Gas Energia

MONOGENERATION OF ELECTRICITY
ENERGY NATURAL GAS AS FUEL

KYB – ENTERGI – GAS PIPELINE ENGINEERING
ENERGY
MONOGENERATION
GAS PIPELINE ENGINEERING

MECHANICAL GUIDE
ELECTRIC MONOGENERATION OF
ELECTRICITY BASED ON 2 x 1.75 MW
CUMMINS ENGINES WITH NATURAL
GAS AS FUEL
SILAO, GUANAJUATO
DEVELOPED BY: TEKMANN

CUSTOMER: CUMMINS / ALESSO / ENTERGI / KYB
25 de Marzo de 2017
Índice: CUMMINS
Elaboró: Revisó: Sección:CO/TRIGENERACION Doc: HT_KYB_GAS Eng Rev: 0
KYB SILAO 2x1.75 MW Subíndice: KYB-SILAO – INGENIERIA Fecha: 25 MZO 2017
JDS GAS PIPELINE ENG r0 Rec: GAS NATURAL
G.Corona GASODUCTO INTERIOR Hoja: 1 de 20
INDEX
1.0 BACKGROUND
2.0 OBJECTIVES
3.0 BLOCK DIAGRAM
4.0 FLOW DIAGRAM
5.0 PIPE AND INSTRUMENTS DIAGRAM
6.0 CONTROL DIAGRAM
7.0 SAFETY LOGIC DIAGRAM
8.0 CALCULATION LOG
9.0 SCOPE OF WORKS TO DEVELOP THE GAS PIPELINE
APPENDIX
Índice: CUMMINS
1.0 BACKGROUND
1.1 Is of the highest interest of the customer to have a reliable and continuous electrical energy
supply, as their activities require such conditions.
1.2 Self-generation being constructed requires of Natural gas as fuel.
1.3 Gas supply to be contracted as a new pipeline with a new reducing, regulating and measuring
station (ERRM1), close to actual station and running directly to generation platform.
ACTUAL POWER ROOM PI
TI
PEAD VALVE
FUTURE POWER ROOM STUB END FLG
UNDERGROUND
PEAD PIPE 8 in
GAS SUPPLIER SCOPE
QUOTATION SCOPE
PI SAMPLER
STUB END FLG
TI
PEAD VALVE
NAT GAS 1 bar-g from ERRM1

8 NPS 106gB CED.40
1.4 This report is based on a similar pipe pressure (1 bar manometric) and running 250 meters
below natural ground on a PEAD pipe type RD-13.5, between two underground registers. All
pipelines over ground to be on carbon steel under SA-106 grB as required by code.
1.5 Desired power supply to be generating at least 4 MWe, at an efficiency of 38.3% shall mean
at least 10.4 MW in fuel.
Índice: CUMMINS
2.0 OBJECTIVE
Design a GAS PIPELINE to supply natural gas from devoted supplier station to electricity
generation system of 4 MW-e, 3 phases, 480 volts and 60 Hz, at KYB México site in Silao,
Guanajuato.
Design capacity should be 4 MWe with a gas velocity inside pipe of 15 m/s (maximum) and
1 bar manometric (gage).
3.0 BLOCK DIAGRAM
9 bar-g
GAS
PIPELINE
ACTUAL PROJECT
SUPPLY SUPPLY
1 bar-g 1 bar-g
ERRM-1
CS SPOOL
HDPE PIPE
CS SPOOL
PWR ROOM
Índice: CUMMINS
4.0 FLOW DIAGRAM
Drawing No. 102-0106 rev.A “GAS LINE FLOW DIAGRAM”
Índice: CUMMINS
5.0 PIPE AND INSTRUMENTS DIAGRAM
Drawing 102-0101 rev.A “P&ID DIAGRAM”
Índice: CUMMINS
6.0 CONTROL DIAGRAM

Drawing 102-0107 rev.A “GASLINE CONTROL LOGIC DIAGRAM”
PARAMETERS OF CONTROL: Flow rate, pressure and temperature are the parameters to control in a gas
flow
DEVICES: NO control devices are on the reach of gas pipeline, as control actions are taken by valve
trains specially built. The first train is under scope of gas supplier, so amount, pressure and temperature
of gas are set by gas supplier. Flow rate and pressure are controlled by valve gas train. No temperature
control is available as supply is always under conditions of gas supplier’s pipeline.
Índice: CUMMINS
7.0 SAFETY LOGIC DIAGRAM

Drawing 102-0108 rev.A “GASLINE SAFETY LOGIC DIAGRAM”
PARAMETERS FOR SAFETY: Automatic closing and opening are done by valves on gas train. Alarms are
also set by gas valve train.
DEVICES: NO control devices are on the reach of gas pipeline, as control and safety are taken by valve
trains specially built. The first train is under scope of gas supplier, so amount, pressure and temperature
of gas are set by gas supplier. Flow rate and pressure are controlled by valve gas train. No temperature
control is available as supply is always under conditions of gas supplier’s pipeline.
OPERATION CONDITIONS: Gas pipeline operation is under manual condition, meaning that operator
has to operate valves under certain conditions:
Opening valves: If engines are to be operated and all operating conditions are secure and confirmed
Closing valves: If any non-secure condition cannot be controlled.
Índice: CUMMINS
8.0 CALCULATION LOG

8.1 DESIGN CRITERIA
8.1.1 Pipeline has to supply natural gas in stable conditions so that engines operating
at 38.3% efficency can generate 4 MW of electricity.
8.1.2 Inlet pressure of pipeline has to be calculated at same pressure actual gas
pipeline operates: 1 bar manometric pressure and no more than 15 C of
temperature. Maximum pressure to be 4 bar.
8.1.3 All underground sections to be built with high density poliethylene pipe
8.1.4 All overground sections to be built with carbon Steel pipe
8.1.5 Pressure drop must be less than 10% considering all posible conditions
8.2 CAPACITY
1 GAS CONSUMPTION
1.1 ENGINES
C1750N6C Energy, kW Natural Gas
CANT CAP Fuel electr ef kg/h m3/h m3/h SCFH m3/h
100% 100% 100% Qm TPN STD STD 15c1747m
1 1,750 4,572 1,750 38.3% 346 434 459 16,204 557
2 3,500 9,144 3,500 38.3% 692 868 918 32,408 1,113
1.2 DESIGN CAPACITY

4 MWe
1.14 veces req x C1750
DESIGN Energy, kW Natural Gas

CAP Fuel electr ef kg/h m3/h m3/h SCFH m3/h
100% 100% 100% Qm TPN STD STD 15c1747m
4,000 10,450 4,000 38.3% 791 992 1,049 37,038 1,272
Índice: CUMMINS
8.3 NATURAL GAS CHARACTERISTICS

Natural Gas, LHV
rTPN TPN,g/L STD,g/L BTU/ft3 J/g Wh/g
0.60 0.7968 0.7539 962.8 47583 13.217
NOTES
1 Calculations are set under FAPPSA natural gas analysis
2 Composition supplied by ENTERGI is theoretical, as PEMEX has to supply
3 Comparison
%content CH4 C2H6 C3H8 C4H10+ S N2 CO2
ENTERGI 83 11 6 3 103
FAPPSA 88.6 8.2 0.7 0.3 NR 1.9 0.5 100.2
8.4 REGULATING VALVE AT GAS SUPPLIER STATION
2 REGULATING VALVE CAPACITY

2.1 ERRM1
FISHER
299H model
2 DN50 Conection, external registration
8.6 bar.g Pr.In
1 bar.g Pr.Out
red spring
0.5 in oriffice 0.75 in oriffice
36,050 SCFH Qv max 77,500 SCFH Qv max
1.11 times req x C1750

0.97 times req x DESIGN
2.2 ERRM2
NOT REQUIRED BY PRESSURE CONDITIONS
Índice: CUMMINS
2.3 ERRM3a/b
DUNGS One per engine, on each valve train
RS251/050/275 model
2 DN50 Conection, external registration
0.55/1.5 bar.g Pr.In
0.21/0.15 bar.g Pr.Out
ND spring
ND in oriffice
550/200 Sm3/h Qv max/min
8.5 HDPE PIPELINE
3 NATURAL GAS FLOW IN HDPE PIPE

Pressure higher than 1 psig: Mueller equation
1 DATA
0.8243 0.8243 0.8243 0.8243 a tm Site atmospheric pressure
15 15 15 15 C Gas temp at site
7.350 7.350 7.350 7.350 i n Inside diameter
14.22 14.22 14.22 14.22 ps i g Inlet pressure
14.13 13.92 13.6 13.19 ps i g Outlet pressure
0.09 0.30 0.62 1.03 ps i Pressure drop
99.4% 97.9% 95.6% 92.8% P.in / P.out
0.597 0.597 0.597 0.597 ga s /a i r Specific gravity
800 800 800 800 ft Equivalent legth
2 CALCULATIONS
4.8 9.6 14.5 19.4 MWe MWe at 38.3% efficiency
44,607 88,951 134,598 179,473 s cfh Max gas flow
1,263 2,519 3,811 5,082 m3/h Max gas flow
12.8 25.6 38.7 51.6 m/s Average velocity
0.623 0.623 0.623 0.623 kg/m3 Nat gas density at inlet conditions
786 1,568 2,373 3,164 kg/h Max gas flow
10,395 20,729 31,366 41,823 kW Energy flow
1.14 2.27 3.43 4.57 Times required energy by 2xC1750
0.99 1.98 3.00 4.00 Times 4 Mwe at average efficency
Índice: CUMMINS
8.6 Carbon Steel pipe (SA-106 grB Sch.40)
4 NATURAL GAS FLOW IN CARBON STEEL PIPE

Calculator: EngineeringToolbox
4.1 ERRM1: Natural gas supplier station
3 m Max length of pipe 3 m Max length of pipe 3 m Max length of pipe

1 in c.a. Drop pressure 2 in c.a. Drop pressure 4 in c.a. Drop pressure
0.04 psi 0.07 psi 0.14 psi
NPS OD,in wall th ID,in SCFHmax NPS OD,in wall th ID,in SCFHmax NPS OD,in wall th ID,in SCFHmax
3 3.5 0.216 3.068 15,875 3 3.5 0.216 3.068 22,451 3 3.5 0.216 3.068 31,750
4 4.5 0.237 4.026 33,205 4 4.5 0.237 4.026 46,959 4 4.5 0.237 4.026 66,410
6 6.625 0.28 6.065 98,530 6 6.625 0.28 6.065 139,342 6 6.625 0.28 6.065 197,059
8 8.625 0.322 7.981 200,580 8 8.625 0.322 7.981 283,663 8 8.625 0.322 7.981 401,161
Índice: CUMMINS
DROP PRESSURE CALCULATIONS
L eq 4 6 8
cod90 0.0 0.0 28.4
cod45 0.0 0.0 6.5
tee.l a t 0.0 9.1 0.0
va l v.bol a 2.0 0.0 0.0
reducc 4.1 0.0 0.0
6.1 9.1 35.0 m
L horiz 1.0 3.0 55.8 m
L total 7.1 12.1 90.8 m
23.3 39.8 297.7 ft
SUMMARY: DROP PRESSURE
44,607 88,951 134,598 179,473 scfh Ma x ga s fl ow

4.8 9.6 14.5 19.4 MWe MWe a t 38.3% effi ci ency
0.0004 0.0004 0.0004 0.0004 kg/cm2 hei ght di fferences
0.02 0.12 0.28 0.49 kg/cm2 due to fl ow
0.02 0.12 0.28 0.49 kg/cm2 Tota l drop Pr
Índice: CUMMINS
SELECTED PIPE DIMENSIONS
HDPE PIPE:
8 NPS
STEEL PIPE:
8 NPS FOR GENERAL FLOW,
6 NPS FOR INDIVIDUAL FLOW,
4 NPS FOR VALVE ARRANGEMENTS
Selected Pipe diameters will produce a pressure drop of 0.02 kg/cm2 at 4 MW rate, if used to feed 8
MW generation, drop pressure raises to 0.12 kg/cm2, still aceptable. But increasing flow will produce
severe pressure drop: 0.28 kg/cm2 at 6 MW generation rate and 0.49 kg/cm2 at 8 MW rate.
9.0 SCOPE OF WORKS TO DEVELOP THE GAS PIPELINE

9.1 Carbon Steel pipe (8 NPS, SA-106 grB Sch.40) from flange exiting ERRM No.1 to register No.1
at no more than 25 m from external Wall of ERRM No.1, includes a manual operation 4 in
flanged ball valve able to shutt off gas supply (CONBRACO 88 A-10 A-024 fire safe or
equivalent). A boudon type manometer (0-3.5 kg/cm2) and a bimetallic thermometer 0-50
C with 2 in SS well.
9.2 Register No.1. Built underground with 100 mm thick walls, 2000 mm (L) x 2000 mm (W) x
1500 mm (D), receiving metallic pipe and connecting via stub end flanges to PEAD (High
density polyethilene) type RD-13.5, with yellow strips, 8 in diameter, that will carry natural
gas to site. Sample gas valve and venting valve are required.
9.3 HDPE pipe, 8 in diameter, for approximately 250 m length underground, 1 m below actual
soil level, run at side of existing water channel up to register No.2. Includes 2 poliethilene
gas valves, one at each end of pipe.
9.4 Register No.2. Built underground with 100 mm thick walls, 2000 mm (L) x 2000 mm (W) x
1500 mm (D), exiting metallic pipe and connecting via stub end flanges to PEAD (High density
polyethilene) type RD-13.5, with yellow strips, 8 in diameter, that will carry natural gas to
site. Sample gas valve and venting valve are required.
Índice: CUMMINS
9.5 Pipe spools from register No.2 to Power room under construction, with a tee and valve to
supply future Power Room, similar in capacity of actual. Built with SA-106grB Sch.40 pipe,
fittings SA-234 WPB Sch.40 and flanges SA-105. Spool climbs from register to center of Street
between Pwr room No.1 and No.2, at 1150 mm above soil, goes to a tee looking upward to
climb control room (future connections), runs to a straight tee looking horizontal with
manual shutt off valves, one to supply power room No.1, ball valves to be certified to handle
natural gas (CONBRACO 88 A-10 A-024 fire safe), as they should serve as manual shutt off
valves in case of emergency. A bourdon type manometer and a thermometer is also
required.
9.6 For better understanding please see drawings 102-0101 to 102-0112 at appendix.
Índice: CUMMINS
9.7 QUALITY PROGRAM
UNID VERIFICACION ORIGIN CERTIFICATES DIMENSION REPORT

ENGINEERING REVIEW
PURCHASING NOTIFICATION NOTIFICATION N/A
COMPONENTS
NOTIFICATION NOTIFICATION NOTIFICATION
ARRIVAL TO SITE
WELDING HDPE CERTIFICATION N/A NOTIFICATION
WELDING CS PIPE CERTIFICATION N/A NOTIFICATION
PRESSURE TESTING VINCULATED N/A N/A
TRENCH FILLING SOIL TESTING-NOTIFI N/A NOTIFICATION
PRESSURE TESTING VINCULATED N/A NOTIFICATION
PAINTING NOTIFICATION NOTIFICATION NOTIFICATION
DELIVERY VINCULATED
NOTE: NOTIFICATION means only notifying is required,

CERTIFICATION means welders are to be certified
VINCULATED means actions are to be witnessed
9.8 INSTRUMENTS LIST
QTY INSTRUMENT DIAMETERS MATERIALS

Manometer boudon type, 0-3.5 ½ NPT lower Bourdon: bronze
2 kg/cm2 range, with bronze ball connection, 4.5 in Box: stainless Steel
valve to connect process diameter dial
Thermometer bimetallic type, ½ NPT with SS well
2 mínimum 2 in long for sensing ½ NPT, 4 in dial Case: stainless steel
element, 0-50 C range diameter
½ NPT ball valve
with close position
2 Sampling port Bronze
locking device and
plug
6 Thredolets ½x8 SA-105
Índice: CUMMINS
9.9 PIPE AND FITTINGS LIST
Flange connecting to ERRM No.1 is to be specified when valve gas train of gas supplier information is
available or at arrival of equipment.
QTY ELEMENT DIAMETER MATERIALS

56 m CS pipe 8 NPS SA-106grB, Schedule 40
3m CS pipe 6 NPS SA-106grB, Schedule 40
2 Flanges Stub end type, ANSI-150 8 NPS SA-105
6 Flanges WNRF type, ANSI-150 4 NPS SA-105
2 Flanges BLIND type, ANSI-150 4 NPS SA-105
5 Elbow 90 deg, LR, BW 8 NPS SA-234-WPB, Sch 40
1 Elbow 45 deg, LR, BW 8 NPS SA-234-WPB, Sch 40
2 Straight Tee, BW 8 NPS SA-234-WPB, Sch 40
1 Concentric reduction 8x4, BW 4 NPS SA-234-WPB, Sch 40
2 Eccentric reduction 8x4, BW 8 NPS SA-234-WPB, Sch 40
1 Eccentric reduction 8x6, BW 8 NPS SA-234-WPB, Sch 40
4 Ball valve fire safe, UL listed for nat.gas 4 NPS CS
QTY ELEMENT DIAMETER MATERIALS

250 m HDPE pipe 8 NPS HDPE RD 13.5
2 Flanges and inserts, ANSI-150 8 NPS HDPE
2 Gas ball valves, 100 psig 8 NPS HDPE
9.10 CONSTRUCTION PARTS
9.10.1 Registers No.1 and No.2

9.10.1.1 Walls and floor to be concrete unitary poured, at least with f’c = 150
kg/cm2, polypropilene fiber added, Steel covers to pour, 100 mm
thick, Steel reinforcement with 6x6 8/8 mesh.
9.10.1.2 Registers must have a concrete or carbon Steel corrosión protected
removable cover to service them when required
9.10.1.3 Supports to be in CS A36 or similar
9.10.1.4 A three cooper bar delta must be installed in each register and all
pipes to be connected so that no electric charges can accumulate.
9.10.1.5 Inside walls to be painted RAL 9002 or similar, protected with
polyurethane film
9.10.1.6 HDPE pipe must be properly secured to walls with protection against
any damage with elastomeric joints.
Índice: CUMMINS
APPENDIX
1. Cad drawings 100% compatible with AutoCad®
a. 13 Drawings, numbers 102-0101 rev.A to 102-0112 rev.A

b. Delivered in printed versión and Cad electronic copy
2. Technical sheet for Conbraco gas valves
3. Technical sheet for Fisher regulating valve
Índice: CUMMINS
Índice: CUMMINS
Índice: CUMMINS

Gas Energia

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MONOGENERATION OF ELECTRICITY

ENERGY NATURAL GAS AS FUEL

GAS PIPELINE ENGINEERING

DEVELOPED BY: TEKMANN

ACTUAL POWER ROOM PI

FUTURE POWER ROOM STUB END FLG

NAT GAS 1 bar-g from ERRM1

3.0 BLOCK DIAGRAM

4.0 FLOW DIAGRAM

Drawing No. 102-0106 rev.A “GAS LINE FLOW DIAGRAM”

5.0 PIPE AND INSTRUMENTS DIAGRAM

Drawing 102-0101 rev.A “P&ID DIAGRAM”

6.0 CONTROL DIAGRAM

7.0 SAFETY LOGIC DIAGRAM

Closing valves: If any non-secure condition cannot be controlled.

8.0 CALCULATION LOG

8.1.4 All overground sections to be built with carbon Steel pipe

1.2 DESIGN CAPACITY

DESIGN Energy, kW Natural Gas

8.3 NATURAL GAS CHARACTERISTICS

8.4 REGULATING VALVE AT GAS SUPPLIER STATION

2 REGULATING VALVE CAPACITY

1.11 times req x C1750

8.5 HDPE PIPELINE

3 NATURAL GAS FLOW IN HDPE PIPE

8.6 Carbon Steel pipe (SA-106 grB Sch.40)

4 NATURAL GAS FLOW IN CARBON STEEL PIPE

4.1 ERRM1: Natural gas supplier station

3 m Max length of pipe 3 m Max length of pipe 3 m Max length of pipe

DROP PRESSURE CALCULATIONS

SUMMARY: DROP PRESSURE

44,607 88,951 134,598 179,473 scfh Ma x ga s fl ow

SELECTED PIPE DIMENSIONS

9.0 SCOPE OF WORKS TO DEVELOP THE GAS PIPELINE

9.7 QUALITY PROGRAM

UNID VERIFICACION ORIGIN CERTIFICATES DIMENSION REPORT

NOTE: NOTIFICATION means only notifying is required,

9.8 INSTRUMENTS LIST

QTY INSTRUMENT DIAMETERS MATERIALS

9.9 PIPE AND FITTINGS LIST

QTY ELEMENT DIAMETER MATERIALS

QTY ELEMENT DIAMETER MATERIALS

9.10 CONSTRUCTION PARTS

9.10.1 Registers No.1 and No.2

a. 13 Drawings, numbers 102-0101 rev.A to 102-0112 rev.A

2. Technical sheet for Conbraco gas valves

3. Technical sheet for Fisher regulating valve

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