1.

1 Turbine
1.1.1 Gas Turbine
In This Process, a gas turbine is used as utility to produce electricity and supply
power to for generator. For the utility and sizing we leave it to the vendor. The
methane gas is leaving the combustion with 1039,5 kg/day.
For gas turbine specification, methane data must be completed.
Specification of methane gas
LHV : 940 (Btu/scf)

Equipment Specification
Equipment Name Siemens Gas Turbine SST5-4000
Turbine Series
High-pressure (H) modules
and combined intermediate-pressure / low-pressure (IL)
modules for 50 Hz
Equipment Code SGT4-4000F
Function Decreasing the gas pressure and produce electricity
Number of stages 4
Fuel Natural Gas
Drive Cold end, direct coupled
Dimension
Quantity 1
Equipment Type Gas Turbine
Weight package 312000 kg
Blade Diameter 311.9 mm
Package Height 4.9 m
Package Widht 4.9 m
Package Lenght 11 m
Operating Condition
Flow rate (m
3
/hr) 573.5
Power (MW) 210
Heat Rate(kj/kWh) 9,001
Rotor Speed 3000 rpm
Efficiency 40%
Turbine Data
Pressure Ratio 2,416x10
4

Inlet Pressure (kPa) 2662
Outlet Pressure (kPa) 0.6432
Power (MW) 210
Exhaust Flow (kg/s) 723
Exhaust Temperature 579

1.2 Pumps
Both of in natural gas combined cycle power plant and acid plant needs pump to
increase the pressure of the fluid. It essentially needs to flow the fluid from higher
pressure to the lower pressure

Table 1. 1 Specification of Pump J-101
J-101
Function Pumping water from water tank to HRSG
Type Single Stage Centrifugal Pump
Impeller Francis Vane
Material Stainless Steel
Pressure ratio 15.2
Flow (m3/s) 0.0266
Efficiency 75%
Suction Pressure (kPa) 6.895
Discharge Pressure
(kPa)
104.8
Head 32.709 ft
BHP 4.6 HP
(Source: Authors Personal Data)
Table 1. 2 Specification of Pump J-102
J-102
Function As the backup of main pump J-101 which
serves to pumping water from water tank
to HRSG
Type Single Stage Centrifugal Pump
Impeller Francis Vane
Material Stainless Steel
Pressure ratio 15.2
Flow (m3/s) 0.0266
Efficiency 75%
Suction Pressure (kPa) 6.895
Discharge Pressure
(kPa)
104.8
Head 32.709 ft
BHP 4.6 HP
(Source: Authors Personal Data)
Table 1. 3 Specification of Pump J-102
J-201
Function Pumping sulfuric acid to electrolytic cell
Type Single Stage Centrifugal Pump
Impeller Mixed Flow
Material Stainless Steel
Flow (m3/s) 0.001
Efficiency 75%
Pressure Difference (kPa) 96,526
Head 17.576 ft
BHP 4.57 HP
(Source: Authors Personal Data)
Table 1. 4 Specification of Pump J-401
J-401
Function Pumping water to waste heat boiler
Type Single Stage Centrifugal Pump
Impeller Francis Vane
Material Stainless Steel
Quantity (m3/s) 0.0068
Efficiency 75%
Suction Pressure (kPa) 100
Discharge Pressure
(kPa)
200
Head 15.255 ft
BHP 1,22 Hp
(Source: Authors Personal Data)
Table 1. 5 Specification of Acid Pump
J-402
Function Pumping water to waste heat boiler
Type Single Stage Centrifugal Pump
Impeller Radial Vane
Material Cast Iron
Quantity (m3/s) 0.0074
Efficiency 75%
Suction Pressure (kPa) 100
Discharge Pressure
(kPa)
200
Head 33.597 ft
BHP 1,323 Hp
(Source: Authors Personal Data)

Acid Plant Piping Selection

Table 1. 6 Specification of Pipes in Acid Plant
Pipe
Nominal Pipe
Size (in)
ID (in) OD (in) Length (ft)
Pipe for Water
Utility
3 3.068 3.5 100
Pipe for Water
Utility
2 1/2 2.469 2.88 100
Pipe for SO2 to
Converter
12 12.09 12.75 80
Pipe for O2 to
Converter
12 12.09 12.75 80
Pipe for SO3 to
absorber
12 12.09 12.75 100
(Source: Authors Personal Data)

Air Separation Plant Piping Selection

Table 1. 7 Specification of Pipes in Air Separation Plant
Pipe
Nominal Pipe
Size (in)
ID (in) OD (in) Length (ft)
Pipe for Air to
Hydroylone
12 12.09 312.75 80
Pipe for
Condensate
3 3.068 23.5 120
Pipe for Air to
Adsorber
12 12.09 12.75 60
Pipe for Air to
Adsorber
12 12.09 12.75 60
Pipe for N2 12 12.09 12.75 100
Pipe For O2 12 12.09 12.75 100
(Source: Authors Personal Data)
APPENDIX
A.7 Pump Calculation
The following are the steps performed in determining the design and sizing on each
pump:
1. Determine the type and materials used by the pump fluid properties
2. Calculate the pressure difference ( ) on the suction and discharge
3. Calculate the density of the flow at the pump

4. Calculate the total head at each pump

5. Determine the type of impeller used based on specific speed of each pump

()()
[()]

Figure A. 1 Impeller shapes related to specific speed
6. Determining pump power used

Below is just a calculation to pump J-401 that we display. For other pumps we
just attach Specification table for each pump based on the calculation that we have
done based on those steps above

J-101
1. Determining the type of pump and Material
The pump used is a type of centrifugal pumps and the material is stainless
steel
2. Calculation
14.2 psi
Mass Flow = 9.566 x 10
4
kg/h

Flowrate = 95.39 m
3
/h = 419.98 GPM

Efficiency = 75%
1800 rpm

()()
[()]

Figure A. 2 Impeller shapes related to specific speed
From Figure above, it can be seen thay type of impeller for this pump is the
Francis Vane.

Pump Horsepower

BHP = 4.638 hp

WHP = 3.479 hp

Figure A. 3 Pump J-101
(Source: Authors Personal Data)
Acid Plant Piping Selection
The materials of construction for piping are dependent on fluid flow velocities
and quality concerns. In general, seamless carbon steel piping is used for flow
velocities between 1-3 feet per second (fps). 316 SS is acceptable for flow velocities
of 0-8 fps. Alloy 20 works for flow velocities of 0-20 fps, and Teflon-lined pipe
works for all ranges of fluid velocity. If iron contamination is a concern for the
process, stay away from carbon steel. These recommendations assume ambient
temperatures. All metal piping should be welded per "ANSI B31.3 - Normal Service"
specifications. Screwed fittings are discouraged. PVC and CPVC piping is
recommended for vent/vapor lines only. They are not recommended for liquid service.
The "Rules of Thumb" for flow limitation when designing piping system at
ambient temperatures are:
Carbon Steel: 1-3 feet per second (fps)
304 and 304L stainless steel: 0-6 fps
316 and 316L stainless steel: 0-8 fps
Alloy 20: 0-20 fps
Teflon and Kynar lined: 0-50 fps
Based on the rules of thumb above we choose 304 and 304L stainless steel for piping
material.
Two shortcut rules have been derivied by Peters and Timmerhaus (1980) for
optimum diameters of steel pipes of 1-in size or greater, for turbulent and laminar
flow:

, turbulent flow

, laminar flow
a. Pipe for Water Utilty

()

()

()

()

From Appendix A5 (Stanley M. Walas,), we choose commercial steel pipe with
specification below:
Nominal Size = 3 in
Schedule Number = 40
Inside Diameter (ID) = 3.068 in
Outside Diam. (OD) = 3.5 in
Inside Sec. Area = 0.804 ft
2

Length = 100 ft

()

()

()

()

From Appendix A5 (Stanley M. Walas,), we choose commercial steel pipe with
specification below:
Nominal Size = 2 1/2 in
Schedule Number = 40
Inside Diameter (ID) = 2.469 in
Outside Diam. (OD) = 2.88 in
Inside Sec. Area = 0.647 ft
2

Length = 100 ft

b. Pipe for SO2 to Converter

()

()

()

()

From Appendix A5 (Stanley M. Walas,), we choose commercial steel pipe with
specification below:
Nominal Size = 12 in
Inside Diameter (ID) = 12.09 in
Outside Diam. (OD) = 12.75 in
Inside Sec. Area = 3.17 ft
2

Length = 100 ft

c. Pipe for O2 to Converter

()

()

()

()

From Appendix A5 (Stanley M. Walas,), we choose commercial steel pipe with
specification below:
d. Nominal Size = 12 in
e. Inside Diameter (ID) = 12.09 in
f. Outside Diam. (OD) = 12.75 in
g. Inside Sec. Area = 3.17 ft
2

h. Length = 80 ft

i. Pipe for SO3 to Absorber

()

()

()

()

From Appendix A5 (Stanley M. Walas,), we choose commercial steel pipe with
specification below:
Nominal Size = 12 in
Inside Diameter (ID) = 12.09 in
Outside Diam. (OD) = 12.75 in
Inside Sec. Area = 3.17 ft
2

Length = 100 ft

In general, piping is formally externally inspected visually every five years,
and ultrasonic thickness tested biennially. Again, actual plant experience may dictate
an increase or decrease in this schedule. Extra attention should be paid to elbows,
tees, valves and any other places in the piping where flow disturbances (and
erosion/corrosion) could occur. Use API 570, Class II piping standards for guidance.

Air Seperation Plant Piping Selection
The metals from which an ASU is manufactured have several requirements.
Carbon steel is used for most warm equipment and piping. The cryogenic portion of
the plant must be capable of withstanding temperatures down to 77K while still
being economic. Almost all parts of the ASU will see enriched oxygen, either during
normal operation or upsets. Copper, aluminum, and stainless steel are all good for the
cryogenic temperatures.

Table Piping Materials for Air Separation Unit
Carbon Steel Copper Alumunium Stainless Steel
Suitable for
Low Temps
N Y Y Y
Relative
Strength
2 4 3 1
Cost Low Very High Moderate High
Ignitability
with O2
Moderate N/A Low Low
Intensity of
Burning
Moderate N/A High Moderate
(Source : www. Gasin.com)

Notes:
(a) This is a relative measure of the strength of the materials, 1=highest, 4=lowest
(b) Difficulty of initiating combustion of the metal with O2
(c) Copper is not flammable in O2
The ignitability of any material is a function of the O2 purity, O2 pressure,
and material geometry. Ignitability generally increases with higher pressure, higher
purity, and thinner materials. Aluminum in particular is very sensitive to O2 purity,
with just fractions of percent impurities decreasing the ignitability very significantly.
A three-tier methodology is used to select a material for a given O2 service and to
minimize the risk to personnel:
If possible, all ignition sources are removed. Without ignition, the material cannot
combust. A good example of this is the careful cleaning of carbon steel pipe in
high pressure O2 pipelines. By eliminating the ignition source, carbon steel is an
acceptable material.
In some cases, it is not possible to remove all ignition sources. However, the
material may still be used safely, if it is used where the combustion will not
propagate. An example of this is aluminum pipe. Aluminum/O2 ignition is not
completely understood, so it is difficult to eliminate all ignition sources. However,
by only using aluminum pipe in services where propagation does not occur, it is
possible to safely use aluminum pipe, as the long history of safe service of
aluminum pipe has shown. (Note that when aluminum is used in O2 service, it is
cleaned to eliminate as many ignition sources as possible.)
Based on the considerations above we choose stainless steel as piping material in Air
Separation Unit.
Two shortcut rules have been derivied by Peters and Timmerhaus (1980) for optimum
diameters of steel pipes of 1-in size or greater, for turbulent and laminar flow:

, turbulent flow

, turbulent flow