3689-002-55402257-2009 SPECIFICATIONS
№ РРС 00-35424 Equipment Use Permit

PICTURES QUESTIONNAIRE

FUNCTION

BPG-Series gas heating unit is used for indirect heating of gas to the set temperature. The unit is run as a part of a high gas pressure reducing and metering station to prevent hydrate formation during throttling and maintain preset values of outlet gas temperature. The gas heating unit is also used to supply heat carrier to the heating systems of units and other available heat consumers.

OPERATING CONDITIONS

Gas heating units can be run in macroclimatic areas with the moderate (N) and moderate-cold climate (NF), and also in areas with a cold climate (F). The modification of the heating unit depends on climatic operating conditions and can be determined subject to the area of construction following the requirements of 15150-69 State Standard. The permissible degree of seismicity in the areas where the station can be run constitutes 9 points inclusive, following П-7-81 SNiP Building Specifications. The rated snow loading (200 kg-force/m2) should meet the requirements of area V, and wind loading (85 kg-force/m2) - area VII by 2.01.07-85 SNiP Building Specifications.

The modification of a gas heating box to be run as a part of a high gas pressure reducing and metering station should be determined subject to required outlet gas temperature, thorough operation of station facilities and prevention of ice formation. In case a gas heating unit is used in a heating loop additional thermal load should be considered.

Gas is heated in a shell-and-tube heat exchanger with the help of intermediate heat-carrier heated in a water boiler. Depending on thermal power of the box the heat-carrier is heated up to 110°С and supplied to a shell-and-tube heat exchanger. In the latter facility heat is transmitted to the heated body (gas). Further the cooled heat carrier is supplied from a return heating conduit to the inlet of a water boiler (the temperature of heat carrier constitutes 950C). In case there is an additional heating loop heat carrier is taken from a return heating conduit.

The gas heating unit has two blocks-boxes: the boiler room box and the box of heat exchangers. The equipment of these boxes is installed in the unit tightly divided into two chambers: the boiler room (D category) and the room of heat exchangers (V-Ia category). The block-box is made of “sandwich”-like panels. It has a lift-off cover enabling to ensure the assemblage and repair of heavy and large-size equipment at the shortest possible time.In case station facilities are installed in a permanent-type building turnkey block-boxes are manufactured and supplied on frames. The permissible degree of seismicity is 9 points. The compact size of the box and the turnkey manufacturing design enable to ensure delivery, assemblage and precommissioning works at the earliest possible time. The gas heating unit is designed following the requirements of State Standard, SNiP Building Specifications and meets the last demands of "Gazprom" OJSC management directives.

A Boiler Room

The required thermal power is provided by two water boilers to ensure the reliable operation of the box. In case of malfunction of one of the boilers the other boiler enables to continue the operation of the station in emergency. On customer’s demand additional backup water boilers can be installed (by 50%-100%). The boilers are designed to operate on low pressure gas (supplied from a gas extraction box to boilers). As required by customer’s performance specification a gas-regulating installation can be supplied. Alternate fuel can be used on demand: diesel, liquefied gas, etc.

Circulation pumps are installed at the inlet of water boilers. Their operation is controlled by the pump control and protection device in the mode of working time distribution. In case of

malfunction of one of the pumps the nonfault pump ensures 100% working capacity. To prevent the increase of internal hydraulic pressure and protect the system the boilers are equipped with safety shutoff valves (the discharge is ensured through an expansion vessel).

A manual pump is installed to feed the system.

Power Supply

The power is supplied to the gas heating unit from 220V/50Hz or 380V/50Hz (subject to customer’s demands) industrial circuit. The power is supplied through the input box equipped with protecting cutout switchers. The input box is installed in a boiler room.

The consumers of power supply are the following:

  • Lighting (external and internal)
  • Circulation pumps
  • Boilers
  • Automatic Control System (ACS)

Standby power supply of a gas heating unit can be ensured on customer’s demand with the help of helium accumulators.Standby power supply of a gas heating unit can be ensured on customer’s demand with the help of helium accumulators.

The Heat Exchangers Box

Shell-and-tube heat exchangers are used as heat exchanging devices of the box. Their quantity, modification and material are determined subject to the output of the gas heating unit and customer’s

demands. Each heat exchanger has the following devices: the system of protection of a coolant circuit from high pressure gas inrush, safety relief valves preventing the increase in pressure in the shell of the heat exchanger in case of gas inrush, shutoff valves in heating conduits for switching-off in case repairs are made, instrumentation, the pipes for discharging of condensate from a distributor box of a heat exchanger, a blowdown pipe of the shell and a heat carrier discharge pipe. The binding fulfilled with the help of a pipeline enables to ensure successive and parallel activation of heat exchangers. The block-box has a bypass line. Vent pipes ensure emergency removal of gas from technological pipelines.

On customer’s demand the group of pipes (matrix) can be made of the following materials: steel 20, corrosion-resistant steel, titanium metal.

The following antifreezing liquids are used as heat-carrier: diethyleneglycol, chemically prepared water. The use of unprepared water reduces the efficiency and operation life of the gas heating unit.

The chambers are ventilated with the help of supply and exhaust grills installed in outside walls of the unit and also with the help of deflectors located on the roof.

The Heating unit automation system meets the demands of “The Main Regulations on Automation of Pressure Reducing and Metering Stations” approved by “Gazprom” OJSC and corresponds to VRD 39-1.10-005-2000. The forced ventilation in the unit of heat exchangers is ensured by ROSENBERG axial fan installed into the wall of the chamber. The fan is protected from external factors (wind, rain, snow, etc.) with the help of inertial grating made from shockproof nylon materials resistant to weather impact.

Technical specifications of the Heating unit

Parameters BPG-5 BPG-10 BPG-15 BPG-20 BPG-30 BPG-40 BPG-50
Working pressure, mega pascal Pipeline
8 8 8 8 8 8 8
Tube space of a heat exchanger 2,5 2,5 2,5 2,5 2,5 2,5 2,5
Nominal output, m3/h 5000 10000 15000 20000 30000 40000 50000
Heating temperature, °С 01.10.70 01.10.70 01.10.70 01.10.70 01.10.70 01.10.70 01.10.70

Heat power*, kW

22,2-155,4 44,5-311 66,6-466,3 88,8-622 133,5-933 177,6-1244 222,5-1555
Maximum power consumption, kW 1,2 1,6 1,8 2,2 3,3 3,8 4,2
Operating environment Tube space Natural gas, 51.40-93 State Standard
Inter-tube space Antifreezing agent («DIXIS», tossol, ethylene glycol solution), water **
Heat carrier temperature, °С 110-95
Fuel gas pressure, kg/cm2 0,3-0,7
Fuel gas consumption, m3/mega watt-second 0,1134-0,1137 0,112-0,1134
Fuel gas consumption, m3/h 2,8-18,3 5,7-38,5 7,9-49,1 9,4 - 78,3 16,4- 102,5 19,7- 134,5 27,4- 162,3
Overall dimensions& 6000x3000x3000 8000x3000x3000 8700x3000x3000
* Subject to required heat power of a gas heating unit the quantity and modification of boilers and heat exchangers are determined.
** Not recommended.
&The final dimensions of block-boxes are determined after the review of customer’s performance specification.

 

Automation

The heating unit devices can be used in V-Ia explosive areas. The rating of accuracy is 0,5%. They unit devices are produced by the leading Russian plants and proved to be reliably operated in nuclear and oil industries. The unit facilities comply with ISO — 9000 standard.

Parameters are controlled both locally and from operator’s console. On demand any of the above-mentioned parameters can be registered both with the help of a diagram and electronically (for further processing at a workstation).

The control cabinet of a heating unit is installed in a boiler room. It ensures the fulfillment of the following functions:

  • To signal about gas contamination in a boiler room and in a box of heat exchangers; to switch on forced exhaust ventilation in the box of heat exchangers in case level 1 of methane contamination is reached; to switch off the boilers in case level 2 of gas contamination in a boiler room is reached.
  • To signal about CO-contamination in a boiler room in case levels 1 and 2 are reached; to switch off the boilers in case level 2 of gas contamination is reached.
  • To switch off the boilers in case of malfunction of both circulation pumps (when the signal is received from a discharge head relay)
  • To switch off the boilers in case the pressure of gas supplied to boilers either decreases or increases.
  • To switch off the boilers in case smoke fumes are not drawn.
  • To signal about the malfunction boilers
  • To signal about pressure increase in the shell of a heat exchanger (in case of matrix breakage).
  • To signal about the malfunction of circulation pumps
  • Automatic activation of circulation pumps after the power is supplied to boilers
  • To prevent unauthorized access to boxes the limit switches are installed on the doors of each box.
  • Fire alarm detectors are installed in the boiler room and in the box of heat exchangers (the quantity of detectors in a loop, the number of loops in a box and the type of detectors are to be determined by the customer). On demand the heating unit can be equipped with a separate fire alarm device. In this case each box has 2 detectors in each separate loop. “Fire” signal is sent when two detectors (one in each loop of the box) are activated simultaneously. In case one or two detectors are activated only in one loop the signal “loop malfunction” is sent.
  • The list of alarm signals and protecting cutouts can be edited by a customer when a questionnaire is filled in.
  • On demand the signals of divergence of parameters can be sent in the following ways:
    • locally or in a remote way with the help of a distant control and attention device;
    • The transmission of “dry contact” discrete signals to the automatic control system of a Pipeline Control Station.
    • The transmission of signals from Simatic S7–200 controller to the automatic control system of a Pipeline Control Station. The signals are transmitted through a digital channel (Modbus RTU Protocol, Slave mode). The addresses are enclosed to engineering documentation.

Different modifications can be manufactured:

  • On demand the temperature control loop can be installed in the ACS of the heating unit to ensure automatic maintenance of preset outlet gas temperature. In this case the automatic control system is equipped with a character display to input ACS operation process-related parameters.

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