technical specification gas extractor monterotondo … · the generator transforms mechanical power...

Engineering & Construction

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EGP.EEC.S.72.IT.G.48658.02.003.03

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TITLE: AVAILABLE LANGUAGE: EN

File: EGP.EEC.S.72.IT.G.48658.02.003.03_(ST_EG_IGV)

REV. DATE DESCRIPTION PREPARED by COLLABORATORS VERIFIED by VALIDATED by

PROJECT / PLANT

EGP CODE

GROUP FUNCTION TYPE ISSUER COUNTRY TEC PLANT SYSTEM PROGRESSIVE REVISION

EGP EEC

CLASSIFICATION

PUBLIC

COMPANY

CONFIDENTIAL RESTRICTED

UTILIZATION SCOPE

This document is property of Enel Green Power S.p.A. It is strictly forbidden to reproduce this document, in whole or in part, and to provide to others any related information without the previous written consent by Enel Green Power S.p.A.

TECHNICAL SPECIFICATION

GAS EXTRACTOR

“MONTEROTONDO 2” POWER PLANT

MECHANICALLY DRIVEN CENTRIFUGAL COMPRESSOR WITH IGV

03 14/11/2017 Issue for tender Del Ferraro S. Fontana M. Molfese E. Luperini F.

Basili M. Marsili F.





00 20/04/2017 Issue for budgetary offer Luperini F. - Fedeli M. Galainena M.

-

Monterotondo 2

S 7 2 I T G 4 8 6 5 8 0 2 0 0 3 0 3

Basic Design, Detailed Design Issue for Tender


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INDEX

1. SCOPE OF THIS SPECIFICATION .............................................................................................. 4

2. APPLICABLE DOCUMENTATION AND STANDARDS ....................................................................... 4

2.1. Applicable documents .................................................................................................. 4

2.1.1. Turbo-generator general lay-out (typical) ................................................................ 4

2.1.2. Foundation plates lay-out ...................................................................................... 4

2.1.3. Mechanical battery limits – data-sheet .................................................................... 4

2.1.4. Table of loads on foundations ................................................................................. 4

2.1.5. Interface of the Turbine – Gas Extractor coupling ..................................................... 4

2.1.6. SG003 - Technical specifications for electrical and electronic components and

accessories for geothermal plants ...................................................................................... 4

2.1.7. Low voltage power and control cables ..................................................................... 4

2.1.8. SG009 – Strumenti ............................................................................................... 4

2.1.9. Instrumentation characteristics .............................................................................. 4

2.1.10. Schema dimensionale RG401_ID2300 (preliminary) .................................................. 4

2.1.11. Venturi Tube Low Pressure - preliminary sizing ......................................................... 4

2.1.12. Venturi Tube High Pressure - preliminary sizing ........................................................ 4

2.1.13. Anti-surging valves sizing - preliminary (for information only) .................................... 4

2.2. Norms and standards ................................................................................................... 4

2.3. Languages.................................................................................................................. 5

3. SCOPE OF SUPPLY .................................................................................................................. 6

4. GENERAL CHARACTERISTICS OF THE PLANT ............................................................................. 8

4.1. Plant description ......................................................................................................... 8

4.2. Plant availability .......................................................................................................... 9

4.3. Machinery lay-out ....................................................................................................... 9

4.4. Foundations................................................................................................................ 9

4.5. Remote control ........................................................................................................... 9

4.6. Compressed air ........................................................................................................... 9

4.7. Travelling crane inside machinery building...................................................................... 9

5. DESIGN AND REFERENCE CONDITIONS .................................................................................. 10

5.1. General characteristics ............................................................................................... 10

5.2. Design data .............................................................................................................. 10

5.2.1. Design point ...................................................................................................... 10

5.2.2. Off-design conditions .......................................................................................... 10

5.2.3. Ranges .............................................................................................................. 11

5.2.4. Inter-cooler ....................................................................................................... 11

5.3. Chemical composition of the fluids............................................................................... 11

5.3.1. Geothermal fluids ............................................................................................... 11

5.3.2. Cooling water ..................................................................................................... 11

5.3.3. Atmospheric air .................................................................................................. 11

6. CONSTRUCTIONAL FEATURES ................................................................................................ 12

6.1. General .................................................................................................................... 12

6.2. Impellers ................................................................................................................. 12

6.3. Sense of rotation....................................................................................................... 12

6.4. Coupling between turbine and compressor ................................................................... 12


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6.5. Rotor dynamics ......................................................................................................... 13

6.6. Materials .................................................................................................................. 13

6.7. Paintings and coatings ............................................................................................... 13

6.8. IGV actuation ........................................................................................................... 13

6.9. Lube oil system ......................................................................................................... 14

6.10. Soundproofing cabinet (noise-hood) ............................................................................ 14

6.11. Anti-surging system and machine protection ................................................................ 14

6.12. Piping and inter-cooler ............................................................................................... 15

7. ELECTRICAL EQUIPMENT AND INSTRUMENTATIONS ................................................................. 15

8. QUALITY ASSURANCE ........................................................................................................... 16

8.1. FACTORY AND ON-SITE TESTS ................................................................................... 16

8.2. Quality Control Plan ................................................................................................... 16

9. PERFORMANCE GUARANTEE .................................................................................................. 20

9.1. Guaranteed figures .................................................................................................... 20

9.2. Performance test ....................................................................................................... 20

10. PACKAGING AND SHIPPING ............................................................................................ 21

10.1. Packaging ................................................................................................................ 21

10.2. Shipment ................................................................................................................. 21

11. DOCUMENTATION TO BE PROVIDED ................................................................................ 22

11.1. Technical offer .......................................................................................................... 22

11.2. After order awarding ................................................................................................. 22

11.2.1. Additional requests for Operation and Maintenance manual ...................................... 22

11.2.2. Additional requests for Spare Parts Manual ............................................................ 23

11.2.3. List of documents ............................................................................................... 23

11.3. Approval of executive documentations ......................................................................... 24


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1. SCOPE OF THIS SPECIFICATION

This specification covers the technical requirements for the supply of a three (3) stages

centrifugal compressor with IGV (Inlet Guide Vanes) and its auxiliaries for the extraction of non-condensable gases (NCG) – naturally contained in the geothermal fluid - from a direct contact condenser of a geothermal power plant. The compressor will be driven by a steam turbine rotating at 3000 rpm, supplied by EGP.

2. APPLICABLE DOCUMENTATION AND STANDARDS

2.1. Applicable documents

TITLE EGP CODE

2.1.1. Turbo-generator general lay-out (typical)

I.D.G28.00.00.012

2.1.2. Foundation plates lay-out EGP.EEC.D.28.IT.G.48658.00.034.01

2.1.3. Mechanical battery limits – data-sheet S.G28.01.02.002.00

2.1.4. Table of loads on foundations GRE.EEC.D.28.IT.G.48658.00.041.00

2.1.5. Interface of the Turbine – Gas Extractor coupling

GRE.OEM.D.88.IT.G.82300.00.043.00

2.1.6. SG003 - Technical specifications for

electrical and electronic components and accessories for geothermal plants

S.24.IT.G.00000.00.024

2.1.7. Low voltage power and control cables EGP.EEC.S.24.XX.X.00000.09.002.00

2.1.8. SG009 – Strumenti S.24.IT.G.00000.00.009

2.1.9. Instrumentation characteristics S.24.IT.G.34.329.08.009

2.1.10. Schema dimensionale RG401_ID2300

(preliminary) GRE.EEC.D.72.IT.G.48658.02.004.01

2.1.11. Venturi Tube Low Pressure - preliminary sizing

Attachment A

2.1.12. Venturi Tube High Pressure - preliminary sizing

Attachment B

2.1.13. Anti-surging valves sizing - preliminary (for information only)

EGP.EEC.S.72.IT.G.25000.02.165

2.2. Norms and standards

The centrifugal compressor shall be designed according to API 617, last revision. The Supplier

shall send its standard API deviation for EGP’s check and approval. All the scope of supply (SoS) shall be designed in accordance to the following standards:

API

ANSI ISO


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IEC UNI

Furthermore, the supply shall comply with national and international laws. All the equipment included within the SoS shall be in accordance with Machinery Directive 2006/42/CE. The Supplier shall deliver to Enel Green Power (EGP) the appropriate certificates for the equipment provided.

2.3. Languages

All the documentation for offer and after order award can be sent to EGP both in Italian or

English. Installation, operation and maintenance manuals shall be sent in Italian.

Machinery’s nameplate shall be provided in Italian.


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3. SCOPE OF SUPPLY

Legend:

I = Included in the SoS O = Optional E = Excluded

ITEM SCOPE OF

SUPPLY

NOTE

N° 1 integrally geared centrifugal compressor with integrated gearbox

I

N° 3 IGV system, one for each stage, complete of

hydraulic actuators, for machine regulation I

N° 1 compete set of counter-flanges and bolting for connection of the process piping to the machine

I

Applicable also in case of different systems, such as Victaulic® (in

this case also the fixing rings shall be included

in the SoS)

N° 1 complete set of machine instrumentation as described in [6.1], wired up to junction boxes

I

N° 1 set of labyrinth shaft seals, dry I

N° 1 coupling between steam turbine and compressor, as per [6.4], complete of torquemeter and anti-sparkling coupling guard

I

N° 1 vibration machine monitoring system, Bently Nevada 3500

I

N° 1 PLC for anti-surge control I

N° 1 PLC for IGV control I

N° 1 complete set of foundation bolts I

Supplied loose,

installation by EGP

Engineering and procurement activities for what included in the SoS

I

Rotordynamic analyses, lateral and train torsional

I

EGP will provide the

necessary information for turbine and

generator

Documentation as per [11.2] with mutually agreed deviations and according to Supplier’s standard document list

I

Inspection Test Plan according to [8.2] with mutually agreed deviations

I

Special tools necessary for maintenance I

Packing and transportation at site I

Unloading from the truck in charge of EGP

Commissioning spare parts I

Capital spare parts: N° 1 set of pinions

N° 1 bull gear incl. bull gear shaft N° 1 set of impellers N° 1 set of labyrinth dry seals N° 1 set of bearings N° 1 set of oil seals N° 1 set of spare parts for IGV (1 for each

stage)

I

Spare coupling without torquemeter

I

Spacer to be supplied for the installation

instead of the torquemeter

Internal surfaces of the

hubs shall be provided with 5 mm of


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machining allowance

(the machining will be in charge of EGP)

Unloading on Site O

Supervision to erection and commissioning O

Performance test, on-site, customized procedure O

On-site installation and commissioning of the compressor

O

Training on site O

Foundation plates E

Venturi tubes FE401, FE402 E

Designed, supplied and installed by EGP

N° 1 gas inter-cooler RG401 E


N° 2 anti-surge, fail open, control valves VG401, VG402

E Designed, supplied and

installed by EGP

N° 1 on/off fail close, compressor discharge valve

VG403 E

Designed, supplied and

installed by EGP

Process piping and anti-surge piping E


Process and anti-surge instrumentation

E

Supplied and installed

by EGP on the basis of Supplier’s information

HMI E Provided by EGP

Lube oil system E Provided by EGP

HP control oil system E Provided by EGP

Noise hood E Provided by EGP

Two years spare parts E


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4. GENERAL CHARACTERISTICS OF THE PLANT

4.1. Plant description

The equipment described in the present specification will be installed in a new geothermal power plant named “Monterotondo 2” located near Grosseto, Tuscany. The nominal size of the power plant will be 20 MW. Geothermal power plants are fed by endogenous fluid from the geothermal wells. The endogenous fluid is composed by a mixture of steam and non-condensable gases (mainly carbide-dioxide, hydrogen sulfide and methane). The endogenous fluid feds directly the

steam turbine in order to produce the mechanical power. The plants are of condensing type, with direct contact condensers. The exhaust steam is condensed by the water coming from the cooling towers. The cold water is delivered to the

condenser by means of the differential pressure between the water contained in the cooling tower basin and the absolute pressure inside the condenser. One extraction pump delivers the cooling water and the condensed steam to the cooling tower through a regulating valve placed on the delivery pipe of the pump.

The excess of water due to the condensation of endogenous steam is conveyed to reinjection wells.

A gas extraction system (centrifugal compressor) removes the non-condensable gases (NCG) plus vapor from the direct contact condenser in order to maintain the requested pressure. The generator transforms mechanical power produced by the turbine in electric power delivered to the HV grid by means of a step – up transformer and relevant HV sub-station. The electrical auxiliaries of the plant are fed through an auxiliary transformer connected to the generator lead.

During the plant start-up, the electrical auxiliaries are fed directly from the HV grid through the step-up transformer and the auxiliary transformer.

EGP own more than 30 plants, most of them with a nominal size of 20 MW. For all the 20 MW plants (fed with different steam conditions in terms of pressure, temperature, mass flow and non-condensable gas content) a standardized lay-out has been developed. The new

supply shall comply with the existing interfaces and installation area available, according to the standardized lay-out abovementioned. The power plant is unattended and designed to be remote-operated from the Larderello remote control center (PT) (Pisa – Italy). The compressor shall be suitable for safe operation without the presence of any personnel during the normal operation. In case of malfunctions and/or equipment failures, the compressor shall be capable of implementing a safe

emergency shut-down procedure without incurring in any damage to itself or its auxiliaries. In case of failure on the HV transmission line, to which the plant is connected, the plant will shift to island-mode operation. When the fault is eliminated, it will be possible to reconnect the generator to the HV transmission line from the remote control center. The compressor shall be designed to allow such operations.

Cooling Tower

Centrifugal compressor Turbo-generator

Condenser

Water circul. pump Production wells

Reinjection wells

Separator

Steam

Water

Steam


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4.2. Plant availability

Availability of a geothermal power plant in Italy is 8600 hours\year. The equipment shall be

designed taking into account this feature and in any case maximizing availability, considering that a failure of the compressor causes the stop of the entire plant.

4.3. Machinery lay-out

Plant’s machinery (turbo-generator and centrifugal compressor) will be installed inside the machinery building on a concrete base, manufactured according to [2.1.2]. The Supplier shall design its compressor taking into account the availability of anchoring

plates positioned according to [2.1.2], marked as “EG”; the use of a metal skid is allowed. Leveling shims shall be provided by the Supplier.

The anchor plates will have the following characteristics: - Rugosity: Ra 12.5 μm – UNI 3963 - Planarity: 0.15 mm – UNI 7226/1

4.4. Foundations

The position of anchoring plates is showed in [2.1.2]. The Supplier shall send to EGP its own document showing the loads on foundation which, in any case, shall be lower than the maximum allowable indicated in [2.1.4].

4.5. Remote control

The power plant will be remotely operated, without the continuous presence of personnel.

In case of trip of the plant, the compressor shall be capable to perform automatically all the operations necessary to preserve the machine and the safety, avoiding any damage.

4.6. Compressed air

No compressed air will be available in the power plant.

4.7. Travelling crane inside machinery building

Machinery building will be equipped with a travelling crane to be used for maintenance. The

main hook will have 20 tons of maximum carrying capacity, while the secondary hook will have 3 tons of maximum carrying capacity. Maximum hook high will be +6500 mm from the 0 level, see [2.1.1].


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5. DESIGN AND REFERENCE CONDITIONS

5.1. General characteristics

The gas extractor shall be a centrifugal compressor, integrally geared, Three (3) compression stages, one inter-cooler between the 1st and the 2nd compression stage, driven by the steam turbine provided by EGP. An IGV (Inlet Guide Vanes) system shall be provided for each stage, allowing to adjust the variation of volumetric flow of the stream coming from the direct contact condenser, while maintaining the 3rd stage discharge pressure. This variation occurs mainly because of the changing in the ambient air temperature and consequently of the cooling water temperature

that in the end affects the gas inlet pressure and temperature. More rarely the volumetric flow variations are due to changings in the NCG content in the fluid that feeds the turbine, for instance because new wells are opened and come into

production or old wells are closed. The design of the machine shall maximize the operational range before to reach surging and chocking limits.

5.2. Design data

5.2.1. Design point

- @ compressor suction flange o NCG mass flow, dry: 5850 kg/h o NCG molecular weight, dry: 43 kg/kmol o Steam in the NCG: 2543 kg/h o Degasing air from the condenser: 250 kg/h

o TOTAL WET MASS FLOW: 8643 kg/h o Pressure: 0.070 bar/abs o Temperature: 27 °C

- @ 2nd stage suction flange

o Temperature: 27 °C 1 - @ compressor discharge

o Pressure: 1.3 bar/abs

- Pressure @ condenser flange: 0.072 bar/abs 2 - Cooling water temperature: 25 °C Only one inter-stage cooler between discharge of the 1st stage and suction of the 2nd stage shall be foreseen; a pressure drop of 20 mbar shall be considered between this two stages, taking into account the presence of the inter-cooler. Between the discharge of the 2nd stage and suction of 3rd stage, a pressure drop of 10 mbar

shall be considered.

5.2.2. Off-design conditions

By keeping constant the design discharge pressure, the Supplier shall show in the technical offer the API 617 data-sheet and performance curves also for the following off-design

conditions:

Gas inlet pressure

Gas inlet temperature

NCG mass flow (dry)

Steam in the NCG

mbar/abs °C kg/h kg/h

Off-design 1 95 31.5 5850 2323

Off-design 2 70 27.0 6100 2651

These off-design conditions corresponds to 70% and 105% of design volume flow rate (wet).

The Supplier shall take into account these off-design conditions for the correct and most appropriate design and sizing of the entire SoS.

1 See [5.2.4] 2 The design of the suction pipe from the condenser to the compressor’s suction flange will consider 2 mbar of pressure drop at the design point.


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5.2.3. Ranges

NCG molecular weight, dry: 37 – 44

The Supplier shall take into account this range for the correct and most appropriate design and sizing of the entire SoS.

5.2.4. Inter-cooler

The inter-cooler will be of the direct contact type. The approach between the cooling water inlet and the gas outlet shall be 2 °C.

5.3. Chemical composition of the fluids

5.3.1. Geothermal fluids

Non condensable gases (volume %): CO2 87 ÷ 97 H2S 0.4 ÷ 4.5 CH4 0.4 ÷ 4 N2 0.5 ÷ 1.2 H2 0.3 ÷ 3.5

Steam condensate:

pH 5.8 ÷ 7.2 T.D.S. (total salinity) 50 ÷ 700 ppm NH4 34 ÷ 300 ppm H3BO3 50 ÷ 650 ppm

SO4 traces ÷ 19 ppm Cl- traces ÷ 35 ppm Ca++ 0 ÷ 5 ppm

Mg++ 0 ÷ 4.5 ppm H2S 10 ÷ 100 ppm As++ 0.03 ÷ 0.25 ppm

5.3.2. Cooling water

Dissolved gases (% in volume): CO2 68.5 ÷ 70.5 O2 0.4 ÷ 0.8 H2O 0.1 ÷ 0.7 Other (methane, hydrogen, nitrogen) 19.5 ÷ 30.9

Water: pH 7.1 ÷ 7.8

NH4 190 ÷ 200 ppm H3BO3 550 ÷ 850 ppm SO4 150 ÷ 200 ppm Cl- 0.2 ÷ 7 ppm

Ca++ 0.2 ÷ 2 ppm Mg++ 0.2 ÷ 0.5 ppm

Na+ 0.1 ÷ 0.3 ppm K+ 0.1 ÷ 0.2 ppm

Cooling water may contain thiosulfate.

5.3.3. Atmospheric air

H2S 4 ÷ 8 ppm CO2 1000 ÷ 1500 ppm


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6. CONSTRUCTIONAL FEATURES

6.1. General

The centrifugal compressor will be mechanically driven by the steam turbine provided by EGP, rotating at 3000 rpm counterclockwise looking from the head of the machine towards the exhaust. The trip speed of the driver will be set at 3300 rpm (110% of nominal speed), consequently the compressor shall be designed to withstand this condition without problems and damages, allowing to continuously operate the plant.

The shaft seals shall be of the labyrinth type, dry, without the use of liquid or gas sealing fluid.

Each bearing shall be provided of: n° 2 proximitor probes for vibration monitoring n° 1 axial displacement probe for each shaft, bull-gear included n° 1 key-phasor probe

n°2 simplex PT 100 temperature elements at each bearing For the mechanical disposition of the shaft-line, see [2.1.1]. The compressor shall be designed to comply with this disposition, no modifications are allowed. The machine shall be designed so that the operation of bolts removal during maintenance

activities shall be possible without the necessity of removing the volutes. All the parts that have to be moved for maintenance with a weight higher than 25 kg, shall be provided with suitable tools for lifting (eyebolt, special tools, etc.). A table listing the special tools in association with the relevant compressor’s part for which the special tool is given shall be provided.

Inspection flanges with a weight higher than 25 kg shall be properly hinged, if possible;

otherwise eyebolts shall be foreseen. ISO VG46 oil type (provided by EGP) will be used both for lube and control oil. The compressor shall be designed for a minimum of 25 years of running life and continuous operation at full load. The equipment shall be designed for at least 5 years between two main scheduled

maintenances.

6.2. Impellers

Impellers balancing shall be made by means of balancing groove; balancing by grinding is not allowed. The assembly of impellers with pinions shall be made without hirth coupling. Supplier shall

send to Enel for check and approval the assembly drawings. All assembly and disassembly

tools shall be included in SoS.

6.3. Sense of rotation

The motive gear of the compressor’s gearbox will be coupled directly to the shaft of the steam turbine. The sense of rotation of the turbine is counterclockwise looking from the head of the machine towards the exhaust.

6.4. Coupling between turbine and compressor

The compressor will be coupled to the steam turbine through a toothed coupling, included in the SoS. The interface with the turbine’s shaft-end is described in [2.1.5]. No modifications to the turbine’s shaft-end are allowed. The compressor shaft-end shall be keyless hydraulically fitted hub type, conical. Shear-pins are not allowed.

An induction type torquemeter shall be installed on the coupling in order to measure the


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centrifugal compressor adsorbed power. The torquemeter shall have an accuracy ≤ 1%.

In case of spare coupling, it will be supplied without torquemeter, the Supplier will provide a spacer to be installed instead of the torquemeter. Internal surfaces of the hubs of the spare coupling shall be provided with 5 mm of machining allowance; the machining before installation will be in charge of EGP. Anti-sparkling coupling guard shall also be provided.

To guarantee a proper design of the coupling and coupling guard, the Supplier shall consider the following thermal expansion values:

+7 mm for the turbine shaft, directed towards the compressor; +8 mm for the turbine front support, directed towards the compressor.

6.5. Rotor dynamics

Supplier shall perform the lateral rotordynamic analysis for the compressor.

The Supplier shall also perform the torsional analysis for the entire train (compressor-steam turbine-generator). EGP will provide the necessary information in order to carry on the analysis.

6.6. Materials

Materials suitable for continuously operate with geothermal fluids shall be provided, taking

into account corrosive and erosive phenomena. According to EGP experience, materials listed here below are the most appropriate for geothermal applications. In any case the Supplier can propose different materials, sending to EGP, along with the technical offer, references of their use in similar environments and

technical information. EGP reserves the right to accept\reject the proposed solution.

Impellers: ASTM A705 TP.630 (17-4 PH) Diffusers: X12Cr13 Inlet diaphragms: ASTM A536 Gr.60-40-18 Lube oil pipes: AISI 316L

Supplier in its technical offer shall send the list of materials used for all the part of the compressor.

The Supplier, in his technical offer, shall send to EGP information about impellers heat treatment, for EGP check and approval. The Supplier shall not accept exceptions on mechanical characteristics of the impellers (yield and rupture strength, hardness and resilience).

6.7. Paintings and coatings

The Supplier will send its painting cycle to EGP for approval.

6.8. IGV actuation

The compressor shall be provided with IGV on each compression stage. The actuators that move the IGV shall be hydraulic; EGP will provide high pressure oil through a dedicated hydraulic control oil system, so this system will be excluded from the SoS. High pressure oil characteristics will be according to the following:

Type of oil = ISO VG46 Oil pressure (minimum guarantee @ actuator interface) = 75 bar-g Maximum oil working pressure = 112 bar-g Maximum oil pressure (design) = 170 bar-g Min\Max oil temperature = 0 – 80 °C Oil flow (approx.) = 40 liters\min Maximum counter-pressure @ actuator discharge = 10 bar-g

The IGV system shall be flanged for easy assembly-disassembly operations.


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6.9. Lube oil system

The lube oil for the compressor will be provided by the turbo-generator lube oil system.

Piping between the compressor’s inlet and outlet lube oil flanges and turbo-generator lube oil system will be provided by EGP. The lube oil system will provide oil with the following characteristics:

Type of oil: ISO VG46 Maximum available flow rate: 500 liters/min

Nominal oil pressure @ main collector: 2,5 bar/abs Pressure range: 1,9 (trip) – 2,7 bar/abs Nominal oil temperature: 45 °C Cleanliness level: 16/13 – ISO 4406

During a hot start-up the lube oil can reach a temperature of 55 – 65 °C; the compressor’s bearings shall be suitable to operate without damages at such temperature for a limited time.

All the oil pipes provided in the supply shall be in AISI 316L. An emergency lube oil pump will be installed to guarantee the minimum oil flow rate to all the machinery in case of emergency shutdown.

6.10. Soundproofing cabinet (noise-hood)

Not in the SoS.

6.11. Anti-surging system and machine protection

The compressor shall be provided with automatic anti-surging system, one anti-surge for the 1st compression stage and one for the 2nd – 3rd compression stages.

The anti-surge piping and its accessories (supports, valves, instruments, etc.) are excluded from the SoS. EGP will design, supply and install the piping system according to the functional indications given by the Supplier (PFD, P&IDs, instrument list and data-sheets).

Consequently, all the materials necessary to build the anti-surge piping is excluded from the SoS. Venturi tubes for measuring the volumetric flows at suction of the 1st stage and discharge of the 3rd stage will be designed and supplied by EGP. The anti-surging valves will be designed and supplied by EGP. The butterfly valves will be:

Modulating hydraulic actuated Flanged rating 150 Fail open

The anti-surging valves will be designed according to the preliminary drawing indicated in [2.1.13] with possible minor modifications that could occur during the detailed design phase.

The Supplier will check and validate the drawing abovementioned. A butterfly valve, fail-close, will be installed at compressor discharge pipe. This valve will be closed during plant’s start-up in order to allow the creation of vacuum; during normal operation the valve will be fully open. The valve will be designed and supplied by EGP. The butterfly valves will be:

Hydraulic actuated

Flanged rating 150 Fail close

As a preliminary sizing the valves and related piping should be:

Description Piping

upstream

Valve

sizing

Piping

downstream

Anti-surging Low Pressure Valve 18” 18” 24”

Anti-surging High Pressure Valve 12” 12” 14”

Butterfly valve at discharge pipe 14” 14” 18”

Anti-surge control system (PLC) shall be included in the SoS.


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6.12. Piping and inter-cooler

Process piping, will be designed, supplied and installed by EGP.

Water flow lines from and to inter-cooler and compressor’s drainage lines will be designed, supplied and installed by EGP. Process instrumentation will be provided and installed by EGP according to Supplier’s P&ID, instrument list and data-sheets. Inter-stage piping will be designed, supplied and installed by EGP according to Supplier’s

P&ID, instrument list and data-sheets, including connection piping to and from the inter-cooler. The instrument for the primary measurement of the mass-flow (i.e. venturi tube) will be

designed, supplied and installed by EGP. A preliminary dimensioning of the instruments is showed in [2.1.11] and [2.1.12] for Supplier’s check and validation.

EGP will buy and install the inter-cooler suitable for process conditions; the inter-cooler will be built according to the preliminary drawing indicated in [2.1.10Errore. L'origine riferimento non è stata trovata.] with possible minor modifications that could occur during the detailed design phase related to elevation of water inlet (S3 nozzle) and the packing position.

The Supplier will check and validate the drawing abovementioned. The cooling water will came from cooling tower basin, with characteristics described in [5.3.2]. Natural circulation of the water inside the inter-cooler will be possible, avoiding the use of circulation pumps.

7. ELECTRICAL EQUIPMENT AND INSTRUMENTATIONS

All the electrical equipment and instrumentation included in the SoS shall be in accordance

to [2.1.6], [2.1.7], [2.1.8] and [2.1.9]. According to Italian Decree 106/17, starting from last August the 9th, the prescription of UE regulation (Construction Products Regulation) shall be applied. The electrical cables design shall consider the above mentioned prescription, even if not specified in the related technical specification.


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8. QUALITY ASSURANCE

The Supplier shall perform all the inspection and the testing necessary to guarantee the

complete constructive and functional correspondence of the supply to the technical prescriptions given in the present specification.

8.1. FACTORY AND ON-SITE TESTS

The Supplier shall perform in factory and on-site all the controls and tests deemed necessary to guarantee the compliance of the supply to the technical specifications. The Supplier shall submit the factory Quality Control Plan (QCP) in the technical offer. The

QCP shall contain the minimum tests required by EGP (as indicated in [8.2]) implemented with anything deemed necessary for a correct control of the materials and equipment supplied. The QCP proposed by the Supplier shall contain information about the technical

specifications and reference standards applicable for each test. EGP will indicate which tests wishes to be notified so as to attend with one of its representatives. The notice of the execution of the tests shall be transmitted with 15 calendar

days of advance via e-mail to the address agreed upon order. At the end of the manufacturing phase, the Supplier shall submit to EGP for approval a copy of the Quality Book containing all the certificates, test reports, etc., carried out at subcontractors' or at his own factory.

8.2. Quality Control Plan

For all the equipment in the SoS, the Supplier shall carry out on at least the tests indicated in this paragraph. For each test is indicated whether EGP representatives shall attend the test (by witness or

hold point convocation) or if a Supplier test report is sufficient, according to the following levels of participation:

R (Review) = EGP will perform a documentation review of the inspection or test.

O (Observed) = Supplier shall notify to EGP on the timing of the test with the notice above indicated; the test will be carried out as scheduled regardless of whether EGP representative is present or not.

W (Witness) = Supplier shall notify to EGP on the timing of the test with the notice above indicated; a hold is placed on the inspection or test until EGP or his representative is in attendance.

When required, the Supplier shall send to the Purchaser the applicable test specifications before performing the test, with sufficient advance to allow the Purchaser to check and evaluate the specification and eventually make comments.

DESCRIPTION OF THE TEST

EGP LEVEL OF PARTECIPATION

HEAD FLANGE(S)

Raw

Ladle analysis R

Mechanical properties R

Ultrasonic test R

Dye penetrant test on austenitic stainless steel R

DIAPHRAGMS/DIFFUSERS/PLENUMS

Raw (forged stainless steel)

Ladle analysis R


Ultrasonic test R

Dye penetrant test on austenitic stainless steel R


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Raw (cast iron)

Ladle analysis R


Magnetic particle test R

CASING

Raw (casing pressure retaining parts)

Ladle analysis R


Magnetic particle test R

Assembled casing

Hydrostatic pressure test O

GEAR BOX

Raw

Ladle analysis R

Mechanical properties (including impact test) R

Heat treatment chart R

Ultrasonic test (including bearing babbitt) R

Machined

Hardness test R

Magnetic particle test or dye penetrant test R

Balancing check R

Electrical and mechanical run out check R

Casing composition / machining

Casing contact check O

Bearings

Dye penetrant test R

Assembled

Tooth contact check O

Interference check bearings/casings R

Mechanical running test O

Sound pressure level test (during running test) R

Visual inspection of tooth and bearings (after MRT) O

Painting check R

Dimensional check O

Visual check R

IMPELLERS

Raw

Ladle analysis R

Ultrasonic test R


Machined

Mechanical properties O

Metallographic replica (to be performed on 3 different radius) O

Balancing check R

Over speed test O


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Dimensional and geometric check (after over speed test) R

Dye penetrant test (after over speed test) O

SHAFT(S)

Raw

Ladle analysis R


Ultrasonic test R

ROTOR(S)

Assembled

Combined run out test (on radial probes target areas), including residual magnetism check

O

Dynamic balancing (at low speed) O

CENTRIFUGAL COMPRESSOR

Mechanical running test

Mechanical running test under vacuum W

Post mechanical running tests

Bearings inspection and labyrinth seals external inspection W

PIPING

Raw / material certificates of piping components

Ladle analysis R


Assembled / welded piping

Welding map, weld. proc. specifications (WPS) and procedure qualif. rec. (PQR)

R

NDT on weldings R

Hydrostatic pressure test R

Stainless steel pickling & passivation check R

Painting check (where applicable) R

Final, visual inspection (this includes cleanliness check) R

CENTRIFUGAL COMPRESSOR SKID

Raw (baseplate)

Ladle analysis of components R

Mechanical properties of components R

Fabricated / machined (baseplate)

Non destructive examinations on welds R

Eyebolts/lifting bitts welds NDT R

Painting check R

Dimensional check R

Final, visual and cleanliness check R

Electrical system assembly

Electrical and instrumentation installation checks (including tagging)

W

Final tests


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Painting check O

Dimensional check (on limits of supply and foundations) W

Final, visual and documentation check W

CERTIFICATION OF ELECTRIC AND ELECTRONIC DEVICES

CE/ATEX compliance

ATEX certification R

UNIT CONTROL SYSTEM

Assembled

System hardware and steelwork check (visual and dimensional check of structural characteristics)

W

Electric inspection (including: wiring inspection, vertical selectivity of automatic breakers, check of correct signals splitting/segregation, point to point wiring verification, AC/DC functionality test, dielectric and insulation test, protective bonding circuit continuity test, earthing check)

W

Functional test (on job functions only; I/O check spot (e.g. 20%), main start/stop/aux. sequences)

W

Communication test (communication links between all systems inside UCS and the external systems to which they are connected (e.g. Bently Nevada, ccc))

W

Painting check W

Final visual check (including terminal board check and certification and documentation check)

W


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9. PERFORMANCE GUARANTEE

9.1. Guaranteed figures

The Supplier shall send in the technical offer the API 617 compressor data-sheet completed in all its parts, including construction features. The “kW required at driver incl. ext losses (gear, etc)” indicated in the API 617 data-sheet will be taken as the guarantee figure for the power adsorbed by the machine and it will be used for the technical alignment of the competitors.

9.2. Performance test

The Supplier after the order will propose an on-site performance test procedure for EGP approval. On the basis of the procedure mutually agreed the performance test will be carried

out.


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10. PACKAGING AND SHIPPING

10.1. Packaging

Packaging, shipment and unload to the site of all equipment and accessories are at Supplier's expenses. The package shall be made according to the following considerations:

Type and duration of shipment Package handling Law prescriptions

The package may be left in open storage at the designated place for a maximum period of

three (3) months, thus appropriate protection from geothermal environment, water and weather damage shall be provided.

10.2. Shipment

The Supplier shall provide the drawings with dimensions and weights of the equipment and accessories to be shipped. The Supplier shall inform EGP via e-mail within 15 calendar days from shipment and shall agree with EGP the dates of effective arrival of the materials.

The locations where the equipment shall be assembled shall be specified by EGP in the order, or subsequently. In any case EGP is entitled to change the destination place of the machinery. The Supplier is also solely responsible for the obtaining of all permits and authorizations required for equipment transportation. The Supplier shall check the practicability of roads from the factory to the target power plant: any modification necessary to remove obstacles on the road and allow the transit of the truck

trailer shall be at Supplier's expense. Supplier is solely responsible for shipment of the goods to the power plant and all relevant expenses and compliance to local laws, rules and regulations. In order to reduce the erection time, the machine shall be shipped assembled. Any deviation from this requirement shall be discussed with EGP.


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11. DOCUMENTATION TO BE PROVIDED

11.1. Technical offer

The following documents shall be included in the technical offer: Deviations and Clarifications list API 617 Supplier’s deviations Technical description of the proposal Technical description of IGV system and related drawings Machinery drawings and sections (lay-out, elevations, cross-sections, etc.) Performance curves showing the operational ranges, surge limit curve and anti-surge

intervention curve Process Flow Diagram (PFD) showing process data for the entire cycle P&IDs

Machinery main mechanical interfaces (suction and discharge flanges, for each stage) Electrical functional diagrams with main interfaces; API 617 data-sheet, complete List of materials

Impellers heat treatment procedure QCP Weights of main parts of machine and the total one Guaranteed figures and correction curves Safety and measurement devices List of strategically spare parts suggested

Time chart of activities (GANTT) Components not described into TS Vendor List for sub-order

11.2. After order awarding

The Supplier shall issue a Design Plan and Program (DPP), containing the list of documents

to be issued after the order award with purpose and schedule. The DPP shall contain at least the document indicated in [11.2.3]

The DPP shall contain all the documents related to interfaces with the equipment excluded by the SoS, issued with a proper schedule for EGP approval. Furthermore, all the documents necessary for the interaction of the SoS with the rest of the plant shall be issued to EGP with a suitable schedule. The DPP shall be sent to EGP for approval. The documentation contained in the DPP shall be delivered to EGP in digital/electronic format,

Portable Document Format (PDF), Italian or English language, exception made for: Operating and Maintenance manual, to be issued in Italian, N° 3 paper copies in

addition to electronic format. The electronic manual shall contain hyper-links to allow an easy browsing of the pages.

Spare Parts manual, to be issued in Italian, N° 3 paper copies in addition to electronic format. See [11.2.2] for additional information.

Upon agreement between EGP and the Supplier, the Supplier will send to EGP some document in original format (AUTOCAD® saved in 2015 or previous version or for drawings and single line diagrams, Microsoft WORD® saved in 2013 or previous version for written documents, etc.), such as:

Lay-out, AUTOCAD® Elevation drawings, AUTOCAD®

Skid drawing, AUTOCAD® 3D model, AUTOCAD®.

11.2.1. Additional requests for Operation and Maintenance manual

The O&M manual shall be exhaustive and contain all the necessary information; it shall also contain the following job-specific information:

Machinery drawings and cross-sections P&IDs

API 617 data-sheet

Performance curves Primary connections drawings and data-sheets Loads on foundations


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Table of compressor clearances Loads and displacements at flanges

Compressor’s alignment specification Gearbox drawings, including sections Sub-supply O&M manuals Weights of main parts of machine and the total one.

11.2.2. Additional requests for Spare Parts Manual

All the spare parts shall be indicated on suitable cross-sections and, in any case, they shall be indicated on drawings in order to be easily located. For each spare part, relevant material

code shall be written on the drawing so that it shall be easy to identify the part in object. In case of spare parts that are recalled more than one time within the manual (i.e. identical parts used more than one time in the machine), a sum up table shall be provided in order to

easily identify the quantities to be ordered. For paper copy, in case of drawing referring to machine’s sub-groups drawing, the page number of the manual linking to the sub-group in object shall be indicated on the drawing in order to allow a quick individuation of the sub-group drawing.

The electronic manual shall be drawn up using hyperlinks in order to link between them all the sub-groups of the machinery and allow a quick surfing of the manual.

11.2.3. List of documents

The DPP shall contain, but is not limited to, the following documents:

11.2.3.1. Each month

Monthly report, containing at least:

o GANTT diagram (PERT- CPM diagram) o Updated DPP o State of sub-orders

o State of progress in manufacturing of the machine/equipment o Inspection Test Plan, updated with the results of tests and state of possible

NCs o Photographic report of the main phases\events

11.2.3.2. Within two months from IPC (start of the chronological program

Quality Control Plan Outline drawing of the machinery and equipment Machine’s and equipment dimensions and weights PFD(s) P&IDs Interfaces between machinery/equipment and civil works

Static and dynamic foundation loads Field instrument list indicating type of instrument, range, precision, Supplier etc. Parasitic loads of auxiliaries included in the scope of supply Compressor sense of rotation

11.2.3.3. Within three months from IPC

Mechanical, electrical and I&C interface data and drawings. In particular:

o Compressor process interfaces, along with details about flanges, counter-flanges, etc.

o Lube oil interfaces o Drainages, siphon details o Coupling, interface with the turbine shaft-end o IGV actuator, to be feed by control oil provided by EGP o I&C interfaces

o Electrical interfaces.

11.2.3.4. Within four months from IPC

List of instruments and electric components;

Rotordynamic report Outline drawings of the electric equipment (cubicles, terminal blocks, motor,

actuators, etc.)


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Outline drawings and weight of electrical boards Acceptance criteria for impellers mechanical characteristics (yield and rupture

strength, hardness, resilience, etc.) Compressor’s API 617 data-sheet, complete in all the parts Compressor’s performance curves, showing surge limit curve and anti-surge

intervention curve

11.2.3.5. Within six months from IPC

Values to be implemented in EGP’s Supervision & Control System (SCS) for the protection of the machine

Single line of the equipment supplied Instruments outline drawings Principal hook-up and electrical hook-up

Shipment sketches Wiring list and cable schedule Functional and logic diagrams and control sequences relating to control, regulations

and alarms

Special tools list with table listing the special tools in association with the relevant compressor’s part for which the special tool is provided

Brochures/catalogues of the instruments supplied Brochures/catalogues of the main components of the cubicles Cables schedule relating cubicles and electrical auxiliary interconnection Instruments schedule (marks, model, accuracy, instrument operating limits),

identification codes, set-up limits Earthing connection diagrams Table of Content for Operating & Maintenance and Spare Parts manuals All the documentation required within the technical specifications attached to the

present specification On-site performance test procedure

11.2.3.6. Within the term of workshop preparation deadline (Ex-Works):

All the equipment main drawings, reporting the bill of materials and related weights. All the drawings shall indicate the necessaries dimensions and information for maintenance, assembly and handling

Italian law, national and international standards compliance for the machines/equipment supplied

CE and PED certificates for the machines/equipment supplied Setting certificates for every instrument provided

Licenses software use and programs on CD (compact disc) Software on CD including source files Software instruction manuals Earthing connections cables schedule Instrumentation electromagnetic compatibility test certification Quality Book of each machine/equipment

Preliminary copy of Operating & Maintenance and Spare Parts manuals

All the documentation listed in chapter [11] and in general requested within all the specification attached to the present, in final version

11.2.3.7. Within the end of the commissioning (TA)

"As built" documentation Operating & Maintenance and Spare Parts manuals, final version Certifications of conformity in compliance with standards and law in force

11.3. Approval of executive documentations

The supplier will send in its technical offer the Design Plan and Program (DPP) containing the list of documents that will be issued during the executive design, the schedule will be expressed in weeks and the scope of issue suggested, that will be “I” for information and “A” for Approval. The DPP shall contain at least the documents indicated in [11.2]. EGP shall modify during the technical bid phase the scope of issue according its needs. The documents having scope of issue “A” shall be approved by EGP in order to carry on the

engineering and procurement activity.


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EGP will communicate to Supplier their comments or approval within 21 calendar days from the official transmittal date. If EGP will not reply within the agreed time, the documentation

shall be considered approved by Supplier. The approval of executive documentation:

is only related to verify the compliance of the project to contract requirements (materials, pressure and temperature, dimensions, interfaces, etc.)

does not relieve the Supplier to all responsibilities due to non-compliance with the order requirements, Enel Green Power technical specifications, and the applicable laws (i.e. Machinery Directive).

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