Compressor

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 1 of 123 15/11/2002 REV 0 10. COMPRESSORS 10.1

PREFACE

This lesson will cover the procedures required for compressor equipment studies, their supporting equipment and the piping connected to them. Two things to keep in mind; first, use Fluor standards as a guide, and second, the guidelines mentioned in this lesson may be different than jobs you may have worked on in the past. Some clients have their own engineering standards. 10.1.1 Lesson Objectives Lessons provide self-teaching piping layout training to designers who have basic piping design skills. Training material can be applied to manual or electronic applications. Lesson objectives are: •

To become familiar with the more commonly used compressors, how they operate and some of their uses.

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To know the types of compressors.

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To know how to determine where compressors should be located.

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To know how to make compressor studies avoiding major mistakes and costly changes.

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To familiarize you with Fluor standard compressor design. (Fluor standards are a guide; the standards used on your contract shall govern.

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To know procedures for checking foreign prints of compressors.

10.1.2 Lesson Study Plan Take the time to familiarize yourself with the lesson sections. The following information will be required to support your self-study: • • •

Previous lesson plans; e.g. Pipe Stress Lesson #1. Your copy of the Reference Data Book (R.D.B. Fluor Technical Practices. The following Practices (not included) support this lesson.

It should take you approximately 80 hours to read this lesson plan and be prepared to take the lesson test. If you have questions concerning this lesson your immediate supervisor is available to assist you. If you have general questions about the lesson contact Piping Staff Group.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 2 of 123 15/11/2002 REV 0 Additional support information: • Your copy of the Piping Engineering Design Guide. • Previous lesson plans; e.g. Pipe Stress section, Lesson #1. 10.1.3 Study Aid Videos on Piping Design Layout Practices supplement your layout training. It is suggested that you view these videos prior to stating the layout training. You may check out a copy of the videos from the Knowledge Centre (Library). 10.1.4 Proficiency Testing A self-test on your comprehension of this lesson is provided at the back of the lesson. A self-grading master immediately follows the test. The test is divided into three separate test sections: General introduction and administration activities of compressors Plot Layout and Layout Guide Compressor Specialty Items Testing Questions are manual fill-in and True / False. The tests should take approximately one and one half hours. You may use your layout training Reference Data Book and material from previous layout training lessons during the testing.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 3 of 123 15/11/2002 REV 0 10.2

DEFINITIONS

Compressors provide a mechanical means of increasing vapor pressure by intaking the vapor at a relatively low pressure, compressing it, and discharging it at a higher pressure. Essentially, there are two classifications for compressors: Dynamic and Positive-Displacement. Dynamic type compressors are continuous flow machines in which vapor is compressed by the dynamic action of rotating impellers or vanes imparting velocity and pressure to the vapor flow. Two common variations are: Centrifugal and Axial Compressors. Centrifugal compressors impart velocity and pressure to the vapor in a radial direction by one or more impeller diffuser combinations, of which, each represents one stage of compression. Axial compressors impart velocity and pressure to the vapor in an axial direction through one or more sets of moving and stationary rows of blades. Positive Displacement (intermittent flow) type compressors successively confines a vapor-volume within a closed space. The vapor-volume is compressed and the pressure is increased as the vaporvolume is decreased. Four general variations are available as follows: Reciprocating compressors utilize a piston as the compressing element moving in a back and forth motion within a cylinder. Rotary Sliding-Vane compressors employ longitudinal vanes that slide radially in a rotor mounted eccentrically in a cylinder. Rotary Lobe compressors use two mating lobed impellers which revolve within a cylinder. Timing gears, mounted outside of the cylinder, prevent any contact between the lobes. Rotary Liquid Piston compressors employ a liquid, usually in a single rotating, to displace the vapor being compressed. As a general rule, positive displacement compressors are used for small capacity requirements and dynamic machines are employed for medium and large capacities, i.e., centrifugal and axial, respectively. Centrifugal and reciprocating compressors are available in single and multi-stage units. The number of stages is dependent upon mechanical considerations and process requirements. Every compressor is made up of one or more basic elements. A single element, or a group of elements in parallel, comprises a single-stage compressor. A combination of elements or groups of elements in series forms a multistage unit, in which there are two or more steps of compression. Note that each stage is a basic individual compressor within itself.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 4 of 123 15/11/2002 REV 0

10.3

CENTRIFUGAL COMPRESSORS

Centrifugal compressors are simple in construction and can be described by relatively simple means. Essentially, a single-stage (Fig.#10-1) centrifugal compressor consists of the following basic elements: (1) inlet or suction connection, (2) impeller, (3) diffuser, (4) casing (or volute), (5) shaft and bearings, (6) shaft seals and (7) outlet or discharge connection. The inlet or suction connection allows the air or gas entrance into the case. This connection is proportioned so as to minimize shock from the fluid flow.

Figure #10-1 Typical overhung impeller single -stage centrifugal compressor

Figure #10-2 Cross-section of a typical multistage (5 stage) centrifugal compressor

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 5 of 123 15/11/2002 REV 0 The fluid flows into the eye of the impeller that imparts velocity to the air or gas and delivers it to the diffuser. The diffuser gradually converts the velocity energy into pressure energy. The casing (or volute) is a protective cover designed to confine the air or gas being compressed and also serves as a support for the rotor. The rotor is the rotating element consisting of a shaft about which the impeller is attached. Seals are provided at both ends of the shaft to minimize gas leakage from the case and to prevent introduction of outside air. When the pressure level requirement exceeds the limit of a single-stage, a multistage compressor (Fig. #10-2) must be used. This requires a return passage that transfers the gas from one stage (impeller) to the next succeeding stage. A single case is limited to twelve stages (12 impellers) of compression. When thirteen or more stages is required two or more cases must be coupled together in single file, i.e. tandem as shown in Figure #10-3.

Figure #10-3 Cross-section of two multistage units in tandem 10.3.1 Impeller and Nozzle Arrangements for Centrifugal Compressors The multistage centrifugal compressor is a highly flexible machine. It can be easily adapted to suit varied process and mechanical considerations. For example, depending on flow and head requirements, the number of impellers may be as high as twelve. Suction and discharge nozzles may be located up, up and down, down, or offset at an angle. In addition, nozzles for economizers, side streams, or iso-cooling can easily be incorporated into the design.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 6 of 123 15/11/2002 REV 0 Several of the most common arrangements are shown schematically in Figures #10-4 through #10-8. Down nozzles are shown exclusively for simplicity and because this location permits easy access to internals without disturbing the major piping systems and is usually preferred for horizontally split compressors.

Figure #10-4 Straight-through Flow Figure #10-7 Iso-cooling (cooling between stages)

Figure #10-5 Double flow

Figure #10-8 Double Iso-Cooling (cooling between stages)

Figure #10-6 Side Streams

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 2 of 123 15/11/2002 REV 0 Straight-Through Flow - Maximum of twelve stages of compression. Used primarily for low-pressure process compression. Double Flow - The maximum flow capability is doubled since the number of impellers assigned to each inlet flow is one half that of a straight-through machine. Side Streams - Side stream nozzles allow the introduction or extraction of gas at selected pressure levels. Iso-Cooling - In a compressor where the gas temperature has climbed to 200°F to 400°F, improved efficiency and horsepower reduction is achieved by cooling the gas. Iso-cooling nozzles permit the hot gas flow to be extracted and circulate through an external heat exchanger, then returned to the successive impeller at reduced temperature for further compression. Double Iso-Cooling - High mole weight gases such as chlorine heat much more rapidly during compression than the low mole weight gases. This type of service may require the hot gases to be removed at two interstages and circulated through two intercoolers, in order to maintain compressor efficiency. 10.3.2 Case Types - Centrifugal Compressors Centrifugal compressors (Figure #10-9) are available in two types: vertically split and horizontally split cases. In general, vertically split (barrel case) machines are used for high-pressure applications and horizontally split machines are used for low pressure and medium to high volume applications. 10.4

RECIPROCATING COMPRESSORS

The basic reciprocating compressor consists of (1) frame, (2) crankshaft, (3) flywheel, (4) cross head housing, (5) distance piece, (6) cylinder, (7) piston, (8) piston rod and (9) connecting rod. Their principal functions are: The frame is a protective cover that supports and houses the crankshaft The crankshaft, with its offset(s), converts circular motion into a reciprocating, back and forth, motion. The flywheel opposes and moderates by its inertia any fluctuation of speed in the compressor. It is connected to the driver end of the crankshaft. The crosshead housing supports the reciprocating action of the connecting rod that is attached to the offset of the crankshaft. Where the process gas must be oil free, a distance piece is used to prevent any part of the piston rod from alternately entering the frame and the cylinder. It also supports the piston rod reciprocating action.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 3 of 123 15/11/2002 REV 0 The cylinder is the compression chamber. It is fastened to the crosshead housing or distance piece and houses the piston. The piston is the basic reciprocating compression element. The various steps in a reciprocating compressor cycle are shown in Figure #10-10.

Figure 10-9 Basic case designs of centrifugal compressor


Figure 10-10 Steps in a Reciprocating Compressor Cycle

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 5 of 123 15/11/2002 REV 0 10.4.1 Cylinder Arrangements - Reciprocating Compressors The reciprocating compressor is, essentially, a fixed capacity compressor with a variable capacity accomplished by altering the speed of the driver or the clearance volume space. There are three variations widely used in refinery and petrochemical installations. Horizontal or Straight-Line (Fig. #10-11) compressor has only one cylinder. It is the most basic of all reciprocating compressor designs. Balanced Opposed (Fig.#10-12) design features one or more cylinders mounted on both sides of the frame. Angle Type (Fig.#10-13) is an engine driven unit with all cylinders mounted on one side of the frame. 10.5

COMPRESSOR DRIVERS

Compressors utilize electric motors, steam turbines, gas engines, and gas turbines as drivers, to name a few. These drivers are basically a means of converting available energy into mechanical work. Electric Motors - There are two types used in geared or non-geared applications. (a) Induction Motor. (Fig.#10-14) (b) Synchronous Motor. (Fig.#10-15) Steam Turbines - There are two basic types of steam turbines, namely, condensing and noncondensing (back pressure). Condensing turbines exhaust below atmospheric pressure to a surface condenser. Noncondensing turbines exhaust at atmospheric pressure or higher into a steam piping system. Four variations of the two basic types are briefly described in Figure #10-16. Gas Turbines - In its simplest form, a gas turbine consists of a centrifugal compressor supplying air for combustion, a combustion chamber with a fuel-injection system and a turbine wheel through which the expansion of hot gases provides rotary power to the turbines. They have been classified as follows: (a) Single or two-shaft. (b) Simple or regenerative cycle.


Figure #10-11 Typical Horizontal Straight-Line Compressor

Figure #10-12 Typical Multiple-Service Reciprocating Compressor Handling Six Service Streams in Twelve Cylinders


Figure 10-13 Cross-Section of a Typical Turbo-Charged Engine Driven Compressor. This arrangement is commonly known as an angle compressor.


Figure #10-14 Induction Motor Driver

Figure #10-15 Synchronous Motor Driver


Figure 10-16 Steam Turbine Types

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 10 of 123 15/11/2002 REV 0 Expansion Turbines - Convert gas or vapor energy into mechanical work as the gas or vapor expands through the turbine. There are two types: axial flow and radial flow. (a) Axial flow expansion turbines are like conventional steam turbines. (b) Radial flow expansion turbines are normally single stage with a rotor resembling that of a centrifugal pump. Gas Engines are simply internal combustion drivers similar to automobile engines. Liquid Power Recovery Turbines - These are special pumps used to reduce a high pressure liquid stream to a low pressure by pumping it backwards to drive another pump or compressor. Drivers may be connected to compressors with or without speed increasing or reducing gears. The use of this component creates a horizontal offset of the compressor shaft and the driver shaft; thus, it is a very important layout consideration when required. 10.5.1 Auxiliaries for Compressors and Drivers Lubrication requirements, shaft seal design, controls, instrumentation, and other specific items are evaluated and determined by the mechanical and project engineers. A complete lube oil system is required for each type of compressor to supply oil at suitable pressure to vital parts of the machinery. For reciprocating machines, the lube oil system is usually mounted on the compressor. Centrifugal compressors require a separate skid mounted console. A separate oil system (seal oil) for shaft sealing is required for centrifugal compressors when the process gas could leak from the case and enter the lube oil system and eventually cause mechanical damage. The lube and seal oil systems for centrifugal compressors are combined, when feasible, on one console. When the seal oil system must be separate, two consoles are required. Compressor control systems may be pneumatic, hydraulic, electrical, or electronic and may be operated manually or automatically. An instrument control panel is normally required to centrally locate instrumentation for monitoring operating conditions of the compressor. Other auxiliary equipment, such as condensers, intercoolers, aftercoolers, mufflers, air filters, special relief valves, and pulsation suppression devices are used as required and will be discussed in more detail later.


10.6

GLOSSARY OF TERMS

Some of these definitions apply to specific compressors only, therefore, (C) or (R) that designates centrifugal or reciprocating, respectively will precede those definitions. AFTERCOOLER - a heat exchanger that cools a gas following the completion of compression to (1) reduce the temperature and (2) to liquefy condensable vapors. (C) BASE PLATE - a metal structure on which the compressor and possibly the driver are mounted (see sole plate). CAPACITY - the quantity of gas actually delivered when operating between a specified inlet and discharge pressure. (C) CASING - is the pressure containing stationary element that encloses the rotor and associated internal components. It includes inlet and discharge connections, and a means for support and lifting. (R) CLEARANCE - (reciprocating compressor cylinder) that volume contained in one end of the cylinder which is not swept by the movement of the piston. DEW POINT - the temperature of a gas at which the vapor in a space (at a given pressure) will start to condense (form dew). (C) DIFFUSER - a stationary passageway following an impeller in which velocity energy imparted to the gas by the impeller is converted into static pressure. (R) DISPLACEMENT - applies only to positive - displacement compressors. It is the net volume swept by the moving parts in a unit of time, usually one minute. (R) DOUBLE - ACTING - a cylinder where compression takes place on both of the piston strokes per revolution. HORSEPOWER - a unit of work equal to 33,000 foot - pounds per minute. (C) IMPELLER - the part of the rotating element that imparts momentum to the gas by aerodynamic forces. INTERCOOLER - a heat exchanger which cools a gas between stages of compression to (1) reduce the temperature, (2) reduce the volume to be compressed in succeeding stages, (3) to liquefy condensable vapors, and (4) to save power. (R) MANIFOLD - a volume bottle used to join the inlet or discharge connections of cylinders operating in parallel. PRIME MOVER - a generic term for any machinery used to drive a compressor.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 12 of 123 15/11/2002 REV 0 (R) PULSATION DAMPENER - a commercial, internally - baffled device. PURGING - the act of replacing the atmosphere within piping by an inert fluid in such a manner as to prevent the formation of explosive mixtures. RECIPROCATING COMPRESSOR - a positive displacement machine in which the compressing and displacing element is a piston having a reciprocating motion within a cylinder. (C) ROTOR - the rotating element composed of impeller(s) and shaft, and may include shaft sleeves, rotating seal parts, and thrust collar. (C) SEALS - devices used between rotating and stationary parts to minimize gas leakage between areas of unequal pressures. SHAFT BEARINGS - lubricated stationary parts that support and radially locate the compressor shaft. (R) SINGLE - ACTING - a cylinder where compression takes place only on one of the two piston strokes per revolution. STAGE - a period or interval of development. (C) SOLE PLATE - a mounted pad, usually embedded in concrete, on which the compressor is mounted (see base plate). (C) TANDEM - one behind another, close coupled. (C) THRUST BALANCING DEVICE (DRUM, PISTON, OR DISC) - that part(s) utilizing gas pressure to counteract the thrust developed by the impellers. (R) VOLUME BOTTLE - a pressure vessel, unbaffled internally, mounted on a cylinder inlet or discharge. May be used too as a condensate separator. (C) VOLUTE - a stationary, spirally shaped passageway in the casing that collects the flow leaving an impeller or diffuser and converts velocity energy into static pressure.


SPECIFICATION - GENERAL CONTRACT DATA

Mechanical narrative specifications are very important contract documents useful in the layout and design functions. These narratives originate from the compressor group of the Mechanical Engineering department. Because they are contract wide documents they are general in nature. They are an accepted overview of the various engineering and design requirements. These documents are used to communicate to the prospective compressor Vendor the basic requirements of the compressor. All narrative specifications pertinent to the compressor and its auxiliaries should be thoroughly examined by the designer. It is suggested that marginal notation or "yellow-off" be used to emphasize items that affect piping design. It is essential that all these notes be consistent with piping design specifications. Any discrepancies should be brought to the attention of the piping design supervisor and compressor engineer. Often, a condition will exist where some facet of a particular compressor installation will require some adjustment to the narrative specifications, specification sheets, flowsheets, etc. This is to be expected, even desirable because it allows the engineer and designer the feasibility of making a "local" adjustment for improvements. It is very important to document and track the exceptions to the basic specifications. Obviously, the Vendor must be aware of these changes via the compressor engineer. In summary, the narrative specifications relates to the Vendor, client, piping design, etc., brief descriptions of the various design requirements. Obtain the latest complete copy of all pertinent narrative specifications and: 1. Examine in detail for items relating to piping design "yellow-off" the portions so noted. 2. Compare the various items to piping design specifications, etc. 3. Compare results to copies of specifications previously issued to Vendors. 4. Report design inconsistencies to the design supervisor and compressor engineers. 5. Deposit a separate copy of the specifications in each compressor job-book, (see job-book section for comments). 6. Mark-up, adjust and document exceptions to the specifications for each particular compressor installation in the job-book copy.


GENERAL SPECIFICATIONS

The following information covers the specific portions that affect piping design. This information is intended to serve as a guide by directing the piping designer to the specific sections and paragraphs of each particular specification. The number preceding the following paragraphs corresponds with that number which appears in the Fluor Mechanical and the API Standard Specifications. 10.9

GENERAL SPECIFICATION FOR PROCESS CENTRIFUGAL COMPRESSORS

10.9.1 Scope The specification covers the minimum requirements for process centrifugal compressors (of either vertically or horizontally split construction) that are usually unspared and in critical services. Excluded specifically from this specification are light duty centrifugal blowers (below 15 psi) and centrifugal plant air compressors (125 psig and below). This specification supplements the individual mechanical data sheets on which the operating conditions and special requirements are listed in detail. Whenever the data included on the individual specification sheet conflicts with a provision of this general specification, the former shall govern. 10.9.2 Basic Design (API Section 2) Allowable force and moment diagrams shall be submitted to the Purchaser for review. The Vendor shall also review piping and layout drawings, calculations, and design conditions for compatibility with materials not provided by the Vendor. Connections and nozzle arrangements shall be subject to approval and review by the Purchaser. All flanged casing connections except for water and lube oil shall be the same ANSI rating as the major casing nozzles. Each casing drain shall be individually valved and manifolded to a single flanged outlet connection. The number of drains will depend on the service as well as casing construction as noted on the individual data sheets. All oil drains shall be sized to operate no more than half full and shall be arranged to ensure good drainage despite possible foaming. As a minimum, all oil drain lines shall be 1-1/2 inch NPS (flanged with the exception of the inner seal oil drains which may be 1 inch NPS (flanged). Horizontal runs shall slope continuously downward toward the reservoir; the angle of each slope shall be a minimum of 1/2 inch per foot. This may necessitate off-base mounted headers. The various elevation differences necessary to comply with these requirements shall be considered when arranging the equipment, the components, and the reservoir.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 15 of 123 15/11/2002 REV 0 The Vendor shall furnish all couplings for connecting shafts of compressor, gear (if any) and driver. The Vendor shall completely machine all coupling halves and arrange for mounting of gear (if any) and driver half couplings. Keyless shaft ends utilizing hydraulically fit coupling halves are, in general, acceptable. 10.10 GENERAL SPECIFICATION FOR SPECIAL PURPOSE STEAM TURBINES 10.10.1

Scope

The specification covers the minimum requirements for horizontal steam turbines used to drive equipment that is usually unspared and is in critical services such as centrifugal compressors and generators. This specification supplements the individual data sheets on which the operating conditions and special requirements are listed in detail. Whenever the data included on the individual specification sheet conflicts with a provision of this general specification, the former shall govern. 10.10.2

Basic Design (API Section 2)

All turbine case, trip and throttle valve (if required), steam chest and staging drains (if required) shall be separately flanged, piped and valved. The number of drains will depend on the service as well as construction as noted on the individual data sheets. Allowable force and moment diagrams shall be submitted to the Purchaser for review. The Vendor shall also review piping and layout drawings, calculations, and design conditions for compatibility with materials not provided by the Vendor. All flanged casing connections except for water and lube oil shall be the same ANSI rating as the major casing nozzles. Flanged connections shall conform to ANSI B16.1 or B16.5, as applicable, except that cast iron flanges shall be flat faced. Face and drilling requirements shall also apply to studded connections for which studs shall be furnished. Flat-faced flanges are acceptable on steel cases with the Purchaser's approval. Flanges thicker or of a larger outside diameter (OD) than required by this standard are acceptable. If the Vendor used flanges or connections other than those covered by ANSI, the Vendor shall supply all required mating parts and the Purchaser shall approve details of the connections. All oil drains shall be sized to operate no more than half full and shall be arranged to ensure good drainage despite possible foaming. As a minimum, all oil drain lines shall be 1-1/2 inch NPS (flanged). Horizontal runs shall slope continuously downward toward the reservoir; the angle to each slope shall be a minimum of 1/2 inch per foot.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 16 of 123 15/11/2002 REV 0 This may necessitate off-base mounted headers. The various elevation differences necessary to comply with these requirements shall be considered when arranging the equipment, the components, and the reservoir. The gland seal steam system shall be complete with automatic steam seal regulator (if required), all piping, valves and fittings. A gland steam condenser of the shell and tube type and a suitable steam ejector shall be provided and will be mounted and piped by the Purchaser.Refer to Purchaser's specification data sheets for heat exchanger and ejector design requirements. If so specified on the individual data sheets, the Vendor shall furnish the insulation for the turbine, do the insulation in the shop and supply a readily removable painted metal jacket that is to cover the steam chest and/or high pressure casing. The insulation shall keep the jacket skin temperature below 165°F. Insulation containing asbestos is unacceptable. 10.11 GENERAL SPECIFICATION FOR PROCESS RECIPROCATING COMPRESSORS (400 HP AND ABOVE) 10.11.1

Scope

This specification covers the general requirements for process reciprocating compressors, 400 hp and above, to be purchased for refinery services in handling air or gas. Such services are normally considered critical in nature and may or may not be spared. Excluded specifically from these requirements are single acting (water or air-cooled) compressors, portable air compressors and utility plant and instrument air compressors at 125 psig and below. This specification supplements the individual data sheets on which the operating conditions and special requirements are listed in detail. Whenever the data included on the individual specification sheet conflicts with a provision of this general specification, the former shall govern. 10.11.2

Basic Design (API Section 2)

In some instances, a self-contained closed coolant system is required. If such a system is specified, it shall meet the following criteria and design requirements. A means shall be provided to permit supplying coolant to the cylinder jackets at an entering jacket temperature 15 degrees (unless otherwise accepted) above inlet gas temperature. To accomplish this, a packaged jacket coolant system as described herewith, or as mutually agreed, shall be furnished. The suction of dual centrifugal motor driven circulating pumps shall be taken directly from a self venting, vertical stand pipe reservoir (capable of steam heating) and discharge through a suitable coolant-to-water heat exchanger with automatic bypass temperature control to the compressor jacket piping system.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 17 of 123 15/11/2002 REV 0 The quantity of coolant circulated to each pump shall be sufficient to maintain a 10°F temperature rise across any individual cylinder. The system shall be pre-piped and factory skid mounted, and be complete with the various pressure and temperature indicators, alarms, and other instrumentation as specified on the individual data sheets. Cooling water jackets shall be of cored or bolted construction and designed for not less than 75 psig operating pressure. The jackets shall be accessible for thorough cleaning. Piping drains shall be provided at the lowest points. A minimum of one drain connection with a plugged valve shall be provided on each distance piece compartment including those with internal reinforcing ribs. A separate vent connection shall be included for each distance piece compartment. All external connections on distance pieces shall be 3/4 inch NPT minimum (including the packing vent connection). Internal packing vent tubing shall be 304 stainless. Frame lubrication system for each unit shall also include a thermostatically controlled valve to control oil bypassing of the oil cooler in order to maintain desired oil temperature. Suction and discharge block valves, relief valve, discharge check valve, and discharge pressure gauge shall be furnished for each pump, except that suction and discharge block valves are not required for shaft driven pumps. The complete system must be shop mounted and match-marked for field assembly. In some instances, a self-contained, separately packaged lube system is required. If such a system is specified, it shall meet the following criteria and design requirements. A complete pre-piped and base mounted packaged frame oil system shall be furnished by the Vendor and shipped as a packaged assembly. The suction of the dual motor driven gear pumps shall be taken directly from the compressor crankcase sump and discharged through an oil-to-water heat exchanger with an automatic temperature controlled bypass, a set of twin oil filters with a suitable transfer valve into the internal frame lubrication system. The system shall be complete with the proper valving, pressure and temperature indicators, various alarms and other instrumentation, etc., as specified on the individual data sheets. A barring-over device is required for field use at startup and during maintenance. See the individual data sheets for type (manual or pneumatic) required. In either case, the barring wheel shall be statically balanced and marked on the frame side for proper installation. 10.11.3

Piping and Appurtenances (API Section 3)

The Vendor shall conduct an active electrical analog review to determine the acoustical response of the piping system based on isometric drawings (provided by the Purchaser) of all piping and appurtenances.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 18 of 123 15/11/2002 REV 0 A mechanical response analysis of the piping support system is required only if specifically noted on the individual data sheets and/or the formal purchase order. A sight flow indicator, temperature indicator and globe valve shall be installed in cooling water outlet piping for each cylinder whether single or multistage. Similar configuration is also required for rod coolant and intercoolers if furnished by the Vendor. Refer to Purchase Specification covering Pulsation Suppression Devices. This specification shall apply specifically if machine mounted terminal pulsation devices and/or interstage equipment is to be furnished by the compressor Vendor. Refer to the individual data sheets for specific intercooler and/or aftercooler requirements. In general, all coolers will be the shell and tube type of the water through tube design. Finned tubes and U-tubes are not acceptable unless specifically approved by the Purchaser. The individual data sheets delineate whether the Vendor or the Purchaser will furnish the coolers as well as their mounting configuration. 10.11.4

Controls and Instrumentation (API Section 4)

The Purchaser will furnish a freestanding local control and instrument panel. The Purchaser with reference to the Vendor's requirements and in accordance with the Purchaser's specifications will purchase instruments mounted on the panel. 10.12 GENERAL SPECIFICATION FOR PULSATION SUPPRESSION DEVICES ON RECIPROCATING COMPRESSORS 10.12.1

Scope

The specification covers the basic minimum requirements for inlet and discharge pulsation suppression devices for reciprocating compressors of either single or multistage designs intended for process air or gas service. This specification supplements the individual data sheets on which the construction details and special requirements are listed in detail. Whenever the data included on the individual specification sheet conflicts with a provision of this general specification, the former shall govern. This specification applies to all process reciprocating compressors with discharge pressures of 5000 psig and below and with brake horsepower requirements of 75 and above. Discharge pressures above 5000 psig are normally considered "special" and will be treated separately if so noted on the individual data sheets. Units below 75 BHP will apply if so determined by the Purchaser as influenced by compression ratio and pressure level.


10.12.2

Design Approach

When specified on the individual data sheets, volume bottles may be supplied as an alternate pulsation suppression device. A volume bottle is defined as an empty vessel with, at least twice the diameter of the line connection utilizing volume as a mass slug dissipater to accomplish acoustical suppression. A minimum mass slug-ratio of twelve (12) shall be used. For interstage systems furnished by the compressor Vendor, the maximum allowable peak-to-peak residual pulsation levels (PN) at the line side of all types of interstage suppression devices shall be limited to 5 percent as qualified by an active analog study. The compressor Vendor shall guarantee that interstage equipment vibration in any plane, with respect to the compressor cylinders, shall not exceed 8 mils (peak-to-peak). The compressor Vendor shall be responsible for proper fit without interference (valve and unloader removal, as an example) and shall furnish all supports necessary for both acoustical and mechanical stability. The compressor Vendor shall also meet the design criteria previously outlined above unless otherwise mutually agreed. The suppressor Vendor shall perform a manual mechanical - acoustical response analysis of the Fluor piping isometric drawings to review holddown and resonant length characteristics as well as possible acoustical resonances and to suggest solutions to problem areas. In all cases, the compressor Vendor shall conduct an active electrical analog review that simulates the entire compressor, pulsation devices, piping and other system equipment, and considers the dynamic interaction of these elements. Each suppression device of commercial design shall be provided with maximum size drain openings through each baffle. In no case shall they be less than 1 inch. Where drains are impracticable, circular notched openings in the bulkheads extending to the vessel wall may be used with approval. The effect of such drain openings on pulsation suppressor performance should be considered. Arrangement of internals shall insure that liquids will flow to drain connections under all operating conditions. The nozzle length from the pulsation suppressor shell to the cylinder flange shall be held to a minimum consistent with thermal flexibility and alignment limitations. The nozzle area shall be at least equal to the area of the compressor opening. Adequate space shall be allowed for full access to and maintenance of cylinder working parts such as valves and unloader assemblies. All pulsation suppressers shall be hydrotested to 1-1/2 times the design pressure.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 20 of 123 15/11/2002 REV 0 Vendor shall furnish the tie-in structure for attachment of supports if required. Purchaser will supply supports, holddowns and anchors. The Purchaser will supply installation of companion flanges, gaskets, bolts, and nuts. The Vendor shall supply all blind flanges complete with gaskets (suitable for the process involved), nuts, and bolts. Fabrication drawings, including specific weld details, external drain details, and the like shall be submitted to Purchaser for review and approval. 10.13 SPECIFICATION SHEETS Engineering specification sheets, commonly called "data sheets," unlike narrative specifications, provide both general and detail information on a specific compressor, driver and/or its auxiliaries. They are a great asset to the layout designer during preliminary stages of a contract; therefore, greater emphasis is placed on their use rather than the narrative specification. All specification sheets related to the compressor and its auxiliaries should be filed in the appropriate section of the compressor job book and must be carefully examined by the layout designer. It is suggested that "yellow-off or some other suitable means be used to "pinpoint" items that would affect piping. If conflicting requirements should be found, for example, between the specification sheets and the narrative specification, generally, the specification sheet will take precedence. However, such a situation must be presented to the piping design supervisor and mechanical (compressor) engineer. The discussion of certain major pieces of equipment in this guide material is supplemented in this section by a copy of the specification sheet with notes indicating items that are directly useful to piping design functions, therefore, greater emphasis is placed on their use rather than the narrative specification.


10.13.1

Specification sheet notes for centrifugal compressors. 1.

It is important to note the job number and item number, especially when handling several items.

2.

Verify that the latest revision is being used.

3.

Inlet and discharge conditions are helpful in preliminary stress analysis.

4.

Information provided under location will predicate shelter requirements and basic elevation of the compressor.

5.

Model number is useful for obtaining catalog information. Casing type will be indicated as vertical or horizontal split.

6.

Seal system type.

7.

Provided is the main process connection design information.

8.

Limiting criteria for forces and moments.

9.

Auxiliary piping connections.

10. Using make and model number, obtain information for coupling which will establish the distance between shaft ends of compressor and drive system. 11. Use this section to determine heaviest maintenance lift requirement. 12. Preliminary space requirements for developing plot layout. 13. Straight run requirement for suction piping.


10.13.2

Specification sheet notes for reciprocating compressors. 1.

It is important to note job number and item number especially when handling several items.

2.


3.

Inlet and discharge conditions are helpful in preliminary stress analysis.

4.

Listed are auxiliaries to be furnished by compressor manufacturer.

5.

This section provides heaviest maintenance lift, approximate floor space, and rod removal requirements.

6.

The important items to note are suction and discharge connections, single or double acting cylinder, and cylinder bore and stroke which are required for calculating the forcing frequency and volumes for dampening devices.

7.

The distance piece vent requirement is provided here and basic construction features.

8. 9.

Manufacturer and model number will be useful in obtaining preliminary catalog information. Shelter requirements.

10. Cooling water requirements for cylinders, lube oil cooler, intercoolers and rod packing. 10.13.3

Specification sheet notes for electric motors. 1.

It is important to note the job number and item number especially when handling several items.

2.


3.

If a gear is required in the drive system, it will affect floor layout.

4.

Baseplate or soleplate will affect foundation design. Investigate conduit box requirements.

5.

Type of motor required; induction or synchronous.


10.13.4

Specification sheet notes for special purpose steam turbines. 1.

It is important to note the job number and item number especially when handling several items.

2.


3.

Steam inlet and exhaust conditions are needed for preliminary stress analysis.

4.

Shelter requirements are provided under location.

5.

Casing type is indicated as horizontal or vertical split.

6.

Baseplate or soleplate will affect foundation design.

7.

Requirements for gland condenser and/or ejectors are provided.

8.

Design of main connections are given.

9.

This section provides limiting criteria for forces and moments.

10. Maintenance lifting requirements and approximate floor space required is shown. 11. Lube oil system requirements. 12. Coupling requirement will affect spacing of compressor and driver. 13. Gear, when required, will also affect spacing of compressor and driver. 14. Contact instrument engineer for control panel size when vendor does not furnish it. 10.13.5

Specification sheet notes for surface condensers. 1.

It is important to note the item and job numbers, especially when handling several items. Verify that the latest revision is being used.

2.

Inlet and outlet pressure/temperature conditions are provided and are helpful in preliminary stress analysis.

3.

The size and rating of the main process nozzles are given. In addition, auxiliary equipment vendors are listed.

4.

Air removal equipment - usually 2 stage - is specified.

5.

Ejector shell sizes and weights are provided.


10.14 VENDOR' S DRAWING AND DATA COMMITMENT This document is extremely important for many reasons. It lists all the drawings the vendor is required to submit for Fluor approval. It gives the listing of the priority status of each drawing. That is the sequence of delivery and scheduled delivery date of each drawing. The designer must verify the priority according to his needs. Also, using the scheduled delivery dates, the Unit Piping Supervisor should update and revise the piping activities on the Control Level Schedule accordingly. This document is the schedule the vendor will maintain. Completed Vendor's Drawing and Data Commitment forms are not formally issued to piping. Copies must be obtained by request to Equipment Engineer or Vendor Information Control group. 10.15

CATALOG INFORMATION

During the early stages of a contract, the compressor engineer will furnish catalog drawings of the compressor and driver to be used for preliminary layout. The possibilities for compressor driver combinations vary in many ways; manufacturer, size, type, to name a few. In view of this fact, sufficient space is not available here to satisfy the varied possibilities that are available. The layout designer must obtain the correct catalog sheets from either the unit piping supervisor or the compressor engineer. 10.16 CENTRIFUGAL COMPRESSOR PLOT LAYOUT The location of the compressor installation must be influenced by physical size, process consideration, fire and safety hazards, economic pipe runs, accessibility, stress requirements and maintenance and operation requirements. Research all pertinent preliminary flow diagrams to determine the physical affect on the plot plan. The compressor must be located as close as possible to its suction source. An excessively long suction line will increase costs by consuming extra driver horsepower. The suction line must be short and direct. If interstage equipment is required, make a detailed flow transposition for proving the best arrangement. Other important items to be considered include, operating valves, meter runs, N.P.S.H. for surface condenser condensate pumps, vertical vs. horizontal K.O. drums unusually large lube and seal oil consoles, and interstage separators. The interrelationships of all major components should be determined through discussion with Process and Mechanical Engineering. Color code and make free-hand sketches of physical requirements such as mezzanines, or heat exchanger structures. "Look at it as a system" and lay it out accordingly. The compressor installation must be located close to a service road so that it is readily accessible by mobile equipment. Research past contract estimates and model photos for similar installations.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 25 of 123 15/11/2002 REV 0 At this stage, very preliminary information is OK, but allow for at least 20% more workable area. Compressors sometimes have the luxury of "growing". Before final release of location, review for following: 1. 2. 3. 4.

Access for large lifts Feasibility of structural requirements. Power source for motor drivers. Piping support requirements for large lines. Electrical rack requirements and control panel requirements. 5. Distance from heaters, boilers and high frequency roads. 6. Conformance with all equipment narrative specifications and individual specification sheets. Several typical plot arrangements are provided in Figure #10-17 & #10-18. After the location of the compressor is finalized, select a plot arrangement and modify it to suit known contract requirements. For simplicity, single compressor arrangements have been shown exclusively, however, these arrangements may be applied to multicompressor installations also. For example, a given contract might have the following compression requirements: 1) air compressor, 2) feed gas compressor and 3) synthesis gas compressors to be installed in an ammonia plant. Regardless of the type of drivers used, it would be most economical to place the compressors in single file parallel to the pipeway on a common support structure. An arrangement (similar to Case 3) would evolve as shown in Figure #1019. Maintenance and operation requirements must be provided for in the placement of each major component. In general, allow for access on all sides of equipment. The immediate overhead area for horizontally split compressors must be clear for lifting off the top half of the case and rotor removal (Figure #10-20). If the compressor suction, interstage, and discharge connections are top oriented, then the piping must be designed for easy disassembly. The vertically split case requires absolutely no obstructions in front of the machine which would impede removal of the inner casing (Figure #10-20). Motor drivers require clearance for rotor removal. Check for location and size of the conduit boxes, motor starter (push button), and vibration sensors. Steam turbine drivers, like centrifugal compressors, may be horizontally or vertically split for rotor access. Be sure adequate clearance is incorporated into the design concept for the execution of these maintenance requirements. One of the functions of the Trip and Throttle valve is throttling during startup. For this reason it must be reachable from a platform and easily accessible for operation. Allow adequate space for the removal of tube bundles from oil coolers, surface condensers and other heat exchangers in the system. If the oil reservoir has steam coils, space must be provided for its removal. Access requirements for oil consoles is depicted in Figure #10-21.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 26 of 123 15/11/2002 REV 0 In summary, all equipment must be arranged so that access for maintenance and operation is possible without great difficulty. Adequate space must be provided for removing parts for cleaning and servicing. The Oil Insurance Association has published material on fire and safety precautions. Some of the material is reprinted here.

Figure 10-17 Typical Plot Arrangements for Centrifugal Compressors with Motor or Back Pressure Noncondensing Turbine Driver.


Figure 10-18 Typical Plot Arrangements for Centrifugal Compressors with Condensing Turbine Driver.


Figure 10-19 Multi-Compressor Arrangement


Figure 10-20 Two Basic Casing Designs for Centrifugal Compressors, Horizontally split and Vertically Split


Figure 10-21 Access Requirements for Oil Consoles

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 31 of 123 15/11/2002 REV 0 10.17 PIPING DESIGN: CENTRIFUGAL COMPRESSORS The piping designer must be keenly aware of the principles of both piping and equipment arrangement, for these are two inseparable facets of the overall problem of piping design. The approach to compressor piping design can be simplified by breaking down the big problem (design concept) into a number of smaller ones (individual systems). However, the intent here is only to make the designer aware of the possible extent of a given conceptual design effort. The employment of certain components and systems is dependent upon individual contract requirements. The three major categories are (l) process systems, (2) auxiliary systems, and (3) driver systems. Process System - The process piping system consists of the suction piping, interstage piping, when required, and the discharge piping. The aerodynamic performance of centrifugal compressors can be adversely affected by a number of variables, one being the distribution of flow at the suction flange. The quality of flow distribution is a direct function of the suction piping configuration adjacent to the compressor. 1.

The ASME Power Test Code requires a minimum of three (3) diameters of straight pipe between an elbow, in a plane parallel to the shaft, and the compressor suction flange (Figure #10-22).

2.

The normal-oriented inlet elbow, 90° to the compressor shaft, creates irregular gas distribution to the impeller. Therefore, for best performance, suction piping must be laid out for a uniform velocity profile over the entire area of any compressor inlet. The minimum requirement is a long sweep elbow (3 diameter). The preferred method is a straight (no branches) run of pipe after a long radius elbow. If the above guidelines are applied, the velocity profile entering the suction nozzle will be nearly uniform as shown in Figure #10-23.

3.

A space is provided in the specification sheet, under the heading Miscellaneous, for the compressor engineer to indicate "recommended straight run of pipe diameters before suction."

Figure #10-23


Figure 10-22 ASME Power Test Code

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 33 of 123 15/11/2002 REV 0 It is suggested that temporary suction strainers be placed in piping with the small diameter or the point of the cone down stream of the retaining flange. The principle reason being greater bursting strength. The alternative of placing the small diameter or cone point upstream offers the advantage of easier cleaning since particles are not trapped in less accessible areas of the strainer but even slight pressures can generate tremendous compression forces on the exterior and cause collapse. It is imperative that a removable spool, flanged both ends, be provided in the suction piping to allow installation and removal of the temporary start-up strainer. The length of the spool is based on the strainer requirements. In addition, on top nozzle oriented compressors, a larger removable spool must be provided in both suction and discharge piping for maintenance lifts. Centrifugal compressor manufacturers have standard case designs. Suction nozzles are sometimes much larger or smaller than the piping line size. For example, a 30-inch suction nozzle may be furnished for 20-inch suction line. The designer's first reaction might be to ask the vendor to change the compressor nozzle to 20 inch. But since this is a stock design case, the vendor cannot make such a change without a complete, costly redesign. Therefore, it becomes the piping designer's problem to make the transition. Line-size changes at compressor suction nozzles must be made smoothly as possible, i.e. use a concentric reducer or transition reducer. Never use a reducing flange. This would introduce full velocity to the rotor at a turbulent condition that would hinder performance. Some compressor vendors require a transition reducer of not more than 6° (Figure 10-24).

Figure #10-24


When interstage cooling is required, the fluid being compressed is discharged to an intercooler and an interstage K.O. Drum. 1.

Intercoolers are, typically, shell and tube heat exchangers which cool the fluid between stages to (1) reduce the temperature, (2) reduce the volume to be compressed in succeeding stages, (3) to liquefy condensable vapors, and (4) to save power.

2.

Intercoolers should be located close to the compressor with consideration for access, maintenance and operation, process conditions, supports and anchors, and economic, uniform piping arrangements.

3.

The discharged fluid, especially when cooled, may contain entrained liquid that is undesirable to retain. The interstage K.O. drum is installed downstream of the intercooler so that any entrained liquids are removed before further compression.

4.

The interstage K.O drum may be either a vertical or horizontal vessel. It should be located as close as possible to the compressor allowing for the traditional considerations. (Figure #10-25, Figure #10-26.)

The compressor discharge line should be routed close to the suction line so that a common support may be used and platform requirements for such items as block valves, and instruments can be simplified. An aftercooler is normally required for iso-cooled arrangements. It is usually a shell and tube heat exchanger which cools the fluid following the completion of compression to (1) reduce the temperature and (2) to liquefy condensable vapors. (Figure #10-27 for reference.)


Figure 10-25


Figure 10-26


10.17.1

Auxiliary Piping Systems

NOTE: This section was missing from package


10.18 PROCEDURES FOR ESTABLISHING COMPRESSOR ELEVATION 10.18.1

Centrifugal Compressors With Bottom Oriented Connections:

Normally, the compressor elevation is determined from process, mechanical and support requirements of the suction line. (Figure #10-37). 1. 2. 3.

Bottom of pipe will be set by clearance established for support and process drain requirements. Larger lines will require miters (check radius and weld requirements). Process straight run requirements on suction lines, plus clearance of any instrumentation, flushing or special support requirements.


Figure 10-37 Centrifugal Compressors with Bottom Oriented Connections


10.18.2

Centrifugal Compressors With Top Connections (Figure #10-38):

Normally, the height of this unit will be established by a combination of: 1. The height of the lube oil reservoir inlet. 2. 3.

Maintaining a minimum slope of 1/4" (use 1/2" for layout) per foot from the compressor casing drain to the reservoir inlet connection. Clearance of oil return line from structural steel.

Figure 10-38 Centrifugal Compressors with Top Connections


10.18.3 Centrifugal Compressors (Top Connections) With Non-Condensing Turbine Driver (Bottom Connections): Normally, the compressor elevation is set by the oil drain requirements. (Figure #10-39). 1.

Elevation of oil return connection at reservoir located on console.

2.

Slope requirement of oil drain line (normally 1/2" per foot).

3.

Elevation of oil drain connection at compressor.

4.

Check location and orientation of oil drain at compressor and oil return at reservoir to assure shortest possible routing of drain line.

5.

The elevation of the compressor must be high enough to accommodate Items 1, 2 and 3. See Figure #10-39 below.

Figure 10-39

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 42 of 123 15/11/2002 REV 0 6. Another item for consideration in setting the compressor elevation is clearance of the exhaust line out of the bottom of the turbine. (a) Exhaust line must clear foundation and be high enough to allow for a boot, drain and trap. See Figures #10-40, 10-41 and 10-42 below.


10.18.4

Centrifugal Compressors With Condensing Turbine Driver (Bottom Exhaust):

Normally, the compressor elevation is set by the requirements of the surface condenser. (Figure #10-43). 1. Diameter of surface condenser (largest) clearance from structures. 2. Suction requirements (NPSH), elevation (support) requirements of condensate pumps and hotwell nozzle orientation and clearance requirements. 3. Exhaust inlet connection size and projection and clearance from structure. 4. The requirements of an expansion joint and clearance from structure. The expansion joint is supplied by Purchaser or by the condenser manufacturer. 5. Transition piece may be required between exhaust connection expansion joint at turbine and inlet connection at surface condenser, and should be supplied by the surface condenser manufacturer. 6. Clearance of exhaust connection at turbine from oil piping and clearance from structure and access for installing transition piece and expansion joint.


Figure 10-43 Centrifugal Compressors with Condensing Turbine Driver


10.19 BASIC STRESS CONSIDERATIONS Centrifugal compressors present the same basic problems that are encountered at pumps, turbines and blowers. Alignment of the shaft connecting the compressor and the compressor driver is critical to the operation of the machine. The external forces on both machines must be limited to avoid distortion of casings, base plate or any other part of the assembly which would cause shaft misalignment or would impede the impeller. Compressor manufacturers have, consequently, devised a method of limiting loads on equipment that is nearly infallible from their point of view, but impractical for piping layout. NEMA (National Electrical Manufacturers Association) developed the basic formula for use on turbines. There is no analytical basis for the formula nor is there any test data to substantiate the use of the NEMA-SM20 criteria for any equipment. In fact, the criteria is so limiting that the compressor manufacturers generally accept NEMA allowable loads multiplied by a factor of 1.85 which is better but still extremely low. Without delving into the actual mathematics, the formula is arranged so that with a force of any nominal magnitude the allowable bending moment is zero and vice versa. The piping layout must then be made flexible to a ridiculous extent by addition of "doglegs", loops, tie rods, struts, directional anchors, etc. to protect the equipment nozzle. The solution to the problem is in the handling of the vendor prior to and after purchase of the compressor. When the standard specifications are drafted by the mechanical engineering group there can be no statement regarding forces moments and stresses which would discourage a vendor from bidding. However, there should not be a blind acceptance of NEMA-SM20 as a limiting criteria in either its original or modified form. The specification should state that limiting forces and moments are subject to review by the purchaser. In the event that the purchaser presents the vendor with calculations which he judged to be within reason, the vendor would be obligated to review the calculations for possible acceptance and present changes along with a cost analysis to modify the compressor to handle the forces and moments as or if necessary. The analysis would be at the vendor's cost and the modifications at Purchasers cost. There are precedents to justify this type of arrangement as itemized below: 1.

Three compressors in a normal refinery (B.P.O.C. in Philadelphia, Penna.) were modified for a total cost of $1000.00 to withstand forces and moments above vendor's limitations. Aesthetic appearance and economics in piping layout by far compensated the nominal cost.

2.

Several compressors in an LNG plant (Pacific Alaska) were overloaded by a large margin but, because of line size and critical nature of the system, calculations were sent to the vendor for review. The vendor reviewed the calculations at $4000.00 per system and with no modifications to the machine, approved the loads in less then a week's time. This averted using expansion joints in a highly critical system where rupture could easily have caused a catastrophe.

3.

Compressors in high temperature service 600°F - 700°F at a normal refinery (Exxon, Baytown) were overloaded by a high percentage compared to vendor limitations in three separate instances. Calculations were reviewed and accepted by the vendor at no additional cost to the purchaser.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 46 of 123 15/11/2002 REV 0 Another device that frequently helps in acquiring approval is delivering forces and moments to the vendor before he is awarded the contract to provide the compressor. Frequently the vendor will accept the loads as presented at that time with no further effort on the purchasers' part. One aspect of the layout that has caused problems in the past with regard to dead weight loading is the position taken by vendor representatives in the field. Whenever there is a problem in shaft alignment the piping arrangement is subject to question by the vendor representative. He is generally convinced that the misalignment is caused by the dead weight of the pipe whether it is or not. The initial step he makes is to check to determine if all the dead weight has been removed from the nozzle. If it has not been removed, he will invariably insist that additional supports be provided in the piping system to handle the dead weight. In most cases the field will accommodate this request regardless of the actual cause of misalignment. There are many cases where the piping system is bent into position to fit because of dimensional discrepancies or over-under loading of springs exists in the system or slight machine imbalances are present which are the real causes of misalignment. By removing the dead load from the nozzle the overall distortion is relieved to the extent that misalignment problem is solved. All too frequently this operation is undertaken even though the vendor has agreed to the loading on the compressor. For this reason, the piping at the compressor nozzles should be supported so that there is no dead load on the nozzle. The designer than can accomplish these supports in a more orderly fashion if it is designed as an after thought in the field. Recommended procedure is to support the piping at the nozzle. The additional steel can also be used for anchors, guides, or struts to control the forces on the compressor nozzle and meet Fluor or Vendor limitations. Piping flexibility requirements are difficult to determine because of the wide variety of limitations from various vendors, types of machines and casing materials. Cast iron nozzles and casings can take about 1/4 of the strain of a steel casing, consequently, the piping arrangement at a compressor of cast iron construction will require considerably more flexibility (piping) than at identical compressor constructed from steel. Using standard criteria, the cast iron nozzle can take 50 x IPS of force in lbs. with 500 lbs. maximum and steel can take 200 x IPS of force in lbs. with 2000 lbs. maximum. To facilitate layout to satisfy stress requirements, a nomogram has been developed which minimizes the designers work. An example problem (Figure #10-46) best demonstrates the use of the nomograph. The inlet line as shown in Figures #10-46 and 10-47 requires analysis. Figure #10-48 represents the isometric stress sketch as it should be presented to the stress analyst in an early layout stage. It is recommended to submit all lines connecting to the compressor simultaneously. Before submitting, the designer should check the flexibility with the nomogram as follows:


Figure #10-44 FS-2s Caused Walkway Problems on Platform and Looked Terrible

Figure 10-45 Operating Room below Compressors Hampered


Figure 10-46


Figure 10-47 Section A-A


Figure 10-48 Example Problem for Use of Nomograph

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 52 of 123 15/11/2002 REV 0 Step 1. Enter the nomograph at Column II on the steel (nozzle size) side and mark the line at the 10" nozzle - Point A. Step 2. Step 3.

Calculate the total expansion in the East-West direction. (6'-0") + (35'-0") .027 = 1.107" - mark Column V (thermal expansion) at 1.107" Point B. Draw a line between Point A and Point B.

Step 4.

Where the line between Point A and Point B intersects Column IV mark the intersection Point C.

Step 5.

Locate the pipe line size (18") on Column I (pipe size) and mark it Point D.

Step 6.

Draw a line between Point D and Point C.

Step 7.

Where the line between Point D and Point C intersects Column III (pipe length) read the required length (39').

Step 8.

The sum of all the pipe lengths perpendicular to the East-West expansion must be greater than 39'. (5'-0") + (10'-0") + (9'-0") + (5'-0") + (3'-0") = 32'-0" 7'-0" additional pipe is required either in the North-South or Vertical direction.

The same procedure is followed for the expansion in the remaining two directions. Step 1.

Same as before.

Step 2.

North-South expansion = (5'-0") + (10'-0") .027 = .405" Locate in Column V mark Point B.

Step 3.

Same instruction.

Step 4.

Same instruction.

Step 5.

Same instruction.

Step 6.

Same instruction

Step 7.

Read approximately 28' on Column III.

Step 8.

Sum of the East-West and vertical lengths must be greater than 28', (5'-0") + (35'-0") + (9'-0") = 49'= O.K.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 53 of 123 15/11/2002 REV 0 Finally the vertical expansion. Step 1.

Same as before.

Step 2.

Calculate the vertical expansion. (15.0 x .0316) + (3 x .027) - (9-0" + 5-0" + 4-0") .027 = .483"

Step 3.

Same instruction.

Step 4

Same instruction.

Step 5

Same instruction.

Step 6

Same instruction.

Step 7.

Read approximately 29' on Column III.

Step 8.

The sum of all the pipe lengths in the East-West and North-South direction which can bend without hitting a support is (10'-0") + (35'-0") = 45' - 0"

The only flexibility requirement for the entire problem then is an additional 7'-0" in either the East-West or Vertical direction. Drop off the North side of the vessel. If pressure drop is critical, both the shorter configuration as well as the more flexible one (satisfying the nomogram) should be submitted for analysis. Consultation with the process engineer is recommended. To satisfy the requirement of no weight load on the compressor flange, careful consideration must be given to the location and type of supports. For the configuration in the example (Figure #10-46), springs at 1 and 2 will minimize the load at the nozzle, while offering a practical solution.



There are a number of configurations that satisfy the nomogram but are not acceptable when thoroughly analyzed. The designer should be aware of this fact so that he is not overly alarmed by changes. Close cooperation between the layout designer, stress analyst and process engineer is extremely important when routing compressor piping. 10.20 STRUCTURAL CONSIDERATIONS Compressors may be installed indoors, outdoors, or under a shelter. They may be mounted on a foundation at "grade" or on a mezzanine. The basic shelter requirements are provided in the specification sheet under LOCATION. Where climate conditions demand a permanently housed compressor, two basic building types are common; the fully enclosed building and the tropical type shelter. However, whether the compressor is installed in a building, outdoors, or in a shelter, the operating floor layout should be based upon specific considerations (Figure #10-49). The height of the operating floor, of course, is established by applying the procedures provided in this manual. Floor size will be dependent upon clearance for compressor and driver periphery - including furnished appurtenances - and maintenance and operation considerations. The instrument control panel requires both front and rear access. A preliminary size may be obtained from the control systems engineer. In areas of heavy snow where blowing winds create tail drifts, the fully enclosed building becomes a necessity; however, in mild climate areas a tropical type shelter is adequate. This provides a roof with drop curtains; i.e. building walls extending from the eaves to within 8' of the operating floor line. (Verify that the "drop curtains" do not alter the wind direction to air coolers mounted over the pipeway). When a permanent shelter is specified, normally a traveling crane is required capable of handling the heaviest maintenance removable piece refer to specification sheet for weights) of the compressor or drive assembly. Figure #10-50 shows the two basic types of foundations common to centrifugal compressor installations. The layout designer must work closely with the structural group during the design phase of the foundation, especially on mezzanine installations where usually the compressor and driver are provided with down connections that require large openings in the top of the foundation. It is important to note that these openings must be of sufficient area to accommodate large flange connections and some of the auxiliary piping. Verify clearance for lines passing beneath the horizontal beam, especially oil return piping which must slope 1/2" per foot. All special pipe supports and platforms must be sketched and submitted to the structural group as soon as possible for preliminary design. For example, gland condensers may be supported from the compressor foundation; the overhead seal oil tank requires a platform. The sketches must include both the method of support and loads the support will be required to withstand.


Figure 10-49 Basic Platform Considerations for Centrifugal Compressors Mounted at "Grade"


Figure 10-50 Typical Foundation for Centrifugal Compressors 10.21 RECIPROCATING COMPRESSOR PLOT LAYOUT The location of the compressor installation must be influenced by size, process consideration, fire and safety hazards, economic pipe runs, accessibility, stress requirements and maintenance and operation requirements. To determine the physical affect on the plot plan, research all pertinent preliminary flow diagrams, especially for gas engine driven compressors, as these installations have many and varied auxiliaries. The compressor must be located as close as possible to its suction source. An excessively long suction line will increase costs by consuming extra driver horsepower. The suction line should be short and direct. If interstage equipment is required, make a detailed flow transposition for proving the best arrangement. Other important items to be considered include, operating valves, elevation requirements, remote lubrication requirements, vertical vs. horizontal K.O. drums, interstage

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 58 of 123 15/11/2002 REV 0 separators, and cylinder jacket water equipment. The interrelationships of all major components should be determined through discussion with Process and Mechanical Engineering. Color code and make freehand sketches of physical requirements such as heat exchanger structures. "Look at it as a system" and lay it out accordingly. The compressor installation must be located close to a service road so that it is readily accessible by mobile equipment. Research past contract estimates and model photos for similar installations. At this stage, very preliminary information is OK, but allow for at least 30% more workable area. Compressors sometimes have the luxury of "growing". Before final release of location, review for following: 1. 2.

Access for large lifts. Type of handling equipment. Access for maintenance, i.e., piston pull, cylinder removal, lubrication equipment; drop area requirements.

3.

Power source for motor drivers.

4.

Area for headers and laterals.

5.

Distance from control rooms, heaters, boilers and high frequency roads.

6. 7.

Conformance with all equipment narrative specifications and individual specification sheets. Auxiliary equipment requirements

After the location of the compressor installation is finalized, the plot arrangement for the compression equipment must be planned. The major factor at the installation is orientation of the compressor relative to the headers. Orientation is, primarily, predicated by area available and the size of the compressor and driver. The prime consideration is the piping, especially on multi-stage units. An arrangement with the compressor piston rod perpendicular to the headers causes short piping runs for horizontal straight line and gas engine driven units (Figure #10-51), but will necessitate some long piping runs and limited access for balance opposed machines (Figure #10-52). An arrangement with the piston rod parallel to the headers causes long piping runs for multi-horizontal straight line compressors and gas engine driven units (Figure #1053) but shorter piping runs are possible with balanced opposed machines (Figure #10-54). Therefore, orientation of the compressor will be dependent, primarily, upon type of compressor, economic pipe runs, and available plot space.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 59 of 123 15/11/2002 REV 0 Specific clearance considerations must be applied during plot arrangement so that piping systems, equipment installation, maintenance and operation can be effectively executed without unnecessary difficulties. Sufficient unobstructed space must be provided for piston and piston rod removal. During preliminary layout stages, use 6'-0" as the minimum requirement (Figure #10-55). After vendor outline and cylinder specification sheets are available for size, weights, and removal distances, then final clearances can be established.

Figure 10-55 Basic Clearance Considerations


Figure #10-51 Preferred Orientation for Piping Economy and Optimum Access

Figure #10-53 Alternate Orientation for Gas Engine Driven Compressors and Horizontal Straight-Line Compressors


Figure #10-52 Alternate Orientation Produces Longer Laterals and Limited Access

Figure #10-54 Preferred Orientation for Balance-Opposed Compressors

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 62 of 123 15/11/2002 REV 0 Motor drivers require clearance for rotor removal. Check for location and size of the conduit boxes, motor starter (push button), and vibration sensors. Steam turbine drivers, like centrifugal compressors, may be horizontally or vertically split for rotor access. Be sure adequate clearance is incorporated into the design concept for the execution of these maintenance requirements. One of the functions of the Trip and Throttle valve is throttling during startup. For this reason it must be reachable from a platform and easily accessible for operation. Allow adequate space for the removal of tube bundles from oil coolers and other heat exchanger in the system. Clearance pocket valves are frequently required for compressor cylinders. The handwheel will be at the center of the cylinder and project horizontally from the end of the cylinder (Figure #10-56). The walkway must be outside the extremity of these handwheels. In summary, all equipment must be arranged so that access for maintenance and operation is possible. Adequate space must be provided for removing parts for cleaning and servicing. Investigate drop area requirements; type of equipment to be used for maintenance (Austin-Western, bridge crane, etc.).


Figure 10-56 Two Typical Clearance Valve


10.22 PIPING DESIGN: RECIPROCATING COMPRESSORS A reciprocating compressor alternately withdraws gas from and delivers it to a piping system in a series of pulses. Vibration is introduced into the piping system as a direct result of these pressure pulses and/or mechanical natural frequencies. Piping system design may be resolved into two categories: (1) applied measures for the prevention of vibration of the piping, and (2) system design that will provide the maximum compressor efficiency. These two categories are closely related. For instance, it is sometimes necessary to install flow resistance devices at specific points to reduce pressure pulsations, thereby minimizing the vibration problem. The efficiency may be reduced by such a step, but vibration that could lead to possible failure would be averted. The piping designer must be keenly aware of the principles of both piping and equipment arrangement, for these are two inseparable facets of the overall problem of piping design. The approach to compressor piping design can be simplified by breaking down the big problem (design concept) into a number of smaller ones (individual systems). However, the intent here is only to make the designer aware of the possible extent of a given conceptual design effort. The employment of certain components and systems is dependent upon individual contract requirements. The three major categories are (1) process systems, (2) auxiliary systems, and (3) driver systems. The process piping system consists of the suction piping, interstage piping, when required, and the discharge piping. Common system equipment requirements include pulsation suppression devices, K.O. (knockout) drums, separators, intercoolers, and aftercoolers. All of the process piping which accommodates these systems must be routed close to "grade" on sleepers to facilitate the application of suitable hold-downs for the prevention of vibration of the piping. One of the prime considerations during layout of suction piping is to ensure that absolutely no liquid may enter the compression cylinder; liquids do not compress and cannot be tolerated in a reciprocating cycle. Many times the gas temperature is higher than ambient, especially at night. The gas may slowly condense on the pipe wall and accumulate in low spots in the piping. Given sufficient time, it fills the line to the point where it can "slug" and cause severe mechanical damage. The suction K.O. Drum is used to remove entrained liquid from the gas before introduction into the compressor. It should be located as close as possible to the compressor cylinder to keep suction lines relatively short. The preferred takeoff point from the suction header to the compressor cylinder is from the top. This arrangement provides maximum protection from liquid that might collect and be carried into the cylinder. A bottom takeoff may be used only when approved by process and equipment engineers. Suction piping may sometimes be insulated and steam traced to help prevent condensation, but there can be no substitution for good drains. All headers, and lateral pipe runs between the headers and compressor, are routed as close as possible to the high point of finished surface to permit easy installation of restraints. The elevation of the headers will be determined from drainage requirements.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 65 of 123 15/11/2002 REV 0 Operational requirements for valving will be predicated by contract narrative specification and/or Client instructions. A temporary suction strainer is required in the suction piping for all reciprocating compressors. For optimum protection of the compressor, it should be located in the outlet nozzle of the suction pulsation suppression device (Figure #10-58). However, since this is only a recommendation that may be challenged and/or rejected by some Clients, actual strainer location must be reviewed early in the job in order to avoid problems in the design of pulsation suppression devices and the piping system. 10.22.1

Pulsation Suppression Devices

All large reciprocating process compressors require "pulsation suppression devices" immediately adjacent to the suction and discharge flanges of each compression cylinder. These "devices" serve two purposes: (1) they help reduce the transmission of pressure pulsations into the piping system, and (2) provide sufficient surge capacity, resulting in more efficient compressor operation. Basically, all pulsation suppression devices may be categorized as either a volume bottle or dampener, an empty vessel or one with internals, respectively. Volumes and basic dimensions are the responsibility of the mechanical engineer, but the piping designer predicates orientation and location of the nozzles. The required connections and other design information are tabulated and furnished with the "pulsation suppression device" narrative specification. A typical "device" has the following connections: 1. Inlet connection 2. Outlet connection 3. Vent connections (flg'd w/blind) 4. Drain connections (flg'd w/blind) 5. Pressure test connections 6. Temperature connections 7. Inspection openings In addition to the above connections, a suction pulsation dampener may require a sump for liquid collection and control. The mechanical engineer will specify the need (Figure #10-57). The effective layout of pulsation suppression devices requires the application of varied considerations by the layout designer.


Figure 10-57 Internals for a Typical Pulsation Dampener The cylinder connections (outlet of suction device, inlet of discharge device) must be of sufficient length to allow unobstructed removal of cylinder valves, clearance from platforms, structural steel and instruments, as shown in Figure #10-58 and 10-59. Figure #10-60 depicts a simple method for location of these nozzles. Vents and drains are required for each compartment of dampening devices with internals. Verify that structural steel or foundations do not obstruct these connections. Instrument connections must be easily accessible and visible. When the temporary strainer is to be installed in the outlet nozzle of the suction pulsation suppression device, the strainer length, or the nozzle length may require adjusting so that clearance of any internals is realized.


Figure 10-58 Typical Suction Pulsation Dampener and Elevation Requirements


Figure 10-59 Typical Discharge Pulsation Dampener and Elevation Requirements

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 69 of 123 15/11/2002 REV 0 Another important aspect to be considered during layout is the position and support of pulsation suppression devices and filters. Spherical pulsation suppression devices are sometimes used and should be given certain considerations. This subject is discussed later in this section. During preliminary layout, the layout designer may use the following formulae for estimating basic volumes and dimensions of pulsation devices. It is recommended that 24 inches be considered the maximum diameter size. Essentially, the estimate is based on piston displacement. (a) SV = .7854 B2S (b) PVmin = 12 SV (c) H =

PV .7854 D 2

(d) Definitions: SV = slug volume PV = estimated pulsation device volume B = cylinder bore - inches (from equip. spec. sheet) S = stroke - inches (from equip. spec. sheet) H = length of pulsation device D = diameter of pulsation device - inches (e) Sample problem: To find "H" Given data: B = 21" S = 9"

D = 24" (max.)

(1) SV = .7854 B2S = 3117.253 in. (2) PV = 3117.25 x 12 = 374073 in. (3) H =

PV 37407 37407 = or = etc. 2 2 .7854 D .7854 × 24 .7854 × 20 2

=82.68"

=119.07"


Figure 10-60 An interstage piping system is required when fluid compression must be accomplished in two or more stages before final discharge. 1. Normally, valves should be located so that they are accessible from the operating platform level. However, the piping and valve requirements may be quite complex on some multistage units in which case a stile may be employed to obtain adequate accessibility to valves. 2. The location of interstage equipment, K.O. drums, intercoolers, and aftercoolers will be dependent upon type, size, available space, and piping requirements. For instance, a contract might require the use of air coolers as intercoolers. Since the piping system is a potential vibration source, it would not be practical to follow the traditional practice of locating the air coolers over the pipeway. It is, by far, easier to control the system which is close to "grade." Therefore, it would be more feasible to minimize elevation and support requirements by locating the air coolers as shown in Figure #10-61. If more than one compressor is required, be sure to leave adequate space between the air coolers for access.


Figure 10-61 Relationship of Air Cooler (Intercooler) to Compressor

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 72 of 123 15/11/2002 REV 0 3. Intercoolers are, typically, shell and tube heat exchangers (air coolers may be used also) which cool the fluid between stages to (1) reduce the temperature, (2) reduce the volume to be compressed in succeeding stages, (3) to liquefy condensable vapors, and (4) to save power. 4. Intercoolers should be located close to the compressor with consideration for access, maintenance and operation, process conditions, supports and anchors, and economic, uniform piping arrangements. 5. The discharged fluid, especially when cooled, may contain entrained liquid that is undesirable to retain. The interstage K.O. drum is installed downstream of the intercooler so that any entrained liquids are removed before further compression. 6. The interstage K.O. drum may be either a vertical or horizontal vessel. It should be located as close as possible to the compressor allowing for the traditional considerations. 10.22.2

Discharge Piping

The last stage discharge piping, generally, should be held down about 25 feet from the compressor mat before rising into the pipeway. Machinery-mass excited frequencies have little or no transmission 20 to 50 feet from the mat; as lines extend from the compressor, pulsation usually decreases due to the greater volume of gas serving as a "cushion." All compressor process piping in the pipeway will not be provided with hold-downs or supports on a frequency basis. Normal pipe support spacing will be used. However, the piping will be routed so that it is in close proximity to other larger diameter piping which is not subject to temperatures over 180F or it shall be routed next to pipe support struts. This procedure should be followed so that strapping the vibrating line to either the larger diameter piping or the pipe support struts can control vibration induced after startup. An aftercooler is normally required for multistage arrangements. It is usually a shell and tube heat exchanger (air coolers may be used also) which cools the fluid following the completion of compression to (1) reduce the temperature and (2) to liquefy condensable vapors. Vibration of the compressor piping system is minimized through the proper application of supports, hold-downs, and wedges. Figure #10-62 shows how these measures help prevent excessive vibration in the system.


Figure 10-62 How Natural Frequency Should Match Supports Line spacing should be based on the dimensional chart line spacing found in Piping Engineering Design Guide, 000 250 9815. However, the dimension given in the chart may require adjusting if the laterals tie in at a 45° angle. For example, line spacing for two 16-inch headers is 2'-0". If the lateral is 16 inches also, this dimension must be greater (Figure #10-63), because the lateral will interfere with one header.

Figure 10-63 Line Spacing Problem Pipe Support and hold-down spacing should be based on Piping Engineering Design Guide 000 250 2481.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 74 of 123 15/11/2002 REV 0 The last stage discharge piping will always have a check valve installed in it to prevent flow-reversal. This particular check valve is frequently a specialty item, i.e., silent in operation; it is especially designed for installation in the discharge line of reciprocating compressors. Because of normal pulsations in a gas system, ordinary check valves installed in this service in the past usually hammered and pounded themselves to destruction. Be sure to direct inquires to Piping Material Engineering to ascertain the type of check valve that will be used. The location of this check valve is important. For example, if a condenser, downstream of the check valve, is installed considerably higher (in a structure) than the compressors, then the check valve should be located as close as possible to the condenser so condensed gases cannot fill the line and drain back to the compressor. In addition, the line should slope toward the condenser. 10.22.3

Auxiliary Piping Systems

Auxiliary piping systems include all necessary lube oil, drains, vents, steam and water lines that are attendant to the compressor, the driver, and the auxiliary equipment. These systems are shown on the auxiliary flow diagram(s). A solid line designates piping and components furnished by the vendor, piping and components furnished by Purchaser are designated by a dashed line. Compressor frame lubrication system is a pressure system that consists of an oil pump with suction strainer, a supply-and-return system, an oil cooler (when required), a full flow filter, and other necessary instruments. 1.

The main oil pump is driven from the crankshaft and shall be accessible for maintenance.

2.

An oil cooler is provided to maintain lube oil supply temperature at or below 150°F. The cooler is normally a shell-and-tube type, heat exchanger, water-cooled (tube side).

3.

When specified, a removable steam heating element external to the oil reservoir is provided for heating the charge capacity of oil prior to start up in cold weather.

Forced-feed mechanical lubricators separate from the frame lubrication pump accomplish lubrication to the cylinder and packing. The Vendor supplies all the necessary hardware. Distance pieces are available in four basic designs (Figure #10-64) with connections for venting, draining, and cooling water (when required to cool packing gland). Access openings are provided to permit removal of the packing case. All connections shall be 1-inch pipe size, minimum. The auxiliary flow diagram(s) will indicate where vents and drains are to be piped. The compressor lube oil system is normally piped and located by the Vendor at the front of the frame and supported at the same elevation as the distance piece. However, it should be lowered and supported from the "basement floor". Since the Vendor furnishes the piping, the squad check should be marked-up to reflect this modification.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 75 of 123 15/11/2002 REV 0 1.

Some reciprocating compressors are furnished with a separate lube oil console in which case Purchaser furnishes the interconnecting.

2.

Some Clients may reject the standard practice of locating the lube oil equipment beneath the operating platform. Therefore, it would advantageous to ask early if such a preference exists.

Elevation of the compressor is normally established by a combination of the following: 1.

Elevation of headers set by B.O.P clearance from grade and drain requirements.

2.

Lateral takeoffs from top of headers and clearance for crossing headers.

3.

Discharge pulsation suppression device inlet nozzle requirements and support methods.

4.

Maintenance and operational requirements for equipment, valving, instruments, etc. below the floor.


Figure 10-64 Distance Piece Basic Designs

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 77 of 123 15/11/2002 REV 0 10.23 VIBRATION: PREVENTION AND CONTROL The aim of this chapter is to summarize the essentials of vibration as applied to reciprocating compressor piping systems that will minimize the occurrence of objectionable or damaging piping vibration. 10.23.1

Types and Causes of Vibration

The most important facet in the design of piping to and from compressors is the vibration problem. Vibration is introduced into the piping system by pressure pulses into the lines from the compressor piston. The lines are also subject to vibration from the elongation of the compressor cylinder at the compressor stroke of the piston and the vibration of the foundation as the driver and flywheel of the compressor operate. Three main types of oscillation (vibration) must be carefully distinguished: free, forced, and self-excited. In free vibration, the system is excited by an external transient impulse (persisting for only a short time) and the system vibrates under no external force. The frequencies at which the system vibrates are called natural frequencies. The lowest natural frequency is the fundamental frequency. In forced vibration, the system oscillates under the external or internal excitation by a periodic disturbing force. The forcing vibrations that are of primary concern are mechanical and acoustical. Mechanical vibration - A vibration which can be attributed to the mechanical imbalance of rotating and reciprocating equipment, or elongation of a high pressure cylinder or some mechanical action which can generally be confined to the immediate vicinity of its source. Normally the foundation or mat is designed to dampen this vibration; however, the pulse is transmitted to everything on the mat and within a certain radius depending upon the effectiveness of dampening. Acoustic vibration - This vibration is a function of the power stroke on piston and plunger type pumps, compressors and the general configuration of the line with respect to length, directional changes, volume changes and dampening devices. This phenomenon will exist for the entire length of the line up to a significant volume or area change. It is directly related to pressure surge and sonic velocity. Self-exciting vibration - The source of this type of vibration is an internal energy in the form of combustion, flashing, or unstable flow. Vibration of this type is nearly impossible to predict accurately and is normally handled only as it occurs in the field. 10.23.2

Forcing Frequency

The forcing frequency is the number of times (cycles per second) a reciprocating compressor introduces (forces) a pressure pulse into a piping system.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 78 of 123 15/11/2002 REV 0 The primary prerequisite of vibration prevention and control is the determination of the forcing frequency. Knowing the possible forcing frequency (e.g. from specification sheets or calculations) an attempt can then be made to prevent resonance of the piping system. Resonance occurs when a system (mechanical or acoustic) is excited periodically with a frequency at or near the natural frequency of the system. This may result in excessive deflection (amplitude magnification) causing high repeated stresses and ultimate fatigue failure. The vibrations that can be calculated or estimated are mechanical and acoustic. Investigation of acoustic vibration can be divided into (a) an overall investigation which is made with an analog computer to determine the need for further dampening devices or additional line length to prevent unstable flow and large pressure surges and (b) a segmental investigation which is identical to the mechanical vibration in frequency but caused by the pressure peaks due to the reciprocating action of the compressing cylinder. 10.23.3

Explanation of Symbols

ff1

= fundamental forcing frequency (cycles per second)

RPM

= Maximum machine speed in revolutions per minute

Nc

= Number of compressor cylinders connected to a common manifold

Fc

= 1.0 for single acting cylinder (or double acting cylinder unloaded one end)

Fc

= 2.0 for double acting cylinder

fn

= natural frequency

ff4

10.23.4

ff 1 =

= Fourth harmonic of forcing frequency. (Response to the forcing frequency has been found to be dangerous up to its fourth harmonic. Therefore, the natural frequency of the piping segment - dependent on distance between hold-downs and/or supports should be higher than the fourth harmonic of the forcing frequency.) Calculation of Fundamental and Fourth Harmonic Frequencies

( RPM ) FC N C = .01667 RPM x FC x N C 60 Therefore

ff 4 = 4 x ff 1 = 4 x .01667 RPM x FC x N C = .667 RPM x FC x N C

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 79 of 123 15/11/2002 REV 0 To avoid resonance the natural frequency of the piping system should be higher than the fourth harmonic (ff4) of the forcing frequency. fn > ff4

f n > .0667 RPM x FC N C or f n > .07 RPM x FC N C The following examples illustrate how the forcing frequency and natural frequency calculations may be applied to reciprocating compressor piping systems. Referring to Figure #10-65, if the pulse from compressor A is introduced into the piping system so that it is diametrically opposed to the pressure pulse from compressor B then, assuming the two compressors to be identical, the pulses are introduced into the piping system at twice the rate as they would be if only compressor A were operating. The number of cylinders attached to a common manifold is noted as "Nc" in the formula.

ff 1 = a.

If compressor A and B operate at 420 RPM and are single acting, the forcing frequency is:

ff 1 = b.

( RPM ) x FC x N C = .01667 (RPM) ( FC ) ( N C ) 60

420 x 1 x 2 = 14 60

If compressors A and B had double-acting (D.A.) cylinders, "ff1" or the forcing frequency would change.

ff 1 =

420 x 2 x 2 = 28 60


Figure 10-65 Identical Compressors Operating at 420 RPM with Single-Acting Cylinders Discharging into a Common Manifold




PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 84 of 123 15/11/2002 REV 0 10.23.5

Hold-Downs and Supports

The natural frequency of the pipe is a function of the dead weight deflection of the pipe, the end conditions at the supports (Hold-down = fixed end, simple support = pinned end) and distance between supports and hold-downs. These distances are illustrated in the Pipe Stress Analysis Design Guide, the Piping Engineering Design Guide (000 250 2480). This approach to setting distance between hold-downs and supports is conservative because it allows the compressors to be operated at any speed up to and including its rated RPM with no danger of failure in the piping system. If the compressor operation (RPM) is not subject to change, then a range of frequencies can be predicted and a series of lengths to be avoided can be calculated with piping laid out to avoid these lengths between supports. However, this would be a large number of lengths and they would vary for each piping system and size. Another point to remember when considering this less conservative approach is that all piping systems have at least three natural frequencies corresponding to the three major axis. North-South, East-West, and vertical. More complex systems require more complex calculations to determine frequencies. Consequently we do not design our piping system in this manner. Although a great deal of the material presented so far sounds as if it is based on strictly hypothetical and theoretical possibilities, there are sufficient historical records of failure to justify the use of these parameters. 10.23.6

Orientation and Support of Pulsation Suppression Devices

One of the most important areas to consider in the layout of piping systems is the position and support of pulsation suppression devices and filters. In hydrogen service, the filter is usually placed as close as possible to the cylinder so that the pulsation bottle is installed as a fitting makeup item (Figure #10-73) connecting the filter with the compressor cylinder.

Figure 10-73 Preferred Location of Filters, especially in Hydrogen Service

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 85 of 123 15/11/2002 REV 0 The support point on the cylinder should be within a foot up or down of the tangent line of the filter. If the filter has supports on the shell, then the cylinder support point should be within a foot up or down of the bottom of the filter support to equalize vertical expansion. The nozzle neck length between the cylinder head and the pulsation device must be kept to a minimum. The mass of the pulsation device mounted on an excessively long nozzle neck will have a low natural frequency and will more than likely vibrate. In addition to pulse vibration and machine vibration, the cylinder of the compressor tends to elongate and even if this is infinitesimal at the cylinder, it becomes magnified at the end of the distance piece. The action on the pipe system can be related to whiplash in an automobile accident (only with a continuous impact based on the compression stroke of the cylinder). There have been several cases where the movement of the pulsation device has necessitated use of additional dampers and supports to rectify the problem. In at least one instance, the problem could not be resolved without shortening the nozzle neck. However, the normal solution to a vibration problem of this nature is to first add adjustable spring wedge supports to one or both ends of the pulsation suppression device, brace the bottle back to the frame of the compressor (Figure #10-74) and as a last resort cut the distance piece shorter and reroute the pipe.

Figure 10-74 A Solution to Pulsation Bottle Vibration

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 86 of 123 15/11/2002 REV 0 If the cylinder stretch is too much (average is about 10 mils), the nozzle neck may be overstressed when the brace is added. Analysis will be necessary before the brace is added. The layout with piping and the pulsation suppression device in a straight (Figure #10-73) line between the compressor cylinder and the filter is a good arrangement considering vibration. However, if the spool piece between flanges is in error or if the foundation of either the filter or compressor is slightly off in any direction, field fit up is nearly impossible without moving the filter or refabricating the spool. For this reason, construction prefers an arrangement with at least one elbow to help them fit the piping system in the field (Figure #10-75).

Figure 10-75 Straight-Line Layout is Good for Vibration but Poor for Erection This arrangement (Figure #10-76) does present several problems that are not as serious as in the direct hookup. The weight of the pulsation suppression device in the first case is distributed between the filter nozzle and the compressor nozzle. In the second case, nearly all of the weight of the "device" is on the compressor nozzle along with a large bending moment caused by the overhanging position. Most "devices" are relatively heavy, 6000 pounds is not unusual, so the support of the system must be considered because of weight loading on the nozzle in addition to the natural frequency which is much lower on "L" shape pipe configurations. Frequently, the compressor manufacturer can stand larger loads on the cylinder than is normally recommended, because of the location of the cylinder support. However, if the natural frequency of the piping and the "device" nearly coincides with the forcing frequency of the compressor or its harmonics, then additional support will be required regardless of the allowable load on the nozzle. The supports and hold-downs on the "device" must be adjustable to accommodate the vertical expansion while holding the weight of the pipe; usually a column from grade or the compressor structure is required.


Figure 10-76 Support Method for Pulsation Suppression Devices A more efficient method of supporting pulsation suppression devices is to use the compressor frame as a support point (Figure #10-77). The structure to grade can often be eliminated through use of this method.

Figure 10-77 Support Method for Pulsation Suppression Device Using Compressor Frame

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 88 of 123 15/11/2002 REV 0 The support can be placed directly on the pulsation suppression device on the pipe or on a dummy provided as an integral attachment to the bottle by the manufacturer. A wide variety of arrangements are available.

Figure 10-78 Support of Pulsation Suppression Devices When the pulsation suppression device is not connected to the filter and the piping descends close to grade, arrangements must be provided to carry its weight and to hold down the piping. Additional care must be taken to avoid restriction of thermal expansion of the pipe. This is accomplished through the use of adjustable spring wedges or side mounted hold-downs on the line and/or "device" (Figure #1078). If the line drops down from the bottom of the pulsation device and the thermal expansion vertically is less than 1/8" down; the line may be used to support the pulsation suppression device. Guides are required for stability (Figure #10-79).


Figure 10-79 Utilization of the Piping to Help Support the Pulsation Device

Figure 10-80 Support Methods for Large and Small Pulsation Devices

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 90 of 123 15/11/2002 REV 0 The pulsation suppression device on the lower cylinder nozzle also presents unique problems related to support, expansion and vibration. A horizontal application can normally be handled by supports on piers from grade. Hold-downs must be positioned so that movement of the "device" can accommodate any cylinder stretch. This is true of vertical applications as well. Never position hold-downs so that the holddown bolts run parallel to the motion of the piston. Small pulsation suppression devices will probably only require a single adjustable spring wedge if positioned correctly. Large varieties will require two adjustable spring wedges and a hold-down (Figure #10-80) and cylinder stretch is parallel to the motion of the piston. Another arrangement is the vertical pulsation suppression device, used primarily when the lower cylinder nozzle is elevated. There are two basic methods for supporting these "devices." The most preferable is the attachment of a permanent skirt to the "device" and using an adjustable spring wedge to hold its weight. If the "device" is sufficiently long, one or more hold-downs may be required to dampen vibration. That requirement will depend on the forcing frequency of the compressor and the natural frequency of the device between supports. If cylinder stretch is into pier, the pier will break. Cylinder stretch is parallel to the motion of the piston. Hold-downs on pulsation suppression devices and pipes must be positioned for expansion or motion (Figure #10-81). The alternate support method is to rely on the friction of two hold-downs on the vertical "device" for support. This is not advisable unless some type of safety device is used to limit the movement through the hold-downs and insure a positive support.


Figure 10-81 Example of Vertical Mounted Pulsation Suppression Device


Figure 10-82 Example of Vertical Pulsation Suppression Device at Vertical or Angle Compressor

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 93 of 123 15/11/2002 REV 0 10.24 ANALOG AND COMPRESSOR PIPING SYSTEM DESIGN The analog approach to compressor piping systems began when several members of the Southern Gas Association (SGA) formed the Pipeline Compressor Research Council within the SGA to improve techniques in compressor system design. The Council developed the first electro-acoustical analog of a compressor system that subsequently evolved into a highly sophisticated "tool" for design of reciprocating and rotating machinery systems. Certain elements within a reciprocating compressor piping system can combine to form resonant pulsations with the compressor and thereby alter its normal compression cycle. These pulsations frequently create severe vibratory motion of the system and sometimes cause rupture. The analog, by accurately predicting total system response, has proved to be a highly successful "tool" in the elimination of potentially hazardous natural frequencies of pulsation. A reciprocating compressor alternately withdraws gas from and delivers it to a piping system in a series of pulses created by the action of the piston and valves. This action produces oscillations in the gas pressure that travels through the system like sound waves. A simple explanation of pulsation: On the suction stroke of the piston all the little gas molecules rush toward the cylinder. They beat on each other and the walls of the pipe in their anxiety to get in through the open cylinder suction valves. Then for an instant the suction valves close on the compression stroke and the gas molecules are squeezed to a point that they are ready to explode. Now on the discharge stroke the discharge valves open for an instant, a given volume of these gas molecules rush down the pipe pushing whatever is in front of them until their push is exhausted; because the discharge valves have closed, they have lost their (pressure) source. Now what they were pushing starts pushing them back (pressure) toward the compressor and into the successive discharged volumes of gas. These actions of the piston, gas molecules, and cylinder valves causes the gas molecules to collide with each other producing (pressure) shocks. These collisions are pulsations and if transmitted back to the cylinder, can be destructive. To reduce the shocks a pulsation suppression device is installed in the system providing a "ballroom" where the shocks are spread out and minimized. The analog is actually an electrical model of the compressor and the piping system. It provides a means of determining pressure, frequency and other values related to a compressor piping system by measuring their electrical equivalents. The sets of analogies relating the characteristics of one system to the other are as follows: Electrical Quantity Actual Quantity Pressure Voltage Mass flow Current Acoustic frequency Electric frequency Acoustic wave velocity Electric wave velocity Acoustic impedance Electric impedance

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 94 of 123 15/11/2002 REV 0 10.25 MANUAL REVIEW AND ANALOG STUDY PROCEDURE FOR RECIPROCATING COMPRESSOR PIPING SYSTEMS This recommended procedure outlines the requirements for planning, developing, and issuing data required to conduct a manual piping review and analog study of a reciprocating compressor installation. The objective of the manual piping review is to evaluate hold-down locations through a segmental analysis to insure optimum prevention of mechanical vibration. The objective of the analog study is evaluate the acoustic characteristics of a compressor piping system, including the pulsation suppression devices, to determine if these systems meet with predetermined pulsation requirements. This procedure applies to the design of piping systems that will control the amplitudes of pulsations generated by the compressor. Most reciprocating compressor piping systems are analyzed first by means of manual calculations performed by the pulsation suppression device supplier and secondly on an electric analog simulator. These analyses are required to avoid potentially hazardous natural frequencies of pulsation. Responsible Parties Project Engineer Mechanical Engineer Piping Stress Engineer Piping Design Engineer Process Engineer Vessel Engineer Control Systems Engineer Structural Engineer

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 95 of 123 15/11/2002 REV 0 Each individual is responsible for supplying the information and data required for the manual review and analog study as indicated below. It is suggested that this information be retained in "ANALOG DATA BOOK". Suggested Table of Contents for "Analog Data Book" Table of Contents SECTION I - COMPRESSOR DATA Analog Specification Compressor Identification & Basic Data Compressor Cylinder Data Compressor Operational Data Compressor Drawings including cylinder drawings (list all compressor and cylinder drawings by drawing number and title) SECTION II - COMPRESSOR AREA PLAN DRAWINGS (List all piping layout plan drawings by drawing number and title) SECTION III - COMPRESSOR SUCTION & DISCHARGE ISOMETRICS (List all suction and discharge isometrics by drawing number and title) SECTION IV - EQUIPMENT SPECIFICATIONS & DRAWINGS (List all equipment specifications and drawings by drawing number and title - include all suction and discharge bottles, scrubbers, intercoolers, K.O. drums, filters, control valves, strainers, etc.) SECTION V - FLOW DIAGRAMS (For multiple service operations, it may be necessary to provide flow diagrams for the various alternate or multiple flow arrangements. This may be accomplished by using color coded mechanical flow diagrams or drawing simplified individual flow schematics for each case. List by drawing number and title. Limits of the study should be defined on a mechanical flow diagram(s). NOTE:

Additional sections covering other items or data may be included as required for individual contract requirements. Step by step activities by responsible parties are covered in the Interface Practices practice 090.200.0744.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 96 of 123 15/11/2002 REV 0 For Supplier Drawing and Data Review - Reciprocating Compressor see Piping Engineering Design Guide, Practice 000.250.1063. 10.26 INTERNAL CLEANING AND PROTECTION OF PIPING The suction piping to compressors should be thoroughly cleaned prior to the machine being first put into operation. This precautionary measure is used to assure the removal of accumulations of pipe mill scale, sand, grit, rust, weld splatter, oil, grease or any other foreign objects which would cause mechanical damage if retained in the piping. Fluor Engineering Practices (000.250.50001) recommends internal cleaning. Piping Systems is covered in Master Specification 000.250.50028.

Internal cleaning of

The Piping Design Supervisor should determine the use and verify the applications of this document to suit each individual contract. Since only a portion of the compressor piping system requires internal cleaning, a note must be included on those spools where cleaning is required. Such a note might read as follows: THIS LINE IS TO BE CLEANED PER SP-50-2, PAGE 6, PARA. 13.2, REV. 4. In general, internal cleaning is limited to the piping from the inlet of the compressor to the outlet of first major vessel (suction source). However, the mechanical commodity (compressor) engineer should be consulted to ascertain the correct requirements. It is important to clarify, early in the job, any special Client requirements such as headers having to be blinded at each end to allow access for inspection and/or cleaning after installation. A temporary strainer is installed in the suction line as a final measure to protect the integrity of the compressor. 10.27 PIPING DESIGN DRIVERS FOR COMPRESSORS A driver (together with any connecting medium between it and the compressor such as a gear) must do more than just drive the unit at rated condition. It must first start the compressor from rest, accelerate it to full speed, and then maintain operation of the unit under any design condition of capacity and power. There are many types of machinery available for driving compressors; electric motors, steam turbines, gas turbines, expansion turbines, gas engines, and liquid power recovery turbines among others. At times, the type of power most readily available determines the economic reasoning for the selection of a particular driver. At other times, relative cost provides the answer.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 97 of 123 15/11/2002 REV 0 The Table below shows typical driver systems that are used with compressors. Not all combinations are shown. Compressor Type Driver Type Induction Motor Synchronous Motor Steam Engine Steam Turbine Gas Turbine Hydraulic Turbine Gas Engine (Heavy-Duty) Diesel Engine (Heavy-Duty) Industrial Engine Expander

Reciprocating Vane Rotary B-C-F-G C-E-F-G I G ........ G C-I C-I B-C I-G

Key--B--Belted C--Coupled E--Engine-Type Direct-Connected

B-C Seldom ......... G ........ ........ ........ ......... B-C .........

Helical-Lobe Rotary

Dynamic

B-C-B C-G ........ C-G G C-G G G C-G C-G

C-G C-G ........ C-G C-G ........ G G B-G C

F--Flange-Mounted G--Geared I--Integral

Some of the basic available drivers and several variations of each were discussed. This writing will focus on the specific piping requirements and accepted applications of systems design for steam turbines (special purpose), gas turbines and gas engines. 10.27.1 STEAM TURBINES present the same basic problems that are encountered at pumps, compressors and blowers, i.e., alignment of the shaft connecting the turbine and the driven equipment is critical to the operation of the assembly. The external forces on the assembly must be limited to avoid distortion of casings, base plate or any other part of assembly which would cause shaft misalignment or would impede the rotating assembly. Typical inlet and exhaust steam piping for noncondensing (backpressure) turbines is shown in Figure #10-83. Inlet and exhaust block valves should be located close to the steam headers. This greatly reduces the possibility of accidental closing. The trip and throttle valve must be reachable from a permanent platform, usually the operating platform. However, on some of the large varieties the trip and throttle valve may be mounted on the turbine at a height that would necessitate constructing a small platform and ladder arrangement above the normal operating level to make this valve accessible.


Figure 10-83 Typical Steam Piping

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 99 of 123 15/11/2002 REV 0 10.27.2 Condensing turbines require a surface condenser that is mounted beneath the turbine with bottom exhaust or adjacent to the turbine with top exhaust. Figure #10-84 shows a typical surface condenser used for condensing turbines that drive compressors; there are many other designs. An expansion joint is utilized in all exhaust systems to minimize forces and stresses on the turbine nozzle. In addition, where the turbine exhaust flange differs from the surface condenser inlet flange, a transition piece is required. The Stress Engineer usually designs this item. Be sure to consult with the Stress Engineer during layout as these requirements have a direct effect on the turbine elevation (Figure #10-85). Surface condensers are equipped with an atmospheric relief valve of which there are three types commonly used (Figure #10-84). Selection should be based on piping layout requirements. The exhaust steam system and surface condenser operate on a vacuum and the relief valve is designed to open at the slightest positive pressure above atmospheric pressure. Note that each relief valve has a water seal, a continuous water supply, and an overflow that is routed to a drain funnel. Figure #10-86 diagrammatically describes how vacuum is maintained in the surface condenser by continuous removal of air by ejectors. Common auxiliary connections that are found on special purpose steam turbines are indicated below. Where a down orientation has been specified for the exhaust, be sure all auxiliary connections not requiring valves, be extended to a common face of flange elevation and all connections requiring valves be accessible at operating level. Steam chest drains. Casing drains. Shaft packing leakoff. Trip valve or trip and throttle valve above seat drains. Trip valve or trip and throttle valve and governor valve steam leakoffs. Steam seal (condensing turbines only). Lube oil piping for the turbine and gear (when required) is manifolded and combined with the compress lube oil piping. (Figure #10-87).


Figure 10-84


Figure 10-85


Figure 10-86

Figure 10-87


10.28 PIPING DESIGN: PACKAGE COMPRESSOR UNITS 10.28.1

Open End Intake Piping

10.28.2

Discharge Piping

NOTE: Not included in package


10.29 COMPRESSOR INSTRUMENTATION AND CONTROLS 10.29.1

Instrumentation

10.29.2

Summary

Note: Not included in package


10.30 COMPRESSOR BUILDINGS AND MAINTENANCE EQUIPMENT General Where equipment is specified by the Specification Sheets as being designed for outdoor installation, no building or shelter is required. Where equipment is specified by the Specification Sheets as being designed for indoor installation, the extent of the building or shelter and type of maintenance facilities to be used will be determined for the individual contract. Normal maintenance equipment that may be used includes mobile cranes, overhead bridge cranes and monorails. The identification of basic building and maintenance requirements should be effected early in the contract during the job conference. The length and width of the building is established by clearance for compressor and driver including furnished appurtenances, maintenance requirements, control panel(s), and an office or wash room, if required. A laydown area or drop area should be provided. Traveling crane rails should extend past the floor perimeter to allow trucks to enter, load and unload parts. Since some repairs may be performed locally, ample space must be provided. 10.30.1

Accessibility

The compressor building should be readily accessible from a roadway to allow transport of major pieces of equipment. Stairways, from "grade" to the operating level, should be provided on both the front and rear of the building (diagonally opposed). Of course, for fully enclosed buildings, a door must be included at the stairways. Open and tropical shelters may require removable wall or roof panels to allow access by a mobile crane. Platform elevations are designed to fit standard stair risers (Figure #10-105). Where it is deemed feasible, a roll-up door may be used as a mode of access for maintenance operations.


10.31 TYPES OF COMPRESSOR BUILDINGS 10.31.1

Tropical Shelter

In mild climate areas a tropical shelter is usually adequate protection. This type of shelter provides a roof with drop curtains, i.e. walls that extend from building eaves to approximately 8' above the operating floor line (Figure #10-94). Verify that the drop curtains do not adversely alter the wind direction to air coolers mounted over the pipeway.

Figure 10-94 Elevation of a Typical Tropical Shelter

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 107 of 123 15/11/2002 REV 0 10.31.2

Open Shelter

Open shelters consist of a roof only with steel support columns. 10.31.3

Fully-Enclosed Building

The fully enclosed building is used in areas of heavy snow where blowing winds create tail drifts. This type of building is used to not only house and protect the machinery, but most importantly, to protect the maintenance personnel. 10.32 ESTABLISHMENT OF BUILDING HEIGHT The prime considerations in establishing the building heights are maintenance equipment to be used, clearance of other equipment during removal and removal path. The following material deals with overhead bridge cranes, mobile equipment and monorails. 10.32.1

Overhead Bridge Cranes

An overhead traveling crane provides full accessibility to all points within a definite area (Figure #1095). There are two basic types of overhead traveling cranes; underhung and top running. Underhung Cranes are used if the crane and its load are to be supported from the roof truss as shown in Figure #10-96. Single beam cranes are available hand operated or motorized. Hand chain operated is recommended for short travel distances and infrequent use; for long travel distances or more frequent use, a motorized single beam crane is recommended. Top Running Cranes are used if the crane and its load are to be supported from the building columns (Figure #10-97). There are two types of top running cranes; single beam and double beam. The single beam type may be used where maximum height of vertical load travel is not important and low initial cost is desirable (Figure #10-97). The double beam crane allows maximum height of vertical load travel. This type crane requires a top running trolley hoist (Figure #10-98). The crane railways may extend through the end of building for loading and unloading pieces of equipment onto trucks (Figure #10-99). Building height with overhead crane facilities as a basis may be derived in the following manner (refer to Figure #10-100 and 10-101). This procedure is applicable to either underhung or top running bridge cranes with underhung or top running trolley hoist. 1. 2.

Outline the largest obstruction which must be cleared (usually the compressor or driver). Determine and outline the largest piece of equipment to be removed for a maintenance procedure.


Figure 10-95 General Handling Capabilities of Overhead Traveling Cranes


Figure 10-96 Typical Underhung Traveling Crane with an Underhung Trolley Hoist

Figure 10-97 Typical Top-Running Traveling Crane with an Underhung Trolley Hoist


Figure 10-98 Typical Top-Running Double Beam Crane with a Top-Running Trolley Hoist. (Handling Capabilities of 5 to 10 Tons with Spans up to 60 Feet)

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS Page 111 of 123 15/11/2002 REV 0 3.

4. 5.

Determine the equipment's removal path, i.e. "overhead" or "floor level". (It may be necessary to make a study of each of the aforementioned cases to illustrate the affect it has on the building height). Establish the required hook height for unobstructed removal of equipment. Using vendor dimensional outlines, establish crane beam elevation and transmit to Structural Engineer.

Hook height should be set early because the hook height will determine crane elevation which will set the building eave height; a necessary dimension for obtaining building estimates. 10.32.2

Mobile Handling Equipment

Mobile handling equipment is normally used for handling electric motor drivers and large parts of other drivers. Driver piece weights should be investigated in order to determine if it is not within the overhead crane's lifting capacity and type of mobile crane required. Figures 10-102 and 10-103 indicate an outline drawing of a typical mobile crane and its lifting range diagram. The type and capacity of mobiles will be determined for the individual contract. The project engineer should provide this information. Removable wall or roof panels will be required for access. Establish an acceptable position for crane operations. Determine the crane's pivot point and make a "motion study" indicating equipment removal requirements (Figure #10-104). This will help determine building height. 10.33 MONO-RAILS Monorails cover a very limited area in comparison to an overhead bridge crane. In general, their effective usefulness is confined to the vertical area directly beneath the rail.


Figure 10-99 Crane Extension Beyond Building for Loading and Unloading of Equipment


Figure 10-100 Building Height Considerations for Overhead Traveling Cranes. Equipment Removal at "Floor Level".


Figure 10-101 Building Height Considerations for Overhead Traveling Cranes. Equipment Removal by "Overhead" Method.


Figure 10-102 Typical Mobile Crane


Figure 10-103 Typical Lifting Range Diagram for a Mobile Crane


Figure 10-104 "Motion Study" for Equipment Removal Using a Mobile Crane


Figure 10-105 Stair Details (Reference)

This copy is intended for use solely with Piping Design Layout Training. For other purposes, refer to the original document available through Knowledge Online.







FLUOR DANIEL

Practice 000 200 0744 Publication Date 17Apr00 Page 1 of 2

COMPRESSORS AND DRIVERS PROJECT DISCIPLINE INTERFACE PURPOSE This practice establishes guidelines, required interfaces and the assignment of primary responsibilities in the development of design requirements, specifications, layouts, and procurement steps for compressors and associated drivers.

SCOPE This practice defines the sequence of activities, functions, and responsibilities of the participants involved in technical development, procurement processes, and engineering follow-up for compressors and drivers.

APPLICATION This practice is apply in the execution of all projects. In the event that Project Management deems it necessary to alter this practice on an exception basis, a project bulletin will be issued to all concerned parties and will provide details of the specific deviations.

RESPONSIBILITY The responsibility for the review, approval, and sign-off of Interface Practices and their communication to task force personnel rests with the Lead Engineer or Supervisor from the following groups/disciplines: Project/Engineering Mgr. Process Mechanical Piping Procurement

Sign/___________________ Date/____________ Sign/___________________ Date/____________ Sign/___________________ Date/____________ Sign/___________________ Date/____________ Sign/___________________ Date/____________

Additionally, involvement by other project, engineering or design groups, and TDC is as noted in this practice. The following materials must be available prior to beginning the sequence of activities: Preliminary Flow Diagrams Preliminary Plot Plan/Plant Layout Client Specifications and Requirements Fluor Daniel Guideline Specifications and Practices Project Design Basis Project Procedure Manual

REFERENCES Practice 000.200.0752:

Flow Diagram Production - Project Discipline Interface.

Practice 000.200.0759:

Supplier Flow Diagram Utilization Project Discipline Interface.

General Engineering


Practice 000 200 0744 Publication Date 17Apr00 Page 2 of 2

FLUOR DANIEL COMPRESSORS AND DRIVERS PROJECT DISCIPLINE INTERFACE Practice 000.200.0831:

Procurement Practice for Engineered Equipment Project Discipline Interface.

ATTACHMENTS Attachment 01: (17Apr00) Compressors and Drives Project Discipline Interface

General Engineering

Practice 000 200 0744 Publication Date 17Apr00 Attachment 01 Page 1 of 8


FLUOR DANIEL COMPRESSORS AND DRIVERS PROJECT DISCIPLINE INTERFACE

SEQ 01

ACTIVITY Job Planning Meeting (as required)

RESPONSIBILITY Rotating Equipment Engineer

ACTIVITY DESCRIPTION Calls and chairs a meeting attended by: Project Engineer and/or Engineering Manager Process Engineer Piping Engineer Control Systems Engineer Structural Engineer Electrical Engineer Quality Assurance Engineer Stress Engineer Environmental Engineering Project Controls Project Procurement Materials required: Design Criteria - As Available Client Specifications - As Available Preliminary Flow Diagrams Preliminary Plot Plan Preliminary Data Sheets Process Front-End Schedule Fluor Daniel Narrative Compressor and Systems Specifications Agenda: 1.

Project presents a brief description of the scope of work, job philosophy, unusual job requirements or restrictions, and schedules.

2.

Process gives a detailed process description together with what is known of utilities to date.

3.

Rotating Equipment Engineer gives a description of the machinery involved with as much information as is available to date. Pay particular attention to Client specifications relating to vibration amplitude limits, frequency ranges, and dampening restrictions as these influence foundation design.

General Engineering




SEQ

ACTIVITY

RESPONSIBILITY

ACTIVITY DESCRIPTION 4.

Participants review design criteria, draw up a needs list, and agree on any required revisions to the project milestone schedule.

5.

Rotating Equipment Engineer prepares a summary of needs list and open questions and issue it to all disciplines.

6.

Process submits a detailed schedule for issuance of compressor process data sheets.

7.

Environmental advises limitations imposed by noise and emission restrictions.

8.

Structural Engineer advises seismic, grouting and anchor bolt requirements. Preliminary information required from the equipment supplier regarding anchoring, support and foundation design shall be discussed.

9.

Piping advises any special preferences for nozzle orientation. Plot plan is reviewed for equipment access and maintenance requirements.

10. Discuss equipment criticality ratings. 02

Development of Narrative Specifications

Rotating Equipment Engineer

Uses Fluor Daniel standard compressor and driver narrative specifications as a basis. Client and Project requirements are to be added to specifications or engineering notes in the Request for Quotation (RFQ) or used to amend the Fluor Daniel specification depending upon the task force requirements.

03

Mechanical Control Rotating Equipment Level Schedule Engineer

The Rotating Equipment Engineer prepares the Control Level Schedule based on the Master Schedule. The Control Level schedule is distributed per project procedures and continually reviewed and updated during the course of the job. This input shall be used by all disciplines in scheduling their work. In addition procurement shall use this as input for developing material milestones.

04

Issue of Narrative Specifications

Issue narrative specifications per Project procedures.

05

Process Data Sheets Process Engineer


Process prepares and issue process data sheets per project procedures.

General Engineering




SEQ 06

ACTIVITY Equipment Data Sheet


ACTIVITY DESCRIPTION Obtains needed information as well as answers to open questions from participants of the Job Conference. Rotating Equipment Engineer will confirm this information to all participants. (See Sequence 01, Items 4, 5 and 6.) Completes the compressor data sheets and issues to the Process Engineer for immediate approval. Original data sheets are initialed by process. Copies are issued through TDC after RFQ issuance per project procedure.

07

Estimate Equipment Rotating Equipment Engineer

Based on data sheets, estimates as closely as possible the compressor type, configuration, weights, dimensions and cost. Provide information to Piping, Project Controls, Structural, and Project.

08

Nozzle Loading Requirements

Arranges meeting with Rotating Equipment Engineer to determine special nozzle loading requirements which exceed API/NEMA or Fluor Daniel standards.

09

Preliminary Layout Piping Supervisor and/or Plot Location Piping Designer Stress Engineer Process Engineer

Stress Engineer

Using data sheets and information received from the Rotating Equipment Engineer, the Piping Supervisor makes preliminary estimates of the following: 1.

Location and orientation of compressor installation.

2.

Overall space requirements (including maintenance space).

3.

Structural and Piping requirements: Grade Mount Hold-Downs Mezzanine Liquid Knockout walk-in Basement Supports Shelter Line Slopes Expansion Joints

4.

Location of related equipment such as lube and seal systems, pulsation dampers, local control panels, conduit boxes, etc.

The Piping Supervisor may call a compressor installation planning conference to establish required information. The Rotating Equipment Engineer shall provide the other disciplines with information that is as accurate as possible at this early stage. He will continue to update this information as more accurate data is received.

General Engineering




SEQ

ACTIVITY

RESPONSIBILITY

ACTIVITY DESCRIPTION

10

Review of Piping Supervisor Preliminary Layout and/or Plot Location

Upon completion of the preliminary layout(s), Project, Piping Supervisor, Structural Engineer, Electrical Engineer, Control Systems, Process, Stress and Rotating Equipment Engineer will review the drawings and will mutually agree upon the layout including pipeway utility locations, foundation requirements and all auxiliary equipment.

11

Auxiliary Flow Diagram

Prepares a schedule of auxiliary flow diagrams if required and identifies the standard to be used. Refer to Project Discipline Interface 000.200.0752/0759 and the Mechanical Engineering Desktop Procedure Manual for squad check procedures for these diagrams.

12

Prepares and Issues Rotating Equipment Auxiliary Flow Engineer Diagram

Prepares auxiliary flow diagram and issues per Project procedures.

13

Preparation of Bidders List

Rotating Equipment, Project Engineer, Project Procurement Manager

Jointly discuss general equipment requirements, Client needs, etc., and establish a list of qualified bidders. Project shall obtain Client approval.

14.

Preparation and Issue of RFQ Package

Rotating Equipment, Project Prepare and issue to procurement the Request for Procurement Manager Quotation in accordance with Mechanical Desktop Reference Manual and Project Discipline Interface 000.200.0831.

15

Bid Evaluation

Rotating Equipment Engineer, Buyer


Evaluates economics, schedule, layouts, configurations, specification compliance and design offered by Suppliers. Involves other disciplines as required. Prepares quotation summary of the compressor and drivers and makes a recommendation per Project Discipline Practice Interface 000.200.0831. Recommends Suppliers and follows project procedures to obtain Fluor Daniel approval. This is given to Procurement after the Rotating Equipment Project Lead or Group Leader/Section Supervisor's approval. While reviewing the quotations, the Rotating Equipment Engineer notes anything that will affect the decisions reached in prior sequences and immediately brings it to the attention of the disciplines affected.

16

Bid Conditioning Meeting

Rotating Equipment Engineer, Buyer

For selected supplier(s), Rotating Equipment Engineer and Buyer shall initiate and co-chair conferences to resolve all commercial, technical, and supply details. Purchasing will contact Supplier(s) and arrange conferences.

General Engineering




SEQ

ACTIVITY

RESPONSIBILITY

ACTIVITY DESCRIPTION Participants: Client Supplier Representation for the Compressor and Buyer Project Procurement Project Engineer* Process Engineer* Piping Supervisor* Stress Engineer*

Environmental Engineer* Quality Assurance* Driver Structural Engineer* Electrical Engineer* Control Systems Engineer* Technical Document Control* Rotating Equipment Engineer

*As Needed Review nozzle loading and suction/discharge piping design. During review of inspection activities the extent of Control Systems/Electrical supply should be used to evaluate the necessity for source inspection of packaged systems by the Control Systems/Electrical Engineering personnel. Upon completion of the meeting, the Rotating Equipment Engineer and Buyer will issue conference notes per project procedures. 17

Purchase Request


The Rotating Equipment Engineer updates and/or prepares the Piping and Instrumentation Diagrams (P&IDs), Auxiliary Flow Diagrams, Equipment Data Sheets, Narrative Specifications, Signed Suppliers Data Commitment Forms and Engineering Notes to an as purchase condition. Rotating Equipment Engineer obtains Process initials on As-Purchased Equipment Data Sheets. Rotating Equipment Engineer completes the purchase request and issues to Procurement. TDC issues revised equipment data sheets per project distribution.

18

Update Control Level Schedule


Updates Control Level Schedule to current Supplier Drawing and Delivery Schedules per Coordination Meeting and issue to Project Controls for update and issue to all disciplines.

General Engineering




SEQ 19

ACTIVITY Seller's Plant Coordination Meeting


ACTIVITY DESCRIPTION Prior to Supplier drawing issuance, a meeting is held at the Supplier's plant to resolve all outstanding engineering details and review the scope of supply with Supplier's engineering department. Drawings shall be checked for completeness to avoid future reissue. Inspection typical schedules the pre-inspection coordination meeting at this time to include the Engineer and mutually resolve any conflicting requirements.

20

Seller Drawings

Technical Document Control Supplier submits drawings per the Supplier's data commitment form. Technical Document Control (TDC) implements the project Squad Check Procedure. TDC also issues advance prints if requested by the design disciplines. The Piping Supervisor will receive an advance copy of all outline drawings.

21

Update P&IDs and AFDs


Continue to update flow diagrams per standard procedures.

22

Specify and Rate Fluor Daniel Interconnecting Piping on AFD

Process Engineer Rotating Equipment Engineer

On receipt of Supplier's data, the Process Engineer, with the assistance of the Rotating Equipment Engineer, will rate Fluor Daniel 's interconnecting piping as to size, service, material, pressure and temperature in order to permit Fluor Daniel line numbers and specifications to be added to the P&IDs and AFDs by Piping Materials Engineer.

23

Design Data

Stress Engineer

Determine extent of hold-downs, frequencies, etc., with the assistance of Piping Supervisor and Rotating Equipment Engineer.

24

Acoustic Analysis Isometric Piping Drawings


The Rotating Equipment Engineer together with the Process, Insulation and Coatings, and Piping Engineers determine the extent of piping to be cleaned and this information added to the Master P&IDs and Auxiliary Flow Diagrams.

25

Temporary and/or Permanent Inlet Strainers, Check Valves

Piping Material Engineer

Piping Material Engineer reviews P&IDs for non-slam check valves and strainers and initiates Inlet Strainer Information Request Form. Rotating Equipment Engineer receives form, completes pertinent data and returns to Piping Material Control for preparation of Request for Quote. Mechanical Engineer is to review final design before purchase.

26

Extent of Piping Cleaning Specifications

Piping Material Engineer The Rotating Equipment Engineer together with the Process Engineer Insulation Process, Insulation and Coatings, and Piping Engineers and Coating Engineer determine the extent of piping to be cleaned and this information added to the Master P&IDs and Auxiliary Flow Diagrams.

27

Acoustic Analysis

Rotating Equipment

The Rotating Equipment Engineer if necessary

General Engineering




SEQ

ACTIVITY

RESPONSIBILITY

ACTIVITY DESCRIPTION

Engineer, Piping Supervisor participates in Supplier Acoustic Analysis Simulations, Piping participation is optional. 28

Preparation of Specifications and Methods for Cleaning

Insulation and Coating Engineer

Establishes method, reviews with Piping and Mechanical Engineers and prepares specification.

29

Model Review

Lead Piping Supervisor

Calls a conference to approve final layout design and resolve all outstanding problems. The discipline Guide Book checklist shall be utilized during this review. Material Required: Final Layouts Plot Plan Job Standard and Specifications Supplier Outlines Applicable Vessel, Structural, Electrical Drawings P&IDs and Auxiliary Flow Diagrams (to yellow off) Acoustic Analysis Results Contract assigned personnel present: Rotating Equipment Engineer Unit Supervisor and Layout Designer Process Engineer Structural Engineer Control Systems Engineer Stress Engineer Electrical Engineer

30

Revisions

All disciplines

No revisions will be allowed to a Supplier's drawing once an "A" instruction review distribution has been made. The equipment shall be considered to be in accordance with the specification and purchase order. All shall "make do," rather than attempt to optimize designs. Exceptions to this will only be considered by the Rotating Equipment Engineer when: 1.

The process conditions change.

2.

The equipment is found not to meet safety codes.

3.

The equipment is impossible to operate or maintain.

4.

The Client requests the change.

General Engineering




SEQ

ACTIVITY

RESPONSIBILITY

ACTIVITY DESCRIPTION The project shall be alerted by the Rotating Equipment Engineer of any revision that may impact cost or schedules of any Fluor Daniel discipline.

31

Shop Testing


Witnesses performance and mechanical tests conducted by Suppliers, as required. Rotating Equipment Engineer interprets results, and reports all data tot he Project Manager and other interested parties.

General Engineering



Practice 000 250 1063 Publication Date 11Feb00 Page 1 of 5

FLUOR DANIEL SUPPLIER DRAWING AND DATA REVIEW - RECIPROCATING COMPRESSORS

PURPOSE This practice provides a general guide for squad checking seller drawings of reciprocating compressors and associated drawings.

SCOPE This practice includes the following major sections: RESPONSIBILITY SELLER DRAWING LIST GENERAL SQUAD CHECKLIST ADDITIONAL SQUAD CHECK ITEMS GENERAL NOTES REFERENCES

APPLICATION The primary function of squad checking seller drawings for reciprocating compressors is to convey any required changes to the seller, and to ensure that design criteria are met and that data are correctly documented. Seller drawings should show all required information to allow for accurate piping design and layout. Refer to Piping Engineering Practice 000.250.1060: Supplier Drawing And Data Review for guidelines in reviewing and handling of seller drawings.

RESPONSIBILITY Design Supervisor and Area Lead Designer will enforce the utilization of this standard. Piping Designer/Checker who is responsible for squad checking the applicable drawings will ensure that seller data and drawings are carefully reviewed.

SELLER DRAWING LIST The following is a list of seller drawings that Piping Designer may be required to squad check: Composite outline drawing of driver and compressor Driver outline Jacket water piping schematic Lube oil schematic Packing vent and drain schematic Interstage equipment and piping drawings Lube oil cooler outline Oil filter outline Lube oil pump outline (when not integral part of compressor) Auxiliary lube oil pump outline Gage board outline Vent and drain schematic (for hazardous gases) Piping Engineering




Moisture trap outline Lube oil piping drawing

GENERAL SQUAD CHECKLIST Composite Outline Of Compressor And Driver Overall Dimensions: Adequately dimensioned for space and orientation requirements. Be sure that the location for external connection points of piping are clearly dimensioned. Check totally enclosed motors for maintenance requirements with Electrical Supervisor. Piston Pull: Check piping layout drawing for space requirements. Centerline of Shaft above Floor: Check against the piping layout elevation requirements. Check the horizontal offset between compressor shaft and driver shaft if gear box is required. Cylinder Valve: Check cylinder valve orientation and removal requirements plus manual clearance pocket requirements against suction and discharge bottle orientation and nozzle lengths. Cylinder Support: Check cylinder support and distance piece support (if required) against piping layout elevation and check clearance from bottom bottle to cylinder support. Dimensions: Check dimensions from centerline of cylinder to inlet and outlet face connections. Suction and Discharge Size, Rating, and Facing: Ensure that piping nozzles are in accordance with applicable piping specifications for items such as material type, pressure ratings, pipe schedules, and type of facing. If the seller drawings are from an offshore manufacturer, verify that piping connections meet ASTM, ANSI, or other applicable codes. Ensure that all nozzles are adequately dimensioned. Stud Projections: The bottom cylinder bottle connection must be long enough for double nuts (stud removal) for bottle removal.

Piping Engineering




Drawings: Review the drawings against the P&IDs to verify that piping and instrument connections are accounted for. Maintenance Lifts: Check against piping layout drawing for handling requirements. Verify weight of heaviest component that might be removed and check facility to be employed. Also, check piping layout for overhead clearance and required breakout flanges in piping. Allowable Nozzle Loads: The maximum limitations for allowable loads, forces, and moments by the seller should be clearly indicated on the compressor drawing or datasheet. Foundation Requirement: Check against compressor structure plan drawing. On seller's first squad check, show extent of concrete around the unit and the minimum clearance dimension to edge of concrete for seller fittings, piping, or down connections to auxiliary equipment. Auxiliary Piping Connections: Check against auxiliary and P&ID (process and instrument diagram) for identifying symbols, size, rating, and facing. Connection points should be verified for erection ease. Driver Outline (Motor) Overall Dimensions: Check that all dimensions required for space and orientation are shown. If external piping connections are required, be sure they are sized and dimensioned correctly. Also, if driver sound enclosure is required, check overall dimensions and accessibility to driver. Rotor Removal: Check for space and handling requirements. Equipment Weight: Weights should be listed to determine handling requirements in accordance with the piping layout drawing. Driver Outline (Turbine) Refer to Piping Engineering Practice 000.250.1062: Supplier Drawing and Data Review - Pumps and Turbines, for seller squad checklists on special purpose steam turbines.

ADDITIONAL SQUAD CHECK ITEMS Additional items that must be squad checked but that may or may not appear on the composite outline drawing are indicated as follows:

Piping Engineering




Jacket Water Schematic: Check only that routing of supply and return piping can accommodate seller's connections. Lube Oil Schematic: If piping not furnished by seller, check that routing of supply and return piping can accommodate seller's connections. Packing Vent and Drain Schematic: Check that routing of piping can accommodate seller's connections. Interstage Equipment and Piping Drawing: Verify accessibility, removal, and operation requirements. Check with stress for support requirements, especially on cylinder mounted intercoolers and furnished piping. Lube Oil Cooler Requirements: Check bundle pull area only upon evaluation of main suction and discharge piping routing. If cooler is located below steel platforming, removable floor steel is required. Check weight of these lifts involved. Oil Filter Outline: Check size, rating, facing, and dimensional data for piping connections only if Fluor Daniel is furnishing the piping. Lube Oil Pump Outline: Lube oil pump outline and auxiliary lube oil pump outline (when not integral part of compressor): For pump squad checklist, refer to Piping Engineering Practice 000.250.1062. Gage Board: Check for accessibility and orientation. Vent and Drain Schematic (For hazardous gases): Check that routing of piping can accommodate seller's connections. Moisture Trap Outline: If trap is to be used in unfurnished piping, check operational requirements with the mechanical engineer. Lube Oil Piping: Check accessibility of in-line items and support requirements.

GENERAL NOTES For reciprocating compressors, the lube oil system equipment is usually mounted on the compressor and supplied and piped by the seller. For all seller schematic drawings, verify with Fluor Daniel auxiliary flow diagrams for process requirements. Check that all devices and piping furnished by the seller, and devices and piping required to complete the installation have been so indicated. Following are general sources of reference material to check: Piping Engineering




Piping layout drawings Structural and Civil drawings Mechanical equipment datasheets Auxiliary and process flow diagrams The following sources should be checked for special requirements as they apply to seller equipment: Engineering conference notes Fluor Daniel narrative equipment specifications Seller equipment drawing notes Fluor Daniel mechanical equipment engineer Seller's service manual Squad checking should be avoided on all unchecked certified drawings submitted for approval.

REFERENCES Piping Engineering Practice 000.250.1060: Supplier Drawing And Data Review Piping Engineering Practice 000.250.1062: Supplier Drawing And Data Review - Pumps And Turbines Piping Engineering Practice 000.250.2470: Compressor Piping - Reciprocating Compressors - Piping And Arrangement

Piping Engineering


Client Name Project Name Contract Number


Master Specification 000 250 50001 Date 18Jan00 Page 1 of 16 Revision

PROCESS AND UTILITY PIPING DESIGN, LAYOUT, AND DRAWING

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.

Revision No.

Date

Originator's Name & Initials

APPROVALS

Reviewed/Checked By Name & Initials

SIGNATURES

Pages

DATE

Lead Engineer Project Manager: Client Approval: ISSUED FOR :

00025050001.doc

Construction

Other

Piping Engineering





Record of Revisions Revision No.

00025050001.doc

Date

Description

Piping Engineering





1.0

GENERAL 1.1

Summary A.

Scope of Specification This specification prescribes the design of above ground pressure piping systems, equipment layout, pipe routing, and drawing practices for refineries, chemical plants, and similar facilities (except plumbing inside of buildings).

B.

Related Specifications The following specifications prescribe items of related Work:

00025050001.doc

•

000.210.02720:

Storm Sewer Systems And Culverts

•

000.210.02730:

Sanitary Sewer Systems

•

000.245.45001:

Fire Protection Design Criteria For Refinery And Petrochemical Facilities

•

000.250.50003:

Piping-Material Specification Line Class-Process And Utility Piping

•

000.250.50025:

Shop Fabrication And Handling-Process And Utility Piping

•

000.250.50026:

Field Fabrication And Installation Process And Utility Piping

•

000.250.50027:

Piping Tie-Ins

•

000.250.50030:

Geographic Color Coding

•

000.250.50050:

Piping Pressure Testing

•

000.250.50112:

Packaged Equipment Piping

•

000.250.50200:

Piping Flexibility

•

000.250.50300:

Heat Tracing For Piping, Equipment, And Instruments

•

000.285.50028:

Internal Cleaning Of Piping Systems

•

000.285.86110:

Hot Insulation

•

000.285.86130:

Cold Insulation

•

000.285.86210:

Painting Piping Engineering





Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications. 1.2

References The following referenced publications form part of this specification. Each publication is the latest revision and addendum in effect at the time of the project's execution unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, all Work included in this specification shall conform to the applicable provisions of the following referenced publications: A.

Applicable Codes 1.

ASME/ANSI (American Society of Mechanical Engineers/American National Standards Institute) Code for Pressure Piping, B31.3: Chemical Plant and Petroleum Refinery Piping. Note!!! The limits of piping covered by codes other than ASME/ANSI B31.3 shall be indicated on the P&IDs (piping and instrumentation diagrams). This specification may be used with other sections of the ASME/ANSI B31 Code and Section 1 of the ASME Code, where applicable.

B.

2.

OSHA Part 1910.

3.

National Fire Protection Association, Code No. 30.

4.

Applicable plumbing, heating and ventilation, or refrigeration codes for piping serving buildings and areas other than plant or process areas.

5.

Sour service piping (subject to sulfide stress cracking) shall be in accordance with NACE specification MR0175.

Design Documents Detail and specification numbers in this specification refer to Fluor Daniel practices and specifications, respectively.

1.3

00025050001.doc

Quality Assurance A.

Approved department design guidelines and methods are used in conjunction with project requirements to achieve the desired level of quality.

B.

Project piping engineers and piping design supervisors monitor, review, and control the design and planning activities of personnel assigned to the project to ensure that applicable codes, practices, and specifications are being followed to meet project quality goals.

C.

Quality criteria shall be reviewed constantly during design planning activity.

Piping Engineering


Master Specification 000 250 50001 Date 18Jan00 This copy is intended for use solely with Page 5 of 16 Piping Design Layout Training. Revision For other purposes, refer to the original document available through Knowledge Online.


2.0

PRODUCTS 2.1

2.2

00025050001.doc

Materials A.

Piping material shall be in accordance with Specification 000.250.50003; note any deviations on the piping drawings. Prepiped or packaged items shall be in accordance with Specification 000.250.50112.

B.

Install flat face flanges against flat face cast iron valves and equipment.

C.

Locking devices for valves shall be provided by the client.

D.

Minimum pipe size shall be 1/2 of an inch, except for connections to equipment.

E.

Do not use pipe sizes 1-1/4 inch, 2-1/2 inch, 3-1/2 inch, and 5 inch except for connections to equipment.

Design Summary A.

Base relation of units, location of equipment, and routing of pipe on economics, safety, ease of maintenance, operation, and construction requirements. The alignment of equipment and routing of pipe shall offer an organized appearance.

B.

Major lines normally shall be carried on overhead pipeways. In certain instances, they may be buried, providing they are adequately protected. Lines that must be run below grade, and must be periodically inspected or replaced, shall be identified on the P&IDs; Place these lines in covered concrete trenches. Cooling water may be run above or below ground, based on economics. Domestic or potable water shall be run underground. Pipe support spacings shall be maximized using the limits of pipe spans and structural integrity.

C.

Do not provide space for future equipment, pipe, or units unless required by the client or for process considerations. This requirement shall be indicated on the plot plan and P&IDs.

D.

Avoid dead ends, especially for piping where solids or fluids may congeal or form corrosive condensate.

E.

The location and spacing of offsite storage tanks and dike requirements shall be in accordance with National Fire Protection Association, Code No. 30, and OSHA part 1910.106 (b), where applicable. Spacing may be increased for construction requirements.

F.

Normally, route piping in offsite areas on sleepers. Stagger the sleeper elevations to permit ease of crossing or change of direction at intersections. Flat turns may be used when entire sleeperways change direction.

G.

Group offsite equipment, pumps, and exchangers to permit economical pipe routing. Locate this equipment outside of diked storage areas, except where indicated otherwise on the P&IDs.

Piping Engineering





2.3

H.

Locate cooling towers downwind of buildings and equipment to keep spray from falling on them. Orient the short side of the tower into the prevailing summer wind for maximum efficiency. Locate cooling towers a minimum of 100 feet from process units, utility units, fired equipment, and process equipment.

I.

Locate the flare stack upwind of process units, with a minimum distance of 200 feet from process equipment, tanks, and cooling towers. If the stack height is less than 75 feet, increase this distance to a minimum of 300 feet. These minimum distances shall be verified by Fluor Daniel Process Engineering.

J.

Keep the loading and unloading facilities that handle flammable commodities a minimum of 200 feet from process equipment, and 250 feet from tankage.

K.

Piping flexibility shall be in accordance with Specification 000.250.50200.

L.

The plant layout of equipment shall utilize common structures for equipment, vessels, and pumps. As a rule single installation of equipment will not require a structure.

M.

Project Specifications shall be reviewed and modified as necessary to reduce the Total Installed Cost on a project by using alternative Piping materials & components and alternative Pipeline fabrication & installation methods. Examples of these alternatives include the use of pipe bends instead of elbows and the use of hydraulically installed LOKRING ™ Fittings.

Design Requirements A.

B.

Pumps 1.

Locate pumps close to the equipment from which they take suction.

2.

Design piping to provide clearance for pump or driver removal. Similarly, on end suction pumps, piping shall permit removing suction cover and pump impeller while the suction and discharge valves are in place.

3.

Arrange suction lines to minimize offsets. The suction lines shall be short and as direct as possible, and shall step down from the equipment to the pump. Suction lines routed on sleeperways may rise to pump suction nozzle elevation, subject to approval of Fluor Daniel Process Engineering.

4.

Orient valve handwheels or handles so they will not interfere with pump maintenance or motor removal. Valve handwheels or handles shall be readily operable from grade.

Exchangers 1.

00025050001.doc

Group exchangers together wherever possible.

Piping Engineering





C.

D.

00025050001.doc

2.

Limit stacked shell and tube exchangers to four shells high in similar service; however, the top exchanger shall not exceed a centerline elevation of 18 feet above high point of finished surface, unless mounted in a structure.

3.

Keep channel end and shell covers clear of obstructions such as piping and structural members to allow unbolting of exchanger flanges, and removal of heads and tube bundles.

4.

Locate reboilers as close as possible to the equipment they serve.

5.

Normally, locate air coolers above pipeways.

Vessels and Columns 1.

Wherever possible, locate piping at columns radially about the columns on the pipeway side; locate manway and platforms on the access side. Manways should be on or about a common centerline to make use of a common lifting device or davit.

2.

Provide platforms at manways above 15 feet centerline elevation from high point of finished surface. The maximum distance for ladder runs and space between offset platforms shall be 30 feet.

3.

Position platforms so the manhole centerline is no less than 2 feet above the platform, with 2'- 6" preferred. The bottom of the manhole entry shall not be more than 3'- 6" above the platform.

4.

Provide combined platforms, where practical and economical, at multiple tower arrangements with common manway elevations.

5.

Provide vessel davits for handling items such as internals and relief valves on vessels exceeding a height of 30 feet above the high point of the finished surface, and on vessels not accessible by mobile crane. Orient davits to allow the lowering of appurtenances into the access area.

6.

Wherever possible, orient level instruments on the side toward the pipeway.

7.

Stacking two or more vertical vessels shall be investigated. This investigation shall consider the process conditions (commodities, temperatures, pressures), vertical height limitations, and piping layout for economic advantages. The stacking of vessels requires the acceptance of Process and Vessel engineering.

Fired Equipment 1.

Locate fired equipment, if practical, so that flammable gases from hydrocarbon and other processing areas cannot be blown into the open flames by prevailing winds.

2.

Locate snuffing steam manifolds and fuel gas shutoff valves a minimum of 50 feet horizontally from the heaters they protect.

Piping Engineering





3.

E.

F.

a.

Floor Fired Furnaces: Combination oil and gas firing valves shall be operable from burner observation door platform. For those fired by gas only, the valves shall be near the burner and shall be operable from grade.

b.

Side Fired Furnaces: Locate firing valves so they can be operated while the flame is viewed from the observation door.

4.

Terminate heater stacks a minimum of 15 feet above any platform within a radius of 40 feet.

5.

Access and platforming requirements shall be in accordance with the contract fired equipment narrative specification.

6.

Pressure relief doors and tube access doors shall be free from obstructions. Orient pressure relief doors so as not to blow into adjacent equipment.

7.

The elevation of the bottom of the heater above the high point of the finished surface shall be in accordance with the contract fired equipment narrative specification.

Reciprocating Compressors 1.

Suction and discharge lines that are subject to vibration (mechanical and acoustical) normally shall be routed at grade and held down at points established by analysis of the system.

2.

Accessibility and maintenance for large lifts such as cylinder, motor rotor, and piston removal shall be by mobile equipment.

3.

Clean suction lines internally per Specification 000.285.50028. The extent of cleaning shall be indicated on the P&IDs.

4.

Horizontal, straight line, reciprocating compressors shall have access to cylinder valves. Access shall be from grade or platform if required.

5.

Depending on unit size and installation height, horizontal-opposed and gas engine driven reciprocating compressors may require full platforming at the operating level.

6.

The sizing, routing, supporting, and restraining of the suction and discharge piping is subject to review by means of an analog computer study, as outlined in the compression specifications.

Centrifugal Compressors 1.

00025050001.doc

Burner Valving

Top suction and discharge lines either shall be routed to provide clearance for overhead maintenance requirements, or shall be made up with removable spool pieces.

Piping Engineering





G.

00025050001.doc

2.

Locate lube and seal oil consoles adjacent to and as close as possible to the compressor. Oil return lines from the compressor and driver shall have a minimum slope of 1/2 inch per foot to the inlet connection of seal traps, degassing tanks, and oil reservoir. Review the equipment arrangement for access and operation.

3.

Pipe the reservoir, compressor bearing, and seal oil vents to a safe location at least 6 feet above operator head level.

4.

Heavy parts such as upper or inner casing and rotor shall be accessible to mobile equipment.

5.

Support piping so as to minimize dead load on compressor nozzles; the load shall be within the recommended allowance of API-617.

6.

Clean suction lines internally per Specification 000.285.50028. The extent of cleaning shall be indicated on the P&IDs.

7.

Centrifugal compressors shall have full platforming at operating level.

In-Line Instruments 1.

Locate liquid level controllers and level glasses so as to be accessible from grade, platform, or permanent ladder. The level glass shall be readable from grade wherever practical.

2.

Relief valves shall be accessible. Wherever feasible, locate them at platforms that are designed for other purposes. Relief valves with a centerline elevation over 15 feet above high point of finish surface (except in pipeways) shall be accessible from platform or permanent ladder.

3.

Install thermal relief valves, 1 inch and smaller, in a horizontal position when it is impractical to install in the vertical position. Install relief valves, 1 1/2 inch and larger, in a vertical position.

4.

Normally, install relief valves that discharge to a closed system higher than the collection header. There shall be no pockets in the discharge line.

5.

Relief valves that discharge to the atmosphere shall have tail pipes extended to a minimum of 8 feet above the nearest operating platform that is within a radius of 25 feet. This requirement may be waived, provided a review of the proposed arrangement indicates that it does not present a hazard.

6.

Review relief valves discharging hydrocarbon vapors to the atmosphere within 100 feet of fired equipment for vapor dissipation.

7.

Provide steam traps at pocketed low points and at dead ends of steam headers. Also, provide traps on excessively long runs of steam piping, for sufficient condensate removal, and to ensure dry quality steam at destination. Steam traps located more than 15 feet above high point of finish surface, except in pipeways, shall be accessible from the platform. Piping Engineering





8.

Indicate control, block, and bypass valve sizes on the P&IDs. Control valves shall be accessible from grade or platforms. In general, the instruments or indicators showing the process variables shall be visible from the control valve.

9.

Orifice runs should be located in the horizontal. Vertical orifice runs may be used with the approval of Fluor Daniel Control Systems Engineering. Orifice flanges with a centerline elevation over 15 feet above the high point of finished surface, except in pipeways, shall be accessible from a platform or permanent ladder.

10. Locate orifice taps shall be located as follows:

H.

2.4

Air and Gas [- Top vertical centerline (preferred)] [- 45 degrees above horizontal centerline (alternate)]

b.

Liquid and Steam [- Horizontal centerline (preferred)] [- 45 degrees below horizontal centerline (alternate)]

c.

The piping isometrics details shall show the required tap orientations.

Temperature and Pressure Instrument Accessibility and Visibility 1.

Temperature test wells located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by a portable ladder. Those located over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder.

2.

Temperature indicators shall be visible from grade, ladder, or platform.

3.

Thermocouple and temperature indicators located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder.

4.

Local pressure indicators shall be visible from grade, permanent ladder, or platform. Those located less than 15 feet above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 15 feet above high point of finished surface shall be accessible from a platform or permanent ladder.

Plant Operation A.

00025050001.doc

a.

Valve Operation 1.

Indicate operating valves requiring attention, observation, or adjustment during normal plant operation on the P&IDs with the symbols O.V. They shall be located so as to be within reach from grade, platform, or permanent ladder.

2.

Operating valves may be chain-operated if the bottom of handwheel is over 7 feet above high point of finished surface or operating platform. Piping Engineering





B.

C.

D.

00025050001.doc

3.

The centerline of handwheel or handles on block valves used for shutdown only, located less than 15 feet above high point of finished surface, and those located in pipeways, may be accessible by portable ladder.

4.

The centerline of handwheel or handles on block valves used for shutdown only and located over 15 feet above high point of finished surface, except those located in pipeways, shall be operable from permanent ladder or platform.

5.

In general, keep valve handwheels, handles, and stems out of operating aisles. Where this is not practical, elevate the valve to 6'- 6" (plus or minus 3 inches) clear from high point of finished surface to bottom of handwheel.

6.

Utility piping systems (air, water, steam, condensate, and nitrogen) going into separate process units shall have a battery limit block valves with a line blind only. Individual block valves to users within the process units are not required unless specified by the Client or Process engineering.

Sample Connections 1.

Provide sample and test connections as indicated on P&IDs. They shall be readily accessible from grade or platform.

2.

In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free running of the liquid before sampling.

3.

Note samples that require cooling on the P&IDs, and provide a cooler.

Vents and Drains 1.

The P&IDs shall indicate and size the vents, drains, and bleeds required for plant operation, except as noted in section C3 below.

2.

Provide plugged hydrostatic vents and drains without valves at the high and low points of piping.

3.

Provide valved bleeds at control valve stations, level switches, level controllers, and gauge glasses per job standard.

Line Strainers 1.

Provide temporary conical type strainers in 2 inch and larger butt weld pump suction lines for use during startup. Arrange piping to facilitate removal.

2.

Use permanent Y-type strainers on 2 inch and smaller screwed or socket weld pump suction piping.

3.

Provide temporary basket type strainers located at the suction pulsation device inlet for startup of reciprocating compressors. Arrange piping to facilitate removal of the strainer.

Piping Engineering




4.

E.

Provide temporary basket type strainers and locate them as close as possible to the compressor inlet flange for startup of centrifugal compressors. Arrange piping to facilitate removal of the strainer.

Insulation Hot insulation for piping and equipment shall be in accordance with Specification 000.285.86110; cold insulation, with Specification 000.285.86130.

F.

Insulation Shoes 1.

2.

G.

Provide insulation shoes where a line crosses a support for hot insulated piping in the following categories only: a.

Aluminum lines.

b.

3 inch and larger carbon and alloy steel lines with design temperatures over 650 degrees F.

Large diameter lines (20 inches and over), stainless steel lines where galvanic corrosion may exist, lines with wall thickness less than standard weight, and vacuum lines shall be analyzed to determine if shoes or wear plates are needed.

Cradles Provide cradles at supports for insulated lines in cold service and for acoustical applications.

H.

2.5

Personnel Protection 1.

Provide eyewash and emergency showers in areas where operating personnel are subject to hazardous sprays or spills, such as acid. Indicate these items on the P&IDs.

2.

Provide personnel protection at uninsulated lines and for equipment operating above 140 degrees F when they constitute a hazard to the operators during the normal operating routine. Lines that are infrequently used, such as snuffing steam and relief valve discharges, do not require protective shields or coverings.

3.

Note valve and flange shields, if required, in the piping material specifications.

Maintenance A.

Clearances Minimum clearances for equipment, structures, platforms, and supports shall be in accordance with the following table:

00025050001.doc

Piping Engineering




ITEM ROADS

RAILROADS

DESCRIPTION

Headroom for primary access roads (from the crown) ..................... Width of primary access roads excluding 5 foot shoulders ............. Headroom for secondary roads (from the crown) ............................ Width of secondary roads excluding 3 foot shoulders ..................... Clearance from edge of road shoulders to platforms, equipment, pipe associated with equipment, or similar features ...........................

21' - 0" 20' - 0" 12' - 0" 10' – 0" 5' - 0"

Headroom over through-railroads (from top rail) ........................... **22' - 6" Clearance from track centerline to obstruction ................................ **10' - 0"

MAINTENANCE Horizontal clearance for equipment maintenance by hydraulic AISLEWAYS AT GRADE crane (12T capacity) .......................................................................... Vertical clearance for equipment maintenance by hydraulic crane (12T capacity) ..................................................................................... Horizontal clearance for fork lift (5000 lbs capability) and similar equipment ........................................................................................... Vertical clearance for fork lift (5000 lbs capability) and similar equipment ........................................................................................... Horizontal clearance for equipment maintenance by portable manual equipment (A-frames, hand trucks, dollies, or similar equipment) .......................................................................................... Vertical clearance for equipment maintenance by portable manual equipment (A-frames, hand trucks, or similar equipment) .................

10' - 0" 12' - 0" 6" - 0" 8' – 0"

3' - 0" 8' - 0"

WALKWAYS

Horizontal clearance, not necessarily in a straight line .................... 2' - 6" Headroom (except for handwheels) ................................................. 7' - 0"

PLATFORMS

Minimum width ............................................................................... Minimum clearance around any obstruction on the platforms ......... Headroom ......................................................................................... Maximum vertical distance between platforms ................................

EQUIPMENT

FIRED EQUIPMENT

Minimum maintenance space required between flanges of exchangers or other equipment arranged in pairs ................................ 1' - 6" Minimum maintenance space required for structural member or pipe ..................................................................................................... 1' - 0" Clearance from edge of road shoulder (the extreme projection) ...... 5' - 0"

00025050001.doc

2' - 6" 1' - 6" 7' - 0" 30' - 0"

Horizontal clearance from hydrocarbon equipment (shell to shell) . 50' - 0" Exception: Reactors or equipment in alloy systems shall be located for economical piping arrangement. Clearance from edge of roads to shell .............................................. 10' - 0"

Piping Engineering




ITEM

DESCRIPTION

PIPE (aboveground)

Clearance between the outside diameter of flange and the outside diameter of pipe insulation .................................................................. *0' - 1" Clearance between the outside diameter of pipe, flange, or insulation and structural member ........................................................ *0' - 2"

[** Verify conformance with local regulations]

B.

*With full consideration of thermal movements

Accessibility 1.

Provide a means of egress (a continuous and unobstructed way of exit travel) from any point in a building, elevated equipment, or structure.

2.

Provide a secondary means of escape where the travel distance from the furthest point on a platform to an exit exceeds 75 feet.

3.

Access to elevated platforms shall be by permanent ladder. The need for stairways shall be determined by platform elevation, number of items requiring attention, observation and adjustment, and the frequency of items. Indicate stairways at structures on the plot plan.

4.

Provide safety cages and ladders per applicable details of Practice 000.215.5130 (Structural) and Practice 000.258.58045 (Vessels).

5.

Ladder safety devices such as safety belts and harnesses, may be used on boiler, flare stack, water tank, and chimney ladders over 20 feet in unbroken lengths in lieu of cage protection and landing platforms [Refer to OSHA 1910.27 (d)(5)].

6.

Arrange equipment, structures, and piping to permit maintenance and service by means of mobile equipment. Provide permanent facilities as indicated on the plot plan where maintenance by mobile equipment is impractical.

7.

Provide a clear access area at grade for vessels with removable internals or for vessels requiring loading and unloading.

8.

Exchangers with removable tube bundles shall have maintenance clearance equal to the bundle length plus 5 feet measured from the tube sheet.

9.

Provide sufficient access and clearance at fired equipment for removal of tubes, sootblowers, air preheater baskets, burners, fans, and other related serviceable equipment.

10. Plant roads may be used as tube pull areas. C.

Spectacle Blinds 1.

00025050001.doc

Provide spectacle blinds as indicated on the P&IDs. Piping Engineering





D.

2.

Spectacle blinds shall be accessible from grade or platform. Blinds located in a pipeway are considered accessible. Blinds that weigh over 100 lbs shall be accessible by mobile equipment. Where this is not possible, provide davits or hitching points.

3.

Stagger closely grouped flanges with blinds.

Utility Stations Provide utility stations with water, steam, or air as indicated below. Use a single 50 foot length of hose to reach the entire working area from the station. Hose, hose rack, and hose connections shall be provided by the client.

3.0

1.

Provide water outlets at grade level only, in pump areas, and near equipment that shall be water washed during maintenance.

2.

Provide steam outlets at grade level only in areas subject to product spills, and near equipment that requires steaming out during maintenance.

3.

Provide air outlets in areas where air-driven tools are used such as at exchangers, both ends of heaters, compressor area, top platform of reactors, and on columns, so that each manway to be serviced is within the reach of a 50 foot hose.

EXECUTION 3.1

Design And Drawing Practices A.

Model When called for in the Scope of Work an electronic model shall be built using the appropriate design program (PDS or PDMS). It shall be built in accordance with the applicable section of the project CAD documents and the PAG (Piping Applications Guide) Manual. When called for in the Scope of Work a physical model shall be built in accordance with the applicable section of the project physical model documents and Specification 670.250.50002.

B.

Types of Piping Documents 1.

00025050001.doc

Aboveground piping plans: Drawings with sufficient detail to indicate pipe routing, intersections, anchors, guides, supports, provisions for expansion, spare equipment, and connections to associated apparatus. Show piping plan dimensions in feet and inches. When the dimensions are less than 1 foot, use inches. Draw sections and details to show routing of piping that cannot be clearly shown in the plan drawing. Draw piping as a single line, except in areas where double line may be required for verification of clearances. Show all piping on the piping plan.

Piping Engineering





C.

2.

Piping isometrics: 11 inch by 17 inch drawings of individual lines, or portions of lines, complete with all information required for fabrication and installation. Provide isometrics when required by Fluor Daniel to expedite the fabrication and installation of pipe. The isometric drawing number is the same as the line number.

3.

Heat tracing schedules and details shall indicate the extent, size, routing, and tracing material.

4.

Pressure Test Summary and related documents shall indicate line test pressure, test medium, and other supporting data. These documents shall be issued to Field Construction for pressure testing.

Symbols Piping symbols shall be in accordance with Practice 000.250.9817 and Practice 000.250.9818. Identify special items of piping material by an item code number on the P&IDs and isometrics. The symbol "F" in a hexagon may be used on drawings to denote that the line beyond this symbol shall be routed at the jobsite by the field, including location of valves, field supports, and instruments.

D.

Line Identification Clearly identify pipe lines by line numbers on P&IDs and drawings, and summarize on the Pipe Line List.

4.0

ATTACHMENTS Not applicable.

End of Specification

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FLUOR DANIEL


INTERNAL CLEANING OF NON-HYGIENIC PIPING SYSTEMS

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.

Revision No.

Date

Originator's Name & Initials

APPROVALS

Reviewed/Checked By Name & Initials

SIGNATURES

Pages

DATE

Lead Engineer Project Manager: Client Approval: ISSUED FOR :

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Construction

Other

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FLUOR DANIEL



Record of Revisions Revision No.

67525050028.doc

Date

Description

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FLUOR DANIEL



1.0

GENERAL 1.1

Summary A.

Scope of Specification 1.

This specification prescribes the requirements for internal cleaning procedures for all non-hygienic piping systems, including the following: a. b. c. d.

B.

Cleaning contractor requirements. Precleaned material requirements. Field flushing and cleaning requirements Field passivation of stainless steel piping systems

Work Not Included Not included in this specification are the flushing, cleaning, passivation and sterilization of stainless steel hygienic tubing systems (line classes TG03, TG04, and TG05). These procedures shall be included in Specification 50029.

C.

Related Specifications The following specifications prescribe items of related Work: • 50003: Piping - Material Line Class Specification • 50025: Fabrication & Handling of Non-Hygienic Process & Utility Piping (Shop/Field) • 50029: Cleaning and Passivation of Hygienic Systems • 50050: Piping Pressure Testing Coordinate Work prescribed by this specification with Work prescribed by the above listed specifications.

D.

Related Technical Requirements Attachments to specification include the following: 1. 2.

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Complete service index and assigned cleaning procedure. Individual cleaning procedures.

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E.

Terminology 1.

Blowout: Blowing of a vapor (such as air, nitrogen, or steam) at sufficient velocity to remove all foreign matter from piping systems.

2.

Chemical Cleaning: Cleaning which involves the use of chemical agents to dissolve and remove the contaminants.

3.

Cleaning: The process of removing deposits, scales, corrosion products or other foulants which restrict flow, impair heat transfer, or contaminate product being conveyed in the piping systems.

4.

Degree of Cleaning: A detailed description of exactly to what extent contaminants will be removed from the piping system.

5.

Disinfecting: Removal of biological contaminants harmful to human health if contained in potable water.

6.

Field Cleaning: Any cleaning procedure performed on piping systems after field installation.

7.

Flushing: Circulating flushing fluid at sufficient velocity to remove all foreign matter.

8.

Mechanical Cleaning: Cleaning accomplished by hand, power tool, or abrasive cleaning.

9.

Neutralization: Reaction between hydrogen ion from an acid and hydroxyl ion from a base to produce pH neutral water.

10. Paint Stripping: Removal of mill applied varnishes or other paint. 11. Passivation: Process of forming a protective film on metal; typically refers to exposure of stainless steel parts, systems or equipment to an oxidizing environment such as nitric acid or a mild organic acid, which removes light surface contaminants, enhances the protective chromium oxide film, and increases resistance to corrosive environments. 12. Pickling: Chemical removal of heavy, tightly adhering oxide films or scales resulting from welding operations, thermal treatments (such as annealing or hardening), and hotforming by immersion, swabbing, or spraying with an aqueous mineral acid solution. Pickling also removes 1 to 1.5 mils of the substrate metal. 13. Precleaned Products: Materials that have been chemically cleaned, mechanically cleaned, paint stripped, disinfected, passivated, rinsed, pickled, or protected from corrosion by shop fabricator or manufacturer before installation.

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14. Rinsing: Removal of residual cleaning agents by washing out with fresh or de-ionized water. 1.2

References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, Work included in this specification shall conform to the applicable provisions of these publications. A.

ASME (American Society of Mechanical Engineers) 1.

B.

CGA (Compressed Gas Association, Inc.) 1.

C.

A380 Standard practice for cleaning and descaling Stainless Steel parts, equipment and systems.

Federal Specification 1.

1.3

C651, latest edition.

ASTM 1.

F.

Pamphlet 6.

AWWA (American Water Works Association) 1.

E.

G4.1. - Cleaning Equipment for Oxygen Service

Chlorine Institute 1.

D.

ASME Code for Pressure Piping, B31.3, latest edition Chemical Plant and Petroleum Refinery Piping.

QQ-P-35C Passivation treatment for corrosion resistant steels - 1988

Submittals A.

Cleaning Contractor Requirements Alternative cleaning procedures not specified in this document shall be prepared and submitted to Fluor Daniel Engineering's Material Engineer. The procedure shall include the following: 1.

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Steps of the cleaning or passivating procedure.

Piping Engineering


Client Name Project Name Contract Number FLUOR DANIEL



2. 3. 4. 5.

Chemicals and equipment to be used. Required time for each step. Process temperatures. Inspection Procedures

Contractor's procedures will be evaluated based on, but not limited to, the following criteria. 1. 2. 3. 4. 5. 6. 1.4

Ability to clean and remove surface contaminants. Ability to guarantee a high surface Chromium/Iron ratio. Ability to reduced heat tinting near heat effected zones. Safety and ease of disposal of chemical solutions. Cost. Documented results of corrosion testing.

Quality Assurance A.

General 1.

Cleaning Procedures All cleaning procedures shall be specified with a degree of cleaning required and an inspection procedure to assure the degree of cleanliness has been achieved.

2.

Precleaned Material Upon delivery of precleaned material to the jobsite, inspection, storage, and installation procedures shall be done in accordance with Specification 50025.

B.

2.0

Qualifications 1.

Cleaning procedures shall be performed by a reputable cleaning contractor, approved by Fluor Daniel Engineering.

2.

Utilize personnel who are trained in the cleaning, protection techniques and safety rules.

MATERIALS Manufacturer Cleaning Requirements - Precleaned materials to be supplied by the manufacturer or vendor are specified in Specification 50003.

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3.0

EXECUTION The requirements and procedures for Field Cleaning and protection of all process and utility piping after installation and before commissioning are included in this section. 3.1

3.2

Field Cleaning Requirements A.

Completely remove weld slag, flux, debris, grease, oil, and any foreign matter on the surfaces of field fabricated items using cleaning methods as specified in Attachment 02.

B.

Reclean all precleaned surfaces as specified in accordance with this specification.

C.

Protect cleaned surfaces in accordance with this specification.

General Preparation For Cleaning A.

All cleaning shall be done after pressure testing.

B.

Schedule field cleaning as close to the commissioning of the equipment as possible.

C.

Protect threaded connections, flange faces, and valves to prevent damage by abrasion.

D.

Block off, disconnect or remove the following items from the piping system to be cleaned: • • • • • • •

67525050028.doc

Filters Exposed instruments, gages, and cylinders Orifice plates Oil reservoirs Relief valves, control valves, and plug cocks Expansion joints Materials that may become damaged by cleaning solutions or procedures

E.

Do not allow aluminum, copper, galvanized steel, magnesium, or zinc surfaces to come in contact with solutions having a pH of less than 4.0 or a pH of more than 10.

F.

Do not contact equipment containing austenitic material with the following materials: 1.

Acid solutions containing halides or chemicals such as hydrochloric acid. Alternative solvents are acceptable provided the chloride content does not exceed 50 ppm (50 cm3/m3).

2.

Caustic soda (NaOH) solutions. If degreasing is required, Sodium Carbonate and Trisodium Phosphate solutions may be used, provided the chloride content does not exceed 50 ppm (50 cm3/m3).

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3.3

G.

Do not introduce chemical solution into equipment unless high point vents and low point drains (supplied by piping contractor) are available to ensure proper filling and complete removal of solutions.

H.

Do not apply heat directly to equipment containing acid solutions. Boilers may be fired for degreasing, but acid solutions must be diluted and heated externally to the equipment.

Cleaning Procedures After Installation A.

Cleaning Procedure Index Cleaning procedures shall be selected based on service and line class according to Attachment 01.

B.

Cleaning Procedures 1.

Cleaning procedures are included in Attachment 02 and outlined as follows: a. b. c. d. e. f. g. h. i.

2.

Cleaning documentation form is included in Attachment 03 and is outlined as follows: a. b. c. d. e. f.

C.

Objects Being Cleaned Cleaning Date Cleaning Procedure Performed By Witnessed By Date

Identification of Cleaned Item 1.

67525050028.doc

Scope of Procedure. Preparation for Cleaning Procedure. Materials. Equipment. Cleaning Procedure. Chemical Solution and Rinse Disposal. Degree of Cleaning. Inspection Procedure. Post Cleaning Procedures.

Metal tag cleaned items at all valves and connections to avoid subsequent contamination and to identify potential hazard. Tag shall read as follows:

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FLUOR DANIEL



WARNING: INTERNALLY CLEANED AND PRESSURIZED; KEEP SEALED UNTIL COMMISSIONING. (DATE) 2.

4.0

Tag shall be yellow with black letters and at least 8 inches (200 mm) by 10 inches (250mm), secured with 14 gage stainless steel wire.

ATTACHMENTS Attachment 01: 26Jan98 Cleaning Procedure Index Attachment 02: 26Jan98 Cleaning Procedures After Installation Attachment 03: 26Jan98 Cleaning Documentation Form

End of Specification

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FLUOR DANIEL

Master Specification 675 250 50028 Date 26Jan98 Attachment 01 - Sheet 1 of 2 Revision


Cleaning Procedure Index

SERVICE ABBREV. AP

SERVICE PLANT AIR

MATERIAL LINE CLASS

MATERIAL

CLEANING PROCEDURE

BA21

COPPER/CS

1 and then 2

TG01

316 SS

2

BBD

BOILER BLOW DOWN

AA21

CS

1

BFW

BOILER FEED WATER

AA21

CARBON STEEL

1

BW

BIOWASTE (AG)

AG01

316L SS

1

BWD

BIOWASTE DRAIN (UG)

BU03

Double Walled FRP

1

CA

CLEAN AIR

AG01

316L SS

2

TG01

316 SS

CC

CLEAN CONDENSATE

TG01

316 SS

1

C02

CARBON DIOXIDE

BA21

COPPER/CS

1 and then 2

TG01

316 SS

2

CSH

HIGH PRESSURE CONDENSATE

AA21

CARBON STEEL

1

CSM

MEDIUM PRESSURE CONDENSATE

AA21

CARBON STEEL

1

CWR

HVAC CHILLED WATER RETURN

BA21

COPPER/CS

1

CWS

HVAC CHILLED WATER SUPPLY

BA21

COPPER/CS

1

GR

GLYCOL RETURN

BA21

COPPER/CS

1

GS

GLYCOL SUPPLY

BA21

COPPER/CS

1

HWR

HEATING HOT WATER RET

BA21

COPPER/CS

1

HWS

HEATING HOT WATER SUP

BA21

COPPER/CS

1

IA

INSTRUMENT AIR

BA21

COPPER/CS

1 and then 2

N2

NITROGEN

BA21

COPPER/CS

1 and then 2

NAOH

SODIUM HYDROXIDE

AG01

316L SS

1

NG

NATURAL GAS

BA22

CS

2 - Nitrogen

PD

PROCESS WASTE DRAIN (UG)

BU01

FRP

4

PW

PROCESS WASTE

(AG)

BA21

COPPER/CS

4

(UG)

BU01

FRP

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FLUOR DANIEL



Cleaning Procedure Index

SERVICE ABBREV. SD

MATERIAL LINE CLASS

MATERIAL

CLEANING PROCEDURE

(AG)

BR02

CAST IRON

4

(UG)

BR01

CAST IRON

SERVICE STORM DRAINAGE

SH

HIGH PRESSURE STEAM

AA21

CARBON STEEL

2

SM

MEDIUM PRESSURE STEAM

AA21

CARBON STEEL

2

SS

SANITARY SEWER

(AG)

BR02

CAST IRON

4

(UG)

BR01

CAST IRON

WC

CITY WATER

BC01

COPPER

3

WDHR

DOMESTIC HOT WATER RETURN

BA21

COPPER/CS

3

WDHS

DOMESTIC HOT WATER SUPPLY

BA21

COPPER/CS

3

WP

PLANT WATER

BA21

COPPER/CS

1

WHPOT

HOT POTABLE WATER

BC01

COPPER

3

WPOT

POTABLE WATER

BC01

COPPER

3

WTR

TOWER WATER RETURN

BA21

COPPER/CS

1

WTS

TOWER WATER SUPPLY

BA21

COPPER/CS

1

WW

WASTE WATER

BU01

FRP

1

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INTERNAL CLEANING OF NON-HYGENIC PIPING SYSTEMS

Cleaning Procedures After Installation

Contents ·

Cleaning Procedure 1 Cleaning and Water Flushing

·

Cleaning Procedure 2 Air, Nitrogen, and Steam Cleaning

·

Cleaning Procedure 3 Water Flushing and Disinfection

·

Cleaning Procedure 4 Water Flush of Precleaned Systems

·

Cleaning Procedure 5 Chemical Cleaning for Oxygen Service

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CLEANING PROCEDURE 1 Cleaning and Water Flushing A.

Scope of Procedure This procedure covers flushing and cleaning of piping systems after assembly and erection.

B.

C.

Preparation for Cleaning Procedure 1.

All pipe runs and joints shall be visually inspected for proper installation and continuity.

2.

Equipment with restricted flow passages or inaccessible areas where sediment could collect shall either be bypassed or furnished with adequately sized temporary protection strainers.

3.

If system pumps are to be used for flushing and do not have a permanent suction strainer, they shall then have a temporary strainer installed between the suction valve and the pump. The temporary strainer shall be galvanized woven wire cloth, wire diameter 0.035 of an inch mesh, 6 x 6.

4.

Where flushing water is recirculated and not wasted to sewers, temporary strainers and/or baskets shall be installed at all sumps, tanks, and other accessible areas where extraneous material flushed from the piping system can be collected and removed.

5.

To prevent contamination of instruments, all instrumentation lines shall be disconnected during the flushing operation. These lines shall be cleaned separately by blowing out with air or flushing with water. All instrumentation lines are to be reconnected after completion of the cleaning operation.

Materials Fresh, clean water shall be used as the flushing and cleaning agent.

D.

Equipment Not applicable.

E.

Cleaning Procedure 1.

67525050028a02.doc

All pipe lines shall be flushed at no less than their design flow rate. Where possible, piping systems should be sectionalized, and full system flow rates provided through individual sections. Large diameter lines where design flow rates are not practical shall have flow rates specified by Fluor Daniel Engineering's field engineer.

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FLUOR DANIEL




2.

F.

Strainers and baskets should be inspected frequently during the flushing operation and cleaned if necessary.

Chemical Solution and Rinse Disposal Not applicable.

G.

Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment.

H.

Inspection Procedure Flushing operations shall continue until extraneous material is no longer collected at strainers and baskets. Final flush shall be witnessed by a representative of the owner. It is the responsibility of the contractor to continue the flush and clean operation until the owner approves of the final condition. The contractor is to take all steps necessary to insure an acceptable flush to include but not limited to removal and replacement of any associated work in place. This at no additional cost or schedule impact to the owner.

I.

Post-Cleaning Procedure Upon completion of flushing, all temporary strainers and baskets shall be removed from the Piping system unless otherwise specified. Tanks and sumps are to be drained and thoroughly cleaned. Equipment and piping shall be returned to their preflush condition.

End of Cleaning Procedure 1

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FLUOR DANIEL




CLEANING PROCEDURE 2 Air, Nitrogen, and Steam Cleaning A.

Scope of Procedure This procedure covers the blowing-out of piping systems after assembly and erection.

B.

C.


All pipe runs and joints shall be visually inspected for proper installation and continuity.

2.

Equipment that has restricted flow passages or inaccessible areas where scale or particles could collect shall either be bypassed or removed and replaced by a spool piece.

3.

To prevent contamination of the instruments, all instrumentation lines shall be disconnected during the blowing-out operation. These lines shall be blown-out separately and reconnected at the conclusion of the cleaning operation.

4.

All low points and dirt legs must have blow-off valves.

Materials 1.

Blowing agent shall be one of the following (as determined by field engineer): • • •

D.

Oil free air Nitrogen Steam


E.


All pipe lines shall be thoroughly blown through to ensure complete cleansing of all foreign matter. Care shall be taken that the discharge point of the pipe line is in a safe location and so arranged that the discharge stream is dissipated harmlessly. All personnel shall be kept clear of the discharge area during the blowing-out operation.

2.

Steam lines that are to be blown-out with steam shall have a warm-up period to allow gradual expansion and metal warm-up before high volume blow-out is commenced.

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FLUOR DANIEL




F.


G.

Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment.

H.

Inspection Procedure Following blow-through, all low points and dirt legs are to be blown-down until all residual matter is removed. Final blow-down shall be witnessed by a representative of the owner. It is the responsibility of the contractor to continue the blow-down operation until the owner approves of the final condition. The contractor is to take all steps necessary to insure an acceptable blow-through to include but not limited to removal and replacement of any associated work in place. This at no additional cost or schedule impact to the owner.

I.

Post-Cleaning Procedure All piping and equipment shall be returned to their preblow-out condition.


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FLUOR DANIEL




CLEANING PROCEDURE 3 Water Flushing and Disinfection A.

B.

C.

Scope of Procedure 1.

This procedure covers flushing and disinfecting of above- and below ground potable water piping systems after assembly and erection.

2.

This procedure requires compliance with all federal, state, and local laws and regulations that may be applicable.


All pipe runs and joints shall be visually examined for proper installation and continuity.

2.

Equipment that has restricted flow passages or inaccessible areas where sediment could collect, shall either be bypassed or removed and replaced by a spool piece.

Materials 1.

Flushing procedure - potable water

2.

Disinfecting Procedure a.

Forms of chlorine can be calcium hypochlorite, sodium hypochlorite or liquid chlorine packaged in steel cylinders. Note!!! Liquid chlorine must be used in conjunction with a chlorinator.

D.

b.

Solution strength shall be in accordance with AWWA C651.

c.

Due to its hazardous nature, adequate safety precautions and instruction shall be employed when handling any form of chlorine.

Equipment Dependent on system to be disinfected.

E.


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Flushing Procedure prior to disinfecting.

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FLUOR DANIEL




2.

a.

All pipe lines shall be flushed with potable water before disinfecting. Minimum flushing velocity should be 2.5 feet per second for water mains.

b.

Flushing operations shall continue until water discharges are clear and free from turbidity and extraneous materials and is approved by the owner's representative. The contractor is to take all steps necessary to insure an acceptable system condition. This to include but not be limited to removal and replacement of any or all associated work in place. This at no additional cost or schedule impact to the owner.

c.

Upon completion of the flushing operation, systems shall be drained and all items previously removed, bypassed, or disassembled shall be reinstalled, reassembled, and made ready for the disinfecting procedure.

Disinfecting Procedure Piping systems shall be filled with a chlorine solution and left standing for an adequate contact period. Note!!! Contact time shall be in accordance with AWWA C651, latest edition. a.

3.

Chlorine Application (1)

For large systems a concentrated chlorine solution feed can be proportioned with the incoming potable water filling the system.

(2)

On small systems the chlorine solution can be mixed in a container to the required concentration and fed into the piping by gravity feed or pump.

Post-Flushing Procedure After the applicable contact period, the heavily chlorinated water shall be flushed from the system with potable water until the chlorine concentration in the water leaving the system is no higher than that in the incoming potable water, or less than 1 ppm.

F.

Chemical Solution and Rinse Disposal 1.

Outlet pipes or nozzles at flushing discharges shall be directed to a safe location where chance of damage from disposal of flushing water is minimal.

2.

All spent chemical solutions and rinses must be disposed of in an environmentally acceptable manner.

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3.

G.

H.

If any liquid effluent streams are discharged to a sewer system connected to a public sewage treatment plant, they must comply with the applicable provincial and local pretreatment regulations.

Degree of Cleaning 1.

Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment.

2.

Disinfection of contaminants harmful to human health if consumed.

Inspection Procedure Inspection shall be in accordance with AWWA C651, latest edition.

I.

Post-Cleaning Procedure Reassembly procedures shall be in accordance with Section E.1.c before disinfecting procedure.


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FLUOR DANIEL




CLEANING PROCEDURE 4 Water Flush of Precleaned Systems A.

Scope of Procedure This procedure covers flushing of precleaned piping systems after assembly, erection, and testing.

B.

C.

Preparation for Flushing Procedure 1.

Before installation, all piping sections (spools) shall be swabbed clean and flushed so that the erected piping will be clean and free from foreign material.

2.

Hydrostatic testing requirements must be completed before flushing.

Materials Hydrostatic Test Fluid

D.


E.

Cleaning Procedure Flushing shall be accomplished after completion of pressure testing and all necessary corrections have been made. The extent of flushing will be the drawing off of the water used for hydrostatic testing of the piping.

F.


G.

Degree of Cleaning Removal of all loose non-adherent material together with all adherent material that could break away du ring operation of the equipment.

H.

Inspection Procedure Piping spools shall be clean and free from foreign material before installation. Care shall be taken to insure cleanliness during installation. Final flush shall be witnessed by a representative of the owner. It is the responsibility of the contractor to continue the flush and clean operation until the owner approves of the final condition.

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FLUOR DANIEL




The contractor is to take all steps necessary to insure an acceptable flush to include but not limited to r emoval and replacement of any associated work in place. This at no additional cost or schedule impact to the owner. I.

Post-Cleaning Procedures Not applicable. End of Cleaning Procedure 4

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CLEANING PROCEDURE 5 Chemical Cleaning for Oxygen Service

A.

Scope of Procedure This procedure covers chemical cleaning, drying and purging of oxygen piping systems after assembly, erection and pre-cleaning testing. Cleaning of the system shall be accomplished by flushing with chemicals at sufficient temperature, concentration, velocity and contact time to remove all contaminants, passivating and drying. The following procurement and erection procedures have been followed:

B.

1.

All pipe, tubing, fittings and valves purchased for the system have been pre-cleaned by the manufacturer or supplier.

2.

All pipe, tubing, fittings and valves have been capped and sealed during shipping and storage to preclude rust and contamination.

3.

All pipe, tubing, fittings and valves have been tungsten inert gas (TIG) welded on the fir st sealing pass.

4.

Piping system has been kept clean and rust free during fabrication and erection, contamination kept to a minimum.


All pipe runs and joints shall be visually inspected for proper installation a nd continuity.

2.

Adequate drains shall be provided at low points and vents at high points.

3.

Pre-cleaned components, valves, filters, regulators and any other equipment that may be damaged or contaminated during the cleaning operation shall either not be installed until after the cleaning operation is completed or be by-passed. Spool pieces and jumpers along with required unions or flanges shall be provided and installed by the piping contractor. Inline socketweld valves subjected to chemical cleaning shall require valve manufacturer's approval of the cleaning procedures and the valve must be in its full open position during the cleaning operation.

4.

Before cleaning with spool pieces in place, the system shall be hydrostatically tested in accordance with Specification 50050.

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C.

Materials Water connections will be available in some areas of the plant. Contractor is to contact field representative for availability and pressure. Contractor shall supply nitrogen and water when not available on site.

D.

Equipment Cleaning equipment and all mixing and blending equipment shall be provided by contractor and shall be located in a safe designated working area.

E.


Chemical cleaning is a highly specialized service and shall be done by a reputable cleaning contractor.

2.

Cleaning procedures shall be prepared by contractor and submitted to engineer for review and approval.

3.

Provide necessary safety ropes or isolation barricades to enclose all working area possible.

4.

Supply water connections to wash down any chemicals spilled during cleaning.

5.

Unauthorized personnel, as determined by the field engineer, are not permitted in the cleaning area during hazardous cleaning operations.

6.

Drain, vents and temporary effluent piping shal l be piped to ground level, use only gate valves on these lines. These drop lines should be posted and/or barricaded to keep out unauthorized personnel.

7.

The cleaning and flushing operation shall be witnessed and approved by a representative of the owner. It is the responsibility of the contractor to continue the flush and clean operation until the owner approves of the final condition. The contractor is to take all steps necessary to insure an acceptable flush to include but not limited to removal and replacement of any associated work in place. This at no additional cost or schedule impact to the owner.

F.

Chemical Solution and Rinse Disposal 1.

Outlet pipes or nozzles at flushing discharges shall be directed to a safe location where chance of damage from disposal of flushing water is minimal.

2.

All spent chemical solutions and rinses must be disposed of in an environmentally acceptable manner. Confirm offsite disposal of waste chemicals.

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3.

G.

H.

If any liquid effluent streams are discharged to a sewer system connected to a public sewage treatment plant, they must comply with the applicable provincial and local pretreatment regulations.

Degree of Cleaning 1.

Removal of all loose non-adherent material together with all adherent material that could break away during operation of the equipment.

2.

Removal of all traces of hydrocarbons in the system.

Inspection Procedure The following tests shall be performed on interior of line while spool pieces are being removed and on interior of valves and equipment being installed to insure cleanliness of the system.

I.

1.

Fluorescent test: random surfaces shall be examined with ultraviolet light ("black light") for traces of hydrocarbons. Any trace of hydrocarbons shall be reason for rejection. Filter paper may be used to wipe areas inaccessible to fluorescent test. Use hard filter paper to avoid leaving paper fibers behind.

2.

Water break test: for use on small parts - clean water poured on a metal surface should form a thin, unbroken film. Formation of droplets shall be considered evidence of contamination.

3.

Visual examination: shall show no mill scale or rust. Any mill scale or rust shall be considered reason for rejection.

Post-Cleaning Procedure Remove all spools, contaminated gaskets and jumpers used in the cleaning operations and install all precleaned components. Inspect each component before installation into the clean system. Any component that is contaminated or suspected of being contaminated must be re-cleaned. After cleaning is completed and system is assembled and ready for operation, the system will be pneumatically tested using oil free nitrogen in accordance with Specification 50050. After testing is completed, the system shall be purged with oil free nitrogen and maintained under pressure until ready for placement into service.


67525050028a02.doc

Piping Engineering



FLUOR DANIEL



Cleaning Documentation Form

Object(s) being cleaned:

Cleaning Date: ______________________________________________________________________________

Cleaning Procedure: __________________________________________________________________________

Performed by: ________________________________

Date: ______________________________

Witnessed by: ________________________________

Date: _______________________________

Note!!!

Copies of marked-up isometrics or P&IDs showing blinding points may be used in lieu of ahanddrawn sketch to show the extent of systems being cleaned.

67525050028a03.doc

Piping Engineering

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS TEST Page 1 of 3 15/11/2002 Rev. 0

LESSON 10 - TEST 1 COMPRESSORS Name: ________________________________ 1.

List at least four important items that affect centrifugal compressor piping layout that will be found in the Mechanical Data Sheet Specifications. a. b. c. d.

2.

Name three basic types of Compressor Drivers. a. b. c.

3.

Name the basic classifications of compressors and give at least two types of each classification.

4.

Give a brief description of a compressor.

5.

Name and briefly describe the two basic types of steam turbines.

6.

What is the purpose of the Vendor's Drawing and Data Commitment?

7.

Name four important documents that should be maintained in the Piping Compressor Job Book. a. b. c. d.


LESSON 10 - TEST 2 CENTRIFUGAL COMPRESSOR DESIGN NAME ____________________________ T

F

1.

The compressor suction drum must always be located within the immediate vicinity of the compressor.

T

F

2.

The area directly above vertically split compressors must be clear for lifting off the upper half of the case.

T

F

3.

The trip and throttle valve must be accessible from a platform.

T

F

4.

A reducing flange may be used at the compressor inlet for special applications.

T

F

5.

Horizontally split compressors are usually mezzanine mounted.

T

F

6.

A tentative date for the Engineering Conference should be established prior to starting preliminary layout.

T

F

7.

Steam turbine driver cases are horizontally split or vertically split.

T

F

8.

Each flow diagram should be reviewed for physical affect on plot plan.

T

F

9.

Interstage equipment is usually furnished and piped by the compressor Vendor.

T

F

10. It is a good practice to make a flow transposition for installations which have interstage equipment.

T

F

11. It is important to ascertain the validity of outline material with the Mechanical Engineer before starting work for presentation at the Engineering Conference.

T

F

12. The performance of centrifugal compressors can be adversely affected by the suction piping configuration.

T

F

13. The ASME Code minimum straight run requirement is 4 pipe diameters.

T

F

14. The overhead seal oil tank need not be accessible when the compressor is located within a building.

T

F

15. The piping at the compressor nozzles should be supported so that there is no dead load on the nozzle.


LESSON 10 - TEST 3 RECIPROCATING COMPRESSOR DESIGN Name ________________________________ T

F

1.

Handwheels for clearance pocket valves must be accessible during operation and start-up.

T

F

2.

A transposition should be made, regardless of size, for any reciprocating compressor.

T

F

3.

The preferred orientation of the balanced-opposed compressor is with its piston rod parallel to the headers.

T

F

4.

A bottom takeoff from the compressor header may be used if adequate drains are provided.

T

F

5.

Vibration of the piping system is reduced` through the installation of pulsation suppression devices.

T

F

6.

Each compartment of a volume bottle must be equipped with a drain connection.

T

F

7.

Machinery-mass excited frequencies have little or no transmission 10 to 20 feet from the mat.

T

F

8.

The last discharge piping must be held down in the pipeway.

T

F

9.

The distance between hold downs is determined from the natural frequency of the pipe.

T

F

10.

Pulsation suppression devices are not required on interstage systems.

T

F

11.

Temporary suction strainers should always be located in accordance with Fluor Daniel standards.

T

F

12.

One major layout factor is orientation of the compressor relative to interstage equipment.

T

F

13.

The angle type reciprocating compressor has all compression cylinders on one side of its crankshaft.

PIPING DESIGN LAYOUT TRAINING LESSON 10 COMPRESSORS TEST – GRADING MASTER Page 1 of 4 15/11/2002 REV 0

COMPRESSORS TEST - GRADING MASTER Encircle each wrong answer on the students test. Minimum passing grade is 71. GRADE AVG: 100-96 EXCELLENT 95-83 VERY GOOD 82-71 GOOD 70 and below FAIL


TEST 1 INTRODUCTION OF COMPRESSORS 1.

List at least four important items that affect centrifugal compressor piping layout that will be found in the Mechanical Data Sheet Specifications. (5pts each answer = 20 pts)

a. Design and operating inlet and discharge conditions c. Location e. Casing Connections (size, rating, type, etc.) g. Weight and general space requirements. i. Mounting plate type 2.

Name three basic types of Compressor Drivers. (5pts each answer = 15 pts)

a. Electric motors c. Gas Turbines 3.

b . Maximum allowable nozzle forces and moments d. Casing split Connections (size, f. Auxiliary rating, type, etc.) type and utility h. Driver requirements and conditions see page 28 through 30 for others j b.

Steam Turbines

Name the basic classifications of compressors and give at least two types of each classification. (5 pts each answer = 10 pts)

Dynamic: Centrifugal and Axial, Positive-displacement: Reciprocating, Rotary sliding-vane, Rotary lube, Rotary liquid piston. 4.

Give a brief description of a compressor. (10 pts )

Compressors provide a mechanical means of increasing vapor pressure by intaking the vapor at a relatively low pressure, compressing it, and discharging it at a higher pressure. 5.

6.

Name and briefly describe the two basic types of steam turbines. (10 pts) Condensing turbines exhaust below atmospheric pressure to a surface condenser. Noncondensing turbines exhaust at atmospheric pressure or higher into a steam piping system. What is the purpose of the Vendor's Drawing and Data Commitment? (15 pts)

It lists all the drawings the vendor is required to submit for Fluor Daniel approval and gives a priority status for each drawing. Piping activities are scheduled to conform to vendor sequence of delivery and scheduled delivery date of each drawing. 7.

Name four important documents that should be maintained in the Piping Compressor Job Book. (5 pts each answer = 20 pts)

a. Schedules & Due Dates

b.

c. Mechanical Data Sheets e. Flow Diagrams

d. f.

g. Vendor Drawings i. Client Design Info

h. j.

Mechanical Narrative Specifications Catalog Information Communications and Ref. Material Analog Isometrics Layout Drawings & Sketches


TEST 2 CENTRIFUGAL COMPRESSOR DESIGN T

1.

(6.7 pts each answer) The compressor suction drum must always be located within the immediate vicinity of the compressor.

2.

The area directly above vertically split compressors must be clear for lifting off the upper half of the case.

3.

The trip and throttle valve must be accessible from a platform.

4.

A reducing flange may be used at the compressor inlet for special applications.

T

5.

Horizontally split compressors are usually mezzanine mounted.

T

6.

A tentative date for the Engineering Conference should be established prior to starting preliminary layout.

T

7.

Steam turbine driver cases are horizontally split or vertically split.

T

8.

Each flow diagram should be reviewed for physical affect on plot plan.

9.

Interstage equipment is usually furnished and piped by the compressor Vendor.

F T F

F T

10. It is a good practice to make a flow transposition for installations which have interstage equipment.

T

11. It is important to ascertain the validity of outline material with the Mechanical Engineer before starting work for presentation at the Engineering Conference.

T

12. The performance of centrifugal compressors can be adversely affected by the suction piping configuration.

T

F

13. The ASME Code minimum straight run requirement is 4 pipe diameters.

F

14. The overhead seal oil tank need not be accessible when the compressor is located within a building. 15. The piping at the compressor nozzles should be supported so that there is no dead load on the nozzle.


TEST 3 RECIPROCATING COMPRESSOR DESIGN (7.7 pts each answer) T

1.

Handwheels for clearance pocket valves must be accessible during operation and start-up.

T

2.

A transposition should be made, regardless of size, for any reciprocating compressor.

T

3.

The preferred orientation of the balanced-opposed compressor is with its piston rod parallel to the headers.

T

4.

A bottom takeoff from the compressor header may be used if adequate drains are provided.

T

5.

Vibration of the piping system is reduced` through the installation of pulsation suppression devices.

T

6.

Each compartment of a volume bottle must be equipped with a drain connection.

F

7.

Machinery-mass excited frequencies have little or no transmission 10 to 20 feet from the mat.

F

8.

The last discharge piping must be held down in the pipeway.

9.

The distance between hold downs is determined from the natural frequency of the pipe.

10.

Pulsation suppression devices are not required on interstage systems.

T

11.

Temporary suction strainers should always be located in accordance with Fluor Daniel standards.

T

12.

One major layout factor is orientation of the compressor relative to interstage equipment.

T

13.

The angle type reciprocating compressor has all compression cylinders on one side of its crankshaft.

T F

Compressor

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