Station 130 (Maple) Compressor Upgrade Project

Transcription

1 Station 130 (Maple) Compressor Upgrade Project Application August 2012 Supplied to: The Secretary National Energy Board 444 7th Avenue SW Calgary, Alberta T2P 0X8

2 TransCanada Pipelines Limited APPENDIX E1 ENGINEERING AND TECHNICAL DESCRIPTION

3 Page 1 of PROJECT OVERVIEW This Project involves the relocation, refurbishment and installation of two Solar Mars 100 C65 turbo-compressor packages at the existing Maple compressor station (Station 130). The two units will be designated as Unit B1 and B2, and will be permanent units that operate in parallel with the existing European gas turbine Tornado unit, which is currently designated as Unit P. The A plant s reciprocating compressor units currently located at the station are not expected to operate regularly in parallel with the new plant, and are scheduled for deactivation by the end of PRINCIPAL COMPONENTS OF PROJECT The main components of the Project are: one new steel frame compressor building designed to house both Solar Mars 100 turbo compressor packages a skid-mounted control building to contain the motor control centre, station control panel and the uninterruptible power supply a skid-mounted utility building to house the air compressors, air dryers, air bottles and a glycol heating system a skid-mounted auxiliary power unit (APU) building along with an auxiliary generator unit a skid-mounted building used to house the station control panel, supervisory control and data acquisition system and general office space a single dry-type, pad-mounted step-down transformer for the primary incoming electrical feed yard piping, primarily consisting of NPS 42 Grade 483 MPa submerged arc welded (SAW) pipe with a wall thickness of 16 mm Appendix E-2 is a plot plan showing the location of the new components at Station 130. The compressor unit building in the yard, designated as Unit B, is shown as Item 11 on the plot plan. The utility building is labeled as Item 12. The APU building is labeled as Item 13 and the control building is labeled as Item 14. Also depicted on the plot plan are the suction scrubber, the discharge lines leading to the station blowdown, and the station relief lines. 2.1 Relocated Equipment The Project includes the reuse of driver skids from two Solar 90 Mars turbo compressor packages from other TransCanada compressor station sites. These driver skids will be mated to a new C65-2 natural gas compressor. The skids will be

4 Page 2 of 10 completed, refurbished and updated by Solar Turbines to include new dry low emissions controls technology. 3. STANDARDS AND SPECIFICATIONS Name The proposed compressor station unit additions will be designed, constructed and tested in accordance with the provisions of the Onshore Pipelines Regulations, 1999, TransCanada s specifications and the following standards: CSA Z662-11, Oil and Gas Pipelines ASME B , Process Piping CSA Z , Steel Line Pipe CSA Z , Steel Fittings CSA Z , Steel Valves CSA C22.1 Electrical Code, Part 1, Safety Standards for Electrical Installations CSA C22.2 No- 0-M91, General Requirements Canadian Electrical Code, Part II 2007 ASME Boiler and Pressure Vessel Code, Section VIII, Division 1: Pressure Vessels National Building Codes of Canada (2005) and Ontario Building Code (2012) Table 3-1 provides a preliminary list of the TransCanada standards and specifications that will be used for this Project. A final list of applicable standards and specifications will evolve as project planning progresses through detailed design and as individual specifications and procedures are added, updated or replaced to incorporate legislative and regulatory changes, and technological advances. Table 3-1: Preliminary List of TransCanada Standards and Specifications TES-MATL-MD1 Piping System Materials for Pipeline, Compression and Metering Facilities TES-MATL-PV1 Specification for Pressure Vessels TES-FLGE-LD Specification for Carbon Steel Buttwelding Flanges TES-FITG-LD Specification for Carbon Steel Buttwelding Fittings, Grade 290 and Higher EDMS No. Effective Date Rev No. Content Name Dec-02 0 Pipe Apr Pressure Vessel Nov Flange Dec Fitting TES-FITG-EC1 Specification for End Closures Apr Fitting TES-FITG-CIF Specification for Contoured Mar Fitting Insert Fittings (Cdn-US)

5 Page 3 of 10 Name Table 3-1: Preliminary List of TransCanada Standards and Specifications EDMS No. Effective Date Rev No. Content Name TES-FITG-T01 Instrument Tube Fitting, Apr Fitting Instrument Pipe Fitting and Tubing Material Specification TES-PIPE-SAW Specification for Double Sep Pipe Submerged Arc Welded Pipe TES-VALV-LD Specification for Steel Valves Oct Valve TES-VOPR-GH Gas Hydraulic Valve Operator Specification TES-HYDRO-HT1 Primary Test Specs for Hydrostatic Testing New Buried, Pipelines, Compressor Station & Meter Station Piping TES-HYDRO-HT2 Secondary Test Specs for Fully Exposed Pipe, Valves & Piping Assemblies (Hydrostatic or N2 Testing) TES-HYDRO-HTS Hydrostatic Testing Specification TES-WELD-AS Welding of Assemblies and Station Piping TES-NDT-RT Radiographic Examination of Pipeline and Facilities Welds (Cdn) TES-CP-MS Cathodic Protection Materials Specification (Cdn-US) TES-COAT-FBE External Fusion Bond Epoxy for Steel Pipe (Cdn-US) TES-COAT-P1 Paint Systems for Above Ground Facilities (Non-Coastal) (Cdn-US- Mex) Nov-99 0 High Pressure System May Hydrotesting May Hydrotesting May Hydrotesting Apr Joint, Weld Mar Joint, Weld Oct Cathodic Protection Jan Coating, Protection Oct Coating, Protection TES-PROJ-EXC Excavation Specification Jan Excavation TES-DV Excavating, Backfilling and Dec-09 0 Excavation Site Grading

6 Page 4 of FILING MANUAL GUIDANCE 4.1 Compression Table 4-1 provides information identified in the Filing Manual guidance for compression facilities. Table 4-1: Filing Manual Guidance for Compression Filing Guidance Type and power of pumps/compressors Fuel type and source of pumps/compressors MOP, inlet and outlet design pressures Inlet and outlet temperature Station schematic of buildings, relief valves Project Information Two Solar Mars 100 C65 turbo-compressor packages consisting of a Solar Mars T15000S SoLoNox engine (nominal ISO at 11.9 MW) and Solar C65-2 centrifugal compressor. The compressor package employs an aero-derivative gas turbine prime mover, which runs on pipeline quality natural gas. The natural gas is taken from the suction piping and is then filtered and regulated prior to injection into the combustors of the gas turbine. The station operating MOP is 6450 kpag. Inlet and outlet piping is designed to operate at 7240 kpag. Inlet and outlet design temperature -45C to +75C. The compressor building will be designed to withstand loads as defined by the Ontario Building Codes, National Building Code, the Project service loads, and applicable climatic conditions for the area. The compressor building will be a free-standing steel rigid-frame structure, supported by reinforced concrete grade beams and piles and completed with acoustically designed walls and roof. All auxiliary buildings are skid mounted and will be supported on steel driven piles. The buildings are complete with heating and ventilation equipment. The discharge relief valve/blow off valve will be sized for maximum rated flow rate from the compressor at a relief pressure as prescribed by TransCanada s Operating Procedure for Compressor Station Pressure Limits and Settings for the Canadian Mainline System. The design relief set pressure is 6720 kpag. Basic description of surge control system, pressure control and overpressure control Similarly, the suction relief valve/blow off valve will be sized in the same manner and the set pressure will also be 6720 kpag. The recycle (anti-surge) valve is connected downstream of the compressor nozzle and upstream of the compressor discharge valve. The surge control valve is controlled by the unit Program Logic Controller (PLC) so as to ensure sufficient flow is available through the compressor at all times. Under conditions of extremely high head and low flow, the surge valve will open, permitting gas to circle back into the compressor through the recycle piping. The unit PLC will ensure that the anti surge valve will not close the unit valve until the

7 Page 5 of 10 Table 4-1: Filing Manual Guidance for Compression Filing Guidance Project Information compressor has come to a complete stop. Unit discharge pressure is controlled by the unit PLC which provides suitable commands to the compressor package to either slow or shut down the compressor when high pressures are encountered. The maximum set point of the discharge pressure controller is the MOP of 6450 kpag. Basic description of emergency shutdown Description of boilers and pressure vessels System overpressure control is provided by a pressure limiting system and a pressure relieving system. The pressure limiting system consists of a Step-To-Idle (STI) control function to slow down the compressor or a high pressure shut down (HPSD) control setting to shut down the compressor when the discharge pressure reaches 6585 kpag. The pressure relieving system consists of the suction and discharge pressure relief valve/blow off valves. Each relief valve/blow off valve is designed to ensure that the piping pressure will not exceed 6720 kpag under any condition. An emergency shutdown (ESD) pushbutton will be installed at all personnel doors in the compressor building and near the scrubber. Perimeter ESD pushbuttons will be added to all new gates and tied into existing fence ESD. New site ESD pushbutton will be added to the control panel in the relocated control building. ESD pushbuttons will trigger a station ESD. Fire and/or gas detection in new compressor building will also trigger a station ESD. Fire detection in the auxiliary buildings will cause an alarm. The suction scrubber will be designed to handle the design flow. Automatic liquid level control will be performed by the station PLC by actuating pneumatic operated control valves that will drain the scrubber liquids to an aboveground storage tank via an above ground cyclone separator. A local pneumatic (natural gas) supply will be used to provide power gas to the liquid level valves. The scrubber will have a pressure differential gauge, pressure gauge, suction temperature RTD and thermowell. Boilers enclosed in the mechanical skid are expected as part of the glycol heating system for the units. Description of corrosion control elements All new pressure vessels will be built to TransCanada s specification for pressure vessels TES-MATL-PV1 Specification for Pressure Vessels. Active cathodic protection (CP) will be incorporated, as appropriate.

8 Page 6 of Pipe Table 4-2 provides information identified in the Filing Manual guidance for pipe. Table 4-2: Filing Manual Guidance for Yard Piping Additions Filing Guidance High-pressure pipe - outside diameter (OD) Pipe wall thickness (WT) and grade Maximum operating pressure Length Location Burial depth 1067 mm (NPS 42) Project Information Suction and discharge high 16.0 mm WT Grade 483 pressure pipe (NPS 42) Yard Piping (NPS 30) 16.4 mm WT Grade 483 Yard Piping (NPS 24) 9.2 mm WT Grade 483 Yard Piping (NPS 20) 8.2 mm WT Grade 448 Inlet and outlet piping is designed to operate at 7240 kpag. Approximately 250 m of NPS 42, 250 m of NPS 30, 110 m of NPS 24, and 90 m of NPS N and W (approximately 1 km northwest of Vaughan, Ontario) 1.2 m The minimum depth of cover will also comply with all applicable federal, provincial, territorial, municipal and county regulations. Coatings Product carried Description of corrosion control elements External coating fusion bond epoxy (FBE) The proposed facilities will transport sweet natural gas, which meets TransCanada s gas quality specifications, as outlined in the TransCanada tariff. Both aboveground and belowground piping will be coated. Belowground piping will be coated with FBE as per TransCanada s specification TES-COAT-FBE External Fusion Bond Epoxy for Steel Pipe (Cdn-US). Aboveground piping will be coated with paint as per TES-COAT-P1 Paint Systems for Above Ground Facilities (Non-Coastal) (Cdn-Us- Mex). Crossings CP will be provided either by existing TransCanada facilities or the installation of new CP facilities. The requirement for additional CP facilities will be determined during detailed design. A postconstruction CP survey will be conducted to confirm the operation of the CP system and modifications will be made, if necessary. Not applicable.

9 Page 7 of CAPABILITY IMPACT OF THE PROPOSED FACILITIES Table 5-1 provides capability versus requirements information for TransCanada s design season (i.e., peak winter day with loss of critical unit). This table shows that with the new firm contractual requirements of 130,107 GJ/d and without the proposed facilities, system capability would be short by 152 TJ/d. Figures 5-1 and 5-2 are capability flow schematics for the same two conditions, i.e., without and with the proposed facilities. When reading the values on Figure 5-1 and 5-2, note that: The Flow into Station 130 differs from the addition of Barrie Start and Montreal Line Start by the fuel amount listed in the compressor tables at the bottom of each schematic. The Parkway Receipts differs from the Flow into Station 130 by the amount of deliveries at Parkway and between the two points. This value is shown as Parkway to Maple Deliveries. When comparing capability values between Figures 5-1 and 5-2, note the following changes to TransCanada s design since its 2012 Eastern Mainline Expansion application (NEB Filing ID A35884). the installation of the applied for facilities the deactivation of the Station 130 A plant reduces the available power shown in the with facilities schematic the increase in the transient pressure buffer at Parkway by 125 kpa as a result of the impact of the unit additions on transient gas flows in the area the capability shortfall without the proposed facilities (152 TJ/d) is greater than the new contracts (130 TJ/d) because of gas temperature increases at the Parkway receipt point the capability shortfall resulting from the gas temperature increase is also overcome by adding the proposed facilities

10 Page 8 of 10 Table 5-1: Capabilities versus Requirements Ontario Triangle (Peak Winter 2013/2014) Peak Winter Contracts Loss of Unit Without With Proposed Facilities (TJ/d) Proposed Facilities (TJ/d) Ontario Triangle Requirements 1. North Bay Short Cut Deliveries Montreal Line Deliveries Barrie Line Deliveries Trans Quebec & Maritimes Deliveries Niagara Line Deliveries Compressor fuel Total Delivery Requirements (1 through 6) Supply Requirements 8. Northern Ontario Line Supply Parkway Requirement (7-8) Parkway Capability 10. Parkway Supply Capability Excess from Parkway 11. Parkway Supply Excess (10-9)

11 Page 9 of 10 Figure 5-1: Capability Schematic (Without Proposed Facilities) To Stn To Stn 136 Barrie Start 24, m 3 /d 917,423 GJ/d Flow into Station , m 3 /d Montreal Line Start 1,928,594 GJ/d 26, m 3 /d 1,009,713 GJ/d Flow Bypassing Stn , m 3 /d Parkway to Maple Deliveries 1,143,439 GJ/d 8, m 3 /d 329,141 GJ/d Parkway Parkway Receipts 59, m 3 /d 2,257,735 GJ/d 6125 kpa From Union Gas To Niagara Domestic m 3 /d 0GJ/d Compressor Station Data in 10 6 m 3 T /d STN MWA MWR P Suc P Dis Ratio Fuel Flow TS/TD 7/22 21/36 7/42 Station 130 Flow Schematic System Capability Peak Winter Day LOU without Facilities Operating Year: 2013/ Page 1/1

12 Page 10 of 10 Figure 5-2: Capability Schematic (With Proposed Facilities) To Stn To Stn 136 Barrie Start 29, m 3 /d 1,126,370 GJ/d Flow into Station , m 3 /d Montreal Line Start 2,089,850 GJ/d 25, m 3 /d 957,424 GJ/d Parkway to Maple Deliveries 8, m 3 /d 329,140 GJ/d Parkway Parkway Receipts 64, m 3 /d 2,418,990 GJ/d 6000 kpa From Union Gas To Niagara Domestic m 3 /d 0GJ/d B Compressor Station Data in 10 6 m 3 T /d STN MWA MWR P Suc P Dis Ratio Fuel Flow TS/TD 13/25 19/38 10/45 Station 130 Flow Schematic System Capability Peak Winter Day LOU with Facilities Operating Year: 2013/ Page 1/1

13 TransCanada Pipelines Limited Appendix E2 Plot Plan Page 1 of 1