NGP-001-PCS-15.03-0001!00!00_Specification for Gas Engine Driven Reciprocating Compressor

NASHPA Gas Processing and LPG Recovery Plant PROC-FC-CB/NASHPA/PROJ-1247/2015 PROJECT NO.: NASHPA 1247

DOCUMENT NO.: NGP-001-PCS-15.03-0001-00

SPECIFICATION

PAGE 1 OF 39

Specification for Gas Engine Driven Reciprocating Compressor

REVISION

DETAILS

00

18/07/2016 Approved for Design

Cui Xiaobo

Mei Chunlin

Wang Dongjun

Wei Xiao

C

27/04/2016 Issued for Approval

Cui Xiaobo

Mei Chunlin

Wang Dongjun

Wei Xiao

B2 07/03/2016 Issued for Review

Cui Xiaobo

Mei Chunlin

Wang Dongjun

Wei Xiao

B1 04/02/2016 Issued for Review

Cui Xiaobo

Mei Chunlin

Wang Dongjun

Wei Xiao

Cui Xiaobo

Mei Chunlin

Wang Dongjun

Wei Xiao

PRPD

CHKD

REVD

APPD

B REV

01/02/2016 Issued for Review DATE

DESCRIPTION

NASHPA Gas Processing and LPG Recovery Plant PROC-FC-CB/NASHPA/PROJ-1247/2015 DOC. NO. DESCRIPTION

NGP-001-PCS-15.03-0001-00 Specification for Gas Engine Driven Reciprocating Compressor

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REVISION HISTORY

REV.

DATE

REVISION DESCRIPTION

A

15/01/2016 15/01/2016

Internal Discipline Discipline Check

B

01/02/2016

Issued for Review

B1

04/02/2016

Issued for Review

B2

07/03/2016

Issued for Review

C

27/04/2016

Issued for Approval

00

18/07/2016

Approved for Design



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TABLE OF CONTENTS 1.0

GENERAL ..................................................................... ........................................................................................................................................... ..................................................................................... ............... 4

2.0

CODES, STANDARDS AND PROJECT SPECIFICATIONS .......................................................... ............................................................................ .................. 7

3.0

ENVIRONMENTAL DESIGN CRITERIA ................................................................... ........................................................................................................... ........................................ 9

4.0

GENERAL REQUIREMENTS ............................................................. ............................................................................................................................ ............................................................... 9

5.0

DESIGN REQUIREMENTS ................................................................. ............................................................................................................................. ............................................................ 12

6.0

ENGINE AND AUXILIARIES .............................................................. ........................................................................................................................... ............................................................. 13

7.0

GAS COMPRESSOR .............................................................. .................................................................................................................................... ........................................................................ .. 21

8.0

ELECTRICAL REQUIREMENTS ........................................................ ..................................................................................................................... ............................................................. 24

9.0

INSTRUMENTATION REQUIREMENTS .................................................................. ........................................................................................................ ...................................... 24

10.0

CONTROL REQUIREMENTS ............................................................ ......................................................................................................................... ............................................................. 27

11.0

FIRE DETECTION .................................................................... ......................................................................................................................................... ....................................................................... .. 32

12.0

PIPING ............................................................... ..................................................................................................................................... .............................................................................................. ........................ 33

13.0

UTILITIES & TIE-INS ............................................................... ..................................................................................................................................... ........................................................................ .. 33

14.0

EQUIPMENT TAGGING AND NAMEPLATES .......................................................... ................................................................................................ ...................................... 34

15.0

INSPECTION AND TESTING ............................................................. .......................................................................................................................... ............................................................. 34

16.0

PRODUCTION INSPECTION ............................................................. .......................................................................................................................... ............................................................. 35

17.0

CONTROL FUNCTIONAL TEST ........................................................ ..................................................................................................................... ............................................................. 35

18.0

MECHANICAL RUN TESTS ............................................................... ............................................................................................................................ ............................................................. 35

19.0

PERFORMANCE / FACTORY ACCEPTANCE TEST (FAT) .......................................................... .......................................................................... ................ 35

20.0

FIELD TESTS ............................................................... ..................................................................................................................................... ................................................................................... ............. 37

21.0

PREPARATION FOR SHIPMENT .................................................................. ................................................................................................................... ................................................. 37

22.0

WEIGHT CONTROL ................................................................. ...................................................................................................................................... ....................................................................... .. 39

23.0

HAZOP STUDY ............................................................ ............................................................................................................................... ................................................................................... ................ 39

24.0

GUARANTEE AND WARRANTY ................................................................... .................................................................................................................... ................................................. 39

25.0

SPECIAL TOOLS ...................................................................... ........................................................................................................................................... ....................................................................... .. 39



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1.0 GENERAL 1.1 Introduction OIL & GAS Development Company Ltd. (OGDCL) is operating NASHPA Oil & Gas fields in Khyber Pakhtunkhwa of Islamic Republic of Pakistan. OGDCL intends to install Gas Processing and LPG Recovery Plant at the oil field. 1.2 Scope This specification defines the minimum requirements for the design, fabrication, assembly, inspection, testing, packaging, shipment, supervision during installation, commissioning and site acceptance testing of gas engine driven reciprocating compressor package for NASHPA Gas Processing Plant. The package shall be mounted on a common base with all necessary auxiliary equipment. The Gas Engine Driven Reciprocating Compressor (including auxiliaries) shall be designed and constructed for a minimum service life of 25 years and at least 25,000 hours of uninterrupted operation. The packages are to be supplied as per the Datasheets, Specifications & P&IDs assembled as pre-tested skid mounted units. The packages shall be supplied fully assembled, piped to skid edge terminations. 1.3 Definitions Within this document the following definitions apply: Project

NASHPA

Gas

Processing

and

LPG

Recovery

Plant

PROC-FC-CB/NASHPA/PROJ-1247/2015 Company/Owner

Oil & Gas Development Company Ltd.(OGDCL)

Consultant

Zishan Engineers (Pvt.) Ltd.

Contractor

Hong Kong Huihua Global Technology Limited Wholly owned Subsidiary of China OIL HBP Science and Technology Corporation Ltd.

Manufacturer/Vendor/Supplier

Patry(ies), which manufactures and/or supplies material, equipment and service to perform the duties as specified by CONTRACTOR in the scope of supply

Shall

Indicates a mandatory requirement

Should

Indicates a strong recommendation to comply with the requirement of this document

1.4 Errors or Omissions 1.4.1

The review and comment by COMPANY / CONSULTANT / CONTRACTOR of any VENDOR‟s drawings, procedures or documents shall only indicate acceptance of general requirements and shall not relieve VENDOR of its obligations to comply with the requirements of this specification and other related parts of the Contract Documents.

NASHPA Gas Processing and LPG Recovery Plant PROC-FC-CB/NASHPA/PROJ-1247/2015 DOC. NO.

1.4.2

DESCRIPTION


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5 OF 39 PAGE Any errors or omissions noted by VENDOR in this Specification shall be immediately brought to the attention of COMPANY / CONSULTANT / CONTRACTOR.

1.5 Deviations All deviations to this Specification, other related specifications or attachments shall be brought to the knowledge of COMPANY / CONSULTANT / CONTRACTOR as a section in the bid. Alleviations made during the procurement, design, manufacturing, testing and inspection shall be with written approval of COMPANY / CONSULTANT / CONTRACTOR prior to execution of Work. Such deviations shall be shown in the documentation prepared by VENDOR. 1.6 Conflicting Requirement In the event of any conflict, inconsistency or ambiguity between VENDOR‟s scope of work, this Specification, National Codes and Standards, and referenced in the Project Specification or any other documents, VENDOR shall refer to COMPANY / CONSULTANT / CONTRACTOR whose decision shall prevail. 1.7 Reporting Procedure 1.7.1

A reporting and documentation system shall be agreed between VENDOR and COMPANY / CONSULTANT / CONTRACTOR for the status of procurement, design, manufacturing, inspection, testing and shipment of the equipment/material to be supplied under this specification. VENDOR shall provide reports and summaries for production performance and testing operations in conformance with a manufacturing schedule approved by COMPANY / CONSULTANT / CONTRACTOR.

1.7.2

Daily, weekly, monthly and run summaries of all major aspects of the production process shall be provided as reports to COMPANY / CONSULTANT / CONTRACTOR.

1.7.3

Third Party Inspection In addition to the inspection and witnessing of tests by the inspectors to be appointed by the COMPANY / CONSULTANT / CONTRACTOR during the manufacturing and shipment of the equipment/material, COMPANY / CONSULTANT / CONTRACTOR may appoint a third party or its own inspector for witnessing of the inspection and tests to be carried out at VENDOR‟s facility under this specification.

1.8 Unit Responsibility VENDOR shall assume full responsibility for the complete Gas Engine Driven Reciprocating Compressor Package and all ancillaries as described herein, in other attached specifications, data sheets and P&IDs. VENDOR‟s responsibilities shall include all design criteria such as speed, direction of rotation, all necessary analysis such as lateral critical speeds, discrete resonance sensitivities, start-up requirements, lube oil and seals systems, etc. VENDOR shall handle and expedite drawings and data, and supervise and coordinate all inspection testing specified. VENDOR shall guarantee that all material and parts included in the construction of the Gas Engine Driven Reciprocating Compressor Package shall be new, unused and of the required/specified grade. 1.9 Design Basis



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1.9.1

6 OF 39 PAGE Equipment shall be of the latest international standard design.

1.9.2

VENDOR shall certify that the equipment supplied is suitable for the purpose intended, and that it shall meet or exceed COMPANY / CONSULTANT / CONTRACTOR ‟s needs as specified in this document, other project specifications, data sheets and P&IDs.

1.9.3

VENDOR is responsible for providing any material, accessory items or equipment, in addition to that referred to in this specification, which is required to provide a safe and efficient Gas Engine Driven Reciprocating Compressor Unit.

1.10 Documentation 1.10.1 Documents, calculation sheets, drawings, etc., to be submitted to COMPANY / CONSULTANT / CONTRACTOR shall be in English Language. 1.10.2 The following units will be used in design and listed on all drawings and documents. Gauges and plant equipment shall be selected to indicate values only in the specified units. Description Temperature

Unit °F

Pressure(gauge)

psig

Pressure(absolute)

psia

Mass

lb

Volume

ft³

Length

ft, m, mm

AlternateLength

in

LiquidRelativeDensity

sp gr T F/60 °F

LiquidAbsoluteDensity

API and lb/gal @ 60 °F

VaporFlowingDensity

lb/ft³

FlowingQuantities Mass

lb/h

Vapor

ft³/s

Liquid

US GPM

StandardQuantities Vapor

MMSCFD at 60 °Fand 14.65 psia

Liquid

bpd at 60 °F

Enthalpy

Btu/lb

HeatRate

MM Btu/h

ElectricalPower

kW

Electricvoltage

Volts

CompressionPower Time

kW Seconds, min, hours, days



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Description

Unit

Viscosity

cP

Concretedensity

Pounds per cubic foot (pcf)

Concretestrength

Pounds per square inch (Ksi)

SteelStrength

Ksi

Instrument air volume flowrate

SCFM

1.10.3 The form of drawings and documents may be as per CONTRACTOR/VENDOR‟s Standards. However, the format of the data sheet will be submitted to COMPANY / CONSULTANT for approval. 1.10.4 Variations from or additions to this specification shall be called to the attention of COMPANY / CONSULTANT / CONTRACTOR and approved in writing by COMPANY / CONSULTANT / CONTRACTOR prior to starting fabrication. 1.10.5 Information for installation, operating, maintenance or inspection purposes shall be submitted to COMPANY / CONSULTANT / CONTRACTOR.

2.0 CODES, STANDARDS AND PROJECT SPECIFICATIONS The latest editions of the following codes, standards, and regulations form a part of this specification except as modified herein. 2.1 Local Laws, Regulations and Permits 2.2 Industrial Codes and Standards ISO 3046-1

Reciprocating internal combustion engines – Performance Part 1: Declarations of power, fuel and lubricating oil consumptions and test methods - Additional requirements for engines for general use

ISO 3046-3

Part 3 : Test measurements

ISO 3046-4

Part 4 : Speed governing

ISO 3046-5

Part 5 : Torsional vibrations

ISO 3046-6

Part 6: Specification for overspeed protection

ISO 3046-7

Part 7: Codes for engine power

API 618

Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services

API SPEC 11P

Specification for Packaged Reciprocating Compressors for oil and Gas production Services

API 614

Lubrication, Shaft-Sealing, and Oil-control Systems and Auxiliaries

API 613

Special Purpose Gears Units for Petroleum, Chemical, and Gas Industry Services

API 661

Petroleum, Petrochemical, and Natural Gas Industries Air-Cooled Heat Exchangers



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API 670

Machinery Protection System

API 671

Special Purpose Couplings for Petroleum, Chemical and Gas Industry Services

ABMA 9

Load Rating and Fatigue Life for Ball Bearings

ABMA 11

Load Ratings and Fatigue Life for Roller Bearings

API 678

Accelerometer Based Vibration Monitoring System

API RP 684

API Standard Paragraphs Rotordynamic Tutorial : Lateral Critical Speeds, Unbalance Response, Stability, Train Torsionals, and Rotor Balancing

ISO 9001

Quality System - Model for Quality Assurance for Design and Development, Production, Installation and Servicing

API RP 505

Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2

OPC

OLE for Process Control Standard, Version 1.0A

ASME B31.3

Process Piping

ASME B16.5

Pipe Flanges and Flanged Fittings NPS ½” Through NPS 24” Metric/Inch Standard

ASME B16.9

Factory-Made Wrought Butt-Welding Fittings

ASME Sec VIII

Rules for Construction of Pressure Vessels Div. 1 and Div. 2

ASME PTC 10

Performance Test Code on Compressors and Exhausters

AWS D1.1

Structural Welding Code

ANSI

American National Standard Institute (as applicable)

Electrical Code

IEC,

British

Standards,

CENELEC,

ISO,

NEMA.

(as

applicable) Instrument Code

ISA, API RP 551, IEC, NEMA (as applicable)

NFPA 12

Standard on Carbon Dioxide Extinguishing Systems

OSHA

Occupational Safety and Health Act.

2.3 Project Specification Environmental Conditions

NGP-000-COM-15.05-0001-00

Specification for Export Packing and Crating

NGP-000-COM-15.05-0002-00

Piping Material Specification

NGP-000-PIP-15.03-0001-00

Specification for Skid Mounted Packages

NGP-000-PIP-15.03-0013-00

Specification For (Evaporative) Air Cooled Heat Exchangers

NGP-001-PCS-15.03-0006-00

Specification for Fabrication / Installation of Equipment & Piping

NGP-000-PIP-15.03-0005-00

Specification for Ball, Gate, Globe and Check Valves

NGP-000-PIP-15.03-0010-00

Specification for Production Welding

NGP-000-PIP-15.03-0017-00

Specification for Coating and Painting

NGP-000-PAI-15.03-0001-00



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PAGE Specification for Unfired Pressure Vessel

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Specification for Structure Steel Works

NGP-000-STA-15.03-0001-00 NGP-000-SCW-15.03-0004-00

Specification for Instrumentation for Packaged Unit

NGP-000-INS-15.03-0004-00

Specification for Electrical requirements of Packaged Equipment

NGP-000-ELE-15.03-0006-00

Specification for Motors

NGP-000-ELE-15.03-0003-00

Specification for insulation

NGP-000-PIP-15.03-0004-00

In case of any conflict between this specification and the requirements of other COMPANY / CONSULTANT / CONTRACTOR‟s specifications, industry standards, codes, regulations, data sheets or drawings, the most stringent requirements shall apply with the written approval of COMPANY / CONSULTANT / CONTRACTOR.

3.0 ENVIRONMENTAL DESIGN CRITERIA 3.1 General Unless otherwise stated on the datasheet, the equipment will be installed in an open, exposed area. 3.2 Area Classification The unit shall be installed in an area where hazardous fumes may be present. The electrical hazard classification for the area is IEC Zone 2 area. 3.3 Environmental Data Environmental conditions for the equipment covered by this specification shall be in accordance with Environmental Conditions (NGP-000-COM-15.05-0001-00).

4.0 GENERAL REQUIREMENTS 4.1 The compressors shall be Lubricated or Non-Lubricated Reciprocating Compressors driven by gas engine with or without gearbox with suction / discharge volume bottles (dam peners), mist separators or dampener cum mist separator at each stage and coalescent filters with timer based automatic drain system, lube oil system, closed circuit cooling water (console type) / air cooled system as required. However the manufacturer can locate various components of package unit as per their patent design. All the components will be mounted on rigid structural steel base. Each unit shall be completed with all associated equipment, controls, instrumentation and protective devices.Supply of Compressor package shall include but not limited to the following: 

Gas Engine with auxiliary equipment



Reciprocating compressor with auxiliary equipment



Control Panels



Process equipment such as inter/after coolers and scrubbers etc.



Fire & gas detection system



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

LV Motor Control Center (MCC) for auxiliary motors and other LV supplies



CO2 Extinguishing System

4.2 Gas engine complete with lube o il, closed cooling system, fuel (Natural Gas) supp ly module, inlet air intake system, exhaust system with silencer, stack etc. 4.3 VENDOR shall get the pulsation studies (API 618 third approach shall be applied) for compressors suction and discharge conducted by a 3rd party and shall provide pulsation bottles as required. Report shall be submitted to COMPANY / CONSULTANT / CONTRACTOR for information. 4.4 VENDOR shall provide all instrumentation required for stable operation, startup, shutdown, emergency shutdown, train blowdown, monitoring, and alarm of the gas engine driven compressor train and communication with other control systems and equipment. As minimum, all instruments, controls and annunciation points shall be provided as specified by the data sheets and P&IDs included with the Tender Document. VENDOR shall also refer to attached Specification for Instrumentation for Packaged Unit (NGP-000-INS-15.03-0004-00) for detailed technical requirements and shall comply with the same. 4.5 For each Engine driven-Compressor train, a Unit Control Panel (UCP) shall be provided by vendor for the overall Engine-Compressor Controls with integrated Load sharing control, compressor flow control, machine vibration and temperature control, F&G monitoring/alarm, unit shutdown and blowdown controls, fire suppression system, engine speed control and engine safety systems. 4.6 VENDOR shall provide common structural steel skid for the compressor-engine combination and for all auxiliary systems with foundation bolts. VENDOR shall provide the inlet and outlet with matching flanges, bolts, nuts, gaskets, etc., 2 sets of all gaskets, bolts and nuts at least 10% spares. 4.7 Wherever not expected to be damaged during transportation, insulation shall be installed prior to shipment for all on-skid equipment and piping while remaining to be shipped lose for site installation. 4.8 Dedicated instrumentation and flow controlling of each compressor shall be provided by VENDOR, and integrated into the unit control panels. 4.9 After successful shop testing, the Packages shall be prepared for shipment, delivered according to the project requirements and the delivery terms of the contract. 4.10 Provision of supervision services for installation/erection of compressor packages and auxiliaries at key points through a dedicated team of experts/engineers. 4.11 During re-assembly, re-connections and rechecks, as well as during on-site testing, VENDOR shall provide assistance services as necessary. After final installation and hook up, the packages shall be commissioned and finally performance tested. VENDOR shall provide assistance services for the timely pre-commissioning, commissioning and startup of the packages. 4.12 Until satisfactory operation (uninterrupted 480 hrs and 72 hrs performance test) of the packages, COMPANY / CONSULTANT / CONTRACTOR ‟s team at site shall be assisting CONTRACTOR/VENDOR‟s operational and commissioning personnel in all matters related to the perform ance of the Packages. During this period informal hands on training to COMPANY / CONSULTANT / CONTRACTOR ‟s personnel will also be provided.



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11 OF 39 PAGE 4.13 VENDOR shall provide all services required for the implementation of the work in accordance with the tender documents, drawings & technical specifications and in conformity with the requirements indicated therein. 4.14 In case of any conflict in the tender document, VENDOR shall immediately refer the matter to COMPANY / CONSULTANT / CONTRACTOR. COMPANY / CONSULTANT / CONTRACTOR ‟s decision regarding the matter shall be final. 4.15 Prototype or unproven equipment not having a well-established operation record will not be considered. Only standard designs that are in regular and current production and manufactured for the service and site conditions specified, shall be offered. Equipment, piping and valves shall meet or exceed the design pressures and temperatures shown on the drawings and specifications. 4.16 Where COMPANY / CONSULTANT / CONTRACTOR has pre-sized equipment, controls, instruments, valves, piping, etc. shown on the accompanying data sheets and P&IDs, these sizes shall be considered the minimum required by process conditions. VENDOR shall confirm the sizing and shall be responsible for the design of all components, piping and controls. 4.17 A lifting frame shall be provided to permit single point lifting. When the multiple section base plates are provided, VENDOR shall provide a lifting frame or frames that permit single point lifting of each skid. All lifting frames shall be complete with all necessary slings and shackles. All lifting equipment shall be proof tested at not less than 125% of the safe working load; the safe working load shall be certified and marked on the equipment. 4.18 Non-skid grating shall be provided covering all walk and working area on top of the base plate for the compressor and the gearbox. 4.19 Mass Flow meter to measure the Natural Gas consumption at packages inlet, package discharge and fuel consumption at Gas Engine inlet with online test arrangement. 4.20 Suction vertical scrubber and temporary suction inline strainer at the compressor package inlet. 4.21 Air-cooled heat exchanger for interstage and discharge gas as well as for engine coolant. 4.22 Impulse and pneumatic piping/tubing for all valves, fittings as specified & required for m ounting the instruments. Block and bleed valves to be provided for pressure gauges and pressure transducer. 4.23 Structural supports within the compressor package for all piping, instruments etc. 4.24 NRV at final discharge, Relief valve at stage discharge, Blow Down Valve (BDV), Inlet and outlet isolating valves, Flexible Coupling/V-belts/pulleys. 4.25 Y- type strainers, valves, sight flow indicators, check valves, auto & manual drain traps etc. as required for various auxiliary systems i.e. frame lube oil, cylinder lubrication system, cooling water systems etc. 4.26 Complete Erection, Testing & Commissioning of compressor packages including supply of all Mandatory spares as required for erection & commissioning. 4.27 Spare parts suitable for two year's continuous operation (including consumption of spare parts required for annual survey and a list of wearing parts).



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12 OF 39 PAGE 4.28 First filling for all consumable such as grease, lube oil, fuse, etc. to be used during commissioning. 4.29 Operation and maintenance manual of complete Gas Engine Driven Reciprocating Compressor Unit. 4.30 3D model (.step file) for the whole Gas Engine Driven Reciprocating Compressor Unit shall be provided by VENDOR and 3D model(.step file) is mandatory. 4.31 VENDOR shall provide one set of special tools and fixtures for the equipment. One set of shipping containers for compressor bundles and engines shall also be provided. (API RP 11PGT 2.2.16.1). 4.32 VENDOR shall complete and s ubmit the data sheets with his proposal using data shee ts forms recommended by ISO 3046, API 613, 614, 11P, and 671 (API RP 11PGT2.3.1.3). 4.33 Automatic carbon dioxide extinguishing system shall be considered to suppress fires for the compressor. The carbon dioxide extinguishing system shall be suitable for fire Class B. The design, fabrication, inspection and testing shall conform to NFPA12.

5.0 DESIGN REQUIREMENTS VENDOR shall minimize the points and locations of interface and locate them at the unit skid edge. Piping interface with the off-skid piping shall be provided with isolation valves and flanges as shown in the P&IDs attached. Common service piping such as drain, vent and utility piping shall be manifolded to interface with the off-skid piping where it is safe to do so. All instrumentation and control wiring shall be wired to the junction boxes located at the skid edge for interface with the off-skid wiring. The compressor and gas engine shall be skid mounted and coupled together (through a gearbox if required). For satisfying the requirement of noise level ([email protected]), the acoustic panel enclosure shall be compulsory provided and weatherproof and made of carbon steel and coated as per paints specification. The enclosure shall be framed and supported from the skid. The gas engine ancillar y package including combustion air intake system and the engine exhaust duct and silencer system shall be provided with support framework for quick hook-up and for mounting on top of the enclosure. Access ways and maintenance platforms shall be provided where routine maintenance and operation checks are required. All foundation requirements including for main skid, ancillary bases and support frames shall be provided with details for COMPANY / CONSULTANT / CONTRACTOR‟s review and approval. All piping, wiring, and tubing within V ENDOR‟s supply shall be fully supported by VEN DOR. All terminations at which the off-skid lines are to make connections shall be fully anchored on VENDOR‟s side. Foundations required for supports will be provided by an off-skid installer. Any limitation on loads and movements imposed by the off-skid piping shall be defined on VENDOR‟s drawings. VENDOR shall provide complete structural loading drawings. These shall indicate details of all support points, relevant dimensions, load directions, load types and load magnitudes of all equipment supplied by VENDOR including main components, all auxiliaries, duct work and support frame steelwork. VENDOR shall clearly indicate in his proposal all items covered by this specification which are located “off -skid” and to specify dimensions, weights and interface details required for installation and hook-up. VENDOR shall fully define all piping, mechanical connections, electrical wiring, instrumentation and control interfaces with size, schedule, type, location, rating, design and operation ranges.



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6.0 ENGINE AND AUXILIARIES 6.1 General The engine driver shall be a reciprocating internal combustion natural gas engine com plying BS 5514/ISO 3046 or equal. The engine shall have a continuous rating, derated for site conditions at the maximum air ambient, minimum fuel gas pressure and all power transmission losses, at least equal to 110 percent of the bhp required for continuous operation supplying the maximum compressor‟s demand specified. The engine-driven train shall not have any torsional natural frequencies within 10 percent of the first or second harmonic of the rotational frequency of any shaft in the operating speed range. Constant speed applications shall be considered to have an operating speed range of ±10 percent of rated speed. The engine shall include replaceable cylinder liners of the wet sleeve type and replaceable valve seat inserts. Combustion chambers shall be of the open type. Connecting rods and crankshaft shall be of forged steel. Engine drive for attached auxiliaries shall be gear, V-belt or chain type.V-belt and chain drives shall be furnished with adjustable tensioning devices. Bearings shall be manufacturer's standard. Shims shall not be used for any bearing. The engine shall be designed to minimize the requirement of special tools for installation and maintenance. One set of such tools with a description and instructions for their use shall be supplied. 6.2 Intake Air System The engine shall be provided with one or more engine-mounted dry-type air cleaners/filters of sufficient capacity to protect the working parts of the engine from dust, grit and moisture laden air. The filter shall be fitted with a differential pressure indicator (transmitter) to show when the filter requires attention. If the air filter is to be installed remotely from the engine, VENDOR shall supply the filter loose. The pipework between the filter and the engine shall be either stainless steel or marine grade aluminium with less than 3% magnesium. VENDOR shall recommend the size of the intake pipe between the filter and the engine. VENDOR shall ensure that the pipework does not impose unacceptable strains on the engine. VENDOR shall supply a flexible joint between the intake pipe and the engine. Unless absolutely essential, internal fasteners shall not be used downstream of the air filter.Where unavoidable, internal fasteners shall be positively secured. Intake pipes 250 mm or larger in diameter shall be fitted with a BICERI type explosion relief valve with integral flame trap between the engine and the air filter (or the silencer, if fitted). All external connections from the engine shall terminate in flanges to ASME B16.5. An air intake silencer shall be provided if the air intake noise level exceeds that permitted.



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6.3 Starting System VENDOR shall furnish a complete starting system for gas engine driver.The starting system shall be instrument air. Starting devices operating on the flywheel shall have enclosed rotating parts. 6.4 Fuel System VENDOR shall provide complete fuel system comprising of but not limited to Carburetion System, Vertical Separator/Filters, Interconnection piping, fittings, Solenoid actuated fuel shutoff valve, Solenoid actuator fuel line vent valve, Fuel gas pressure regulator, Pressure Safety Valve, Fuel Consumption Meter. Clean, dry natural gas as the fuel at 2.5 barg minimum shall be provided. For Fuel Gas properties, refer attached datasheet. VENDOR shall provide a complete on-skid fuel system. All necessary valves and regulators shall be consistent with the pressure. Fisher gas regulators or equivalent with steel bodies shall be provided for pressure reduction, if required. An explosion-proof, all steel, solenoid type fuel valve shall be furnished and installed in the fuel gas supply line on the engine. This valve shall be automatically latched to start the engine and electrically tripped. The engine shutdown devices shall be configured to electrically trip the engine by at least closing the fuel valve. The strainer shall be 200 µm nominal, and shall act only as a guard filter. T he strainer shall be fitted with a drain valve. A swing-type or wing-type non-return valve shall be provided to prevent pressure surges from engine "spit-back" disturbing the fuel system. VENDOR shall provide system with fuel filters (vertical separator), inter-connection piping, fitting, solenoid actuated fuel shut off valve, fuel line vent valve and fuel consumption meter. 6.5 Lubrication System The lubrication system shall be a pressure-type system. It shall consist of, but not be limited to sump (wet type) with level indication, fill filter, vented and valve drain, circulation pumps (shaft driven) with pressure relief valve, duplex filters with replaceable cartridge elements, full flow transfer valve and differential pressure gauge across filters, cooling equipment with thermostatically controlled bypass valve, valves for relief and pressure regulation, low level alarm switch and automatic shutdown devices. The oil sump shall be integral with the engine and shall be large enough to contain all the oil in the system when the engine and pumps are shutdown. The minimum capacity shall be an amount of oil equal to the lubrication pump's working capacity for a period of two minutes. The filters for the lube oil system shall be sized to meet the engine manufacturer's required filtration for a minimum of 500 hours of continuous operation. The oil filter shall be equipped with a differential pressure gauge, and a bypass valve to assure engine oil flow in the event of filter plugging. All filters shall utilize replaceable elements. A Kenco or equivalent oil level regulator with block valves and a 100 litre (30 gallons) lube oil storage drum with stand shall be provided on each unit.



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15 OF 39 PAGE If aluminium, micro-Babbitt or equivalent bearings are provided, a bypass filter rated for five (5) micron nominal filtration or better shall be provided. This bleed off filtration line shall be sized to filter the total oil capacity in 24 hours or less. Filter casings and heads shall be suitable for operation at a pressure of not less than 10 percent over the relief valve settings of the lube pumps. Strainers (20 meshes) shall be provided in the lube oil pump suction header. The pump shall be driven by 24V DC batteries. Internal relief valves in filters shall not be acceptable. Crankcase shall be explosion proof. Pre-lube and/or post-lube pumps shall be provided. Pre-lube pump drivers shall operate on the electrical source. VENDOR‟s standard pre-lube pump shall operate as follows:

–

The pump shall run when automatically started by the engine control panel.

–

The pump shall run when the lube-oil heater is energized and allowed by the skid mounted ON/OFF selector switch.

–

The post-lube pump shall be locked out from running when the engine is locked out manually.

–

The pump shall be inhibited from running when the engine is running.

VENDOR shall provide the recommended lubricant for start-up. The start-up lubricants shall not be those used during testing. (Units shall be shipped dry). The engine oil temperature shall not exceed VENDOR‟s recommendations and shall never exceed 91°C (195°F) for continuous operation. The oil temperature should never exceed 107°C (225°F) for short term operation (one hour or less) during an overload condition. The cr ankcase oil temperature shall be m aintained at a differential of 6°C to 12°C (10°F to 20°F) above jacket water temperature under any conditions using jacket water cooling. The crankcase oil temperature shall be maintained at a differential of 6°C to 9°C (10°F to 15°F) below jacket water temperature under any conditions when an oil cooler with a separate cooling water system is provided. The lube oil dip stick shall be calibrated for oil pan level with the engine running and not running, to permit checking during normal operation and when the engine is stopped. 6.6 Cooling System The engine shall be furnished with a closed loop, jacket cooling water system and a centrifugal engine-driven jacket water pump. The cooling system shall be sized for the continuous maximum bhp load at the max. ambient temperature. The cooling water heat exchanger shall be of the finned radiator type. The radiator shall be mounted on the engine skid and shall have a tin or solder coated core and shall have carbo zinc #11 on all exposed steel surfaces. The material shall be suitable for operation in a moist air environment. Coolant shall be com patible for operation within tropic locations as well. Radiator shall be filled out and sealed prior to test running. The cooling



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16 OF 39 PAGE system shall include one (1) 1" stainless steel valve for external fill and one (1) 1" stainless steel valve for draining. System shall also include pusher type, engine dri ven fan, four ply hoses, water pump with carbon seal and radiator fan guard. Radiator and fan selection shall be based on a -10°C (15°F) approach temperature. Dual cores may be used to provide jacket water and utility water circuits. Automatic thermostat contr ol with bypass valves shall be provided to control engine jacket water temperature. Bypass shall operate so that cooling water flow shall never be throttled. Expansion or surge tanks shall be integrally mounted. Lube oil coolers may utilize jacket for cooling. Engine jacket water coolers may also be utilized to cool the engine lube oil system. Thermometers shall be installed in stainless steel thermowells at the inlet and outlet connection of each cooling water circuit in the heat exchanger (radiator). Thermometers shall be installed in such a way that they may be easily read from ground level without having to climb up on the skid assembly. 6.7 Governor The governor supplied for engine speed regulation and load control shall be electronic utilizing digital technology. The governor actuator shall be Woodward model (or equivalent) direct acting, UL A pproved for use in IEC Zone 2 area. The actuator and magnetic pickup shall be mounted on the engine. Controller stability shall be within + 3.0% at rated load. The maximum deviation relative to the rated speed for the range between no load and full load shall be 1/4 %. The amount of droop shall be field adjustable from 0 to 10%. The governor shall be provided with a droop reset control feature to maintain system frequency to within ±0.5% when in droop control. The governor shall monitor the speed sensor for loss of speed signal, calling for minimum fuel when signal loss is detected. The governor shall have the following adjustments:

–

Rated speed

–

Idle Speed

–

Acceleration ramp time

–

Deceleration ramp time

–

Start fuel limit

–

Gain and reset

–

Actuator compensation

–

Load gain

–

Droop



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17 OF 39

6.8 Engine Exhaust System The engine exhaust manifold shall be water cooled. A hospital grade, muffler with spark arresting capability shall be installed in the exhaust system unless the pressure drop across the silencer raises engine exhaust pressure t o unacceptably high pressure, in which case, a lower grade Maxim muffler may be used with COMPANY / CONSULTANT / CONTRACTOR ‟s approval. Silencers with flange sizes over 15 cm (6 inches) shall be provided with an inspection opening or draw out cover. The exhaust silencer shall attenuate the engine exhaust to 85 dB(A) at 1 m unless otherwise specified. Engine-mounted silencers shall be provided with a bellows-type, stainless steel expansion joints. All carbon steel piping, silencers etc. subjected to exhaust temperatures and exposed to the atmosphere shall be blast cleaned and flame sprayed aluminium coated for corrosion protection. Alternatively, stainless steel may be used. Exhaust duct for gas engine to have provision for heat recovery coil. Heat recovery unit shall be provided by VENDOR only for each sale gas compressor unit. The heat recovery is for pre-heating hot oil. The hot oil temperature entering waste heat recovery unit is 391°F, the hot oil pressure is 100-125 psig. The maximum allowable pressure drop of waste heat recovery is 5 psi. Waste heat recovery unit should assure the back-pressure requirement of sales gas compressor. 6.9 Insulation Thermal blankets shall be installed where surface temperatures exceed 60°C (140°F) for personnel protection. Ceramic fiber silicone treated glass cloth, covered with a 316L stainless steel knitted mesh good to 1260°C (2300°F) shall be provided on the exhaust line. A minimum of 2.5 to 4 cm (1 to 1-1/2 inch) calcium silicate covered with aluminium shall be provided where rigid insulation is required, such as on water lines. 6.10 Engine Shutdown Devices Each engine shall be equipped, as a minimum, with the following safety shutdown devices:

–

Low oil pressure pre-alarm and shutdown with time delay for starting

–

Low water level alarm and shutdown

–

High oil temperature alarm and shutdown

–

High water temperature alarm and shutdown

–

Engine vibration

–

Cooler vibration

–

Over speed shutdown

–

Air inlet shutoff, electrically actuated, manually reset

–

Over crank start sequence shutdown



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18 OF 39

–

Manual lockout at skid

–

Fire detectors

–

Red mushroom head Emergency Stop pushbutton located at the engine skid and on the engine control panel face.

All shutdown and alarm switches shall be hermetically sealed whenever possible and shall be UL listed, as a minimum, for IEC Zone 2 hazardous locations. 6.11 Engine Instruments Panel A package mounted powder paint coated sheet steel instrument panel for engine shall be provided. Panel shall be located on the edge of the engine skid so that it may be viewed from outside the enclosure and shall be mounted on isolation mounts in such a way as to prevent vibration damage to instruments. The following instruments shall be provided on the instrument panel as a minimum:

–

Lube oil pressure gauge

–

Electronic (LCD) tachometer

–

Engine outlet water temperature gauge

–

Engine outlet oil temperature gauge

–

Engine oil filter differential pressure gauge

–

Intake manifold vacuum/pressure gauge

–

Fuel pressure gauge

–

Running hour meters

–

Fuel filter differential pressure gauge

–

Engine inlet water temperature gauge

–

Cooler outlet oil temperature gauge

–

Gauge for diesel engines with after cooling

–

Red maintained mushroom head emergency stop pushbutton, hermetically sealed contacts

–

Frequency Meter

–

Voltage Meter / Load

Additional instruments required by the Contractor/supplier shall be provided. Instrumentation shall conform, in general, with API STD 670. Instrumentation and associated local panel monitor for vibration, axial position and bearing temperature shall conform, in general, with API STD 670.



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19 OF 39 PAGE Gauges shall be provided with glycerin filled stainless steel cases with a minimum 100 mm (4 inch) face, identification labels, including tab number, and normal and maximum reading markers. Pressure gauges shall have 316L stainless steel bourdon elements and 316L stainless steel cases. Thermometers shall be mounted in 316L stainless steel wells. Gas-filled thermometers shall have leads and shall be no longer t han 3 meters (10 feet). 6.12 Ignition System 

Engine VENDOR‟sstandard, shielded, lowtension, capacitive discharge ignition system shall be used.



All cables and harnesses shall be shielded with stainless steel braid. Primary cables shall also be vinyl

covered. 

Ignition transformers shall be integral with the spark plugs eliminating the need for separate spark plug

wires. 

Engine VENDOR‟s standard electronic ignition diagnostic system shal l be used.



Magnetos if used, coils and plugs shall be certified by IEC, U.L., C.S.A, or F.M.

6.13 Over-speed Protection The engine shall be fitted with an overspeed protection device in accordance with ISO 3046-6. This device shall shutdown the engine by both earthing the ignition and shutting off the fuel independently of the speed governor. The overspeed protection device shall be manual reset only. 6.14 Torsional Vibration The assessment and prevention of torsional vibration in the engine and its driving train shall be as specified in ISO 3046-5. VENDOR shall provide all the necessary information regarding the engine including enabling the torsional vibration calculations. Alternator drives shall be regarded as having a speed range of 90 to 110% of synchronous speed for the torsional analysis. Use of torsionally flexible couplings and torsional dampers (separate from those fitted as standard to the engine) for tuning the torsional critical speeds shall require the approval of the consultant. VENDOR shall advise the life of viscous type torsional dampers fitted to the engine. 6.15 Lateral Vibration and Vibration Suppression VENDOR shall provide the anticipated lateral vibration levels of the engine relating to measurements made directly on the crankcase or main frame of the engine, expressed both as a filtered response at each of the major excitation frequencies and as unfiltered vibration with the engine running at rated power and speed. The vibration information shall include the magnitude and direction of unbalanced primary and secondary unbalanced forces and couples.



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20 OF 39 PAGE Suitable anti-vibration mounts shall be supplied to limit the engine vibrations transmitted to the foundations or surroundings if a vibration analysis study reveals that the package requires isolation from the supporting structure. Anti-vibration mounts shall be of totally enclosed design, suitable for the environment, and have an isolation efficiency of at least 90% in respect of all engine induced vibrations. Unless otherwise dictated by the arrangement of the engine and the driven equipment or by the lateral vibration analysis, any anti-vibration mounts required shall be installed between the baseplate and the supporting structure. VENDOR shall supply the anti-vibration mounts. Full details, including drawings of the anti-vibration mounts shall be submitted to the COMPANY / CONSULTANT / CONTRACTOR together with the frequencies and magnitude of any unbalanced forces and moments that will be transmitted through the supports into the supporting structure. 6.16 Shaft Couplings and Guards VENDOR shall supply shaft couplings between the engine and the driven compressor. All couplings shall be either flange bolted to shafts or be hydraulically fitted to cylindrical or tapered shafts. Couplings requiring heating for installation or removal are prohibited. All couplings shall be of the non-lubricated type. All moving parts shall be protected from human contact by suitable guards of either sheet or m esh material. All such guards shall be non-sparking. Aluminium is not regarded as a non-sparking material. 6.17 Crankcase Explosion Relief 3

Engines having a crankcase volume of over 0.6 m shall be provided with crankcase explosion relief devices. Explosion relief valves of the BICERI design or approved equal with integral flame traps shall be used. 2

3

Sufficient relief valves shall be installed to provide more than 115 cm of relief valve free lift area per m of crankcase volume. Dipsticks and/or filler caps shall be effectively secured against ejection following a crankcase explosion. The crankcase breather shall be as small as possible and located to minimize air inrush into the crankcase following an explosion. 6.18 Miscellaneous Requirements Relief valves shall be provided as necessary for the fuel supply, engine crankcase pressure and lube oil supply. Governor setting controls shall be mounted on the governor. The engine over-speed shutdown will be easily accessible and capable of being manually tripped and reset with fuel pressure on the line. T rip mechanism shall be spark proof and s uitable for use in hazardous locations. Trip device, valve, valve stem, packing and interconnecting linkage shall be of suitable material and so designed that they may be expected to perform satisfactorily under conditions of minimum lubrication, infrequent tripping and outdoor installation. Automatic safety stops shall be entirely independent of the speed governor. They shall operate to ground the ignition, shut off the fuel and vent fuel from the engine.



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21 OF 39 PAGE Interlocks shall be provided to override shutdown signals when starting the engine. Some means of positive fuel shut-off should be provided for emergency use. Pressurized fuel (natural gas) should have another shut off valve, preferably automatic, other than those in the carburettor or gas pressure regulator equipment.

7.0 GAS COMPRESSOR 7.1 General The Compressor shall meet all the technical requirements as specified in:

–

Data Sheets

–

Technical Specification

–

Code and specification API 618, API-11P, OISD 179, NFPA 37, NFPA 52, ANSI, ASTM, NEC, NEMA, Indian Electricity Rules and Indian Explosives Act are referenced to and made part of specification.

Gas composition given in Data Sheets shall be used for Compressor sizing and performance guarantee estimates. However compressor shall be suitable for continuous operation with the indicated gas composition range and operating parameters given in the data sheet. Vendor‟s offer shall be based on firm and final compressor models on which basis the offer shall be evaluated. All Vendors shall take full recognisance of this matter before submitting the bid. Note that the pressures given on the data sheet are at the compressor package battery limits, Vendor shall consider all pressure losses at suction, interstage and discharge at the specified capacity (with none tolerance) for compressor/engine and indicate the same on the data sheets. No venting of the gas is allowed at any point during operation. The compressor driver shall be capable of running the compressor under loaded condition with each stage pressurized to its respective specified pressure and final pressure upto PSV set pressure. 7.2 Allowable Speeds, Temperature and Vibration Levels The rotational speed of both compressor & engine (driver) shall be limited to maximum of 1500 rpm. The maximum discharge gas temperature of compressor for each stage shall be limited to 150ºC (300ºF). Compressor maximum vibrations of cylinders shall be as per VENDOR‟s standard. VENDOR shall provide for all structural support within the package so that t hese levels can be achieved. The Co mpressor shall stop if the vibration limit crosses as specified above or manufacture‟s specified limit. 7.3 Piston Rod, Bearings and Cross Heads The surface hardness of Rockwell C 50 minimum is required on piston rods in the areas that pass through the packing if applicable. Crosshead shall be as per manufacturer‟s standard material and designs. Adequate openings for removal of the crossheads shall be provided.



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22 OF 39 PAGE Piston rod and cross head pin loading at any specified operating condition including the relief valve set condition shall not exceed 80% of the maximum design rod load of the offered compressor. Rod loads shall have sufficient reversals in direction for all specified operating conditions including PSV Settings and part load operation if applicable. 7.4 Packing Cases and Pressure Packing (If Applicable) All oil wiper intermediate gas cylinder pressure packing shall be segmental rings with stainless steel garter springs. The pressure packing case shall be provided with a common vent and drain routed outside the package enclosure. Seamless steel tubing conforming to ASTM A-192 or series 300 stainless steel tubing conforming to ASTM A-269/DIN with minimum thickness as specified in Cl. 7.11 of API-11P shall be used for vent piping. Packing vent piping inside of the distance piece shall be d esigned for the maximum allowable working pressure of the cylinder. 7.5 Compressor Frame Lubrication Compressor frame lubrication shall be pressurized system with main oil pump driven directly by compressor shaft. All lube oil piping after oil filter shall be 300 series stainless steel conforming to ASTM A 269. Heating shall be provided for reservoir when the minimum ambient temperature is less than VENDOR's required minimum start up temperature. For inherent design, VENDOR shall submit lubrication process detail along with the bid. 7.6 Distance Pieces (If Applicable) Type-1 or Type-2 distance pieces as per API 11 P can be provided as per compressor design requirement. 7.7 Cylinder and Packing Lubrication Single plunger per point force feed mechanical lubricator or divider block system shall provide lubrication to compressor cylinders. Lubricators shall be driven by crankshaft and VENDOR shall highlight any pre lubrication requirements of the cylinders and the method of achieving the same. Lubricators shall have a sight flow indicator for lubrication points and a stainless steel double ball check valve shall be provided at each lubrication point. Digital no flow switch shall be provided to stop the compressor in case of loss of cylinder lubrication in all stages. Lubricator reservoir capacity shall be adequate for 50 Hrs of normal operation, and shall be equipped with low-level alarm.



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23 OF 39 PAGE VENDOR shall furnish along with their bids the details of the recommended Lubricating oil type, International Grades & Specifications along with their quantity and changing frequency/ schedule. The recommended oil shall be compatible with gaskets, „O‟ rings, seals, packing, lubricating parts and other parts coming into contact. For inherent design the Vendor shall subm it write up along with sketches explaining lubrication detail along with the bid. 7.8 Cooling System Compressor cylinders may be air cooled; in case water-cooled cylinders are offered the VENDOR shall conceive and design the common or separate Compressor cylinder cooling water (CW) system. Vendor shall submit the authentication from respective equipment manufacturer for the same. The Cooling Water shall be cooled by an air-cooled heat exchanger. For the sizing of Air Cooled Heat Exchangers, dry bulb temperature of 104 °F shall be considered. For the sizing of Evaporative Air Cooled Heat Exchangers, dry bulb temperature of 104 °F and relative humidity of 70% shall be considered. 7.9 Inter / After Gas Coolers Air-cooled Interstage and Final stage discharge cooler s shall be provided which shall limit the gas temperature after the after cooler to maximum 120°F for Sale Gas Compressors and 130°F for Stabilized Gas Compressor. For calculating the surface area of the air cooler, the maximum ambient air temperature and 90% RH shall be considered. Cooler design shall be on the basis of 20% extra margin on the heat load at most severe condition corresponding to suction pressure. Gas sections of coolers shall be designed as per API 661 requirements and shall be inspected by any approved 3rd party inspection agency. Engine oil cooler and jacket water coolers shall be so designed that VENDOR‟s maximum permissible temperature is not exceeded at the maximum ambient temperature. The sizing shall be done in such a way so that at no point of time the discharge gas temperature exceeds 120°F for Sale Gas Compressors and 130°F for Stabilized Gas Compressor. The angle of louver shall be automatically adjusted to control condensing temperature by Unit Control Panel. 7.10 Separators & Oil Removal System Carbon Steel separators at suction and inter-stage along with 300 series stainless steel, mist extractors, auto drain system (timer based) shall be provided for the capacity as required. All pressure vessels shall be designed as per ASME VIII Div 1 latest edition. The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in the discharge gas of compressor and the equipment shall be designed accordingly. All pressure vessels including pulsation dampers shall be fully (100%) radiographed as per ASME VIII UW ( a) Minimum design temperature for separators shall be 100ºC (212°F) and minimum design pressure shall be maximum operating pressure plus 15% for interstages and plus 10% for final stage. 7.11 Pulsation, Vibration Control and Analog Study VENDOR shall provide pulsation, suppression devices at each suction and discharge of compressor cylinders.



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24 OF 39 PAGE The design of pulsation suppressing devices shall be based on the acoustic and mechanical evaluation carried out as per relevant standard. These devices must reduce pressure pulsation in piping within 3%. These pulsation dam pers shall be designed to limit pressure drop to 1%. The minimum acceptable volume of pulsation suppression device shall be 10 times the cylinder swept volume. VENDOR shall get the acoustic and mechanical evaluation study carried out for compressor package (from inlet flange to discharge on skid edge Plus 200 ft piping) by a certified agency. VENDOR shall be totally responsible for all the coordination with the agency carrying out the study. VENDOR shall submit acoustic and mechanical evaluation report to COMPANY / CONSULTANT / CONTRACTOR.

8.0 ELECTRICAL REQUIREMENTS All electrical equipment shall be designed, purchased, and installed in accordance with Specification for Electrical requirements of Packaged Equipment (NGP-000-ELE-15.03-0006-00) and Specification for Motors (NGP-000-ELE-15.03-0003-00) and all additional requirements specified in the tender document/relevant standards. All electrical devices shall be suitable for out-door location and IEC Zone 2 area. All electrical devices on site shall be IP65 (excluding Low Voltage motors) at least, junction box need IP65. Explosion-proof grade of motor shall be d IIB T4. Space heater shall be provided for motors (which power is more than 75kw), the space heater shall be energized while motors are stopped. VENDOR shall provide motor control center (MCC) which size shall be 1000mmx1000mmx2200mm

for the

，

package auxiliary equipment including pump and fan motors, heaters, battery chargers, etc. The MCC shall incorporate one fully equipped spare starter and feeder unit for each type installed within the MCC. Generally, following criteria shall be followed for selection of starter type for motors: motors below 37KW shall be Direct-on-line starting; motors between 37KW and 100KW shall have Star/Delta starter; Motor above 100KW shall have Soft starters. Motor starter will be supplied by VENDOR and be installed inside the MCC. CONTRACTOR shall provide incoming feeder to this MCC at 400 volt AC, 3 phase 4 wires, 50Hz for electrical power. VENDOR shall provide the power usage tables and requirements in his proposal including start-up, normal operation, emergency, and post running requirements. For design purposes, the short circuit rating of the MCC shall be taken by VENDOR according to the system parameters. The MCC shall be provided as loose item but shall have internal wiring installed and terminated complete in all respects, ready for receiving external cabling connections at terminals designated by VENDOR. This includes complete control circuits for motor starter controls. The MCC will be placed in plant‟ s main electrical room, which is non-hazardous classified location. In addition to the MCC, VENDOR shall provide a local control station comprising of LOCAL-OFF-REMOTE selector switch and indication light(s) for run-stop status. This shall be provided as pre-installed assemblies near respective AC motors.



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25 OF 39 PAGE When the drive is selected in LOCAL mode, it can be started locally if process interlocks are satisfied. When selected in REMOTE mode the drive can be started automatically (and or remotely if remote START/STOP controls are provided) and by the local START pushbutton with all interlocks operational. If the OFF mode is selected, the drive cannot be started. NOTE: Personal and electrical protection interlocks shall remain operational in all modes. Engine Star ter Control circuits in VENDOR‟s MCC shall be designed by VENDOR to accommodate the above mentioned scheme. Furthermore, control circuits shall also incorporate incoming Automatic start-stop signals from UCP IO / marshalling. The logic for such automatic operation shall be configured in the UCP. VENDOR shall submit engine control schematic drawings. The control cabling requirements between UCP and MCC shall be specified by VENDOR in the form of a control cable list. The cable shall be supplied and installed by CONTRACTOR. VENDOR shall also furnish detailed termination drawings for CONTRACTOR to execute. The AC power cabling from outgoing circuits of MCC upto the above stated auxiliary loads shall be provided by CONTRACTOR. Same also applies to control cable from L-O-R switch to MCC. However, VENDOR shall provide and install cable tray/ladder/conduits from each consumer upto the skid edge so that same may be used to lay the power/control cable by CONTRACTOR. VENDOR shall ensure, as much as practicable that:

–

Cable tray/conduit rating shall be such that cable (by others) from all loads (within package) can reach the skid edge at a single point (or as minimum points as possible) for ease of on-ward cable trench routing (by others)

–

Such point on skid edge shall be located at grade level.

–

All tray/ladder/conduit sizes and routing shall be suitable for respective bending radii of cable.

–

VENDOR shall also provide detailed on-skid cable layout showing the above mentioned cable tray/ladder/conduit routing.

AC Power 400V or 230V for each UCP shall be provided b y CONTRACTOR from its main UPS through feeder cables. All other voltage levels (including DC) required for control equipment shall be furnished by VENDOR. For engine starting, VENDOR shall supply independent DC power supply system with battery backup. The system shall include batteries, battery charger, and a DC distribution panel. This DC supply system shall be provided as skid mounted package in enclosures suitable for the applicable area classification. The system shall be provided as a complete pre- wired system including complete DC power cabling upto the DC power consumers on skid. The input AC power for the above mentioned DC supply system shall be sourced by VENDOR from its MCC. However, the AC power cable, from MCC to inlet connection point of DC system, will be provided by the CONTRACTOR. VENDOR shall submit a detailed list of AC power and control cables re quired from CONTRACTOR. Such a list shall indicate the rated power of the consumer as well as the Number of cores required for each application (3phase, 1-phase or multicore control cable). All entries in the list shall be provided with cable tag identification. Same tags shall be shown on the cable layout on VENDOR designed cable tray / conduit routes.



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26 OF 39 PAGE In general area lighting outside the packaged unit will be provided by CONTRACTOR. Where additional lighting inside the package, is required (such as on local gauge boards or panels, etc.), VENDOR shall design and supply the same as a complete system includin g cable‟s wired up to the local switch /junction box(es) for CONTRACTOR‟s onward cable connection. Single phase circuit shall be used by VENDOR for lighting. Each circuit shall be wired to separate Junction boxes. Each junction box shall include a plugged cable entry for CONTRACTOR‟s cable connection. VE NDOR shall include adequately rated circuit breakers in its MCC from where these lights shall be fed. The cable from light fixtures to JBs / switches shall be provided and pre-installed by VENDOR. However the cable from JB to MCC shall be sized, supplied and laid by CONTRACTOR. However, VENDOR shall indicate the required number of cable runs with circuit load in the elaborated. Fluorescent lights shall generally be used for on-skid lighting. All inter-connecting wiring and cabling within the equipment skid shall be provided by VENDOR. Low voltage electrical wiring shall have multi-stranded copper conductors, continuously tinned, 0.6/1kV Cu/PVC/SWA/PVC. All gauges, emergency stop buttons, etc., shall be fully visible and accessible from outside the enclosure. Top entry of cables or conduits into enclosures or equipment will not be accepted without prior approval. Vendor should provide requirements of common ground network system and requirement of grounding resistance. All equipment shall be connected to the main earth network through minimum 2 earthing terminals located at opposite sides. Power distribution and control shall be installed in 2 separate sections of the panel. Junction boxes shall be provided with appropriately sized internal and external earthing terminals. Signal and control loop circuits of input and output of units shall install lightening arrester. VENDOR shall indicate the maximum capacity of UPS in KVA and designate the surge current.

9.0 INSTRUMENTATION REQUIREMENTS All instrumentation shall be designed, purchased, and installed in accordance with project specification for instrumentation for packaged unit (NGP-000-INS-15.03-0004-00) and all additional requirements specified in the instrumentation specifications included in the Tender Document. VENDOR shall provide all instrumentation required for stable operation, startup, shutdown, emergency shutdown, train blowdown, monitoring, and alarm of the engine driven compressor train and communication with other control systems and equipment. As minimum, all instruments, controls and annunciation points shall be provided as specified by the data sheets and P&IDs .etc. VENDOR shall supply the packaged instrumentation as pre- installed assemblies, as much as practicable, complete in all respects including all tubing, tubing fittings, instrument valve manifolds/block & bleed assemblies, mounting structure/supports for instruments, other installation accessories, etc.



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27 OF 39 PAGE If any instrument, related to packaged units, has to be supplied separately, then supply of complete installation material and detailed documents, drawings etc. shall also be included in scope of VENDOR. VENDOR shall also be responsible to provide all instrumentation and contro l cabling within the package battery limit including, but not limited to: 

Cabling from skid mounted field instruments to skid m ounted JBs.



Multi-pair cabling from JBs to UCPs.



All cabling / wiring within the UCP including control / interface cabling between various control modules

within the UCP. Cabling from F&G detectors to skid mounted JBs and onwards to UCP.





All cabling between panels / equipment supplied by VENDOR.

All junction boxes required for establishing the above mentioned instrumentation and control cabling system shall be supplied by VENDOR, generally as a pre-wired and pre-installed assembly on skid including mounting stands and support structures. Separate Junction boxes shall be provided for analog and digital signals to UCP. Similarly, separate JBs shall be used for F&G related cables. VENDOR shall supply and install all Cable trays/ladders, GI conduits for laying of above mentioned cable from instrument to edge of package JBs. All cable routing within the package shall be designed by the package VENDOR, including design, supply and installation of tray/ladder/conduit supports/ fittings complete in all respects. Cable termination accessories including suitable explosion proof cable glands (at both instrument and JB ends), shrouds, cable lugs, cable tags, etc. for all cabling within VENDOR‟s battery limit.

10.0

CONTROL REQUIREMENTS VENDOR shall provide the engine - compressor control system for full automatic control of start-up, stable operation, monitoring operation, stop, alarm, and shutdown of the unit including process and utility valves and instrumentation from a unit control panel (UCP) provided for each unit. The UCPs will be located in the local control room (an air purged building)and capable of communicating with the plant‟s main D istributed control system (DCS) and the main ESD System located in the plant‟s Central Control Room (CCR). Control system shall be capable of monitoring actual valve open and close positions and detect out of sequence conditions of the suction SDV, discharge SDV, flow control valves, loading valves and blowdown valves. Each UCP shall, as a minimum contain the following: 

A Dual Redundant and synchronized Programmable Logic Controller (PLC) System of proven

experience and in compliance with the minimum requirements laid down in referred Specifications for Instrumentation & Control for Packaged Equipment. 

I/O Modules to interface field devices. ((Redundant IO modules shall be used for critical loops and

ESD related signals)




DESCRIPTION


REVISION

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28 OF 39

Redundant Communication modules for interfacing with DCS as well as with control modules within

the UCP. 

Redundant Power Supply Units (CONTRACTOR will provide dual 230 VAC power inputs from Plant

UPS. Vendor shall convert from 230 VAC to any other voltages required for control equipment) 

Panel mounted VDU / HMI display screen (19” TFT colour screen, touch type) complete with integral

panel mounted PC fully loaded with HMI software, Operating system and all allied application software. 

Licensed Configuration Software for whole system including any required license required for

interfacing with CONTRACTOR‟s DCS. 

System Marshalling Terminal blocks, including marshalling relays for hard wired signal transmission to

and from main ESD PLC, DCS and MCC. 

Selector switches, push buttons, and digital indicators.



Bearing vibration and temperature monitoring system.



Capacity Control, load sharing, and performance controllers, as further elaborated in the subsequent

clauses. VENDOR shall procure, install and integrate all such proprietary control modules/equipment in the UCP. 

F&G detection controller for F&G detection on Compressor Skid.



Panel-mounted manual governor “Raise / Lower” speed switch wired as an input to the CCC Load

Sharing Controller. This governor manual control shall be a spring-return to neutral switch, and not a pushbutton. Major functions provided by the UCP shall include, but not limited to: 





Manual Crank. Auto Mode. Control and display of all engine and compressor control and safety systems (including proprietary

controls mentioned above), and those process signals as depicted on the project‟s Piping and Instrument Diagrams (P&IDs) and relevant package data sheets. 

Automatic sequencing and positioning the compressor train suction and discharge valves, surge

control valves, purge and vent valves during the start, stop and purge sequences. 

Sequencing, control, and monitoring of the compressor train utilities, lube oil system, fuel gas system,

inlet air system, enclosure ventilation, etc. 

Manual „Start‟ switche, to be operated by the operator.



Normal and Emergency Stop (Manual) from the UCP.



Normal and Emergency stop activation on receipt of signal from DCS and ESD PLC respectively, for

which VENDOR shall provide 24 Volts DC interposing relays that will be connected to CONTRACTOR‟s above mentioned controls in CCR.




DESCRIPTION


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Monitor for the presence of fire or combustible gas and provide the necessary automated shutdown

actions. 

Communicate Unit Shutdown status to CONTRACTOR‟s ESD PLC including shutdown due to process

/ equipment upset and shutdown / blowdown due to presence of fire an combustible gas on the packaged equipment. 

Receive Emergency Shutdown signals from ESD PLC (ESD-1 or ESD-2) and execute the Engine

driven Compressor unit shutdown sequence. Blowdown shall only be executed on receipt of ESD-1. 

Interface with CONTRACTOR‟s DCS through serial communication for remote monitoring of all

compressor functions to the Central Control Room (CCR). The UCP shall have the capability to transfer data for every IO to the DCS to achieve the desired interface. 

Receive control set point from DCS via serial interface and use the same in load sharing co ntrols.

For Control Panel Interfacing requirements, Each UCP shall be provided with dual redundant serial data communication port supporting MODBUS RS-485 protocol for communication with CONTRACTOR‟s DCS in CCR. In addition, dual Ethernet IEEE 802.3 10/100 Base-T communication port (supporting TCP/IP protocol) shall also be provided. 10.1 Vibration Monitoring VENDOR shall furnish a vibration monitoring system for each compressor package comprising the following, as a minimum: 

X-Y radial vibration adjacent to each gear and compressor journal bearing.



Dual voting axial position monitors on gear and compressor.



Probes shall be complete with cables and proximeters mounted in NEMA 4X enclosures.

Each vibration monitoring system shall be mounted within their respect ive UCP and wired to the UCP‟s main PLC system for local display on the panel‟s VDU/HMI. VENDOR shall also provide requisite application software and hardware to support the HMI graphics interface, as well as providing the engineering configuration software for on-line diagnostics and future programming changes. 10.2 Bearing Temperature Monitoring System A bearing temperature monitoring system shall be incorporated into the UCP and shall include two embedded dual element RTDs (100 Ohm platinum) temperature sensors as follows: 

Each compressor radial bearing.



Each gear radial bearing.



Each compressor active and inactive thrust bearing.



Each gear active and inactive thrust bearing.



One element from each RTD shall be monitored.



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10.3 Capacity Control and Parallel Operation VENDOR shall provide requisite capacity controls based on estimated yearly flow rate and the resulting turndown requirements. VENDOR shall consider the control methods for constant speed mode as specified in API 11P. Use of variable speed control is not preferred. VENDOR may also utilize a combination of the above referred methods for optimization of capacity control. VENDOR shall also incorporate controls for optimum load sharing between 2 Nos. operating compressors operating in parallel. 10.4 Monitor and Display The compressor control system (UCP) shall provide complete capability to monitor, display and alarm process variables for loops associated with the compressor package through the compressor‟s Unit Control Panel. For this, UCP shall include an integral panel mounted HMI display / Video Display Unit comprising of 19” TFT coloured screen, touch type, an integral panel mounted industrial PC for storing HMI software. The PC shall have Core-i5 processor as a minimum with min. 8 GB RAM, 500GB hard drive, communication ports for Ethernet and modbus, USB ports, etc. The PC shall be pre-loaded with all requisite licensed HMI and application software. This VDU/HMI shall act as the main man- machine-interface for all engine and compressor control functions associated with its' specific train. The PC/HMI shall also have the provision to optionally connect external Keyboard and mouse. VENDOR shall fully describe the Man-machine capabilities in the technical offering and shall provide the following as a minimum: 

Overview of each compressor.



Engine controls and associated auxiliary graphics (major parameters only).



Compressor controls and associated auxiliary graphics.



Display process related data as shown on the project P&IDs and package datasheets.



Engine / compressor vibration and RTD measurements and alarms.



F&G related alarms.



PLC Fault Alarms and associated diagnostics.



Current and historical trending.



Alarm Manager with “first out” alarming.



Tag List Display.



Sequence of Events Logging and Reporting with time stamps.



Logon display to provide a password-secured means of making programming revisions.

10.5 Controls, Alarm and Shutdown System



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PAGE The following shall be provided:

31 OF 39



PLC monitoring of field devices and conditions for safe operation and shutdown.



Indication of alarm and shutdown conditions.



Sequencing a shutdown following detection of a shutdown condition.



VENDOR shall provide a contact output from the UCP for each of the following alarms / status for each

train. These outputs shall be hard wired to CONTRACTOR‟s main ESD / F&G System.

–

Common engine-compressor trouble alarm.

–

Common engine-compressor shutdown alarm.

–

Fire or gas alarm.

–

Local Control Building fire or gas alarm.

–

Fire and gas system fault.

–

Fire and gas detection system “in bypass” alarm.



Furthermore, The UCP shall provide two interposing relays, with 24 Volt DC coils, which will receive

signal from CONTRACTOR‟s ESD / F&G PLC to effect the following functions:

–

Normal shutdown without blowdown (ESD-2)

–

Emergency shutdown with blowdown. (ESD-1)

Each control panel shall include the following face mounted items. 

Digital indicators.

–

Gas compressor speed (dual scale %/rpm).

–

Engine speed (dual scale %/rpm).

–

Load Compressor Speed (dual scale % rpm).



Selector Switches for:

–

Mode (off / manual / auto / crank / wash)

–

Main lube oil pump

–

Governor raise/lower (spring return to neutral)



Control Push Buttons:

–

Unit stop.

–

Unit start.

–

Emergency stop.


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–

Lamp test.

–

Shutdown reset.

–

Acknowledge (with horn silence).

–

Emergency lube oil pump reset.



11.0

DESCRIPTION


Status Lights:

–

Permissive to start.

–

Stand by lube oil pump running.

–

Unit-in sequence / running.

–

Stop (normal).

–

Stop (emergency).

–

Watchdog timer time-out shutdown.

–

Two spares.



Sonalert (horn).



Start Counter.



Fired Hours Meter.

FIRE DETECTION VENDOR shall provide a fire and gas detection system for each unit. The each system shall include, as minimum: 

UV/IR flame detectors.



Gas detectors at engine air intake.



Gas detectors near likely gas leakage sources.

The fire and gas panel shall be provided for each unit as a part of UCP. The panel shall be provided with a watch dog system monitoring the system conditions continuously and alarm the status change. The panel shall perform the following function: 

Upon fire detection by UV or heat detector, initiate fire alarm horn and strobe light, initiate ESD, isolate

fuel gas to the unit, close fire dampers, stop fans, and send a signal to the ESD PLC. The gas detectors shall provide an alarm signal on 20% LEL and a shutdown signal on 60% LEL. Shutdown signal shall only be permitted by a voting system of any two gas detectors installed. All gas detectors, UV detectors, and heat of rise detectors shall be provided with features to allow calibration while the compressor is operating. Bypass conditions shall be clearly indicated both locally and by an alarm on the UCP as well as on the main control panel.


12.0

DESCRIPTION


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PIPING VENDOR shall provide process tie-in sizes and required pressure drops for preparation of arrangement drawings and isometrics of all off skid process, flare, fuel gas and utilities piping necessary for the unit operation, start-up and shutdown. The on-skid piping supply shall include all piping components, such as valves, fittings, pipe shoes, springs, expansion bellow and all in-line items. The on-skid piping shall be installed prior to shipment (if required may be supplied loose). On-skid piping shall be fully assembled, tested and painted prior to shipment. Piping design shall be based on ASME Standard B31.3 and materials shall be according to ASTM standards as applicable. Piping shall be suitably insulated according to services. Application & selection of material for insulation and weatherproofing shall be in accordance with the specs. All on-skid piping, including auxiliary piping systems, shall conform to ASME B31.3. These shall include the following as a minimum:

–

Lube oil lines.

–

Seal gas and thrust balance lines.

–

Drain and vent lines (check valves are required to prevent back flow of liquids or gases from the relief system).

–

The mounting of all associated valves, controls, pressure reducers, thermometers, pressure gauges, or instrumentation.

–

Thermowells shall not extend into any pipe more than 20 percent of the internal diameter of the pipe.

VENDOR shall furnish all auxiliary piping with its mounted appurtenances located within the confines of Gas Engine Driven Reciprocating Compressor Unit.

–

Piping shall terminate with ANSI flanged connections at the edge of the skid. All the outside connection should preferably terminate on one side of skid.

–

The piping shall be designed to provide proper flexibility and normal accessibility for operation, maintenance, and thorough cleaning. A space of 800 mm after application of insulation should be available for passage of operation and maintenance personnel.

13.0

–

Small piping shall be securely fastened or supported to minimize vibration and prevent breakage.

–

All oil piping and reservoirs shall be 304SS, valve body and valve trim shall be ASTM A312 316SS.

UTILITIES & TIE-INS

13.1 Utilities



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34 OF 39 PAGE Cooling water is not available as utility and the package shall be provided with self-sufficient cooling water system for Engine & Compressor, as required, with makeup tank. 13.2 Tie-Ins All customer interface connections (i.e. Gas Inlet & Gas Outlet) shall b e brought out to the package edge. Gas inlet shall be terminated in nozzles with isolation valves having flange connections and Gas outlet (priority panel outlet connection) shall be terminated through high- pressure ¾” full flow ball valves for ¾” SS tube connections. As and where specified on the data sheets all vents (i.e. Relief valve, distance piece, packing and starting air) shall be manifolded and terminated at skid edge outside the enclosure and vented to safe height at package roof. Silencer has to be provided in the starting air vent line. All drains from different process equipment, distance piece and packing shall be manifolded and term inated as single point for customer interface duly flanged with isolation valve. Drains should be through a common header and discharge to be allowed in a pit to avoid spillage around compressor package.

14.0

EQUIPMENT TAGGING AND NAMEPLATES Each main item of equipment of the package (e.g. gas compressor, gearbox, gas engine) shall have an easily visible nameplate. The following data shall be clearly stamped or engraved on the name plate: 

VENDOR‟s name



Serial number



Size, type and model (If applicable)



Rated capacity (If applicable)



Rated power (If applicable)



Lateral critical speeds up to and including the next lateral above maximum allowable speed (if

applicable)

15.0



CONTRACTOR item number or other reference.



Maximum allowable working pressure (if applicable)



Minimum and maximum allowable working temperature (if applicable)



Minimum operating speed (if applicable)



Maximum continuous speed (if applicable)



Trip speed (if applicable)



Hydrostatic test pressure (if applicable)

INSPECTION AND TESTING



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35 OF 39 PAGE All equipment supplied by VENDOR shall be subjected to inspection by COMPANY / CONSULTANT / CONTRACTOR, his authorized agents and other certifying authority if required. All test certificates for materials used during fabrication shall be available prior to final inspection. VENDOR shall coordinate with COMPANY / CONSULTANT / CONTRACTOR or his authorized agents and conduct the inspection in accordance with the Inspection Requirements and Specified in the Tender Document. Inspection by COMPANY / CONSULTANT / CONTRACTOR does not relieve VENDOR of his responsibility to carry out inspection and testing as required by codes, standards and specifications.

16.0

PRODUCTION INSPECTION VENDOR‟s and sub- VENDORS‟ manufacturing and production inspections shall consist of his standard quality control program procedures plus the requirements of Inspection included in the Tender Document. During any inspection or test, COMPANY / CONSULTANT / CONTRACTOR or its designated representative shall have the right to reject any part of the work not in compliance with this specification including all applicable specifications, tender requirements, or not in compliance with VENDOR‟s or sub -VENDOR‟s quality control standards.

17.0

CONTROL FUNCTIONAL TEST All control panels inclusive of remote control panels and local control panels shall be functional tested at manufacturer‟s shop. VENDOR shall submit the test procedures for the COMPANY / CONSULTANT / CONTRACTOR‟s approval.

18.0

MECHANICAL RUN TESTS A compressor mechanical running test shall be performed at the compressor manufacturer‟s shop in accordance with API SPEC 11P. Hydrostatic test of compressor shall be performed in accordance with API SPEC 11P. Gear box mechanical running test shall be performed at the gear box manufacturer‟s shop in accordance with API 613. A post-test bearing inspection shall be performed. The impeller over speed test of compressor shall be conducted in accordance with API SPEC 11P. Any permanent deformation of the bore measured after the over speed test will be case of rejection All parts of the engine and its auxiliaries which are subject to cooling water pressure during operation shall undergo a witnessed hydrostatic test of at least 1- 1/2 times the maximum allowable working pressure for ½ hour without leakage.

19.0

PERFORMANCE / FACTORY ACCEPTANCE TEST (FAT) VENDOR shall submit detailed inspection and test plan at least 8 weeks prior to the proposed test date, for review and approval by COMPANY / CONSULTANT / CONTRACTOR. The test shall include, but not be lim ited to, the following: 

VENDOR shall submit specific test agendas (procedures) to COMPANY / CONSULTANT /

CONTRACTOR for review and approval. All pertinent test conditions, procedures and acceptance criteria



REVISION

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36 OF 39 PAGE should be clearly mentioned and should be conformance to the purchase order and pertinent test codes. It is critical that all aspects of the test be mutually agreed upon in writing in the form of a final test agenda. This final test agenda must be completed prior to the start of any testing program. 

Auxiliary system shall have to receive a functional test and a four-hour minimum mechanical running

test prior to shipment. 

The overall test shall be considered satisfactory when no abnormal conditions occur during the

operational phase. An abnormal condition is defined as system instability, relief valves listing, alarm or shutdown signals or any other condition that would require operator attention to correct. 

Allow a 10 percent maximum pressure accumulation above relief valve set pressure.Verify relief valve

set point by testing. 

Complete a filter-cooler changeover without the system's delivery pressure dropping to the

automatic-start setting of the standby pump or increasing to the high differential pressure alarm set point. 

Determine correctness of switch action and settings for all safety switches.



Determine correct response of all pressure control valves for all possible transient conditions.



Observe operation of oil temperature control valve.



Verify the nameplates and ratings of relief valves.



Verify acceptable changeover of transfer valve and valve leakage. Acceptable leakage is defined as

leakage that does not increase filter oil level above drain line with drain valve open. 

All instruments, temperature gauges pressure gauges, tachometers, thermometers, pressure switches,

temperature sensors etc., shall be calibrated and certified, prior to commencement of the test. Calibrated records shall be submitted to COMPANY / CONSULTANT / CONTRACTOR's representative. 

All bearings, crossheads, pistons and liner clearances, rod run out and alignment reading, shall be

recorded and submitted to COMPANY / CONSULTANT / CONTRACT OR's representative before and after, the Mechanical Running Test. 

VENDOR shall provide COMPANY / CONSULTANT / CONTRACTOR with his proposed no-load test

procedures for review and approval. The compressor shall be run with the valves installed, if possible. 

All shutdown simulations shall be initiated at the source instrument and not at the control panel. Each

shutdown function shall be tested by disconnecting pressure lines to simulate a shutdown signal. Level switches shall be mutually tripped and other instrument switches manually vented or pressure/temperature simulated. Panel display shall indicate the correct annunciation on each shutdown. 

A m echanical, no-load witnessed run test shall be carried out on the complete compressor package

unit, to ensure that the unit operates over the specified speed range, without evidence of vibration, malfunction, etc., and also to ensure the integrity of the alarm and shutdown features of the unit. The witnessed mechanical no-load run shall include 4 hours uninterrupted running at maximum duty compressor speed.


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DESCRIPTION


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Vibration measurements shall be carried out on the compressor unit during the mechanical running

test. The vibration levels shall be within limits. 

Resonance of any skid mounted component shall be identified and removed prior to release from

VENDOR works. 

During the witnessed no-load test, all equipment including their controls, cooling and lubrication

system and emergency shutdown systems shall be tested. All start stop alarm and speed control function shall be proved during this test. To ensure satisfactory governing of the engine, VENDOR shall partially load the compressor by running gas around the recycle loop. 

The engine shall be subjected to tests in accordance with ISO 3046-1.



The fuel for performance tests shall be as close as practicable to the specified fuel in respect of

heating value, Wobbe index and density. 

The works performance test shall be conducted with coolant and intake air temperatures adjusted to

correspond with the maximum ambient temperatures on site unless otherwise agreed by the consultant. 

Compressor performance test shall be performed in accordance with ASME Performance Test Code

10 Type 2 and API SPEC 11P.

20.0

FIELD TESTS VENDOR shall perform a field mechanical reliability test of Gas Engine driven compressor package to demonstrate the mechanical integrity, operability and controllability of the package. During the test sound levels (dBA) and exhaust emission levels shall be measured. VENDOR shall develop the detail test procedure for COMPANY / CONSULTANT / CONTRACTOR‟s approval. The minimum duration of the field test shall be 72 hours running at the compressor site rated conditions. The complete set of data shall be taken, at least, every four hours or any time the process conditions at the inlet have changed. Adequate time, at least one hour should be taken to allow for the process stabilization after the process conditions have changed or fluctuated. VENDOR shall submit detailed test specification, procedure and program for test on completion to CONTRACTOR for approval at least 12 weeks prior to start of commissioning. This shall include a detailed step by step procedure and program with details of measurements to be taken and curves for correcting departure from guarantee test conditions. COMPANY / CONSULTANT / CONTRACTOR shall comment within 04 weeks. The test procedure shall be mutually agreed prior to start of tests on completion. Following completion of tests VENDOR shall prepare a performance test report for review and approval by COMPANY / CONSULTANT / CONTRACTOR. Test reading shall be recorded in a test protocol and signed by VENDOR. COMPANY / CONSULTANT / CONTRACTOR‟s representative shall also sign “witnessed”.

21.0

PREPARATION FOR SHIPMENT Gas engine driven compressor package shall be properly protected during the time of shipment from the factory until installation at site including the storage period at the factory and the site before installation. COMPANY / CONSULTANT / CONTRACTOR shall approve the release of the Gas Engine driven compressor



REVISION

00

38 OF 39 PAGE package sets prior to shipment. VENDOR shall provide corrosion inhibitor protection for all internal and external machine parts for sea shipment and six months outdoor storage. VENDOR shall be solely responsible for the adequacy of the preparation of shipment and the equipment preservation provisions employed with respect to material and application. The minimum requirements for export packing are specified in the Tender Document. VENDOR shall submit his preparation for shipment procedure and equipment preservation procedure for the COMPANY / CONSULTANT / CONTRACTOR ‟s approval. Flanged openings shall be provided with metal closures at least 5 millimetres thick, with synthetic rubber gaskets. At least four full-diameter bolts shall be used for flanged openings, wire locked and tag sealed to prevent unauthorized entry. Seal shall not be removed without COMPANY / CONSULTANT / CONTRACTOR ‟s written approval and CONTRACTOR/VENDOR‟s representative present. 21.1

Equipment shall be suitably prepared for the type of shipment specified, including blocking of the

rotor when necessary. The preparation shall make the equipment suitable for 6 months of outdoor storage from the time of shipment, with no disassembly required before operation, except for inspection of bearings and seals. 21.2

VENDOR shall provide CONTRACTOR with the instructions necessary to preserve the integrity of

the storage preparation after the equipment arrives at the job site and before start-up. 21.3

The equipment shall be prepared for shipment after all testing and inspection has been completed

and the equipment has been approved by CONTRACTOR. The preparation shall include the following: 1.

Exterior machined surfaces shall be coated with suitable rust preventive.

2.

The interior of the equipment shall be clean; free from scale, welding spatter and foreign objects; and sprayed or flushed with suitable rust preventive that can be removed with solvent. The rust preventive shall be applied through all openings while the machine is slow-rolled.

3.

Internal steel areas of bearing housings and carbon steel oil systems' auxiliary equipment such as reservoirs, vessels and piping shall be coated with suitable oil-soluble rust preventive.

4.

Flanged openings shall be provided with metal closures at least 3/16 inch (5 mm) thick with rubber gaskets and at least four full- diameter bolts. For studded openings, all nuts needed for the intended service shall be used to secure closures.

5.

Threaded openings shall be provided with steel caps or solid shank steel plugs whose metallurgy is equal to or better than that of the pressure casing. In no case shall non-metallic (such as plastic) plugs or caps be used.

6.

Lifting points and lifting lugs shall be clearly identified.

7.

The equipment shall be identified with item and serial numbers.Material shipped loose or separately shall be identified with securely aff ixed, corrosion-resistant metal tags indicating the item and serial number of the equipment for which it is intended. In addition, crated equipment shall be shipped with duplicate packing lists, one inside and one on the outside of the shipping container.

NGP-001-PCS-15.03-0001!00!00_Specification for Gas Engine Driven Reciprocating Compressor

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