Gas Conditioning Skid

NORTH-WEST POWER GENERATION COMPANY
LIMITED
BHERAMARA COMBINED CYCLE POWERPLANT (360 MW) DEVELOPMENT
PROJECT
Contract No. : BD-P71-14022
Owner’s Engineer
Joint Venture of
TOKYO ELECTRIC POWER SERVICES CO. LTD.
And
FICHTNER GmbH&Co. KG
EPC Contractor
MARUBENI CORPORATION
EPC Sub Contractor:

LARSEN & TOUBRO LIMITED
Contractor’s Consultant:
L&T–SARGENT & LUNDY LIMITED
Vendor:
GASTECH PROCESS ENGG. (I) PVT. LTD
Title:
OPERATION & MAINTENANCE MANUAL
Doc/Drg No.: BHE-L826-CQ02-01-EKE-86-0001-00 Rev.: P0 Pages :1-15
REVISION STATUS
Prepared Reviewed Approved
Detail / Prepared Name / Sign
Rev. Name / Name /
Description Date General
Sign Elec Civil C&I SES Sign
Document
FOR Rahul Sunny Sunny
P0 14-APR-16 -- --- ---- ---
INFORMATION RAJ AHUJA AHUJA
Notice:
√ We declare that the document is prepared in accordance with the Contract except the item
specifically highlighted are deviated from the Contract and also declare that the document is
ready for use
√ Specially highlighted deviations are included in attached Deviation sheet

GasTech®
Process Engineering (India) Pvt Ltd.
GASTECH PROCESS ENGINEERING(I) PVT. LTD.
OPERATION AND MAINTENANCE MANUAL
OWNER: NORTH WEST POWER GENERATION COMPANY LTD.
CLIENT: LARSEN & TOUBRO LTD.
PROJECT: BHERAMARA COMBINED CYCLE POWER PLANT (360 MW)
DEVELOPMENT PROJECT
CONRACT No: BD-P71-14022
Doc. No.: BHE-L826-CQ02-01-EKE-86-0001-00
Rev No: P0
Dated: 14.04.2016
1/14
CONTENTS
1.0 EQUIPMENT DESCRIPTION
2.0 SAFETY
3.0 EQUIPMENT INSTALLATION
4.0 OPERATION OF FGCS
5.0 MAINTENANCE OF FGCS
6.0 FUNCTIONAL TEST PROCEDURE
7.0 TROUBLE SHOOTING
2/14
1.0 EQUIPMENT DESCRIPTION :-
Fuel Gas Conditioning skid is controlled from DCS, located in control room in control building.
The Fuel Gas Conditioning System consists of the following equipment:
MODULE-1
(1) Emergency Shut Down Valve, 1 x 100%

(2) Knock-out Drum, 2 x 100%
(3) Fuel Gas Condensate Drain Tank, 1 x 100%
(4) Nitrogen Purging System
MODULE-3
(1) Horizontal Filter Separators, 2 x 100%

(3) Cold Vent Stack
The gas available from Remote Monitoring station (RMS) is used as the fuel gas
source for the Fuel gas conditioning system.
The Fuel Gas Conditioning System shall be sized to meet the fuel gas requirements of
Gas Turbine. The system shall remove 100% of solid particles and liquid droplets of
size 10 micron and larger in knock-out drum; 100% of solid particles and liquid droplets
of size 5 micron and larger & 99.98% of solid particles and liquid droplets of size 1
micron and larger in filter separators.
1.1 Emergency shutdown valve (ESDV)
The natural gas inters the skid at a pressure of 11.26 barg. An emergency shutdown
valve 01EK76-AA051 is provided to shutdown the entire gas conditioning skid in case
of low pressure (set at 10 barg) and fire signals. For this 3 nos. of Pressure
Transmitters (01EK76-CP101/102/103) are provided to operate 2 out of 3 logic.
An ultrasonic flow meter is provided to monitor the flow rate.
1.2 Knockout Drum 01EK76-BB001 & 01EK76-BB002
The gas exiting from the ESDV is received in the KOD. The KOD is used to
separate/arrest any hydrocarbon condensate or water entrained in the fuel gas. There are
two numbers of KOD’s each of 100% capacity. One will be in operation while the other will
be in standby mode. The standby equipment can be taken in line when pressure drop
across the operating KOD rises. Arrangement is provided to isolate the Knock out Drum.
The KOD is a cylindrical vessel having internals like baffle, and demister (double pocket
vane). The gas enters the vessel through the inlet nozzle on the shell and passes through
the baffle located at the inlet nozzle part and then through the demister. While passing
through these internals, the liquid particles get separated and the clean gas goes out. The
liquid particle arrested in the KOD is taken out through level control valve to the
Condensate Drain Tank. The KOD consists of an upper section and a lower section. The
upper section contains a demister section and the lower section contains the liquid
3/14
collection section.
The KOD is provided with level gauge, level transmitter, pressure differential indicating
transmitter, thermal relief valve, drain control valve, vent valve, drain valve, check valve
and bypass valve for drain control valve.
The upper section includes gas inlet, gas outlet connection, thermal relief valve (01EK76-
AA192/193 set at 13.65 barg) and vent. The lower section includes connections for level
Transmitter 01EK76-CL101/103(For high level) and 01EK76-CL102/104(For low level) set
at 80% & 20% respectively to open and close drain valve 01EK76-AA081/082 and a level
gauge 01EK76-CL501/502.
1.3 Fuel Gas Condensate Drain Tank 01EK76-BB003
There is 1x100% Condensate Drain Tank – for module 1. The Condensate Drain Tank is
horizontal vessel. Automated controlled discharged liquids separated from the KOD are
collected in the condensate drain tank and stored until removed. The drain pump transfer
the collected condensate to tankers as desired manually by local push button station. The
condensate drain tank is provided with Top mounted level transmitter 01EK76-CL105 (set
at 80% for drain pump start) 01EK76-CL106 (set at 20% for drain pump stop) a level
indicator 01EK76-CL503, liquid inlet, vent, man way, drain.
1.4 Horizontal Filter Seperator 01EK76-BB004 & 01EK76-BB005
Fuel Gas from the KOD passes to the Horizontal Filter Separator for further fine
separation of entrained liquid particles. There are two numbers of Filter Separator each of
100% capacity. One will be in operation while the other will be in standby mode. The
standby equipment can be taken in line when pressure drop across the operating Filter
Separator rises. Arrangement is provided to isolate the Filter Separator. A closure is
provided to allow for removal and replacement of the filter elements. The first stage is the
filter compartment and the second stage is the high efficiency liquid separator or mist
eliminator.
The horizontal filter separator consists of two horizontal chambers, upper chamber and a
lower chamber. The upper chamber consists of the filter elements (held in place with
adjustable filter retainers & stand-off pipes) and the double pocket vane. The lower
chamber collects the separated liquid particles. The liquid separated from the gas passes
through the level control drain valve to the Condensate Drain Tank.
The horizontal filter separators are provided with level gauge, level transmitter, thermal
relief valve, pressure differential indicating transmitter, drain control valve, vent valve,
drain valve, check valve and bypass valve for drain control valve.
Filter separator 01EK76-BB004 includes gas inlet, gas outlet connection, thermal relief
valve (01EK76-AA195 set at 48.40 barg) and vent. It also includes level Transmitter
01EK76-CL107/109(For high level) and 01EK76-CL108/110(For low level) set at 80% &
20% respectively to open and close drain valve 01EK76-AA083/084 and a level gauge
01EK76-CL505/506.
Filter separator 01EK76-BB005 includes gas inlet, gas outlet connection, thermal relief
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valve (01EK76-AA196 set at 48.40 barg) and vent. It also includes level Transmitter
01EK76-CL111/113(For high level) and 01EK76-CL112/114(For low level) set at 80% &
20% respectively to open and close drain valve 01EK76-AA085/086 and a level gauge
01EK76-CL507/508.
1.5 Fuel Gas Condensate Drain Tank-B01EK76-BB006
horizontal vessel. Automated controlled discharged liquids separated from the Horizontal
filter separators are collected in the condensate drain tank and stored until removed. The
drain pump transfer the collected condensate to tankers as desired manually by local
push button station.
The condensate drain tank is provided with Top mounted level transmitter 01EK76-CL115
(set at 80% for drain pump start) 01EK76-CL116 (set at 20% for drain pump stop) a level
indicator 01EK76-CL504, liquid inlet, vent, man way, drain and a level indicator.
2.0 SAFETY
Safety is a very special commitment at GasTech. Good safety performance is an item of

added value that GasTech takes pride in bringing to our projects.
The heart of our safety program is a firm commitment by all members of management,
supervision and our craftsmen to prevent accidents and the conditions that lead to
injuries. This commitment applies to not only our own in-house activities during
fabrication, but to the design and performance of the equipment that we manufacture.
Although safety flows from top down, it depends on the awareness and cooperation of
each individual employee in his or her daily work assignment to meet this challenge.
Management must provide effective safety training, must provide a safe environment to
work in and must enforce the developed safety program.
At GasTech, safety is viewed as a quality that cannot be delegated. The level of safety
performance on a project is a direct reflection of the project leadership. Each supervisor
must accept the responsibility and be held accountable for the safety performance of
those employees under his direct supervision. In a like manner, each employee has the
responsibility to perform the work in a safe manner and for reporting unsafe acts or
conditions to his supervisor. At GasTech, working safely is a condition of employment for
all employees.
Carrying this safety message to the field, the end user should be aware that the
equipment supplied under this contract is potentially hazardous to operate. Therefore, the
end user is expected to provide adequate barriers, warning signs and supervision to
prevent the exposure of any uniformed personnel to this potent ional hazard.
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3.0 EQUIPMENT INSTALLATION
Each Fuel Gas Conditioning Skid consists of the following equipment:
MODULE-1
(1) Emergency Shut Down Valve, 1 x 100%

(2) Knock-out Drum, 2 x 100%
(4) Nitrogen Purging System
MODULE-3
(1) Horizontal Filter Separators, 2 x 100%

(3) Cold Vent Stack
Place the skid assembles on a suitably designed level foundation.
Inspect all items, either assembled or shipped loosed, for any damage that may have
occurred in transit. If damage is discovered, notify the appropriate authorities.
Remove any shipping braces that may have been employed.
Various instruments and equipment may have been disassembled prior to shipping.
This was done to prevent damage and/or to comply with shipping limitations. Any such
items must be reassembles prior to start-up.
Install any temperature or pressure indicators shipped loose.
Filter elements in the Filters were installed prior to shipping. Open filters and look for
any damage due to shipping.
Examine the gas piping for loose fittings. Tighten as required.
Examine instrumentation for loose fittings or damage in transit. Tighten as required.
Examine the piping flanges for loose bolts. Tighten as required.
Assemble field process piping to the skid assembly’s inlet and skid assembly’s outlet
flanged connections. Sufficient support of field piping must be provided to prevent any
external loads being applied to the flanged connections.
Connect the off skid piping for process operation and utility requirements.
6/14
4.0 OPERATION OF FUEL GAS CONDITIONING SKID
4.1 SKID INLET
A pressure indicator 01EK76-CP501 is provided for indicating fuel gas inlet pressure. A
triple redundant pressure transmitters 01EK76CP-101/102/103 are provided to supply an
analog signal to the customer DCS for pressure monitoring and shutdown ESD valve
01EK76-AA051 on 2 out of 3 logic. The Gas Conditioning Skid DCS initiates a trip if the
fuel gas pressure rise above the set point 13.65 bar. Shutting down the fail close ESD
valve 01EK76-AA051 .The position of the ESD valve 01EK76-AA051 is monitored, by the
DCS by limit switches 01EK76CG-051A and 01EK76CG-051B to indicate the open or
closed position of the valve.
ESD valve 01EK76-AA051 will have open/close facility from the DCS. The ESD valve
closes automatically whenever a control room fire Signal is given to the DCS. Apart from
the automatic operation described above the ESD Valve is also provided with a manual
override facility on SOV.
A pressure relief valve 01EK76-AA191 set at 13.65 barg is provided to pop up if over
pressure occurs in the inlet line, a shut down valve 01EK76-AA052 is provided at the inlet
line of KOD to release the gas from inlet line and KOD to vent header at the time of
maintenance or plant shutdown or in case of fire emergency. A temperature gauge,
01EK76-CT501 and pressure gauge, 01EK76-CP501 is provided at upstream of ESDV for
local Inlet Fuel Gas Supply indication. A temperature element 01EK76-CT-001 is also
provided on the inlet fuel gas piping for customer use in their DCS. Pressure gauge,
01EK76-CP-502, is provided at the Inlet to the KO Drum.
4.2 Knockout Drum 01EK76-BB001 & 01EK76-BB002
The first stage of conditioning to the gas stream starts with the Gas Knockout. The
process gas enters the upper section of the Knockout Drum through the gas inlet
connection and is entrained on the surface of a vane pack as it exits the vessel. Any
moisture is coalesced into droplets then falls into the bottom of the lower chamber. Level
control in the Knockout Drum is achieved by using level Transmitter 01EK76-CL101/103
and 01EK76-CL102/104 in conjunction with a solenoid operated level control valve
(open/closed) 01Ek76-AA081/082.
The DCS monitors the entire Level transmitter to ensure a signal for valve control. The
DCS actuates the 3-way solenoid valve, which operates (open/close) pneumatic level
control valve, 01Ek76-AA081/082 to drain the liquid separated, when a high level,
01EK76-CL101/103 (set at 80%) and/or 01EK76-CL102/104(set at 20%), detects.
01Ek76-AA081/082 closes when the liquid level falls to a level where the low level is
detected by level transmitter – 01EK76-CL102/104 and 01Ek76-AA081/082 opens when
the liquid level became high to a level where the high level is detected by level transmitter
– 01EK76-CL101/103.The level control valve 01Ek76-AA081/082 is provided with position
switches 01EK76CG-081A/B and 01EK76CG-082A/B to give valve open/close indication
on DCS.
7/14
Level Gauge 01EK76-CL501/502 is provided for a visual indication of the knock Out Drum
Level. A Differential Pressure transmitter, 01EK76-CP151/152 is provided to find out the
differential pressure across the KOD. Liquids discharged from the Knockout Drum are tied
to a common drain header, which is directed to the condensate drain tank. A pressure
indicator 01EK76-CP503 and a temperature indicator 01EK76-CT502 is provided at the
Gas outlet of KOD’s for local display of pressure and temperature of gas outlet.
A thermal relief valve 01EK76-AA192/193 is provided on the Knockout Drum to protect the
vessel in an event of over pressure due to thermal expansion. A manual vent is provided
with a check valve to vent any gas in the Knockout during maintenance. All relief valve
and vent outlets are tied, to a common vent header. A sample connection is provided at
discharge at KOD for customer use. A Nitrogen purge connection is provided at the inlet
of the Knockout Drum. Gas Chromatograph connection has been provided at the gas
outlet of KOD.
4.3 Fuel Gas Condensate Drain Tank 01EK76-BB003
horizontal vessel. Automated controlled discharged liquids separated from the KOD are
collected in the condensate drain tank and stored until removed. The drain pump 01EK76-
AP001 transfer the collected condensate to tankers as desired manually by local push
button station. The condensate drain tank is provided with Top mounted level transmitter
01EK76-CL105 (set at 80%) to monitor high level at which the DCS will provide alarm and
01EK76-CL106 (set at 20%) to monitor low level at which the DCS will stop the drain
pump. But pump shall trip when tank level is low-low. A level indicator 01EK76-CL503 is
provided for local indication of level, a pressure indicator 01EK76-CP504 is provided at
the discharge of drain pump for local display of discharge line pressure.
A Flame Arrestor is furnished for the Drain Tank Vent.
4.4 Horizontal Filter Separator 01EK76-BB004 & 01EK76-BB005
Fuel Gas from the KOD passes from gas booster compressor to the Horizontal Filter
Separator for further fine separation of entrained liquid particles. Three redundant
temperature elements 01EK76-CT002/003/004 are provided at the common inlet line of
both filter separators for indication of inlet gas temperature in the filter separator. A
pressure indicator and a temperature indicator is also provided for local display of inlet
gas pressure and temperature respectively.
Fuel Gas from the KOD passes to the Horizontal Filter Separator for further fine
separation of entrained liquid particles. There are two numbers of Filter Separator each of
100% capacity. One will be in operation while the other will be in standby mode. The
standby equipment can be taken in line when pressure drop across the operating Filter
Separator rises. Arrangement is provided to isolate the Filter Separator. A closure is
8/14
provided to allow for removal and replacement of the filter elements.
The first stage is the filter compartment and the second stage is the high efficiency liquid
separator or mist eliminator.
This is the final stage of level of filtration directly upstream of Gas Turbine. The primary
function, of the -separator, is the removal of small contaminants and liquids from a stream
of flowing natural gas. The process gas enters the lower chamber of the filter separator
through the gas inlet connection and impacts a vane pack. This is the first step in
separating liquids. Mist from the gas is trapped by the mist extractor and coalesces into
droplets on the surfaces of the mist extractor vanes. These droplets flow down the vanes
and fall into the liquid reservoir in the bottom of the vessel. Any liquid particles that remain
with the process gas after flowing into the vane pack then flows through multiple filter
cartridges. The cartridges are designed so mist particles coalesce into droplets on the
outside surface, as the gas flows from the inside to the outside of each element. The
liquids that coalesce and drop out of the gas stream are accumulated in the bottom of the
upper chamber.
4.4.1 Filter Upper Chamber
Level control in the Filter Separator upper chamber is achieved by using level transmitter
01EK76-CL107/108 (for filter separator - A) and 01EK76-CL111/112 (for filter separator -
B) in conjunction with a pneumatic level control valve (on/off) 01EK76-AA083 (for filter-A)
and 01EK76-AA085 (for filter-B). When a high level is detected, the DCS actuates a 3-way
solenoid valve, which operates a pneumatic level control valve (on/off) to drain the liquid
separated. When the liquid level starts to fall and the low level is detected based on the
time delay (60 - 70 sec )and the DCS de energizes the 3-way solenoid valve to cut off the
pneumatic supply to the fail close level valve 01EK76-AA083(for filter-A) and 01EK76-
AA085(for filter-B) causing it to close. The level control valve 01EK76-AA083 is provided
with position switches 01EK76-CG083A/B and 01EK76-AA085 with position switches
01EK76-CG085A/B to indicate the open or close position of the valve.
4.4.2 Filter Lower Chamber
Level control in the Filter Separator lower chamber is achieved by using level transmitter
01EK76-CL109/110 (for filter separator - A) and 01EK76-CL113/114 (for filter separator -
B) in conjunction with a pneumatic level control valve (on/off) 01EK76-AA084 (for filter-A)
and 01EK76-AA086 (for filter-B). When a high level is detected (01EK76-CL107/109
Filter-A & 01EK76-CL111/113 Filter-B), the DCS actuates a 3-way solenoid valve, which
operates a pneumatic level control valve (on/off) to drain the liquid separated. When the
liquid level starts to fall and the low level is detected (01EK76-CL108/110 Filter-A &
01EK76-CL112/114 Filter-B ) based on the time delay (60 - 70 sec )and the DCS de
energizes the 3-way solenoid valve to cut off the pneumatic supply to the fail close level
valve 01EK76-AA084(for filter-A) and 01EK76-AA086(for filter-B) causing it to close. The
level control valve 01EK76-AA084 is provided with position switches 01EK76-CG084A/B
and 01EK76-AA086 with position switches 01EK76-CG086A/B to indicate the open or
close position of the valve. The set point for high level is 80% and for low level is 20%.
9/14
Liquids discharged from the Filter Separator are tied to a common drain header, which is
directed to the drain tank 01EK76-BB006.
A level gauges 01EK76-CL108/112 and 01EK76-CL110/114 are provided in the upper

chamber and the lower chamber of the Filter Separators for visual inspection of the liquid
level.
A temperature indicator 01EK76-CT503 and a pressure indicator 01EK76-CP505 is

provided at the inlet to the Filter Separators for indicating inlet gas temperature and
pressure respectively.
A thermal relief valve 01EK76-AA195/196 set at 48.40 barg is provided on the Filter
Separator to protect the vessel in an event of over pressure due to thermal expansion. A
vent is provided with a check valve to vent any gas in the Coalescing Filter Separator
during maintenance. All relief valve and vent outlets are tied to a common vent header.
The Solids trapped in the filter elements will gradually increase the pressure drop across
the Filter Separator and a pressure differential transmitter 01EK76-CP153/154 monitors
this pressure differential. When a recommended high limit differential pressure (0.4 Bar) is
detected the DCS will initiate an alarm. Do not exceed the recommend maximum pressure
drop (15 PSIG) across the filter elements. During commissioning filter replacement may
be required often.
A manual vent is provided with a check valve to vent any gas in the filter seperators during
maintenance. All relief valve and vent outlets are tied, to a common vent header.
4.5 Fuel Gas Condensate Drain Tank-B01EK76-BB006
horizontal vessel. Automated controlled discharged liquids separated from the filter
separator are collected in the condensate drain tank and stored until removed. The drain
pump 01EK76-AP002 transfer the collected condensate to tankers as desired manually by
local push button station. The condensate drain tank is provided with Top mounted level
transmitters 01EK76-CL115 (set at 80%) to monitor high level at which the DCS will
provide alarm and 01EK76-CL116 (set at 20%) to monitor low level at which the DCS will
stop the drain pump. But pump shall trip when tank level is low-low A level indicator
01EK76-CL504, for local indication of level, a pressure indicator 01EK76-CP507 is
provided at the discharge of drain pump for local display of discharge line pressure.
A Flame Arrestor is furnished for the Drain Tank Vent.
10/14
5.0 MAINTENANCE OF FUEL GAS CONDITIONING SKID
5.1.1 Preventative Maintenance
a) The method of eliminating potential operating problems is to have an effective

maintenance program.
b) A complete checkout of the FGCS should be made at least every 30 days to
ensure good operation.
5.1.2 Process Checks
a) Always maintain liquid levels in the gauge glasses in the vessels.

b) Check and log levels, temperatures, pressures and flow rates regularly. This
information will help diagnose problems and prevent unplanned shutdown.
c) Check for leaks and repair as required.
5.1.3 Mechanical
a) Safety valves - safety valves require periodic inspection to assure the Operator
that the valves are not sticking and will provide safety relief. Pressure testing with
a calibrated source is the approved method.
b) Periodic Shutdown and General Inspection
Every year or when required by operation, a shutdown and complete inspection

and Maintenance of the units are desirable.
c) If differential pressure across the filter goes beyond the high set point, then there
may be requirement of cleaning the filter element after taking stand-by filter in-line.
6.0 FUNCTIONAL TEST PROCEDURE

A) SCOPE
The scope of this document is to describe the functional tests to be carried out on
the various assembled skid packages prior to dispatch from the vendor’s skid
fabrication yard or after erection at site.
B) GENERAL
1. A full ‘as built’ P&ID/hook-up check and record is to be carried out prior to
commencement of any testing to ensure all instruments are in their correct
location, hooked-up as required and tagged correctly.
2. Prior to commencement of the functional test all cables are to be fully

checked for continuity and subjected to an insulation resistance test.
3. Where standard calibrated gauges or similar are used during a test its
reference number and calibration date shall be recorded against the result of
each of the tests for which it was used.
11/14
4. All test instruments shall hold a current (no more than 6 months old)
calibration certificate, available for review during testing. A verified copy of
the calibration certificate for each test instrument shall be included with the
test results.
5. All transmitters will be subjected to a three point calibration check (range

and mid-range) rising and falling. Results to be recorded
6. Where instrument calibrations are found to be incorrect, recalibration of the

Instrument will be carried out
C) Reference should be made to the following drawings and documents:-
1. P & I Diagrams
2. Electrical Interconnection Diagram
3. Instrument Data Sheets
4. Individual Instrument Operating & Maintenance Manuals
5. Instrument Manufacturer's Calibration Certificates
D) LEVEL INSTRUMENT FUNCTION TESTS
1. LEVEL TRANSMITTERS: GWR TYPE
a) Apply a 24V DC supply to the corresponding terminals of the level

transmitter connections in the associated skid junction box and measure the
mA output of the transmitter (at the JB terminals) from high to low "level".
Reasonable correlation to the factory calibration is acceptable at this
juncture (i.e. approximately 4 - 20 mA over the "level" range).
E) TEMPERATURE GAUGES:
a) Remove the temperature gauge from its respective thermo-well and

Place in calibrator unit. Check gauge reading against calibration unit
Reading across the full range.
F) SHUTDOWN VALVE:
1). Pneumatic Only Test: Stroke valve utilizing a Pneumatic Calibration

Unit
2). Electro-Pneumatic Test
a) Apply air supply to the shutdown valve as per supply pressure

Mentioned on name plate of valve.
b) Remove air from valve and confirm failure mode.
c) Remove signal from valve and confirm failure mode.
G) CABLE TESTS
a) Carry out insulation resistance tests on all instrumentation electrical

cables and record results.
12/14
b) Carry out continuity check on all instrumentation electrical cables
and record results.
H) VALVES
a) Where required check that all valves are correctly installed in relationship to
flow direction.
b) Check orientation of each valve lever/hand wheel to ensure operation is not
restricted.
c) Check operation of all hand valves by fully opening and closing each valve.
d) Check accessibility to all instruments/valves, etc., required for normal

operation.
7.0 TROUBLE-SHOOTING
It is the responsibility of the operator in the field to quickly identify and if possible,
eliminate an operating problem. A delay in correcting a malfunction can be very
costly both in sales and damage to equipment.
Problem: Leaking Flanges
Possible cause:
1. Flange bolts need tightening
2. Check Gasket for damage and replace as necessary.
3. Carry out pneumatic test after reinstatement of pipes and equipment.
Problem: Level Transmitter not functioning
Possible Cause:
1. Defective Level Transmitter
Solution: Replace Level Transmitter.
2. Reading is fluctuating/Incorrect
Solution:
a) Check loose connection of wire. Probe may be stuck up. Open the Chamber &
Re-insert the probe.
b) Compare transmitter indicated value to level gauge reading.
Problem shut down Valve not functioning

Possible Cause:
1. Insufficient instrument air supply
Solution: Provide instrument air supply through air filter regulator by the seeing
the supply pressure written on the tag plate of valve.
2. Feedback of open/close limit is incorrect.
Solution: a) Check the continuity test of limit switch.
b) Adjust the proximity switch sensor inside the limit switch box.
Problem: Temperature Element not functioning

Possible Cause:
1. RTD connection is incorrect.
2. Check the loosening of terminal.
3. Check the continuity test for RTD.
4. Check ohms value with multi meter.
13/14
Problem: Pressure Transmitter not functioning
Possible Cause:
1. PCB card not working
2. Check the loosening of terminal.
3. LCD not working. Check power supply condition of LCD ( Voltage, Current,
grounded etc)
14/14
LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
L&T-SARGENT & LUNDY LIMITED
EPC Contractor Action 1 (One) DATE 23-Oct-2015
MARUBENI CORPORATION Action 1 Approved
Action 2 Approved except as commented; Forward final drawing
Action 3 Not Approved; Resubmission required incorporating comments
Action 4 For information/reference only
EPC Sub Contractor: Action 5 For Information/reference with observations, resubmission required
SPEC. NO. & BHE-L826-DC01-01-EKE-12-0001
LARSEN & TOUBRO LIMITED E-MAIL REF. E-(LTSL-BHE-6164)
SIGNATURE BJB/MYV
Drawing/Document reviewed only for general compliance with specifications. Action shown above is
subject to the terms and conditions of contract and does not relieve the Contractor from his obligations
under the contract including design and detailing.
Vendor:
Title:
MECHANICAL DATA SHEET FOR FUEL GAS KNOCK OUT
DRUM
Doc/Drg No.:BHE-L826-YT01-01-EKE-12-0001-00 Rev.: P3 Pages :1-5
REVISION STATUS
Detail / Prepared
Rev. Name / Name / Sign Name /
Description Date
Sign Mech Elect Civil C&I SES Sign
RA FOR APPROVAL 10-Apr-15 SK YK -- --- ---- --- YK
RB FOR APPROVAL 18-Apr-15 SK YK -- --- ---- --- YK
P2 FOR APPROVAL 3-Jul-15 SK YK -- --- ---- --- YK
P3 FOR APPROVAL 9-Sep-15 SK YK -- --- ---- --- YK
Notice:
ready for use
Specially highlighted deviations are included in attached Deviation sheet

Data Sheet No & BHE-L826-YT01-01-EKE-12-
Rev 0001, Rev P3
Sheet No 2 of 5
MECHANICAL DATA SHEET (MDS) 01-EK76-BB001 / 01-EK76-
KNOCK OUT DRUM Item No
BB002
Service Knock Out Drum
Quantity 2 nos
1 DOC. NO BHE-L826-YT01-01-EKE-12-0001 CLIENT NORTH-WEST POWER GENERATION COMPANY
BHERAMARA COMBINED CYCLE POWER PLANT
PROJECT NO. L826 PROJECT
2 (360MW) DEVELOPMENT PROJECT
3 EPC CONTRACTOR MARUBENI CORPORATION EPC SUB-CONTRACTOR LARSEN & TOUBRO
4 PACKAGE: FUEL GAS CONDITIONING SKID

5
6 PERFORMANCE / OPERATING / PROCESS DATA
7 Type - Knock Out Drum
8 Allowable Pressure Drop bar Clean- 0.072 (max) ; 50% choked - 0.1 (max)
9 Fluid - Fuel Gas / Hydrocarbon
10 Service Classification - Non-Lethal
11 Operating Pressure (max) barg 11.262
o
12 Operating Temparature C 10-50
13 Sour Service Requirement - NACE MR-0175
14 Gas Density kg/m3 6.462-10.99 P3
15 Fluid Density kg/m3 605.38
16
17
18
19
20
21 MECHANICAL DESIGN DATA
22 Design Code - ASME Sec. VIII Div.1, Edition 2013
BHE-L826-DC01-01-EKE-12-0001, Rev RA and Amendment-1 of Technical Specification of
23 Specification -
Fuel Gas Conditioing System , Rev RA
24 Design Pressure barg 13.65 P3
o
25 Design Temparature C 55
26 Vessel Size mm 1575 ID x 3000 (wl-wl)
27 Vessel Position - Vertical
28 Support Type - Skirt
29 Radiography % RT1 (100%)
30 Joint Efficiency ` 1
31 Type Of Head ` Ellipsoidal Heads
32 Corrosion Allowance mm 3
33 Wind Design UBC / BNBC-2006, Wind speed-215 km/hr, Elevation 10,000 mm
34 Siesmic Factor UBC / BNBC-2006, Zone-1, Importance factor = 1.25,Seismic Coefficient-0.1g
35 Transpotation Load NA
36 Blast Load Bar(g) NA
37
40
41 MATERIAL OF CONSTRUCTION
42 Shell SA 516 Gr70 Internals SS304
43 Heads SA 516 Gr70 Cladding / Linning NA
44 Nozzles SA 106 Gr B / SA516, Gr 70
45 Nozzle Flanges SA 105
46 Reinforcing Pad SA 516 Gr70
47 Supports SA 36
48
49
50 P3 07-Sep-15 Comments incorported SK YK YK
P2 03-Jul-15 Comments incorported SK YK YK
RB 18-Apr-15 Submitted for Review SK YK YK
RA 10-Apr-15 Submitted for Review SK YK YK
Revision Date Description Prep. Checked Approved
Rev 0001, Rev P3
Sheet No 3 of 5
BB002
Quantity 2 nos
52 PROJECT NO. L826 PROJECT
(360MW) DEVELOPMENT PROJECT

55
56 FABRICATION AND INSPECTION
57 ASME Code Stamping Yes
58 Hydrostatic Test 17.7 barg {As per UG-99 (34)}
59 External Coating As per Section III, MFR-1 and painting spec. BHE-L826-DC01-01-ZEN-12-0010
60 Third Party Inspection AI
61 PWHT / Stress Relieving No (exempted as per Code)
62 Material Certificates Required
63 Impact Testing No (exempted as per Code)
64
65
66
67 ACCESSORIES
68 Lifting Lugs Required
69 Name plate Required
70 Earthing Boss Required
71 Vortex Breaker NO
72 Insulation NO
73 External Painting As per Section III, MFR-1 and painting spec. BHE-L826-DC01-01-ZEN-12-0010
74
75
76 NOZZLE SCHEDULE
77 Mark Qty Size (NB) Rating Type Service
78 N1 1 350 150# WNRF Inlet
79 N2 1 350 150# WNRF Outlet
80 N3 1 50 150# WNRF Condensate Outlet
81 N4 1 50 150# WNRF Drain
82 N5 1 25 150# WNRF Vent
83 N6 1 50 150# WNRF TSV
84 N7A/B 2 50 150# WNRF LT
85 N8A/B 2 50 150# WNRF LT
86 N9A/B 2 25 150# WNRF LI
87 N10 1 15 150# WNRF PDIT
88 N11 1 15 150# WNRF PDIT
89 MH 1 500 150# WNRF Manway with Davit
90
91
92
93
94
95 Empty Weight 4063 kg Internals Weight 200 kg
96 Operating Weight 5109 kg
97 HydroTest Weight 11122 kg
99 P2 03-Jul-15 Comments incorported SK YK YK
100 RB 18-Apr-15 Submitted for Review SK YK YK
Rev 0001, Rev P3
Sheet No 4 of 5
MECHANICAL DATA SHEET (MDS)
01-EK76-BB001 / 01-EK76-
BB002
Quantity 2 nos

105
106 VESSEL SKETCH
107
108
109
110
111
112
113
114
115
116
117
118
119
120
1575 ID X 14 THK.
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
149
RB 18-Apr-15 Submitted for Review SK YK YK
Rev 0001, Rev P3
Sheet No 5 of 5
01-EK76-BB001 / 01-EK76-
BB002
Quantity 2 nos

155
156 NOTES
157 1 All Pressures are Gauge (g) Pressures unless otherwise specified.
158 2 Vessel is with elliptical heads.
159 3 MOC of all components in contact with Process Fluid shall comply NACE MR 0175 requirements.
160 4 All Dimensions are in Metric System , unless otherwise specified.
161 5 No welding is permitted after Hydrotest.
162 6 External Gasket " SS Spiral Wound Flexible with Graphite Filler and with SS 304 Inner ring" shall be used.
163 7 All welds shall be continuous unless otherwise noted.
164 8 Longitudinal & Circuferential seams shall not interfere with nozzle openings.
165 9 Inside diameter of weldneck flange shall match with corrosponding ID of nozzle.
166 10 Heads shall be of seamless construction. DP check of Head shall be cariied out after PFHT, If applicable. P3
167 11 Hardness of Base Metal+Weld + HAZ shall not exceed HRC 22

168 12 All Flanges shall confirm to ASME B 16.5
169 13 All butt- weld shall be 100% radiographed . Where radiography is considered to be impractical, UT may be carried out.
170 14 All external surfaces shall be painted as per Specification BHE-L826-DC01-01-ZEN-12-0010
171 15. Vane Pack shall be segmented to pass through Manway
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
200 RB 18-Apr-15 Submitted for Review SK YK YK
LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
EPC Contractor
Action DATE
MARUBENI CORPORATION Action 1
1 (One)
Approved
23-Oct-2015

SPEC. NO. &
LARSEN & TOUBRO LIMITED E-MAIL REF.
BHE-L826-DC01-01-EKE-12-0001
E-(LTSL-BHE-6164)
SIGNATURE BJB/MYV
Vendor:
Title:
MECHANICAL DATASHEET FOR FUEL GAS HORIZONTAL FILTER SEPARATOR
Doc/Drg No.: BHE-L826-YT01-01-EKE-12-0002-00 Rev.: P2 Pages :1-5
REVISION STATUS
Detail / Prepared
Description Date
Sign Mech Elec Civil C&I SES Sign
RA FOR APPROVAL 06-APR-15 SK YK -- --- ---- --- YK
RB FOR APPROVAL 18-APR-15 SK YK -- --- ---- --- YK
Notice:
We declare that the document is prepared in accordance with the Contract except the item
√ specifically highlighted are deviated from the Contract and also declare that the document is
ready for use

Rev 0002, Rev P2
Sheet No 2 of 5
HORIZONTAL FILTER SEPARATOR Item No
BB005
Service Horizontal Filter Separator
Quantity 2 nos

5
7 Type - Separator with Double Vane Pack
8 Separation efficiency 99.3% removal for particles of 0.3 micron and larger (refer note 16 on sheet 5 of 5)
9 Allowable Pressure Drop bar Clean- 0.2 (max) ; 50% choked - 0.4 (max)
10 Fluid - Fuel Gas / Hydrocarbon
12 Operating Pressure barg 40.5
o
13 Operating Temparature C 120
15 Flow Rate(Design) TPH 67.51
16 Molecular weight kg/kmol 16.835
17 Fluid Density kg/m3 Gas-21.8498; Condensate-538
18
19
20
22 Design Code - ASME Sec. VIII Div.1, Edition 2013
23 Specification - P2
24 Design Pressure barg 48.4
o
26 Vessel Size mm 815OD x 2000 (wl-wl)
27 Vessel Position - Horizontal
28 Support Type - Saddles
29 Radiography % RT1 (100%)
30 Joint Efficiency ` 1
31 Type Of Head ` LH-QOC-600# / RH-Dishend 18 min / 22 nom
33 Wind Design UBC / BNBC-2006, Wind speed=215 km/hr, Elevation 10,000 mm
34 Seismic Factor UBC / BNBC-2006, Zone-1, Importance factor = 1.25,Seismic Coefficient-0.1g
35 Transportation Load NA
37
38
40 Shell SA 516 Gr70 Internals SS 304
41 Heads SA 516 Gr70 Cladding / Lining NA
42 QOC (Refer note 17) SA 516 Gr70 / SA 105 Filter Elements Fiber glass
43 Nozzles SA 106 Gr B
46 Supports SA 36
47
48
49
50 P2 9-Sep-15 Comment incorported SK YK YK
RB 18-Apr-15 Submitted for Approval SK YK YK
Rev 0002, Rev P2
Sheet No 3 of 5
BB005
Quantity 2 nos

105
107 ASME Code Stamping yes
108 Hydrostatic Test 62.92 barg {As per UG-99 (34)}
59 External Coating As per Section III, MFR-1 and painting spec. BHE-L826-DC01-01-ZEN-12-0010
60 Third Party Inspection AI
61 Stress Relieving No (exempted as per Code) For Filter vessel, Yes- for Drain Tank
64
65
66
67 ACCESSORIES
68 Lifting Lugs Required QOC Required
71 Vortex Breaker NA
72 Insulation Required (38 mm thk)
73 External Painting As per Section III, MFR-1 and painting spec. BHE-L826-DC01-01-ZEN-12-0010
74
75
76 NOZZLE SCHEDULE
78 N1 1 250 600# WNRF Inlet
79 N2 1 250 600# WNRF Outlet
82 N5 1 50.8 ID 600# LWNRF TSV
83 N6 1 25.4 ID 600# LWNRF Vent
84 N7A/B 1 25.4 ID 600# LWNRF PDIT
85 N8A/B 1 50 600# WNRF LT
86 N9A/B 1 50 600# WNRF LT
87 N10A/B 1 50 600# WNRF LT
88 N11A/B 1 50 600# WNRF LT
89 N12A/B 1 25 600# WNRF LI
90 N13A/B 1 25 600# WNRF LI
91 N14A/B 1 50 - Forged Nozzle Down comer pipe
92 N15 1 50 600# WNRF Drain
93 N16 1 50 600# WNRF Drain
94 N17A/B 1 50 - WNRF Down comer pipe
95
96 Empty Weight 3637 kg (Including Tank) Internals Weight 90 kg (Filter Elements)
97 Operating Weight P2 3764 kg
98 Test Weight 4676 kg
99
Rev 0002, Rev P2
Sheet No 4 of 5
01-EK76-BB004 / 01-EK76-
BB005
Quantity 2 nos

105
106 VESSEL SKETCH
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
150 RB 18-Apr-15 Submitted for Approval SK YK YK
Rev 0002, Rev P2
Sheet No 5 of 5
01-EK76-BB004 / 01-EK76-
BB005
Quantity 2 nos

155
156 NOTES
157
159 2 Filter Vessel is with elliptical head ( RH Side) + and Quick Opening Closure (QOC) at LH side
167 10 Heads shall be of seamless construction. DP check of Head shall be cariied out after PFHT, If applicable.
170 13 All butt- weld shall be 100% radiographed . Where radiography is considered to be impractical, UT may be carried out.
172 15 Insulation shall be as per Specification BHE-L826-DC01-01-ZEN-12-0013
173 16. Filter efficiency shall be as below::
174 - Solid particlesof 5 micron size and above 100% removal
175 - Solid particlesof 1 micron size and above 99.98% removal
176 - Liquid droplets of 5 micron size and above 100% removal P2
177 - Liquid droplets of 1 micron size and above 99.98% removal
178 17. QOC- Quick Opening Closure (Part 'U' stamped)
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
EPC Contractor Action 1 (One) DATE 23-Oct-2015
SPEC. NO. &
LARSEN & TOUBRO LIMITED E-MAIL REF.
BHE-L826-DC01-01-EKE-12-0001
E-(LTSL-BHE-6164)
SIGNATURE BJB/MYV
Vendor:
Title:
MECHANICAL DATA SHEET FOR CONDENSATE TANK
REVISION STATUS
Rev Detail / Prepared
Name / Name / Sign Name /
. Description Date
Sign Mech Elect Civil C&I SES Sign
RA FOR APPROVAL 06-Apr-15 SK YK -- --- ---- --- YK
RB FOR APPROVAL 18-Apr-15 SK YK -- --- ---- --- YK
P2 FOR APPROVAL 10-Jul-15 SK YK -- --- ---- --- YK
Notice:
ready for use

Rev 0003, Rev P3
Sheet No 2 of 5
CONDENSATE TANK Item No
BB006
Service Condensate Tank
Quantity 2 nos

5
7 Type - Condensate Drain Tank
8 Separation efficiency - NA
9 Allowable Pressure Drop NA
10 Fluid - Condensate
12 Operating Pressure barg Atmospheric
o
13 Operating Temparature C Atmospheric
3
15 Fluid Density kg/m ^605.38 for 01-EK76-BB003 and 538.0 for 01-EK76-BB006
16
17
18
19
20
22 Design Code - Good Engineering Practice + ASME Sec. VIII Div.1, Edition 2013
23 Specification - P3
24 Design Pressure barg Atmospheric (Total Static head considered for Calculations)
o
26 Vessel Size mm 1050 ID x 2000 (wl-wl)
27 Vessel Position - Horizontal
28 Support Type - Saddles
29 Radiography % SPOT (RT2)
30 Joint Efficiency ` 0.85
31 Type Of Head ` Ellipsoidal Head
33 Wind Design UBC / BNBC-2006, Wind speed=215 km/hr, Elevation 10,000 mm
34 Siesmic Factor UBC / BNBC-2006, Zone-1, Importance factor = 1.25,Seismic Coefficient-0.1g
35 Transpotation Load NA
37
39 Shell SA 516 Gr70 Internals NA
40 Heads SA 516 Gr70 Cladding / Linning NA
41 Nozzles SA 106 Gr B / SA516, Gr 70
44 Supports SA 36
45
46
48 P2 10-Jul-15 Revised to match GAD SK YK YK
50 RA 6-Apr-15 Submitted for Review SK YK YK
Rev 0003, Rev P3
Sheet No 3 of 5
BB006
Quantity 2 nos

55
57 ASME Code Stamping NO
58 Hydrostatic Test Water Fill test
59 External Coating As per spec.
60 Third Party Inspection TPI
61 Stress Relieving No (exempted as per Code)
64
65
66
67 ACCESSORIES
68 Lifting Lugs Required
71 Vortex Breaker NA
72 Insulation NO
73 External Painting As per system 3 of spec.
74
75
76 NOZZLE SCHEDULE
78 N1 1 50 150# WNRF Inlet
79 N2 1 100 150# WNRF LI
80 N3 1 100 150# WNRF LT
81 N4 1 100 150# WNRF LT
82 N5 1 50 150# WNRF Vent
83 N6 1 50 150# WNRF Vent
84 N7 1 500 150# SORF Pump Mounting Connection
85 N8 1 50 150# WNRF Flame Arrester
86 N9 1 25 150# WNRF Drain
87 N10 1 50 150# WNRF Spare+Blind
88 MH 1 450 150# SORF Manway+ Davit
89
90
91
92
93
94
95 Empty Weight 1155 kg Internals Weight nil
96 Operating Weight 2413 kg
97 Test Weight 3276 kg
98
Rev 0003, Rev P3
Sheet No 4 of 5
01-EK76-BB003 / 01-EK76-
BB006
Quantity 2 nos

105
106 VESSEL SKETCH
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
Rev 0003, Rev P3
Sheet No 5 of 5
01-EK76-BB003 / 01-EK76-
BB006
Quantity 2 nos

155
156 NOTES
157
159 2 Vessel is with elliptical heads.
167 10 Heads shall be of seamless construction. DP check of Head shall be cariied out after PFHT, If applicable.
170 13 All butt- weld shall be spot radiographed as per code + all T-Joints.
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
EPC Contractor Action 1 (One) DATE 19-Mar-2016
SIGNATURE BJB/MYV/HPK
Vendor:
Title:
CONDENSATE PUMP MOTOR DATA SHEET
Doc/Drg No.: BHE-L826-YM01-01-EKE-14-0001-00 Rev.: P2 Pages :1-3
REVISION STATUS
Detail / Prepared
Description Date
Sign INSTRUMENT Elect Civil C&I SES Sign
RA FOR APPROVAL 10-APR-15 SUNNY R.K JHA -- --- ---- --- R.K JHA
P1 FOR APPROVAL 6-Jan-16 SUNNY R.K JHA -- --- ---- --- R.K JHA
P2 FOR APPROVAL 3-Mar-16 SUNNY R.K JHA -- --- ---- --- R.K JHA
Notice:
ready for use

North- West Power Generation Company Limited
Bheramara CCPP (360MW
Project No. L826000
Development Project)
Rev. Date Purpose Page : 2 OF 2
ISSUED FOR
Doc. No.BHE-L826-YM01-
P1 06-Jan-16 CLIENT
01-EKE-14-0001-00
COMMENTS
ISSUED FOR
P2 03-Mar-16 CLIENT
COMMENTS
MOTOR DATASHEETS
01EK76AP001-M
TAG NO. 01EK76AP002-M
SERVICE For condensate pump 01EK76-AP001/002
QUANTITY 2 nos.
OUTPUT ( KW / HP) 0.75/1
MOTOR FRAME SIZE 80

STANDARS TO WHICH THE MOTOR
COMPLIES IEC 60034
VOLTAGE & IT'S VARIATION 400+/-10%
FREQUENCY & IT'S VARIATION 50+/-5%

Zone 2, IEC Gas Group - II A, Temperature Class – T3
HAZ. AREA CLASSIFICATION / GAS GROUP
P2
INSULATION CLASS F( temperature rise shall be limited to class B)
AMBIENT TEMP/ TEMP RISE* (IN DEG. C) 40 Deg C
DUTY Continuous, S1
MOUNTING FLANGE MTD
MOTOR TYPE Squirrel cage induction motor
EXPLOSION PROTECTION TYPE Ex’ d’
ELECTRICAL PERFORMANCE
FULL LOAD CURRENT (AMPS) 1.65
FULL LOAD TORQUE (KGM) 0.26
FULL LOAD SPEED (RPM) 1500 RPM
STARTING CURRENT AS % OF FLC 600
STARTING TORQUE AS % OF FLT 250
%EFFICIENCY AT 100% 79.6
AT 75% 76
AT 50% 72
0.82
POWER FACTOR AT 100%
0.74
AT 75%
0.62
AT 50%
LR WITHSTAND TIME - HOT/ COLD (SECS) 30/15
PHASE/ CONNECTION/ NO. OF TERMINALS 3 / STAR / 6
STATOR/ ROTOR TIME CONSTANT (MIN.) 40 / 40
MECHANICAL DETAILS
ROTATION VIEWED FROM DE Clock wise
MAXIMUM CABLE SIZE (MM2) 3C X 2.5 MM2 XLPE insulated armoured cable
DEGREE OF PROTECTION IP - 65
METHOD OF COOLING TEFC (TOTALLY ENCLOSED FAN COOLED)

GREASE /UNIREX
TYPE OF LUBRICATION NS ESSO
BEARING TYPE BALL
GROSS WEIGHT (KG) 30
PAINT RAL 7035

Action 1 (One) DATE 11-Sep-2015
Action 1 Approved
Action 5 For Information/reference with observations, resubmission required
E-MAIL REF. E-(LTSL-BHE-5927)
SIGNATURE BJB/MYV
Action 1 Approved
SIGNATURE BJB/MYV
Action 1 Approved
SIGNATURE BJB/MYV/MPR
Action 4 (Four) DATE 14-Sep-2015
Action 1 Approved
SIGNATURE BJB/MYV/SHP
LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
EPC Contractor L&T-SARGENT & LUNDY LIMITED

MARUBENI CORPORATION Action 1 (One) DATE 05-Nov-2015
Action 1 Approved
EPC Sub Contractor: Action 4 For information/reference only
LARSEN & TOUBRO LIMITED

SIGNATURE BJB/MYV/PHJ/PMS
Contractor’s subject to the terms and conditions of contract and does not relieve the Contractor from his obligations
Consultant:
Vendor:
Title:
SKID GAD FOR NITROGEN PURGING SYSTEM
Doc/Drg No.: BHE-L826-XK00-01-EKE-13-0003 Rev.: P2 Pages :4
REVISION STATUS
Detail / Prepared
Description Date
Sign STRL Elec Civil C&I SES Sign
P0 FOR APPROVAL 26-Jun-15 S.S J.P ------ ----- ---- ------ J.P
P1 FOR APPROVAL 31-Jul-15 S.S J.P ------ ----- ---- ------ J.P
P2 FOR APPROVAL 11-Sep-15 S.S J.P ------ ----- ---- ------ J.P
Notice:
ready for use

LIMITED
PROJECT
Owner’s Engineer
Joint Venture of
And
EPC Contractor Action 1 (One) DATE 29-Jan-2016


SIGNATURE BJB/MYV
Vendor:
Title:
DATA SHEET FOR CONDENSATE DRAIN PUMP
REVISION STATUS
Detail / Prepared
Description Date
Sign Mech Elec Civil C&I SES Sign
JP
RA FOR APPROVAL 13-APR-15 ILA -- --- ---- --- JP SINGH
SINGH
JP
P1 FOR APPROVAL 11-Sep-15 ILA -- --- ---- --- JP SINGH
SINGH
JP
P2 FOR APPROVAL 6-Jan-16 ILA -- --- ---- --- JP SINGH
SINGH
Notice:
ready for use

North-West Power Generation Company Limited
Bheramara CCPP (360MW) Development Project Proj. No. L826000 Spec. No.
Rev. Date Purpose Page: 1 of 1 Data sht. No: BHE-L826-YT01-01-EKE-12-0004-00
P1 10/9/2015 ISSUED FOR CLIENT COMMENTS Reviewed Appd. Appd.
Prep.
P2 6/1/2016 Inst. Mech.
Data Sheet for Condensate Drain Pump

Tag 01EK76-AP001 & BHE-L826-XG01-01-EKE-11-0001-01 &
P&ID No.: Service: Hydrocarbon condensate discharge
No.: 01EK76-AP002 BHE-L826-XG01-01-EKE-11-0001-02
Fluid : Condensate
1 Pump designation Vertical sump Pump 53 Casing Carbon Steel

2 Number of pumps No’s 2 No. (1 No. for each condansate Tank) 54 Impeller SS-304
3 Name of manufacturer Dencil Pumps & Systems Pvt Ltd 55 Casing wearing ring Carbon Steel
4 Model no. DPSVP - 125 56 Impeller wearing ring SS 304
5 Type of pump Vertical sump Pump 57 Pump Shaft SS-304
MATERIALS OF CONSTRUCTION
Direction of rotation of pump viewed from
6 Clock Wise Rotation 58 Shaft sleeve SS-304
driver (motor) end
7 Prime mover Motor 59 Column & Delivery Pipe SA-106 Gr.B
8 Type of duty/ operation Continuous 60 Base / Sole Pate IS-2062
9 Design Code API 610 ( V4 ) 61 Coupling Carbon Steel
10 Test code API 610 62 Fasteners in pump Assembly MS
External water inlet and outlet
11 Rated capacity m3/hr 2 63 Not applicable
connection (if applicable)
12 Suction Temperature deg C 55 deg C 64 Performance test Yes.
13 Suction Pressure Atm. 65 Testing standard API 610
GENERAL
Sole Plate, Coupling, Foundation Bolts

14 Total head developed at rated capacity Mlc 17 Mlc P2 66 Supply of Accessories
( if any additional vendor to mention)
15 Head developed by pump at bowl kg/cm^2 1.5 67 Prime Mover Crompton / Kirloskar 01 HP Motor
Weight of the pump assembly
WEIGHT AND
DIMENSIONS
16 Shut-off head Mlc 20 Mlc 68 Kg 95
(approx)
DATA
Approximate weight of the pump
17 Runout capacity m3/hr 2.3 69 Kg 105
P2 and drive assembly
Dimension and weight of largest
18 Runout head Mlc 15 Mlc 70 Kg 95 Max.
removable piece
19 Pump efficiency at rated capacity KW 0.69 Kw 71
Guaranteed Pump shaft input power at rated
20 KW 0.75 Kw 72
capacity
21 Pump shaft input required at runout capacity KW 0.75 Kw 73

Maximum pump shaft input power required
22 KW 0.75 Kw 74
within the working range of the pump
23 Motor rating KW 0.75 Kw 75
24 Pump rated speed (Nominal Design Speed) RPM 0.75 Kw 76

Noise level at a distance of 1m from outline
25 dB(A) 85 at 1m. Distance 77
of equipment
26 Type of lubrication Self Lubricant 78
27 Automatic float level switch for start/stop N.A 79

Suction strainer (mesh size, material, flow,
28 25 Mesh 80
area)
29 Liquid handled Hydrocarbon Condensate 81
30 Viscosity 0.71 to 0.73 cp 82
31 SP. Gravity 0.715 to 0.72 83
32 Vessel ID 1050 84
33 Suspension Depth Provided the Tank Dwg 85
34 Type of casing Cast Steel 86
35 Type of impeller SS 304 87
36 Type of shaft SS 304 88
CONSTRUCTION FEATURES
37 Strainer body CS 89
38 Strainer mesh 25 Mesh 90
39 Chain length As per P.I Drawing 91
40 Cable length As per P.I Drawing 92
41 Hose length N.A 93
42 Suction connection (size / rating / type) 40 mm Flanged End ANSI 16.5 150 # 94
43 Discharge connection (size / rating / type) 25 mm Flanged End ANSI 16.5 150 # 95
44 No. of stages (if applicable) Nos Single Stage 96
45 Volute Volute type 97
46 Shaft size (under pump-motor coupling) mm 28 98
47 Bearing (type,rated life) Ball Bearing , Basic rating Life 132473 Hrs 99
48 Sealing arrangement Double Mechanical Sealing arrangement 100
49 Type of Coupling between pump and motor Flexible Shaft Coupling 101
Is the pump suitable for reversed Flow
50 Yes 102
condition?
51 Mode of pump Starting DOL Starting 103
52 Diametrical clearance between wear rings mm 0.05 to 0.1 in 104
To be filled-up by the pump vendor when marked as “ * “

The datasheet shall be subject to L&T approval.
Data sht. No: BHE-L826-YT01-01-EKE-12-0004-00

Gas Conditioning Skid

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Gas Conditioning Skid

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NORTH-WEST POWER GENERATION COMPANY

EPC Sub Contractor:

√ Specially highlighted deviations are included in attached Deviation sheet

GASTECH PROCESS ENGINEERING(I) PVT. LTD.

OPERATION AND MAINTENANCE MANUAL

OWNER: NORTH WEST POWER GENERATION COMPANY LTD.

CLIENT: LARSEN & TOUBRO LTD.

PROJECT: BHERAMARA COMBINED CYCLE POWER PLANT (360 MW)

CONRACT No: BD-P71-14022

Doc. No.: BHE-L826-CQ02-01-EKE-86-0001-00

1.0 EQUIPMENT DESCRIPTION

The Fuel Gas Conditioning System consists of the following equipment:

(1) Emergency Shut Down Valve, 1 x 100%

(1) Horizontal Filter Separators, 2 x 100%

1.1 Emergency shutdown valve (ESDV)

An ultrasonic flow meter is provided to monitor the flow rate.

1.2 Knockout Drum 01EK76-BB001 & 01EK76-BB002

1.3 Fuel Gas Condensate Drain Tank 01EK76-BB003

1.4 Horizontal Filter Seperator 01EK76-BB004 & 01EK76-BB005

1.5 Fuel Gas Condensate Drain Tank-B01EK76-BB006

Safety is a very special commitment at GasTech. Good safety performance is an item of

(1) Emergency Shut Down Valve, 1 x 100%

(1) Horizontal Filter Separators, 2 x 100%

Place the skid assembles on a suitably designed level foundation.

Remove any shipping braces that may have been employed.

Install any temperature or pressure indicators shipped loose.

Examine the gas piping for loose fittings. Tighten as required.

Examine instrumentation for loose fittings or damage in transit. Tighten as required.

Examine the piping flanges for loose bolts. Tighten as required.

4.1 SKID INLET

4.2 Knockout Drum 01EK76-BB001 & 01EK76-BB002

4.3 Fuel Gas Condensate Drain Tank 01EK76-BB003

A Flame Arrestor is furnished for the Drain Tank Vent.

4.4 Horizontal Filter Separator 01EK76-BB004 & 01EK76-BB005

4.4.1 Filter Upper Chamber

4.4.2 Filter Lower Chamber

A level gauges 01EK76-CL108/112 and 01EK76-CL110/114 are provided in the upper

A temperature indicator 01EK76-CT503 and a pressure indicator 01EK76-CP505 is

4.5 Fuel Gas Condensate Drain Tank-B01EK76-BB006

A Flame Arrestor is furnished for the Drain Tank Vent.

a) The method of eliminating potential operating problems is to have an effective

5.1.2 Process Checks

a) Always maintain liquid levels in the gauge glasses in the vessels.

b) Periodic Shutdown and General Inspection

Every year or when required by operation, a shutdown and complete inspection

6.0 FUNCTIONAL TEST PROCEDURE

2. Prior to commencement of the functional test all cables are to be fully

5. All transmitters will be subjected to a three point calibration check (range

6. Where instrument calibrations are found to be incorrect, recalibration of the

C) Reference should be made to the following drawings and documents:-

D) LEVEL INSTRUMENT FUNCTION TESTS

1. LEVEL TRANSMITTERS: GWR TYPE

a) Apply a 24V DC supply to the corresponding terminals of the level

a) Remove the temperature gauge from its respective thermo-well and

1). Pneumatic Only Test: Stroke valve utilizing a Pneumatic Calibration

2). Electro-Pneumatic Test

a) Apply air supply to the shutdown valve as per supply pressure

b) Remove air from valve and confirm failure mode.

c) Remove signal from valve and confirm failure mode.

a) Carry out insulation resistance tests on all instrumentation electrical

d) Check accessibility to all instruments/valves, etc., required for normal

Problem: Leaking Flanges

Problem: Level Transmitter not functioning

Problem shut down Valve not functioning