DHG PVE DD 3 ME SPC 007_Spec for Gas Engine Screw Compressor Package

8/10/2019 DHG PVE DD 3 ME SPC 007_Spec for Gas Engine Screw Compressor Package

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PETROVIETNAM DOMESTIC EXPLORATIONPRODUCTION OPERATINGCOMPANY LIMITED

PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINESCREW COMPRESSOR PACKAGE

A 23/05/14 Issued for Review

Rev. Date Description PVEVSP

ApprovalPVEP POCApproval

CAApproval

EpCI CONTRACTOR

(VIETSOVPETRO JOINT VENTURE)

Document Number:

DHG-PVE-DD-3-ME-SPC-007

Number of pages: 61

(including the cover page)


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PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINE

SCREW COMPRESSOR PACKAGE

A 23/05/14Issued for

ReviewN.T.K.Ngoc V.T.Quan D.T.Dung V.V.Hung

Rev. Date Description

Prepared

by

Checked

by EM PM Discipline

Team

Leader SPMB

Sub-Contractor EpCI Contractor

EpCI CONTRACTOR(VIETSOVPETRO JOINT VENTURE)

PV ENGINEERING J.S.C

Document Number:

DHG-PVE-DD-3-ME-SPC-007


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DAI HUNG GAS GATHERING PROJECT

DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREWCOMPRESSOR PACKAGE

Doc No: DHG-PVE-DD-3-ME-SPC-007 Rev. A Page 3/61

REVISION LOG

Date

Revision

No. Section Revision Description

23/05/14 A All Issued For Review


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TABLE OF CONTENTS

1.

INTRODUCTION ...................................................................................... 9

1.1

Project Overview ..................................................................................... 9

1.2

Purpose of Document ............................................................................ 10

1.3 Definitions and Abbreviations ................................................................. 10

1.3.1 Definitions ................................................................................. 10

1.3.2

Abbreviations ............................................................................ 11

1.4 Codes and Standards ............................................................................. 12

1.5 References ........................................................................................... 14

2.

GENERAL REQUIREMENTS ..................................................................... 14

2.1 CONTRACTORS Responsibility ................................................................ 14

2.2

Operation and Design Life ...................................................................... 15

2.3

CONTRACTORs Exceptions .................................................................... 15

2.4 Weight Control ...................................................................................... 16

3. LOCATION AND ENVIRONMENTAL CONDITIONS ..................................... 16

4. UTILITY DATA ...................................................................................... 17

4.1

Electrical ............................................................................................... 17

4.2

Instrument air: ...................................................................................... 17

4.3 Fuel gas ............................................................................................... 17

4.4 Units .................................................................................................... 18

5.

SCOPE OF WORK & SUPPLY ................................................................... 18


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6. DESIGN REQUIREMENTS ....................................................................... 21

7.

ENGINE AND AUXILIARIES ..................................................................... 21

7.1 General ................................................................................................ 21

7.2

Intake Air System .................................................................................. 22

7.3

Starting System ..................................................................................... 23

7.3.1 Electric Starting System .............................................................. 23

7.3.2

Hydraulic Starting System ........................................................... 24

7.4

Fuel Gas Treatment Package .................................................................. 25

7.5 Lubrication System ................................................................................ 25

7.6 Cooling System ..................................................................................... 27

7.7

Governor .............................................................................................. 27

7.8 Engine Exhaust System .......................................................................... 28

7.9

Insulation ............................................................................................. 29

7.10 Engine Shutdown Devices ...................................................................... 29

7.11 Engine Instruments Panel ...................................................................... 29

7.12 Ignition System ..................................................................................... 30

7.13 Over-speed Protection ........................................................................... 31

7.14

Torsional Vibration ................................................................................ 31

7.15

Lateral Vibration and Vibration Suppression ............................................. 31

7.16

Shaft Couplings and Guards ................................................................... 32

7.17

Crankcase Explosion Relief ..................................................................... 32

7.18 Miscellaneous Requirements ................................................................... 32


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8. GAS COMPRESSOR ................................................................................ 33

8.1

General ................................................................................................ 33

8.2 Compressor Performance ....................................................................... 34

8.3 Compressor Construction ....................................................................... 35

8.3.1

Materials of Construction ............................................................ 35

8.3.2

Bearings ................................................................................... 35

8.3.3 Compressor Rotor ...................................................................... 35

8.3.4

Coupling and Guard ................................................................... 35

8.3.5

Casing ...................................................................................... 36

8.3.6

Shaft seals ................................................................................ 36

8.3.7

Miscellaneous ............................................................................ 36

8.4 Auxiliary Systems .................................................................................. 37

8.4.1

Cooling Systems ........................................................................ 37

8.4.2

Lubrication System .................................................................... 38

8.4.3 Gas Scrubbing and Filtration ....................................................... 39

8.5 Pulsation, Vibration Control and Analog Study .......................................... 41

9.

TECHNICAL REQUIREMENTS FOR ELECTRICAL ........................................ 41

10.

TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL .... 43

10.1

General Instrumentation Requirements ................................................... 43

10.2 General Control Requirements ................................................................ 44

10.3 Unit Control Panel (UCP) ........................................................................ 44

10.4

Interface with Platform PCS/SSD/FGS System .......................................... 48


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10.4.1 PCS ........................................................................................ 48

10.4.2 SSD ........................................................................................ 48

10.4.3 FGS ........................................................................................ 48

10.5 Vibration Monitoring .............................................................................. 49

10.6 Bearing Temperature Monitoring System ................................................. 49

11.

PIPING ................................................................................................. 50

11.1

Valves .................................................................................................. 50

11.2

Piping and Accessories ........................................................................... 51

11.3

Welding and Weld Repairs ..................................................................... 51

12. UTILITIES & TIE-INS ............................................................................. 52

12.1 Utilities ................................................................................................. 52

12.2 Tie-Ins ................................................................................................. 52

13.

EQUIPMENT TAGGING AND NAMEPLATES ............................................... 52

14. INSPECTION AND TESTING ................................................................... 53

15. QUALITY CONTROL PROGRAM ............................................................... 53

16. PRODUCTION INSPECTION .................................................................... 53

17.

CONTROL FUNCTIONAL TEST ................................................................ 54

18. MECHANICAL RUN TESTS ...................................................................... 54

19.

PERFORMANCE/ FACTORY ACCEPTANCE TEST (FAT) ............................... 54

20.

FIELD TESTS ........................................................................................ 56


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21. CERTIFICATION .................................................................................... 57

22.

SPARES AND SPECIAL TOOLS ................................................................ 58

22.1 Spare Parts ........................................................................................... 58

22.2

Special Tools ......................................................................................... 58

23. PREPARATION FOR SHIPMENT ............................................................... 58

24. DOCUMENTATION ................................................................................. 59

25.

GUARANTEES ........................................................................................ 60

26. PROTECTIVE COATING .......................................................................... 61

27. TRAINING (OPTION) ............................................................................. 61


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1.

INTRODUCTION

1.1

Project OverviewDai Hung Field is located at Block 05-1a at North-West of Nam Con Son basin

within South-East continental shelf, Viet Nam, 260km far from Vung Tau

seashore. This field was discovered in 1988 by DH-1X.

In 2011, WHP-DH2 with existing system is operated to increase the capacity of

associated gas up to 1 MMSCMD. Besides the associated gas there is

considerable volume of natural gas located in bottom and middle of Mioxen

layer.

The overall Dai Hung Gas Gathering Project as show in figure 1 below:

Figure 1: Block Diagram Dai Hung Gas Gathering System

Modifying WHP-DH2 and installation pipeline between WHP-DH2 and BK-TNG

is to gather and transport 1.9 BMSCM of associated gas at outlet of HHP

Separator and Test Separator of WHP-DH2 to BK-TNG platform. Gas from

WHP-DH2 shall be transported to TEG skid on BK-TNG platform before being

routed to NCS2 gas pipeline phase 1.


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Preliminary configuration of Dai Hung Gas Gathering Project is as follows:

On WHP-DH2: Gas Cooler, Gas Scrubber, Gas Engine Generator, Corrosion

Inhibitor Injection Skid, Electrical System, Instrumentation System, Fuel

Gas System, Fire Fighting System, Telecommunication System and other

Utility Systems.

The 16 subsea gas pipeline (approximately 20 km) from existing 10 riser

at WHP-DH2 to BK-TNG Platform and 16 Y-Tee for future connection.

On BK-TNG Platform: 16 Riser, Slug Catcher, DH Gas Custody Metering

System, DH Gas Compressor Suction Scrubber, DH Gas Compressor

Package, DH Gas Compressor After Cooler, Fuel Gas System, Piping

System, Instrumentation System, Telecommunication System, Open/Closed Drain System, and other Utility Systems.

1.2

Purpose of Document

This document, together with the project data sheets provided separately,

defines the minimum requirements for supply, engineering, mechanical design,

performance guarantee (where specified), materials, fabrication, inspection,

testing, certification, painting, preparation for shipment, packing, forwarding,

transport and documentation for the Gas Engine Screw Compressor Package to

be installed as part of the Thien Ung Platform.

The CONTRACTOR shall ensure that all equipment and services supplied meet

the requirements of this specification, the project data sheets, codes and

standards and specifications specified herein, whether CONTRACTOR supplies

the equipment and services directly. CONTRACTOR shall supply the equipment

in line with the scope of supply as indicated in this specification.

1.3

Definitions and Abbreviations

1.3.1 Definitions

PROJECT : Dai Hung Gas Gathering Project

CLIENT : PetroVietnam Domestic Exploration

Production Operating Company Limited

(PVEP POC)

EpCI CONTRACTOR : VIETSOVPETRO JOINT VENTURE (VSP)

ENGINEERING SUB-CONTRACTOR : PetroVietnam Engineering Consultancy

Joint Stock Company (PVE)


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CONTRACTOR : Party, which supplies material,

equipment and services to perform the

duties as specified by CLIENT in the

scope of supply

1.3.2 Abbreviations

FPU-DH1 Dai Hung 1 Floating Production Unit Platform

WHP-DH2 Dai Hung 2 Wellhead Platform

BK-TNG Thien Ung Platform

MMSCMD Million Metric Standard Cubic Meter Per Day

BMSCM Billion Metric Standard Cubic Meter

ESD Emergency Shut-Down

FGS Fire & Gas

HMI Human Machine Interface

HSE Health Safety and Environmental

ICSS Integrated Control and Safety system

IOM Installation Operation and Maintenance

ITP Inspection and Test Plan

LV Low Voltage

HV High Voltage

VFD Variable Frequency Drive

UPS Uninterruptible Power Supply

AC Alternating Current

DC Directing Current

SGR Switch Gear Room

RTD Resistance Temperature Detector

IEC International Electrical Commission

IP Ingress Protection

MCC Motor Control Centre

MDR Manufacturers Data Report


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MPI Magnetic Particle Inspection

NDT Non-Destructive Testing

PWHT Post Weld Heat Treatment

TBA To Be Advised

VDRL CONTRACTOR Data Requirements List

VDS CONTRACTOR Data Schedule

FAT Factory Acceptance Test

SAT Site Acceptance Test

SSD Safety Shut Down/ Safety Shut Down PLC

PPLC Process Programable Logic controller

SIS Safety Interated System

TEG Triethylene Glycol Dehydration

PCS Process Control System

APS Abandon Platform Shutdown

LCP Local Control Panel

UCP Unit Control Panel

1.4 Codes and Standards

In addition to the requirements of this specification and the referred or

attached individual specification and data sheets together with the statutory

requirements of the Vietnam Authorities, the general design, fabrication,

assembling and testing of this package shall follow the indicated editions of the

following API standards and the latest edition of international codes and

standards including any addenda published for the edition listed, which shall

form part of this specification. These shall include but not be limited to the

following:

ISO 3046-1 Part 1 Standard reference conditions, declarations of power, fuel

and lubricating oil consumptions and test methods

ISO 3046-3 Part 3 Test measurements

ISO 3046-4 Part 4 Speed governing

ISO 3046-5 Part 5 Torsional vibrations


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ISO 3046-6 Part 6 Overspeed protection

ISO 3046-7 Part 7 Codes for engine power

ISO 13631 Petroleum and natural gas industries Packaged

reciprocating gas compressors

ISO 9001 Quality System - Model for Quality Assurance for Design

and Development, Production, Installation and Servicing.

ABMA 9 Load Rating and Fatigue Life for Ball Bearings

ABMA 11 Load Ratings and Fatigue Life for Roller Bearings

API 613 Special Purpose Gears Units for Petroleum, Chemical, and

Gas Industry ServicesAPI 614 Lubrication, Shaft-Sealing, and Control Oil Systems for

Special-Purpose Applications

API 618 Reciprocating Compressors for Petroleum, Chemical and

Gas Industry Services

API 661 Air-Cooled Heat Exchangers for Petroleum, Chemical, and

Gas Industry Services.

API 670 Machinery Protection Systems

API 671 Special Purpose Couplings for Petroleum, Chemical andGas Industry Services.

API 678 Accelerometer Based Vibration Monitoring System

API RP 505 Recommended Practice for Classification of Locations for

Electrical Installations at Petroleum Facilities Classified as

Class I, Zone 0, Zone 1, and Zone 2.

API RP 684 Lateral Critical Speeds, Unbalance Response, Stability,

Train Torsionals and Rotor Balancing

OPC OLE Process Control Standard, Version 1.0A

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME B16.5 Pipe Flanges and Flanged Fittings NPS Through NPS

24

ASME B16.9 Factory-Made Wrought Butt-Welding Fittings.


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ASME B16.20 Metallic Gaskets for Pipe Flanges (Ring-Joint, Spiral-Wound

and Jacketed)

ASME Sec VIII Rules for Construction of Pressure Vessels Div. 1 and Div.

2

ASME PTC 10 Performance Test Code on Compressors and Exhausters

AWS D1.1 Structural Welding Code.

ANSI American National Standard Institute (as applicable)

Electrical Code IEC, British Standards, CENELEC, ISO, NEMA. (as

applicable)

Instrument Code ISA, API RP 551, IEC, NEMA (as applicable)NFPA 12 CO2 Fire Extinguishing System.

OSHA Occupational Safety and Health Act

NACE-MR0175 Petroleum and natural gas industries materials for use in

H2S-containing environments in oil and gas production.

UL Underwriters Laboratories

1.5 References

DHG-PVE-DD-3-ME-DAS-007 Datasheet for Screw Compressor

DHG-PVE-DD-3-ME-DAS-009 Datasheet for Gas Engine

1014-BKTNG-PR-PID-2023 PID DH Gas Compressor Package

In case of any conflict between this specification and the requirements of other

CLIENT specifications, industry standards, codes, regulations, data sheets or

drawings, the most stringent requirements shall apply with the written

approval of CLIENT.

2. GENERAL REQUIREMENTS

2.1

CONTRACTORS Responsibility

The CONTRACTOR shall have full responsibility for design, selection of

materials, fabrication, Certification, testing, inspection and transportation of

PACKAGE based on relevant project documents. Review and approval of

CONTRACTORs documents or inspection by the CLIENT shall not relieve the

CONTRACTOR of any of these responsibilities.


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The Overall PACKAGE Responsibility shall be with the CONTRACTOR. That

responsibility shall include coordination of scope boundaries between

Compressor, Engine and Other Components of the PACKAGE. TheCONTRACTOR has responsibility shall be liable for filling any scope gaps

between the compressor, Engine and Other Components of the PACKAGE

being supplied. The responsibility includes, but not limited to, the following:

Transmission to CONTRACTOR of all contractual requirements.

Compliance of CONTRACTORs item to the applicable specification and

standards

Basic design definition of CONTRACTOR equipment or works and technical

coordination with CONTRACTOR.

Co-ordination and checking of CONTRACTORs drawings and documents

before submission to the CLIENT

Co-ordination with CONTRACTOR for inspection including notification to

the CLIENT

Co-ordination of expediting of all CONTRACTOR items such as

compressor, drive gas engine, motors, gas seals panel, oil cooler,

coupling, and etc.

Ensuring that the design of CONTRACTOR items are compatible with each

other equipment in all respects. In particular, they shall be compatible

dimensionally, in performance, in control and in vibration characteristics

such that a fully integrated unit is achieved.

The CONTRACTOR shall be responsible for commissioning works of his

equipment and ensuring all performance guarantees as detailed in this

specifications are met.

The CONTRACTOR shall give with the tender the list of expected CONTRACTOR

with referenced list.

2.2

Operation and Design Life

The equipment shall be designed for a minimum service life of 20 years with

an uninterrupted operation of 4 years.

2.3 CONTRACTORs Exceptions

The CONTRACTOR Exceptions to this specification, project data sheets and

other project documents including the codes and standards agreed upon and


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recorded in the Bid Clarification Meeting Minutes which are part of the

Purchase Order shall be applicable.

2.4

Weight Control

The CONTRACTOR shall exercise an active weight control system throughout

the design and fabrication.

The CONTRACTOR shall submit the weight data sheet attached with the data

sheets, which shall contain the following details:

Dry weight Installed weight excluding operating fluids, spares, tools and

temporary packing.

Lift weight Dry weight + Packing weight

Operating weight Dry weight + Weight of operating fluids

Test weight - Dry weight + Weight of test medium

Heaviest maintenance lifts weight

The location of the COG in the X, Y, and Z planes for each designated

weight Condition

Design calculations, lifting procedures and lift arrangement drawings shall be

reviewed and approved by the CLIENT and CA. Final weighing shall be

performed prior to preparation of shipment. Final weighing shall achieve anoverall accuracy of +3%.

3.

LOCATION AND ENVIRONMENTAL CONDITIONS

The equipment will be installed on an offshore platform in the south of the

coast of Vietnam.

Location:Out door, Zone 2, Gas Group IIA, Temperature Class T3 Hazardous

Area.

The area in which the Gas Engine Screw Compressor Package is designated as

hazardous Zone 2 Area. All equipment installed within the module shall be

suitable for a Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area.

However, in order to permit interchange of instrument, a zone 1, gas group IIB

and temperature rating T6 certification shall be generally specified.

Electrical equipment supplied outdoors shall be protected to IP 56, while IP 42

protection shall be specified for equipment installed indoors.

Ambient Temperature:


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Extreme High Temperature 39.0 Deg C

Extreme Low Temperature 21.0 Deg C

Average Annual Temperature 27.1 Deg C

Design Ambient Temperature 35 Deg C

Environment:

Salt Laden: Salinity 35%

Max. Relative Humidity 100%

Wind Speed:

Maximum 34.2 m/s (3 sec gust)

Design Wind Speed 34.2 m/s

The equipment will exposed to the weather without further protection.

4.

UTILITY DATA

4.1 Electrical

The following electrical power supplies shall be made available for use by the

CLIENT:

Normal Power supply: 400V10% AC, 3 phase, 4 wire, neutral solidly

earthed, 50 Hz 5%.

Non-UPS Power Supply: 230V 10%AC, 1 phase, 2 wire, neutral solidly

earthed, 50 Hz 5%.

UPS power supply: 230V 5%AC, 1 phase, 2 wire, neutral solidly earthed,

50 Hz 2%.

Power supply: 24VDC 5% for Control system.

4.2 Instrument air:

7 barg (Norm), 5 barg (Min), 8 barg (Max) / 10 barg (Design).

4.3 Fuel gas

The fuel gas supply for operation of PACKAGE is taken from Fuel Gas System,

which is designed for high-pressure gaseous fuel of main Turbine generator on

platform. The system also supplies low-pressure fuel gas, purge gas, blanket

gas, etc.

Fuel Gas System is designed to cater for the overall fuel requirement on BK


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TNG platform. The system consists of Pre-heater, Pressure Control Valve,

Scrubber, Filter and Super heater. The normal fuel gas supply is dehydrated

gas from TEG Contactor with back-up fuel gas supply tapped from theProduction Separator gas outlet.

4.4

Units

SI units shall be used for the project with certain exceptions where oil-field

units are to be adopted. Pressure shall be indicated in bar, kpa and

temperature in degrees Celsius.

5. SCOPE OF WORK & SUPPLY

The CONTRACTOR shall design and furnish all components and ancillary

equipment necessary to make compressor package complete, safe and ready

for trouble free operation. Equipment and services shall include but not be

limited to the following for PACKAGE:

Screw compressor.

Gas Engine driver

Suction scrubber.

Outlet Cooler.

Speed reduction gearbox (shall comply with API 613).

Couplings and coupling guards.

Lube oil system(s) complete with one 100% main oil pump, one 100%

auxiliary oil pump, emergency lube oil pumps, air fin cooler(s), and a dual

oil filters with change over valves. The main oil pump should be a shaft

driven as external power supply is not available.

Fuel gas treatment package.

All on skid piping including valves, flanges and fittings with appropriate

supports.

Access for exhaust emission measurements.

Walkway, platform, ladders, handrails, safety cage, and non-skid grating

for safe access to all PACKAGER supplied equipment, instruments, valves,

and other devices requiring routine monitoring and maintenance.

Weather protection shed for Equipment.


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Structural skids with framework to support Engine, compressor, gear box

and ancillaries.

Air intake system, exhaust system, ventilation system and ancillaries with

intake silencers, exhaust silencers, exhaust ducts with motorized dampers

of heat recovery system, exhaust system thermal insulation, shielding,

cladding exhaust expansion joints, insect screens at all intakes, and

support structure.

Engine control system including all associated instrumentation and

cabling.

Compressor control system including Capacity/ Load sharing Controls,

Vibration & Temperature Monitoring, etc. including all associated instrumentation and

cabling

Process yard valve control system.

Control panels and instrumentation including local gauge panel, local

compressor seal gas gauge panel as well as main microprocessor-based

control panel (UCP).

Shaft coupled AC alternator of adequate size to power to UCP and

auxiliary drivers on DC control power supply unit including batteries, battery charger, DC

panel and all DC Cabling.

DC emergency lube oil pump system complete with pump, motor.

Temperature and vibration monitoring system.

Complete Instrumentation & Control Cabling

Fire & gas detection.

Package and equipment leveling and alignment devices.

Package and equipment lifting lugs and eyebolts.

Personnel protection insulation.

Commissioning parts.

Inspection and Tests Plan

Third Party Certificate for entire PACKAGE.


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Documentation for project

Commissioning activities (Supervision).

Training courses (Option).

Special Tools for engine & compressor (Option).

Spares for 2 years operation (Option).

Anchor bolts for package frame.

The CONTRACTOR shall include in his supply:

With the exception of process gas connections all piping and tubing

connections for interfacing with the CLIENT shall be brought to the edge

of each compressor flanges and terminated with a complete companionANSI flange or Swage lock bulkhead fitting.

The CONTRACTOR shall take technical support to CLIENT in:

Mechanical Interface drawings between PACKAGE and CLIENTs

equipments such as inlet/outlet piping.

Interface drawings of Inlet system, Exhaust system, lubrication oil cooler

system.

Provide drawings of Interconnecting electrical cables/instrument cables,

between the PACKAGE and loosed items such as UCP, oil cooler, anti

surge.

Responsible for Technical support to CLIENT for PACKAGE interface

engineering.

Interface and successful communication between CONTRACTORs UCP

and CLIENTs DCS system shall be carried out.

Supply E&I cable list and interconnection for E&I wiring diagram.

EXCLUSION:

Interconnecting piping between PACKAGE to oil cooler and field piping.

Interconnecting electrical cables/instrument cables, between the

PACKAGE and UCP/PCS/SIS/MCC.

UPS system for the UCP.

MCC.

Process Vessels.


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Installation and Hook-up works for PACKAGE in CLIENTs site.

6.

DESIGN REQUIREMENTSThe CONTRACTOR shall minimize the points and locations of interface and

locate them at the unit skid edge. Piping interface with the off-skid piping shall

be provided with isolation valves and flanges. Common service piping such as

drain, vent and utility piping shall be manifold to interface with the off-skid

piping where it is safe to do so. All instrumentation and control wiring shall be

wired to the junction boxes located at the skid edge for interface with the off-

skid wiring.

The compressor and gas engine shall be skid mounted and coupled together.

The acoustic panel enclosure shall be weatherproof and made of carbon steeland coated as per paints specification. The enclosure shall be framed and

supported from the skid. The gas engine ancillary package including

combustion air intake system and the engine exhaust duct and silencer system

shall be provided with support framework for quick hook-up and for mounting

on top of the enclosure. Access ways and maintenance platforms shall be

provided where routine maintenance and operation checks are required. All

foundation requirements including for main skid, ancillary bases and support

frames shall be provided with details for CLIENTs review and approval.

All piping, wiring, and tubing within the CONTRACTOR supply shall be fullysupported by the CONTRACTOR. All terminations at which the off-skid lines are

to make connections shall be fully anchored on the CONTRACTOR side.

Foundations required for supports will be provided by an off-skid installer. Any

limitation on loads and movements imposed by the off-skid piping shall be

defined on the CONTRACTORs drawings.

The CONTRACTOR shall clearly indicate in his proposal all items covered by

this specification which are located off-skid and to specify dimensions,

weights and interface details required for installation and hook-up.

The CONTRACTOR shall fully define all piping, mechanical connections,

electrical wiring, instrumentation and control interfaces with size, schedule,

type, location, rating, design and operation ranges.

7.

ENGINE AND AUXILIARIES

7.1

General

The engine driver shall be a reciprocating internal combustion associated gas


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engine complying ISO 3046 or equal. The engine shall have a continuous

rating, de-rated for site conditions at the maximum air ambient, minimum fuel

gas pressure and all power transmission losses, at least equal to 110 percentof the BHP required for continuous operation supplying the maximum

compressors demand specified.

The engine shall not have any torsional natural frequencies within 10 percent

of the first or second harmonic of the rotational frequency of any shaft in the

operating speed range.

Constant speed applications shall be considered to have an operating speed

range of 10 percent of rated speed.

The engine shall include replaceable cylinder liners of the wet sleeve type andreplaceable valve seat inserts. Combustion chambers shall be of the open type.

Connecting rods and crankshaft shall be of forged steel.

Engine drive for attached auxiliaries shall be gear, V-belt or chain type. V-belt

and chain drives shall be furnished with adjustable tensioning devices.

Bearings shall be manufacturer's standard. Shims shall not be used for any

bearing.

The engine shall be designed to minimize the requirement of special tools for

installation and maintenance. One set of such tools with a description and

instructions for their use shall be supplied.

7.2 Intake Air System

The engine shall be provided with one or more engine-mounted dry-type air

cleaners/ filters of sufficient capacity to protect the working parts of the engine

from dust, grit and moisture laden air.

The filter shall be fitted with a differential pressure indicator (Transmitter) to

show when the filter requires attention.

If the air filter is to be installed remotely from the engine, the CONTRACTOR

shall supply the filter loose. The pipework between the filter and the engine

shall be either stainless steel or marine grade aluminum with less than 3%

magnesium.

The CONTRACTOR shall recommend the size of the intake pipe between the

filter and the engine. CONTRACTOR shall ensure that the pipework does not

impose unacceptable strains on the engine. The CONTRACTOR shall supply a

flexible joint between the intake pipe and the engine.


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Unless absolutely essential, internal fasteners shall not be used downstream of

the air filter. Where unavoidable, internal fasteners shall be positively secured.

Intake pipes 250 mm or larger in diameter shall be fitted with a BICERI type

explosion relief valve with integral flame trap between the engine and the air

filter (or the silencer, if fitted).

All external connections from the engine shall terminate in flanges to ASME

B16.5.

An air intake silencer shall be provided if the air intake noise level exceeds that

permitted.

7.3 Starting System

CONTRACTOR shall supply complete starting system(s) as specified in the

generator gas engine data sheet. Two (2) independent starting systems shall

be required.

The Gas Engine shall be able to cold start at the minimum ambient conditions.

7.3.1 Electric Starting System

This is the main starting system for the Gas Engine. The system shall be a

24 VDC electric starting system, with the battery, engine start controls

and battery charger located on the skid. The controls and charger shall be

suitable for the engine vibration and outdoors site conditions. The 24 VDCbattery and charger shall also supply power to the Gas Engine control

system.

Cranking time and pause between starts shall be adjustable. The battery

charger shall automatically disconnect from the battery during engine

cranking. The starting current for the first start shall be provided by the

first set of batteries and the subsequent start by the next set of batteries.

Cranking logic shall be designed such that the starting circuit is

deactivated after six (6) unsuccessful consecutive start cycles. Further

starting shall be only possible from field control panel.

CLIENT shall provide one (1) 220 VAC feeder cable on cable gland for the

battery charger and anti-condensation heaters (< 3kW) during platform

normal operation.

The battery shall be sealed, maintenance free type suitable for heavy-

duty Gas Engine starting and shall be supplied in a fully charged condition

and complete with copper links. The battery shall be positioned such that


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possible leakage of electrolyte or emission of gaseous product, if any will

not cause damage to other equipment or adjacent cells. The battery shall

be mounted in a robust fibreglass box (suitably rated for outdoorinstallation, IP56).

Two (2) x100% trains of battery starting system shall be provided. Each

battery train shall have efficient capacity for six (6) consecutive 15-

seconds start cycles.

The charger shall keep the battery in fully charged condition and supply

all auxiliary loads on the skid simultaneously. The charger shall also be

capable of float-charging the battery from fully discharged condition to

fully charged condition within eight (8) hours.

Automatically regulated output voltage of the battery charger shall be

maintained within plus or minus 1% for load changes from zero to full

load and line voltage variations of plus or minus 10% and frequency

variations of plus or minus 5%. An over-current limit shall be adjustable

and preset at 105% of rated output to prevent overloading of the charger

during the starting of the engine.

Both the positive and negative terminals and conductors of DC power

supply shall be isolated from earth.

All connections shall be made at terminal strips provided at the chargerunit.

CONTRACTOR shall carry out industry standard testing for the battery and

charger as per CONTRACTORs CLIENT approved procedure.

7.3.2

Hydraulic Starting System

Hydraulic starting system shall be complete with reservoir, shaft driven

charging pump, accumulators, hydraulic motor starter with pre-engaged

non-sparking pinion type, piping, valves, solenoid etc. as required.

The hydraulic electrical motor, if provided, shall be as per CLIENTSpecification,.

The engine driven pump shall be sized to completely charge the

accumulator in not more than 15 minutes when operating at design

speed. The CONTRACTOR shall describe the method of declutching

/disengaging the engine-driven pump once recharging is complete. The

power absorbed by the engine-driven pump shall be advised by the


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CONTRACTOR. A hand pump for recharging the accumulator shall also be

supplied.

Accumulator capacity shall be sufficient for a minimum of six (6) starts. Each

start attempt must be distinct and separate. If the engine fails to start within

the time required for 12 complete revolutions, the starting control system shall

abort the start.

7.4 Fuel Gas Treatment Package

CONTRACTOR shall provide complete fuel system comprising of but not limited

to Carburetion System, Vertical Separator / Filters, heater (VTA),

Interconnection piping, fittings, Solenoid actuated fuel shutoff valve, Solenoid

actuator fuel line vent valve, Fuel gas pressure regulator, Pressure SafetyValve, Fuel Consumption Meter. Fuel gas will be used as a starting gas for the

gas engine(s) i.e. it will crank the engine.

For Fuel Gas properties, refer attached data sheet. CONTRACTOR shall provide

a complete on-skid fuel system. All necessary valves and regulators shall be

consistent with the pressure. Fisher gas regulators or equivalent with steel

bodies shall be provided for pressure reduction, if required. An explosion-proof,

all steel, solenoid type fuel valve shall be furnished and installed in the fuel gas

supply line on the engine. This valve shall be automatically latched to start the

engine and electrically tripped. The engine shutdown devices shall beconfigured to electrically trip the engine by at least closing the fuel valve.

The strainer shall be 200 m nominal, and shall act only as a guard filter. The

strainer shall be fitted with a drain valve.

A swing-type or wing-type non-return valve shall be provided to prevent

pressure surges from engine "spit back" disturbing the fuel system.

CONTRACTOR shall provide system with fuel filters (vertical separator), inter-

connection piping, fitting, solenoid actuated fuel shut off valve, fuel line vent

valve and fuel consumption meter.

7.5

Lubrication System

The lubrication system shall be a pressure-type system. It shall consist of, but

not be limited to Sump (wet type) with level indication, fill filter, vented and

valve drain, Circulation pumps (shaft driven) with pressure relief valve, Duplex

filters with replaceable cartridge elements, full flow transfer valve and

differential pressure gauge across filters, Cooling equipment with


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thermostatically controlled bypass valve, Valves for relief and pressure

regulation, Low Level Alarm Switch and Automatic shutdown devices.

The oil sump shall be integral with the engine and shall be large enough to

contain all the oil in the system when the engine and pumps are shutdown.

The minimum capacity shall be an amount of oil equal to the lubrication

pump's working capacity for a period of two minutes.

The filters for the lube oil system shall be sized to meet the engine

manufacturer's filtration requirement. The oil filter shall be equipped with a

differential pressure gauge, and a bypass valve to assure engine oil flow in the

event of filter plugging. All filters shall utilize replaceable elements.

If aluminum, micro-Babbitt or equivalent bearings are provided, a bypass filterrated for five (5) micron nominal filtration or better shall be provided. This

bleed off filtration line shall be sized to filter the total oil capacity in 24 hours or

less. Filter casings and heads shall be suitable for operation at a pressure of

not less than 10 percent over the relief valve settings of the lube pumps.

Strainers (20 mesh) shall be provided in the lube oil pump suction header.

Internal relief valves in filters shall not be acceptable.

Crankcase shall be explosion proof.

Pre-lube and/or post-lube pumps shall be provided. Pre-lube pump drivers shalloperate on the same energy source as the engine starter.

The CONTRACTORs standard pre-lube pump shall operate as follows:

The pump shall run when automatically started by the engine control

panel.

The pump shall run when the lube-oil heater is energized and allowed by

the skid mounted ON/OFF selector switch.

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

locked out manually.

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

The CONTRACTOR shall provide the recommended lubricant for start-up. The

start-up lubricants shall not be those used during testing.

The engine oil temperature shall not exceed CONTRACTORs recommendations

and shall never exceed 91C (195F) for continuous operation. The oil

temperature should never exceed 107C (225F) for short term operation (one


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hour or less) during an overload condition. The crankcase oil temperature shall

be maintained at a differential of 6C to 12C (10F to 20F) above jacket

water temperature under any conditions using jacket water cooling.

The crankcase oil temperature shall be maintained at a differential of 6C to

9C (10F to 15F) below jacket water temperature under any conditions when

an oil cooler with a separate cooling water system is provided.

The lube oil dip stick shall be calibrated for oil pan level with the engine

running and not running, to permit checking during normal operation and

when the engine is stopped.

7.6

Cooling System

The engines cooling system shall be furnished with a closed loop, jacketcooling system and a centrifugal pump. The cooling system shall be sized for

the continuous maximum BHP load at the max. ambient temperature.

The cooling coolant heat exchanger shall be of the finned radiator type. The

radiator shall be mounted on the engine skid and shall have a tin or solder

coated core and shall have carbo zinc #11 on all exposed steel surfaces. The

material shall be suitable for operation in a moist air environment. Coolant

shall be compatible for operation within tropic locations as well. Radiator shall

be filled out and sealed prior to test running. The cooling system shall include

one (01) 1" stainless steel valve for external fill and one (01) 1" stainless steelvalve for draining. System shall also include pusher type, fan, four ply hoses,

pump with carbon seal and radiator fan guard.

Automatic thermostat control with bypass valves shall be provided to control

engine temperature. Bypass shall operate so that cooling medium flow shall

never be throttled. Expansion or surge tanks shall be integrally mounted.

Thermometers shall be installed in stainless steel thermowells at the inlet and

outlet connection of each cooling coolant circuit in the heat exchanger

(radiator). Thermometers shall be installed in such a way that they may be

easily read from ground level without having to climb up on the skid assembly.

7.7

Governor

The governor supplied for engine speed regulation and load control shall be

electronic utilizing digital technology.

The governor actuator shall be direct acting, UL Approved for use in Zone 2,

Group II. The actuator and magnetic pickup shall be mounted on the engine.


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Controller stability shall be within + 3.0% at rated load. The maximum

deviation relative to the rated speed for the range between no load and full

load shall be 1/4 %.

The amount of droop shall be field adjustable from 0 to 10%. The governor

shall be provided with a droop reset control feature to maintain system

frequency to within 0.5% when in droop control.

The governor shall monitor the speed sensor for loss of speed signal, calling

for minimum fuel when signal loss is detected.

The governor shall have the following adjustments:

Rated speed

Idle Speed

Acceleration ramp time

Deceleration ramp time

Start fuel limit

Gain and reset

Actuator compensation

Load gain

Droop

7.8

Engine Exhaust System

A hospital grade, muffler with spark arresting capability shall be installed in the

exhaust system unless the pressure drop across the silencer raises engine

exhaust pressure to unacceptably high pressure, in which case, a lower grade

Maxim muffler may be used with CLIENTs approval.

Silencers with flange sizes over 15 cm (6 inches) shall be provided with an

inspection opening or draw out cover. The exhaust silencer shall attenuate the

engine exhaust to 85 dB(A) at 1 m unless otherwise specified.

Engine-mounted silencers shall be provided with a bellows-type, stainless steel

expansion joints.

All carbon steel piping, silencers etc. subjected to exhaust temperatures and

exposed to the atmosphere shall be blast cleaned and flame sprayed

aluminium coated for corrosion protection. Alternatively, stainless steel may be

used.


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7.9 Insulation

Thermal blankets shall be installed where surface temperatures exceed 60C

for personnel protection.

Ceramic fiber silicone treated glass cloth, covered with a 316L stainless steel

knitted mesh good to 1260C (2300F) shall be provided on the exhaust line. A

minimum of 2.5 to 4 cm (1 to 1-1/2 inch) calcium silicate covered with

aluminum shall be provided where rigid insulation is required, such as on water

lines.

7.10

Engine Shutdown Devices

Each engine shall be equipped, as a minimum, with the following safety

shutdown devices:

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

Low coolant level alarm and shutdown

High oil temperature alarm and shutdown

High coolant temperature alarm and shutdown

Engine vibration

High Cooler vibration alarm and shutdown

Over speed alarm and shutdown

Over crank start sequence shutdown

Manual lockout at skid

Fire & gas detectors

Red mushroom head Emergency Stop pushbutton located at the engine

skid and on the engine control panel face.

All shutdown and alarm switches shall be hermetically sealed whenever

possible and shall be UL listed, as a minimum, for Zone 2, Group II hazardous

locations.

7.11 Engine Instruments Panel

A package mounted powder paint coated sheet steel instrument panel for

engine shall be provided. Panel shall be located on the edge of the engine skid

so that it may be viewed from outside skid and shall be mounted on isolation

mounts in such a way as to prevent vibration damage to instruments. The

following instruments shall be provided on the instrument panel as a minimum:


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Lube oil pressure gauge

Electronic (LCD) tachometer

Engine outlet coolant temperature gauge

Engine outlet oil temperature gauge

Engine oil filter differential pressure gauge

Intake manifold vacuum/pressure gauge

Fuel pressure gauge

Running hour meters

Fuel filter differential pressure gauge

Engine inlet coolant temperature gauge

Cooler outlet oil temperature gauge

Gauge for diesel engines with after cooling

Red maintained mushroom head emergency stop pushbutton,

hermetically sealed contacts

Frequency Meter

Voltage Mete / Load

Additional instruments required by the CONTRACTOR shall be provided.

Instrumentation shall conform, in general, with API STD 670.

Instrumentation and associated local panel monitor for vibration, axial position

and bearing temperature shall conform, in general, with API STD 670.

Gauges shall be provided with glycerin filled stainless steel cases with a

minimum 100 mm (4 in.) face, identification labels, including tab number, and

normal and maximum reading markers. Pressure gauges shall have 316L

stainless steel bourdon elements and 316L stainless steel cases. Thermometers

shall be mounted in 316L stainless steel wells. Gas-filled thermometers shallhave leads and shall be no longer than 3 meters (10 feet).

7.12 Ignition System

Engine CONTRACTORs standard, shielded, low tension, capacitive discharge

ignition system shall be used.

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

cables shall also be vinyl covered.


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Ignition transformers shall be integral with the spark plugs eliminating the

need for separate spark plug wires.

Engine CONTRACTORs standard electronic ignition diagnostic system shall be

used.

7.13 Over-speed Protection

The engine shall be fitted with an over-speed protection device in accordance

with ISO 3046-6. This device shall shut down the engine by both earthing the

ignition and shutting off the fuel independently of the speed governor.

The over-speed protection device shall be manual reset only.

7.14

Torsional Vibration

The assessment and prevention of Torsional vibration in the engine and its

driving train shall be as specified in ISO 3046-5.

The CONTRACTOR shall provide all the necessary information regarding the

engine including to enable the Torsional vibration calculations.

Alternator drives shall be regarded as having a speed range of 90 to 110% of

synchronous speed for the Torsional analysis.

Use of torsionally flexible couplings and torsional dampers (separate from

those fitted as standard to the engine) for tuning the torsional critical speeds

shall require the approval of the consultant.

The CONTRACTOR shall advise the life of viscous type torsional dampers fitted

to the engine.

7.15 Lateral Vibration and Vibration Suppression

The CONTRACTOR shall provide the anticipated lateral vibration levels of the

engine relating to measurements made directly on the crankcase or main

frame of the engine, expressed both as a filtered response at each of the

major excitation frequencies and as unfiltered vibration with the engine

running at rated power and speed. The vibration information shall include themagnitude and direction of unbalanced primary and secondary unbalanced

forces and couples.

Suitable anti-vibration mounts shall be supplied to limit the engine vibrations

transmitted to the foundations or surroundings if a vibration analysis study

reveals that the package requires isolation from the supporting structure. Anti-

vibration mounts shall be of totally enclosed design, suitable for the


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environment, and have an isolation efficiency of at least 90% in respect of all

engine induced vibrations.

Unless otherwise dictated by the arrangement of the engine and the driven

equipment or by the lateral vibration analysis, any anti-vibration mounts

required shall be installed between the baseplate and the supporting structure.

The CONTRACTOR shall supply the anti-vibration mounts.

Full details, including drawings of the anti-vibration mounts shall be submitted

to the CLIENT together with the frequencies and magnitude of any unbalanced

forces and moments that will be transmitted through the supports into the

supporting structure.

7.16

Shaft Couplings and GuardsThe CONTRACTOR shall supply shaft couplings between the engine and the

driven compressor.

All couplings shall be either flange bolted to shafts or be hydraulically fitted to

cylindrical or tapered shafts.

All couplings shall be of the non-lubricated type.

All moving parts shall be protected from human contact by suitable guards of

either sheet or mesh material. All such guards shall be non sparking. Aluminum

is not regarded as a non-sparking material & should be prohibited.7.17

Crankcase Explosion Relief

Engines having a crankcase volume of over 0.6 m shall be provided with

crankcase explosion relief devices. Explosion relief valves of the BICERI design

or approved equal with integral flame traps shall be used. Sufficient relief

valves shall be installed to provide more than 115 cm of relief valve free lift

area per m of crankcase volume.

Dipsticks and/or filler caps shall be effectively secured against ejection

following a crankcase explosion.

The crankcase breather shall be as small as possible and located to minimize

air inrush into the crankcase following an explosion.

7.18 Miscellaneous Requirements

Relief valves shall be provided as necessary for the fuel supply, engine

crankcase pressure and lube oil supply.

Governor setting controls shall be mounted on the governor.


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The engine over-speed shutdown will be easily accessible and capable of being

manually tripped and reset with fuel pressure on the line. Trip mechanism shall

be spark proof and suitable for use in hazardous locations. Trip device, valve,valve stem, packing and interconnecting linkage shall be of suitable material

and so designed that they may be expected to perform satisfactorily under

conditions of minimum lubrication, infrequent tripping and outdoor installation.

Automatic safety stops shall be entirely independent of the speed governor.

They shall operate to ground the ignition, shut off the fuel and vent fuel from

the engine.

Interlocks shall be provided to override shutdown signals when starting the

engine.

Some means of positive fuel shut-off should be provided for emergency use.

Pressurized fuel should have another shut off valve, preferably automatic,

other than those in the carburetor or gas pressure regulator equipment.

8. GAS COMPRESSOR

8.1 General

The Compressor gas engine driven, heavy-duty, rotating-type, positive

displacement screw compressor shall meet all the technical requirements as

specified in: Data Sheets

Technical Specification

International Codes & Standards

Gas composition given in Data Sheets shall be used for Compressor sizing and

performance guarantee estimates. However compressor shall be suitable for

continuous operation with the indicated gas composition range and operating

parameters given in the data sheet.

CONTRACTOR offer shall be based on firm and final compressor models on

which basis the offer shall be evaluated. CONTRACTOR shall take full

recognizance of this matter before submitting the bid.

Note that the pressures given on the data sheet are at the compressor

package battery limits, CONTRACTOR shall consider all pressure losses at

suction, inter stage (VTA) and discharge at the specified capacity for


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compressor/engine and indicate the same on the data sheets. No venting of

the gas is allowed at any point during operation except PSV lines.

The compressor Driver shall be capable of running the compressor under

loaded condition with each stage pressurized to its respective specified

pressure and final pressure up to PSV set pressure.

Certificate shall be supplied from the CONTRACTOR assuring that components

and manufacturing techniques meet the requirements of NACE MR 0175

(Latest Revision).

The Contractor shall provide all equipment completely fabricated, assembled,

and tested. The equipment shall be dismantled only to the extent necessary for

inspection and practical shipping. If the compressor package components areto be mounted and/or tested at the Manufacturers plant, the Manufacturer

shall provide and take responsibility for the following:

Coordination of arrangements for receipt, handling, and set up of compressor

package components.

Testing of compressor package in accordance with applicable standards.

Preparation for shipment of the entire compressor package in accordance with

applicable standards.

Coordination and cost for correction of compressor package problemsdiscovered at the Manufacturers factory during test or assembly.

All control equipment for integral units shall be furnished.

All equipment shall be rated for installation in a Zone 2, Group IIB, T3

hazardous locations

The compressor, gas engine, and all accessories shall be completely factory

assembled on a common, fabricated steel base and be ready for installation.

Internal piping shall be such that only single point connections for gas inlet,

gas outlet, drains, vents, cooling system fill/makeup (if required), cooling waterinlet and outlet (if available), and instrument air supply (if available) are

necessary for the compressor package.

8.2 Compressor Performance

The Contractor shall provide a complete capacity/ pressure control system. The

compressor shall provide a constant discharge gas pressure at any gas flow

rate and any suction pressure. The discharge pressure control system shall use


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slide valves to adjust the flow rate due to suction pressure swings and capacity

changes. In addition, a recirculation line may be used, as necessary, to

supplement the slide valve, and to allow for fully unloaded compressoroperation. Gas recirculation shall be to a point upstream of the inlet gas

scrubber. The gas recirculation valve shall include a valve positioner with a

position transmitter.

The control system shall include a manual override (local manual start and

control).

The compressor shall operate without excessive vibration or noise.

8.3

Compressor Construction

The compressors shall be constructed as specified herein. The maximumallowable working pressure (MAWP) shall be at least 110% of or 25 psig

greater than the maximum operating pressure, whichever is higher.

8.3.1

Materials of Construction

Materials of construction for the compressors and auxiliaries shall be the

manufacturer's standard for the specified operating conditions unless otherwise

specified in API Standard 619.

8.3.2 Bearings

Bearings shall be replaceable sleeve type or antifriction of the tapered orspherical roller type.

8.3.3 Compressor Rotor

The rotor assembly including thrust disk, balance piston (when applicable) and

half key on shaft end shall be dynamically balanced with manufacturer's

specified criteria and in accordance with Section 5.7.3.3 of API STD 619 prior

to compressor assembly.

The rotor shaft shall be key way or keyless shaft end and manufactured from

forged steel and shall be one (1) piece with helical rotor, statically anddynamically balanced to provide vibration free operation.

8.3.4

Coupling and Guard

When a torsional damping or resilient type coupling is required by analysis, the

coupling shall be in accordance with API STD 671, Appendix B.


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The coupling connecting the compressor and drive motor shall be sized for all

operating conditions. The drive coupling assembly shall be protected with a

removable, non-sparking guard.

8.3.5 Casing

The main pressure casing shall be bolted and main casing split face shall use a

metal-to-metal joint (such as O-ring) to avoid gas leakage due to high

pressure. Gasketed joints are not acceptable.

A flat surface of an agreed size and location shall be provided on the casing as

close as possible to the bearing locations for mounting of magnetic-based

seismic vibration measuring equipment. See Section 5.9.8 of API STD 619 for

further details.8.3.6

Shaft seals

Gas leakage to the atmosphere is not permissible. The CONTRACTOR shall

provide either a dual mechanical contact-type seal design with an independent

seal fluid system (Section 5.6.4.2 of API STD 619) or a double or tandem self-

acting dry gas seal in accordance with API STD 614 Chapters 1 and 4. See

Section 5.6 of API STD 619 for further details.

The CONTRACTOR shall furnish complete seal support system, as described in

Section 5.6.2 of API STD 619.

8.3.7 Miscellaneous

Name plate data shall be permanently etched, stamped, or embossed into the

metal surface. Printing or painting data onto the nameplate is not permitted.

The nameplate shall be in the English language.

An allowance for laser-based engine and coupling alignment shall be inherent

in the design of the equipment base. Alignment shall be verified just prior to

shipment and at site. All bolting shall be confirmed as tightened to the proper

torque value.

Epoxy grout shall be used around all embedded items.

Compressor and engine mounting base shall be machined after all welding is

completed so that all the machined mounting pads contacting with compressor

and motor legs are within 0.005" of each other in parallel when measured on

the milling machine.


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0.2" - 0.25" thickness adjustable shims shall be installed under motor legs only.

Compressor is fixed and adjustment shall be done by engine location. These

shims shall be adjusted during cool conditions.

All machine mounted equipment, piping, and tubing shall be fitted and

assembled in the Manufacturers shop.

8.4

Auxiliary Systems

As indicated, the gas compressor shall be supplied with cooling, lubrication,

and gas scrubbing and filtration systems as specified herein.

8.4.1 Cooling Systems

The compressor shall be furnished with a complete cooling system.

The base scope shall include a fin fan/lube oil cooler suitable for ambient

conditions. The system shall be designed to prevent the lube oil temperature

from dropping below the start permissive while the compressor is off line.

The compressor cooling system shall be complete with pumps, strainers,

isolation valves, sight flow indicators, flow control valves, surge tank,

instrumentation, interconnecting pipe, and all other devices required for a

complete system.

The compressor cooling system shall provide cooling for the lube oil coolers,

recirculation coolers, inter stage (VTA) coolers, and after coolers, as required.

An after cooler shall be provided. If a multistage unit is provided, and if

required by compressor design, the compressors shall be furnished with an

intercooler for reducing the gas temperature. Intercoolers or after coolers shall

be air cooled with electric motor driven fans.

Intercoolers shall be machine mounted with all interconnecting piping and

accessories furnished in accordance with ASME B31.1. Intercoolers and inter

stage equipment shall be shop mounted to check for proper fit and match

marked prior to disassembly and shipment.

A recirculation gas cooler shall be supplied in the recirculation line. This cooler

shall reduce the recirculated gas temperature to inlet conditions.

Lube oil coolers, intercoolers, after coolers, and recirculation coolers shall be

mounted with the compressor as part of the skid mounted unit and arranged

to allow space for installation and ease of maintenance.


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Inter stage (If required) coolers shall be provided with scrubbers, gauge

glasses, automatic condensate traps, valves, thermal relief valves, and drain

piping.

All gas cooler inlets and outlets shall be provided with thermometers.

8.4.2 Lubrication System

Each compressor shall be provided with a complete, force-feed, lube oil system

designed to furnish all lubricating oil required for the compressor and the drive

motor. The lubrication system shall be per API STD 619, and as specified

herein.

Each lube oil system shall include the following:

The lube oil system shall be equipped with the alarms, indicators and

shutdowns

Dual flow filter assembly including 10-micron replaceable element and

differential pressure indicator and continuous flow transfer valve with

isolation valves to facilitate the replacement of a filter element while the

other filter is in use. The filters shall be located in an easily maintainable

place.

Temperature control valve.

Strainer.

System relief valve for full pressure lubrication to bearings and seals.

Thermal relief valves for blocked-in equipment (i.e. coolers and filters) in

accordance with Section 5.10.1.2 of API STD 619.

Control oil system for hydraulic cylinder for slide valve movement. It may

be common oil system with lube oil.

Positive displacement lube oil pumps shall be supplied in accordance with

API STD 614 as follows:

When a lube oil pump is not necessary in normal operation, theManufacturer shall provide a motor driven pre-lube pump which has alsoautomatic cut in function when lube oil supply pressure hits low alarmpoint. If the pre-lube pump starts and oil pressure continues to fall, thecompressor shall automatically shut down.


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When a lube oil pump is necessary in normal operation, theManufacturer shall provide two motor driven positive displacement

pumps, one for main and another for stand-by. The stand-by pump shallbe a 100% capacity pump and have automatic cut in function when lubeoil supply pressure hits low alarm point. If the stand-by pump starts andoil pressure continues to fall, the compressor shall automatically shutdown.

Isolation valves and break-out union for pump removal and maintenance

without draining system.

Initial oil fill with recommended lubricant (regular oil and flushing oil).

Compressor oil reservoir with level instrumentation.

Thermostatically controlled electric immersion heaters shall be provided tomaintain the minimum required lube oil reservoir temperature such that

each compressor can start immediately upon a start signal, with no lube oil

preheating required. Oil heaters shall be sized and configured to have a

maximum surface temperature of 400 F exposed to the oil. A low oil level

switch shall be provided to de-energize the oil heater.

The lube pump shall be located in an accessible location and shall be piped

with block valves, strainer and a downstream check valve, and appropriate

flanges for ease of break-out and to allow removal with minimal

compressor oil loss.

All piping and equipment supports shall be supplied. The piping shall be

butt-welded stainless steel seamless pipe downstream of filters, and

upstream of filters may be socket or butt-welded stainless steel or carbon

steel seamless pipe. All piping shall be pre-piped and base mounted and

shipped as a packaged assembly.

8.4.3

Gas Scrubbing and Filtration

Gas separation and scrubbing equipment for equipment protection shall be

supplied for the compressor package to meet the exhaust gas requirements as

defined below:

A gas scrubber shall be supplied for the compressor inlet. The scrubber may

utilize mist demister pads or vanes to remove entrained liquid from the gas.


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The scrubber shall be designed and constructed in accordance with the ASME

Pressure Vessel Code and shall have an ASME stamp.

The scrubber shall be provided with the following accessories:

External level controller for auto drain

High level shut-down switch

Level gauge

Thermal relief valve

Dump valve

Vent valve

Manual drain valve

The scrubber vessels shall be skirt or leg supported and vertical, with

horizontal inlet and outlet connections.

Each vessel shall be provided with a gauge glass and angle type isolation

valves. The gauge glasses shall have a minimum length of 12 inches (300

mm). The vessels shall be provided with an automatic drain valve for the

discharge of liquids. All necessary controls for the drain valves shall be

supplied. A flanged cleanout connection shall be provided for each vessel. A

vent connection shall also be provided for each vessel.

A liquid filter/ separator or combination of bulk oil separators and coalescing oil

separators shall be supplied for the compressor outlet. The filter/separators

shall be a vane type line separator designed to remove entrained liquid from

the gas. Coalescing filters shall be supplied, as necessary, to meet the exhaust

gas purity requirements. The liquid separator and coalescing filters shall be

designed and constructed in accordance with the ASME Pressure Vessel Code

and shall have an ASME stamp. Bulk oil separator may be demister pad with

vertical type coalescing element, and coalescing oil separator may be

coalescing element type.

The separator and coalescing oil filter shall be provided with the following in

accordance with Section 5.10.3.5.5 of API STD 619:

High-level/ low level alarm, set point, and switch (two level switches)

External level controller for auto drain, or drain line back to compressor oil

system.


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Dump valve or drain line back to compressor oil system.

Level gauge

Vent valve

Thermal relief valve

Manual drain

Differential Pressure transmitter for oil coalescing element.

Electric heater for bulk oil separator

The separator vessels shall be skirt or leg supported and vertical, with

horizontal inlet and outlet connections.

Each vessel shall be provided with a gauge glass and angle type isolationvalves. The gauge glasses shall have a minimum length of 12 inches (300

mm). The vessels shall be provided with an automatic drain valve for the

discharge of liquids. All necessary controls for the drain valves shall be

supplied. A flanged cleanout connection shall be provided for each vessel. A

vent connection shall also be provided for each vessel.

8.5 Pulsation, Vibration Control and Analog Study

CONTRACTOR shall get the acoustic and mechanical evaluation study carried

out for compressor package (from inlet flange to discharge on skid edge Plus

200 ft piping) by a certified agency. The compressor CONTRACTOR shall be

totally responsible for all the coordination with the agency carrying out the

study. CONTRACTOR shall submit acoustic and mechanical evaluation report to

CLIENT.

9.

TECHNICAL REQUIREMENTS FOR ELECTRICAL

The Gas Engine Compressor Package shall be designed for installation in a

Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area. All equipment

installed within the module shall be suitable for a Zone 2 Gas Group IIA,

Temperature Class T3 Hazardous Area. Electrical equipment supplied outdoors

shall be protected to IP 56, while IP 42 protection shall be specified for

equipment installed indoors.

The CONTRACTOR shall provide appropriately certified stainless steel

interfacing junction boxes for all power and control signals on each separate

equipment for GEC. Separate junction boxes shall be provided for power, shut-

down, fire and gas, control and I.S. circuit.


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Electric motors shall be of the 3-phase, 50Hz cage induction, totally enclosed,

fan-cooled type and rated to start and accelerate the load with 80% voltage at

their terminals.

For EExd motors/enclosures, all cable gland entries shall be provided. A valid

Ex certificate shall be supplied for each Ex certified item (motor, enclosure,

junction box, cable gland, etc.)

Power supply for equipment such as circuit breaker shall be provided in Exd

explosion proof enclosure

All junction boxes shall be provided with 20% spare terminals so that all spare

cores of incoming cables can be terminated.

Separately installed equipments shall be suitably earthed by connection to theplatform deck via two earth M10 screwed bosses positioned on diagonally

opposite corners of the equipments.

Nameplates of electrical equipment shall be carried electrical classification

information.

Electrical power will be provided by the CLIENT at 400V AC, 3-phase 4 wires /

230V AC, 1-phase, 50Hz, neutral solidly earthed at source for lighting and

small power and 230V AC (UPS), 1-phase, 50Hz neutral earthed for UCP.

All AC electric motors, such as lube oil pumps, engine enclosure ventilatingfans, etc., shall be rated 400 volts AC, 3-phase, 50 Hz. All motors shall conform

to relevant IEC standards.

CONTRACTOR shall provide lighting fixtures for inside the gas engine enclosure

and inlet air filter. A battery pack that will allow the fixture to continue to

operate after a power outage for approximately 90 minutes shall be supplied in

the fixture.

Power and control wiring within the GEC package shall be in accordance with

BS 7671 IEE Wiring regulations 17th edition, and Specification for Electrical

Requirement for Packaged Equipment.

Solenoid coils furnished by CONTRACTOR shall be rated 24 VDC unless

otherwise specified.

Motors, switches, etc. shall receive full tropic

DHG PVE DD 3 ME SPC 007_Spec for Gas Engine Screw Compressor Package

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Transcript of DHG PVE DD 3 ME SPC 007_Spec for Gas Engine Screw Compressor Package