NGP 001 PCS 15.03 0002 04B_00_Specification for Turbo Expander Recompressor

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

DOCUMENT NO.: NGP-001-PCS-15.03-0002-04B

SPECIFICATION

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Specification for Turbo-Expander Recompressor

REVISION DETAILS

00

18/07/2016 Approved for Design

Cui Xiaobo

Qi Dezhen

Wang Dongjun

Wei Xiao

C

27/04/2016 27/04/2016 Issued for Approval

Cui Xiaobo

Qi Dezhen

Wang Dongjun

Wei Xiao

B

01/02/2016 Issued for Review

Cui Xiaobo

Qi Dezhen

Wang Dongjun

Wei Xiao

A

15/01/2016 15/01/2016 Internal Discipline Discipline Check

Cui Xiaobo

Qi Dezhen

Wang Dongjun

Wei Xiao

PRPD

CHKD

REVD

APPD

REV

DATE

DESCRIPTION

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

NGP-001-PCS-15.03-0002-0 NGP-001-PCS-15.03-0002-04B 4B

DESCRIPTION

Specification for Turbo-Expander Turbo-Expander Recompressor Recompressor

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DATE

REVISION DESCRIPTION

A

15/01/2 15/01/2016 016

Internal Internal Disciplin Discipline e Check Check

B

01/02/2016

Issued for Review

C

27/04/2016

Issued for Approval

00

18/07/2016

Approved for Design

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

NGP-001-PCS-15.03-0002-0 NGP-001-PCS-15.03-0002-04B 4B

DESCRIPTION

Specification for Turbo-Expander Turbo-Expander Recompressor Recompressor

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TABLE OF CONTENTS

1.0

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

2.0

CODES AND STANDARDS .............................................................................................................................. .............................................................................................................................. 7

3.0

ENVIRONMENTAL DESIGN CRITERIA ........................................................................................................... ........................................................................................................... 8

4.0

SCOPE OF SUPPLY ......................................................................................................................................... ......................................................................................................................................... 8

5.0

TECHNICAL.................................................................................................. ..................................................................................................................................................... ................................................... 10

6.0

MATERIALS.................................................................................................. ..................................................................................................................................................... ................................................... 21

7.0

DELIVERY ................................................................... ...................................................................................................................................... .................................................................................... ................. 24

8.0

SITE ACCEPTANCE TEST (SAT) AND COMMISSIONING ASSISTANCE ................................................... 30

9.0

GUARANTEE AND WARRANTY .................................................................................................................... .................................................................................................................... 30

10.0

SPECIAL TOOLS ............................................................................... ............................................................................................................................................. .............................................................. 31

11.0

HAZOP STUDY ......................................................... .............................................................................................................................. ...................................................................................... ................. 31

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

NGP-001-PCS-15.03-0002-04B

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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 this oil field. 1.2 Scope This Specification covers the minimum requirements for the design, supply, fabrication and testing of a radial-inflow, Turbo-Expander Recompressor in natural gas service, complete with controls, instrumentation, and auxiliaries for installation at NASHPA Gas Processing Plant. The Turbo-Expander Recompressor shall be mounted on a common base with all necessary auxiliary equipment. The Turbo-Expander Recompressor (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. The package shall contain the following equipment as a minimum: 

Turbo-Expander



Compressor



Lube oil and seal gas system

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


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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. 1.4.2 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. All deviations 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 Weekly, monthly and run summaries of all major aspects of t he 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 unit responsibility for the complete Turbo Expander Compressor Package and all ancillaries as described herein, in other attached specifications, data s heets 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,


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6 OF 31 PAGE 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 Turbo-Expander Recompressor Package shall be new, unused and of the required/specified grade. 1.9 Design Basis 1.9.1 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 Turbo-Expander Recompressor Unit. 1.10 Documentation 1.10.1Documents, 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

Alternate Length

in

Liquid Relative Density

sp gr T F/60 °F

Liquid Absolute Density

API and lb/gal @ 60 °F

Vapor Flowing Density

lb/ft³

Flowing Quantities Mass

lb/h

Vapor

ft³/s

Liquid

US GPM

Standard Quantities Vapor

MMSCFD at 60 °F and 14.65 psia

Liquid

bpd at 60 °F

Enthalpy

Btu/lb


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Description

Unit

Heat Rate

MM Btu/h

Electrical Power

kW

Electric voltage

Volts

Compression Power

kW

Time

Seconds, min, hours, days

Viscosity

cP

Concrete density

Pounds per cubic foot (pcf)

Concrete strength

Pounds per square inch (Ksi)

Steel Strength

Ksi

Instrument air volume flowrate

SCFM

1.10.3The 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. 1.10.4Variations from or additions to this specification shall be called to the attention of COMPANY / CONSULTANT and approved in writing by COMPANY / CONSULTANT prior to starting fabrication. 1.10.5Information for installation, operating, maintenance or inspection purposes shall be submitted to COMPANY / CONSULTANT.

2.0 CODES AND STANDARDS 2.1 Codes, Standards and Regulations The minimum requirements shall be in accordance with applicable portions of the latest editions of the following codes and standards: API 617

Centrifugal Compressors for General Refinery Services

API 614

Lubrication, Shaft Sealing and Control Oil Systems for Special Purpose Application

API 670

Non-contacting Vibration and Axial Position Monitoring System

API 615

Sound Control of Mechanical Equipment for Refinery Services

ASME Section VIII, Division I

Pressure Vessels

ASME Section IX

Welding and Brazing Qualifications

ASME B31.3

Process Piping

ASME B16.5

Pipe Flanges and Flanged Fittings

TEMA Class "R"

Tubular Exchanger Manufacturer's Association

2.2 In addition to the requirements of this General Specification, all requirements of the governing Statutory Authority, i.e., in the country and/or its subdivision where turbo-expander recompressor to be installed shall be met.


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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 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

Specification for Equipment with Low Temperature Service and

NGP-000-STA-15.03-0006-00

Their Materials of Construction Specification for Unfired Pressure Vessel

NGP-000-STA-15.03-0001-00

Specification for Structure Steel Works

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

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 SCOPE OF SUPPLY 4.1 General The Turbo-Expander Recompressor units shall be assembled, installed, functioning as the package. The package shall consist of, but not be limited to, the following items: turbine expander, coaxial centrifugal compressor, lube oil system, control system, seal gas s ystem and other auxiliary system necessary for the unit


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9 OF 31 PAGE running safety and continuously. 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. 4.2 Scope of Supply 4.2.1 VENDOR shall provide, but not limited to the following: 

The whole Turbo Expander Compressor Unit, ancillary facilities mounted on structural steel skid and

anchor bolts of skid base. 

Variable inlet guide vanes for the expander complete with air diaphragm actuator.



Inlet strainer, 60 mesh stainless steel, suitable for installation in VENDOR’s piping for minimum

pressure loss. 

Lubrication system complete with all controls and instrumentation.

Vendor shall provide Lube oil system and fault alarm, shut down system and oil cooling system. Oil cooler, oil separator, oil filter, oil pump, oil temperature control valve, accumulator, dismountable coalescer at the gas outlet of lube oil tank shall be furnished. 

Sealing gas and heating system.



Vibration monitoring system.



Fluid leakage control system.



Compressor inter-stage piping. (if required)



Surge control and/or capacity control system complete with all necessary instrumentation.



Expander inter-stage piping, including a liquid knockout drum, if required.



PLC based control panel with all necessary control instrumentation and accessories. This Control

Panel shall be interfaced with UCP of LPG Recovery Package, via serial interface. 

All necessary analyses and calculations for Turbo-Expander Recompressor Unit, including system

control recommendations for stable reduced load operations. 

Special non-sparking type tools needed for installation and maintenance.



Inspection and test reports.



Spare parts suitable for two year's continuous operation (including consumption of spare parts

required for annual survey and a list of wearing parts). 

First filling for all consumable such as grease, lube oil, fuse, etc. to be used during commissioning.



On skid piping and electric circuit.



Control system

Loose shipped instruments, such as pressure transmitter and temperature transmitter on expander outlet, pressure transmitter and temperature transmitter on compressor inlet, compressor inlet flow meter, recycle


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10 OF 31 PAGE valve. Differential pressure transmitters for expander inlet and compressor inlet filter. 

Overhaul/ Maintenance Spare parts.



Commissioning/ Start-up tools & spare parts.



Operation and maintenance manual of complete Turbo-Expander Recompressor Unit.



Process and utility control instrumentation system.



Complete load data required for foundation and anchor bolts design.



Quick closing shutdown valve on Expander inlet and outlet.



Complete process and utility piping within the package.



Inter-skid piping in case the package has more than one skid.



All shutdown Switchover / ON-OFF and control valves required for the successful operation of the

Turbo-Expander Recompressor Unit. 

3D model (.step file) for the whole Turbo-Expander Recompressor Unit shall be provided by VENDOR

and 3D model (.step file) is mandatory. 4.2.2 Vendor shall provide local PLC control panel for Turbo-Expander Recompressor unit, provide communication with UCP of LPG Recovery Package, local control panel shall be mounted on skid base. Spare parts for control system shall include controller module and I/O modules, push button, lamp, siren and light, vibration probe and CPU backup battery. 4.2.3 Vendor shall provide Turbo-Expander Recompressor unit inlet and outlet with matching flanges, bolts, nuts, gaskets, etc., 2 sets of all gaskets, bolts and nuts at least 10% spares. 4.2.4 Vendor shall provide a perfect self-protection measure for the unit protection while the unit is shut down because of fault. If the unit is damaged due to the imperfect self-protection measures, vendor must repair or replace the unit components for free and therefore in charge of all the consequences and responsibility. 4.2.5 Vendor shall design and supply the skids based on the utility supply. Any other equipment required will be Vendor’s scope of supply including MCC (located on the remotely electrical room) .etc.

5.0 TECHNICAL VENDOR shall furnish the Turbo Expander Recompressor Unit, controls, valves and auxiliaries in accordance with the requirements mentioned herein, other in project specifications, data sheets and P&IDs. VENDOR shall be fully responsible for the determination and application of the thermodynamic properties of the specified gas on the design features, as well as performance of the Turbo Expander Recompressor Package. VENDOR shall be directly responsible for ensuring the proper operation of any Sub- VENDOR’s ancillary equipment supplied with the equipment package. VENDOR’s on -site representative is expected to be fully knowledgeable of the equipment and shall be capable of trouble shooting and correcting problems should this equipment do not perform as per design specifications.


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11 OF 31 PAGE The expander-compressor package will be installed outdoor. Vendor shall design and fabricate the units to withstand all climatic conditions. The controls, control panel and all other parts of the unit shall be protected accordingly. 5.1 Gas Physical Properties Gas Analysis and the values of molecular weight, Cp/Cv and compressibility factor which may be shown on the applicable datasheet for the specified operating conditions are given to facilitate the Turbo Expander Compressor Package computations. The VENDOR shall independently compute the gas physical properties and take full responsibility for any Turbo Expander Compressor Package design features affected by the physical properties. VENDOR shall state the values for Cp/Cv and compressibility factors used in his computations. 5.2 Design 5.2.1 Expander The expander design shall be in accordance with the latest international standard design parameters and criteria. VENDOR shall ensure minimum leakage across the expander casing shaft seals. It is essential that there is no lubrication oil migration or blow-by along the shaft and into the process stream during normal operation or during abnormal conditions, which accompany process upsets and shutdowns. Bearings shall be located in a common housing. The expander casing end bearing shall be adequately buffered from freezing temperatures during all phases and conditions of operation. 5.2.2 Inlet Guide Vanes Air-diaphragm actuated variable inlet guide vanes shall be furnished for capacity control, responding to COMPANY / CONSULTANT’s signal as described in the applicable specification. An increase in the signal value shall increase expander capacity. The air diaphragm actuator shall be mounted at least three feet from the expander centre line and be provided with provision for purge gas at the actuator stem. 5.2.3 Seal System VENDOR shall furnish a float trap to separate seal gas from the Expander seal leak-off cavity from the bearing lube oil, and vent into the compressor suction piping or another acceptable delivery point. VENDOR shall provide connections for vent piping and furnish the seal system complete with 10-micron filter, control valves, instrumentation, and control system. A pressure switch shall actuate a low seal pressure alarm. During operating condition, controls for the float trap, seal supply and lube oil system shall be prevented from reverse flow from the trap and leak-off piping into the Expander-Compressor casing. Seal piping downstream of filter shall be 304SS. The sealing gas system shall consist of the sealing gas heater (if necessary) with auto control device, strainer, flow meter transmitter, block valve, temperature transmitter, pressure transmitter etc. 5.2.4 Lubrication


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12 OF 31 PAGE VENDOR shall furnish a suitable pressurized lubrication system. VENDOR shall provide two pumps (one operating and one standby) and lube oil tank along with all instrumentation and control system. The VENDOR shall make provision for prevention of bearing failure because of frozen lubrication medium. All piping connections shall be flanged. Lubrication piping downstream of filter shall be 304SS. Lubrication system 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. Air-Fan Cooler shall be provided. at Max. Ambient temperature 115°F, design temperature at 104 °F. Vendor shall guarante the equipment is sufficient for 115°F for short period of time (several hours at noon). 5.2.5 Base-plate All VENDOR furnished items shall be mounted to provide a single, complete package that is pre-wired, pre-piped, assembled and aligned. The base plate shall be a welded structural steel frame, designed and constructed to support all component parts, vibration free. The frame shall be sufficiently rigid to enable lifting from lugs only, without additional support, and with all supplied equipment mounted thereon. The Package Skid base shall be designed in accordance with the Specification for Skid Mounted Packages (NGP-000-PIP-15.03-0013-00). All members shall be braced and gusseted so that there will be no sagging or distortion of the unit. Skip or stitch welding is prohibited. The skid base frames shall be painted in accordance with the Specification for Coating and Painting (NGP-000-PAI-15.03-0001-00). 5.2.6 Levelling Unless otherwise specified, the base plate shall be provided with leveling pads protected with removable covers. The pads shall be accessible for field leveling after installation. 5.2.7 Lifting The base plate shall be sufficiently rigid to be lifted using a three point lift. Lifting lugs for three point lift shall be installed on the base. Lifting the base plate, complete with all equipment mounted, shall not permanently distort or otherwise damage the base plate or the mounted machinery. Each lug shall be designed to carry the total shipping weight of the unit. Slugs and shackles (certified) suitable for safe lifting of the package skid(s) along with the detailed lifting plan/study shall be provided with the unit. 5.2.8 Area Classification Refer to section 3.2 Area Classification. 5.2.9 Welding Welding procedure specifications, welders and welding operator shall be qualified in accordance with ASME Section IX. Welding Procedures Specifications, Procedure Qualification Records (PQR) and welder performance qualifications shall be available for COMPANY / CONSULTANT / CONTRACTOR’s review at all times.


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13 OF 31 PAGE Procedures for full penetration welds shall identify methods used to guarantee soundness at the weld root and shall include non- destructive testing sufficient to prove that welds are full penetration. Radiography or ultrasonic testing per ASME is permissible. Repairs shall be brought to the attention of the COMPANY / CONSULTANT / CONTRACTOR or his representative prior to actual repair. Extent and method of repair shall be agreed upon between COMPANY / CONSULTANT / CONTRACTOR and VENDOR. The

welding

procedure

shall

be

in

accordance

with

Specification

for

Production

Welding

(NGP-000-PIP-15.03-0017-00). 5.2.10 Low Temperature Minimum design metal temperatures and impact testing when required by the Code shall be in accordance with the applicable edition and addenda of ASME Section VIII. 5.2.11 Pressure Vessels All pressure vessels shall be designed, fabricated, inspected, tested and stamped in accordance with ASME

pressure

vessel

code

section

VIII

and

Specification

for

Unfired

Pressure

Vessels

(NGP-000-STA-15.03-0001-00). All carbon steel pressure vessels shall have a minimum 1/8 inch internal corrosion allowance. All pressure vessels’ design pressure shall be at least 10% above the maximum operating pressure or 14.5 psig plus maximum operating pressure, whichever the larger. The required design pressures, temperatures, dimensions, capacities and other data of pressure vessels shall be shown on Vendor’s drawings. Insulation clips (if required) shall be provided for all pressure vessels. 5.3 Materials 5.3.1 Material of Construction 5.3.1.1 The materials of construction for the major parts shall be as follows: 

Expander case: 304 stainless steel



Compressor case to be specified by VENDOR



Expander impeller to be specified by VENDOR



Compressor impeller to be specified by VENDOR



Expander casing joint gaskets to be specified by VENDOR



Nozzle segment to be specified by VENDOR



Shaft to be specified by VENDOR



Bearings to be specified by VENDOR



Inlet strainer: 304 stainless steel


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"O” rings Silicone type

5.3.1.2 No copper or copper bearing alloys except Monel, bearing Babbitt, or precipitation hardened stainless steels shall be used for any components of expander, accessories, instrumentation, and control air tubing. Copper may be used for control and power wiring as well as motor windings. 5.3.1.3 VENDOR shall provide the complete details of materials of construction along with the bid.

The

VENDOR shall specify the complete list of ASTM tests and inspection procedures necessary to ensure that all materials are satisfactory for the service. Such tests and inspections shall be listed in the bid. Positive material identification is required. 5.4 Dynamics 5.4.1 Lateral Analysis An undamped critical speed map shall be furnished with support stiffness curves for both minimum and maximum clearances superimposed on the plot. 5.4.2 Vibration and Balancing All major parts of the rotating element shall be individually, statically, and dynamically balanced. An assembly checks balance will be required. Care should be exercised in selecting a balance machine for a component such that the machine sensitivity is greater than the unbalance tolerance specified for that part. A four-point check is required to insure that the sensitivity meets the requirement of the particular component. Preferably the mandrels and balanced components shall be marked to permit selective fitting of the balanced parts of the shaft. The intent is to use selective fitting to cancel the influence of manufacturing tolerances on balance. Rotor balance shall be such that during shop test and operation at a maximum continuous speed, the peak-to-peak unfiltered displacement measurement in any plane measured on the shaft adjacent to the bearing housing shall not exceed 0.6 mil not including in phase mechanical and electrical runout. These runouts may be vectorially added if their values are determined by slow roll at the time of the test. Total runout allowance shall not exceed 0.2 mil. 5.5 Auxiliary Piping and Tubing 5.5.1 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.


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

5.5.2 VENDOR shall furnish all auxiliary piping with its mounted appurtenances located within the confines of Turbo Expander Recompressor 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. 



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.

5.6 Instrumentation & Control Instrumentation & Control on the Turbo-expander compressor unit shall conform to specification for instrumentation for packaged unit (NGP-000-INS-15.03-0004-00). All requirements mentioned there-in shall remain applicable on Turbo-expander compressor as part of LPG Recovery Unit. The following clauses are meant to define requirements specific to turbo-expander compressor unit. 5.6.1 Process Control Instrumentation VENDOR shall supply and install all primary sensing instrumentation for monitoring and controlling the process. This shall include all transmitters, switches, valves, gauges including compressor surge control instrumentation and by- pass valve and any other instruments deemed necessary to monitor and control the equipment to meet the process requirements. The expander inlet nozzle control signal will come from a pressure controller. The expander nozzles should stroke from full closed to full open with this 3-9 psig signal, subject to confirmation by COMPANY / CONSULTANT / CONTRACTOR. A manually adjustable regulator for each expander in series with this process controller signal and the nozzle actuator shall be supplied on the control panel. Pressure gauges for process controller output and signal to the nozzle actuator shall be provided. CONTRACTOR/VENDOR shall provide PSLL on inlet of TE-2401 (if pressure low low, trip TE-2401) and PSHH on inlet of TER-2401 (if pressure high high, trip TER-2401). 5.6.2 Lube Oil and Seal Instrumentation The VENDOR shall supply and install all primary sensing instrumentation for monitoring and controlling the lube oil and seal systems. VENDOR shall evaluate the complete applications and shall propose the most appropriate type of seal system. This shall include all transmitters, switches, valves, gauges and any other instruments deemed necessary to monitor and control the lube oil system to meet the equipment operational requirements.


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16 OF 31 PAGE Local mounted thermometers shall be provided before and after the lube oil cooler and in each machine's lube oil drain. A seal gas supply differential pressure regulator and pressure gauge shall be supplied for each seal gas pressure level required. Also, supply low seal gas differential pressure switch and alarm for each pressure level. Lube oil reservoir shall have a reflex type level gauge. 5.6.3 Speed Control Instrumentation The VENDOR shall supply and install all primary sensing instruments to provide a speed measurement system complete with sensor, local tachometers, transmitters including over-speed alarm and shutdown switches. 5.6.4 Vibration Monitoring System VENDOR shall supply and install vibration monitoring instrument for safe operation of Turbo-Expander Compressor and shall transmit signal to local PLC base control panel (LCP). The vibration system shall be a Bentley-Nevada series 3300 system or equipment. The system shall be installed as per API 670. 5.6.5 Temperature Monitoring A bearing temperature indicator shall be supplied for each bearing. Each bearing shall have a high temperature alarm switch and a high temperature shutdown switch. Each expander end bearing temperature indicator shall also have a low temperature switch, which must be satisfied before the unit can be started. VENDOR shall supply RTD's to monitor bearing oil temperature. This will be wired to unit (PLC based) control panel (LCP). Local temperature indicators shall be bi-metal thermometers with 5" dials, hermetically sealed stainless steel construction. All temperature instrument bulbs and dial thermometers shall be installed in drilled stainless steel wells. 5.6.6 Local Control Panel VENDOR shall supply dedicated PLC for Turbo Expander-Compressor. This unit PLC will be termed as Local Control Panel (LCP) and shall form a part of the main Unit Control System (specified for the overall control, monitoring and safety of LPG Recovery of which Turbo-expander is a part). 

This LCP shall be responsible for entire control, monitoring, alarm and shutdown of the

Turbo-Expander Recompressor unit. 



All instrumentation on Turbo-expander recompressor shall be connected to this LCP’s IOs. This LCP shall be connected to Package UCP through Modbus Serial Link for communication of key

process data, alarm etc. to UCP. 

LCP shall also be responsible to shutdown the Turbo- expander compressor unit on any major upset


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17 OF 31 PAGE within the unit or on command from ESD (through hard-wired IOs). 

Turbo-expander compressor’s control panel (LCP) shall be suitable for installation in hazardous area

classified as section 3.2. 

LCP shall also include marshalling terminals/panel and local annunciation.



LCP shall be supplied power through COMPANY / CONSULTANT / CONTRACTOR ’s UPS System at

230V AC, single phase, 50Hz. VENDOR shall be responsible for converting into any other voltages required for the system. VENDOR shall furnish a field mounted first-out annunciator for alarms and shutdown in PLC based Control Panel. Annunciators will be by-passed only for the purpose of preset time lockout for use on certain shutdown devices during startup and manual test. The control panel (LCP) shall include an interlock system which prevents energizing the expander inlet block valve solenoids until all operating conditions are safe for expander start-up. All shutdown conditions must be cleared to permit starting of each expander-compressor unit. The following indicators shall be provided on the control panel as a minimum: 

Tachometer for each machine.



Vibration indicator for each machine.



Bearing temperature indicator for each bearing.

The alarm and shutdown system shall include the necessary devices, alarm lights and circuitry for first out annunciation and/or shutdown for the following malfunction (as a minimum): 

High screen DP, expander and compressor-alarm



High thrust-shutdown for each machine, either direction



Low seal gas pressure-alarm for each supply pressure



High bearing temperature-alarm and shutdown, each bearing



High vibration-alarm and shutdown, each machine



High lube oil cooler outlet temperature-alarm



Low lube oil supply pressure upstream of accumulators- alarm and start auxiliary pump, shutdown



Auxiliary pump on-alarm



Low lube oil pressure to each machine-shutdown



Low reservoir oil level-alarm and heater shutdown



Low expander end bearing temperature-shutdown, each machine



Over speed-alarm and shutdown, each machine

Note:


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18 OF 31 PAGE All the above malfunction conditions associated with a machine must be cleared before the inlet block valve solenoid for the machine can be energized. The control panel shall include status lights for following as a minimum: 

Lube oil pump running



Heater on



Expander ready



Expander solenoid energized

The panel shall contain test, reset and silence switches on the front of the panel. Alarm signals shall be "locked-in" until acknowledged with "first out" sequencing provided for all points. Manual reset or time delay shall be provided on shutdown devices where necessary for start-up 5.6.7 F&G Detectors The

F&G

detectors

requirements

in

specification

for

instrumentation

for

packaged

unit

(NGP-000-INS-15.03-0004-00) shall be applicable for Turbo-Expander Recompressor unit. 5.7 Electrical All electrical equipment, apparatus, materials and installation shall be 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). 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. The electricity supply for the motor is 400V, 3 phase, 50Hz, meanwhile for space heater, lighting fixture and other device is 230V, single phase, 50Hz. Space heater shall be provided for motors ( ≥75kW), the space heater shall be energized while motors are stopped. The space heaters leads shall be brought out into a separate terminal box from the motor main terminal box. MCC (including the motor starter) will be remotely mounted and supplied by Vendor (Generally, following criteria shall be followed for selection of starter type for motors: All motors below 37KW shall be Direct-on-line starting; All motors between 37KW and 100KW shall have Star/Delta starter; Motor above 100KW shall have Soft starters) and be installed in the MCC. All inter-connecting wiring and cabling within the equipment skid shall be provided by the VENDOR. Low voltage electrical wiring shall have multi-stranded copper conductors, continuously tinned, 0.6/1kV Cu/XLPE/PVC/SWA/PVC . Vendor shall provide the HOA switch and the junction box (include the relay, if required). All gauges, emergency stop buttons, etc., shall be fully visible and accessible from outside the enclosure.


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19 OF 31 PAGE 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. 5.8 Drawing, Calculations and Documentation VENDOR shall provide all information specified in VENDOR Data Requirements Schedule supplied with the requisition documentation. In addition, VENDOR shall provide a comprehensive operations & Maintenance Manual to cover the entire supplied system. The manual will include but not limited to the following details: 

Detailed PFD & P&IDs of complete Turbo-Expander Recompressor Unit



Unit layout



Anchor bolt plan



Details of process and vent gas, lube & oil piping etc.



Skid layout of motor, Turbo- Expander Recompressor Unit, vessels, piping and auxiliaries



Detailed panel schematic



Mechanical flow drawings of all packaged systems



Skid structural design



Piping layouts and details of the complete Unit



Isometrics of the complete Unit



Description of individual equipment & components



Description of control system



Step-wise start-up, purging, and shutdown procedures



Pre-start-up checklists



Thermal growth information for start up alignment



Maintenance & lubrication schedules


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

Emergency shutdown & re-start procedures



Relief valve set pressure schedule



Performance simulations for various operating conditions along with capacity control adjustments



Cause & effect charts / schedule



Process / General arrangement drawings



Control panel wiring details, logic diagrams and tubing schematics



Cable layout plan on Skid



ISA data sheets for all VENDOR’s supplied instruments



List of recommended start-up, two years operation and overhaul spares for Turbo-Expander Recompressor Unit.



Data sheets of vessels, control valves & instruments.



General arrangement showing skid dimensions, connection sizes and locations, and general configuration of all equipment supplied, with operating/erection weights.



Equipment details and internal components suitable to assist VENDOR in installation re-assembly, operation, maintenance and troubleshooting.



Furnish a curve of rated load plotted against speed for the thrust bearing being furnished. On the curve shall be plotted the expected actual load imposed on the thrust bearing by all operating conditions specified.



Supply sufficient information to permit the COMPANY / CONSULTANT / CONTRACTOR or others designated by COMPANY / CONSULTANT / CONTRACTOR to check the system critical and rotor response characteristics or rotor dynamics. This requirement does not relieve VENDOR of any design responsibility.



Wiring diagrams shall plainly indicate connections for remote cabling.



Drawings shall show the location and connection of all instruments, identified with alpha-numeric tag numbers. The drawings shall identify VENDOR furnished instruments.



Furnish a bill of material listing all components and instrument range as a minimum. The location of the item shall be noted by name or as part of a subassembly.



Provide a detailed drawing indicating exactly how the RTD’s and proximity probes are to be mounted and their location.



Provide a document as an outline of the degree of field assembly and erection required, such as rotors in or out, seals in or out, degreasing required, etc. This description shall be sufficient to permit an estimate of field assembly labor and materials to place the unit in operation.

VENDOR shall make detailed calculations and shall prepare detailed shop drawings.


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21 OF 31 PAGE VENDOR shall concurrently submit to COMPANY / CONSULTANT / CONTRACTOR, fabrication drawings and detailed calculations for approval in accordance with the requisition. Shop details shall be complete with all dimensions. The assembly drawings shall contain all pertinent information relating to the standards, codes and specifications used in the design, fabrication, inspection and testing of the equipment, including the materials used, plus the total weight. Review of drawings, calculations and other documents by COMPANY / CONSULTANT / CONTRACTOR does not relieve VENDOR’s responsibility for the suitability of the design to suit the stated conditions. 5.9 Noise Noise limitations shall be less than 85dBA at 1 meter distance from the Turbo-Expander Recompressor unit. 5.10 Painting The complete unit shall be thoroughly cleaned and painted in accordance with the Specification for Coating and Painting(NGP-000-PAI-15.03-0001-00). Surface preparation, primer, paint and paint color shall be manufacturer's standard unless otherwise specified. 5.11 Nameplate Each main item of equipment of the package (e.g. Turbo-expander recompressor, gearbox) 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) 

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)

6.0 MATERIALS


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PAGE 6.1 Materials in Compressor for Cold Service

TABLE – 1 Compressors with minimum operating temperature ≥ 0 °C Material of Pressure Containing Parts

Lower Design Temperature (ABP/AFT

Remarks

of Contents)

Carbon steel or

-30 °C

Design stresses in accordance with ASME

nodular cast iron

code -50 °C

Design stresses 50% of allowable by ASME code

LT30

-50 °C

Design stresses in accordance with ASME code

-80 °C


Legend:

1)

LT = Low Temperature

2)

LT 20 = Material impact tested at -20

℃

3)

LT 30 = Material impact tested at -30

℃

NOTES: 1.

All compressor materials shall be properly heat treated, i.e. normalized, and tempered, or quenched and tempered. Post Weld Heat Treatment (PWHT) shall be applied after welding.

2.

Materials with a nominal wall thickness below 6 mm are exempted from impact testing, if permitted by the ASME code.

3.

For reciprocating compressors, grey cast iron is considered acceptable.


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TABLE – 2 Compressors with minimum operating temperature below 0 °C Material of Pressure Containing Parts

Lower Design Temperature (ABP/AFT

Remarks

of Contents)

LT0

-50 °C


LT30

-50 °C


-80 °C


LT80

-100 °C


-130 °C


LT100

-120 °C


-150 °C


Legend:

1)

LT0

- Material impact tested at 0 ºC

2)

LT 80 - Material impact tested at -80 ºC

3)

LT 100 - Material impact tested at -100 ºC

NOTES:

1.

All compressor materials shall be properly heat treated, i.e. normalized and tempered, or quenched and tempered. PWHT shall be applied after welding.

2.

Materials with a nominal wall thickness below 6 mm are exempted from impact testing, if permitted by the ASME code.


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24 OF 31 TABLE – 3

Compressors Made of Austenitic Materials Material of

Lower Design

Pressure Containing

Temperature (ABP/AFT

Parts

of Contents)

Ductile austenitic cast iron (ASTM A-571)

-150 °C


-180 °C


-200 °C


LT196

Legend:

Remarks

LT 196 – material impact tested at -196 ºC

7.0 DELIVERY 7.1 Inspection and Testing 7.1.1

General

Inspection and testing shall also be carried out at VENDOR's works, and shall be witnessed by COMPANY / CONSULTANT / CONTRACTOR's authorized and/or certifying authority, if required. The responsibility for inspection rests with VENDOR. However, COMPANY / CONSULTANT / CONTRACTOR and their authorized representatives reserve the right to inspect the equipment at any time during fabrication to ensure that materials and workmanship are in accordance with this specification, project specifications, equipment data sheets and P&IDs. VENDOR shall provide a projected shop schedule with appropriate fabrication stages at the time drawings are submitted for approval, to highlight the inspection activity schedule. The approval of any work by COMPANY / CONSULTANT / CONTRACTOR, or their authorized representative, shall in no way relieve the VENDOR of any responsibility for carrying out the provisions of this specification. 7.1.2

Inspection 7.1.2.1

General

VENDOR shall keep the following data available for examination by COMPANY / CONSULTANT / CONTRACTOR or his representative upon request. VENDOR shall compile these documents in the form of a dossier and shall submit to COMPANY / CONSULTANT / CONTRACTOR for their record and reference. 

Necessary certification of material, such as mill test reports.



Purchase specifications for all items on bills of materials.



Test data to verify that the requirements of the specification have been met.


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

Results of quality control tests and inspections.



Final assembly maintenance and running clearances.

Pressure-containing parts shall not be painted until the specified inspection or test of the parts is completed. VENDOR will specify the following with written approval of COMPANY / CONSULTANT / CONTRACTOR: 

Parts that shall be subjected to surface and subsurface examination.



The type of examination required, such as magnetic particle, liquid penetrant, radiographic and

ultrasonic examination. 7.1.2.2

Material Inspection

When radiographic, ultrasonic, magnetic particle or liquid penetrant examination of welds or materials is required or specified, the procedure and acceptance criteria in the following paragraphs shall apply, except as noted. 

Radiographic examination shall be in accordance with Section VIII, Division I, UW-51 (100%) and

UW-52 (spot) of the ASME Code. Spot radiography shall consist of a minimum of one 6" spot radiograph for each 25 feet of weld on each casing. As a minimum, one spot radiograph is required for each welding procedure and welder used for pressure containing welds. With COMPANY / CONSULTANT / CONTRACTOR’s approval, ultrasonic may be used in lieu of radiographic. 

Ultrasonic examination shall be in accordance with Section VIII, Division I, UW-53 and Appendix 12 of

the ASME Code. 

Magnetic particle examination shall be in accordance with Section VIII, Division 1, UW-50 and UG-100

of the ASME Code. 

Liquid penetrant examination shall be in accordance with Section VIII, Division I, UW-50 and UG-100

of the ASME Code. Fully identified records of all heat treatment and radiography, whether performed in the normal course of manufacture or as part of a repair procedure, shall be kept available for 5 years for review by the COMPANY / CONSULTANT / CONTRACTOR and shall be submitted to COMPANY / CONSULTANT / CONTRACTOR for reference and record. Cast steel casing parts shall be examined by magnetic particle methods. Acceptability of defects shall be based on a comparison with the photographs in ASTM E125. For each type of defect, the degree of severity shall not exceed the following limits: Type

Degree

I

1

II

2

III

2

IV

1

V

1


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Type

Degree

VI

1

Regardless of these generalized limits, it shall be VENDOR's responsibility to review the design limits of all castings in the event more stringent requirements are specified. Defects that exceed the limits imposed above shall be cleaned out to meet the quality standards cited above, as determined by additional magnetic particle examination, before repair welding. Forgings used for expander-compressor shafts and integrally forged disks shall be inspected by ultrasonic methods per ASTM A418. Within 15 calendar days of the final successful tests, VENDOR must send to COMPANY / CONSULTANT / CONTRACTOR one original, eight (8) hard and three (3) soft copies of all material and test certificates. 7.1.2.3

Mechanical Inspection

During assembly of the Turbo-Expander Recompressor Unit and before testing, each fixed component, including cast-in passages of these components and all piping and appurtenances, shall be cleaned by chemical pickling or by another appropriate method to remove foreign materials, corrosion products and mill scale. Any portion of the oil system furnished with the expander shall meet the cleanliness requirements of API Standard 614. COMPANY / CONSULTANT / CONTRACTOR shall inspect for cleanliness of the equipment and all piping and appurtenances furnished by or through VENDOR before final assembly of piping or closure of openings. COMPANY / CONSULTANT / CONTRACTOR’s representative shall have access to VENDOR's quality-control program for review. 7.1.3

Testing 7.1.3.1

Hydrostatic Test

Pressure containing parts (including auxiliaries) shall be tested hydrostatically with non-flammable liquid at a minimum of 1½ times the maximum allowable working pressure but not less than 20 psig. The test liquid shall be at a higher temperature than the nil ductility transition temperature of the material being tested. If the part tested is to operate at a temperature at which the strength of a material is below the strength of that material at room temperature, the hydrostatic test pressure shall be multiplied by a factor obtained by dividing the allowable working stress for the material at room temperature by that at operating temperature. The stress values used shall conform to those given in ANSI/ASME B31.3 for the vessels. The pressure thus obtained shall be the minimum pressure at which the hydrostatic test shall be performed. VENDOR shall list on the Data Sheets actual hydrostatic test pressures. Where applicable, tests shall be in accordance with ANSI/ASME B31.3 Code. In the event that a discrepancy exists between the code test pressure and the test pressure in this standard, the higher pressure shall govern.


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27 OF 31 PAGE The chloride content of liquids used to hydrotest austenitic stainless steel materials shall not exceed 30 parts per million. To prevent disposition of chlorides as a result of evaporative drying, all residual liquid shall be removed from tested parts at the conclusion of the test. Tests shall be maintained for a sufficient period of time to permit complete examination of parts under pressure. The hydrostatic test shall be considered satisfactory when neither leaks nor seepage through the casing or casing joint is observed for a minimum of 60 minutes. Larger, heavy castings may require a long testing period to be agreed upon by COMPANY / CONSULTANT / CONTRACTOR and VENDOR. Seepage past internal test closures, required for testing of segmented cases, and operation of a test pump to maintain pressure is acceptable. Use of a sealant compound on the casing joints is acceptable during hydro test. 7.1.3.2 Over-speed Test The Turbo-Expander Recompressor Unit shall be given a mechanical run test with contact lubrication, seal and instrumentation systems. The test shall be in accordance with manufacturer's standard practice and include the uninterrupted run for a period of four hours at rated speed. VENDOR shall comment in the proposal on need to use dummy fluid during mechanical run test. The test shall confirm the quoted values of speed, power absorption, differential temperature, compressor heat and capacity, and sound levels. Bearing RTD temperatures and vibration levels shall be monitored and reported. The speed controller shall be tested and the operation of the emergency over-speed trip system verified. An oscilloscope should be used for vibration analysis during the test and the traces photographed. Vibration amplitude versus frequency plots at maximum continuous speed and vibration amplitude versus speed plots shall be made from zero to trip speed. VENDOR shall determine and report on the significant vibrational modes and resonant frequencies existing in the expander-compressor steel. If such resonance is indicated for rotational speeds at or below 125 percent of the over-speed trip setting, VENDOR shall modify the design to avoid any operational restraints. All test data such as over-speed trip setting, vibration measurements and bearing oil temperature data shall be recorded and the required number of certified copies of the test data supplied to COMPANY / CONSULTANT / CONTRACTOR. VENDOR shall provide details of wheel natural frequency prediction and testing. VENDOR shall provide a tape recording of vibration amplitudes at the test stand, utilizing the package vibration monitoring equipment. All joints and connections shall be checked for tightness and any leaks shall be corrected. The vibration characteristics determined by the use of instrumentation specified in section 5.6 shall serve as the basis for acceptance or rejection of the machine. The following requirements shall be met after the mechanical run test is completed:




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Hydrodynamic bearings shall be removed, inspected and reassembled after the mechanical running

test is completed. 

If replacement or modification of bearings or seals or dismantling of the case to replace or modify other

parts is required to correct mechanical or performance deficiencies, the initial test will not be acceptable and the final shop test shall be run after these replacements or corrections are made. When spare rotating sections are ordered to permit concurrent manufacture, each spare rotating section shall also be given a mechanical running test in accordance with the requirements of this specification. 7.2 Preparation for Shipping VENDOR shall furnish shipping preparation procedures to COMPANY / CONSULTANT / CONTRACTOR for review with the proposal. VENDOR shall provide corrosion inhibitor protection for all internal and external machine parts for sea shipment and six months outdoor storage. 7.2.1 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. 7.2.2 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. 7.2.3 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: 

Exterior machined surfaces shall be coated with suitable rust preventive.



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. 

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. 

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. 

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. 

Lifting points and lifting lugs shall be clearly identified.



The equipment shall be identified with item and serial numbers. Material shipped loose or separately

shall be identified with securely affixed, 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.




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Exposed and shaft couplings shall be wrapped with waterproof, moldable waxed cloth or vapour phase

inhibitor paper. The seams will be sealed with oil-proof adhesive tape. 7.2.4 Auxiliary piping connections furnished on the purchased equipment shall be impression stamped or permanently tagged to agree with VENDOR's connection table or general arrangement drawing. Service and connection designations shall be indicated. 7.2.5 One copy of VENDOR’s standard installation instructions shall be packed and shipped with the equipment. 7.3 Information to be Supplied with Bid Package VENDOR shall include the following data and drawings in the bid:

a)

Completed Data Sheets

b)

Process flow diagrams

c)

General arrangement drawing with operating/erection weights

d)

Catalogue data

e)

Unit performance data for all specified conditions

7.4 Information Required from Successful Bidder 7.4.1 General All VENDOR's drawings and data shall be identified with the unit tag number and purchase order number. 7.4.2 Drawing and Data Furnish a complete set of drawings as follows: 

P&ID's showing line specifications, equipment design parameters, instruments, etc.



General arrangement showing skid dimensions, connection sizes and locations, and general

configuration of all equipment supplied, with operating/erection weights. 

Equipment details and internal components suitable to assist CONTRACTOR in installation

re-assembly, operation, maintenance and troubleshooting. 

Specify the maximum forces and moments that can be imposed by CONTRACTOR's piping on the

units. 

Furnish a list of piping, wiring and utility connections, including type, size and functional description.



Furnish a curve of rated load plotted against speed for the thrust bearing being furnished. On the curve

shall be plotted the expected actual load imposed on the thrust bearing by all operating conditions specified. 

Supply sufficient information to permit the Contractor or others designated by CONTRACTOR to check

the system critical and rotor response characteristics or rotor dynamics. This requirement does not relieve VENDOR of any design responsibility.


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

Wiring diagrams shall plainly indicate connections for remote cabling.



Drawings shall show the location and connection of all instruments, identified with alpha-numeric tag

numbers. The drawings shall identify VENDOR and CONTRACTOR furnished instruments. 

Furnish a bill of material listing all components and instrument range as a minimum. The location of the

item shall be noted by name or as part of a subassembly. 

Provide a detailed drawing indicating exactly how the RTD's and proximity probes are to be mounted

and their location. 

Provide a document as an outline of the degree of field assembly and erection required, such as rotors

in or out, seals in or out, degreasing required, etc. This description shall be sufficient to permit an estimate of field assembly labor and materials to place the unit in operation. 

Indicate the approximate size and weight of each major component to be shipped. Balance point

should also be indicated. 

Indicate the expected sound levels emanating from the unit measures on the a-weighted scale at a

distance of 1 m. 7.4.3 Operating and Maintenance Manuals Ten (10) sets of operating and maintenance manuals shall be provided to enable CONTRACTOR to install, operate and maintain the complete equipment ordered. VENDOR list shall show original manufacturer and local representative name, address and phone number for each item not manufactured by VENDOR. The information and material supplied shall pertain directly to the unit purchased. Generalized or typical material shall not be included. 7.5 Spare Parts VENDOR shall submit a priced list of recommended two years spare parts (optional) with his proposal. This list shall include original manufacturer and local representative name, address and phone number for each item.

8.0 SITE ACCEPTANCE TEST (SAT) AND COMMISSIONING ASSISTANCE VENDOR shall be responsible to undertake a SAT prior to the commissioning and pre-commissioning activities. It is also envisaged that VENDOR’s expert(s) will be required to assist during pre -commissioning and commissioning of the equipment at the time of plant start-up. The duration of the stay is expected to be about four (4) weeks. VENDOR’s expert(s) will be also required to train (Classroo m and field training) COMPANY / CONSULTANT / CONTRACTOR’s operations and maintenance personnel. All costs associated to the logistics required to perform these activities shall be included in the bid price. COMPANY / CONSULTANT / CONTRACTOR will reimburse only local transportation at actual costs.

9.0 GUARANTEE AND WARRANTY The warranty shall be for a period of 18 months from date of initial commissioning or for a period of not less than 24 months from date of shipment/dispatch, whichever is earlier. VENDOR will warrant the equipment to be

NGP 001 PCS 15.03 0002 04B_00_Specification for Turbo Expander Recompressor

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