M I N I S T RY O F E N E R G Y

IRAN POWER DEVELOPMENT CO.

I PD C
PROJECT : 22 COMBINED CYCLE POWER PLANTS YAZD COMBINED CYCLE POWER PLANT

SYSTEM DESCRIPTION FOR NITROGEN GAS SYSTEM

FOR CONSTRUCTION

C B A REV

IN CORPORATED MOM DATED 27~31 AUG. AND 08~12 SEP. 04 FOR CONSTRUCTION FIRST ISSUE DESIGNATION

Nov.09,04 D.C.KIM Nov.09,04 H. C. YOO Nov.09,04 W. Y. LEE Nov.09,04 July 5,04 Dec.5,03
DATE D.C.KIM D.C.KIM DESIGN

July 5,04 H. C. YOO July 5,04 W. Y. LEE July 5,04 Dec.5,03 H. C. YOO Dec.5,03 W. Y. LEE Dec.5,03
DATE CHKD DATE APPROVED DATE

MAPNA C o .
( PRIVATE JOINT STOCK ) IRAN POWER PLANT PROJECTS MANAGEMENT Co. ORIGINATOR

DOCUMENT NO. : CONTRACT NO. : ORIGINATOR NO. :

MP-YZC-GA-04-AM0-001 22-0701/BA/TL YZC-A-SP-261-SDE-005

REV.

PAGE 1 OF 10

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO.,LTD.

ORIG ORIG. PROJ. DISC. DOC. AREA SYS. LOC. DEPT. NAME TYPE TYPE FA.N

REV.

M I N I S T RY O F E N E R G Y
IRAN POWER DEVELOPMENT CO.

I PD C
PROJECT : 22 COMBINED CYCLE POWER PLANTS YAZD COMBINED CYCLE POWER PLANT
REVISION A
X X X X X

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B
X X X X X

C
X X X X X X X X X X

REMARKS

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REVISION A B C D E F G H

REMARKS

MAPNA C o .
( PRIVATE JOINT STOCK ) IRAN POWER PLANT PROJECTS MANAGEMENT Co. ORIGINATOR

DOCUMENT NO. : CONTRACT NO. : ORIGINATOR NO. :

MP-YZC-GA-04-AM0-001 22-0701/BA/TL YZC-A-SP-261-SDE-005

REV.

PAGE 2 OF 10

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO.,LTD.

ORIG ORIG. PROJ. DISC. DOC. AREA SYS. LOC. DEPT. NAME TYPE TYPE FA.N

REV.

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 3 OF 10

NITROGEN SYSTEM

CONTENTS

CLAUSE NO.

DESCRIPTION

PAGE NO.

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0

REFERENCE DRAWINGS INTRODUCTION NITROGEN SYSTEM CONFIGURATION DESIGN BASIS OPERATION GENERAL CONTROL DESCRIPTION CALCULATION FOR NITROGEN GAS CAPACITY PIPE SIZING FOR NITROGEN GAS LINE

4 4 4 5 5 6 6 9

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 4 OF 10

1.0.0

REFERENCE DRAWINGS Nitrogen System P&I diagrams (MP-YZC-GA-02-AM0-001)

2.0.0

INTRODUCTION The nitrogen system is designed to store and provide nitrogen for blanketing the HRSGs and deaerators (Dry Preservation Type) requiring corrosion protection during anticipated a long term unit shut down/laying up/dry storage or when drained for maintenance.

3.0.0

NITROGEN SYSTEM Nitrogen distribution system consists of N2 cylinder connection fed by rack mounted, high pressure portable cylinders complete with 1st pressure self-regulating valve (AQLB30AA151) with pressure indicator (AQLB 10/20 CP501) and 2nd pressure selfregulating valve (1/2 QLB50AA151) with pressure indicator (AQLB40CP501), pressure transmitter (AQLB40CP101), safety valve (AQLB40AA191), distribution piping and valves. Nitrogen storage capacity is based on the amount of gas required for dry storage of one (1) HRSG and one (1) Deaerator. When N2 gas cylinders mounted on two (2) rack are empty after filling the first HRSG with nitrogen gas, close the nitrogen system isolation valves and loosen the cylinder connections from connection header and then move empty cylinders to recharging station or recharge by portable gas supplier for the second HRSG nitrogen gas blanketing. Recharged N2 cylinders with racks shall be assembled with connection header and then open the isolation valve. Charged another N2 cylinders with racks will be very useful and convenience for the second HRSG nitrogen gas blanketing and placed into N2 gas servicing area. Safety valve is provided to prevent over-pressure of the equipment from being blanketed.

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 5 OF 10

4.0.0

DESIGN BASIS The nitrogen gas system is designed to satisfy the following requirements: Each containing gas cylinder Pressure gas cylinder The 1st regulated pressure The 2nd regulated pressure : : : : 50 Litters 173.6 Bara 3 Bara 1.5 Bara

The total volume of HRSG to be filled by the nitrogen gas system including the integral deaerator is 200 . Below metioned HRSG area equipments which will be filled with nitrogen gas. Equipment Capa. () 9.3 70 8.6 14.2 14.2 3.4 13.9 30 23 13.7 200 CPH Integ. Dea. ID Eva. LP Drum LP Eva. LP S/H HP Eco. HP Drum HP Eva. HP S/H Total

5.0.0

OPERATION Plant is equipped with a two (2) N2 cylinder connection manifolds with two (2) cylinder racks. Nitrogen gas is supplied from N2 cylinder connection manifold to a 1st pressure self-regulating valve (AQLB30AA151) to reduce the high gas pressure and then distributed to 2nd pressure self-regulating valve (1/2 QLB50AA151) to supply gas to the equipment from being blanketed. The nitrogen gas pressure is modulated by 1st pressure self-regulating valve (AQLB30AA151) and 2nd pressure self-regulating valve (1/2 QLB50AA151) to maintain proper pressure of the equipment being blanketed.

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 6 OF 10

6.0.0 6.1.0

GENERAL CONTROL DESCRIPTION Monitor of Nitrogen Gas Pressure Nitrogen gas pressure is reduced to the desired pressure (3 Bara) via a 1st pressure self-regulating valve (AQLB30AA151) and then distributed to the 2nd pressure selfregulating valve (1/2 QLB50AA151) to supply a gas for the HRSG dry lay-up. Also, the nitrogen gas pressure downstream of the 1st pressure self-regulating valve is monitored by the pressure transmitter (AQLB40CP101) for the following purpose. To monitor the leakage of nitrogen gas in no operation of nitrogen gas supply system To monitor the nitrogen pressure downstream of the 1st pressure self-regulating valve (AQLB30AA151) during the HRSG dry lay-up

7.0.0 7.1.0 7.1.1

CALCULATION FOR NITROGEN GAS CAPACITY Basic Assumption The pressure & temperature of N2 gas in cylinder is 173.6 bara, at 17.3 filling temperature.

7.1.2

The charging pressure & temperature of N2 gas is 1.32 bara, at 17.3 ambient temperature based on the HRSG preservation.

7.1.3 7.1.4

N2 gas is regarded as ideal gas. Nitrogen gas will be used for the preservation of HRSG Drums, Deaerators, Feed water storage tanks & miscellaneous piping during the long time shutdown period.

7.1.5

The required quantity of N2 gas cylinder is calculated based on the condition of the One(1) HRSG shutdown at a time.

7.1.6

N2 gas is rechargeable when N2 gas cylinder is empty.

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 7 OF 10

7.2.0

Basic Formula The ideal gas equation of state is as follows ; (P1 X V1) / T1 = (P2 X V2) / T2 Cylinder P1, T1, V1 Where, P1 = Pressure (bara) , T1 : Temperature (K) , V1: Volume (m3) in Cylinder P2 = Pressure (bara) , T2 : Temperature (K) , V2: Volume (m3) in Consumer V2 = V1 X (P1 / P2) X (T2 / T1) Consumer P2, T2, V2

7.3.0 7.3.1

Calculation Procedure Nitrogen gas condition before injection Pressure (P1): 173.6 bara (177 kg/,a) Max. Average Ambient Temperature (T1): 26.3 26.3 + 273 = 299.3 K Volume (VC): 0.05 m3

7.3.2

Nitrogen gas condition after injection Pressure (P2): 1.32 bara (1.35 kg/,a) Min. Average Ambient Temperature (T2): 11.4 11.4 + 273 = 284.4 K Volume (V2): 260 m3 for one(1) HRSG preservation (HRSG drum & internal piping volume (185 m3) + Feed water storage tank & Deaerator volume (15 m3) + 5% margin for ten days + 25 % margin for waste)

7.3.3

Required Volume of Nitrogen Cylinders for HRSG Preservation (V1) V1 = V2 X (P2 / P1) X (T1 / T2) = 260 X (1.32 / 173.6) X (299.3 / 284.4) = 2.08 m3

7.3.4

The minimum required quantity of Nitrogen gas cylinder The minimum required number of cylinder = 2.08 / 0.05 = 41.6 EA

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 8 OF 10

7.3.5

The supplied quantity of Nitrogen gas cylinder The number of row to be installed in the cylinder rack : Two(2) row in each rack X Two(2) racks = 4 rows The proper quantity of cylinder in each row : 41.6/ 4 = 10.4 EA = 11 EA The total quantity of cylinder to be supplied: 11 EA in each row X 4 rows = 44 EA

7.3.6

The delivery rate of nitrogen gas at operating condition The filling time (t) : 2 (t1) 3 (t2) hours The operating condition of nitrogen gas after injection 0. Pressure (P2): 1.32 bara (1.35 kg/,a) 0. Min. Average Ambient Temperature (T2): 11.4 11.4 + 273 = 284.4 K 0. Gas Constant for Nitrogen gas (R): 296.8 J/ K 0. Density (2) = P2 / (R T2) = (1.32 105) / (296.8 284.4) = 1.5637 (kg/ m3) The delivery rate of nitrogen gas at operating condition 0. The required volume flow rate at operating condition (Q2) = Required gas cylinder volume / Filling time = V2 / t2 = 260 / 3 = 86.7 (m3/hr) V2 / t1 = 260 / 2 = 130 (m3/hr) Density (2) = 136 204 (kg/hr) 87130 (m3/hr)

0. The required mass flow rate at operating condition (m) = Volume flow rate (Q2) /

7.3.7

The delivery rate of nitrogen gas at Normal condition The normal condition of nitrogen gas after injection 0. Pressure (P0): 1.013 bara (1 atm) 0. Max. Average Ambient Temperature (T0): 0 0 + 273 = 273 K 0. Gas Constant for Nitrogen gas (R): 296.8 J/ K 0. Density (0) = P0 / (R T0) = (1.013 105) / (296.8 273) = 1.2502 (kg/ m3)

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 9 OF 10

The required volume flow rate at normal condition (Q0) = The required mass flow rate at operating condition (m) / Density at normal condition (0) = (136/1.2502) (204/1.2502)=108.8163.2 (Nm3/hr) (To be informed to the sub-supplier of Nitrogen gas system for determining the capacity of the pressure self-reducing valve)

8.0.0 8.1.0 8.1.1

PIPE SIZING FOR NITROGEN GAS LINE Determination of Piping Design Condition Design Pressure Design pressure for pipe on outlet of nitrogen gas bottle shall be equal to the design pressure of nitrogen gas bottle. And, after reducing pressure (i.e. downstream of PRV), design pressure is considered as 11.6 bar.a, in the basis of Doosans experiences. Operating condition (upstream / downstream of 1st PRV ) = 173.6 bar.a / 3 bar.a

Design pressure (upstream / downstream of 1st PRV ) = 201 bar.a / 11.6 bar.a 8.1.2 Design Temperature Design temperature is considered as 93 , in the basis of Doosans experiences. Design temperature (upstream / downstream of 1st PRV ) = 93 / 8.2.0 8.2.1 Determination of Design Flow for Pipe Sizing Design flow rate of N2 gas for pipe sizing can be determined in the basis of the expected filling time for preservation of HRSG. 8.2.2 When the filling time for preservation of HRSG is considered as 2 ~ 3 hours, the calculated mass flow rate of N2 gas is 109 Nm3/hr 164 Nm3/hr. 8.2.3 Selected Design flow = 150 Nm3/hr. 93

YAZD Combined Cycle Contract No. : 22-0701/BA/TL

SYSTEM DESCRIPTION NITROGEN GAS SYSTEM Doc. No. : MP-YZC-GA-04-AM0-001 Revision : C Originator No. : YZC-A- Date : Nov. 09, 04

DOOSAN
Changwon, KOREA

Page: 10 OF 10

8.3.0 8.3.1

Selection of Velocity Limitation Nitrogen(N2) gas velocity for pipe sizing is generally selected in the general range for natural gas pipe, 15 ~ 25 m/s.

8.3.2 8.3.3

Velocity Limitation for N2 Line = 15 m/s Actual velocity 1st PRV upstream line (AQLB30BR001) 0. Piping Spec. : DN40 (1.5), Sch.160, Piping Class CC-6. 0. N2 Gas Flow : 150 N m3/hr (at 1.2502 kg/m3 density) Mass flow = 0.0521 kg/s Specific volume = 0.005 m3/kg (at 173.6 bar.a, 17.3). 0. Calculated velocity = 0.3 m/s. 1st PRV downstream line (AOLB40BR001) 0. Piping Spec. : DN50 (2),
3

Sch.80, Piping Class CC-2.

0. N2 Gas Flow : 150 N m /hr (at 1.2502 kg/m3 density) Mass flow = 0.0521 kg/s Specific volume = 0.251 m3/kg (at 3 bar.a, 17.3). 0. Calculated velocity = 6.9 m/s.