Solar_ Mars 100 Power Generation

Solar Turbines International Company Tel: (858) 694-1616 9330 Sky Park Court Fax: (858) 694-6267 San Diego, CA 92123-5398

Technical Proposal Submitted to:

Dragados for the:

Dragados Global Water Offshore Power Generation Project

Mars 100 Generator Set (Qty:3) February 2, 2016 : Rev 0 Solar Inquiry No: ME15-0029

Cat and Caterpillar are registered trademarks of Cater pillar Inc. Solar, Titan, Mars, Taurus, Mercury, Centaur,Saturn, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated. Specifications subject to change without notice. Printed in U.S.A. © 2016 Solar Turbines Incorporated. All rights reserved.

Solar Turbines OG & il as

Dragados Mar1s0G 0 ener atoSret

TABLE OF CONTENTS 1.0 INTRODUCTION .................................................................................................................... 3 1.1 Executive Summary ....................................................... ...................................................... 4 1.2 World Leader in Industria l Gas Turbines ........ ........................................................ ................. 5 1.3 Delivery Performance ..................................................... ...................................................... 6

2.0 SCOPE................................................................................................................................... 7 2.1 General Description ..................................... ........................................................ ................. 8 2.2 Gas Turbine Package ..................................................... ...................................................... 9 2.3 Gas Turbine Engine ..................................... ........................................................ ............... 12 2.4 Gearbox ............................................ ........................................................ ........................ 13 2.5 Generator General Description ............................... ....................................................... ...... 14 2.6 Generator Datasheet ................. ........................................................ ................................. 15 2.7 Start System ............................................... ........................................................ ............... 24 2.8 Fuel System . ........................................................ ....................................................... ...... 26 2.9 Lubrication System .................................................................. ........................................... 29 2.10 Controls System .................................................................... ........................................... 33 2.11 Generator Control ................................................ ....................................................... ...... 44 2.12 Enclosure ............................... ........................................................ ................................. 49 2.13 Marinization ................................................................. .................................................... 53 2.14 Turbine Air Inlet System ................................................ .................................................... 55 2.15 Exhaust System ........................................ ........................................................ ............... 57 2.16 Accessory Equipment .............. ........................................................ ................................. 59 2.17 Quality Assurance and Testing ............................................... ........................................... 62 2.18 Preservation, Installation and Documentation ...................................................... ............... 65 2.19 Certification ............................ ........................................................ ................................. 74

3.0 SITE INFORMATION ........................................................................................................... 75 3.1 Package Utility Requirements .................................................. ........................................... 76

4.0 PERFORMANCE .................................................................................................................80 4.1 Expected Performance ................................................... .................................................... 81 4.1.1 Gas Turbine Performance Data ...................................................... .............................. 81

5.0 COMMENTS......................................................................................................................... 84 5.1 General Comments ........................................................ .................................................... 85

6.0 QUALITY ..............................................................................................................................88 6.1 Inspection and Test Plan / Project Quality Plan ................. .................................................... 89

7.0 TYPICAL DRAWINGS .......................................................................................................105 7.1 Disclaimer Statement ..................................................... .................................................. 106 7.2 Standard Ancillary Arrangement Drawings ................................................... ...................... 107

Caterpillar Confidential: Do Not Disclose Without Solar's Approval

ME15-0029 February 2, 2016 Page 2


1


INTRODUCTION





1.1 EXECUTIVE SUMMARY Solar is pleased to provide our proposal in response to your application requirements and have selected the following equipment to meet your needs: DRIVER EQUIPMENT 3 Mars 100 Generator Sets DRIVEN EQUIPMENT •

Ideal 4160 V Generator

We want to note that Solar considers the information included in this proposal to be confidential. As such, this proposal is submitted subject to the terms and conditions regarding confidentiality. None of the information included in this proposal should be disclosed to any consultant employed by our competitors, unless they agree to be bound by the confidentiality agreement. Under no circumstances should any confidential information included in this proposal leave Dragados' offices. We appreciate the opportunity to submit this offering and look forward to working with Dragados on this very important project. We trust this proposal meets your requirements. Should you have any questions or require clarification, please do not hesitate to contact the assigned Sales Engineer, Gabriel Cuenca, or Project Applications Engineer, Alejandro Franco.



Dragados


Mar1s0G 0 ener atoSret

1.2 WORLD LEADER IN INDUSTRIAL GAS TURBINES Solar Turbines Incorporated is a world leading producer of industrial gas turbines and turbomachinery packages in the 1.2 – 21.7 MW (1,600 – 30,000 hp) range. Solar gas turbine units are operating in over 100 different countries and under varying conditions, including arctic, desert, coastal/tropical and offshore. Even in the harshest environments, Solar gas turbines continue to provide safe and reliable power. Solar Industrial Gas Turbine Operating Experience Summary Experience by Package Compressor Sets Mechanical Drives Generator Sets TOTAL

UnitsSold 4,580 2,700 8,000 15, 280

EstimatedHours (000's) 882,000 540,000 1,020,000 2,442,000

NOTE: Total includes >1,200 Spartan generator sets Effective: 12/31/15, © Solar Turbines Incorporated

Mars Industrial Gas Turbine Operating Experience Summary Experience by Package Compressor Sets Mechanical Drives Generator Sets TOTAL

UnitsSold 550 430 410 1, 390

EstimatedHours (000's) 52,000 56,800 60,900 169,700

Effective: 12/31/15, © Solar Turbines Incorporated

SoLoNOx Industrial Gas Turbine Operating Experience Summary Compressor Sets and Mechanical Drive Packages Titan Mars Taurus 70 Taurus 60 Centaur 50 Centaur 40 Generator Sets Packages Titan Mars Taurus 70 Taurus 65 Taurus 60 Mercury 50 Centaur 50 Centaur 40 TOTAL

Units Sold 250 509 486 252 228 115 Units Sold 241 105 312 28 551 95 67 67 3, 306

Estimated Hours (000's) 7,700 32,200 15,500 22,000 13,700 10,600 Estimated Hours (000's) 11,900 13,300 21,000 1,500 49,200 5,500 9,800 6,300 220,200

Effective: 12/31/15, © Solar Turbines Incorporated





1.3 DELIVERY PERFORMANCE

Confidential: Do Not Forward Without Solar's Written Approval



2


SC O PE





2.1 GENERAL DESCRIPTION This proposal describes product features and provides turbomachinery specifications for the Mars 100 generator set. Presented are descriptions of the basic configuration, ancillary systems, and installation requirements available at the time of publication. The Mars 100 gas turbine generator set is completely integrated, fully operational and equipped with the accessories and auxiliary systems required for operation. Designed specifically for industrial service, Mars 100 generator sets are compact, lightweight units requiring minimal floor space for installation. Proven packaging designs greatly reduce installation costs, time, materials, and labor.





2.2 GAS TURBINE PACKAGE Package Description The Mars 100 gas turbine generator set consists of an axial-flow gas turbine engine, generator, and reduction-drive gearbox. These components are installed in-line on a heavy-steel base frame referred to as the skid. The skid is a structural steel assembly with beam sections and cross members welded together. The two sections of the skid can be separated to facilitate handling and shipment but when bolted together they form a rigid structure suitable for three-point mounting. The gearbox and generator are connected by means of a flexible dry-disk, shear-type coupling enclosed in a spark-proof coupling guard. Jacking points are provided to facilitate alignment of the generator to the gearbox. Drip pans are included to collect any potential liquid leakage. Skid connection points for fuel, lube oil, air, and water are located on the outer edge of the skid. Electrical connections are made in on-skid junction boxes. Machined mounting surfaces on the base frame facilitate component alignment. All skid labels will be written in Spanish and English. Major Components and Systems Major components and systems of the Mars 100 generator set include: Gas turbine Start system Fuel system Reduction-drive gearbox Generator Lubricating oil system Turbotronic 4 control system Onskid electrical wiring

• • •

• • • • • • • •

o

o

o

Skid with pans Piping anddrip manifolds Package enclosure with: Ventilation system Fire detection and suppression system Combustible gas detection

Skid Electrical System Certification and Type The onskid electrical system will be furnished to meet the following certification requirements: •

National Electrical Code (NEC)

NEC Class I, Group D, Division 2 Electrical System Onskid electrical equipment is in accordance with NFPA 70 (NEC) requirements for electrical equipment installed in Class I, Group D, Division 2 hazardous locations. All onskid package wiring is made with cable in covered stainless steel cable trays for physical protection. Solar supplied turbine control console, variable frequency drives, and battery charger are non-explosion proof and must be installed in a nonhazardous location. Three-Phase and Single Phase Electrical Rating





The skid will be rated for 60 Hz applications. All three-phase and single-phase motors and electrical components will have a 460 VAC, 3 Phase / 120 VAC, 1 Phase voltage rating. Unless specifically referenced in this proposal, motor starters and contactors are not provided in Solar's scope of supply. Stainless Steel Instrument Tags Stainless steel tags with Solar's device identification are provided for onskid instruments and hydromechanical components.

Skid Connections Skid connection points for fuel, lube oil, air, and water are conveniently located on the outer edge of the skid.

ADDITIONAL FEATURES: Y-type Gas Fuel Strainer Solar to provide Y-type gas fuel strainer Solar is to provide a loose shipped stainless steel Y-type gas fuel strainer to be installed upstream of the package fuel connection point. Utility List





A Utility List is to be provided. This list will provide information on electrical loads and utility consumables that the customer must supply to the package. Only provided in Solar format and not subject to customization. Package Dynamic Pad Loads Package dynamic load calculation table will be provided on MID (Rev B) package tie-down sheet. Vibration dynamic load calculations for GS packages will be provided on the Mechancial Interface Drawing (Rev B). The certified generator drawing must be available. Calculations do not include seismic (earthquake), and wind loads. Generator short circu it loads are provided as standard. Pressure Vessels- ASME Pressure Vessels - ASME All pressure vessels that fall under the ASME Pressure Vessel Code requirements must be code stamped and include material certificates and all documentation.including but not limited to the U1A form, AMSE code calculations, and material test repor ts.





2.3 GAS TURBINE ENGINE The Mars 100 two-shaft gas turbine engine is a completely integrated and self-contained prime mover. The gas turbine combines high performance operation with rugged industrial construction. This design philosophy allows for high efficiency performance, low maintenance, and a long service life. The Mars 100 gas turbine is designed for a high degree of compliance with American Petroleum Institute (API) requirements. Inlet Orientation The gas turbine air inlet flange terminates in the up position. Exhaust Orientation The gas turbine exhaust flange terminates in the up position. Hot Section Coating Special coatings are applied to key areas of the turbine hot section to provide protection against hot corrosion. SoLoNOx Combustion System Solar’s proprietary SoLoNOx dry low emissions system reduces pollution by limiting the formation of nitrous oxides (NOx), carbon monoxide (CO), and unburned hydrocarbons (UHC). This system uses lean premixed combustion to lower the maximum flame temperature and reduce pollution formation in the engine exhaust gas. Solar’s engineering staff works with customer’s to meet local permitting emission requirements.





2.4 GEARBOX Reduction Drive Gearbox The reduction-drive gearbox is an industrial, epicyclic, star-gear design selected specifically for generator set applications. The gearbox uses relatively few moving parts, which provides high reliability and ease of assembly and disassembly. The reduction gearbox is designed for continuous-duty operation and reduces the output speed of the turbine to the required operating speed of the generator. The gearbox is coupled to the gas turbine through a balanced high-speed shaft, splined at both ends. The output shaft is coupled to the generator through a flexible disk-type dry coupling enclosed in a spark-proof coupling guard. The design of the gearbox facilitates straight-through shafting, avoiding offset problems and permitting engine, gear, and generator alignment from a common base. Gear lubrication is provided by the package lube oil system. The gearbox is designed to provide 99% reliability between major inspections and overhauls. Coupling and Guard, Kop-Flex Low speed couplings are included in the scope of the generator package. The coupling is a dry disc pack style. The coupling is not designed specifically to API 671, and a list of comments and exceptions can be provided. Generator set couplings have a shear element designed to be the first point of failure in case of an overload event. The driving and driven hubs are a cylindrical double key design. Coupling Guards are manufactured from painted carbon steel.





2.5 GENERATOR GENERAL DESCRIPTION Unless otherwise stated, the generator is rated per NEMA MG1 standards, and is sized to meet or exceed gas turbine performance over the site ambient temperature range as stated in Site Conditions. Design Specifications For 60 Hz applications, the generator is constructed per NEMA MG 1. For 50 Hz applications, the generator is constructed per IEC 60034 or NEMA MG 1. Standard Features The synchronous brushless revolving field generator is an independent two-bearing design with a shaft extension suitable for direct drive by a gas turbine engine, and includes the following accessories: • • • •

Permanent Magnet Alternator (PMA) Anti-condensation Space Heaters (see the Utility List for specific loads) Terminal box for medium voltage terminations Permanently-affixed rating nameplate(s)

Generator Medium Voltage Terminal Box: • •

Current Transformers – See table on the following page NEMA 4-hole terminals are provided for customer termination

Exception: Unless otherwise stated, Potential/Voltage Transformers (PT/VT) are not included and shall be provided and installed in the switchgear by Others for Solar use. Electrical interconnection is by Others. Medium voltage interconnecting leads, insulation and lugs are not included in Solar's scope of supply, and shall be provided by others. Generator Data Sheets: •

Preliminary generator data can be provided upon request. Certified generator data will be furnished per the Drawing Schedule in the commercial proposal.

Note: For water cooled Generator configurations (TEWAC/CACW), refer to Utility List for water quality requirements.





2.6 GENERATOR DATASHEET











Dragados



REACTIVE CAPABILITY CURVE 100

0.70 PF Overexcited

80

0.80 PF 0.85 PF

60

0.90 PF 40 A V K d te a r f o t n e c r e p in R A V

0.95 PF

20

0 0

20

40

60

80

100

120

-20

K

0.95 PF -40 0.90 PF -60

0.85 PF 0.80 PF

-80

Underexcited

0.70 PF -100 KW in percent of rated KVA

Rating: 12500 KVA 4160 Volts 1735 Amps 0.80 P.F. 1800 RPM rev. 0


EE - 99 23 A


Dragados



SHORT CIRCUIT DECREMENT CURVES

10 9 8 7 ti n u r e p n i t n e rr u C

6 5 4 3 2 1 0 0.010

0.100

1.000

10.000

Time (sec) 3Phase

Line-Line

Rating: 12500 KVA 4160 Volts 1735 Amps 0.80 P.F. 1800 RPM

rev. 0 Caterpillar Confidential: Do Not Disclose Without Solar's Approval

EE - 99 23 B


Dragados



EFFICIENCY CURVES

99.0%

98.0%

97.0% y c n ie ic f f E96.0% t n e c r e P

95.0%

94.0%

93.0% 20%

40%

60%

80%

100%

120%

Percent Load Rated PF

1.0 PF

100% Load = 10,000 kW Rating: 12500 4160 1735 0.80 1800

KVA Volts Amps P.F. RPM


EE- 9923C


Dragados



SATURATION CURVES 1.4

3.5

1.3 1.2

3.0

1.1 1.0

2.5

Open Circuit

e 0.9 g a tl o 0.8 V r o t a t 0.7 S it n 0.6 U r e P 0.5

2.0

1.5

0.4

t n re r u C r o t ta S it n U r e P

1.0

0.3 0.2

0.5 Short Circuit

0.1 0.0

0.0 0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

Per Unit Field Current


rev. 0


EE- 99 23 D


Dragados



Generator Output vs Ambient Temperature

18000

16000 14000 t u p t 12000 u O A10000 V k 8000 6000 4000

2000 0 -30

-20

-10

0

10

20

30

40

50

60

Ambient Temperature °C Generator rated output

Temp °C

rev. 0


12500

kVA at 40°C

k VA

kW at 0.80 PF

55

10763

45

11949

8610 9559

40

12500

10000

35

12885

10308

25

13622

10897

15

14321

11456

5

14987

11990

-5

15625

12500

-15

16238

12990

-25

16829

13463

EE- 9923E ME15-0029 February 2, 2016 Page 22

Dragados



V CURVES

1.2 0.7 PF

Underexcited

0.8 PF

1.0

0.9 PF

0.9 PF 100% KW ) d e t a R f o U P ( t n rre u C e n i L

Overexcited

1.0 PF

0.8

75% KW

0.6

No Load

50% KW

0.4

25% KW

0.2

0.0 0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Field Current (PU of No Load)



EE- 9923G




2.7 START SYSTEM Direct Drive AC Motor Driven Start System General Description The start system provides torque to initiate engine rotation and to assist the engine in reaching a selfsustaining speed. The start system consists of a direct-drive AC starter motor driven by a solid-state variable frequency drive (VFD). Functional Description To begin gas turbine rotation, the VFD initially provides low-frequency AC power to the starter motor. The VFD gradually increases the speed of the starter motor until the gas turbine reaches purging speed. When purging is completed, the control system activates the fuel system. The speed of the starter motor is gradually increased until the gas turbine reaches starter dropout speed. The VFD then deenergizes the starter motor and the motor clutch assembly is disengaged. Assuming a four-minute purge crank, the system is designed to provide three consecutive full-speed start attempts with 10-minute motor rest periods between attempts. Depending upon ambient temperature, turbine conditions purge crank time and motor rest period time, fewer or more consecutive start attempts may be possible. Starter Motor The starter motor provides high breakaway starting torque and acceleration from standstill to starter dropout speed. The motor is a standard frame size and is constructed to be explosion proof and flameproof. The motor includes an integral over-temperature protection thermostat connected to the Turbotronic 4 control system for hazardous area motor certification and protection. Separate cable/conduit entry points are provided for power connections, thermal protection wiring, and the space heater wiring. Starting power is transferred to the gas turbine via the reduction-drive gearbox and over-running clutch and shaft assemblies. Variable Frequency Drive The variable frequency drive (VFD) is a motor speed controller that provides pulse-width modulated power with variable frequency and voltage to the starter motor. Controlled by the Turbotronic 4 control system, the VFD regulates voltage and frequency to the star ter motor to control engine speed from standstill to starter dropout speed. The VFD cabinet is designed for installation in a non-hazardous location. Electrical disconnects and overcurrent protection devices are not provided. Power Wiring The start system requires customer-furnished three-phase AC input. Additional three-phase AC power wiring is required to connect the VFD to the starter motor. A start contactor is not required for VFD operation. A customer-furnished fused disconnect at the VFD input is recommended.





NOTE: A line reactor is not included in Solar's scope of supply. Please refer to Solar's Product Information Letter (PIL) 149 for information on when line reactor(s) may be required.



Solar Turbines OG & ilas

Dragados Ma r1s0G 0 e ner atoSre t

2.8 FUEL SYSTEM General Description The fuel system, in conjunction with the control system, includes all necessary components to control ignition and fuel flow during all modes of operation. Solar has proposed the Natural Gas, SoLoNOx Combustion fuel system for this application. SoLoNOx Combustion System The SoLoNOx combustion uses special injectors with main and pilot fueltoports. The stable fuel injected through these portssystem is controlled during fuel starting and steady-state operation maintain combustion and minimize the formation of nitrous oxides (NOx), carbon monoxide (CO), and unburned hydrocarbon (UHC) emissions. To further regulate emissions levels, combustion airflow is regulated using a bleed valve mounted on the combustor case. Gas Fuel System The fuel system includes: • • • • • • • • • • •

Supply Pressure Transmitter Pilot air operated primary gas fuel shutoff valve Pilot air operated secondary gas fuel shutoff valve Pilot air operated gas vent valve Electrically operated fuel control valve Torch with shutoff valve and pressure regulators Main fuel manifold Fuel injectors Fuel pilot control valve Fuel pilot manifold Inlet gas filter/coalescer loose shipped for field installation

NOTE: Any gas turbine fuels that do not meet Solar Specification ES9-98 can have an impact on engine performance, operating life, and engine warranty. Refer to Solar's Product Information Letter (PIL) 162, "Recommendations and Requirements for the Sourcing, Handling, Storage, and Treatment of Fuels for Solar Gas Turbines," to ensure high fuel quality for optimum performance.





Component Operation The gas fuel pressure supplied to the turbine skid must meet minimum and maximum pressure and flow requirements. If the gas fuel pressure is too high or too low, the control system will prevent turbine operation. Pneumatically actuated primary and secondary gas fuel shutoff valves are controlled using pilot air pressure. For each valve, pilot air pressure is admitted to and exhausted from a pneumatic actuator through a solenoid valve. Fail-safe operation ensures both valves will close in case pilot air pressure is lost. The gas fuel control valve and the SoLoNOx fuel pilot control valve are powered by integrated DC motordriven actuators. Integrated actuator electronics provide precise, closed-loop valve control based on position command inputs versus position feedback outputs. Both valves are fast acting and provide fuel metering for light-off, acceleration, full load, and load transient conditions. Fail-safe operation ensures both valves will close in case the command signal or control power is lost. During the start sequence prior to ignition, the control system will verify gas pressure and perform a gas valve check to ensure proper operation of all gas fuel valves. Fuel Control Valve, Gas Fuel, Stainless Steel Valve Body The gas fuel control valve is electrically operated and electronically controlled by means of an integral 120-Vdc powered actuator that incorporates a brushless dc servo motor, a linear ball screw drive, a digital controller for precise motor control, and a resolver for position feedback. Control outputs and inputs are 0 to 24 Vdc for discrete signals and 4 to 20 mA for analog signals. The valve can operate in ambient temperatures up to 93°C (200°F). It has a turndown ratio that exceeds 400:1 and provides excellent metering of low light-off and acceleration gas fuel flows, as well as full load and load transient flow conditions. Response time is less than 100 msec from 10-to-90% stroke. Fail-safe operation ensures bubble tight valve closing in case of loss of either the command signal or the control power. The valve body is fabricated from stainless steel. ADDITIONAL FEATURES: Insulated Gas Fuel Line





Insulate gas fuel line. Insulate the gas fuel line from the customer connection flange to the gas fuel module. Insulate the main and pilot gas line from the fuel module to the pilot gas manifold. The structure of the flex hose provides insulation so insulating it is not necessary. Lines on the fuel module will not be insulated.





2.9 LUBRICATION SYSTEM General Description The lubrication system circulates oil under pressure to the gas turbine and driven equipment. Lube oil is supplied from the lube oil tank located in the driver skid. The lubrication system incorporates the following components: • • • • • • • • • • • • •

Carbon Steel oil tank and tank covers Oil tank heater Lube oil (customer furnished) AC Motor-driven pre/post lube oil pump DC Motor-driven backup lube oil pump 120 VDC Step starter (ordinary duty) Stainless Steel filter system Duplex lube oil filter system with replaceable elements Oil level, pressure, and temperature indications Pressure and temperature regulators Strainers Oil tank vent separator Oil tank vent flame trap

Petroleum Base Lube Oil, Viscosity Grade C32 (S150) Solar's Specification ES 9-224 defines the type of lube oil acceptable for use in Solar's gas turbine engines, gears and driven equipment during normal operating service. For each type of oil, the specification further defines the appropriate viscosity and other physical and chemical requirements. The acceptable conventional oil types are synthesized hydrocarbon (SHC), Class I and petroleum oils, Class II. These oils are further categorized into viscosity grades ISO VG 32 (C32) and ISO VG 46 (C46). The lube oil system operating temperature range, cooler bypass valve calibration, and temperature protection set points are dependent upon the oil viscosity. The oil system control components and set points for this proposal are based on the use of petroleum base oil, viscosity grade C32 for the rotating machinery oil temperature and viscosity requirements and specified ambient temperature range. If a different type of oil or viscosity grade is preferred by the purchaser, this needs to be communicated to Solar for consideration. AC Motor-Driven Pre/Post Lube Oil Pump The pre/post lube oil pump provides lube oil pressure during package starting and for post-lube cooling of the gas turbine and driven equipment bearings. The pre/post lube oil pump provides lube oil pressure during a gas turbine roll down in the event the main lube oil pump has failed. DC Motor-Driven Backup Lube Oil Pump The backup lube oil pump provides lube oil pressure for post lube cooling of the gas turbine and driven equipment bearings in the event the pre/post lube oil pump fails. It provides lube oil pressure during a gas turbine roll down in the event the main lube oil pump and pre/post lube oil pump have both failed. The backup lube oil pump also provides lube oil pressure during an emergency condition such as a fire, control system failure, emergency stop, or if a turbine over speed is detected by the backup system. The 120 VDC step starter is designed for indoor installation in a nonhazardous area.





Lube Oil Filter A duplex lube oil filter system is supplied with a filter transfer valve and filter differential pressure indication with alarm. The transfer valve allows a filter transfer to be performed while the motor is running. The lube oil filter system is contained completely within the driver skid. The lube oil filter drain connection is located on the side of the package base. Stainless Steel Lube Fi lter Canisters and Transfer Valve Piping The lube oil filter canisters and transfer valve are fabricated from corrosion-resistant 316L stainless steel and painted per Solar's standard paint system. Carbon Steel Lube Oil Tank The lube oil tank and tank covers are fabricated from carbon steel and all external surfaces are painted per Solar's standard paint system. Lube Oil Vent Coalescer An offskid lube oil vent coalescer is provided to remove oil vapor from the lube oil tank vent airflow. The coalescer drains trapped oil vapor back to the lube oil tank and allows the remaining vent airflow to exhaust to the atmosphere. A tank overpressure alarm and shutdown are also included. Unless specifically referenced in this proposal, the lube oil vent coalescer is loose shipped for offskid installation by others.





Lube Oil Vent Flame Arrestor The lube oil vent flame arrestor prevents an ignition source from entering the lube oil tank. Unless specifically referenced in this proposal, the flame arrestor is loose shipped for offskid installation by others. Offskid Lube Oil Cooler, Air/Oil, AC Motor Driven An air-to-oil type cooler is supplied to provide oil cooling for the gas turbine and the driven equipment. The cooler is sized for specified heat loads and ambient temperatures. The cooler is loose shipped for offskid installation by others. The basic cooler features are as follows: • • • • • •

Carbon steel box headers with tube inspection plugs Tube bundle with aluminum fins ASME code stamped Vibration switch Horizontal mounting Vertical air discharge





Note: The interconnect piping between the turbine package and the lube oil cooler is not included in Solar's scope, unless otherwise noted in this proposal. Lube Oil Immersion Tank Heater The lube oil tank immersion heater ensures the lube oil tank temperature is adequate for starting in cold conditions. The tank heater also facilitates a short lube oil temperature warm up period after a cold start. Unless specifically referenced in this proposal, electrical supply contactors are not included. ADDITIONAL FEATURES: Stainless Steel Oil Tank Flame Arrestor The lube oil tank flame arrestor (Including 316SS attaching hardware includes nuts, bolts, and washers.) will be provided in 316SS stainless steel. Includes housing and internal components. Stainless Steel Oil Tank Demister The lube oil tank vent demister (Including 316SS attaching hardware includes nuts, bolts, and washers.) will be provided in stainless steel. Includes element frame and shell. Lube Oil Tank Heater Material The lube oil tank heater is to have the following material: The lube oil tank heater will be provided with 316 SST material only.





2.10 CONTROLS SYSTEM General Description The Turbotronic 4 control system provides for automatic starting, acceleration to operating speed, sequencing control, engine and driven equipment monitoring during operation, and normal and malfunction shutdown. During operation, the control system, by means of automatic warning and shutdown devices, protects the turbine engine and driven equipment from possible damage resulting from hazards such as turbine over speed, high engine temperature or vibration, low lubricating oil pressure and excessive oil temperature. The system input power is 120 Vdc, with internal power conversion providing the 24 Vdc required by the control circuits. The control processor (controller) performs proportional control, start-up, operation and shutdown sequencing and protection functions, as well as detection and annunciation of abnormal operating conditions. Control for these functions comes from signals the controller receives from solid-state devices, control switches, speed, pressure and temperature transmitters, relays, solenoids, and vibration sensors. These components provide the controller with the data necessary to control and maintain desired process conditions, while maintaining engine speed and temperature at safe levels. In the event of an abnormal condition or malfunction, the control system indicates the nature of the malfunction. When an alarm or shutdown is displayed, a sequence of appropriate operations begins in response to the detected condition. In the event of a control system failure, the backup relay system initiates a shutdown while operating the lubricating oil system and other subsystems, as required, to avoid engine and driven equipment damage during shutdown. The Turbotronic 4 control system controls and monitors the turbomachinery package including the gas turbine and driven equipment equipment. The system architecture is based on a Rockwell Automation/ Allen-Bradley hardware and software platform and includes fully integrated driven equipment, vibration, and fire and gas monitoring and control subsystems. An independent backup shutdown system provides additional protection. This shuts the package down in a safe and orderly manner in the event of malfunction of the primary control system. System Architecture Key system components include: • • • • • • • • •

ControlLogix controller (Allen-Bradley) RSLogix 5000 programming software (Rockwell Automation) 1794 Flex I/O input/output modules (Allen-Bradley) Combination Generator Control Module (Allen-Bradley/Basler Electric) Vibration monitoring system ControlNet network (ControlNet International) TT4000S onskid local operator interface (Solar Turbines) Independent backup shutdown system (Solar Turbines) Fire and gas monitoring and control system (Det-tronics)





The ControlNet network provides primary communications between components. Hardwire backup is provided for critical circuits. The variable speed frequency drive (VFD) for the start motor is typically located in a motor control center. All other components are rated NEC Class 1, Division 2 or CENELEC Zone 2 for hazardous area duty and are located on the package skid for the onskid controls configuration or in an auxiliary console for the offskid configuration. Note: Programming terminals used for commissioning and servicing the control system are not suitable for use in a hazardous atmosphere. Provisions must be made through work processes and procedures, or through the installation design, to ensure these devices can be used to access the control system safely.

Typical Turbotronic 4 System Architecture Component Descriptions Controller The ControlLogix controller, running RSLogix 5000 software, provides primary control. Project-specific programs are created in a Windows-based system and uploaded to the controller. The RSLogix 5000 software supports ladder and function block programming and complies with the International Electrical Code (IEC) 61131-3 standard for programmable controllers. ControlNet 1.5 Operating at 5 Mbps, the network is repeatable and deterministic. Cabling is redundant with two separate channels carrying the same information. The maximum total length of the network is 1000 meters without





the use of repeaters. However, this length decreases based on the number of nodes on the network. A practical design limit is 800 meters. Input/Output Modules Flex I/O modules provide an interface between the package instrumentation and the processor. Specific modules handle discrete inputs, analog inputs, temperature inputs, speed inputs, discrete outputs and analog outputs. Bently Nevada Vibration System, X and Y Proximity Probes, and Keyphasor The control system includes a Bently Nevada 1701 Field Monitor and associated vibration sensing devices. The system is physically and functionally integrated with the control system using Flex I/O network adapters. The Field Monitor integrates seamlessly into the ControlNet 1.5 system architecture, providing a distributed vibration monitoring system and mounting of components locally onskid. Each Field Monitor can accommodate up to eight vibration channels. Additional 1701 Field Monitor controllers are added as required depending on the number of vibration signals needed. The vibration data processed by the 1701 is transmitted to the controller through the ControlNet network for alarming and shut down. The vibration data values are displayed by the TT4000 system on a dedicated Vibration Summary screen. Backup Shutdown System The backup shutdown system shuts the package down in a safe and orderly manner without damage to the equipment in the event of a failure in the primary system. The control processor is monitored by both an internal watchdog circuit and by an external watchdog device. If either circuit detects a processor failure, the backup system takes control. It opens the generator circuit breaker, closes the fuel valves, and initiates a post lube cycle to protect the turbine bearings. Once a backup shutdown is initiated, operation can only be restored manually from the control panel after all faults have been cleared. The emergency stop push-button switches are wired to both the primary and backup systems. Fire and Gas System Enclosed packages require fire and gas control protection. The Eagle Quantum Premier system from DetTronics detects combustible gas and/or fire inside the enclosure based on inputs from gas, thermal, and optical flame detectors. If fire is detected, the system releases an extinguishing agent into the enclosure. If a fire or an unacceptable gas level is detected, the system instructs the Turbotronic control processor to initiate a package shutdown. The system is also wired directly to the backup shutdown system. See Enclosure Section of this proposal for a more complete description. Combination Generator Control Module The combination generator control module (CGCM) provides voltage regulation, automatic breaker synchronization, excitation control, power metering, load sharing, and protective relay functions. For a more detailed description of the CGCM capabilities, refer to the Generator Control and Monitoring Section of this proposal. Control System Power Supplies The control system operates on 24 VDC power. The standard battery charge system provides 120 VDC power to the control system. The control system includes a 120 to 24 volt DC-to-DC converter to supply 24 VDC power to the control system. For a more detailed description of the battery charger system, refer to the Accessory Equipment Section of this proposal.





System Monitoring and Control Functions The control system provides sequencing control during gas turbine startup, steady state operation, and shutdown. Protective functions are provided during all stages of operation. Starting and Loading The Start command initiates the sequence. Prior to rotation, the lube oil pump undergoes a test cycle, the enclosure fans are started, and the fuel valves undergo a test cycle with fuel pressure verification. The starter then rotates the gas turbine and the compressor develops airflow to purge any accumulated gas in the gas turbine, air inlet, and exhaust duct. The purge cycle is tailored to the exhaust duct volume. When the engine has reached the required speed and temperature, a small amount of fuel is introduced into the combustor from the gas torch and ignited by the ignitor plug. The fuel control valve gradually opens and admits fuel into the combustor through the injectors. The inlet guide vanes open and the bleed valve gradually closes. Fuel flow, engine temperature, and turbine speed all increase. Once starter dropout speed is exceeded, the starter freewheels and is de-energized. The engine continues to accelerate under its own power. The generator is loaded by closing the generator circuit breaker. The circuit breaker can be closed to a dead (de-energized) or a hot (energized) bus. If a dead bus is detected, the circuit breaker may be closed without synchronization. If a hot bus is detected, the system must synchronize the generator output to the bus before the circuit breaker is closed. Typically, synchronization and closing of the breaker are done automatically. Steady-State Control During steady-state operation, the control system keeps the equipment within specified operating conditions. The maximum power limit is determined by engine temperature and speed. Temperature control is based on the third-stage nozzle temperature (T5). Seventeen thermocouples are used and the values averaged. If one or two thermocouples has a value that deviates from the average by more than a preset amount, an alarm is generated by the control system. If three thermocouples deviate, the package is shut down. Special sensors continuously monitor the gas turbine speed and the control system makes adjustments to meet operating requirements and to keep the speed within specified limits. A separate backup overspeed detection system provides additional protection by automatically shutting the engine down if a preset overspeed limit is reached. Stopping The gas turbine may be shutdown either manually or automatically. The Normal Stop command initiates a cooldown stop. The generator circuit breaker is opened and the gas producer runs at idle speed for a preset time to allow the gas turbine and driven equipment to cool, then the fuel valves close. The Emergency Stop command results in the immediate opening of the generator circuit breaker and closure of the fuel valves without a cooldown period.





In the event of a hazardous condition or equipment malfunction, the control system will shut the package down automatically. These shutdowns are divided into four categories: • • • •

Cooldown stop nonlockout (CN) Cooldown stop lockout (CL) Fast stop nonlockout (FN) Fast stop lockout (FL)

Cooldown and fast stops correspond to the manual normal and emergency stops respectively. Lockout stops inhibit operation of the control system and prevent restarting until the malfunction is reset. Lockout stops result from serious malfunctions that require corrective action before the system can be restarted. Nonlockout stops result from an operational disruption or abnormal condition and can be reset when conditions return to normal. In all cases, after the package has come to a complete stop and the rundown timer has timed out, the control system initiates and supervises a post-lube cycle to protect the gas turbine and driven equipment bearings from thermal damage. If the shutdown is the result of fire being detected, star t of the post lube cycle is delayed for 10 minutes unless an operator intervenes.





ONSKID CONTROL SYSTEM The control system components are mounted in one or more panels located on the driver skid. The panels contain the key elements of the system including the Control Processor, the I/O Modules, the Vibration Monitoring System, the Combination Generator Control Module and the onskid display unit. The operator interface includes lighted switches for Start / Starting, Normal Stop / Stopping and Backup System Active / Reset; and switches for Increase / Decrease, Off / Local / Remote, Horn Silence, Acknowledge, Reset and Emergency Stop. The onskid display unit provides the following key features: • • •

• •

•

•

•

•

Operation Summary – Overview of key operation parameters Temperature Summary – Display of all monitored temperatures Vibration Summary – Display of all vibration readings Alarm Summary – Display of all malfunctions with date and time stamping Event Log – Display of date and time stamped sequence of events with sorting and filtering functions Strip Chart – Display of real time data for selected analog signals in strip chart format. Configurable with legend, cursor and zoom features Trigger Log – Stores data surrounding specified events. Data can be played back using the Strip Chart feature. Program Constants – Password protected display and modification of controls constant values Generator Summary – Display of all monitored generator parameters

Auxiliary Control Console for Offskid Control Interface In addition to the onskid display unit located on the driver skid, a single-bay console is supplied with a Turbine Control Panel (TCP) and TT4000 Display and Monitoring System that allows the operator to address and monitor vital system parameters. The TCP provides the essential controls to start and stop the unit, to make process set-point adjustments, and facilitate other optional control functions. Typical TCP operator switches and indicators are: Switches • •

Start Normal Stop (shutdown with normal no-load cool down)



Solar Turbines OG & il as • • • • • • • • • • •


Emergency Stop (shutdown without cool down) Horn Silence, audible alarm Alarm Acknowledge (warnings and shutdowns) Lamp Test Backup Reset (key switch) Alarm Reset (warnings and shutdowns) Speed Control (increase and decrease) Gas/Liquid (When applicable) Voltage Increase Voltage Decrease Isochronous/Droop

Indicators • • • • • • • • •

Local / Remote Ready Starting Ready to Load On Load Backup Active Cool down Alarm Summary Shutdown Summary (lockout)

Video Display Unit The TT4000 Display and Monitoring System provides all of the information available at the onskid Display as a minimum and includes additional control displays not available onskid, typically including the following standard displays and features: • • • • •

•

•

•

•

Operation Summary – Overview of key operation parameters Temperature Summary – Display of all monitored temperatures Vibration Summary – Display of all vibration readings Alarm Summary – Display of all malfunctions with date and time stamping Event Log – Display of date and time stamped sequence of events with sorting and filtering functions Historical Data – Stores data surrounding specified events. Data can be played back using the Strip Chart feature. Strip Chart – Display of real time data for selected analog signals in strip chart format. Configurable with legend, cursor and zoom features Program Constants – Password protected display and modification of controls constant values Generator Summary – Display of all monitored generator parameters

Screen displays can be selected independent of the onskid display unit and include the ability to start, normal stop, acknowledge, reset and control package speed and / or load set point. The auxiliary console operates over a ControlNet serial link connected to the onskid control processor. Data Storage and Display Data can be viewed in a strip chart format in real time, trended, analyzed online, or exported for off-line viewing. All logs are self-describing repositories, containing site information, tag information, and the historical data itself. The data can be viewed online using the Historical Trend Display. The Historical Trend Display allows selection of up to 10 variables for viewing in a digital strip chart format. The objective of historical data monitoring is to provide information of a type and in a format that allows informed Caterpillar Confidential: Do Not Disclose Without Solar's Approval




decisions to be made in the areas of operation, maintenance, and optimization of the turbomachinery and associated equipment. The information is collected for on-line viewing and analysis or may be exported for storage and off-line analysis. The Discrete Event Log records changes in status for all defined discrete inputs, including operator commands, alarms and shutdown annunciations, and key sequencing and status signals. Up to 5000 events are stored and can be viewed and sorted by heading. Analog Data are collected and saved to disk. The standard data files are: Hourly Log - data are read at hourly intervals for 2 years. Each year’s data are stored in a separate file. Data are recorded whether or not the equipment is operating. Minute Log - data are read and stored at one-minute intervals for the previous 62 days, one file for each day. 10 Second Log - data are read at 10-second intervals for the previous 31 days, one file for each day. Trigger Log - data are read at one-second intervals for 6 minutes before a “trigger” event that is defined in the software. The standard trigger is a shutdown. Six minutes before the trigger of data are written to a file. Up to 50 trigger logs files can be stored. Multi Unit Remote PC Provide a TT4000 multi unit display. The display will duplicate the project specific TT4000 screens. This custom feature is for multiple unit projects, this TT4000 multi unit display is capable of monitoring and control of the units. Solar will supply in each unit a dedicated communications module. TT4000 Display Screens A status bar at the top of every screen displays up to four alarm conditions. Standard display screens include: Operation Summary (complete package data) Temperature Summary (all monitored temperature values) Vibration Summary (all monitored vibration values) Alarm Summary Discrete Event Log Strip Chart Display (real time data) Historical Data Display (strip chart format) Program Constants Gas Turbine Performance Generator Summary (generator operating data) • • • • • • • • •

•





Engine Performance Map Display The engine performance map displays real-time turbine performance corrected to standard conditions. This is a calculated performance based on package instrumentation readings. The performance map is essentially for reference and is used to monitor trends in engine performance, not to verify absolute engine performance levels. The system includes instrumentation to measure flow of the fuel to the turbine. For fuel flow measurement, a loose-shipped flow measuring device (Coriolis Mass Flowmeter) is provided for offskid field installation. Modbus over Ethernet (Modbus TCP/IP) Supervisory Interface A Modbus TCP/IP interface module is installed in the control processor rack and connects to the processor through the rack backplane. The user may connect to the module with a standard 10/100 BaseT Ethernet port. Ethernet is suitable for applications up to 100 m (330 ft). Analog and discrete data are stored in one-dimensional arrays in the control processor, which may be read by the user. In addition, the Caterpillar Confidential: Do Not Disclose Without Solar's Approval




user may send supervisory control signals to the processor. Data available include all input analogs, a number of computed values, status indications, and all active alarms and shutdowns. Typical data include: • • • • • • • • •

Driven equipment status Gas producer turbine speed Power turbine speed Turbine T5 temperature Lube oil header pressure Lube oil temperature Ambient temperature All alarms and shutdowns All panel light status

Supervisory control signals include: • • • •

Start Stop Acknowledge / Reset Remote Speed / Load Set Point

The user is responsible for providing the hardware and software interfaces to the system. Control Screen Engineering Units in Metric - kg/cm2 Temperature values are displayed in °C and pressure values are displayed in kg/cm2. Control Screen Languages in English and Spanish Operator interface screen displays are in both English and Spanish languages with selection by screen menu. 120 Vac, 1 Phase Printer Logger, Quantity 1 The data logging and print system provides event logger, standard report form, and screen print. The system consists of a table top, 80/160-column dot matrix printer (120 Vac, 1 phase, 50/60 Hz) and a 7.6m (25-ft) interconnect cable. The following functions are provided: •

• • • •

Status Print – current value of analog and status of discrete variables. Menu selectable and automatically generated on shutdown event, followed by first out alarm print. Alarm Logging – prints alarm with time and date stamp. Daily Log – last 24 hours of elapsed time data. Print Screen– prints current screen. Historical Files– prints data from all historical files.

Field Programming Terminal, Software, Instruction Manual and Interface, Quantity 1 A specifically configured portable computer is provided to allow field programming of the control sequences and logic within the control processor. The computer contains the required interface hardware and software, and an instruction manual is included. Heat Recovery Application Interface and Control This feature provides interface between the gas turbine control and the exhaust heat recovery system (HRS) control necessary to sequence the start and stop of the gas turbine package and the HRS. This includes start permissives, stop commands, and signals necessary to ensure proper purging of the gas turbine exhaust system and HRS. Also includes some status monitoring and supervisory control of a Caterpillar Confidential: Do Not Disclose Without Solar's Approval




single blade diverter valve to ensure proper timing of the purging of the bypass and HRS ducts. This feature interfaces with the HRS primary control system, which requires only a few interface signals with the gas turbine package controls.





2.11 GENERATOR CONTROL AND MONITORING General Description For generator control and monitoring, the Turbotronic 4 control system incorporates a Rockwell Automation/Allen-Bradley combination generator control module (CGCM). The CGCM provides generator control, protection, and monitoring. Three excitation control modes are provided: • •

•

Automatic voltage regulation (AVR) - A constant generator output voltage is maintained Power factor (PF) control - A constant power factor is maintained when operating in parallel with a large power source Reactive power control - A constant reactive load is maintained when operating in parallel with a large power source

The following excitation control features are provided: • • • • •

Under frequency limiting Over and under excitation limiting Reactive droop compensation Cross-current compensation Line-droop compensation

Protection features for the driver and driven equipment include: • • • • • • • • • • • • • •

Field current limit Generator overcurrent Generator overvoltage Generator undervoltage Loss of excitation current Loss of operating power Loss of sensing Over excitation voltage Overfrequency Underfrequency Phase rotation error Reverse power Reverse volt amp reactive (VAR) Exciter (rotating) diode monitor

The protection features provided do NOT meet the requirements of power utility companies for the general protection of power distribution systems. This can only be done through the use of appropriately certified protective relay components with settings approved by qualified personnel based on a comprehensive analysis of the complete system. This scope is not a part of Solar's supply. Generator Control Functional Description The Turbotronic 4 control system working in conjunction with the generator's excitation system provides control, monitoring, and protection of the generator and its output. The key components are: • •

Permanent magnet generator (PMG) Rotating armature-type AC exciter





Full-wave rectifier assembly Combined generator control module (CGCM)

• •

The exciter armature is mounted on the main generator rotor and generates an AC voltage as it revolves in the magnetic flux produced by the stationary field. The stationary field is wound on salient poles supported by the stator core or frame. The PMG consists of permanent magnets on the generator rotor and a stationary armature, also supported by the generator frame. The rotating rectifier assembly rectifies the exciter armature AC output to DC. In turn, the DC power is applied to the main generator rotating field windings. The complete exciter is enclosed and protected by a removable cover. When the rotor operates at synchronous speed, the PMG provides power to the CGCM. The CGCM provides the appropriate exciter field current to control the exciter armature output, which is rectified to provide DC power to the main generator rotating field winding. During initial turbine generator acceleration, the excitation power is switched off. At approximately 80% speed, the PMG output is connected to the excitation power contacts and voltage begins to build. The CGCM then provides controlled exciter field current at a level to maintain the generator terminal voltage at a predetermined value established by the operator. A potential transformer (supplied with the switchgear by others) provides a voltage level signal to the CGCM. By sensing the generator output voltage and controlling the power to the brushless exciter, the CGCM automatically maintains the generator output voltage at a constant level at all load conditions. Since the PMG output power is independent of the main generator line voltage and current levels, there is no need for additional auxiliary equipment to provide power to the CGCM during transient conditions. The PMG provides sufficient generator terminal voltage during conditions of high generator line current to allow for selective tripping during a shor t-circuit condition. Current, potential, and cross current transformers required for input to the CGCM are not included. A cross-current compensating circuit is included to accommodate reactive load sharing between multiple turbine generators operating in parallel. Instrumentation transformers are supplied by others with the switchgear. Control Modes In addition to voltage regulation, the following generator control modes are also available: •

o

o

•

o

• •

o

Speed/Load Control Isochronous (Isoch) Speed Control Droop Speed Control Reactive Compensation Droop Voltage Control Power Factor Control Reactive Load Volt Amp Reactive Control Differential Cross Current Control





Breaker Synchronization The control system provides automatic generator breaker synchronization control when paralleling to the bus. Automatic synchronization can be initiated by the operator or by a remote signal received from a supervisory control system. Generator Metering Panel Mounted on the front of a control console, the generator metering panel provides meters to monitor generator output and switches to manually adjust generator voltage and to synchronize the generator breaker to the bus. The metering panel typically includes the following analog meters, lights, and switches: • • • • • • • • • • • • •

AC ammeter Frequency meter KW/kVAr meter AC voltmeter Power factor meter Synchroscope Exciter field ammeter Exciter field voltmeter Manual synchronizing lights Manual synchronizing switch Generator breaker Open/Close switch Generator breaker Open/Close status lights Automatic synchronization switch



Solar Turbines OG & il as • • • •


Automatic synchronization fail light Generator line-to-line voltmeter select switch Kilowatt (kW) and kilovolt amp reactive (kVAr) power meter select switch Generator phase current ammeter select switch

All data indicated by the metering panel is also indicated on the video display terminal.

Auto Start and Synchronizing System When the generator set is in standby mode, the control system will automatically start the generator set, accelerate the engine to loading speed, and synchronize the generator breaker to the bus upon receipt of a supervisory command. If the control system detects a hot bus, it will synchronize the generator to the bus and close the breaker. If the control system detects a dead bus, it will close the generator breaker without synchronization. Kilowatt Control (Single Unit) The kW control system controls the real load (kW) on a unit operating in parallel with a large source. The control monitors the load carried by the turbine generator set and adjusts turbine fuel flow to maintain a constant load under conditions of varying infinite bus frequency. Protection against excessive kW load while in parallel with a large source is provided by the turbine T5 temperature limiter system. The kW control system provides additional operational flexibility by allowing unit kW load level to be set at any desired level within the capacity of the unit. Generator Vibration Monitoring System with 2X and 2Y Proximity Probes, 4 Channels The generator vibration monitoring system provides additional package protection through preset warning indication and shutdown initiation in the event of unacceptable vibration levels in the generator. The system uses the Bently Nevada 1701 monitor, as described above, and includes four channels of vibration





to monitor an X and Y proximity probe installed at each generator bearing. Vibration level, alarm, and shutdown indications are displayed on the control system video display unit. Generator Keyphasor A generator keyphasor is included to provide additional vibration diagnostic capability with the use of externally applied diagnostic equipment. The keyphasor signal is available in the Bently Nevada 1701 monitor earlier in this proposal section.





2.12 ENCLOSURE General Description A Driver Only Enclosure is provided. The enclosure housing is a completely self-contained, weatherproof, insulated, and sound-attenuated system. The enclosure is mounted on the package skid. The sides of the enclosure consist mostly of doors supported by narrow panels to allow for access to major components. The engine can be removed from either side of the package after the doors and narrow panels are removed in that area. All maintenance enclosure doors include a stainless steel three-point heavy-duty door locking mechanism, handles, hinges, latching mechanism, internal lock override release, restraining device, and attaching hardware. The enclosure panels are treated with fiberglass material for sound attenuation and thermal insulation. Weather stripping is installed between all panels for sealing and sound attenuation. The enclosure is factory assembled on the package skid prior to shipment. The following standard features are included with the basic enclosure: • • • • • • •

Inlet and exhaust ventilation silencers Dual Fan Ventilation, Stainless Steel Pressurization system AC lighting Equipment handling system Stainless steel door hardware IP34 ingress protection rating

Standard Features Inlet and Exhaust Ventilation Silencers The enclosure ventilation openings are equipped with silencers with weather louvers. Enclosure High Temperature Alarm A heat sensor, completely separate from the fire system thermal detectors, is mounted in the enclosure. The sensor is set to activate an alarm if enclosure temperature is abnormally high. Pressurization System The enclosure has a positive pressure to prevent the ingress of external hazardous atmospheres through the enclosure seams. A differential pressure switch is provided to indicate an alarm when low enclosure pressure is detected. Lighting Fluorescent lighting is provided to illuminate the enclosure interior. Lighting on/off switches are provided on the enclosure exterior. Equipment Handling Kit, Quantity 1 An internal gas turbine and component handling kit is provided that consists of the following: •

Two internal movable trolley rails located over the gas turbine for gas turbine maintenance and removal



Solar Turbines OG & il as •

•


One internal movable trolley rail located over the gearbox for package component maintenance and removal For radial exhaust gas turbines only, one internal fixed trolley beam located aft of the exhaust diffuser for exhaust diffuser maintenance and removal

The trolley beam extension allows gas turbine removal through the side of the enclosure. One end of the beam extension attaches to the inside trolley rail; the other end is floor-standing. The gas turbine can be removed through either enclosure side and placed on a truck bed or cart. Sound Attenuation The sound-attenuated enclosure is intended for use with suitable gas turbine air inlet and exhaust silencing systems in environments where low noise levels are required. Enclosure ventilation openings are equipped with silencers to achieve maximum sound attenuation. The actual achievable noise reduction is a function of the noise source, installation considerations, other equipment in close proximity, and the acoustical characteristics of existing buildings and barriers. The intent of the enclosure design is to comply with U.S. Occupational Safety and Health Administration (OSHA) standards for eight-hour employee exposure. Transmission loss of the panels in decibels is available upon request. Further information is available in Solar's publication SPNP, "Noise Prediction Guidelines for Industrial Gas Turbines." Exterior Connections Connections for oil vent line, fire and gas suppression systems, and gas turbine air inlet and exhaust are terminated outside the enclosure. Fire and Gas Detection System Enclosed packages must include a fire and gas control system. The fire and gas system provides gas monitoring, fire detection, and extinguishing agent release using an advanced distributed architecture to monitor gas, heat, and optical flame detectors. The system communicates with the Turbotronic 4 control system to initiate a shutdown if a fire or a high gas level is detected. On the package exterior, indicator lights, strobe lights, and an alarm horn provide system status. A keyswitch is provided to inhibit the system and a push button switch is provided to manually release the fire-extinguishing agent. The primary fire detection system uses multispectrum infrared (MIR) detectors. The system includes an automatic optical integrity feature to provide a continuous check of the optical surfaces, detector sensitivity, electronic circuitry of the detector-controller system, and automatic fault identification with digital display of system status in numerical code. The secondary detection system consists of ratecompensated thermal detectors. The two detection systems act independently in detecting and reporting a fire. The fire system control panel provides system supervision (for open circuit, ground fault, or loss of integrity), initiates alarm and release of fire suppression agent, and visual display of system status. The suppression system agent release is activated automatically with release solenoids located on the fire suppression skid. If a fire is detected, the fire detectors transmit an electrical signal to the fire system control panel to activate the fire alarm and suppression system. The enclosure is also equipped with two gas detectors: one at the gas turbine enclosure ventilation air inlet and the other at the ventilation exhaust to provide continuous monitoring of combustible gases. The detectors consist of IR hydrocarbon sensors that provide input to the logical operating network (LON) module. The gas turbine start signal is interlocked with the combustible gas monitoring system to ensure the atmosphere is safe prior to initiating a turbine engine start. An alarm is initiated if the gas monitor fails.





Dual Fan Ventilation, Stainless Steel The enclosure is ventilated with a dual AC motor-driven fan system. The ventilation fan provides airflow to ensure the enclosure internal air temperature remains within acceptable limits. Fan size can vary depending on the ventilation system filtration configuration. The fan motor wiring is terminated at the motor junction box. Openings are provided to ensure adequate airflow is circulated through the enclosure. Offshore/Moisture Filter The enclosure ventilation inlet is equipped with a single stage 316L stainless steel filter unit consisting of a first-stage marine vane separator/moisture eliminator and a second-stage G3 barrier-type filter, with the vane separator section hinged for filter access. The unit is equipped with a delta-P alarm switch and gauge. The ventilation exhaust opening is equipped with back-draft dampers to prevent ingress of dust and water when the unit is not running. Two Limit Switches for Automatic Enclosure Dampers, Stainless Steel Two position indication switches are added to standard enclosure isolation dampers to indicate open and closed damper positions. Standby DC Lights Standby lights provide emergency, automatic, and backup lighting inside the enclosure in the event of an AC power loss. A dedicated battery and inverter are added to operate the fluorescent lights and provide emergency lighting in the event of an AC power loss. Door Open Alarm The enclosure doors are equipped with a door position switch that will initiate an alarm when any enclosure door is not closed securely. CO2 Fire Suppression System The enclosure is equipped with a CO2 fire suppression system consisting of a primary total flooding distribution system and a secondary metered distribution system to extend the design concentration of 37% CO2 for 20 minutes. The system is designed in accordance with the U.S. National Fire Protection Association Code 12. The CO2 cylinder storage temperature range is 0 °F (-18 °C) minimum to 131 °F (55 °C) maximum. On fire detection by the fire and gas detection system, the detectors transmit an electrical signal via the fire control panel to activate the fire suppression system release solenoids located in the CO2 fire suppression cylinder cabinets. On receipt of this signal, the solenoid actuated control heads activate the CO2 cylinders, releasing CO2 into the enclosure. CO2 pressure actuates the pressure trip operated dampers that close all vent openings. CO2 release control heads are also provided with manual release levers. The fire suppression equipment is shipped loose for customer installation near the package. The fire suppression equipment electrical system rating is NEC Class I, Group D, Division 2, or CENELEC Zone 2. CO2 Isolation Valves, Pressure Switches, and Software The Turbine Fire and Gas Detection and Control System is provided with two (2) 3-way bypass valves with limit switches for offskid installation, two (2) pressure switches, and the software to monitor the offskid CO2 isolation valves.





Fire Cylinder Cabinets Fire suppressant cylinder cabinets, which are suitable for outdoor installation, are provided to house the extinguishing agent. The cabinets are equipped with service doors. The manual pull levers are routed by cable to the exterior wall of the cabinet. ADDITIONAL FEATURES: H2S Detectors Detectors will be provided for monitoring H2S gas concentration within the enclosure. Detectors are set to alarm at 10 ppm and shutdown at 20 ppm concentration level.Quantity:





2.13 MARINIZATION General Description The Mars 100 unit may be operated in offshore oil and gas applications. Depending upon operating conditions and movement of the underlying support structure, additional package modifications may be required. Solar turbomachinery packages operate successfully on the following types of offshore installations: • • • • • • • •

Fixed Platform (FP) Tension Leg Platform (TLP) Compliant Tower Spar Platform (SP)(CT) Semi-submersible Platform (SSP) Floating Production Systems (FPS) Floating Production, Storage and Offloading (FPSO) Mini-Tension Leg Platform (Mini-TLP)

Applications are evaluated based on the expected motion severity and the degree of package mounting surface flexing. Solar offers the following package modifications to achieve successful long-term operation. Refer to Solar's Engineering Specification ES 2379 for additional information. Basic Package Capabilities with No Motion Modifications The turbomachinery package is provided without special modifications for motion in marine applications. The following limits must not be exceeded: • • • • • •

Dynamic angles, pitch: 2 degrees Dynamic angles, roll: 2 degrees Static angles, trim: 2 degrees Static angles, list: 2 degrees "G" force, max., operating: 0.1 g "G" force, max., survival: 0.5 g

Installed package "G" forces can act in any direction independently or in the vector sum of any two directions simultaneously. Gravity is additional. A vessel's deck deflections for multi-point or three-point mounted packages, while experiencing maximum operating "G" forces, must not exceed: •

•

Hogging and sagging: 0.38 mm per meter (0.0046 in. per ft) of mounted span, measured at the midpoint of the span. Deck Twist: 0.02 degrees per meter (0.006 degrees per ft) of mounted span.

Anti-Vibration Mounts Anti-vibration mounts (AVMs) are used to isolate the mounting surface from package-generated vibrations. AVMs do not provide the same level of motion protection as gimbals. AVMs may be used for three-point package mounting.

Main and Auxiliary Service





The information provided in this section does not apply to equipment used in "Main and Auxiliary Marine Service". If equipment is intended for this type of service, please contact Solar Turbines Incorporated for guidance to ensure the correct application and certification requirements are met.





2.14 TURBINE AIR INLET SYSTEM The air inlet system typically consists of all components upstream of the engine inlet collector that are necessary to supply a clean, smooth flow of air to the gas turbine consistent with the requirements of Solar's Engineering Specification ES 9-98 . Solar offers several air filtration systems that conform to a broad range of operating requirements. The basic elements of the system include the following categories of equipment: • • •

filtration/accessories inlet silencing ducting (optional)

The system components are designed to accommodate the gas turbine inlet airflow, with a cumulative air inlet pressure loss of between 4-5 inches W.C. depending on the configuration. See: Site Conditions for the assumed value for this installation. Scope Exclusion: All system components described below are shipped loose, for installation by Others.

Scope Exclusion: All system components described below must be supported with structures independent of the gas turbine package enclosure. Unless otherwise indicated, these support structures are provided by Others. Air Inlet System Scope: Standard System For this application, a complete system is provided consisting of fully pre-engineered standard arrangements, which include all required attaching hardware and gaskets. The arrangements are shown as complete systems on the Mechanical Interface drawing. Only minor changes to the pre-engineered system are permitted without additional commercial impact. Turbine Air Inlet Filtration Refer to Solar Standard Arrangement Drawing for approximate component weights and dimensions. Medium Velocity, 4-Stage Fil ter, Stainless Steel A Camfil-Farr 4-stage, medium velocity barrier type filtration system with front inlet, and back outlet is included. This system provides efficient removal of salt, water, and particulates. Standard features include: • • • • • • • • •

Weatherhood Stage 1: CamVane droplet separator/moisture eliminator Stage 2: pre-filter Stage 3: high-efficiency filter Stage 4: HEPA filters Left-side access door for service (when facing filter inlet) Light fixture Differential pressure transmitter Differential pressure gauge





Transition back outlet flange

Turbine Air Inlet Accessories Insect Screen for Inlet Air Filter, Stainless Steel Stainless steel insect screening is installed on the air filter's inlet area. When large numbers of insects are present, the extended area design reduces the velocity of the airstream through the screen sufficiently to allow most insects to fly away. The screening reduces clogging and premature filter replacement. During cold weather, screens should be removed and stored to avoid clogging due to ice formation or snow buildup. Customer-Supplied Air for Self-Cleaning Filter A supply of clean dry air must be supplied by the purchaser for use by the self-cleaning turbine air inlet filter described in this proposal. Please refer to the filter description for air pressure and flow requirements. Air Inlet Gas Detection – 1 Provided A single gas detector is provided mounted in the air inlet system. For enclosed packages, the signals from the detector are integrated into the enclosure's fire and gas system via that system's local network. Turbine Air Inlet Ducting The following ducting is included in the base price and will have a cross section of: 7.5ft x 7.5ft. • • • •

Unlined Air Inlet Duct, 3 ft Long, Stainless Steel, 1 per unit Unlined Duct, 3 ft Long with 26 in. x 26 in. Access Hatch, Stainless Steel, 1 per unit Unlined Duct, 3 ft Long with Gas Sensor(s), Stainless Steel, 1 per unit 90° Unlined Elbow, Stainless Steel, 1 per unit





2.15 EXHAUST SYSTEM An exhaust system is provided and designed to ensure a smooth transition from the gas turbine to the heat recovery system (for CHP applications), or the exhaust silencer (for simple cycle applications). In either case, proper considerations should be taken into account, which are dependent on the nature of the installation. Ideally, pressure losses should be as low a possible to provide for best possible turbine performance. Typically, pressure losses will be on the order of 4 inches water column (w.c.) (102 mm w.c.) for a system with a silencer, and on the order of 6 to 10 inches w.c. (152 to 254 mm w.c.) for a system with heat recovery. Exhaust system components supplied by Solar are designed to withstand a 120-mile per hour (193 km/hr) wind load when properly installed. Design Considerations: •

•

•

•

• • • • •

Avoid exhaust/ducting configurations that may lead to recirculation of exhaust products through the gas turbine, such as through the turbine air inlet filter, enclosure ventilation inlet filter. Avoid configurations where hot gas turbine exhaust products could impede performance of the lube oil cooler. Where two (2) or more units exhaust into a common header, provisions must be made to prevent hot gases from flowing into the non-operating unit. Note: This practice is not recommended Capability to purge the complete exhaust system prior to light-off of the gas turbine. The following minimum purge times are recommended: At least three (3) volume changes for simple cycle applications At least five (5) volume changes for applications with waste heat recovery equipment Relative height of the exhaust stack above the turbine air inlet Building roof design (if applicable) Direction, and intensity of prevailing winds, and proximity to adjacent structures

For simple cycle applications with exhaust silencer: •

Provisions must be made to adequately mount and suppor t the equipment, and limit the exhaust silencer pressure loss, with no loads transmitted to the turbine exhaust.

Scope Exclusion: All system components described below are shipped loose, for installation by Others. Exhaust System Scope: Standard System For this application, complete system is provided consisting of fully pre-engineered standard arrangements, which include all required attaching hardware and gaskets. The arrangements are shown as complete systems on the Mechanical Interface drawing. Only minor changes to the pre-engineered system are permitted without additional commercial impact.





Turbine Exhaust Si lencer, Vertical Mount, Stainless Steel An in-line silencer with support brackets is provided for mounting in the vertical position. Standard features include: External shell material - 316L stainless steel Internal material - 316L stainless steel

• •

Exhaust noise attenuation is achieved by use of the silencer, which, with associated ducting, must be supported to maintain loads on the engine exhaust connection within the limits shown on the Mechanical Interface Drawing. Thermal expansion loads are avoided by proper location of the silencer and ducting and the use of flexible bellows connections.

Turbine Exhaust Ducting The following ducting is included in the base price and will have a cross section of 7.5 ft x 7.5 ft: Duct with Emissions Test Ports, Stainless Steel, 1 per unit Expansion Bellows, Fabric, 1 per unit A turbine exhaust Expansion Bellows is provided. Standard features include: • •

316L stainless steel flanges 29.5 in. long

The following ducting with the specified cross section is included in the base price: Expansion Bellows, Fabric, 1 per unit A turbine exhaust Expansion Bellows is provided. Standard features include: • • •

421 stainless steel frames and flanges 21 in. long 67.6 in. x 34 in. cross section

The following ducting is included in the base price and will have a cross section of 67.6 in x 34in to 7.5 ft x 7.5 ft: Transition Duct, Stainless Steel, 1 per unit





2.16 ACCESSORY EQUIPMENT Battery Charger System, Nickel Cadmium The battery charger system consists of a battery charger and batteries to provide 120 VDC emergency power to the control console, fuel valve, bleed valve and variable guide vane actuators, and the DC backup lube oil pump. The control console 120 to 24 volt DC-to-DC converter provides 24 VDC power for the control system. The battery charger system is designed for indoor installation in a nonhazardous area. The batteries are mounted on a freestanding, four-step rack. The batteries are shipped wet, fully charged, and ready for use.

Turbine Cleaning System, On-Line / On-Crank Cl eaning System The turbine compressor cleaning system facilitates periodic cleaning of the turbine compressor. The system is designed for use in salt-laden or dusty environments or where compressor contamination from hydrocarbon vapors is possible. The cleaning system includes a distribution manifold with pressure atomizing spray nozzles in the engine air inlet collector, onskid piping, strainer, and solenoid shutoff valves to deliver water or approved cleaning fluid to the manifold. The system requires an external source of clean-filtered air to pressurize the cleaning solutions. The on-crank cleaning system only operates at gas turbine cranking speed with the fuel system and ignition system deactivated. The gas turbine cranking and cleaning solution activation can be initiated from the control console or turbine control junction box. The on-line cleaning system only operates when the gas turbine speed is between 90 and 100% gas producer speed and with or without load. Cleaning solution activation can be initiated from the control console or turbine control junction box. This system is intended to supplement the on-crank system by increasing the time intervals between periodic on-crank cleaning.





Turbine Cleaning Cart, ASME Certified, Quantity 1 A portable offskid cleaning tank is provided to supply cleaning fluid to the skid edge cleaning system connection. The cleaning tank can be used to mix, hold, and pressurize the turbine cleaning solution. The tank comes with wheels that are removable for stationary installation.

Package Lift Kit - Split and Combined Lifts, Quantity 1 A package lift kit is provided to lift the driver package and the driven equipment package separately, and to lift the combined packages (driver and driven equipment) as one entity when they are bolted together. The package lift kit is designed in accordance with Solar's Engineering Specification ES 2335. It may be used to lift the driver and driven equipment packages either with or without the package export crating. It may only be used to lift the combined package without the package export crating. The kit is shipped separately and consists of a spreader bar, slings, and associated lifting hardware.





The package lift kit is not designed to lift the package with ancillary equipment or enclosure ventilation equipment. The lube oil tank must be empty during lifting. The generator terminal boxes and cooler must also be excluded from the lift if they are taller or wider than the package enclosure. The lube oil tank must be empty during lifting.





2.17 QUALITY ASSURANCE AND TESTING STANDARD TESTING PER SOLAR'S SPECIFICATIONS Factory testing is in accordance with Solar's test specifications and as generally outlined below. The purchaser or purchaser's designated representative is provided access to Solar's Production Test facilities to observe factory production tests scheduled in accordance with production and testing schedules. Unavailability of the purchaser or purchaser's representative shall not be cause for delay in the performance of the production tests. Test Facilities Design of the test cells provides for flexibility so that all types of turbine packages can be tested with a minimum of time required for connection of fluid, electrical and instrumentation services needed for each test run. The computerized real-time data acquisition system collects raw digital and analog data from the turbine package and displays or prints out results in customary engineering forms and units. The control and display equipment provide the capability to monitor and control the power and test stimuli to operate the unit under test and to measure and evaluate its performance. The system is used to establish specified test conditions by keying in calibration coefficients, constants and operating limits. Test data are displayed by a video terminal as instructed by the test agenda, which includes selecting various parameters for display, checking values and limits, and generating hard copy records as needed. When performance levels have been achieved, the test technician initiates a command to capture all instrumented points, which initiates automatic performance computations and prints the results for review by Engineering personnel and a permanent test record. Testing Test Phases Solar's Production Test facilities are arranged to provide for a three-phase test program. The first phase uses simulation equipment to perform static testing of the control console and package systems to verify electrical and fluid system continuity and calibration. The second phase consists of interconnecting the turbine generator set package and control console in the pre-test area to undergo additional simulated systems tests of the total package and prepare the unit for interconnection with the test cell facilities. In the final phase, the unit is installed in the test cell where it is controlled and monitored by its own control console and the computerized test facility. Generator Package Acceptance Testing The basic package assembly, including the gas turbine, gearbox, generator (when available), and package-mounted accessories, together with the control console, is tested as a complete system to ensure proper integration and function of the total package in accordance with Solar's package test specifications. Results are recorded and maintained by Solar. The acceptance test generally includes the following: • • • •

• •

Starting and combustion cycles Lubricating oil system, temperature and pressure measurements Vibration measurement Package power and heat rate measurements at partial and full load for ambient conditions, with electrical load at 1.0 power factor Turbine temperature measurement Variable guide vane and bleed valve adjustment




• • • •


Adjustment and calibration of the voltage regulator, fuel control and speed governing system for generator output, frequency regulation and transient response Fuel changeover (on dual fuel units) Load / speed transient test Testing for malfunction and safety devices and circuitry AC metering and control circuitry tests (if ac metering is supplied), calibration of ac metering circuits is performed by bench testing

All packages are tested with contract generator whenever possible. When required due to schedule, availability or test cell limitations, the package may be tested with a slave generator. If so, and the contract generator is available at the completion of testing, the purchased generator will be mounted and aligned prior to shipment. Items excluded from standard package testing are contract inlet and exhaust system ancillary equipment (such as filters, silencers and ducting), battery systems, oil coolers, package enclosure, ancillary skid, switchgear, and any customer-furnished hardware. Generator Testing The generator is tested in accordance with IEEE standard specifications and Solar's specifications at the manufacturer's plant. These tests satisfy requirements for NEMA and Solar. Supplier testing is under Solar's periodic quality control review to ensure compliance with required specifications. Performance Review Acceptance Test Data Acceptance test data are reviewed and approved by Product Engineering, Test Engineering, Quality Engineering and the Project Manager prior to submittal to the purchaser. With this review and approval cycle, the test data are furnished approximately four weeks after completion of acceptance testing. The report provides test results and compares the results to Solar's acceptance test specification requirements by means of calculations, graphs, strip charts and descriptions. Data are provided for each turbine generator set. The acceptance test report generally includes the following types of data: Turbine Fuel Consumption Rates A comparison of measured fuel consumption versus specified fuel consumption, showing correlation of fuel consumption, power output and turbine gas temperature at full load. Voltage and Frequency Transients Computerized traces are provided, showing voltage and frequency deviations during load application and removal. Operating Values A chart showing operating values of the following parameters from no load, with step increments, to full load is included: • • • • • •

Lubricating oil pressure, temperature and flows Turbine gas temperature Generator power Generator voltage, amperage frequency Engine compressor discharge and pressure Package vibration levels

Quality Assurance





All testing operations are conducted under the direct control of Solar's Quality Assurance organization to facilitate compliance with the specified test limits and procedures. In addition to final in-plant testing of the finished generator set, Quality Control engineers maintain surveillance over the manufacture of all purchased parts and subassemblies, and are responsible for functional testing of incoming components. The same rigid standards applied to par ts manufactured by Solar are applied to all parts received by Solar from suppliers. Factory Emissions Testing Per Solar's Specification ES 9-97 In addition to the testing described above, the gas turbine engine will be tested for exhaust emissions of NOx, CO and UHC in accordance with Solar's Specification ES 9-97. Observe on Non-interference Basis The purchaser is invited to tour Solar's Production Test facilities to observe units undergoing factory production testing at that time, but not necessarily the unit(s) purchased. Observation of UCBOP (Unit Control Balance of Plant) software testing is done only as part of the Static Testing of controls software. Observation of package control software is done only as part of the Package Acceptance Test. Please note that the production test facilities are a constrained resource. Accordingly, the unavailability of the purchaser or purchaser's representative shall not be cause for delay/deferment of the scheduled production test(s). Weld Radiography of Piping and Mani folds for Gas Fuel System, 5% of Welds Radiographic inspection of the gas fuel system piping and manifolds is performed in accordance with ASME Section V. 5% of each welder's work (circumferential butt weld only) is inspected by radiographic examination in accordance with ANSI / ASME B31.3. The specific manifolds on a given unit may or may not be part of the 5% of each welder's work that is examined. Weld Radiography of Pressure [15 psig or greater] Piping for Lube Oil System, 5% of Welds Radiographic inspection procedure is performed per ASME V, in accordance with acceptance standard per ASME B31.3. 5% inspection of circumferential butt welds of the lube oil system pressure piping means one in every twenty welds will be radiographed with at least one weld per pipe assembly.





2.18 PRESERVATION, INSTALLATION AND DOCUMENTATION General Description This section describes preservation, general installation requirements, and project documentation. Preservation Long term or short term preservation can be provided for the engine and package. The type of preservation required dependents upon the following: • • • • •

Type of transportation (sea,transport air, or truck) Climatic conditions during and storage Storage period Storage facilities Static and dynamic loads imposed during shipment

Refer to Solar's Product Information Letter 097, "Package Preservation and Preparation for Shipment," for additional guidelines. Long-Term Preservation This proposal is providing for long-term preservation. The following conditions require long-term package preservation: •

• •

•

Equipment will be stored in an unimproved storage area for greater than 6 months before installation Transportation is by ship Transportation includes transshipment (package will go from truck to barge to truck, etc., e.g., rigorous loads will be encountered during shipment) Package will be exposed to severe weather conditions during transport

Site Requirements Solar's gas turbine Generator Sets require minimal site preparation. The Mars 100 Generator Set is supplied with self-contained systems for starting, fuel, lube oil, and control, minimum piping and wiring connections are required for installation. All service connections are conveniently located on the outer edge of the skid. Mechanical Installation Requirements TPIM-1000 Solar's document TPIM-1000 "Package Installation Guidelines - Generator Sets" outlines the responsibilities of the Customer and Solar regarding installation of the package. It provides guidelines for the installation of the standard package design and the interface with the turbine driven generator. Mounting Correct mounting of the gas turbine package is vital to successful package installation and requires adequate preparation by the user. The site pad thickness is governed by soil condition and the weight of the gas turbine package, air inlet system, and exhaust system. Mounting pad locations and loads will differ with each package and will be clearly shown on the installation drawings. The equipment layout





should provide adequate floor space for major components with sufficient room around the package for routine maintenance access. Alignment Tooling, Quantity 1 Alignment tooling is provided to align the reduction gearbox output shaft hub to the generator input shaft hub. The tooling includes: The tooling will include: • • •

Dial indicator kit Gearbox-to-generator alignment tool Axial distance gauge

Order Fulfillment Objective Solar's objective is to fulfill orders efficiently and provide a comprehensive set of accurate project documents in a timely manner. The order fulfillment timeline shown in the figure below illustrates the major events through which a typical project will pass. Some events shown are internal to Solar, however, all events are important in ensuring a successful project outcome.

Major Project Events The following is a description of each event shown in the figure above, and the roles that are expected of both Solar and our Customer: • Receipt of Order is the official starting point of the project and is when Solar assigns a team of technical experts to engineer and execute the project. The team is led by the Project Manager and Project Engineer. They are the respective key commercial and technical contacts for the Customer.





• A Customer Teleconference is normally conducted within one week After Receipt of Order (ARO) and is held between the Solar Team and the Customer to review the project requirements. This meeting includes a review of the project timeline, key deliverables, and data required from both Solar and the Customer. In addition, Solar and the Customer will mutually agree on the timing and location of the Customer Kickoff meeting. The Document List, (Table 1), will be reviewed and document submittal dates agreed upon. The document schedules within Table 1 are dependent on receipt of timely definition from the Customer. • The Customer Kickoff Meeting (CKOM) may be scheduled as early as four weeks after receipt of order. Ideally, by this time, the appropriate technical and commercial customer representatives have been assigned (e.g. Engineering & Procurement Contractor EPC, if applicable). Solar strongly recommends that the Customer Kickoff meeting be held in San Diego, California so the resources of the entire Solar project team can be utilized. The objective of this meeting is to resolve and finalize any open items related to the Package Definition scope of supply. Package Definition covers everything directly associated with the physical package. During this meeting a review of the initial Mechanical Interface Drawing (MID) will be conducted. This document contains package dimensions, external connection points, and other package details. Major supplier OEM equipment, complex air inlet and exhaust systems, and custom features will not be available until subsequent revision of the drawing. • Customer Definition (Tollgate 1) is a major event that can only be passed after project definition is complete and confirmed. Customer Definition should be provided within 1 week after the CKOM to maintain the document commitment dates as shown in Table 1. Once complete definition is received from the customer, the Solar project team incorporates the scope details, supplier OEM equipment definition (as applicable) and customer definition into the documents and issues the next submittal of customer documents for review. Delays in receiving Tollgate 1 project definition will cause delays in issuance of customer documents. Changes to project scope and definition after Tollgate 1 could impact project cost and schedule. • Mechanical and Electrical Design Review Meetings are typically held two weeks after Solar issues the Tollgate 1 document submittal packet to our customer. The exact timing depends on the readiness of Solar, our customer, and on the overall project schedule. The purpose of these meetings is to confirm that all customer requirements, including unit balance of plant items, have been captured accurately and are acceptable to all parties. Timely completion of these review meetings is critical to ensuring that the manufacturing phase remains on schedule. • Customer Validation (Tollgate 2) occurs after the Design Review meetings and is based on the mutual agreement that the project definition is complete and validated. If definition items are still open at this point, passing Tollgate 2 may be delayed. Delays at this point in the project may have an impact on both delivery and cost. Once Tollgate 2 has been passed, the design will be considered validated and firm. Any subsequent scope changes after Tollgate 2 will potentially have a major impact on cost and delivery, and require a Change Order. Project Documentation Electronic Document Control Solar utilizes an Electronic Document Control system based on a collaborative workspace technology. This collaborative workspace allows a single location for project documentation. Document transfers between Solar, Customers, Major Suppliers, and Contractors occurs instantly through this workspace area on the web. Documents are routed and tracked on a real time basis using email tasking and





notifications. This process provides immediate access and complete visibility of all project documentation from the Kickoff all the way through to commissioning of the project. Users are provided with a user name, password, and instructions on how to use the system. The Electronic Document Control operates on standard Internet protocols and meets the highest Internet security standards. Format Documents are submitted electronically through Solar's collaborative workspace. Documents are submitted in English, and in the Adobe PDF format. While Solar's documentation package provided in Table 1 is considered comprehensive, Solar recognizes that some customers have additional requirements. These additional requirements, can be quoted at additional cost and to an agreed upon delivery schedule. Customer Tollgate Definition Requirements In order for the customer to receive timely documents as stated in Table 1, certain definition will be required on a timely basis. The details of what type of definition are required and when, are dependent on the type of project and the overall project schedule. During the course of the project Solar's Project Manager and Project Engineer will communicate the definition requirements to the customer to insure that the project remains on schedule. Delays in receipt of customer definition for a given project Tollgate will cause delays in the issuance of documents and may also cause delays in overall project schedule. Critical Documents The following documents, when provided, are considered critical and require timely review and input in order to avoid delays on the project: • •

Mechanical Interface Drawing requires timely review and re-issuance by the Customer. OEM Supplier Documents are required by Solar in order to maintain the schedule shown in Table 1. Complete definition on the OEM driven equipment, electric motor, gearbox and shaft end details, including an accurate CAD/dxf model of the OEM equipment offered, is required.

Final Documents (As-Shipped) The final documents are issued as stated in Table 1. These final documents capture the design or configuration of the project as it leaves Solar's factory, and are commonly referred to as the As-Shipped documents. Solar considers our documentation commitments to have been fully met when our customer has received the final documents listed in Table 1. Installation & Commissioning During the Installation & Commissioning phase of the project, Solar's field service personnel may mark-up one or more of Solar's "As-Shipped" drawings to reflect any material changes in the design or configuration of the equipment in connection with installation. Solar will issue an As-Installed version of these drawings in order to capture the field mark-ups. These As-Installed drawings will be available 12 weeks after receipt of marked-up drawings in San Diego, California. As a safety check, Solar also requires the updated field software to make sure that all documents are synchronized. Drawing revisions that are necessitated by changes in scope that are either requested by the customer or required due to unexpected site conditions will be evaluated on a case by case basis and may require additional time and/or involve additional cost to the customer. Customer Approval of Documents



Dragados



As defined in the project execution timeline above, project definition is considered complete following the passing of Tollgate 1 and the documents will reflect the design agreed to at that time. The design will proceed based on this definition without further approval of the documents by the customer. Solar Document List NOTES:

KEY:

1. Timing of the initial issue requires Customer to confirm scope and definition no later than CKOM1w. 2. Final project Spare Parts list is submitted when firm definition has been received and bills of materials completed. 3. Initial release reflects the standard package configuration. Excludes supplier OEM definition, custom air inlet & exhaust systems, and custom features. Electric Motor Drive applications are committed to on a project-by-project basis. 4. Generic document is issued with proposal. Initial document requires Customer input & firm P&IDs no later than CKOM1w. 5. Languages other than English require an additional price plus an additional 30 days for drawings, and an additonal 90 days for Solar manuals, beyond deliverable stated below.

w = Work weeks P = Document submitted with the Solar proposal representing a standard or typical configuration CKOM = Customer Kickoff Meeting EXW = Final unit is completed and ready for shipment from Solar's factory in San Diego, California

ITEM

DESCRIPTION

PROJECT DELIVERABLE TIMING PROPOSAL

A

INITIAL

F I NAL / ASSHIPPED

GE N E R A L

A01 Utility List (Reference Only) A02 Inspection Test & Plan

P P

CKOM

-

A03 API616CombustionGasTurbineDataSheets

P

-

A05 GasTurbinePerformanceCurves

P

-

-

A07 Recommended Spare PartsList

P

-

(2)

A08ISO Certificates

P

-

A09 GeneralPackageOutline(ReferenceOnly)

P

A10 DocumentTransmittalRecord(SDRL) A11

-

-

-

-

CKOM

MechanicalInterfaceDrawing(MID)

-

-

CKOM (3)

2nd Submittal

EXW+4w (5)

CKOM+7w (1)

A12

-

CKOM+7w(1)

EXW+4w(5)

Process & Instrumentation Diagram (P&ID) Lube Oil, Fuel , Seal, Start, Turbine, and Enclosure systems A15 ElectricalLoopSchematic A16 FieldCable/WireReport A17 Cause & Effect Drawing A18 B

TurbotronicSoftware(SingleDisplayonly)

-

-

CKOM+7w(1)

-

CKOM+7w(1) EXW+4w(5) EXW+4w (5) -

EXW+4w(5)

EXW+4w(5)

MANUALS & QUALITY ASSURANCE



Dragados



B01

Operation & Maintenance Instruction Manual (Solar Equipment)

B02

QualityAssuranceDataBook(Englishonly)

C

-

-

-

-

EXW+6w

MISCELLANEOUS

C01 Fuel Specification (ES9-98)

P

-

C02 Paint Specification (ES9-58)

P

-

-

EXW+4w (5)

Additional Specifications & OEM Supplier Documents

(As agreed)

-

-

Solar Document Aligned with Customer Needs S olarDocument I. MECHANICAL Mechanical Interface Drawing (A11)

MeetsthefollowingCustomerneeds: • • • • • • • • • • • • • • • •

•

Process & Instrumentation Diagram (P&ID) (A12) Lube Oil, Fuel, Seal, Start, Turbine, and Enclosure systems Utility List (A01)

• • • •

• • • • •

Mechanical Outline Drawings General Arrangement Drawings Skid General Assembly Drawings Combustion Air Inlet System Gas Turbine Exhaust System Enclosure Ventilation System Package Tie-Down Details Dynamic/Static Loads, Center of Gravity List & Dimensions of Connections Piping Connections Anchor Bolt Location Drawings Equipment Weights Lube Oil Cooler Drawings Local & Remote Unit Control Panel Outline Alignment Data Lifting Details Piping & Instrument Diagram Flow Diagrams Piping Schematics & Arrangement Drawings Instrument List Instrument Index Utility Load List Utilities Schedule Utilities Consumption Data Electrical Power Requirements Electric Load List

II. ELECTRICAL Electrical Loop Schematic (A15)

• • • • •

Field Cable/Wire Report (A16)

• • •

Turbotronic Software (A18)

• •


Electrical Schematic Electrical Loop Diagram I/O List Instrument List Instrument Index Cable Schedule System Interconnection Information Wiring Interconnections Control System Software Documentation Ladder Logic


Dragados


Mar1s0G 0 ener atoSret •

Unit Control Balance of Plant (A13) (Generator Sets Excluded)

•

•

Anti-Surge Design (A14) (Solar Surge Control Only) Cause & Effect Drawing (A17)

• •

• • •

Software Listing Control of Devices Outside of the Turbomachinery Package (As agreed) Inputs/Outputs to Solar Control System Anti-Surge System Anti-Surge Valve Sizing Calculations Cause & Effect Diagram HAZOP Study Information Alarms & Shutdowns

II. INSPECTION, TEST & QUALITY Inspection and Test Plan (A02)

•

• • •

Quality Assurance Data Book (B02)

• • • •

Factory/Supplier Testing & Inspections Performed Shop Testing Program Observe Points 3rd Party Inspectorate (As Applicable) Quality Data Book Certified Test Report Statutory Certification (As Required) Certificate of Compliance

IV. OPERATION & MAINTENANCE Operation & Maintenance Instruction Manuals (B01)

• • • • • •

Systems Operator's Guide Maintenance Instructions Supplementary Data Illustrated Parts List Process Control Instructions (As Agreed) Supervisory Control Instructions (As Agreed)

V. DATA SHEETS & CURVES API 616 Gas Turbine Data Sheets (A03) API 617 Gas Compressor Data Sheets (A04) (Not applicable to Gensets) Gas Turbine Performance Curves (A05)

• •

• •

•

Gas Compressor Performance Curves (A06) (Not applicable to Gensets)

• •

Gas Turbine/Compressor Data Performance Data

Performance Data Output Power & Heat Rate vs. Engine Inlet Temperature Output Power & Heat Rate vs. Power Turbine Speed (2 shaft engine only) Performance Data Surge Line

CD-ROM Quality Control Data Books, Quantity 3 Quality Control Data Books are submitted in the Adobe PDF format on CD-ROM. Hard Paper Copy Quality Control Data Books, Q uantity 1 Quality Control Data Books are submitted in hard paper copy. The Quality Control data book typically includes the following:




o

o

• •

•


Inspection and test plan (ITP) Describes the quality assurance requirements for each product on a project basis. Lists the primary controlling and verifying documents, codes and standards used to define the quality requirements, and identifies inspection points. Package certified test report American Society of Mechanical Engineers (ASME) data reports for lube oil filters and lube oil coolers, as applicable Solar's Package Certificate of Compliance

If specified on the final project ITP, the Quality Control data book may also include the following documents at additional cost and increased delivery time: • •

•

•

Engine rotor balance record Engine casing leak test record Documentation from suppliers of major package components such as oil coolers, oil filters, gearboxes and driven equipment Third-Party Certificates and Declarations of Conformity when applicable

Torsional Analysis Repor t A torsional analysis will be performed on the entire drive train to determine if there are any significant torsional resonance conditions within ±10% of the operating speed range. If a resonance condition (interference) is found, then a fatigue analysis is performed to confirm the resonance will not cause fatigue failure in the shafting. If an interference is determined to be potentially harmful then changes to the coupling(s) may be made to either eliminate the interference or reduce its harmful effects. Lateral Analysis Report A lateral forced response analysis of the driven equipment will be performed to confirm that any lateral critical speeds aren’t close enough to the operating speed range to cause lateral vibration problems. CD-ROM Operation & Maintenance Instruction Manuals, Quantity 3 Operation & Maintenance Instruction Manuals are submitted in the Adobe PDF format on CD-ROM in English. Hard Copy Operation & Maintenance Instruction Manuals, Quantity 1 Operation & Maintenance Instruction Manuals are submitted in hard paper copy in English. CD-ROM Operation & Maintenance Instruction Manuals, Quantity 3 Operation & Maintenance Instruction Manuals are submitted in the Adobe PDF format on CD-ROM in Spanish. Hard Copy Operation & Maintenance Instruction Manuals, Quantity 1 Operation & Maintenance Instruction Manuals are submitted in hard paper copy in Spanish. Operation and Maintenance Instruction Manual The Operation and Maintenance Instruction Manual (OMI) provides descriptive and instructional data for operating and servicing the turbomachinery package. General, functional, and component descriptions of the turbine engine and associated package systems with supporting illustrations are included in four volumes:




•

•

•


Systems Operator's Guide - Intended for the equipment operator, the systems operator's guide provides familiarization with controls and indicators, operating procedures, and safety precautions to ensure safe equipment operation. Maintenance Instructions - Intended for maintenance and field service personnel, the maintenance instructions include preventive and corrective procedures, including periodic inspection requirements, alignment procedures, cleaning procedures, removal and installation procedures, adjustment procedures, and tolerances. Supplementary Data - Provided in the form of supplier manuals and data sheets, the supplementary data provides descriptions of components and assemblies not covered or fully discussed in the Maintenance Instructions volume. Due to copyright restrictions, supplementary data from suppliers is available in English only. Illustrated Parts List - Provides part numbers, part names, quantities, reference designators, and illustrations for locating and ordering par ts.

The OMI manual typically includes the following features: • • • • •

Electronic viewing of data in a Windows environment All volumes of the manual set on one CD-ROM Search feature including full text search for supplier data Graphics in a separate window for simultaneous viewing of text with associated illustration PDF version for printing

ADDITIONAL FEATURES: API Data Sheets The following API data sheets are provided in Solar or Equipment Supplier format: API 616 Gas Turbine





2.19 CERTIFICATION General Description Solar's leadership in the gas turbine industry is supported by its ability to comply with regulations, codes, and standards required by industry and/or regional authorities around the world. Solar continually evaluates compliance requirements to ensure conformance with applicable standards. NEC Compliant Package Without Certification The package complies with the applicable requirements of the National Electrical Code (NEC) but overall package certification is not provided. Summary Solar has a continuing program to support customers in ensuring that Solar's products conform to applicable codes and regulations. Solar also has the resources to provide customer guidance and assistance in this process.




3


SITE INFORMATION



Dragados



3.1 PACKAGE UTILITY REQUIREMENTS

Package Utility Requirements Package Type:

Mars 100 Generator Set

Note: The utility list below is pr eliminary and subject to change after final engineering. Electrical Power Requirements Turbine Status Descriptions Standby : Not starting, not running and not in postlube. Starting : From start button initiation through start motor disengagement (includes pre-lube) Running : Normal Operation Postlube w/ AC : Shutdown sequence with AC power and AC pre-post pump available Postlube w/o AC : Shutdown sequence without AC power and AC pre-post pump not available

Electrical Power Requirements (3 Phase) 460 Volts / 60 Hz (NEC) Electrical Schematic Reference

Device

Notes

Rated Power

St a n d b y

St a r t ing

R u n ni n g

Postlube w/ Postlube AC w/o AC

kVA

M3150

Pre/Post Lube Oil Pump Motor 7.5 HP

(A)

8.75

X

M3220

Lube Oil Cooler Fan Motor #1 20 HP

(AQ)

23.44

X

X

M3500

Scavenging Supply 0.5 HP

0.58

M6211

Ventilation System Motor #1 30 HP

34.38

X

X

X

M6212


34.38

M6221


34.38

X

X

X

UF1300

Variable Frequency Drive, DAC Start System

TBD

X

H3103

LubeOilTankImmersionHeater To t a l

(C)

15 k VA

15 0. 91

X

XXXX

X

X

1 5. 5 8

116 . 53

X

9 2. 78

78. 09

0.

Notes: (A) AC power supply is required after engine roll-down is complete to feed the AC Pre/Post Lube Oil Pump. Approximately 70 minutes AC requirement after a shutdown event for C40,C50,T60 packages. Approximately 255 minutes required for T70,M90,M100,T130,T250. Approximately 375 minutes required for a M50. (C) Variable frequency drive will reduce supply voltage to 380 VAC for use with motor. External power supply to VFD only. Start motor is powered and controlled by VFD. (AQ) Space heater for this fan motor is consistently active during standby to eliminate condensation.



Dragados



Electrical Power Requirements (1 Phase) 120 Volts / 60 Hz (NEC) Electrical Schematic Reference

Device

Notes

Rated Power

(T)

0.23

X

X

(T)

X

St a n d b y

St a r t ing

R u n ni n g


kVA

M1300

M3150

Direct Drive Starter Motor #1 Space Heater Pre/Post Lube Oil Pump Motor Space Heater

0.23

X

M3220

Lube Oil Cooler Fan Motor #1 Space (T), (AQ) Heater

0.23

X

M6211

Ventilation System Motor #1 Space Heater

(T)

0.23

X

M6212


(T), (Q)

0.23

XXXX

M6221


(T)

0.23

X

M3170

Back-up Lube Oil Pump Motor Space (B), (W), (T) Heater

0.23

X

H4100

GeneratorSpaceHeater

CC6130

EnclosureLighting

AT0190

AuxiliaryDisplayComputer

X XXXX XXXX

TBD 0.29

To t a l

0.27 k VA

2 . 17

2. 17

X

X X

0. 7 9

X X

1 . 48

1. 2 5

0.

Notes: (B) DC power supply is required after engine roll down to feed the DC Lube Oil Pump on a loss of AC power. Refer to ES2474 for DC power supply load profile after a shutdown. (Q) Enclosure fan motor space heaters are consistently active to eliminate condensation. (T) Rating will not exceed the stated value. (W) DC Lube Oil Pump function will be tested every 24 hours. Test will run for a maximum of 2.5 minutes. (AQ) Space heater for this fan motor is consistently active during standby to eliminate condensation.

Electrical Power Requirements - Battery (1 Phase) 220 Volts / 50/60 Hz Electrical Schematic Reference

Device

GD0525

Battery Charger 120 Vdc Accessory, Nickel Cadmium, HP B

(AP)

6.5

XXXX

Total

k VA

6.5

6. 5

Notes

Rated Power

St a n d b y

St a r t ing

R u n ni n g

6. 5

6.5


kVA

6. 5

0.

Notes:Refer to ES 2474 (AP)



Dragados



Gas Fuel Requirements Customer Interface Connection

20

Device

Gas Fuel System

N ote s

(E), (F), (G), (H), (S), (AE)

M in Pr e s s . Ma x Pr e s s .

TBD

500 PSIG (3447 KPAG)

M a x F lo w

TBD

Min T e mp .

TBD

Ma x T e mp .

200 F (93 C)

Notes: (E) Fuel pressure and flow requirements can be affected by several factors such as; fuel temperature, fuel lower heating value, air inlet temperature, fuel composition, fuel specific gravity, engine injector type, inlet duct loss, relative humidity, site elevation, and piping length and diameter. Minimum fuel pressure and maximum flow requirements at full load operation are stated based on available site conditions. If actual site conditions are different, the stated values will change too. Please contact Solar Turbines for corrected site-specific fuel pressure and flow requirements. (F) Fuel must have a differential temperature (∆T) of at least 50°F (27°C) above fuel dew point temperature and be between –40 to 200°F (–40 to 93 °C). (G) Fuel pressure must be maintained above engine compressor discharge pressure (PCD). (H) Fuel consumption figures provided herein are for the purposes of fuel supply line sizing. It is not intended to be a guaranteed figure. (S) Fuel flow rate is based on full load and acceleration requirement for the turbine. This flow rate is higher than performance full load that is considered steady state. (AE) Any gas turbine fuels that do not meet Solar specification ES9-98 can have an impact on engine performance and operating life.

Air Requirements Customer Interface Connection

Device

N o t es

M in Pr e s s. Ma x . P r e s s .

M a x F lo w

Consumpti on

25 SCFM (0.70 NM3/MIN)

PER START: 2 SCF (0.05 NM3)

85 PSIG 100 PSIG (586 KPAG) (689 KPAG)

2.6 SCFM (0.07 NM3/MIN)

26 GALLON TANK CAPACITY

85 PSIG 100 PSIG (586 KPAG) (689 KPAG)

4.6 SCFM (0.12 NM3/MIN)

26 GALLON TANK CAPACITY

36

Pilot Air Valves, Gas Fuel System

(AG)

100 PSIG (689 KPAG)

536

Engine Online Cleaning System

(AI)

536

Engine Oncrank Cleaning System

(AI)

200 PSIG (1378 KPAG)

Notes: (AG) Clean, Dry Air Refer to ES 2201 (AI) Refer to Solar ES 9-62



Dragados



Water Requirements Customer Interface Connection

Device

N ote s

Pre ss.

F low

V o l um e

538

Engine Online Cleaning System

(AI),(AO)

NA

-

20-40 GALLONS (75.7-151.4 LITERS)

538

Engine Oncrank Cleaning System

(AI),(AO)

NA

-

20-40 GALLONS (75.7-151.4 LITERS)

Notes: (AI) Refer to Solar ES 9-62 (AO) Flow requirements are met with Solar's latest engine cleaning system tank design.

Applicable Engineering Specifications Engr. Spec. Number

Title

ES 9-62

INGESTIVE CLEANING SOLAR GAS TURBINES ENGINES

ES 9-98

FUEL, AIR AND WATER (OR STEAM) FOR SOLAR GAS TURBINES ENGINES.

ES 9-224

LUBRICATION OILS FOR USE IN SOLAR GAS TURBINES ENGINES STANDARDS AND PRACTICES FOR ELECTRICAL SYSTEMS FOR GAS TURBINE PACKAGES INSTALLED IN

ES 1593 ES 1923

HAZARDOUS AREAS (NEC STANDARDS). LOW VOLTAGE AC ELECTRIC MOTORS NEC FRAMES

ES 2201

AUXILIARY SERVICE AIR

ES 2648

CUSTOMER STATION GROUNGING REQUIREMENTS

Applicable Product Information Letters Product Info. Letter Number

Title

Comment

PIL 149

DIRECT-DRIVE AC START SYSTEMS

AVAILABLE UPON REQUEST




4


PER F O R M A N C E





4.1 EXPECTED PERFORMANCE 4.1.1 GAS TURBINE PERFORMANCE DATA The following gas turbine package performance is expected, but not guaranteed. The "Run" numbers correspond to different operating points and/or ambient conditions.



Dragados



Customer

Model

MARS 100-16000S Package Type

GSC Job ID

Match

HIGH AMBIENT R

By un

A leja ndr o F ra nc o E ngine Performance Code

R E V . 4 .1 7 .1 .1 9 .1 1

Date Run

Fuel System

GAS

2 -F e b- 16 Engine Performance Data

Fuel Type

CHOICE GAS

REV. 1.1

DATA FOR NOMINAL PERFORMANCE E le v a t io n I n le tL o s s E x ha u s tL o s s A c c e s so r yo nG PS ha f t

metres m mH 2 O m mH 2 O kW

30 1 0 0 .0 1 0 0 .0 2 0 .7 1

E n g in e In l e t T e m p e r a t u r e d e gC R e la t iv eHu m i d it y % G e a r b o xE f f ic ie n c y G e n e r a t o rE f f ic ie n c y Based On 1.0 Power Factor S p e c i f ie dL o a d * N e tO u t p u tP o w e r * F u e lF lo w H e a tR a t e * T he r mE f f * E n g in e E x h a u s t F l o w P TE x itT e m p e r a t u r e E x ha u s tT e m p e r a t u r e

kW kW G J / hr k J / k W -hr % k g / hr d e gC d e gC

2

2 0 .0 9 5 .0 0 .9 8 6 9 0 .9 7 2 2 F UL L 1 07 4 6 1 2 0.6 3 1 12 2 5 3 2 .0 6 7 1 5 0 5 97 4 87 4 87

Fuel Gas CompositionM e t h a n e( C H4 ) (Volume Percent) E t ha n e( C 2 H6 ) P r o p a n e( C 3 H 8 ) I - B u t a n e( C 4 H 1 0 ) N - B u t a n e( C 4 H 1 0 ) I - P e n t a n e( C 5 H 1 2 ) N - Pe n t a n e (C 5 H1 2) H e x a n e( C 6 H1 4 ) C a r b o n D i o x id e ( C O 2 ) N it r o g e n( N2 ) S u l f u r D io x id e ( S O 2 ) Fuel Gas Properties

L HV ( k J / S t d .m 3 )

3

3 8 .0 9 5 .0 0 .98 6 4 0 .97 2 0 F UL L 9614 1 1 1 .9 8 1 1 6 48 3 0 .9 0 2

42 .0 95 .0 0.9 8 62 0.9 7 18 F UL L 9 27 1 10 9 .52 11813 30 .4 70

13 8 5 8 4 500 500

1 35 0 3 5 504 504

74 .4 2 13 .4 5 2 .9 6 0 .4 0 1 .1 3 0 .3 3 0 .4 9 0 .8 8 0 .01 0 0 5 .9 3 0 .00 0 1

4 0 2 2 1 .2 S p e c i f i c G r a v it y

0 .7 3 1 7 W o b b e In d e x a t 6 0 F

1 2 6 0 .2

*Electric power measured at the generator terminals. This performance was calculated with a basic inlet and exhaust system. Special equipment such as low noise silencers, special filters, heat recovery systems or cooling devices will affect engine performance. Performance shown is "Expected" performance at the pressure drops stated, not guaranteed.



Dragados



Customer

Model

MARS 100-16000S Package Type

GSC Job ID

Match

HIGH AMBIENT R

By un

A leja ndr o F ra nc o E ngine Performance Code

R E V . 4 .1 7 .1 .1 9 .1 1

Date Run

Fuel System

GAS

2 -F e b- 16 Engine Performance Data

Fuel Type

CHOICE GAS

REV. 1.1

DATA FOR NOMINAL PERFORMANCE E le v a t io n I n le tL o s s E x ha u s tL o s s A c c e s so r yo nG PS ha f t

metres m mH 2 O m mH 2 O kW

30 1 0 0 .0 1 0 0 .0 2 0 .7 1

E n g in e In l e t T e m p e r a t u r e d e gC R e la t iv eHu m i d it y % G e a r b o xE f f ic ie n c y G e n e r a t o rE f f ic ie n c y Based On 1.0 Power Factor S p e c i f ie dL o a d * N e tO u t p u tP o w e r * F u e lF lo w H e a tR a t e * T he r mE f f * E n g in e E x h a u s t F l o w P TE x itT e m p e r a t u r e E x ha u s tT e m p e r a t u r e

kW kW G J / hr k J / k W -hr % k g / hr d e gC d e gC

2

2 0 .0 9 5 .0 0 .9 8 6 9 0 .9 7 2 2 F UL L 1 07 8 4 1 2 0.5 9 1 11 8 2 3 2 .1 8 9 1 5 1 3 67 4 84 4 84

Fuel Gas CompositionM e t h a n e( C H4 ) (Volume Percent) E t ha n e( C 2 H6 ) P r o p a n e( C 3 H 8 ) I - B u t a n e( C 4 H 1 0 ) N - B u t a n e( C 4 H 1 0 ) I - P e n t a n e( C 5 H 1 2 ) N - Pe n t a n e (C 5 H1 2) H e x a n e( C 6 H1 4 ) C a r b o n D i o x id e ( C O 2 ) H y d r o g e n S u l f id e ( H 2 S ) N it r o g e n( N2 ) Fuel Gas Properties

L HV ( k J / S t d .m 3 )

3

3 8 .0 9 5 .0 0 .98 6 4 0 .97 2 0 F UL L 9650 1 1 1 .9 4 1 1 6 01 3 1 .0 2 7 13 9 2 9 9 497 497

42 .0 95 .0 0.9 8 62 0.9 7 18 F UL L 9 30 7 10 9 .49 11765 30 .5 95 1 35 7 3 5 501 501

56 .8 5 9 .7 5 5 .7 0 0 .6 7 2 .0 1 0 .4 8 0 .6 2 0 .4 3 0 .5 8 0 .00 0 2 22 .9 1

3 5 3 3 0 .3 S p e c i f i c G r a v it y

0 .8 2 7 2 W o b b e In d e x a t 6 0 F

1 0 4 1 .1

*Electric power measured at the generator terminals. This performance was calculated with a basic inlet and exhaust system. Special equipment such as low noise silencers, special filters, heat recovery systems or cooling devices will affect engine performance. Performance shown is "Expected" performance at the pressure drops stated, not guaranteed.




5


C O M M EN T S





5.1 GENERAL COMMENTS Solar Turbines' proposal represents a value-engineered response to the customer's request for quotation. Solar reserves the right to provide additional comments if further clarification is required. Solar's turbine packages are designed and manufactured in accordance with industry standards including NEC, CENELEC, ASME, CSA, API, IEC, AWS, ANSI and NFPA. There may be some minor variations to these standards and, where conflicts exist, Solar proposes our standard, proven design. Any industry specifications or customer specifications related to this project that are not listed in this section of the proposal have not been reviewed and are deemed not applicable to this proposal. Solar's operates testing on a "build-to-forecast" production all par areand subject manufacturing to certain shopfacility and inspection requirements, which ensureschedule. that everyThus, package is ts built tested to Solar's stringent standards. This production philosophy enables Solar to build a high quality and consistent product; however, it does not necessarily permit Solar to comply with all of the customer requirements that may be specified. In particular, as it applies to the turbomachinery scope of supply, Solar proposes its standard practices and procedures with regards to manufacturing and welding, material selection and sizing, painting, and noise. Please refer to the sections below for additional details. Manufacturing and Welding Procedures Class 1 Components: Pressure Vessels •

•

•

•

Manufacturing is in accordance with ASME Boiler and Pressure Vessel Code, Section VIII. Welders are qualified to ASME Section IX. Per code, welder's qualification period is extended by 6 months each time they use the procedure. Qualification lapses if the procedure is not used during the previous 6 months. Carbon steel pressure vessels are welded with GTAW (gas tungsten arc welding) and GMAW (gas metal arc welding - standard spray transfer mode). Stainless steel pressure vessels are welded with GTAW and FCAW (flux core arc welding). Pressure vessels and components that fall under the rules of ASME Section VIII, Division 1 are code stamped. Typically these include the lube oil coolers, lube oil filters, water wash carts, and some types of gas filters and coalescers. Solar's gas compressors follow the construction requirements of ASME Section VIII, but are technically out-of-scope of ASME Section VIII and are therefore not stamped.

Class 2 Components: Pressure Piping (Manifolds) • •

•

• •

Manufacturing is in accordance with ASME B31.3 for Process Piping. Welders are qualified to ASME Section IX. Per code, welder's qualification period is extended by 6 months each time they use the procedure. Qualification lapses if the procedure is not used during the previous 6 months. Piping is welded either wholly with GTAW (two passes minimum), or with a GTAW root, and possibly a second pass, followed by GMAW-P (gas metal arc welding, pulse spray transfer mode). Solar does not use socket welds. Standard package piping follows ASME B31.3, which does not require a stamp Piping is seamless stainless steel Type 316L; piping less than or equal to 2 inches uses schedule 80 pipe and piping greater than 2 inches uses schedule 40. Flanges are in accordance with ANSI B16.5. Pipe fittings are in accordance with ANSI B16.11 and are minimum 3000 psi rated.



Dragados



For Taurus 70 and Titan 130 onshore generator set package, schedule 10S stainless steel piping is used in the lube oil system, supply, drain and vent lines up to and including 4 inches in diameter. The minimum wall thickness meets Solar's safety requirements for system operational pressures. Solar uses backup rings on schedule 10S piping only. All schedule 10S piping welds meet Solar's safety and fabrication requirements. Pressure and discharge piping manifolds are hydrostatically tested at 1.5 times the maximum allowable working pressure for a minimum of 30 minutes in accordance with ASME Boiler and Pressure Vessel Code, Section VIII. Engine fuel, system, water, and air assist manifolds are leak tested at 780.0 +/- 20.0 psig for a minimum of 10 minutes. Special testing, if requested, may be accommodated as a custom item

•

•

Class 3 Components: Turbomachinery and Structural Components (Not defined as pressure vessels or pressure piping) •

• •

•

o

o

o

Manufacturing is in accordance with the American Welding Society Specification AWS D1.1. Solar uses AWS D1.1 pre-qualified Welding Procedure Specifications (WPS). Welders are qualified to AWS D1.1. Structural components are welded with FCAW (flux core arc welding) or GMAW (gas metal arc welding - short circuit). Welds are primarily fillet welds with some full penetration welds depending on the requirements of the engineering drawing. The typical materials used for structural components are as follows: I-Beams: ASTM A709 Grade 50, ASTM A992 Rectangular Tubing: ASTM A500 Grade B Plate: ASTM A36, ASTM A709 Grade 50

Tubing All tubing is annealed seamless 316L stainless steel per ASTM A269 and supplied with 316 stainless steel flared tube fittings or 316 stainless steel Swagelok fittings. Minimum tubing wall thickness is as follows: Tube S ize, in.

Pressure, psi

Minimum Wall Thickness,in.

3/8

0-2000

.049

1/2

0-2000

.049

3/4

0-500 500-2000

.049 .065

0-500 500-2000

.065 .083

1

Paint Due to the San Diego County Environmental Regulations, Solar must paint and coat equipment according to Solar's Specification ES 9-58 or as required to conform to San Diego County Air Pollution Control District and the United States Environmental Protection Agency. Therefore, general exception is taken to any customer paint specifications. copy ofhas Solar's can be provided upon to request. It is important to note that Solar's paintAsystem beenpaint usedspecification on numerous installations, similar this project, and has been accepted by the industry. Solar's standard paint program for turbomachinery products consists of several paint systems, which are selected according to the nature and function of the component. The paint color used is RAL 7032 Caterpillar Confidential: Do Not Disclose Without Solar's Approval




(International grey color). Solar's most widely used paint system, System E, is intended to apply to steel surfaces, which are continuously exposed to the elements, such as: • • • •

Package base and external surfaces of the enclosure and control panels Oil coolers Air inlet ducts, silencers, and filter housings EP control consoles and non-EP control consoles.

Note: Stainless steel and galvanized surfaces are not typically painted. Solar's System E paint process is a two-coat system consisting of the following: ZINC RICH EPOXY PRIMER – Zinc rich epoxy primer, in accordance with ES9-58-1, will be applied to provide a smooth continuous coating with a minimum dry film thickness of 3 mils (wet film thickness of 5.5 mils produces 3 mils dry). LINEAR POLYURETHANE TOPCOAT- For surfaces exposed to the elements, the finished coat will be one coat of linear polyurethane in accordance with ES9-58-1, applied over the properly cured, primed, or coated surface. The finish coating will be a minimum dry film thickness of 3.0 mil. Noise Solar's acoustical enclosure is designed to maximize noise reduction. The A-weighted sound level of Solar's acoustically enclosed gas turbines at full load operation, when installed in a free field, is estimated to meet an average of 85 dBA (90 dBA for Saturn engines) at a distance of 1 m (3 ft) from the enclosure and 1.5 m (5 ft) above the bottom of the skid. This sound level is measured at points spaced typically 1.5 to 3.0 m (5 to 10 ft) apart on each side of the enclosure and at one position on each end of the enclosure on the longitudinal axis. This sound level applies only to enclosed equipment and is exclusive of sound generated by piping and any other unenclosed equipment. For some enclosed packages, acoustical lagging is required for the combustion air inlet and combustion exhaust ducting in order to meet an average sound level of 85 dBA. Sound levels at a specific site are dependent on multiple variables including but not limited to existing walls, barriers, and equipment in close proximity. Noise surveys are not included. If there is a gap between the bottom of the skid and the housekeeping pad, deck, or ground, this gap must be sealed with a non-hardening caulk. When enclosed packages are installed on elevated mounts, such as gimbals or anti-vibration mounts, the gap between the skid bottom and the deck is typically about 305 to 355 mm (12 to 14 in.), which is too large to seal by caulking. Sound emission from the skid bottom will increase the sound level adjacent to the package by 3 to 4 dBA. For elevated installations, the 85 dBA average sound level can be obtained only through the use of skir ts that extend from the bottom of the skid to the deck. For additional information, a copy of Solar's Noise Brochure can be provided upon request.




6


QUALITY



Dragados



6.1 Inspection and Test Plan / Project Quality Plan Inspection and Test Plan

NEC-GS PD # NEC-GS Revision Number: A

Certification: NEC

Dated: December 04, 2013

Prepared for

Purchaser Company Name This ITP was Prepared By:

Package QE

Equipment includes 1 Each, . Package(s). Powered by turbine(s). PACKAGE TYPE: GENERATOR SET CERTIFICATION: NEC ____ Working Days Notification Required For All Customer INSPECTION/OBSERVATION Items.

Inspection Points: Column A is Solar Inspector / Engineer

ColumnBis Client

ColumnCis

Column D is

The ITP is developed from the Solar Application Check Sheet (ACS) and information provided by the Business Manager and the Project Applications Engineer. Revisions are based on Customer input provided during project execution. Special inspections, documents or tests above and beyond our standard are shown. The legend at the bottom of each page indicates what inspection / test points or documents are required. 'O1' Indicates Customer, Third Party or Certifying Agency inspection on 100% of units, operations or tests on that project. Every effort is made to have the inspector present when these operations are conducted. The inspection or test has not necessarily been performed in advance, prior to the observation point. Should the inspector be unavailable at the time of the actual inspection or test, production is not stopped. Review of verifying documents is included. Equipment in ITP Section 1.0 shall be released if Customer's Inspector fails to respond or fails to appear.

'O2' Identical to 'O1', but performed on a sampling of units, operations or tests on that project (not necessarily 100%). Every effort is made to have the inspector present when these operations are conducted. The inspection or test has not necessarily been performed in advance, prior to the observation point. Should the inspector be unavailable at the time of the actual inspection or test, production is not stopped. Notification requirements are the same as for '01'. Equipment in ITP Section 1.0 shall be released if Customer's Inspector fails to respond or fails to appear.

'A1' Indicates Solar inspection or test on 100% of units, operations or tests on that project. 'A2' Indicates Solar inspection or test on only a sampling of units, operations or tests on that project. 'R1' Indicates an in-process document review is required on 100% of units on that project. The in-process review is to take place at the operation or test location unless the document is included in the databook. A copy of the verifying document is not supplied unless also identified with an 'X' in Solar's column 'A'.

'R2' Indicates an in-process document review is required on only a sample of units on that project. The in-process review is to take place at the operation or test location unless the document is included in the databook. A copy of the verifying document is not supplied unless also identified with an 'X' in Solar's column 'A'.

'M2' Indicates a sample monitoring of Solar's system is required. This monitoring will be on random equipment, and may not be project specific.

'X'

In Solar's column 'A' indicates a copy of the document will be supplied in the Project Quality Assurance Data Book. The Databook contains a reference copy of the ITP. Individual documents are identified with the ITP Item number and are found in the corresponding sections. The documents consist of supplier information and Solar information.

All supplier documents areto be submitted to: or Emailed to: [email protected] Quality Document Coordinator Solar Turbines Incorporated (KM20) PAGE: 1 4200 Ruffin Road San Diego, CA 92123, USA

Caterpillar Confidential: Green



Dragados



Solar Turbines

Inspection and Test Plan

Source Inspection Instructions for ITP Section 1.0 ONLY Suppliers Noted in Section 1.XX of this ITP1. Supplier is to notify customer (email/fax) for any O1, O2, M2 inspection points in columns B, C, D and copy all notifications to Solar representative (Ron Lang) on page 3 of this ITP. Notification should be in accordance with the time period listed on page 1. Contacts for the above inspections are on page 3, items 0.2, 0.3, 0.4, 0.5. Supplier to send (e-mail/fax) 30 day advancedinspection notification to Solar representative (Ron Lang) on page 3, item 0.2 and Solar Supplier Quality Engineer (Seif Almusa) listed on page 3, item 0.1 and applicable rd

customer 3 to party inspector. 2. Supplier send (e-mail/fax) copy of notification to Solar purchasing representative and applicable rd customer 3 party inspector. Supplier is to send (email/fax) “Second Notification” if required to customer inspector on page 3, items 0.3, 0.4, 0.5, Solar Representative (Ron Lang), item 0.2, and Solar Supplier Quality Engineer (Seif Almusa), item 0.1. 3. At Inspector’s arrival, confirm Inspector has latest Purchase Order and Drawing revision, and provide Inspector with current copy(s), if required. 4. If Inspector and/or Solar’s customer’s inspector has not responded to a “Second Notification” within 48 hours, notify Solar representative (Ron Lang) on page 3, item 0.2. 5. All supplier documents required by this ITP are to be emailed to: [email protected]

Solar’s Contracted Source Inspector (Column A of Section 1.0)1. Upon receipt of Solar ITP, purchase order and drawing, notify supplier of your inspection assignment. 2. Upon receiving inspection notification from supplier, send (e-mail/fax) inspection confirmation to the supplier. 3. Send (e-mail/fax) copy of inspection confirmation to Solar Supplier Quality Engineer and inspection agency. 4. Respond to supplier second notification within 48 hours (see supplier Item 6 and Solar Turbines Supplier Quality Engineer Item 5). 5. Please address ITP Section 1.0 source inspection reports to Seif Almusa 858-694-1810, Email address: [email protected].

Solar Turbines Supplier Quality Engineer- ( Seif Almusa) 1. Create project file. 2. Send (email/fax/mail) copies of latest revisions of ITP, unpriced purchase order, drawings, etc. to assigned contracted Inspector. 3. Send (email/fax/mail) copies of latest revisions of ITP, unpriced purchase order, drawings, etc., to inspection agency. 4. Follow up on supplier to inspector “Second Notification”. 5. Reassign inspection to different Solar inspector and/or inspection agency 24 hours after supplier notification to Solar that inspector did not respond to “Second Notification” (see supplier item number 6). 6. Request customer inspection waiver from Project Manager, if customer inspector did not respond to supplier within 48 hours after supplier issued “Second Notification” (see supplier Item 6).

Note: For Solar source inspections, only a Quality Engineer, Quality Manager, or Project Manager can waive source inspection requirements. For customer inspections, only the customer can waive source inspection requirements. All waivers must be in writing (email or faxed). PAGE: 2




Dragados



SOLAR TURBINES INCORPORATED INSPECTION AND TEST PLAN CLIENT:

PROJECT NAME: NAME:

PurchaserCompanyName ITEM 0.0

PD NO:

NEC-GS

ISSUED BY:

PURCHASE ORDER:

1

NO. UNITS:

Quality Engineer

REV:

A

PAGE: 3

December 04, 2013

EQUIPMENT:

.

NEC-GS

ITEM DESCRIPTION

ITEM

ITP approval by Solar Project Management.

0.4

ITEM DESCRIPTION COLUMN C C ONTACT INFORMATION: Company:

DATE:

Project Manager

Contact: Phone #: Fax #: Cell/Pgr #:

0.1

Email:

SOLAR SOURCE INSPECTION CONTACT: Contact: Seif Almusa

0.2

Phone: 858-694-1810 Fax: 858-694-6733

Company:

[email protected]

Contact:

SOLAR CONTACT FOR ALL CUSTOMER INSPECTIONS IN SECTION 1 (01.XX):

Phone #:

Contact:

Cell/Pgr #:

RON LANG

Phone #: 858-694-6121

0.3

Fax #:

858-694-6712

Email:

[email protected]

Fax #:

Email:

Company:

COLUMN B CONTACT INFORMATION:

Contact:

Company:

Phone #:

Contact:

Fax #:

Phone #:

Cell/Pgr #:

Fax #:

Email:

Cell/Pgr #: Email:

Company: Contact: Phone #: Fax #: Cell/Pgr #: Email:

Company: Contact: Phone #: Fax #: Cell/Pgr #: Email:




Dragados




PROJECT NAME: NAME:

PurchaserCompanyName ITEM

PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 4

December04,2013 .

EQUIPMENT:

NEC-GS

ITEMD DESCRIPTION ESCRIPTION DESCRIPTION

CONTROLLING CONTROLLING DOCUMENT

01.00

PACKAGING OPERATIONS PURCHASED PARTS

Solar Quality Management System

01.01

RECEIVING INSPECTION - Inspect material per Solar practices


SUPPLIERS BELOW TO NOTE THE FOLLOWING:

VERIFYING RECORD

Solar

Client

A

B

BAAN Material System

A2

Supplier Certificate of Compliance

R1

X


R1

X


R1

X

C

Engineering Drawings

ALL DOCUMENTATION MARKED WITH 'X' IN Purchase Order COLUMN A SHALL BE PROVIDED TO SOLAR WITHIN 14 CALENDAR DAYS OF COMPLETION OF MANUFACTURING, AND/OR FINAL SOLAR OR CUSTOMER INSPECTION. DOCUMENTATION SHALL INCLUDE SOLAR PO #, SOLAR PART NUMBER AND SOLAR PROJECT NAME/NUMBER. ELECTRONIC TRANSMITTAL OF DOCUMENTS IS PREFERRED. SEND TO: [email protected] DOCUMENTS SHALL BE MAILED TO: QUALITY DOCUMENTS COORDINATOR SOLAR TURBINES INCORPORATED MAIL ZONE: KM20 4200 RUFFIN ROAD SAN DIEGO, CA 92123 NOTE: RECEIVING INSPECTION VERIFYING DOCUMENTS ARE NOT APPLICABLE TO DROP SHIPPED ITEMS. 01.03

Air Inlet Silencer

ES 1692

(Drop Ship Item)

Engineering Drawings Purchase Order

01.04

Air Inlet Filter

ES 1725

(Drop Ship Item)


01.05

Exhaust Silencer

ES 1632

(Drop Ship Item)


A1 SOLAR 100% INSP/TEST

R1 100 % DOCUMENT REVIEW

O1 100 % OBSERVE INSP/TEST

X

SOLAR SUBMIT VERIFYING DOCUMENT

A2SOLAR SAMPLE INSP/TEST

R2 SAMPLE DOCUMENT REVIEW

M2MONITOR SYSTEM O2 SAMPLE OBSERVE INSP/TEST




Dragados




PROJECT NAME: NAME:


PD NO:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 5

December04,2013 .

EQUIPMENT:

NEC-GS



Lube Oil Cooler

ES 2184

(Drop Ship Item)

Engineering Drawings Purchase Order ASME VIII

01.07

NEC-GS

ISSUED BY:

LubeOilFilters


VERIFYING RECORD

Solar

Client

A

B

1. ASME U-1A Manufacturer's Data Report

R1

X

2. Pressure Test Certificate

R1

X

3. Flush Certificate

R1

X

ASME U-1A Manufacturer's Data Report

R1

X

Factory Acceptance Test Report

R1

X

Proof Load Test Records

R1

X

Proof Load Test Records

R1

X

ASME U-1A Manufacturer's Data Report

R1

X

C

Purchase Order ASME VIII 01.08

Generator

SupplierInspection and Test Plan ES 2033 ES 2170 Engineering Drawings Purchase Order

01.12

Package Lifting Kit

ES2335

(Loose Ship Item)


01.13

Internal Equi pment Handling Syst em Includes engine handling kit trolley beam(s), engine handling kit external structure(s), start motor removal kit trolley beam(s), start mot or removal external structure(s), hoists, jib crane, and field tools, as applicable.

01.15

Engine Cleaning Tank

ES2335 Engineering Drawings Purchase Order


(Loose Ship Item) Purchase Order ASME VIII




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 6

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

SKID BASE PL ATE (TURBINE PACKAGE) (TurboFab, Houston) TurboFab Contact: Bryan Hanney Tel: 281-860-6760 Fax: 281-860-6713

02.01

WeldingProcedures

TurboFabQuality Management System

PQR, WPS

M2

WQR

M2

Traveler

A1

Traveler

A1

Inspection Report

A1

Traveler

A1

AWS D1.1 02.02

WelderQualifications

TurboFabQuality Management System AWS D1.1

02.03

Skid Fabrication Inspect skid/lifting bollard welds and perform dimensional and visual inspections in accordance with AWS D1.1.

TurboFab Quality Management System Fabrication Drawings AWS D1.1

02.04

Lube Oil Tank Pneumatic Leak Test

TurboFab Quality Management System

02.05

Skid Surface Preparation and Paint

TurboFab Quality Management System ES 9-58

02.06

Lube Oil Tank Preservation Apply internal coating of Brayco 785.

TurboFab Quality Management System




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 7

December04,2013 .

EQUIPMENT:

NEC-GS



Solar

VERIFYING RECORD

Client

A

B

C

ON-SKID MANIFOLDS Solar Contact: Ron Lang Tel: 858-694-6121

03.01W

elding Procedures

ASME IX

WPS, PQR

03.02

Welder Qualifications

ASME IX

WQR

03.03

Manifolds

WPS

Dimensional check and visual inspection.


Shop Travelers available for review only at Solar's facility.

03.04

Manifold Radiography

M2 M2

Traveler

A1

Hydro Test Records

A1

Engineering Drawings ASME B31.3

Standard is 5% per welder on circumferential butt welds only. NOTE: Not per project. 03.05

Manifold Hydrostatic Pre ssure Test (1.5 times design pressure for 10 minutes minimum) Manifolds are manufactured and leak tested at Solar facilities in San Diego, CA & Tijuana,

Solar Quality Management System Engineering Drawings ASME B31.3

Mexico. Hydro Test Records of standard manifolds without project specific requirements are available for review only at Solar's Facilities.




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 8

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

CONTROLS Solar Contact: Ron Lang Tel: 858-694-6121

04.01

Visual Insp ection of Control Console Wiring

04.02

Control System Hardware Verification This verification is performed on each unit of a multi-unit Sales Order.

04.03

Control System Soft ware Verif ication Verify using software simulators to represent the operation of the equipment controlled by the software. This verification is performed only once on a multi-unit sales order.

Project Electrical Drawings


Control Console Hardware Sheet in 04.02

A1

X

Control Console Hardware Sheet

A1

X

Control Software Verification Sheet

A1

X

Project Electrical Drawings Solar Quality Management System Project Electrical Drawings

Verification of software controlling Balance of Plant equipment provided under separate co ver.




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 9

December04,2013 .

EQUIPMENT:

NEC-GS



GAS TURBINE ENGINE

VERIFYING RECORD

Solar

Client

A

B

C

TMP Quality Managememt System Business Control

Solar Contact: Ron Lang Tel: 858-694-6121

Diagram 05.01

Supplier Quality Engineering


Review and approval of purchase requisitions for first-time buy or revised parts.

BAAN System

R2

BAAN System

A2

Leak Test Chart

A1

Leak Test Chart

A1

Test Records in Section 3

A1

Shop Floor Information System

Solar Certificate of Compliance

R1


Inspection Data

A1

Purchase Order BAAN System

05.02

Receiving Inspection


Inspect material per Solar practices. Purchase Order BAAN System 05.03.A Compressor Case Leak Test


As cases are not assigned to a specific project or a specific engine at the time of leak testing, observation is not available for this operation. 05.03.B Combustor Case Leak Test

Engineering Drawings Shop Floor Information System

As cases are not assigned to a specific project or a specific engine at the time of leak testing, observation is not available for this operation. 05.03.C Engine Manifolds


Refer to Section 3 for applicable manifold test requirements.

ES 9-78 Engineering Drawings ASME B31.3

05.04

ROTOR ASSEMBLY - COMPRESSOR AND TURBINE NOTE: Customer identification is assigned at this point.

05.04.A Gas Producer Compressor Rotor Verify Mechanical and Electrical Runout.





X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 10

December04,2013 .

EQUIPMENT:

NEC-GS


05.04.B Gas Producer Turbine Rotor

CONTROLLING CONTROLLING DOCUMENT Shop Floor Information System

Verify Mechanical and Electrical Runout.

05.04.C Power Turbine Rotor

05.04.D Balance Gas Producer Compressor Rotor

Solar

Client

A

Inspection Data

A1

Inspection Data

A1

Inspection Data

A1

Inspection Data

A1

Inspection Data

A1

Inspection Data

A1

Engine Test Report

A1

B

C


Verify Mechanical and Electrical Runout.

VERIFYING RECORD

Engineering Drawings Shop Floor Information System Engineering Drawings

05.04.E Balance Gas Producer Turbine Rotor

Shop Floor Information System Engineering Drawings

05.04.F BalancePowerTurbineRotor

ShopFloor Information System Engineering Drawings

05.05

ENGINEASSEMBLY

05.06

Gearbox

TMP Quality Managememt System Business Control Diagram Shop Floor Information System Engineering Drawings and Specifications

05.07

EnginePerformanceTest

TMP&PSOQuality Management System

X

O1




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 11

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

THIS SECTION DOES NOT APPLY. SOLAR IS NOT PROVIDING A PROCESS COMPRESSOR.




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 12

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

PACKAGE ASSEMBLY Solar Contact: Ron Lang Tel: 858-694-6121

07.01

Base Qu alification

Project Mechanical Package Assembly Installation Drawings Checklist

A1

Oil tank cleanliness checks and base paint thickness checks prior to build-up of package. 07.02

MechanicalAssembly

SolarQuality Management System

Package Assembly Checklist

A1

07.03

ElectricalAssembly


Electrical Package Checklist

A1

07.04

Alignments

Single Alignment Chart

A1

SolarQuality Management System Project Mechanical Installation Drawings

07.05

Dimensional Che ck of Customer Interface Points During build-up of package. Includes tie down points, customer connection plates and flanges.

Project Mechanical Dimensional Installation Drawings Verification Sheet and Customer Interface Points

A1




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 13

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

PACKAGE TEST Solar Contact: Ron Lang Tel: 858-694-6121

08.01

Package/Console Acceptance Test

08.02

Enclosure Assembly Static Test Including simulated test of fire and combustible gas system, if present.

Solar Quality Management System Solar Quality Management System

Certified Test Report

A1

X

O1

Stamp Off Sheet in 08.01

A1

X

O1




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 14

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

PACKAGE FINAL INSPECTION Solar Contact: Ron Lang Tel: 858-694-6121

09.01

MechanicalFinalInspection


Final Package OK to Paint/Ship Checklist

A1

Final Package OK to Paint/Ship Checklist

A1

Project Mechanical Drawings 09.02

ElectricalFinalInspection

SolarQuality Management System Project Electrical Drawings

09.03

PaintFinalInspection


Final Paint Checklist

A1

09.04

LooseShipVerification


Packing List

A1

09.05

Package Preservation and Preparation for Shipment

Final QA Acceptance Sheet

A1

Solar Quality Management System Shipping/Traffic Functional Practices ES 9-249 ES 9-248




X








Dragados




PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 15

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

DOCUMENTATION / CERTIFICATION Solar Contact: Ron Lang Tel: 858-694-6121

10.01

QC Data Book Review

ITP

(By the Project Quality Engineer)

_______________________________________ QE Signature

1. Package Certificate of Compliance

R1

X

2. ITP (reference copy)

R1

X




X








Dragados




PROJECT PROJECT NAME: NAME:


PD NO:

NEC-GS

ISSUED BY:

1

NO. UNITS:

QualityEngineer

REV: A

PURCHASE ORDER:

PAGE: 16

December04,2013 .

EQUIPMENT:

NEC-GS



VERIFYING RECORD

Solar

Client

A

B

C

REVISION RECORD SHEET REV A

DATE 12/04/13

BY Mia Knecht

REMARKS Revision A is the initial release of the ITP.




X








Solar Turbines GO &aisl

7

Dragados M a1rG 0s0e n e r a tSoer t

TYPICAL DRAWINGS



Solar Turbines GO &aisl

Dragados M a1rG 0s0e n e r a tSoer t

7.1 DISCLAIMER STATEMENT Please note that the following drawings are provided for REFERENCE ONLY and should not be used for detailed design.



Solar_ Mars 100 Power Generation

Recommend Documents