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Steam Generator Units, MPU and SPU Type

TECHNICAL SPECIFICATION

Scope of Supply

The Supplier shall design, manufacture, test, inspect and supply complete Steam Generator Units of MPU and SPU Type, suitable for mobile and field applications in oil & gas production operations.

The Steam Generator Unit shall be supplied as a complete packaged system, including all equipment and accessories necessary for safe, reliable and continuous steam generation.

The scope shall include, as a minimum:

Steam generator/boiler
Combustion chamber
Burner system
Fuel gas/diesel fuel system
Feedwater pump
Feedwater treatment system, where required
Water storage/feed tank
Steam separator
Safety valves
Pressure control system
Temperature and pressure instrumentation
Burner management system
Automatic control system
Local control panel
Fuel train
Feedwater piping
Steam outlet piping
Blowdown system
Drain system
Flue gas stack/chimney
Skid or trailer-mounted structure
Lifting and transportation facilities
Insulation and cladding
Safety devices
Required spare parts and special tools

Equipment Description

The Steam Generator shall be designed to generate saturated steam continuously using natural gas, associated gas, diesel or another approved fuel.

The unit shall be suitable for operation at remote oil and gas production sites and shall be designed for rapid mobilization and installation.

MPU Type

The MPU Type shall be a mobile steam generation package designed for transportation between well sites and field facilities.

The unit shall be mounted on a suitable skid, trailer or mobile platform and shall be capable of independent operation with minimum site preparation.

SPU Type

The SPU Type shall be a skid-mounted steam generation package designed for continuous field operation and shall include all major systems required for steam generation, combustion, feedwater supply and steam distribution.

Main Performance Requirements

The Supplier shall complete the following datasheet for each proposed unit.

Parameter	MPU Type	SPU Type
Steam Generation Capacity	To be specified	To be specified
Steam Type	Saturated	Saturated
Steam Pressure	To be specified	To be specified
Steam Temperature	To be specified	To be specified
Feedwater Temperature	To be specified	To be specified
Thermal Efficiency	≥80% preferred	≥80% preferred
Fuel	Natural Gas / Diesel	Natural Gas / Diesel
Fuel Consumption	Vendor to specify	Vendor to specify
Operating Mode	Continuous	Continuous
Installation	Mobile	Skid Mounted
Start-up Time	Vendor to specify	Vendor to specify
Design Life	≥20 years	≥20 years

Steam Generator

The steam generator shall:

Be designed for continuous steam production.
Be suitable for the specified operating pressure.
Provide stable steam generation under varying load conditions.
Have adequate steam-water separation.
Prevent carry-over of water into the steam outlet.
Be equipped with suitable safety relief devices.
Be designed for safe inspection and maintenance.

The Supplier shall provide complete thermal and mechanical design calculations.

Boiler / Pressure Vessel The pressure-containing components shall be designed and manufactured in accordance with applicable pressure-vessel/boiler codes. The design shall consider: Design pressure Operating pressure Design temperature Operating temperature Thermal cycling Corrosion allowance Fatigue where applicable Water chemistry Hydrostatic test pressure Suitable corrosion allowance shall be provided based on the feedwater quality and expected service conditions.

Burner and Combustion System The burner shall be designed for reliable operation with the specified fuel. The combustion system shall include: Main burner Ignition system Flame detector Fuel control valve Fuel pressure regulator Safety shut-off valves Fuel filter Pressure gauges/transmitters Combustion air system Burner management system The burner shall provide automatic ignition and flame monitoring. Automatic fuel shut-off shall occur in the event of: Flame failure Low fuel pressure High fuel pressure Low water level High steam pressure High furnace temperature Emergency shutdown

Fuel System The unit shall be capable of operation with: Natural gas Associated gas Diesel fuel, if specified The Supplier shall state: Minimum fuel pressure Maximum fuel pressure Fuel consumption at 25%, 50%, 75% and 100% load Minimum calorific value Maximum allowable CO₂ Maximum allowable H₂S Maximum allowable water content Maximum allowable particulate/contaminant content A complete fuel gas train shall be supplied.

Feedwater System The feedwater system shall include: Feedwater tank Feedwater pump(s) Pump suction/discharge piping Check valves Isolation valves Level instrumentation Pressure instrumentation Water treatment system, where required Chemical dosing system, where required The feedwater pump shall have sufficient capacity to supply the steam generator at maximum continuous rating. Where required, one operating + one standby feedwater pump configuration shall be provided.

Water Treatment The Supplier shall specify the required feedwater quality. As a minimum, the Supplier shall define requirements for: pH Hardness Conductivity Chlorides Dissolved oxygen Total dissolved solids Silica Oil contamination The Supplier shall provide recommendations for: Water softening Demineralization Chemical dosing Oxygen scavenging Blowdown control

Steam System The steam outlet shall be equipped with: Steam isolation valve Steam pressure gauge Steam pressure transmitter Temperature indicator Safety relief valve Steam flowmeter, where required Drain connection Sampling connection The steam outlet shall be designed to deliver stable saturated steam at the specified pressure.

Design Codes and Standards The Steam Generator shall comply with applicable international standards and codes, including: ASME BPVC Section I – Rules for Construction of Power Boilers ASME BPVC Section VIII, where applicable ASME B31.3 – Process Piping API 520 / API 521 – Pressure Relief IEC 60079 series – Explosive Atmospheres IEC 60529 – IP Protection ISO 9001 – Quality Management System Applicable EN / DIN / GOST standards Local pressure equipment and boiler regulations The Supplier shall clearly identify the applicable code edition used for design and manufacturing.