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8/10/2019 DHG PVE DD 3 ME SPC 007_Spec for Gas Engine Screw Compressor Package
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PETROVIETNAM DOMESTIC EXPLORATIONPRODUCTION OPERATINGCOMPANY LIMITED
PROJECT DAI HUNG GAS GATHERING PROJECT
PHASE DETAILED ENGINEERING DESIGN
SPECIFICATION FOR GAS ENGINESCREW COMPRESSOR PACKAGE
A 23/05/14 Issued for Review
Rev. Date Description PVEVSP
ApprovalPVEP POCApproval
CAApproval
EpCI CONTRACTOR
(VIETSOVPETRO JOINT VENTURE)
Document Number:
DHG-PVE-DD-3-ME-SPC-007
Number of pages: 61
(including the cover page)
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PROJECT DAI HUNG GAS GATHERING PROJECT
PHASE DETAILED ENGINEERING DESIGN
SPECIFICATION FOR GAS ENGINE
SCREW COMPRESSOR PACKAGE
A 23/05/14Issued for
ReviewN.T.K.Ngoc V.T.Quan D.T.Dung V.V.Hung
Rev. Date Description
Prepared
by
Checked
by EM PM Discipline
Team
Leader SPMB
Sub-Contractor EpCI Contractor
EpCI CONTRACTOR(VIETSOVPETRO JOINT VENTURE)
PV ENGINEERING J.S.C
Document Number:
DHG-PVE-DD-3-ME-SPC-007
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REVISION LOG
Date
Revision
No. Section Revision Description
23/05/14 A All Issued For Review
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TABLE OF CONTENTS
1.
INTRODUCTION ...................................................................................... 9
1.1
Project Overview ..................................................................................... 9
1.2
Purpose of Document ............................................................................ 10
1.3 Definitions and Abbreviations ................................................................. 10
1.3.1 Definitions ................................................................................. 10
1.3.2
Abbreviations ............................................................................ 11
1.4 Codes and Standards ............................................................................. 12
1.5 References ........................................................................................... 14
2.
GENERAL REQUIREMENTS ..................................................................... 14
2.1 CONTRACTORS Responsibility ................................................................ 14
2.2
Operation and Design Life ...................................................................... 15
2.3
CONTRACTORs Exceptions .................................................................... 15
2.4 Weight Control ...................................................................................... 16
3. LOCATION AND ENVIRONMENTAL CONDITIONS ..................................... 16
4. UTILITY DATA ...................................................................................... 17
4.1
Electrical ............................................................................................... 17
4.2
Instrument air: ...................................................................................... 17
4.3 Fuel gas ............................................................................................... 17
4.4 Units .................................................................................................... 18
5.
SCOPE OF WORK & SUPPLY ................................................................... 18
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6. DESIGN REQUIREMENTS ....................................................................... 21
7.
ENGINE AND AUXILIARIES ..................................................................... 21
7.1 General ................................................................................................ 21
7.2
Intake Air System .................................................................................. 22
7.3
Starting System ..................................................................................... 23
7.3.1 Electric Starting System .............................................................. 23
7.3.2
Hydraulic Starting System ........................................................... 24
7.4
Fuel Gas Treatment Package .................................................................. 25
7.5 Lubrication System ................................................................................ 25
7.6 Cooling System ..................................................................................... 27
7.7
Governor .............................................................................................. 27
7.8 Engine Exhaust System .......................................................................... 28
7.9
Insulation ............................................................................................. 29
7.10 Engine Shutdown Devices ...................................................................... 29
7.11 Engine Instruments Panel ...................................................................... 29
7.12 Ignition System ..................................................................................... 30
7.13 Over-speed Protection ........................................................................... 31
7.14
Torsional Vibration ................................................................................ 31
7.15
Lateral Vibration and Vibration Suppression ............................................. 31
7.16
Shaft Couplings and Guards ................................................................... 32
7.17
Crankcase Explosion Relief ..................................................................... 32
7.18 Miscellaneous Requirements ................................................................... 32
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8. GAS COMPRESSOR ................................................................................ 33
8.1
General ................................................................................................ 33
8.2 Compressor Performance ....................................................................... 34
8.3 Compressor Construction ....................................................................... 35
8.3.1
Materials of Construction ............................................................ 35
8.3.2
Bearings ................................................................................... 35
8.3.3 Compressor Rotor ...................................................................... 35
8.3.4
Coupling and Guard ................................................................... 35
8.3.5
Casing ...................................................................................... 36
8.3.6
Shaft seals ................................................................................ 36
8.3.7
Miscellaneous ............................................................................ 36
8.4 Auxiliary Systems .................................................................................. 37
8.4.1
Cooling Systems ........................................................................ 37
8.4.2
Lubrication System .................................................................... 38
8.4.3 Gas Scrubbing and Filtration ....................................................... 39
8.5 Pulsation, Vibration Control and Analog Study .......................................... 41
9.
TECHNICAL REQUIREMENTS FOR ELECTRICAL ........................................ 41
10.
TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL .... 43
10.1
General Instrumentation Requirements ................................................... 43
10.2 General Control Requirements ................................................................ 44
10.3 Unit Control Panel (UCP) ........................................................................ 44
10.4
Interface with Platform PCS/SSD/FGS System .......................................... 48
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10.4.1 PCS ........................................................................................ 48
10.4.2 SSD ........................................................................................ 48
10.4.3 FGS ........................................................................................ 48
10.5 Vibration Monitoring .............................................................................. 49
10.6 Bearing Temperature Monitoring System ................................................. 49
11.
PIPING ................................................................................................. 50
11.1
Valves .................................................................................................. 50
11.2
Piping and Accessories ........................................................................... 51
11.3
Welding and Weld Repairs ..................................................................... 51
12. UTILITIES & TIE-INS ............................................................................. 52
12.1 Utilities ................................................................................................. 52
12.2 Tie-Ins ................................................................................................. 52
13.
EQUIPMENT TAGGING AND NAMEPLATES ............................................... 52
14. INSPECTION AND TESTING ................................................................... 53
15. QUALITY CONTROL PROGRAM ............................................................... 53
16. PRODUCTION INSPECTION .................................................................... 53
17.
CONTROL FUNCTIONAL TEST ................................................................ 54
18. MECHANICAL RUN TESTS ...................................................................... 54
19.
PERFORMANCE/ FACTORY ACCEPTANCE TEST (FAT) ............................... 54
20.
FIELD TESTS ........................................................................................ 56
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21. CERTIFICATION .................................................................................... 57
22.
SPARES AND SPECIAL TOOLS ................................................................ 58
22.1 Spare Parts ........................................................................................... 58
22.2
Special Tools ......................................................................................... 58
23. PREPARATION FOR SHIPMENT ............................................................... 58
24. DOCUMENTATION ................................................................................. 59
25.
GUARANTEES ........................................................................................ 60
26. PROTECTIVE COATING .......................................................................... 61
27. TRAINING (OPTION) ............................................................................. 61
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1.
INTRODUCTION
1.1
Project OverviewDai Hung Field is located at Block 05-1a at North-West of Nam Con Son basin
within South-East continental shelf, Viet Nam, 260km far from Vung Tau
seashore. This field was discovered in 1988 by DH-1X.
In 2011, WHP-DH2 with existing system is operated to increase the capacity of
associated gas up to 1 MMSCMD. Besides the associated gas there is
considerable volume of natural gas located in bottom and middle of Mioxen
layer.
The overall Dai Hung Gas Gathering Project as show in figure 1 below:
Figure 1: Block Diagram Dai Hung Gas Gathering System
Modifying WHP-DH2 and installation pipeline between WHP-DH2 and BK-TNG
is to gather and transport 1.9 BMSCM of associated gas at outlet of HHP
Separator and Test Separator of WHP-DH2 to BK-TNG platform. Gas from
WHP-DH2 shall be transported to TEG skid on BK-TNG platform before being
routed to NCS2 gas pipeline phase 1.
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Preliminary configuration of Dai Hung Gas Gathering Project is as follows:
On WHP-DH2: Gas Cooler, Gas Scrubber, Gas Engine Generator, Corrosion
Inhibitor Injection Skid, Electrical System, Instrumentation System, Fuel
Gas System, Fire Fighting System, Telecommunication System and other
Utility Systems.
The 16 subsea gas pipeline (approximately 20 km) from existing 10 riser
at WHP-DH2 to BK-TNG Platform and 16 Y-Tee for future connection.
On BK-TNG Platform: 16 Riser, Slug Catcher, DH Gas Custody Metering
System, DH Gas Compressor Suction Scrubber, DH Gas Compressor
Package, DH Gas Compressor After Cooler, Fuel Gas System, Piping
System, Instrumentation System, Telecommunication System, Open/Closed Drain System, and other Utility Systems.
1.2
Purpose of Document
This document, together with the project data sheets provided separately,
defines the minimum requirements for supply, engineering, mechanical design,
performance guarantee (where specified), materials, fabrication, inspection,
testing, certification, painting, preparation for shipment, packing, forwarding,
transport and documentation for the Gas Engine Screw Compressor Package to
be installed as part of the Thien Ung Platform.
The CONTRACTOR shall ensure that all equipment and services supplied meet
the requirements of this specification, the project data sheets, codes and
standards and specifications specified herein, whether CONTRACTOR supplies
the equipment and services directly. CONTRACTOR shall supply the equipment
in line with the scope of supply as indicated in this specification.
1.3
Definitions and Abbreviations
1.3.1 Definitions
PROJECT : Dai Hung Gas Gathering Project
CLIENT : PetroVietnam Domestic Exploration
Production Operating Company Limited
(PVEP POC)
EpCI CONTRACTOR : VIETSOVPETRO JOINT VENTURE (VSP)
ENGINEERING SUB-CONTRACTOR : PetroVietnam Engineering Consultancy
Joint Stock Company (PVE)
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CONTRACTOR : Party, which supplies material,
equipment and services to perform the
duties as specified by CLIENT in the
scope of supply
1.3.2 Abbreviations
FPU-DH1 Dai Hung 1 Floating Production Unit Platform
WHP-DH2 Dai Hung 2 Wellhead Platform
BK-TNG Thien Ung Platform
MMSCMD Million Metric Standard Cubic Meter Per Day
BMSCM Billion Metric Standard Cubic Meter
ESD Emergency Shut-Down
FGS Fire & Gas
HMI Human Machine Interface
HSE Health Safety and Environmental
ICSS Integrated Control and Safety system
IOM Installation Operation and Maintenance
ITP Inspection and Test Plan
LV Low Voltage
HV High Voltage
VFD Variable Frequency Drive
UPS Uninterruptible Power Supply
AC Alternating Current
DC Directing Current
SGR Switch Gear Room
RTD Resistance Temperature Detector
IEC International Electrical Commission
IP Ingress Protection
MCC Motor Control Centre
MDR Manufacturers Data Report
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MPI Magnetic Particle Inspection
NDT Non-Destructive Testing
PWHT Post Weld Heat Treatment
TBA To Be Advised
VDRL CONTRACTOR Data Requirements List
VDS CONTRACTOR Data Schedule
FAT Factory Acceptance Test
SAT Site Acceptance Test
SSD Safety Shut Down/ Safety Shut Down PLC
PPLC Process Programable Logic controller
SIS Safety Interated System
TEG Triethylene Glycol Dehydration
PCS Process Control System
APS Abandon Platform Shutdown
LCP Local Control Panel
UCP Unit Control Panel
1.4 Codes and Standards
In addition to the requirements of this specification and the referred or
attached individual specification and data sheets together with the statutory
requirements of the Vietnam Authorities, the general design, fabrication,
assembling and testing of this package shall follow the indicated editions of the
following API standards and the latest edition of international codes and
standards including any addenda published for the edition listed, which shall
form part of this specification. These shall include but not be limited to the
following:
ISO 3046-1 Part 1 Standard reference conditions, declarations of power, fuel
and lubricating oil consumptions and test methods
ISO 3046-3 Part 3 Test measurements
ISO 3046-4 Part 4 Speed governing
ISO 3046-5 Part 5 Torsional vibrations
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ISO 3046-6 Part 6 Overspeed protection
ISO 3046-7 Part 7 Codes for engine power
ISO 13631 Petroleum and natural gas industries Packaged
reciprocating gas compressors
ISO 9001 Quality System - Model for Quality Assurance for Design
and Development, Production, Installation and Servicing.
ABMA 9 Load Rating and Fatigue Life for Ball Bearings
ABMA 11 Load Ratings and Fatigue Life for Roller Bearings
API 613 Special Purpose Gears Units for Petroleum, Chemical, and
Gas Industry ServicesAPI 614 Lubrication, Shaft-Sealing, and Control Oil Systems for
Special-Purpose Applications
API 618 Reciprocating Compressors for Petroleum, Chemical and
Gas Industry Services
API 661 Air-Cooled Heat Exchangers for Petroleum, Chemical, and
Gas Industry Services.
API 670 Machinery Protection Systems
API 671 Special Purpose Couplings for Petroleum, Chemical andGas Industry Services.
API 678 Accelerometer Based Vibration Monitoring System
API RP 505 Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as
Class I, Zone 0, Zone 1, and Zone 2.
API RP 684 Lateral Critical Speeds, Unbalance Response, Stability,
Train Torsionals and Rotor Balancing
OPC OLE Process Control Standard, Version 1.0A
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASME B16.5 Pipe Flanges and Flanged Fittings NPS Through NPS
24
ASME B16.9 Factory-Made Wrought Butt-Welding Fittings.
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ASME B16.20 Metallic Gaskets for Pipe Flanges (Ring-Joint, Spiral-Wound
and Jacketed)
ASME Sec VIII Rules for Construction of Pressure Vessels Div. 1 and Div.
2
ASME PTC 10 Performance Test Code on Compressors and Exhausters
AWS D1.1 Structural Welding Code.
ANSI American National Standard Institute (as applicable)
Electrical Code IEC, British Standards, CENELEC, ISO, NEMA. (as
applicable)
Instrument Code ISA, API RP 551, IEC, NEMA (as applicable)NFPA 12 CO2 Fire Extinguishing System.
OSHA Occupational Safety and Health Act
NACE-MR0175 Petroleum and natural gas industries materials for use in
H2S-containing environments in oil and gas production.
UL Underwriters Laboratories
1.5 References
DHG-PVE-DD-3-ME-DAS-007 Datasheet for Screw Compressor
DHG-PVE-DD-3-ME-DAS-009 Datasheet for Gas Engine
1014-BKTNG-PR-PID-2023 PID DH Gas Compressor Package
In case of any conflict between this specification and the requirements of other
CLIENT specifications, industry standards, codes, regulations, data sheets or
drawings, the most stringent requirements shall apply with the written
approval of CLIENT.
2. GENERAL REQUIREMENTS
2.1
CONTRACTORS Responsibility
The CONTRACTOR shall have full responsibility for design, selection of
materials, fabrication, Certification, testing, inspection and transportation of
PACKAGE based on relevant project documents. Review and approval of
CONTRACTORs documents or inspection by the CLIENT shall not relieve the
CONTRACTOR of any of these responsibilities.
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The Overall PACKAGE Responsibility shall be with the CONTRACTOR. That
responsibility shall include coordination of scope boundaries between
Compressor, Engine and Other Components of the PACKAGE. TheCONTRACTOR has responsibility shall be liable for filling any scope gaps
between the compressor, Engine and Other Components of the PACKAGE
being supplied. The responsibility includes, but not limited to, the following:
Transmission to CONTRACTOR of all contractual requirements.
Compliance of CONTRACTORs item to the applicable specification and
standards
Basic design definition of CONTRACTOR equipment or works and technical
coordination with CONTRACTOR.
Co-ordination and checking of CONTRACTORs drawings and documents
before submission to the CLIENT
Co-ordination with CONTRACTOR for inspection including notification to
the CLIENT
Co-ordination of expediting of all CONTRACTOR items such as
compressor, drive gas engine, motors, gas seals panel, oil cooler,
coupling, and etc.
Ensuring that the design of CONTRACTOR items are compatible with each
other equipment in all respects. In particular, they shall be compatible
dimensionally, in performance, in control and in vibration characteristics
such that a fully integrated unit is achieved.
The CONTRACTOR shall be responsible for commissioning works of his
equipment and ensuring all performance guarantees as detailed in this
specifications are met.
The CONTRACTOR shall give with the tender the list of expected CONTRACTOR
with referenced list.
2.2
Operation and Design Life
The equipment shall be designed for a minimum service life of 20 years with
an uninterrupted operation of 4 years.
2.3 CONTRACTORs Exceptions
The CONTRACTOR Exceptions to this specification, project data sheets and
other project documents including the codes and standards agreed upon and
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recorded in the Bid Clarification Meeting Minutes which are part of the
Purchase Order shall be applicable.
2.4
Weight Control
The CONTRACTOR shall exercise an active weight control system throughout
the design and fabrication.
The CONTRACTOR shall submit the weight data sheet attached with the data
sheets, which shall contain the following details:
Dry weight Installed weight excluding operating fluids, spares, tools and
temporary packing.
Lift weight Dry weight + Packing weight
Operating weight Dry weight + Weight of operating fluids
Test weight - Dry weight + Weight of test medium
Heaviest maintenance lifts weight
The location of the COG in the X, Y, and Z planes for each designated
weight Condition
Design calculations, lifting procedures and lift arrangement drawings shall be
reviewed and approved by the CLIENT and CA. Final weighing shall be
performed prior to preparation of shipment. Final weighing shall achieve anoverall accuracy of +3%.
3.
LOCATION AND ENVIRONMENTAL CONDITIONS
The equipment will be installed on an offshore platform in the south of the
coast of Vietnam.
Location:Out door, Zone 2, Gas Group IIA, Temperature Class T3 Hazardous
Area.
The area in which the Gas Engine Screw Compressor Package is designated as
hazardous Zone 2 Area. All equipment installed within the module shall be
suitable for a Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area.
However, in order to permit interchange of instrument, a zone 1, gas group IIB
and temperature rating T6 certification shall be generally specified.
Electrical equipment supplied outdoors shall be protected to IP 56, while IP 42
protection shall be specified for equipment installed indoors.
Ambient Temperature:
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Extreme High Temperature 39.0 Deg C
Extreme Low Temperature 21.0 Deg C
Average Annual Temperature 27.1 Deg C
Design Ambient Temperature 35 Deg C
Environment:
Salt Laden: Salinity 35%
Max. Relative Humidity 100%
Wind Speed:
Maximum 34.2 m/s (3 sec gust)
Design Wind Speed 34.2 m/s
The equipment will exposed to the weather without further protection.
4.
UTILITY DATA
4.1 Electrical
The following electrical power supplies shall be made available for use by the
CLIENT:
Normal Power supply: 400V10% AC, 3 phase, 4 wire, neutral solidly
earthed, 50 Hz 5%.
Non-UPS Power Supply: 230V 10%AC, 1 phase, 2 wire, neutral solidly
earthed, 50 Hz 5%.
UPS power supply: 230V 5%AC, 1 phase, 2 wire, neutral solidly earthed,
50 Hz 2%.
Power supply: 24VDC 5% for Control system.
4.2 Instrument air:
7 barg (Norm), 5 barg (Min), 8 barg (Max) / 10 barg (Design).
4.3 Fuel gas
The fuel gas supply for operation of PACKAGE is taken from Fuel Gas System,
which is designed for high-pressure gaseous fuel of main Turbine generator on
platform. The system also supplies low-pressure fuel gas, purge gas, blanket
gas, etc.
Fuel Gas System is designed to cater for the overall fuel requirement on BK
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TNG platform. The system consists of Pre-heater, Pressure Control Valve,
Scrubber, Filter and Super heater. The normal fuel gas supply is dehydrated
gas from TEG Contactor with back-up fuel gas supply tapped from theProduction Separator gas outlet.
4.4
Units
SI units shall be used for the project with certain exceptions where oil-field
units are to be adopted. Pressure shall be indicated in bar, kpa and
temperature in degrees Celsius.
5. SCOPE OF WORK & SUPPLY
The CONTRACTOR shall design and furnish all components and ancillary
equipment necessary to make compressor package complete, safe and ready
for trouble free operation. Equipment and services shall include but not be
limited to the following for PACKAGE:
Screw compressor.
Gas Engine driver
Suction scrubber.
Outlet Cooler.
Speed reduction gearbox (shall comply with API 613).
Couplings and coupling guards.
Lube oil system(s) complete with one 100% main oil pump, one 100%
auxiliary oil pump, emergency lube oil pumps, air fin cooler(s), and a dual
oil filters with change over valves. The main oil pump should be a shaft
driven as external power supply is not available.
Fuel gas treatment package.
All on skid piping including valves, flanges and fittings with appropriate
supports.
Access for exhaust emission measurements.
Walkway, platform, ladders, handrails, safety cage, and non-skid grating
for safe access to all PACKAGER supplied equipment, instruments, valves,
and other devices requiring routine monitoring and maintenance.
Weather protection shed for Equipment.
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Structural skids with framework to support Engine, compressor, gear box
and ancillaries.
Air intake system, exhaust system, ventilation system and ancillaries with
intake silencers, exhaust silencers, exhaust ducts with motorized dampers
of heat recovery system, exhaust system thermal insulation, shielding,
cladding exhaust expansion joints, insect screens at all intakes, and
support structure.
Engine control system including all associated instrumentation and
cabling.
Compressor control system including Capacity/ Load sharing Controls,
Vibration & Temperature Monitoring, etc. including all associated instrumentation and
cabling
Process yard valve control system.
Control panels and instrumentation including local gauge panel, local
compressor seal gas gauge panel as well as main microprocessor-based
control panel (UCP).
Shaft coupled AC alternator of adequate size to power to UCP and
auxiliary drivers on DC control power supply unit including batteries, battery charger, DC
panel and all DC Cabling.
DC emergency lube oil pump system complete with pump, motor.
Temperature and vibration monitoring system.
Complete Instrumentation & Control Cabling
Fire & gas detection.
Package and equipment leveling and alignment devices.
Package and equipment lifting lugs and eyebolts.
Personnel protection insulation.
Commissioning parts.
Inspection and Tests Plan
Third Party Certificate for entire PACKAGE.
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Documentation for project
Commissioning activities (Supervision).
Training courses (Option).
Special Tools for engine & compressor (Option).
Spares for 2 years operation (Option).
Anchor bolts for package frame.
The CONTRACTOR shall include in his supply:
With the exception of process gas connections all piping and tubing
connections for interfacing with the CLIENT shall be brought to the edge
of each compressor flanges and terminated with a complete companionANSI flange or Swage lock bulkhead fitting.
The CONTRACTOR shall take technical support to CLIENT in:
Mechanical Interface drawings between PACKAGE and CLIENTs
equipments such as inlet/outlet piping.
Interface drawings of Inlet system, Exhaust system, lubrication oil cooler
system.
Provide drawings of Interconnecting electrical cables/instrument cables,
between the PACKAGE and loosed items such as UCP, oil cooler, anti
surge.
Responsible for Technical support to CLIENT for PACKAGE interface
engineering.
Interface and successful communication between CONTRACTORs UCP
and CLIENTs DCS system shall be carried out.
Supply E&I cable list and interconnection for E&I wiring diagram.
EXCLUSION:
Interconnecting piping between PACKAGE to oil cooler and field piping.
Interconnecting electrical cables/instrument cables, between the
PACKAGE and UCP/PCS/SIS/MCC.
UPS system for the UCP.
MCC.
Process Vessels.
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Installation and Hook-up works for PACKAGE in CLIENTs site.
6.
DESIGN REQUIREMENTSThe CONTRACTOR shall minimize the points and locations of interface and
locate them at the unit skid edge. Piping interface with the off-skid piping shall
be provided with isolation valves and flanges. Common service piping such as
drain, vent and utility piping shall be manifold to interface with the off-skid
piping where it is safe to do so. All instrumentation and control wiring shall be
wired to the junction boxes located at the skid edge for interface with the off-
skid wiring.
The compressor and gas engine shall be skid mounted and coupled together.
The acoustic panel enclosure shall be weatherproof and made of carbon steeland coated as per paints specification. The enclosure shall be framed and
supported from the skid. The gas engine ancillary package including
combustion air intake system and the engine exhaust duct and silencer system
shall be provided with support framework for quick hook-up and for mounting
on top of the enclosure. Access ways and maintenance platforms shall be
provided where routine maintenance and operation checks are required. All
foundation requirements including for main skid, ancillary bases and support
frames shall be provided with details for CLIENTs review and approval.
All piping, wiring, and tubing within the CONTRACTOR supply shall be fullysupported by the CONTRACTOR. All terminations at which the off-skid lines are
to make connections shall be fully anchored on the CONTRACTOR side.
Foundations required for supports will be provided by an off-skid installer. Any
limitation on loads and movements imposed by the off-skid piping shall be
defined on the CONTRACTORs drawings.
The CONTRACTOR shall clearly indicate in his proposal all items covered by
this specification which are located off-skid and to specify dimensions,
weights and interface details required for installation and hook-up.
The CONTRACTOR shall fully define all piping, mechanical connections,
electrical wiring, instrumentation and control interfaces with size, schedule,
type, location, rating, design and operation ranges.
7.
ENGINE AND AUXILIARIES
7.1
General
The engine driver shall be a reciprocating internal combustion associated gas
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engine complying ISO 3046 or equal. The engine shall have a continuous
rating, de-rated for site conditions at the maximum air ambient, minimum fuel
gas pressure and all power transmission losses, at least equal to 110 percentof the BHP required for continuous operation supplying the maximum
compressors demand specified.
The engine shall not have any torsional natural frequencies within 10 percent
of the first or second harmonic of the rotational frequency of any shaft in the
operating speed range.
Constant speed applications shall be considered to have an operating speed
range of 10 percent of rated speed.
The engine shall include replaceable cylinder liners of the wet sleeve type andreplaceable valve seat inserts. Combustion chambers shall be of the open type.
Connecting rods and crankshaft shall be of forged steel.
Engine drive for attached auxiliaries shall be gear, V-belt or chain type. V-belt
and chain drives shall be furnished with adjustable tensioning devices.
Bearings shall be manufacturer's standard. Shims shall not be used for any
bearing.
The engine shall be designed to minimize the requirement of special tools for
installation and maintenance. One set of such tools with a description and
instructions for their use shall be supplied.
7.2 Intake Air System
The engine shall be provided with one or more engine-mounted dry-type air
cleaners/ filters of sufficient capacity to protect the working parts of the engine
from dust, grit and moisture laden air.
The filter shall be fitted with a differential pressure indicator (Transmitter) to
show when the filter requires attention.
If the air filter is to be installed remotely from the engine, the CONTRACTOR
shall supply the filter loose. The pipework between the filter and the engine
shall be either stainless steel or marine grade aluminum with less than 3%
magnesium.
The CONTRACTOR shall recommend the size of the intake pipe between the
filter and the engine. CONTRACTOR shall ensure that the pipework does not
impose unacceptable strains on the engine. The CONTRACTOR shall supply a
flexible joint between the intake pipe and the engine.
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Unless absolutely essential, internal fasteners shall not be used downstream of
the air filter. Where unavoidable, internal fasteners shall be positively secured.
Intake pipes 250 mm or larger in diameter shall be fitted with a BICERI type
explosion relief valve with integral flame trap between the engine and the air
filter (or the silencer, if fitted).
All external connections from the engine shall terminate in flanges to ASME
B16.5.
An air intake silencer shall be provided if the air intake noise level exceeds that
permitted.
7.3 Starting System
CONTRACTOR shall supply complete starting system(s) as specified in the
generator gas engine data sheet. Two (2) independent starting systems shall
be required.
The Gas Engine shall be able to cold start at the minimum ambient conditions.
7.3.1 Electric Starting System
This is the main starting system for the Gas Engine. The system shall be a
24 VDC electric starting system, with the battery, engine start controls
and battery charger located on the skid. The controls and charger shall be
suitable for the engine vibration and outdoors site conditions. The 24 VDCbattery and charger shall also supply power to the Gas Engine control
system.
Cranking time and pause between starts shall be adjustable. The battery
charger shall automatically disconnect from the battery during engine
cranking. The starting current for the first start shall be provided by the
first set of batteries and the subsequent start by the next set of batteries.
Cranking logic shall be designed such that the starting circuit is
deactivated after six (6) unsuccessful consecutive start cycles. Further
starting shall be only possible from field control panel.
CLIENT shall provide one (1) 220 VAC feeder cable on cable gland for the
battery charger and anti-condensation heaters (< 3kW) during platform
normal operation.
The battery shall be sealed, maintenance free type suitable for heavy-
duty Gas Engine starting and shall be supplied in a fully charged condition
and complete with copper links. The battery shall be positioned such that
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possible leakage of electrolyte or emission of gaseous product, if any will
not cause damage to other equipment or adjacent cells. The battery shall
be mounted in a robust fibreglass box (suitably rated for outdoorinstallation, IP56).
Two (2) x100% trains of battery starting system shall be provided. Each
battery train shall have efficient capacity for six (6) consecutive 15-
seconds start cycles.
The charger shall keep the battery in fully charged condition and supply
all auxiliary loads on the skid simultaneously. The charger shall also be
capable of float-charging the battery from fully discharged condition to
fully charged condition within eight (8) hours.
Automatically regulated output voltage of the battery charger shall be
maintained within plus or minus 1% for load changes from zero to full
load and line voltage variations of plus or minus 10% and frequency
variations of plus or minus 5%. An over-current limit shall be adjustable
and preset at 105% of rated output to prevent overloading of the charger
during the starting of the engine.
Both the positive and negative terminals and conductors of DC power
supply shall be isolated from earth.
All connections shall be made at terminal strips provided at the chargerunit.
CONTRACTOR shall carry out industry standard testing for the battery and
charger as per CONTRACTORs CLIENT approved procedure.
7.3.2
Hydraulic Starting System
Hydraulic starting system shall be complete with reservoir, shaft driven
charging pump, accumulators, hydraulic motor starter with pre-engaged
non-sparking pinion type, piping, valves, solenoid etc. as required.
The hydraulic electrical motor, if provided, shall be as per CLIENTSpecification,.
The engine driven pump shall be sized to completely charge the
accumulator in not more than 15 minutes when operating at design
speed. The CONTRACTOR shall describe the method of declutching
/disengaging the engine-driven pump once recharging is complete. The
power absorbed by the engine-driven pump shall be advised by the
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CONTRACTOR. A hand pump for recharging the accumulator shall also be
supplied.
Accumulator capacity shall be sufficient for a minimum of six (6) starts. Each
start attempt must be distinct and separate. If the engine fails to start within
the time required for 12 complete revolutions, the starting control system shall
abort the start.
7.4 Fuel Gas Treatment Package
CONTRACTOR shall provide complete fuel system comprising of but not limited
to Carburetion System, Vertical Separator / Filters, heater (VTA),
Interconnection piping, fittings, Solenoid actuated fuel shutoff valve, Solenoid
actuator fuel line vent valve, Fuel gas pressure regulator, Pressure SafetyValve, Fuel Consumption Meter. Fuel gas will be used as a starting gas for the
gas engine(s) i.e. it will crank the engine.
For Fuel Gas properties, refer attached data sheet. CONTRACTOR shall provide
a complete on-skid fuel system. All necessary valves and regulators shall be
consistent with the pressure. Fisher gas regulators or equivalent with steel
bodies shall be provided for pressure reduction, if required. An explosion-proof,
all steel, solenoid type fuel valve shall be furnished and installed in the fuel gas
supply line on the engine. This valve shall be automatically latched to start the
engine and electrically tripped. The engine shutdown devices shall beconfigured to electrically trip the engine by at least closing the fuel valve.
The strainer shall be 200 m nominal, and shall act only as a guard filter. The
strainer shall be fitted with a drain valve.
A swing-type or wing-type non-return valve shall be provided to prevent
pressure surges from engine "spit back" disturbing the fuel system.
CONTRACTOR shall provide system with fuel filters (vertical separator), inter-
connection piping, fitting, solenoid actuated fuel shut off valve, fuel line vent
valve and fuel consumption meter.
7.5
Lubrication System
The lubrication system shall be a pressure-type system. It shall consist of, but
not be limited to Sump (wet type) with level indication, fill filter, vented and
valve drain, Circulation pumps (shaft driven) with pressure relief valve, Duplex
filters with replaceable cartridge elements, full flow transfer valve and
differential pressure gauge across filters, Cooling equipment with
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thermostatically controlled bypass valve, Valves for relief and pressure
regulation, Low Level Alarm Switch and Automatic shutdown devices.
The oil sump shall be integral with the engine and shall be large enough to
contain all the oil in the system when the engine and pumps are shutdown.
The minimum capacity shall be an amount of oil equal to the lubrication
pump's working capacity for a period of two minutes.
The filters for the lube oil system shall be sized to meet the engine
manufacturer's filtration requirement. The oil filter shall be equipped with a
differential pressure gauge, and a bypass valve to assure engine oil flow in the
event of filter plugging. All filters shall utilize replaceable elements.
If aluminum, micro-Babbitt or equivalent bearings are provided, a bypass filterrated for five (5) micron nominal filtration or better shall be provided. This
bleed off filtration line shall be sized to filter the total oil capacity in 24 hours or
less. Filter casings and heads shall be suitable for operation at a pressure of
not less than 10 percent over the relief valve settings of the lube pumps.
Strainers (20 mesh) shall be provided in the lube oil pump suction header.
Internal relief valves in filters shall not be acceptable.
Crankcase shall be explosion proof.
Pre-lube and/or post-lube pumps shall be provided. Pre-lube pump drivers shalloperate on the same energy source as the engine starter.
The CONTRACTORs standard pre-lube pump shall operate as follows:
The pump shall run when automatically started by the engine control
panel.
The pump shall run when the lube-oil heater is energized and allowed by
the skid mounted ON/OFF selector switch.
The post-lube pump shall be locked out from running when the engine is
locked out manually.
The pump shall be inhibited from running when the engine is running.
The CONTRACTOR shall provide the recommended lubricant for start-up. The
start-up lubricants shall not be those used during testing.
The engine oil temperature shall not exceed CONTRACTORs recommendations
and shall never exceed 91C (195F) for continuous operation. The oil
temperature should never exceed 107C (225F) for short term operation (one
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hour or less) during an overload condition. The crankcase oil temperature shall
be maintained at a differential of 6C to 12C (10F to 20F) above jacket
water temperature under any conditions using jacket water cooling.
The crankcase oil temperature shall be maintained at a differential of 6C to
9C (10F to 15F) below jacket water temperature under any conditions when
an oil cooler with a separate cooling water system is provided.
The lube oil dip stick shall be calibrated for oil pan level with the engine
running and not running, to permit checking during normal operation and
when the engine is stopped.
7.6
Cooling System
The engines cooling system shall be furnished with a closed loop, jacketcooling system and a centrifugal pump. The cooling system shall be sized for
the continuous maximum BHP load at the max. ambient temperature.
The cooling coolant heat exchanger shall be of the finned radiator type. The
radiator shall be mounted on the engine skid and shall have a tin or solder
coated core and shall have carbo zinc #11 on all exposed steel surfaces. The
material shall be suitable for operation in a moist air environment. Coolant
shall be compatible for operation within tropic locations as well. Radiator shall
be filled out and sealed prior to test running. The cooling system shall include
one (01) 1" stainless steel valve for external fill and one (01) 1" stainless steelvalve for draining. System shall also include pusher type, fan, four ply hoses,
pump with carbon seal and radiator fan guard.
Automatic thermostat control with bypass valves shall be provided to control
engine temperature. Bypass shall operate so that cooling medium flow shall
never be throttled. Expansion or surge tanks shall be integrally mounted.
Thermometers shall be installed in stainless steel thermowells at the inlet and
outlet connection of each cooling coolant circuit in the heat exchanger
(radiator). Thermometers shall be installed in such a way that they may be
easily read from ground level without having to climb up on the skid assembly.
7.7
Governor
The governor supplied for engine speed regulation and load control shall be
electronic utilizing digital technology.
The governor actuator shall be direct acting, UL Approved for use in Zone 2,
Group II. The actuator and magnetic pickup shall be mounted on the engine.
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Controller stability shall be within + 3.0% at rated load. The maximum
deviation relative to the rated speed for the range between no load and full
load shall be 1/4 %.
The amount of droop shall be field adjustable from 0 to 10%. The governor
shall be provided with a droop reset control feature to maintain system
frequency to within 0.5% when in droop control.
The governor shall monitor the speed sensor for loss of speed signal, calling
for minimum fuel when signal loss is detected.
The governor shall have the following adjustments:
Rated speed
Idle Speed
Acceleration ramp time
Deceleration ramp time
Start fuel limit
Gain and reset
Actuator compensation
Load gain
Droop
7.8
Engine Exhaust System
A hospital grade, muffler with spark arresting capability shall be installed in the
exhaust system unless the pressure drop across the silencer raises engine
exhaust pressure to unacceptably high pressure, in which case, a lower grade
Maxim muffler may be used with CLIENTs approval.
Silencers with flange sizes over 15 cm (6 inches) shall be provided with an
inspection opening or draw out cover. The exhaust silencer shall attenuate the
engine exhaust to 85 dB(A) at 1 m unless otherwise specified.
Engine-mounted silencers shall be provided with a bellows-type, stainless steel
expansion joints.
All carbon steel piping, silencers etc. subjected to exhaust temperatures and
exposed to the atmosphere shall be blast cleaned and flame sprayed
aluminium coated for corrosion protection. Alternatively, stainless steel may be
used.
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7.9 Insulation
Thermal blankets shall be installed where surface temperatures exceed 60C
for personnel protection.
Ceramic fiber silicone treated glass cloth, covered with a 316L stainless steel
knitted mesh good to 1260C (2300F) shall be provided on the exhaust line. A
minimum of 2.5 to 4 cm (1 to 1-1/2 inch) calcium silicate covered with
aluminum shall be provided where rigid insulation is required, such as on water
lines.
7.10
Engine Shutdown Devices
Each engine shall be equipped, as a minimum, with the following safety
shutdown devices:
Low oil pressure pre-alarm and shutdown with time delay for starting
Low coolant level alarm and shutdown
High oil temperature alarm and shutdown
High coolant temperature alarm and shutdown
Engine vibration
High Cooler vibration alarm and shutdown
Over speed alarm and shutdown
Over crank start sequence shutdown
Manual lockout at skid
Fire & gas detectors
Red mushroom head Emergency Stop pushbutton located at the engine
skid and on the engine control panel face.
All shutdown and alarm switches shall be hermetically sealed whenever
possible and shall be UL listed, as a minimum, for Zone 2, Group II hazardous
locations.
7.11 Engine Instruments Panel
A package mounted powder paint coated sheet steel instrument panel for
engine shall be provided. Panel shall be located on the edge of the engine skid
so that it may be viewed from outside skid and shall be mounted on isolation
mounts in such a way as to prevent vibration damage to instruments. The
following instruments shall be provided on the instrument panel as a minimum:
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Lube oil pressure gauge
Electronic (LCD) tachometer
Engine outlet coolant temperature gauge
Engine outlet oil temperature gauge
Engine oil filter differential pressure gauge
Intake manifold vacuum/pressure gauge
Fuel pressure gauge
Running hour meters
Fuel filter differential pressure gauge
Engine inlet coolant temperature gauge
Cooler outlet oil temperature gauge
Gauge for diesel engines with after cooling
Red maintained mushroom head emergency stop pushbutton,
hermetically sealed contacts
Frequency Meter
Voltage Mete / Load
Additional instruments required by the CONTRACTOR shall be provided.
Instrumentation shall conform, in general, with API STD 670.
Instrumentation and associated local panel monitor for vibration, axial position
and bearing temperature shall conform, in general, with API STD 670.
Gauges shall be provided with glycerin filled stainless steel cases with a
minimum 100 mm (4 in.) face, identification labels, including tab number, and
normal and maximum reading markers. Pressure gauges shall have 316L
stainless steel bourdon elements and 316L stainless steel cases. Thermometers
shall be mounted in 316L stainless steel wells. Gas-filled thermometers shallhave leads and shall be no longer than 3 meters (10 feet).
7.12 Ignition System
Engine CONTRACTORs standard, shielded, low tension, capacitive discharge
ignition system shall be used.
All cables and harnesses shall be shielded with stainless steel braid. Primary
cables shall also be vinyl covered.
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Ignition transformers shall be integral with the spark plugs eliminating the
need for separate spark plug wires.
Engine CONTRACTORs standard electronic ignition diagnostic system shall be
used.
7.13 Over-speed Protection
The engine shall be fitted with an over-speed protection device in accordance
with ISO 3046-6. This device shall shut down the engine by both earthing the
ignition and shutting off the fuel independently of the speed governor.
The over-speed protection device shall be manual reset only.
7.14
Torsional Vibration
The assessment and prevention of Torsional vibration in the engine and its
driving train shall be as specified in ISO 3046-5.
The CONTRACTOR shall provide all the necessary information regarding the
engine including to enable the Torsional vibration calculations.
Alternator drives shall be regarded as having a speed range of 90 to 110% of
synchronous speed for the Torsional analysis.
Use of torsionally flexible couplings and torsional dampers (separate from
those fitted as standard to the engine) for tuning the torsional critical speeds
shall require the approval of the consultant.
The CONTRACTOR shall advise the life of viscous type torsional dampers fitted
to the engine.
7.15 Lateral Vibration and Vibration Suppression
The CONTRACTOR shall provide the anticipated lateral vibration levels of the
engine relating to measurements made directly on the crankcase or main
frame of the engine, expressed both as a filtered response at each of the
major excitation frequencies and as unfiltered vibration with the engine
running at rated power and speed. The vibration information shall include themagnitude and direction of unbalanced primary and secondary unbalanced
forces and couples.
Suitable anti-vibration mounts shall be supplied to limit the engine vibrations
transmitted to the foundations or surroundings if a vibration analysis study
reveals that the package requires isolation from the supporting structure. Anti-
vibration mounts shall be of totally enclosed design, suitable for the
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environment, and have an isolation efficiency of at least 90% in respect of all
engine induced vibrations.
Unless otherwise dictated by the arrangement of the engine and the driven
equipment or by the lateral vibration analysis, any anti-vibration mounts
required shall be installed between the baseplate and the supporting structure.
The CONTRACTOR shall supply the anti-vibration mounts.
Full details, including drawings of the anti-vibration mounts shall be submitted
to the CLIENT together with the frequencies and magnitude of any unbalanced
forces and moments that will be transmitted through the supports into the
supporting structure.
7.16
Shaft Couplings and GuardsThe CONTRACTOR shall supply shaft couplings between the engine and the
driven compressor.
All couplings shall be either flange bolted to shafts or be hydraulically fitted to
cylindrical or tapered shafts.
All couplings shall be of the non-lubricated type.
All moving parts shall be protected from human contact by suitable guards of
either sheet or mesh material. All such guards shall be non sparking. Aluminum
is not regarded as a non-sparking material & should be prohibited.7.17
Crankcase Explosion Relief
Engines having a crankcase volume of over 0.6 m shall be provided with
crankcase explosion relief devices. Explosion relief valves of the BICERI design
or approved equal with integral flame traps shall be used. Sufficient relief
valves shall be installed to provide more than 115 cm of relief valve free lift
area per m of crankcase volume.
Dipsticks and/or filler caps shall be effectively secured against ejection
following a crankcase explosion.
The crankcase breather shall be as small as possible and located to minimize
air inrush into the crankcase following an explosion.
7.18 Miscellaneous Requirements
Relief valves shall be provided as necessary for the fuel supply, engine
crankcase pressure and lube oil supply.
Governor setting controls shall be mounted on the governor.
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The engine over-speed shutdown will be easily accessible and capable of being
manually tripped and reset with fuel pressure on the line. Trip mechanism shall
be spark proof and suitable for use in hazardous locations. Trip device, valve,valve stem, packing and interconnecting linkage shall be of suitable material
and so designed that they may be expected to perform satisfactorily under
conditions of minimum lubrication, infrequent tripping and outdoor installation.
Automatic safety stops shall be entirely independent of the speed governor.
They shall operate to ground the ignition, shut off the fuel and vent fuel from
the engine.
Interlocks shall be provided to override shutdown signals when starting the
engine.
Some means of positive fuel shut-off should be provided for emergency use.
Pressurized fuel should have another shut off valve, preferably automatic,
other than those in the carburetor or gas pressure regulator equipment.
8. GAS COMPRESSOR
8.1 General
The Compressor gas engine driven, heavy-duty, rotating-type, positive
displacement screw compressor shall meet all the technical requirements as
specified in: Data Sheets
Technical Specification
International Codes & Standards
Gas composition given in Data Sheets shall be used for Compressor sizing and
performance guarantee estimates. However compressor shall be suitable for
continuous operation with the indicated gas composition range and operating
parameters given in the data sheet.
CONTRACTOR offer shall be based on firm and final compressor models on
which basis the offer shall be evaluated. CONTRACTOR shall take full
recognizance of this matter before submitting the bid.
Note that the pressures given on the data sheet are at the compressor
package battery limits, CONTRACTOR shall consider all pressure losses at
suction, inter stage (VTA) and discharge at the specified capacity for
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compressor/engine and indicate the same on the data sheets. No venting of
the gas is allowed at any point during operation except PSV lines.
The compressor Driver shall be capable of running the compressor under
loaded condition with each stage pressurized to its respective specified
pressure and final pressure up to PSV set pressure.
Certificate shall be supplied from the CONTRACTOR assuring that components
and manufacturing techniques meet the requirements of NACE MR 0175
(Latest Revision).
The Contractor shall provide all equipment completely fabricated, assembled,
and tested. The equipment shall be dismantled only to the extent necessary for
inspection and practical shipping. If the compressor package components areto be mounted and/or tested at the Manufacturers plant, the Manufacturer
shall provide and take responsibility for the following:
Coordination of arrangements for receipt, handling, and set up of compressor
package components.
Testing of compressor package in accordance with applicable standards.
Preparation for shipment of the entire compressor package in accordance with
applicable standards.
Coordination and cost for correction of compressor package problemsdiscovered at the Manufacturers factory during test or assembly.
All control equipment for integral units shall be furnished.
All equipment shall be rated for installation in a Zone 2, Group IIB, T3
hazardous locations
The compressor, gas engine, and all accessories shall be completely factory
assembled on a common, fabricated steel base and be ready for installation.
Internal piping shall be such that only single point connections for gas inlet,
gas outlet, drains, vents, cooling system fill/makeup (if required), cooling waterinlet and outlet (if available), and instrument air supply (if available) are
necessary for the compressor package.
8.2 Compressor Performance
The Contractor shall provide a complete capacity/ pressure control system. The
compressor shall provide a constant discharge gas pressure at any gas flow
rate and any suction pressure. The discharge pressure control system shall use
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slide valves to adjust the flow rate due to suction pressure swings and capacity
changes. In addition, a recirculation line may be used, as necessary, to
supplement the slide valve, and to allow for fully unloaded compressoroperation. Gas recirculation shall be to a point upstream of the inlet gas
scrubber. The gas recirculation valve shall include a valve positioner with a
position transmitter.
The control system shall include a manual override (local manual start and
control).
The compressor shall operate without excessive vibration or noise.
8.3
Compressor Construction
The compressors shall be constructed as specified herein. The maximumallowable working pressure (MAWP) shall be at least 110% of or 25 psig
greater than the maximum operating pressure, whichever is higher.
8.3.1
Materials of Construction
Materials of construction for the compressors and auxiliaries shall be the
manufacturer's standard for the specified operating conditions unless otherwise
specified in API Standard 619.
8.3.2 Bearings
Bearings shall be replaceable sleeve type or antifriction of the tapered orspherical roller type.
8.3.3 Compressor Rotor
The rotor assembly including thrust disk, balance piston (when applicable) and
half key on shaft end shall be dynamically balanced with manufacturer's
specified criteria and in accordance with Section 5.7.3.3 of API STD 619 prior
to compressor assembly.
The rotor shaft shall be key way or keyless shaft end and manufactured from
forged steel and shall be one (1) piece with helical rotor, statically anddynamically balanced to provide vibration free operation.
8.3.4
Coupling and Guard
When a torsional damping or resilient type coupling is required by analysis, the
coupling shall be in accordance with API STD 671, Appendix B.
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The coupling connecting the compressor and drive motor shall be sized for all
operating conditions. The drive coupling assembly shall be protected with a
removable, non-sparking guard.
8.3.5 Casing
The main pressure casing shall be bolted and main casing split face shall use a
metal-to-metal joint (such as O-ring) to avoid gas leakage due to high
pressure. Gasketed joints are not acceptable.
A flat surface of an agreed size and location shall be provided on the casing as
close as possible to the bearing locations for mounting of magnetic-based
seismic vibration measuring equipment. See Section 5.9.8 of API STD 619 for
further details.8.3.6
Shaft seals
Gas leakage to the atmosphere is not permissible. The CONTRACTOR shall
provide either a dual mechanical contact-type seal design with an independent
seal fluid system (Section 5.6.4.2 of API STD 619) or a double or tandem self-
acting dry gas seal in accordance with API STD 614 Chapters 1 and 4. See
Section 5.6 of API STD 619 for further details.
The CONTRACTOR shall furnish complete seal support system, as described in
Section 5.6.2 of API STD 619.
8.3.7 Miscellaneous
Name plate data shall be permanently etched, stamped, or embossed into the
metal surface. Printing or painting data onto the nameplate is not permitted.
The nameplate shall be in the English language.
An allowance for laser-based engine and coupling alignment shall be inherent
in the design of the equipment base. Alignment shall be verified just prior to
shipment and at site. All bolting shall be confirmed as tightened to the proper
torque value.
Epoxy grout shall be used around all embedded items.
Compressor and engine mounting base shall be machined after all welding is
completed so that all the machined mounting pads contacting with compressor
and motor legs are within 0.005" of each other in parallel when measured on
the milling machine.
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0.2" - 0.25" thickness adjustable shims shall be installed under motor legs only.
Compressor is fixed and adjustment shall be done by engine location. These
shims shall be adjusted during cool conditions.
All machine mounted equipment, piping, and tubing shall be fitted and
assembled in the Manufacturers shop.
8.4
Auxiliary Systems
As indicated, the gas compressor shall be supplied with cooling, lubrication,
and gas scrubbing and filtration systems as specified herein.
8.4.1 Cooling Systems
The compressor shall be furnished with a complete cooling system.
The base scope shall include a fin fan/lube oil cooler suitable for ambient
conditions. The system shall be designed to prevent the lube oil temperature
from dropping below the start permissive while the compressor is off line.
The compressor cooling system shall be complete with pumps, strainers,
isolation valves, sight flow indicators, flow control valves, surge tank,
instrumentation, interconnecting pipe, and all other devices required for a
complete system.
The compressor cooling system shall provide cooling for the lube oil coolers,
recirculation coolers, inter stage (VTA) coolers, and after coolers, as required.
An after cooler shall be provided. If a multistage unit is provided, and if
required by compressor design, the compressors shall be furnished with an
intercooler for reducing the gas temperature. Intercoolers or after coolers shall
be air cooled with electric motor driven fans.
Intercoolers shall be machine mounted with all interconnecting piping and
accessories furnished in accordance with ASME B31.1. Intercoolers and inter
stage equipment shall be shop mounted to check for proper fit and match
marked prior to disassembly and shipment.
A recirculation gas cooler shall be supplied in the recirculation line. This cooler
shall reduce the recirculated gas temperature to inlet conditions.
Lube oil coolers, intercoolers, after coolers, and recirculation coolers shall be
mounted with the compressor as part of the skid mounted unit and arranged
to allow space for installation and ease of maintenance.
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Inter stage (If required) coolers shall be provided with scrubbers, gauge
glasses, automatic condensate traps, valves, thermal relief valves, and drain
piping.
All gas cooler inlets and outlets shall be provided with thermometers.
8.4.2 Lubrication System
Each compressor shall be provided with a complete, force-feed, lube oil system
designed to furnish all lubricating oil required for the compressor and the drive
motor. The lubrication system shall be per API STD 619, and as specified
herein.
Each lube oil system shall include the following:
The lube oil system shall be equipped with the alarms, indicators and
shutdowns
Dual flow filter assembly including 10-micron replaceable element and
differential pressure indicator and continuous flow transfer valve with
isolation valves to facilitate the replacement of a filter element while the
other filter is in use. The filters shall be located in an easily maintainable
place.
Temperature control valve.
Strainer.
System relief valve for full pressure lubrication to bearings and seals.
Thermal relief valves for blocked-in equipment (i.e. coolers and filters) in
accordance with Section 5.10.1.2 of API STD 619.
Control oil system for hydraulic cylinder for slide valve movement. It may
be common oil system with lube oil.
Positive displacement lube oil pumps shall be supplied in accordance with
API STD 614 as follows:
When a lube oil pump is not necessary in normal operation, theManufacturer shall provide a motor driven pre-lube pump which has alsoautomatic cut in function when lube oil supply pressure hits low alarmpoint. If the pre-lube pump starts and oil pressure continues to fall, thecompressor shall automatically shut down.
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When a lube oil pump is necessary in normal operation, theManufacturer shall provide two motor driven positive displacement
pumps, one for main and another for stand-by. The stand-by pump shallbe a 100% capacity pump and have automatic cut in function when lubeoil supply pressure hits low alarm point. If the stand-by pump starts andoil pressure continues to fall, the compressor shall automatically shutdown.
Isolation valves and break-out union for pump removal and maintenance
without draining system.
Initial oil fill with recommended lubricant (regular oil and flushing oil).
Compressor oil reservoir with level instrumentation.
Thermostatically controlled electric immersion heaters shall be provided tomaintain the minimum required lube oil reservoir temperature such that
each compressor can start immediately upon a start signal, with no lube oil
preheating required. Oil heaters shall be sized and configured to have a
maximum surface temperature of 400 F exposed to the oil. A low oil level
switch shall be provided to de-energize the oil heater.
The lube pump shall be located in an accessible location and shall be piped
with block valves, strainer and a downstream check valve, and appropriate
flanges for ease of break-out and to allow removal with minimal
compressor oil loss.
All piping and equipment supports shall be supplied. The piping shall be
butt-welded stainless steel seamless pipe downstream of filters, and
upstream of filters may be socket or butt-welded stainless steel or carbon
steel seamless pipe. All piping shall be pre-piped and base mounted and
shipped as a packaged assembly.
8.4.3
Gas Scrubbing and Filtration
Gas separation and scrubbing equipment for equipment protection shall be
supplied for the compressor package to meet the exhaust gas requirements as
defined below:
A gas scrubber shall be supplied for the compressor inlet. The scrubber may
utilize mist demister pads or vanes to remove entrained liquid from the gas.
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The scrubber shall be designed and constructed in accordance with the ASME
Pressure Vessel Code and shall have an ASME stamp.
The scrubber shall be provided with the following accessories:
External level controller for auto drain
High level shut-down switch
Level gauge
Thermal relief valve
Dump valve
Vent valve
Manual drain valve
The scrubber vessels shall be skirt or leg supported and vertical, with
horizontal inlet and outlet connections.
Each vessel shall be provided with a gauge glass and angle type isolation
valves. The gauge glasses shall have a minimum length of 12 inches (300
mm). The vessels shall be provided with an automatic drain valve for the
discharge of liquids. All necessary controls for the drain valves shall be
supplied. A flanged cleanout connection shall be provided for each vessel. A
vent connection shall also be provided for each vessel.
A liquid filter/ separator or combination of bulk oil separators and coalescing oil
separators shall be supplied for the compressor outlet. The filter/separators
shall be a vane type line separator designed to remove entrained liquid from
the gas. Coalescing filters shall be supplied, as necessary, to meet the exhaust
gas purity requirements. The liquid separator and coalescing filters shall be
designed and constructed in accordance with the ASME Pressure Vessel Code
and shall have an ASME stamp. Bulk oil separator may be demister pad with
vertical type coalescing element, and coalescing oil separator may be
coalescing element type.
The separator and coalescing oil filter shall be provided with the following in
accordance with Section 5.10.3.5.5 of API STD 619:
High-level/ low level alarm, set point, and switch (two level switches)
External level controller for auto drain, or drain line back to compressor oil
system.
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Dump valve or drain line back to compressor oil system.
Level gauge
Vent valve
Thermal relief valve
Manual drain
Differential Pressure transmitter for oil coalescing element.
Electric heater for bulk oil separator
The separator vessels shall be skirt or leg supported and vertical, with
horizontal inlet and outlet connections.
Each vessel shall be provided with a gauge glass and angle type isolationvalves. The gauge glasses shall have a minimum length of 12 inches (300
mm). The vessels shall be provided with an automatic drain valve for the
discharge of liquids. All necessary controls for the drain valves shall be
supplied. A flanged cleanout connection shall be provided for each vessel. A
vent connection shall also be provided for each vessel.
8.5 Pulsation, Vibration Control and Analog Study
CONTRACTOR shall get the acoustic and mechanical evaluation study carried
out for compressor package (from inlet flange to discharge on skid edge Plus
200 ft piping) by a certified agency. The compressor CONTRACTOR shall be
totally responsible for all the coordination with the agency carrying out the
study. CONTRACTOR shall submit acoustic and mechanical evaluation report to
CLIENT.
9.
TECHNICAL REQUIREMENTS FOR ELECTRICAL
The Gas Engine Compressor Package shall be designed for installation in a
Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area. All equipment
installed within the module shall be suitable for a Zone 2 Gas Group IIA,
Temperature Class T3 Hazardous Area. Electrical equipment supplied outdoors
shall be protected to IP 56, while IP 42 protection shall be specified for
equipment installed indoors.
The CONTRACTOR shall provide appropriately certified stainless steel
interfacing junction boxes for all power and control signals on each separate
equipment for GEC. Separate junction boxes shall be provided for power, shut-
down, fire and gas, control and I.S. circuit.
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Electric motors shall be of the 3-phase, 50Hz cage induction, totally enclosed,
fan-cooled type and rated to start and accelerate the load with 80% voltage at
their terminals.
For EExd motors/enclosures, all cable gland entries shall be provided. A valid
Ex certificate shall be supplied for each Ex certified item (motor, enclosure,
junction box, cable gland, etc.)
Power supply for equipment such as circuit breaker shall be provided in Exd
explosion proof enclosure
All junction boxes shall be provided with 20% spare terminals so that all spare
cores of incoming cables can be terminated.
Separately installed equipments shall be suitably earthed by connection to theplatform deck via two earth M10 screwed bosses positioned on diagonally
opposite corners of the equipments.
Nameplates of electrical equipment shall be carried electrical classification
information.
Electrical power will be provided by the CLIENT at 400V AC, 3-phase 4 wires /
230V AC, 1-phase, 50Hz, neutral solidly earthed at source for lighting and
small power and 230V AC (UPS), 1-phase, 50Hz neutral earthed for UCP.
All AC electric motors, such as lube oil pumps, engine enclosure ventilatingfans, etc., shall be rated 400 volts AC, 3-phase, 50 Hz. All motors shall conform
to relevant IEC standards.
CONTRACTOR shall provide lighting fixtures for inside the gas engine enclosure
and inlet air filter. A battery pack that will allow the fixture to continue to
operate after a power outage for approximately 90 minutes shall be supplied in
the fixture.
Power and control wiring within the GEC package shall be in accordance with
BS 7671 IEE Wiring regulations 17th edition, and Specification for Electrical
Requirement for Packaged Equipment.
Solenoid coils furnished by CONTRACTOR shall be rated 24 VDC unless
otherwise specified.
Motors, switches, etc. shall receive full tropic
Recommended