successfully. = Running Manual Excitation systems successfully and switch smoothly. = Make all necessary modifications and tuning for all turbine units “A\B\C\D” governors to unify the droop and MW share responses. - Tuning turbines & PMS PLCs with CGCM units to achieve the best response for MVR share. from Auto to Manual mode Part Ill: GT-2502HPI Control system Upgrade The control system package will be Allen Bradley control Logix PLC based which will be built into a new control cabinet, and include fully configured Bentley Nevada BN3500, and completed fire & gas system. 1) To apply the same points from 1 to 12 at part | of Scope, taking into account this unit is drive a compressors in both hardware & software 2) The distance between the control room & turbine is about 70-80 meters, so supplying any new required cables are contractor responsibility and any civil work will done by SUCO. 4, SUCO Obligations 1) Full accommodation and local transportation of contractor personnel from/to SUCO job site. 2) First aid medical care for contractor personnel at SUCO job site. 3) All facilities required to perform the job at site excluded special tools and equipment. 5. Contractor Obligations 1) A site visit will be conducted prior to tendering for gathering all necessary details required in ‘the modification, Contractor shall provide preliminary project and vendor drawings of the proposed changes for company review. Company will not be liable for any inaccurate information that Contractor may gather. 2) Allist with numbers for each of the recommended spare parts and other consumables will be prepared. 3) The new supplied products will be on-line product for next 5 years ose Page 7ofisT OPERATIONS Dision - Department apnesng Depart 2B turbine control & excitation systems Upgrade TRaaon TO Page: Page 8 of 13, | Scope Of Work Saar op Date 1 4) The validity of spare parts and technical support of the new supplied system is to be confirmed 10-15 years. 5) The contractor will be responsible to check the supplied materials on site before starting the demolition of the old system 6) All new wirings should be numbered & color coded, and all devices will be labeled. 7) The contractor shall observe all safety rules for work, which may be issued by company. 8) The contractor will be responsible of all of site work starting from demolition of the old system, installing of the new system, cold loop checks, hot loop checks, start up, test run, training and ending with the hand over. 9) A project schedule must be supplied, discussed and approved by SUCO. 10) Contractor will be responsible for performing all the tests required according to FAT & SAT procedure: Factory Acceptance Test: * A factory acceptance test (FAT) shall be performed according to vendor test procedures. * Acopy of the test procedure shall be sent to SUCO for approval. Site Acceptance Test: * A copy for test procedure shall be sent to SUCO for approval before system delivery and prior to commissioning the system. The site acceptance test (SAT) shall be done after system installation, commi based on the actual approved SAT procedure. ¢ The SAT test report shall be included in the final site report as well as in the final system documentations. © The final site report will include any punch list items occurred during the SAT and jing any found defect or problem, troubleshooting any found malfunction shall be cleared and all system setting before the system handed over. * All inspection procedures and tests shall be witnessed by (SUCO) representatives based ‘on the agreed procedures after SUCO representative review and approve. 11) The contractor has to run the system for a suitable period as a load running test to observe the new control system performance. peas aX + joning, Page 8 of 13‘OPERATIONS DWsion T Tapa = Engine Deparment ZB turbine control & excitation systems Upgrade Taonaon Ps Page: _| Page 9 of13 Scope Of Work ao Paes 6. Warranty ~ Hardware warranty The contractor will warrants the hardware for one year starting from the date of start- up and not related to the shipment date. - Software warranty The contractor warrants that all software free of defects in design and workmanship ,and will perform accord to specs, and obligates to perform any necessary modification remedy system software bugs identified during two years starting from the date of start-up In addition to there are no security keys \passwords are set by contractor could obstacle the maintenance and\or has any bad impact on the operating of the system without SUCO acceptance 7. Documentation For each phase the contractor must provide the following main documents, where applicable 1), Project Master List. This document shows a detailed list of documents to be issue by the contractor. 2) Project Schedule, Kick-Off Meeting Information, time and agenda, 3) Project Progress Report. 4) System Architecture and System Input - Output List. 5) Control Panel Outlines and Wiring Schematics, 6) Control Narrative. 7) Vibration System Description (hardware and the configuration file) 8) Logic Source Code and HMI Source Code. 9) The Communication System Description, Schematic and list. 10) FAT & SAT test Procedures and Report. 11) Final “As Commissioned” Documentations. S a a we, Page 9 of 13= Depart raat ng Dea 2B turbine control & excitation systems Upgrade Fao iaon | ¢ ° eee Scope Of Work Page Pageioofis | 2 Date Appendix - PMS System Components Guide No. ~ Description Part Number 1_| Control Logix chassis 10 slots T756-A10 2 | Power supply 1756-PB72/8 3 | Control Logix Processor 5561 1756-161 4 | Dual Redundant Control Net 1756-CNBR 5 | Ethernet communication module 1756-ENBT 6 | Control Logix Digital Input 24 Vac, 16 channels 1756-1816 7 | Control Logix Digital Output 24 Vac, 16 channels 1756-OB16E [8 | Controt Logix Analog Input, 16 channels 1756-1F16 [3 | Controt Logix Analog Output, 4 channels 1756-OF4 10 | Control Logix Analog Input, 8 channels 1756-1F8 11 | Control Logix Digital input 24 Vdc, 32 channels 1756-1832 42. | Flexi/O Communication Adapter 1794-ACNRIS 13. | Flex 1/0 Digital Input 24 Vdc, 16 channels 1794-1816 14 | Flex /0 Relay Output, 8 channels 1794-OW8 15 | Combination Generator Control Module 1407-CGeM B. Gas turbine control system Components Guide = Allen Bradley Control Logix PLC system. No. Description Part Number 1 _| Control Logix chassis 7 slots 1756-87 osm te: Page 10 of 13x a | ZBturbine control & excitation systems Upgrade Fao a Scope Of Work rege: _} Page tict 2 Power supply 1756-PB72/B | 3 Control Logix Processor 5561 1756-L61 [a | Duat Redundant Control Net 1756-CNBR 5 Ethernet communication module 1756-ENBT [6 | CFM frequency input module 1756-07 7 Flex |/O Analogue input 8 channels ‘1794-1E8 & [Thermocouple input 8 channels 1794-118 | RTDinput 8 channels 1790-188 10 | Isolated analogue output 1794-OF4L 11 | 24 Vdc Input 32 channels 1794-1832 12. | 24 Vde Output 32 channels 1794-0832 | 13 | XM-220 Dual speed module 1440-SPD02-01RB | } - Bentley Nevada vibration system. No ‘Description Part Number 1 Rack 8 Slots 2 | Low voltage DC power supply 3500/15-04-00-01 3 Rack interface module 3500/20-01-02-01 4 Prox./seismic 4 channels 3500/42M-06-01 5 4 Channels relay module 3500/32-01-01 [| Communication gateway module 3500/92-04-01-01 7 | Internal barrier earthing module 2500/08 Qo Page 11 of 13] Se DBERATIONS Dison Department| iss Engineering SEpariment ZB turbine control & excitation systems Upgrade so Scope Of Work Page 32 of 13, = Detronics fire and gas system. Wo. Description Part Number 1 | EQ3001DCNW controller, DIN mount (007609-063 2 | €03730PW EDIO Module, Panel mount (009174-002 3 | EQ3700PW DCIO Module, Panel mount (007371-002 | Transmitter for 4-20 mA gas detector (006607-017 £022530CU standard digital communication unit 5 | Four UV detectors” Detronie multi-spectrum infra-red UV" © | Two gas sensors ” Det-ronic infra-red gas detector” ~The component of the panel. No. Description Manufacturer | Part Number 1 | HMIPC (AB 1500P) ‘Allen Bradley | 6181P-15TSXP 2 _| Selector switches Allen Bradley | 3 _| Push buttons ‘Allen Bradley al @ | Emergency stop push button (with guard) _| Allen Bradley 5 | Audible alarm ‘Allen Bradley © _ | Digital indicators for PTE GG speed Yokogawa 7 | Ethernet Hub— 6 port N-TRON 3 _| Digital output interposing relay Phoenix 9 | Zener Barriers MTL Sat Te"! Page 12 of 1328 turbine control & excitation systems Upgrade ] | Scope Of Work 8. Price Table 1. The Offer will be based on Lump Sum Basis. 2. The bidder to fil commercial offer sealed envelope. | Department] ‘OPERATIONS Dison Engineering Depar MB Revision: | 0 Page: Page 13 of 13 Date the following table of prices and to be submitted only in the Trem Description Price rer T001D Control system Upgrade and 1 | Manual Excitation replacement GT-2502HPI Control system Upgrade Total we Page 13 of 13OPERATIONS Dison = Deparonen = ‘ater est 2B turbine control & excitation systems Upgrade govicion: | 0 [rage: | Page 13 of Scope Of Work ne 8. Price Table: 1. The Offer will be based on Lump Sum Basis. 2. The bidder to fill in the following table of prices and to be submitted only in the commercial offer sealed envelope. Ttem Description Price GT-1001D Control system Upgrade and 1 | Manual Excitation replacement GT-2502HPT Control system Upgrade Total Page 13 of 13SUES OL COMPANY Te S340 EAN 33038434 +3346 CH 198991 eg, NO : 1070001268 46792 oer Tender Requisition ‘isthe. is eased t0 cover the cost of Power Generators Control Panels Vzrade REQ. Date 30972022, Ser, MESC DESCRIPTION Plant ay. fesm] unr Prorat REQ price [VALLES fi Povwsr Generators Control Panel Uae Zeit Bay fi ‘AU_| 200000.00 | 200000 00 Serial Service Deseription WBS / Cost Center ary [ory] Service | Curr twit | Price 10 | Porner Generators Control Panels upgrale pause. 06.20 100 | av [2000000] usp [ “Total Value 200000,00 LSD. assed dine of ora Fila Diekin ] CNRODNISON | FamserDanie | wns] MATERIALS FeRCINSNG Divistox Requester ‘Cou Acswum ED | Badgerconmt | When Applicable | Coding DEFT Paras Mer Pity ata me oa — ‘tats ty |) 2| omalitange | Do Teer Ew Ae Om n fa | ies bee Dee TSOFORSINO: | Dining Ge ee Sp pe PONS warsratanoa | peg Ort whe “ ayer r)Suez ou conpany PO, BOX 2522CA1RO ARE Tet 3M66a77.33460023 ia7sas-s3asso09 FAX 003604 3460971 Tender Requisition Rog. NO : 1070001262 REQ Date: 15/09/2022 {his Reg. is Raised to Cover the Cost of GT-1001D Contrl Stem Upgrade Sen] MESC DESCRIPTION Plant an. Jes] ex | torar REQ sice |vauves t {G-1001D Cont sestem upgrade Zeit Bay 1 ati | gon00n 00 ona 00 Seriat Service Deseription WBS / Cost Center cary [ary] Service | Curr. Unit | Price ie 1001 Contra stem apes DAIS. 06.15| 100 Tau [ooonooe [esp Tol V ‘qo0n.00 CS wwojeat fochaimen append Fad Divsien | CAIRODINISION | Finance Divhion MDs MATERIALS PURCHASING a DIVISION Tae Guacwns COLT alga Crmd | When Apptcabts | Coding beri. | Porc er at bas Daren Deparment send 26/9]p2 | Comat Nimes | Dae Texter oe bat Con nes Gon Mar PPPS tek Lng SwckCommat | Fign Ke Ease Pate Ta OR on iD HANAN Dat lal a TSOFORMNG: | Dion Gu Ne | F wel PON MATETA.NO1018 ae Bue ait [22* PO BUX 262.CAIROARE TEA S34677-34467022-33479080 SMTRISSMOS0 AN 33035434 334 CR: 198891 Cairo Rea. NO + 1070001832, This Requsition is raised for HP 1 Gi Tender Requisition 502 Control System Upgrade REQ. Date: 19/10/2022 Ser. MESC DESCRIPTION Plant ary. [ox] unr [tora REQ PRICE_| VALUES 1 LHP 1 FT=2502 Control system Lpgrade Zeit Bay 1 AUT scuonn 00 [sono00.00 Serial Service Description WBS / Cost Center ary [ary] service | Curr. Unit | Price io 502 Conical System upgrade D.073-01,06-40 100 [av [sooo [uso “Total Value 500000,00 USD silaye uk Fechadimas af PO Field Divison MDS MATERIALS PURCHASING DIVISION Roweser Com proomt When Applicable [Colin DPE. | Poche Mer. bafta tas Fine Date Deponee Peer Geral Ra ea Dav Tender i lol 2» Do Cont Ase ‘Gon Mer er THR a ‘Sek Control Fors Uhre | Qs Date Tiel MGR oa FD ini | Da Leal We Dus 180 FORM NO: Fl Bo darnahs PON MATA=74.1401-018, Hiine, [26/401 2022 Bee pote