As Built: Ministry of Electricity, IRAQ QUDUS / 3 Gas Turbine Power Plant

AS BUILT
F 07/11/14 As Built BCP BCP CIW

01 09/07/13 ISSUED FOR CONSTRUCTION B. PARKINS B. PARKINS C. WHALE
00 10/04/12 ISSUED FOR APPROVAL I. AHMAD B. PARKINS C. WHALE
REV. DATE DESCRIPTION DSGN CHKD APPD
EMPLOYER :
Ministry of Electricity, IRAQ

PROJECT :
QUDUS / 3 Gas Turbine Power Plant

CONTRACTOR :
SUBCONTRACTOR : PEERLESS EUROPE LIMITED
DESIGNED BY DATE TITLE :
I. AHMAD 10/04/12
SYSTEM DESCRIPTION INCLUDING DESIGN DATA
CHECKED BY DATE &
OPERATION PHILOSPHY
B. PARKINS 10/04/12
APPROVED BY DATE DOCUMENT NUMBER PROJECT NO. REV.
C. WHALE 10/04/12 QHM-FS-28-001 - F

2 Revised 05/04/12 M.M. W.R. C.P.
Operating, Control and 1 Revision 28/02/12 M.M. W.R. C.P.
Safeguarding Philosophy 0 First emission 20/01/12 M.M. W.R. C.P.

REV Descrizione Data Disegnato Controllato Approvato
REV Description Date Prepared Checked Approved
CLIENTE IMPIANTO LOCALITA’ PROGETTO FOGLI

Customer Peerless Europe Plant QUDUS/3 Location BAGHDAD Job No. T1265 Sheets 24
CLIENT:
PEERLESS EUROPE LTD
QUDUS/3 PROJECT
OPERATING, CONTROL AND SAFEGUARDING
PHILOSOPHY
File: 235-T1265-Operating-Control-Safeguarding Philosophy_rev2 Pag. 1 di 24

2 Revised 05/04/12 M.M. W.R. C.P.


INDEX
1 INTRODUCTION.............................................................................................. 5
1.1 Document Purpose .......................................................................................................... 5
1.2 Brief Process Description ................................................................................................ 5
2 INLET SHUTDOWN SKID ............................................................................... 6
2.1 Process controll intent ..................................................................................................... 6

2.1.1 Functional description .................................................................................. 6
2.1.2 Normal steady state ..................................................................................... 6
2.2 Safeguarding intent ......................................................................................................... 6
2.3 Start-up ............................................................................................................................ 6

2.3.1 Safeguards during startup ............................................................................ 6
2.4 Shut-down........................................................................................................................ 6
2.4.1 Safeguards during shut-down ....................................................................... 7
3 FUEL GAS KO VESSEL .................................................................................. 7
3.1 Process control intent ...................................................................................................... 7

3.1.1 Functional Description .................................................................................. 7
3.1.2 Normal Steady State .................................................................................... 7
3.2 Safeguarding intent ......................................................................................................... 7
3.3 Start-up ............................................................................................................................ 8

3.3.1 Safeguards during startup ............................................................................ 9
3.4 Shut-down........................................................................................................................ 9
3.4.1 Safeguards during shut-down ....................................................................... 9
4 FILTER SEPARATORS ................................................................................... 9
4.1 Process control intent .................................................................................................... 10

4.1.1 Functional Description ................................................................................ 10
4.1.2 Normal Steady State .................................................................................. 10
4.2 Safeguarding intent ....................................................................................................... 10
4.3 Start-up .......................................................................................................................... 11

4.3.1 Safeguards during startup .......................................................................... 12
4.4 Shut-down...................................................................................................................... 12
4.4.1 Safeguards during shut-down ..................................................................... 12
5 GAS METERING SKID .................................................................................. 12

2 Revised 05/04/12 M.M. W.R. C.P.



5.3 Start-up .......................................................................................................................... 13

5.4 Shut-down...................................................................................................................... 14
6 WATER BATH HEATERS ............................................................................. 14

6.3 Start-up .......................................................................................................................... 16

6.4 Shut-down...................................................................................................................... 17
7 PRESSURE REDUCING SKID ...................................................................... 17

7.3 Start-up .......................................................................................................................... 19

7.4 Shut-down...................................................................................................................... 20
8 ELECTRIC HEATERS SKIDS ....................................................................... 20

8.3 Start-up .......................................................................................................................... 21

8.4 Shut-down...................................................................................................................... 22

2 Revised 05/04/12 M.M. W.R. C.P.


9 CONDENSATE TANK AND PUMP SKID ...................................................... 22

9.3 Start-up .......................................................................................................................... 22

9.4 Shut-down...................................................................................................................... 23
10 CONDENSATE TANK FOR GT SKID ........................................................... 23

10.1.1 Functional Description ............................................................................ 23
10.1.2 Normal Steady State .............................................................................. 23
10.3 Start-up .......................................................................................................................... 23

10.3.1 Safeguards during startup ...................................................................... 24
10.4 Shut-down...................................................................................................................... 24
10.4.1 Safeguards during shut-down ................................................................. 24

2 Revised 05/04/12 M.M. W.R. C.P.


1 INTRODUCTION
1.1 Document Purpose
This document describes the operating, control and safeguarding philosophy of GTP (Gas
Treatment Plant) facilities to be installed as a part of QUDUS/3 Project.
1.2 Brief Process Description
The fuel gas, received from 12” pipeline, will be conditioned in the GTP Package to get the
required gas quality and parametric conditions (pressure, temperature, etc.) at the battery limit
of Gas Turbines. The conditioned gas will be routed to the Gas Turbine Generators.
The major equipments in Gas Treatment Plant (GTP) packages shall be Fuel Gas KO Vessel
(2x100%), Filter separators (2x100%), gas metering system (1x100%) gas fired indirect water
bath heaters (2x100%), Pressure Reduction Train (2x100%) etc. Common Drain Vessel and
vent stack shall be provided as a part of Gas Treatment Plant.
At fuel gas inlet there is one emergency shutdown ball valves to isolate the GTP in case of
problems.
The fuel gas is treated into the KO vessel (one operating and the other spare), where droplets
and entrained liquids are collected in the bottom of the vessel while the gas goes to the filter
separators one operating and the other spare. Into the filter separator the residual smaller
droplets are separated. After the filters the fuel gas goes through a gas metering unit, in which
the flowrate is measured.
After the gas metering unit the gas is treated into the Water Bath Heaters one operating and
the other in stand-by.
Inside the water bath heater the fuel gas is superheated at least 60°C.
After the heating there are two skid of pressure reduction. Each skid has two pressure reducing
train (one spare), in which the gas is expanded to 27.5 barg. In this condition the fuel gas is
above its dew point and free of droplets and solids.
After each pressure reducing trains there are one pressure transmitter and one temperature
transmitter to control the fuel gas parameters before the gas turbine.
There are four fuel gas electric heater skids between the pressure reduction skids and the gas
turbines (one skid for each gas turbines), in order to heat the fuel gas during the phase of plant
start up.
The liquid collected on the bottom of the KO vessels and filter separators is drained to the drain
vessel.
The vent header is collected to the cold vent stack. The cold vent stack discharges the
vapours/gases in atmosphere.

2 Revised 05/04/12 M.M. W.R. C.P.


2 INLET SHUTDOWN SKID
Refer ro P&I, Dwg. 11-3357-PID-050 rev.1
2.1 Process controll intent
2.1.1 Functional description

The inlet shutdown skid is an emergency shutdown device. In case of emergency somewhere
in the gas treatment plant, the inlet shutdown skid close the fuel gas feed.
In the inlet shutdown skid the gas temperature and pressure are measured by means of the
instrument TT308E and PT307E.
2.1.2 Normal steady state

When the gas treatment plant is normal operating, the valve SDV313E is open. The position of
the valve is measured by open and close limit switches. Fuel gas inlet temperature is
measured by TT308E fuel gas inlet pressure is measured by PT307E and both are indicated
on PLC.
2.2 Safeguarding intent
The main purpose of the safeguarding of the inlet shutdown skid is to prevent damages to the
fuel gas treatment plant in case of plant emergency.
The SDV313E valve position is measured by close and open limit switches and transmitted to
PLC. The valve can be also manually operated.
2.3 Start-up
Caution is necessary during the start-up of the plant where the line downstream is not
pressured up. For this reason for the start-up, the operator shall open the by-pass line. Under
such conditions, flow through the downstream plant should be increased gradually.
When the pressure measured by PT307E has reached the operating value it is possible to
open the SDV313E valve and close the by-pass line.
Before introducing the Fuel Gas, the whole gas treatment plant shall be blanketed with inert
gas (such as nitrogen) to remove oxygen and avoid the formation of explosive and flammable
mixture.
2.3.1 Safeguards during startup

The safeguarding functions will remain the same as during normal operation.
2.4 Shut-down
During the shut-down procedure of the gas treatment plant, the valve SDV313E must be
closed.
The inlet shutdown skid shall be depressurized and vented to the vent so any gas remaining in
the pipe should be purged/vented.
With pipe depressurized and vented it is possible to perform any maintenance activities.
The shutdown sequence is:

2 Revised 05/04/12 M.M. W.R. C.P.


- Turn off the water bath Heaters.

- Close the valve SDV313E.
- Vent gradually the pipe by means of the vent valve of one KO drum.
- Wait until the pressure is closed to atmosphere
- Purge the line with nitrogen
2.4.1 Safeguards during shut-down

3 FUEL GAS KO VESSEL
Refer to P&Id, Drwg. 11-3357-PID-051 rev. 1
3.1 Process control intent

3.1.1 Functional Description
There are two KO drums installed, one operating and one spare.
The fuel gas KO drum separate liquid droplets from the turbine feed gas. The liquid separated
is collected in the bottom section of the equipments.
The level of the bottom section is indicated in field by level gauges LI302A/LI302B. The liquid
level inside the KO drums is controlled by LC301A/LC301B. High level indication is transmitted
to PLC by LSH 303A/LSH303B. Low level indication is transmitted to PLC by LSL303A/
LSL303B.
3.1.2 Normal Steady State

When the package is operating, the shut-off valve SDV313E (on shutdown skid) is open, the
manual valve C-BVF-12-001/2 are open and the manual valve C-BVF-12-003/4 are closed. The
fuel gas flows inside the Fuel Gas KO Vessel operating.
Fuel gas pressure is measured in field by pressure gauges PI305A/PI305B.

During normal steady state the liquid level is controlled by LC301A/ LC301B. These
instruments acts directly ( by means of pneumatic signals) on the level control valve CV304A/
CV304B in order to maintain the liquid level at the specified set point.
The liquid level is readable in field by means of the level gauges LI302A/LI302B.
In any case, the liquid should not rise above the maximum liquid level indicated by the supplier
because excessive liquid height will result in erratic separator performance (liquid carry over).
High level indication is transmitted to PLC by LSH303A/LSH303B. Low level indication is

transmitted to PLC by LSL303A/ LSL303B.

The main purpose of the safeguarding of the Fuel Gas KO Vessels is to prevent liquid carry
over into the filter separators and downstream water bath heaters in case of high level.
Liquid H level measured by LSH303A/ LSH303B on the Fuel Gas KO Vessel activates the H
alarm on the PLC. When H alarm is actives, the operator shall act the changeover of the KO
drums.

2 Revised 05/04/12 M.M. W.R. C.P.


Liquid HH level measured by LSH303A/ LSH303B on the Fuel Gas KO Vessel activates the HH
alarm on the PLC. The HH alarms generate the interlock 1 and 2.
Liquid L level measured by LSL303A/ LSL303B on the Fuel Gas KO Vessel activates the L
alarm on the PLC. When L alarm is actives, the operator shall act the changeover of the KO
drums.
Liquid LL level measured by LSL303A/ LSL303B on the Fuel Gas KO Vessel activates the LL
alarm on the PLC. The LL alarm generates the interlock 3 and 4.
The interlocks 1,2,3 and 4 closes the shutdown valve SDV313E and stops the water bath
heaters.
3.3 Start-up
Caution is necessary during the start-up of the Fuel Gas KO Vessel where the line downstream
is not pressured up.
Before introducing the Fuel Gas, the vessels shall be blanketed with inert gas (such as
nitrogen) to remove oxygen and avoid the formation of explosive and flammable mixture.
Before align the Fuel gas treatment plant to the vessel downstream, be sure to vent all the inert
gas to the flare header to avoid any problem with the downstream turbine.
When the Fuel Gas KO Vessel is installed on a new line there may be a rapid accumulation of
dirt, iron oxide etc.
Before starting-up the Fuel Gas KO Vessel, be sure that the electric heaters are in service.
To start-up the Fuel Gas KO Vessel the following conditions should be healthy:
o Liquid level LSH303A/LSH303B of the KO drums below H and below HH
o Liquid level LSL303A/LSL303B of the KO drums above L and above LL (if not possible,
the interlock 3 and 4 shall be temporary excluded)
o Liquid level LSH303C, LSH303D, LSH303E, LSH303F of the filter separators below H
and below HH
o Liquid level LSL303C, LSL303D, LSL303E, LSL303F of the filter separators above L
and above LL (if not possible, the interlock 7,8,11 and 12 shall pe temporary excluded)
o Common alarm of the water bath heater shall be not active
o Common trip of the water bath heater shall be not active
o Water bath heater interlock I not active
o Water bath heater interlock 13 not active or temporary excluded
o Pressure PT307C/PT307D (downstream PRV skids) below H and HH
o Temperature TT308C/TT308D L and H alarms temporary excluded.
If the following conditions are healthy the operator can open the valve C-BVF-12-001 and C-
BFV-12-002 (the manual valves C-BVF-12-003 and C-BVF-12-004 stay close), and shall
actuate the start-up procedure described in chapter 3.1.3.
In order to put in service the stand by KO vessel the following procedure shall be operated:
- Open the manual valves C-GV-01-006 and C-GV-01-007

- Wait until the pressure measured by the pressure gauge PI305B reach the operating
value
- Open the valves C-BVF-12-004
- Open the valves C-BVF-12-003

2 Revised 05/04/12 M.M. W.R. C.P.


- Close the valves C-GV-01-006 and C-GV-01-007

- Close the valves C-BVF-12-001 and C-BVF-12-002
Vent and purge the out of service KO drum before opening it.

3.4 Shut-down
During the shut-down procedure the Fuel Gas KO Vessels shall be depressurised and vented
to the vent so any gas remaining in the vessel should be purged/vented.
After shutdown, with vessel purged and vented and with satisfactory internal atmosphere
check, it is possible to access the internals via manholes:
o Open the access covers by undoing the bolts around the flanges and remove the blind
covers and the gaskets.
o Check that internally the vessel is free from dirt, grease, moisture and any other
contaminants.
o After checking, and if the vessel is satisfactory, replace the gasket blind flanges, refit
and tighten the bolts.
There aren’t conditions that shall be healthy to allow the shutdown procedure.
The shut down sequence is:
o Turn off the water bath heaters.

o Close the shut-off valve SDV313E
o Close the manual valve C-BVF-12-002 and C-BVF-12-004
o Open partially the manual valves C-GV-01-005 and C-GV-01-021
o Wait until the internal package pressure (PI305A/PI305B) has dropped to vent
pressure.
o Close the manual valves C-GV-01-005 and C-GV-01-021
o Open the manual valves C-GV-01-008 and C-GV-01-022
o Wait until the KO drum is empty of liquid. If necessary use the nitrogen purging system
to drain the vessels.
o Close the manual valves C-GV-01-008 and C-GV-01-022.
o Before opening the vessel or dismantling any equipment or piping be sure that vessel
is purged and that the internal pressure is close to atmospheric pressure by checking
the package pressure gauges (PI305A/ PI305B).

4 FILTER SEPARATORS
Refer to P&Id, Drwg. 11-3357-PID-052-SHT1/SHT2 rev.1

2 Revised 05/04/12 M.M. W.R. C.P.



The filter separator separates liquid and solids from the turbine feed gas. It is composed by two
stages:
o First stage is made by filter cartridge (first section)
o Second stage contains the Peerless chevron vane mist extractor (second section).
A liquid collection zone is provided at the bottom of each section of the filter (first and second),
where the droplets are collected.
There are two filter separator, one operating the other in stand-by with manual change-over in
case of high level of liquids or high differential pressure.

When the filter is operating the manual valves D-BVF-12-001,D-BVF-12-002 are open,D-BVF-
12-003,D-BVF-12-004 are closed and the fuel gas flows inside the filter separator operating.
The first section liquid collection level is controlled by LC301C/ LC301E.

These instruments acts directly ( by means of pneumatic signals) on the level control valve
CV304C/ CV304E in order to maintain the liquid level at the specified set point.
It is possible to read the first section liquid collection level on the level gage LI302C/ LI302E.
If the instrument LSH303C/LSH303E gives a H alarm the operator shall act the changeover of
the filter separators.
If the instrument LSL303C/LSL303E gives a L alarm the operator shall act the changeover of
The second section liquid collection level is controlled by LC301D/ LC301F. These instruments
acts directly ( by means of pneumatic signals) on the level control valve CV304D/ CV304F in
order to maintain the liquid level at the specified set point.
It is possible to read the second section liquid collection level on the level gage LI302D/ LI302F.
If the instrument LSH303D/LSH303F gives a H alarm the operator shall act the changeover of
If the instrument LSL303D/LSL303F gives a L alarm the operator shall act the changeover of
The differential pressure on the filter coalescer is measured by means of PDT309A/PDT309B.

If the measured pressure value is over the set point, the H alarm is activated on PLC and the
operator shall act the changeover of the filter separators. It is possible to read the filter
separator temperature and pressure on the local gauges TI306A/ TI306B and PI305C/ PI305D.

The main purpose of the safeguarding of the Filter separators is to prevent liquid carry over into
the water bath heaters in case of high level.
The first section liquid collection HH level measured by LSH303C/ LSH303E activates the HH
alarm on the PLC and generates the interlock 5 / 6 .
The first section liquid collection LL level measured by LSL303C/ LSL303E activates the LL
alarm on the PLC and generates the interlock 7 / 8 .

2 Revised 05/04/12 M.M. W.R. C.P.


The second section liquid collection HH level measured by LSH303D / LSH303F activates the
HH alarm on the PLC and generates the interlock 9 / 10.
The second section liquid collection LL level measured by LSL303D / LSL303F activates the
LL alarm on the PLC and generates the interlock 11 / 12.
The interlocks 5,6,7,8,9,10,11 and 12 closes the shutdown valve SDV313E and stops the water
bath heaters.
4.3 Start-up
Caution is necessary during the start-up of the Filter Separator where the line down stream is
not pressured up.
Before introducing the Fuel Gas the vessels shall be blanketed with inert gas (such as nitrogen)
to remove oxygen and avoid the formation of explosive and flammable mixture.
When the Filter Separator is installed on a new line there may be a rapid accumulation of dirt,
iron oxide etc. Debris should also be removed from bottom of the vessel if it has accumulated
there. Before starting-up the Filter Separator, be sure that the electric heaters are in service.
To start-up the Filter Separator the following conditions should be healthy:

and below HH
If the following conditions are healthy the operator can open the valve D-BVF-12-001 and D-
BFV-12-002 and shall actuate the start up procedure described in chapter 3.1.3.
In order to put in service the stand by filter separator the following procedure shall be operated:
- Open partially the manual valve D-BVF-12-003.

- Wait until the pressure measured by the pressure gauge PI305D reach the operating
value
- Fully open the valves D-BVF-12-003
- Open the valves D-BVF-12-004
- Close the valves D-BVF-12-001 and D-BVF-12-002
Vent and purge the out of service filter separator before opening it.

2 Revised 05/04/12 M.M. W.R. C.P.



4.4 Shut-down
During the shut-down procedure the Filter Separators shall be depressurised and vented to the
vent so any gas remaining in the vessel should be purged/vented.
After shutdown, with vessel purged and vented and with satisfactory internal atmosphere
check, it is possible to access the internals via manholes:
o Open the access covers by undoing the bolts around the flanges and remove the blind
covers and the gaskets.
o Check that internally the vessel is free from dirt, grease, moisture and any other
contaminants.
o After checking, and if the vessel is satisfactory, replace the gasket blind flanges, refit
and tighten the bolts.

o Close the manual valves D-BVF-12-001/D-BVF-12-003 and D-BVF-12-002/D-BFV-12-
004.
o Open the 1” manual vent valves.
o Wait until the internal package pressure (PI305C/PI305D) has dropped to vent
pressure.
o Close the vent manual valves
o Open the manual valves D-GV-01-011/D-GV-01-031 and D-GV-01-016/D-GV-01-036
o Wait until the filter separators are empty of liquid. If necessary use the nitrogen purging
system to drain the vessels.
o Close the manual valves D-GV-01-011/D-GV-01-031 and D-GV-01-016/D-GV-01-036
o Before opening the vessel or dismantling any equipment or piping be sure that vessel
is purged and that the internal pressure is close to atmospheric pressure by checking
the package pressure gauges (PI305C/ PI305D).
5 GAS METERING SKID
Refer to P&Id, Drwg. 11-3357-PID-053 rev.1

The gas metering skid measures the flowrate of turbines feed. This is a fiscal measure.
There are two measuring trains working in series, but there is also the possibility to have one
train operating and one spare.

2 Revised 05/04/12 M.M. W.R. C.P.



When the gas metering skid is operating the manual valves F-BV-12-003, F-BV-12-005 and F-
BV-12-002 are open, the manual valves F-BV-12-001 and F-BV-12-004 are closed and the gas
flows inside the two trains (in series).
The flowrate is measured and transmitted to PLC by FT310A and FT310B.
It is possible to read the pressure of each train by means of pressure gauges PI305E / PI306F.
The pressure is also measured and transmitted to PLC by PT307A and PT307B.
The temperature is measured and transmitted to PLC by TT308A and TT308B.
The fuel gas is also sampled and analyzed by means of a gas chromatograph connected to the
gas metering skid on a branch line. The gas chromatograph (0Z-FS-MT-002) is connected to
the PLC.

The main purpose of the gas metering skid is to check the gas flowrate that the turbines are
using.
The gas composition is measured by the gas chromatograph in order to check the calorific
power.
5.3 Start-up
Caution is necessary during the start-up of the gas metering skid where the line down stream is
not pressured up.
Before introducing the Fuel Gas the pipes shall be blanketed with inert gas (such as nitrogen)
Before starting-up the gas metering skid, be sure that the electric heaters are in service.
To start-up the gas metering skid the following conditions should be healthy:

and below HH
If the following conditions are healthy the operator can open the valve F-BV-12-003, F-BV-12-
005 and F-BV-12-002. When these manual valves are open the start up procedure described
into chapter 3.1.3 can start.

2 Revised 05/04/12 M.M. W.R. C.P.


5.4 Shut-down
During the shut-down procedure the gas metering skid shall be depressurised and vented to
the vent so any gas remaining in the vessel should be purged/vented.
After shutdown, with pipe purged and vented, it is possible to perform maintenance activities.

o Close the manual valves F-BV-12-002.
o Open the 1” manual vent valves of the filter separators.
o Wait until the internal gas metering skid pressure (PI305E/PI306F) has dropped to vent
pressure.
o Close the vent manual valves
o Close the manual valves F-BV-12-003, F-BV-12-005
o Before dismantling the pipes be sure that vessel is purged and that the internal
pressure is close to atmospheric pressure by checking the package pressure gauges
(PI305E/ PI306F).

6 WATER BATH HEATERS
Refer to P&Id, Drwg. QHM-FS-22-003 rev. 1

The Water Bath Heater overheats the saturated fuel gas from inlet temperature (34°C) to
60.3°C.
Fuel gas is indirectly heated in a water bath. Water is heated by means of fuel gas burner.
There are two water bath heaters, one operating the other in stand-by with manual change-over
logic.
Each water bath heater has a branch line on the main gas line. The branch line is used to feed
the burner. The branch gas line is connected to a valve panel that reduce the gas pressure.
The gas then flows inside the burner box that regulate the final pressure and flowrate of the fuel
gas to the burner.
Each water bath heater has a local control panel, that is interfaced with the PLC.

When the water bath heater is operating the inlet shutdown valves HV (two valves) are open.
The position of the valves HV (two valves) are measured by means of open and close limit
switches. The positions are indicated at PLC.
Fuel gas inlet pressure and temperature are indicated on PI315A/PI315B and TI316A/TI316B.
Water bath temperature is indicated at PLC by TT326C/TT326D (via local control panel).
Water bath temperature is controlled by local panel by TT326C/TT326D.

2 Revised 05/04/12 M.M. W.R. C.P.


If the water bath temperature TT326C/TT326D is below set point, TT326C/TT326D acts on
burner box and increase the fuel gas flowrate to the burner. If TT326C/TT326D is over the set
point, TT326C/TT326D acts on the burner box and decrease the fuel gas flowrate to the burner.
When in DUTY, set point of TT326C/TT326D is given by remote temperature (at turbine’s gas
inlet). If fuel gas inlet turbine temperature is below the set point (fixed by turbines vendor)
then increase the set point of TT326C/TT326D. If fuel gas inlet turbine temperature is over the
set point then decrease the set point of TT326C/TT326D.
When in STAND-BY the set point of TT326C/TT326D can be set by operator.
Fuel gas outlet temperature and pressure are readable in filed by means of TI316C/TI316D and
PI315C/PI315D, and are transmitted to PLC by TT and PT.
If the fuel gas outlet temperature is L, an alarm is activated on PLC and the operator shall act
the change-over of the water bath heaters.
Water bath temperature is measured by TT326E/TT326E. If the temperature is H,L or LL a

common alarm UA338C/UA338D is activated on PLC and the operator shall act the change-
over of the water bath heaters.
Water bath level is measured by LT323A/LT323B. In case of L or H level a common alarm

UA338C/UA338D is activated on PLC and the operator shall act the change-over of the water
bath heaters. The level is readable in field by means of LI324A/LI324B.
Water bath heater stack temperature is measured by TT326E/TT326E. If the temperature is H

a common alarm UA338C/UA338D is activated on PLC and the operator shall act the change-
over of the water bath heaters.
The valve panel reduces the pressure of the fuel gas. If the pressure is H (measured by
PSH318A/PSH318B) a common alarm UA338C/UA338D is activated on PLC and the operator
shall act the change-over of the water bath heaters.
The fuel gas flowrate to the burner is measured and transmitted via local control panel to PLC
by FI317A/FI317B.

The main purpose of the safeguarding of the Water Bath Heaters is to prevent very low level of
the water bath to avoid any damages on the heater and to ensure the correct heating of the fuel
gas.
The water bath heater level LL measured by LSLL352A/LSLL352B activates the common trip
signal UA338A/UA338B to PLC and generates the internal common interlock i. The interlock i is
managed by the local control panel.
Another purpose is to prevent a very high temperature of the water bath.

The water bath temperature HH measured by TT326A/TT326B activates the common trip
signal UA338A/UA338B to PLC and generates the common interlock i. The interlock i is
managed by the local control panel.
If the fuel gas pressure inside the burner box is H (measured by PSH318I/PSH318J), HH
(measured by PSHH318C/PSHH318D) or L (measured by PSL318G/PSL318H) and/or the
combustion air pressure (measured by PSL318E/PSL318F) is L, the common trip signal
UA338A/UA338B to PLC is activated and the common interlock i is managed by the local
control panel.
If the gas detector GD331A/GD331B inside the burner box detects the fuel gas, the common
trip signal UA338A/UA338B to PLC is activated and the common interlock i is managed by the

2 Revised 05/04/12 M.M. W.R. C.P.


local control panel. It is also activated the gas detection HH alarm GAHH331A/GAHH331B to
PLC that generates an interlock I.
The malfunctioning of the burner is detected by FD330A/FD330B. It generates the common

interlock i (managed by the local control panel) and generates the common trip signal
UA338A/UA338B to PLC.
The fuel gas outlet temperature LL measured by TT activates the LL alarm on PLC and
generates the interlock 13.
When the common trip signal UA338A/UA338B to PLC is activated the PLC closes the valve
HV/HV and the operator shall act the water bath heater change-over.
When the interlock I is activated the PLC closes the shutdown valve HV/HV and the operator
shall act the water bath heater change-over.
The interlock 13 closes the shutdown valve SDV313E and stops the water bath heaters.
6.3 Start-up
Caution is necessary during the start-up of the Water bath heater gas side where the line down
stream is not pressured up.
Before introducing the Fuel Gas the Water Bath Heater tube side shall be blanketed with inert
gas (such as nitrogen) to remove oxygen and avoid the formation of explosive and flammable
mixture.
Before align the Water Bath Heater to the line downstream, be sure to vent all the inert gas to
the flare header to avoid any problem with the downstream turbine.
The water bath shall be filled with water to reach the correct level in the expansion tank. Before
starting-up the Water bath heaters, be sure that the electric heaters are in service.
To start-up the water bath heater the following conditions should be healthy:

and below HH
If the following conditions are healthy the operator can open the valve K-BV-12-001/K-BV-12-
002 and shall actuate the start up procedure described in chapter 3.1.3.
The local control panel gives the following signals to the PLC:
- YSO337A/YSO337B: heater running
- YSA332C/YSA332D: heater start permissive
- YSR335A/YSR335B: remote mode
The PLC gives the following signals to the local control panel:
- JYR333A/JYR333B: reset alarm
- JYO333A/JYO333B: remote start

2 Revised 05/04/12 M.M. W.R. C.P.


- JYC333A/JYC333B: remote stop
The water bath heater shall be in remote mode. The status is signaled to PLC by
YSR335A/YSR335B. When the local control panel gives the heater start permissive to PLC
YSA332C/YSA332D, the PLC gives the remote start JYO333A/JYO333B.
When the water bath heater is running the local control panel gives the heater running signal
YSO337A/YSO337B to PLC.
For the start up procedure of the valve panel and the burner box, please refer to manufacturer
instruction.

6.4 Shut-down
The water bath heater can be stopped by PLC (JYC333A/JYC333B).
During the shut-down procedure the Water bath heater shall be depressurised and vented to
the vent so any gas remaining in the tube side should be purged/vented.
After shutdown, with tube side purged and vented and bath side cooled down, it is possible to
start maintenance on the water bath heater.
o Turn off the water bath heater by means of JYC333A/JYC333B.

o Close the shut-off valve HV/HV.
o Close the 12” manual isolation valves.
o Vent the pipe.
o Wait until the water bath heater (gas side) internal pressure
(PI315A/PI315B/PI315C/PI315D) has dropped to the vent pressure.
o If necessary drain the water bath heater.
o Before opening or dismantling any equipment or piping be sure that the piping is
purged and that the internal pressure is close to atmospheric pressure by checking the
package pressure gauges.

7 PRESSURE REDUCING SKID
Refer to P&Id, Drwg. 11-3357-PID-054/055 rev.1

There are two pressure reduction skid installed, one for GT #1A and #1B and one for GT #2A
and #2B.

2 Revised 05/04/12 M.M. W.R. C.P.


Each pressure reducing skid consists of 2 x 100% pressure let down trains operating in parallel
(one operating and one spare).
Each pressure let down train is composed by:
o Nr. 1 automatic slam shutdown valve
o Nr. 1 pressure control valve 100% reducing capacity, self acting.
o Nr. 1 pressure control valve 100% reducing capacity, self acting.
o Nr. 1 pressure gauges
o Nr. 1 temperature gauges
o Nr. 1 PSV
o Nr. 1 check valve
o Nr. 2 manual valves
Downstream of the pressure reduction trains there are:

o Nr. 1 pressure transmitter for H and HH alarm
o Nr. 1 temperature transmitter for L,H,HH alarm

In steady state the automatic slam shutdown valve SDV313A/SDV313C are open and
SDV313B/SDV313D are close. The position of SDV313A/SDV313C and SDV313B/SDV313D
is measured by open and close limit switches. The position is indicated at PLC.
Pressure reducing train # 1 is composed by PCV312A/PCV312B and PCV312C/PCV312D,
pressure reducing train # 2 is composed by PCV312E/PCV312F and PCV312G/PCV312H.
In normal steady state condition the pressure reducing train #1 is in duty (manual valves G-
BVF-10-001A / H-BFV-10-001A G-BVF-10-001B/H-BVF-10-001B open and
SDV313A/SDV313C open) and #2 is in stand-by (manual valves G-BVF-10-002A / H-BFV-10-
002A, G-BVF-10-002B/H-BVF-10-002B open and SDV313B/SDV313D close).
The first pressure reduction valve PCV312A/PCV312E, PCV312B/ PCV312F is the normal duty
pressure reduction valve. It is able to carry the full pressure reduction duty and it is failure open.
The second pressure reduction valve (PCV312C/ PCV312G, PCV312D/ PCV312H) shall
normally be the stand by and be designed to carry out the full pressure reduction duty. It is fail
closed type.
The fuel gas pressure upstream the pressure reduction valves is measured by the pressure
gauges PI305G/PI305H and PI305K/ PI305L.
The fuel gas temperature upstream the pressure reduction valves is measured by the
temperature gauges TI306C/ TI306D and TI306G/ TI306H.
There is an automatic slam shutdown valve (SDV313A/SDV313B/SDV313C/SDV313D)

upstream the pressure reduction valves, that automatically close when the pressure
downstream the pressure reduction valves rise over 29 barg.
The fuel gas pressure downstream the pressure reduction valves is measured by means of the
pressure gauges PI305I/ PI305J and PI305M/ PI305N.
The fuel gas temperature downstream the pressure reduction valves is measured by the
temperature gauges TI306E/ TI306F and TI306I/ TI306J.
Each pressure reduction train is protected against the overpressure by means of one PSV
(PRV300E / PRV300F and PRV300G/ PRV300H) installed downstream the pressure reduction
valves.

2 Revised 05/04/12 M.M. W.R. C.P.


The pressure of the fuel gas is measured and transmitted to PLC downstream both pressure
reduction trains by PT307C / PT307D.
The temperature of the fuel gas is measured and transmitted to PLC downstream both
pressure reduction trains by TT308C / TT308D.

The main purpose of the safeguarding of the pressure reducing station is to prevent high
pressure and low temperature of fuel gas at gas turbine inlet to avoid any problem during the
operation.
H pressure of the fuel gas downstream the pressure reduction trains is measured by
PT307C/PT307D. The H alarm is activated on PLC. With H alarm the PLC shall changeover
the pressure reduction train opening the valve SDV313B/SDV313D and closing the valve
SDV313A/SDV313C.
If the pressure rise up the H value, the automatic slam shut valve
SDV313A/SDV313B/SDV313C/SDV313D shall close by means the slam shut devices. Once
the slam shut device has been tripped, it must be manually reset.
HH pressure of the fuel gas downstream the pressure reduction trains is measured by
PT307C/PT307D. The HH alarm activates the interlock 14 and 15.
The interlocks 14 and 15 closes the shutdown valve SDV313E and stops the water bath
heaters.
The temperature L level is measured by TT308C/TT308D. The L alarm is activated on PLC. In

correspondence of L alarm the operator shall check the water bath heater and shall
changeover them (if any).
The temperature H level is measured by TT308C/TT308D. The H alarm is activated on PLC. In

correspondence of H alarm the operator shall check the water bath heater and shall
changeover them (if any).
7.3 Start-up
Caution is necessary during the start-up of the pressure reduction skid where the line down
Before introducing the Fuel Gas, the pipes shall be blanketed with inert gas (such as nitrogen)

and below HH

2 Revised 05/04/12 M.M. W.R. C.P.



If the following conditions are healthy the operator can open the valve G-BVF-10-001A/H-BFV-
10-001A, G-BVF-10-001B/H-BVF-10-001B, G-BVF-10-002A/H-BVF-10-002A, G-BVF-10-
002B/H-BVF-10-002B and SDV313A/SDV313C. When these manual valves are open the start
up procedure described into chapter 3.1.3 can start.

7.4 Shut-down
During the shut-down procedure the pressure reducing skids shall be depressurised and
vented to the vent so any gas remaining in the pipe should be purged/vented.
After shutdown, with pipe purged and vented, it is possible to start maintenance.
o Turn-off the water bath heaters

o Close the shut-off valve SDV313E.
o Close the manual valves G-BVF-10-001A/H-BFV-10-001A, G-BVF-10-001B/H-BVF-10-
001B, G-BVF-10-002A/H-BVF-10-002B.
o Depressurize the system
o Wait until internal pressure PI305G/PI305K, PI305H/PI305L, PI305I/PI305M and
PI305J/PI305N has dropped to the vent pressure.
o Close the vent valves.
o Before opening or dismantling any equipment or piping be sure that the piping is
purged and the internal pressure is close to atmospheric pressure by checking the
package pressure gauges.

8 ELECTRIC HEATERS SKIDS

There are four electric heater skids, one for each gas turbine.

2 Revised 05/04/12 M.M. W.R. C.P.


The electric gas heaters shall be used during start up of the gas treatment plant, in order to
ensure the minimum fuel gas temperature of 35°C.
The fuel gas temperature in main line is measured and transmitted to PLC of the client by
TT002. It is also possible to measure the temperature by means of the temperature gauges
TI004.

There are four electric heater skids, one for each gas turbine.
The electric gas heaters shall be used during fuel gas treatment plant start up.
The fuel gas temperature in main line is measured and transmitted to PLC of the client by
TT002. It is also possible to measure the temperature by means of the temperature gauges
TI004.
The fuel gas temperature in heaters line is measured and transmitted to PLC of the client by
TT001. This instrument regulates the power of the electric heater. It is also possible to measure
the temperature by means of the temperature gauges TI003.

The main purpose of the safeguarding of the electric heaters skid is to prevent the damage of
the electric resistances and to avoid the low temperature of fuel gas at gas turbine inlet.
The instruments TIT001, and TIT002 measures the skin temperature of the electric resistances.
When the temperature is above the set point, the power supply to the electric heaters is cutted.
8.3 Start-up
Caution is necessary during the start-up of the pressure reduction skid where the line down
Before introducing the Fuel Gas, the pipes shall be blanketed with inert gas (such as nitrogen)
o Skin temperature of the electric heaters resistance below set point.
If the following conditions are healthy the start up procedure described into chapter 3.1.3 can
start.


2 Revised 05/04/12 M.M. W.R. C.P.


8.4 Shut-down
During the shut-down procedure the electric heater skids shall be depressurised and vented to
the vent so any gas remaining in the pipe should be purged/vented.
After shutdown, with pipe purged and vented, it is possible to start maintenance.
Before opening or dismantling any equipment or piping be sure that the piping is purged and
the internal pressure is close to atmospheric.

9 CONDENSATE TANK AND PUMP SKID
Refer to P&Id, Drwg. 11-3357-PID-057 rev. 1

The condensate tank and pump skid collects the process drain coming from KO drums and
from filter separators.
The level of the tank is measured by LI302G
The tank collects the drains automatically discharged by the KO drums and by the filter
separators.
The level of the tank is measured by the level gauge LI302G.
The liquid collected into the tank is transferred on a truck by means of the transfer pump. There
are two pump installed, one operating and one spare. The local switch will start the pump.
When the tank is empty the instrument LSL 303G will stop the pump.

The main purpose of the safeguarding of the condensate tank and pump skid is to prevent the
tank overflow.
H level is measured by LSH303G, that acts an alarm on the PLC. The operator shall empty the
tank.
9.3 Start-up
To start-up the condensate tank and pump skid the following conditions should be healthy:
o H level below set point.

2 Revised 05/04/12 M.M. W.R. C.P.


If the following conditions are healthy the operator can manually align the tank to the plant
opening the manual valve E-BVF-02-001.

9.4 Shut-down
During shutdown procedure the tank shall be empty and purged in order to vent any gas
remaining into the tank.
After shutdown, with tank empty and purged, it is possible to start maintenance.

10 CONDENSATE TANK FOR GT SKID

The condensate tank for GT skid collects the process drain coming from gas turbines.
The level of the tank is measured by LI302H.
The tank collects the drains discharged by the gas turbines.
The level of the tank is measured by the level gauge LI302H.
When the tank is empty the instrument LSL303H stops the liquid transfer.

The main purpose of the safeguarding of the condensate tank for GT skid is to prevent the tank
overflow.
H level is measured by LSH303H, that acts an alarm on the client PLC. The operator shall
empty the tank.
10.3 Start-up
To start-up the condensate tank for GT skids the following conditions should be healthy:

2 Revised 05/04/12 M.M. W.R. C.P.


o H level below set point.
If the following conditions are healthy the operator can manually align the tank to the plant
opening the manual valve J-BVF-02-001.

10.4 Shut-down
During shutdown procedure the tank shall be empty and purged in order to vent any gas
remaining into the tank.
After shutdown, with tank empty and purged, it is possible to start maintenance.


As Built: Ministry of Electricity, IRAQ QUDUS / 3 Gas Turbine Power Plant

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AS BUILT

F 07/11/14 As Built BCP BCP CIW

Ministry of Electricity, IRAQ

QUDUS / 3 Gas Turbine Power Plant

SUBCONTRACTOR : PEERLESS EUROPE LIMITED

DESIGNED BY DATE TITLE :

APPROVED BY DATE DOCUMENT NUMBER PROJECT NO. REV.

C. WHALE 10/04/12 QHM-FS-28-001 - F

Operating, Control and 1 Revision 28/02/12 M.M. W.R. C.P.

Safeguarding Philosophy 0 First emission 20/01/12 M.M. W.R. C.P.

CLIENTE IMPIANTO LOCALITA’ PROGETTO FOGLI

PEERLESS EUROPE LTD

File: 235-T1265-Operating-Control-Safeguarding Philosophy_rev2 Pag. 1 di 24

Operating, Control and 1 Revision 28/02/12 M.M. W.R. C.P.

Safeguarding Philosophy 0 First emission 20/01/12 M.M. W.R. C.P.

CLIENTE IMPIANTO LOCALITA’ PROGETTO FOGLI

1.1 Document Purpose .......................................................................................................... 5

1.2 Brief Process Description ................................................................................................ 5

2 INLET SHUTDOWN SKID ............................................................................... 6

2.1 Process controll intent ..................................................................................................... 6

2.2 Safeguarding intent ......................................................................................................... 6

2.3 Start-up ............................................................................................................................ 6

3 FUEL GAS KO VESSEL .................................................................................. 7

3.1 Process control intent ...................................................................................................... 7

3.2 Safeguarding intent ......................................................................................................... 7

3.3 Start-up ............................................................................................................................ 8

4 FILTER SEPARATORS ................................................................................... 9

4.1 Process control intent .................................................................................................... 10

4.2 Safeguarding intent ....................................................................................................... 10

4.3 Start-up .......................................................................................................................... 11

5 GAS METERING SKID .................................................................................. 12

File: 235-T1265-Operating-Control-Safeguarding Philosophy_rev2 Pag. 2 di 24

Operating, Control and 1 Revision 28/02/12 M.M. W.R. C.P.

Safeguarding Philosophy 0 First emission 20/01/12 M.M. W.R. C.P.

CLIENTE IMPIANTO LOCALITA’ PROGETTO FOGLI

5.1 Process control intent .................................................................................................... 12

5.2 Safeguarding intent ....................................................................................................... 13

5.3 Start-up .......................................................................................................................... 13

6 WATER BATH HEATERS ............................................................................. 14

6.1 Process control intent .................................................................................................... 14

6.2 Safeguarding intent ....................................................................................................... 15

6.3 Start-up .......................................................................................................................... 16

7 PRESSURE REDUCING SKID ...................................................................... 17

7.1 Process control intent .................................................................................................... 17

7.2 Safeguarding intent ....................................................................................................... 19

7.3 Start-up .......................................................................................................................... 19

8 ELECTRIC HEATERS SKIDS ....................................................................... 20

8.1 Process control intent .................................................................................................... 20

8.2 Safeguarding intent ....................................................................................................... 21

8.3 Start-up .......................................................................................................................... 21

File: 235-T1265-Operating-Control-Safeguarding Philosophy_rev2 Pag. 3 di 24

Operating, Control and 1 Revision 28/02/12 M.M. W.R. C.P.

Safeguarding Philosophy 0 First emission 20/01/12 M.M. W.R. C.P.

CLIENTE IMPIANTO LOCALITA’ PROGETTO FOGLI

8.4.1 Safeguards during shut-down ..................................................................... 22

9 CONDENSATE TANK AND PUMP SKID ...................................................... 22

9.1 Process control intent .................................................................................................... 22

9.2 Safeguarding intent ....................................................................................................... 22

9.3 Start-up .......................................................................................................................... 22

10 CONDENSATE TANK FOR GT SKID ........................................................... 23

10.1 Process control intent .................................................................................................... 23

10.2 Safeguarding intent ....................................................................................................... 23

10.3 Start-up .......................................................................................................................... 23