KOC_ME_018

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOCSTANDARD

FOR

RECIPROCATING COMPRESSOR AND DRYER FOR PLANT AND INSTRUMENT AIR SERVICE

(FACTORY ASSEMBLED PACKAGE UNIT)

DOC. NO. KOC-ME-018

STANDARDS DIVISION

1 DOC. NO. KOC-ME-018 I Page 1 of 38 I REV. 1

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC STANDARD

FOR



DOC. NO. KOC-ME-018

STANDARDS DIVISION

DOC. NO. KOC-ME418 I Page 2 of 38 I REV. 1

KOC STANDARD

FOR



DOC. NO. KOC-ME-018 (FORMERL Y 0 75- KH- 7008)

ISSUING AUTHORITY:

STANDARDS DIVISION ,---7

L,

1 3018100 Irrued m Standard Tnk Form (TF-ME101 1

FOREWORD

TABLE OF CONTENTS

Page No.

SCOPE

APPLICATION

TERMINOLOGY

REFERENCE STANDARDS, CODES AND SPECIFICATIONS

ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

MATERIALS

TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION

INSPECTION AND TESTING

QUALITY ASSURANCE

MARKING

DOCUMENTATION

SPARE PARTS & MAINTENANCE DATA

APPENDICES

APPENDIX 1: DATA SHEETS FOR COMPRESSOR

APPENDIX 2: DATA SHEET FOR AIR DRYER

APPENDIX 3: AIR COMPRESSOR PACKAGE INSTRUMENTS AND CONTROLS

APPENDIX 4: DATA SHEET FOR NOISE

APPENDIX 5: DATA SHEET FOR INSPECTION & TESTING

ACKNOWLEDGMENT

FOREWORD

This document "KOC Standard for Reciprocating Compressor and Dryer for Plant and Instrument Air Service (Factory Assembled Package Unit)" is intended to provide the minimum requirements for packaged plant and instrument air compressor and dryer for installation at KOC facilities in Kuwait.

This Standard has been approved by the Standards Division, in consultation with the Standards Technical Committee ( STC ), for use throughout the corporate engineering and operational functions of Kuwait Oil Company.

This Standard sets out to achieve the following objectives:

Specify the standard technical requirements for plant and instrument air compressor and dryer packaged units that have general applicability for all new installations; and help ensure a consistent and cost-effective approach in equipment selection.

Utilize operational experience to consolidate worthwhile and beneficial design, operating and maintenance cost saving features.

Cover the necessary aspects of design, fabrication, inspection & testing for the " package " in order to minimize the need for clarifications and disputes.

Introduce standard data sheets which:

- incorporate all essential features of API 61 8 Standard since API 680 is presently discontinued,

- maintain consistency with the text of this Standard, - provide a checklist to ensure that the specified items are considered.

Feedback, comments or suggestions, derived from the application of this Standard at any stage of design, purchase, manufacture, field construction (installation), operation, and maintenance are encouraged, and should be directed to:

The Superintendent of Standards Division (Chairman, Standards Technical Committee) Engineering Group, KOC P. 0. Box 9758, Ahmadi 61008 State of Kuwait

Task Force Responsible for This Standard

The Standards Technical Committee (STC) has entrusted the preparation of this Standard to the Task Force No. (TF-MEIO1) consisting of the following members:

Mr. S. Henry Hill Maint. Plng. Div. Team Leader Tel. No. 61 602 Mr. A. Macarian (Ex) Standards Div. Member Tel. No. 61 508 (Parsons Secondee) Mr. Met Welke Imp.& Corr. Div. Member Tel. No. 61 365 Mr. Mohd. Aslam lmadi Engg. Design Div. Member Tel. No. 61 102

DOC. NO. KOC-ME-018 I Page 5 of 38 I REV. 1

SCOPE

This Standard for " Reciprocating Compressor and Dryer for Plant and Instrument Air Service (Factory Assembled Package Unit) " specifies the minimum requirements for packaged reciprocating plant and instrument air compressor and dryer ( hereinafter called " the package " ) for Kuwait Oil Company (KOC) facilities in Kuwait.

This Standard covers the requirements for design, selection of materials and equipment, fabrication, assembly, inspection, testing, and packing for shipment of factory assembled and packaged reciprocating compressors, inter-coolers, after-coolers, dryers, lubrication equipment, interconnecting piping, instruments and controls for plant and instrument air service.

Any project-specific requirement will be specified in purchase documents, project specifications and data sheets.

Compressors Not Covered by this Standard

Vertical or y-type trunk piston compressors, without crossheads, for small light duty plant and instrument air, rated at 11 2 kilowatts (1 50 horsepower) or less are excluded from the scope of work of this Standard. However, suppliers may quote this type of light duty compressors to suit the specified capacity, but shall comply with applicable requirements of this Standard in conformity with purchase order data sheets. For such a case, the supplier shall have to obtain prior approval of KOC for any deviations/exceptions.

APPLICATION

All materials and equipment used for fabrication, assembly, inspection, testing, and packing for shipment of the packaged unit(s) shall be new and of high quality conforming to the requirements of this Standard and the reference standards / codes and specifications mentioned herein.

Compliance with this Standard does not of itself confer immunity from legal or statutory obligations.

TERMINOLOGY

Definitions

For the purposes of this Standard, the following definitions apply:

3.1 . I Supplier

The person or firm or vendor that manufactures and/or packages the equipment specified in this Standard.

3.1.2 KOC's Controlling Department

KOC's Project Management, Maintenance, Production Operations, or any other department authorized to initiate a request for procurement of materials and equipment for KOC.

3.1.3 Package

Reciprocating compressor and dryer package for plant and instruinent air.

3.2 Abbreviations

DCS : Distributed Control System ESD : Emergency Shutdown HSE : Health, Safety and Environment ITP : Inspection and Test Plan KOC : Kuwait Oil Company (K.S.C.) MRB : Manufacturing Record Book MSDS : Material Safety Data Sheet NDE : Non-Destructive Examination O&M : Operating and Maintenance PIM : Pre-inspection Meeting PQR : Procedure Qualification Records OAIOC: Quality AssuranceIQuality Control SSLS : Sequencing & Shutdown Logic System WPS : Welding Procedures Specifications

4.0 REFERENCE STANDARDS, CODES, AND SPECIFICATIONS

4.1 Conflicts

In the event of conflicts between this Standard and the standards 81 codes referenced herein, the subject shall be brought to the attention of KOC's Controlling Department for resolution, and review and/or amendment by Standards Division (if required). For sequence of precedence refer to clause 4.5 of this Standard.

4.2 Exceptions or Deviations

Exceptions or deviations from this Standard will only be considered when submitted in writing by the supplier and are supported by evidence of merit or justification.

4.3 List of Standards and Codes

The latest edition of the following standards, codes and specifications shall apply:

4.3.1 National / International Standards

API 613

API 614

API 615

API 618

API 661

API RP 685

ASME Section VIII, Division 1

ASTM 488

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

Lubrication, Shaft-Sealing and Control-Oil Systems for Specific Purpose Application

Sound Control of Mechanical Equipment for Refinery Services

Reciprocating Compressors for Petroleum, Chemical, and Gas Industries

Air-Cooled Heat Exchangers for General Refinery Services

Recommended Practices for Machinery lnstallation and lnstallation Design

Safety Standard for Mechanical Power Transmission Apparatus

Process Piping

Boiler and Pressure Vessel Code

Qualification of Procedures and Personnel for Welding of Steel Castings

Code of Practice for Safety of Machinery

Stationary Air Compressors

Belt Drives - V-Ribbed Belts, Joined V-Belts and V-Belts Including Wide Section Belts and Hexagonal Belts - Electrical Conductivity and Antistatic Belts: Characteristics and Methods of Test

Stationary Air Compressors - Safety Rules and Code of Practice

Quality Management and Quality Assurance Standards

Model for Quality Assurance in Design, Development, Production, Installation and Servicing Parts 1, 2, & 3

Model for Quality Assurance, Final Inspection & Test

Parts 191 0.21 1, OSHA Standard Occupational Safety and Health 1910.21 2 and 1910.219.1.1

Administration (Machinery Safety)

4.3.2 KOC Standards

KOC-E-004 (Part 1 )

KOC-MV-001 (Part. I ) KOC-MV-008

KOC Recommended Practice for Selection, Installation and Testing of Electrical Equipment in Hazardous Areas : General Requirements

KOC Recommended Practice for Design, Selection and Installation of Electric Cables, Cable Systems and Wiring

KOC Recommended Practices for Electrical Installations for Packaged Equipment

KOC Standard for Electrical Power Cables and Wiring

KOC Standard for Hazardous Area Classification

KOC Standard for Packing, Marking and Documentation

KOC Standard for Basic Design Data

KOC Standard for Spare Parts and Maintenance Data

KOC Standard for Instrument Cables

KOC Standard for Unfired Pressure Vessels

KOC Standard for Air Cooled Heat Exchangers

KOC Standard for Painting and Coating of Metal Surfaces - New Construction

4.3.3 Project Specifications

This Standard also makes reference to other specifications, which should be designated by the Controlling Department in KOC, in the absence of any KOC Standard, and Recommended Practice for the subjects listed below:

Title 1 Description

i) Electrical Design, Installation and Testing

ii) Induction Motors

iii) General Instruments

iv)

v

vi)

vii)

viii)

ix)

x

xi)

xii)

xiii)

xiv)

Instrumentation for Packaged Equipment

Plant / Equipment Noise Control

Thermal and Acoustic Insulation

Mechanical Completion of Instrument Systems

Materials and Workmanship for Structural Steelworks

Special Purpose Gearboxes

Nameplates

Recommended Practice for lnspection and Testing of New Equipment in Manufacture

Welding Procedure Approval and Welding Quality Requirements

Non Destructive Testing of Welds

lnspection of Castings for General Pressure Service

Order of Precedence

The supply of equipment, materials, services and documentation shall be in accordance with the State and local regulations, specific project and purchase order requirements. Should any conflict exist among the listed documents, then the most stringent shall govern subject to KOC agreement.

In case further clarifications are required, the subject shall be brought to the attention of KOC in accordance with clause 4.1 of this Standard. In general, the following sequence of precedence shall apply:

a) Kuwait Governmental Rules and Regulations b) Purchase order and specifications C) Data sheets and drawings d) This KOC Standard (KOC-ME-018) e) International codes and standards f) Vendor's standards and specifications.

ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Refer to "KOC Standard for Basic Design Data" (KOC-G-007) which provides general design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

DOC. NO. KOC-ME-018 I Pane 10 of 38 I REV. 1

HEALTH, SAFETY AND ENVIRONMENT

The supplier shall comply with the necessary & relevant health, safety and environmental regulations for the protection of KOC personnel, adjacent equipment, property, and the environment during the installation, operation - and maintenance of the package, manufactured and assembled to this Standard.

All applicable safety requirements of Occupational Safety and Health Administration (OSHA) Standard 191 0.21 9, BS 5304, BS 6244 and IS0 5388 shall be considered in the design, manufacture, and assembly of the equipment covered by this Standard.

MATERIALS

Steel casting repairs, if any, shall be per ASTM 488. Cast iron castings shall not be repair-welded, peened, burnt-in or impregnated.

Piston rod material shall be in accordance with manufacturer's standard appropriate for the service.

Refer specific KOC requirements, listed under clause 8.2 of this Standard, with respect to clause number {Z. 14 - Materials) of API 61 8.

TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION

General

Each compressor package unit shall be designed and constructed as a skid- mounted unit, which shall include, but not be limited to, the following:

Oil-free Reciprocating Compressor(s1, complete with pulsation dampeners.

Electric motor driver(s1.

Reducing gears or belt drives (as applicable).

Lube oil system including lube oil cooler(s) and lube oil filter(s).

Inlet air filtration unit and inlet silencer(s).

Finned type air-cooled heat exchangers for compressor intercooler and aftercooler.

Inter stage and discharge air-water separators.

h) All the associated piping, terminating with flanged outlet connections at skid edge, with counter flanges.

i) Fabricated steel base plate(s) for the complete packaged unit. Inter- coolers and after-coolers may be mounted on a separate skid, if required by shipping size limitations. In such a case, all the pipes and associated items to interconnect the separate skids shall also be included in the supply.

j) Locally skid-mounted panel(s) for monitoring and control.

k) Instrument air-drying system complete with pre-filters and after-filters.

I) Inter-stage and discharge relief valves accessible from grade or operating platform.

m) Moisture analyzers.

n) Condition monitoring system ( Vibration, Bearing / Housing Temp).

0) ~rovision for fixing working platforms.

8.1.2 Data sheets (Appendices 1 through 51, specified KOC Standards and project specifications shall be included in the purchase requisition for each package unit

8.2 Air Compressors, Drivers and Air Intake Filters

Specified below are additional KOC requirements, deletions, and exceptions to API Standard 618 and its appendices (hereafter referred to as API 618). Section, paragraph, and item numbers shown in {bolditalic font style} inside brackets, correspond to those of API 61 8, fourth edition, June1 995. Unless specified otherwise in purchase documents, specifications and data sheets, API 618 specification items not listed below (items with or without a bullet at the beginning of a paragraph in API 618) shall apply:

{Section 2 - &sic Design}

12.1 General)

{2.1.2} Maximum acceptable sound pressure levels (SPL) for remotely located and unmanned packaged units shall be 85-dB(A) measured 1 meter from the edge of a packaged unit.

In the absence of a specification for maximum permissible SPL for manned units, suppliers shall submit noise emission data in accordance with project specification and Noise Data Sheet with their quotation. Supplier shall submit a separate priced quote for noise suppression enclosure/treatment, when sound pressure level exceeds 85 dB(A) or the maximum SPL specified in purchase documents and data sheets.

{2.7.7}

12.7.7 7 )

{Z. 7.12)

{Z. 7.74)

{2.7.76}

{2.2

{2. 3

{2.3.7}

{Z. 3.2a)

f2.3. Zb}

Motor(s) shall be constant speed type. The motor speed shall be rated as specified on the purchase documents and data sheets.

The supplier shall be responsible for the complete packaged unit including overall design, fabrication, assembly, inspection, testing and performance of all the equipment, instrumentation and controls included in this package.

The equipment normal operating points shall be as specified in data sheets and purchase documents.

The packaged equipment shall be suitable for outdoor installation, without a roof, and unattended operation, unless specified otherwise in data sheets.

This clause is not applicable.

Allowable Speeds}

Air compressors shall be rated as specified in the data sheets. Supplier shall confirm that specified rated speeds will not result in high maintenance, or prevent trouble-free operation, under specified conditions. Average piston speed shall not exceed 3 metres per second.

Allowable Discharge Temperature}

The rated discharge temperature resulting from any specified service conditions, including part-load operation for each stage, shall not exceed the following:

a) 182" C (360" F) for non-lubricated cylinders. b) A temperature mutually agreed upon by the supplier and the

purchaser for synthetic oil lubricated cylinders.

An alarm shall be activated when the discharge temperature of any cylinder exceeds the rated discharge temperature by 1 l o C (20' F).

Supplier shall furnish 100% unloading capability for each compressor cylinder. Cylinder discharge high temperature set points and the operating mode will be further specified in purchase documents and data sheets.

t2.3.3 - Additional)

An alarm shall be activated and the compressor shall shut down when the discharge temperature of any cylinder exceeds the rated discharge temperature by 22O C (40" F).

{2.4.2) This clause is not applicable.

DOC. NO. KOC-ME-018

-

12.6.2. 7 ) If cylinder supports are required to avoid misalignment, they shall not be attached to the cylinder head. Rod run out shall not exceed 0.01 2 mm per 25.4 mm (0.0005 inch per inch) of stroke.

{2.6.2.3} Fine finish honed cylinders shall be supplied for oil-f ree compressors. Replaceable cylinder liners are preferred. However, cylinders without liners are also acceptable, if an allowance of a minimum of 3 mm for re-boring is provided. Cylinder orientation shall be in accordance with compressor manufacturer's standard.

The walls of cylinders without liners shall be of a thickness sufficient to provide for a total of 3.2 mm (0.125-inch) diameter of over-boring without encroaching upon either the maximum allowable working pressure or the maximum allowable rod load. Cylinder bores for non- lubricated services shall not exceed 0.81 mm (32 micro-inches) arithmetic average roughness height (Rs).

{2.6.2.6} Cylinder running bore coating is not required.

{2.6.3.7.7 & .2.6.3.7.2 Cylinder Cooling}

Static-filled and atmospheric thermosyphon coolant systems shall not be used.

These clauses are not applicable.

A self-contained, forced circulation, closed jacket cooling water system shall be furnished.

Valves and Unloaders}

Manufacturer's standard valve dynamics report for identical equipment will be acceptable to KOC. '


Manufacturer's standard design for cylinder-unloading method will be acceptable provided requirements of clause {2.3.2a&b} above are satisfied.

tistons, tiston Rods, and tiston Rings}

Unless otherwise specified in purchase documents, wear bands shall. be provided and they shall be single-piece construction designed to prevent

pressurization. If feasible, pistons shall be segmented to facilitate wear band installation. Wear bands and piston rings shall not overrun full open single-hole valve ports or liner counter-bores by more than half the wear band width or piston ring width. Where the cylinder design requires the wear band to overrun the valve ports by more than one-half the band with, the port design shall be of multiple-drilled-hole type to provide sufficient support for the wear band.

The bearing load on wear bands, if used, shall not exceed 0.69 bar (10 psi) based on the weight of the entire piston assembly, plus one-half the weight of the rod divided by the projected area of a 120-degree arc of all wear bands (0.866 OW, where D is the piston diameter and W is total width of all wear bands).

For non-lubricated service, the bearing load of fluorocarbon wear bands shall not exceed 0.34 bar (5 psi) based on the weight of the entire piston assembly, plus one-half the weight of the rod divided by the projected area of a 120-degree arc of all wear bands (0.866 OW, where D is the piston diameter and W is total width of all wear bands).

Piston rod treatment and finish under oil wiper rings shall be compatible with the wiper packing material.


Crankshafts, Connecting Rods, Bearings, and Crossheads}

Crankshaft material shall be forged carbon steel.

Compressor main bearings shall be replaceable split sleeve type for larger than 150-kilowatt packaged units and sleeve bushing type for 150 kilowatt and smaller units.

Replaceable and adjustable top and bottom crosshead slides are preferable, but crosshead guides will be acceptable substitutes for 150 kilowatt and smaller units.


Distance Reces}

Manufacturer's standard design will be acceptable to KOC.

{2.70.7.7, 2.70.7.3) & {2.70.7.4)


{2.70.2) Manufacturer's standard design will be acceptable to KOC.

Packing Case and Pressure Packing}

If particular packing is not specified in purchase documents and data sheets, the supplier shall recommend a packing arrangement. However, all oil wiper and seal rings shall be segmented and have garter springs.

Glands shall be bolted to the cylinder head or to the cylinder.

Adequate radial clearance shall be provided between the piston rod surface and the crank-end cylinder head bore, the compressor cylinder packing case, and the gland bore to eliminate possible scarring, when maximum wear of the piston wear band occurs.

Packing cooling is not preferred. However, if packing cooling is required for large units, supplier shall furnish his standard design for a closed liquid packing cooling system, separate from compressor frametcrankcase lubrication cooling system.

The clauses listed above are not applicable.

Compressor Frame Lubication}

Frame lubrication shall be by a pressurized system.

Unless otherwise specified, the lube oil system shall, in general, conform to API 61 4.

Lube oil cooling shall consist of a self-contained, forced circulation system complete with fans, pumps, expansion tank, piping and instruments. Finned type coolers shall be used. Cooler materials and design shall be per manufacturer's standards unless otherwise noted on purchase documents and data sheets. Two full capacity, full pressure lube oil pumps ( 1 main & 1 auxiliary) with an automatic start at low lubrication oil pressure shall be provided. Provisions shall be made for complete draining and venting of the cooling medium system.

Manufacturer's standard design for mounting location of the relief valve for crankshaft-driven lube oil pump will be acceptable. A permanent Y- type strainer with 20-mesh screen shall be provided for lube oil pump.


Duplex lube oil filters shall be supplied complete with a changeover facility with separate or integral continuous-flow transfer valve that provides for tight shutoff of the idle filter. The system shall be designed to permit replacement of filter element and re-pressurizing during operation.

The crankcase oil reservoir shall be supplied with the following characteristics and accessories:

a) The capacity to settle moisture and foreign matter adequately, to avoid frequent refilling, and to provide adequate allowance for system run down.

b) Fill connections, level indicators, and breather suitable for outdoor use.

C) Sloped bottom and connection for complete drainage.

d) Clean out openings as large as are practicable (but not less 4-inch).

e) An interior that has been descaled and protected from rust by the supplier's standard procedure subject to KOC review and approval. Permanent surface coatings shall not be applied without KOC's specific approval.

12.73 Cylinder and Packing Lubrication)

This clause does not apply.

12.74 Materials)

{2.74.7.6) There may be traces of hydrogen sulfide present in the atmosphere. Copper and copper bearing alloys shall not be used in the pressure containing parts.

{2.74.7.70}, {2.74.7.7 7) & 12. 74.7.73)


12.14.5.2.4) Manufacturer's standard quality control procedures or QA / QC manual shall be submitted to KOC for review.

12.74.7.5.1) Butt welds on pressure containing parts of equipment shall be 100% radiographed, and examined by magnetic particle or liquid penetrant inspection technique.

12.14.7.5.3) Proposed connection sketches shall be submitted to KOC for review before ~ fabrication.

13.7 Drivers}

The package shall include Electric Motor as driver. Electric motor driver(s) shall be in accordance with designated project specification for "Induction Motors" and motor data sheets included in the purchase documents.

13.7.3 Turbine Drivers}


13.2 Couphgs and Guards}

{3.2.7.2} Couplings for drivers shall be forged steel, flexible multiple membrane, non-sparking type. Low speed couplings if required per manufacturer's standard design, shall be soft rubber or steel with a low torsional stiffness, unless torsion analysis of the manufacturer's system will permit the use of a gear type coupling. Taper fit and parallel shaft ends type couplings will be acceptable to KOC (provided "taper lock" type half couplings are supplied).

Coupling guards shall be installed and they shall have sufficient strength to withstand the impact of coupling parts in case of mechanical failure.

Direct motor driven units shall have all steel couplings with a high torsional stiffness factor.

The supplier shall specify the maximum misalignment, both parallel and angular, which can be tolerated without affecting the specified bearing life or any other aspect of the compressor and driver assembly.

13.3 Reduction Gears}

13.3. 7 ) Preference shall be given to direct drive units. When supplier's standard design requires reducing gears they shall be in accordance with designated project specification for "Special-Purpose Gearboxes". Gearmotors, consisting of gear units that are integral with the electric motor, shall not be used. Single reduction gears designed for high reliability, as defined in AGMA 21 1, with a minimum of 80% no-load contact, and a surface finish of 64 root mean square (rms) or better shall be used.

If V-belt drives are used, pulleys shall be dynamically balanced and V-belts shall be of anti-static material.

{3.5 Mounting Hates, Beseplates and Skids)

Compressor, driver, gearbox (if required by supplier's proposed design), and all of the auxiliary equipment shall be mounted on a single fabricated steel baseplate. If multiple-section baseplates are required (based on shipping size limitations) and are approved by KOC, they shall have machined and doweled mating surfaces to ensure accurate field reassembly.

Anti-vibration mounts shall be provided, if required, based on the results of acoustical and vibration analyses.

Lifting lugs and earthing clips shall be provided. The baseplate shall be suitable for installation on concrete foundation. Sub-sole plates shall be provided. Equipment pedestals and baseplate shall be equipped with vertical jackscrews to facilitate shimming. The bottom surfaces of the baseplate shall be coated with a catalyzed epoxy primer applied to degreased white metal (commercially blasted to SSPC SP 6), followed by a top coat.

As a minimum, the instruments and controls listed in Appendix - 3 of this Standard shall be provided for each air compressor and dryer package.

For general design, fabrication, materials of construction, and inspection requirements of controls and instrumentation refer to designated project specification "Instrumentation for Packaged Equipment". All instruments and control devices shall be accessible from grade or operating platform(s), provided by the supplier as part of the packaged equipment.

13.6.2.3) Capacity control shall be obtained by suction and clearance valve unloading as follows:

a) Compressors with a brake horsepower of less than 75 kilowatts (1 00 horsepower) shall normally have a two-step unloading capacity control of 0% and 100%.

b) 75 to 187 kilowatts (100-250 brake horsepower) shall normally have a three-step unloading capacity control to provide 100, 50, and 0 percent nominal capacities.

C) Over 187 kilowatts (250 brake horsepower) shall have a five-step unloading capacity control if specified in purchase documents and data sheet.

Controls and Instrumentatrbn)

1 General)


d) Cylinder unloading may be accomplished by the use of valve depressors, the opening of clearance pockets, an internal bypass, or other methods pre-approved by KOC or specified in purchase documents and data sheets. Valve lifters shall not be used. When data sheets specify valve depressors, all inlet valves of the cylinder ends involved shall be furnished with unloaders.

e) Automatic startup unloading shall be provided to permit automatic starting or re-acceleration after temporary electric power failure.

13.6.2.3.1- Additionag Operating milosoph y

a) The air compressor package shall normally be started, controlled and shutdown by a remote main facility sequencing and shutdown logic system ( SSLS ). This unit shall have executive control of all inputs and outputs from the compressor and shall communicate with the plant Distributed Control System ( DCS ) for display, startlstop instructions, printing and data logging.

b) A local control panel, suitably rated for the hazardous area location, shall be provided on the skid adjacent to the compressor. This control panel shall contain all necessary equipment to enable field pre- commissioning and start-up of the packaged equipment. Local push- button initiators and a local/off/remote selector switch shall be provided.

C) The local/off/remote selector switch shall prevent the compressor from being started remotely by DCS when the switch is in the local selection mode.

d) All on-skid instrumentation and controls shall terminate at segregated junction boxes located at the edge of the skid.

e) The prime operator interface shall be the main DCS system. Dedicated page(s) shall be allocated to display all the equipment status, and

alarms.

f) The alarm and trip inputs shall be integrated into the DCS and main ESD System first-up sequences.

g) If two compressors are specified for a duty, one shall operate and the second one shall be on standby. If the pressure at the package discharge falls to a pre-set level, the standby unit shall automatically be brought on-line and operate in parallel with the lead compressor until the upper pressure limit is reached. The standby compressor shall unload and shut down after the upper pressure limits is reached, then the lead compressor shall unload for a pre-set period (of 30 minutes unless specified otherwise) before shutdown. Leadllag controls shall

be provided at the DCS to enable the operator to switch the electric motor-driven compressors such that each one has equal running and standby time.

h) The plant and instrument air compressors shall have a dual control system switch at the DCS system, whereby operation can either be switched to automatic start-stop or constant speed (automatic unloading) modes. The number of starts per hour shall be limited, within the SSLS logic functions, to the maximum that the electric motor can safely handle.

i) Purchase documents wiii specify any deviations from the operating philosophy stated above, based on varying applications and project requirements.

13.6.2.3.2 - Adi#ritrbnag Con W s and Instrumen tation Requirements

a) Control and instrumentation system shall be designed to protect personnel and existing equipment 1 services against injury or loss under all operating conditions and malfunctions. Remote monitoring and supervisory control instrumentation shall provide diagnostic information and warning of deterioration of equipment conditions.

b) A locally mounted control panel shall be installed on the compressor base plate and the electrical devices shall be housed in a NEMA 4 enclosure, unless specified otherwise in data sheets. Motor-driven compressors shall be started from this local control panel. KOC will specify area classification in data sheets and purchase documents. When specified, purge connections shall be provided and equipped with rotameter-type flow indicators.

C) The following locally mounted instruments shall be furnished, in addition to the instrumentation listed in Appendix-3 of this Standard:

i. Cooling jacket water discharge temperature (if water-cooled) ii. Reservoir oil level indicator . . . 111. Oil cooler inlet and outlet oil temperature.

d) 31 6 stainless steel tubing and double-ferrule compression fittings shall be used throughout for process and pneumatic connections.

e) All instrumentation shall be fully mounted, connected, supported, and protected from damage during shipment to the extent practical. Items

shipped loose shall be properly labelled for ease of identification and field mounting.

f) An instrument air supply header shall be provided on the skid.

g) dl instrumentation shall be readily accessible and adequately supported. Vibration isolation and protection devices shall be considered for all base-mounted instruments and control panel.

h) All instruments and controls, other than shutdown sensing devices, shall be equipped with sufficient number of isolation valves to permit field checking, calibration, and removal, while the system is in operation.

i) All alarm and trip instruments, within the confines of the package, shall be provided with separate taps. All alarms and shutdown shall be reported through the facility SSLS and DCS via hard wired signals and serial link to DCS.

j) Trip functions shall be preceded by an alarm function for providing opportunity for the operator to take corrective action before unit shut down.

k) Within the shutdown system logic, a lockout feature shall be provided at the compressor, with a local manual reset push-button, to prevent an automatic restart after normalisation of the various shutdown conditions.

13.6.6 Electrical Systems}

13.6.6.2) Supplier shall provide control panels suitable for the area classification specified in data sheets. Electrical power supply details for motors, heaters, hazardous area classification will be specified on data sheets and purchase documents.

All electrical equipment and components for hazardous areas shall be certified for the type of protection appropriate to the zone specified on data sheets. They shall also conform to the applicable parts of "KOC Recommended Practice for Selection, Installation and Testing of Electrical Equipment in Hazardous Areas: General Requirements" (KOC- E-004, Pt. 1) and designated project specification for " Electrical Design, Installation and Testing ".

13.6.6.6) All materials shall be suitable for tropical location.

f3.6.7 Vibration and Positfon Detectors}

Manufacturer's standard designs are acceptable unless specified otherwise in purchase documents.

13.7 Piping and Appurtenances}

13.7.1.5) All piping shall be designed, fabricated, installed and .tested in accordance with ASME B31.3. Air discharge and drain piping shall be adequately

I l3.7.2 Frame Lubricating Oil Hping}

supported within the confines of the package and shall be terminated at skid edge.

Piping from the dry-type air intake filters to the air compressor(s) shall be stainless steel to prevent rust and corrosion products from entering the -

fine finishlhoned cylinders.

{3.7.7.6} Supplier shall supply all interconnecting piping for the pieces of equipment on the skid, as well as lines entering and leaving, and ensure that piping, appurtenances, and vessels inside the packaged unit(s) are adequately supported up to the skid edge. Hot compressor discharge lines within operator's reach shall be insulated for personnel burn protection in accordance with designated project specification for "Thermal and Acoustic Insulation". Air piping from compressor to heat exchangers shall be provided protection insulation (IP).

All operating valves, manways, instruments and controls that require adjustment, inspection, and maintenance shall be made accessible from grade or operating platform(s).

{3.7.7.72.79} All gaskets and packing shall be asbestos free.

{3.7. 7.12.24) This clause is not applicable.

{3.7.7.74} All piping shall be manifolded into common headers and terminated with flanges at skid edge.

Bolting shall be furnished as follows:

a) The details of threading shall conform to ASME B1 . I .

b) Studs are preferred to cap screws.

C) Adequate clearance shall be provided at bolting locations to permit the use of socket or box wrenches. The supplier shall supply two sets of any required special tools and fixtures.

d) Socket-, slotted-nut-, or spanner-type bolting shall not be used unless specifically pre-approved by KOC.

e) Jackscrews, guide rods, and casing alignment dowels shall be provided to facilitate disassembly and re-assembly of cylinder heads.

I DOC. NO. KOC-ME-018 I Page 23 of 38 I REV. 1 I 13.7.2.71 Instrument sensing lines to safety switches, if used as manufacturer's

standard design, shall have a continuous flow of oil through them.

13.8 Inter- coolers and A fter-coolers}

a) Cooling water is not available for this application at KOC facilities. Compressor Intercoolers and aftercoolers shall be air-cooled. Air- cooled exchangers shall be manufacturer's standard design and shall conform to API 661 in general.

b) All piping, fittings, valves, including moisture traps, automatic and manual drain shall be installed as part of the reciprocating compressor package unit.

Air piping to and from the air-cooled heat exchangers to the skid of the compressor, shall be furnished by the supplier and shall be three ( 3 meters above the bottom of compressor package baseplate. Air coolers shall be mounted on a separate skid if required by shipping size limitations. Piping materials shall be in accordance with designated project specification for Piping Material Classes, unless specified otherwise in this Standard under {3.7.7.5} and purchase documents.

13.9 Pulsation and Vibration Control Requirements}

{3.9.2.7} Design approach for pulsation and vibration control shall be in accordance with manufacturer's proven standards used on similar size and type of equipment. Supplier shall submit details of design, components, and copies of acoustical and vibration simulation analyses report(s) to KOC for review and approval before start of fabrication or purchase of pulsation suppression devices.

c3.10 Air Intake Filters}

Air intake filters for suction from the atmosphere shall be furnished complete with silencers suitable for outdoor installation. Each filter shall be furnished with a differential pressure indicator and alarm relayed to the local control panel.

The filters shall be two-stage dry type capable of removing 100% of particles larger than one micron and prevent oil from entering the compressed air system. They shall consist of primary cyclone type filters, followed by secondary cartridge type filters and shall be capable of retaining the quantity of dust and sand with minimum pressure drop as specified in project data sheets and purchase documents. The velocity through the cartridge filters shall be reduced to minimise frequent replacement of cartridges. Regardless of type of filters used and specified

pressure drop, supplier's packaged unit shall deliver, at skid edge, plant and instrument air at pressures specified in purchase documents. Filters shall be suitable for extreme desert conditions as stated in "KOC Standard for Basic Design Data" (KOC-G-007).

Filters shall be of self-cleaning type or duplex type, suitable for changing filter elements in one filter while the second one is in operation.

13.7 7 Special Tools}

Manufacturer's standard recommended tools will be acceptable and shall be included as part of supplier's quotation with prices listed as separate items.

14.0 Inspection, Testing, and Reparation for ShMping}

14.7.4) Project data sheets and purchase documents will specify the extent of KOC participation in the inspection and testing of packaged equipment covered by this Standard. Fifteen calendar days of advance notice shall be given to KOC for inspections and tests. Refer to clause 9.0 of this Standard for additional inspection and testing requirements.

{4.4.7& 4.4.3.70 Reparation for Shipment}

For additional KOC requirements regarding packing for shipment, marking, shipping, and documentation refer to "KOC Standard for Packing, Marking and Documentation" ( KOC-G-004 ). Clause 12.0 of this Standard describes additional documentation requirements and deliverables for packaged plant and instrument air compressors.

Surface Preparation and Painting shall be in accordance with " KOC Standard for Painting and Coating of Metal Surfaces - New Construction " ( KOC-P-001 ).

Compressed Air Drying System

The drying system, consisting of air dryers, pre-filters and after filters, shall be designed to deliver dry and dust free air as specified in purchase documents and data sheets for drying system. If replaceable filters are used, the velocity through the filters shall be reduced to minimise frequent replacement of filter elements.

The air drying system shall preferably be mounted on a separate skid away from the compressor skid. If mounted on the same compressor skid, the following aspects shall be ensured :-

a) no vibration be transmitted on to the air drying system;

DOC. NO. KOC-ME-018 1 Pane 25 of 3 8 I REV. 1

b) compressor and dryer systems be easily detachable; C) sufficient space and unfettered access be provided around the air

dryer system.

Air pre-filters for condensate and mist removal shall be of duplex type with pressure differential indicators and alarms, automatic transfer valves and controls. Changeover from one filter to the other shall not interrupt or modify flow of air. Pre-filters shall be fitted with automatic drains and emergency manual drain valve. The system shall be designed to permit cleaning or replacing the filters without interrupting operation. Self- cleaning filters may be offered as an alternate for KOC consideration and approval.

8.3.4 Air Dryers

a) Dryers shall be of heat- less air-purged type. Each dryer column (tower) shall be capable of drying 120% of the rated flow of instrument air from the compressgr(s).

b) Each air dryer package shall provide full duty requirement and shall consist of two drying towers of which one is drying compressed air while the other is being regenerated.

C) The dryer package shall include all piping, valves, instruments, controls and wiring necessary for automatic, efficient and safe operation. Isolation block valves, bypass valves, and liquid traps shall be provided. The system shall include also an automatic moisture draining facility.

d) An automatic system shall control drying, regeneration and cooling cycles.

e) Each dryer column (tower) shall be provided with safety valves, pressure and temperature gauges.

f) Silencers for system de-pressurisation and re-pressurisation shall be included to comply with the noise level limitations as described in designated project specification for "PlantIEquipment Noise Control " and clause 8.2 of this Standard.

g) Valves on the dryer piping system shall permit manual operation.

h) A dew point analyser shall be installed on the air dryer outlet to indicate and alarm high dew point, and to monitor operating efficiency. Volt-free contacts shall be provided for remote indication.

i) The air dryer vessels shall be designed, fabricated and tested .in accordance with the requirements of " KOC Standard for Unfired Pressure Vessels " (KOC-MV-001, Part 1).

j) Automatic switching valves for air inlet to dryer columns shall be stainless steel ball valves. Manual changeover shall also be provided together with isolating valves for each column. The maximum pressure drop over the entire air drying system shall not exceed 0.76 bar (10 psi).

Air Intake Pre-Filters and After-Filters

Air intake pre-filters shall be fitted with automatic drains and emergency manual drain valves.

After-filters shall be of duplex type with pressure differential indicators, alarms, automatic transfer valves and controls. Changeover from one filter to the other shall not interrupt or modify flow of air.

The system shall be designed to permit cleaning or replacing the filters without interrupting operation. Self-cleaning filters may be offered as an alternate for KOC consideration and approval. The filters shall be capable of at least 100% removal of all particles larger than 1 micron.

As an alternative, the suppliers are encouraged to quote their standard packaged unit that meets the performance requirements specified on the equipment data sheets, purchase order, and this Standard, but shall list all exceptions taken with their justifications. Some of the justifications that would be considered by KOC, would be the enhancements of equipment reliability, cost savings and improvements in equipment delivery. However, for comparison, suppliers shall submit a base bid that satisfies all the requirements of this Standard, data sheets, and purchase documents.

INSPECTION AND TESTING

Material Inspection and Certification

Materials of construction and quality of workmanship shall be in accordance with data sheets, referenced standards and codes, and this Standard.

Completely filled out data sheets for equipment, instruments and appurtenances shall be submitted to KOC for review and approval before the start of work. Material test certificates shall be submitted to KOC for review and approval before start of fabrication.

Testing of materials may be carried out by the manufacturer or by a recognized testing organization.

When 1 00% radiography is specified, back gouged surfaces and completed welds on nozzle and flange attachment welds shall be checked by magnetic particle or dye penetrant examination.

All surfaces of forgings, regardless of thickness, shall be magnetic particle inspected in accordance with the requirements of ASME Section VIII, Division 2, Article 9-1 of Appendix 9, after finish machining.

All surfaces where temporary attachment welds have been removed shall receive a magnetic particle inspection after grinding.

All non-destructive examination acceptance tests shall be carried out after completion of post weld heat treatment.

When approved by KOC, radiographic examination may be performed before post weld heat treatment if ultrasonic examination is performed after post weld heat treatment.

Prior to the final inspection, all slag, loose scale, dirt, grit, weld splatter, paint, oil, test medium and other foreign matter shall be removed from inside and outside of the equipment.

For equipment in vibrating service all attachment welds to pressure parts shall have smooth "knuckle-radius" and shall be checked by magnetic particle or dye penetrant examination.

Skirt-to-vessel and saddle-to-vessel welds of air dryer and filter housing vessels shall receive an ultrasonic examination, where it is possible to design the weld detail to permit ultrasonic inspection. If ultrasonic examination is not possible, a magnetic particle or liquid penetrant examination shall be carried out on the first pass and on the completed weld.

Shop Inspection

The supplier shall be responsible for all required QAIQC and inspection work to satisfy the requirements of this Standard. KOC may additionally employ the services of inspectors, as deemed appropriate; to witness the required inspection and testing of materials and equipment covered by this Standard.

KOC inspectors shall have a minimum of 15 days of advance notice, and shall be provided access to supplier's shop(s) during fabrication, assembly, inspection and testing of all pieces of equipment and supplies covered by this Standard.

All shop inspection shall be made at the supplier's facilities prior to shipment. If required, KOC inspector shall be present when work is in progress.

The air compressor package, including auxiliary systems, shall be operated for four hours at the rated speed consisting of two hours of progressive loading and a minimum of two continuous hours at the rated discharge pressure level and full load.


The test shall prove mechanical operation of the compressors, reduction gears if any, drivers, and all auxiliary equipment as a complete unit. The test procedure shall be submitted to KOC for review and approval prior to conducting the test.

All instrumentation shall be calibrated before start of the 4-hour test. Test instrument calibration certificates shall not be older than six (6) months at the start of any test. All oil pressures, viscosities, and temperatures shall be within the operating range.

All connections shall be checked for tightness and any leaks corrected before the test. All warning, protective, and control devices shall be checked, and adjustments shall be made as required.

Compressor package performance in both capacity and dryness of air shall be measured and verified during the factory run test. Supplier shall submit his testing procedure to KOC for review and acceptance before the start of test.

Quality Plan

The equipment supplier shall prepare and submit a detailed quality plan for KOC approval prior to implementation. The quality plan shall consist of the following:

a) Inspection and Test Plan (ITP)

The ITP shall list the sequence of all inspection and testing activities. The plan shall include fabrication, assembly, inspection, testing, and packing for shipment in a chronological order, showing the frequency of control, the acceptance limits, the governing code and whether a document or report is produced for each activity.

b) Pre-inspection Meeting (PIM)

During the PIM the supplier and KOC will review and finalize the mark-up of the ITP, confirm the requirements for witnessing (W), surveillance (S), monitoring (MI, reviewing (R), in the plan. The approved quality plan shall be strictly adhered to throughout the entire fabrication, assembly, inspection, and testing period.

QUALITY ASSURANCE

The Supplier shall operate quality systems to ensure that the requirements of this Standard are achieved. The quality systems shall be preferably based on IS0 9000 series of Standards and the supplier shall demonstrate compliance by providing a copy of the accredited Certificate and a copy their quality manual. Verification of a supplier's quality system is normally part of the pre- qualification procedure and is, therefore, not detailed in th'is Standard.


Packing, marking, and shipping documentation shall comply with " KOC Standard for Packing, Marking and Documentation " (KOC-G-004).

DOCUMENTATION

General

All correspondence, instructions, data sheets, drawings, calculations or any other written information shall be in English language. In case of dual languages, one language shall be English.

All dimensions, units of measurement, physical constants etc. shall be in SI units, unless otherwise specified. (Pipe sizes to be generally mentioned in inches).

In addition to hard copies, all final documents such as texts, specifications, data sheets, and drawings shall be provided in approved electronic software formats (Latest versions of Microsoft Word, Excel, and Autocad). Calculations shall be submitted in widely used software forms agreed upon by KOC.

Delivera bles

Test Certificates and "as-built" Data Sheets of all pieces of equipment, appurtenances, and materials shall be submitted to KOC for review and approval before packing and shipment of equipment and supplies covered by this Standard.

The supplier shall submit to KOC for review and approval the Manufacturer's Record Book (MRB) with all test certificates, documents listed in clause 12.2.5 below, and equipment data sheets, with blanks filled out, for all equipment and materials in accordance with Appendix- 2 of this Standard.

Supplier shall furnish Operation and Maintenance (O&M) Manuals with the equipment. O&M manuals shall include installation, operating, servicing and maintenance instructions, for all major parts & components of equipment in the package. Operating instructions shall provide all the necessary information to allow KOC or contractor to train their personnel in the safe installation, operation and maintenance of the equipment.

Supplier shall provide material safety data sheets ( MSDSs ) for rust preventatives and other chemicals contained in the air compressor and dryer package unit(s). One copy of each MSDS shall be shipped with the packaged equipment.

Performance data and Certificates shall include, but not be limited to, the following :

Performance curves or tables for the compressors showing power and capacity versus discharge pressure; effects of unloading devices; operating limitations; calculation input and output data. Rod load and gas load charts for each step.

The effects of valve failure on rod loads.

Curves of starting speed versus torque for the compressors.

Curves of starting speed Vs electric motor at rated voltage and at the specified voltage reduction per project data sheets.

Dimensional outlines, fabrication drawings, vessel calculations, structural attachment details, and data for air-cooled heat exchangers, air dryers, and air filter container vessels.

Welding Procedures Specifications (WPS) and Procedure Qualification Records (PQR) and nondestructive examination (NDE) records.

Certified mill test reports for all pressure containing materials.

Testing procedures, test logs and test reports.

Torsional analysis and acoustic measurements.

SPARE PARTS & MAINTENANCE DATA

The supplier shall comply with the requirements of "KOC Standard for Spare Parts and Maintenance Data" (KOC-G-009).

The supplier shall provide a list of spares with prices for each of the following items with his quotation:

a) Recommended pre-commissioning and start-up spares b) Recommended spares for two years of satisfactory operation C) Recommended spares for routine overhauls after two years of

operation.

DOC. NO. KOC-ME-018 Page 31 of 38 REV. 1

14.0 APPENDICES APPENDIX-1: DATA SHEETS FOR COMPRESSOR (1 OF 3)

EQUIPMENT NUMBER: PREPARED BY: @ KUWAIT OIL COMPANY DATE: APPLICABLE TO 0 PROPOSALS 0 PURCHASE 0 AS B U I L T FOR KUWAIT O I L COMPANY U N I T : S I T E . KUWAIT SERVICE: PLANT AN0 INSTRUMENT A I R COMPRESSOR NOTE: 0 INDICATES INFORMATION TO BE COMPLETED BY PURCHASER 0 TO BE SUPPLIED BY MANUFACTURER 0 INFORMATION SUPPLIED BY PURCHASER

0 GENERAL MANUFACTURER: SERIAL NO. : TYPE : RPM: M A X . : RATED : M I N COMRPESSOR THROWS: NO. FURNISHED: MAX NO POSSIBLE: MAX. FRAME HP. @ MAX RPM @ RATED RPM.

DIRVER TYPE. ELECTRIC MOTOR. DRIVER RATED HP: RPM : DRIVER FURNISHED BY 0 COMPR. MFR. 0

RATED OPERATING CONDITIONS (EACH MACHINE) APPLICABLE SPECIFICATIONS

SERVICE: NORMAL (OPERATING) DESIGN 0 A P I RECIP. COMPR. STANDARD 6 1 8 .- STAGE : KK-ME-O18_ .................... 0 GAS COMPRESSED: AIR -- , -- ----..-- AIR .......... .....---.....p-p...

0 CORROSIVE DUE TO. . ------.p-.--,.-,..----- .... . 0 RELATIVE ............. HUMIDITY , % : ... 40 tO 100% ... 100% (WINTER . ..,., - 100k) 0 DESIGN DATA PER KOC-6-007 .................................. 0 MOL. W 28.13 . ---. 28.13 ... ACCESSOR I ES ....

1.39 1.39 '&~GJALUE~AT.~Y_C~~.~NL ..... .LL..L..L.L.~ . - - ................ COMPRESSOR MFR . SHALL FURNISH :

D Cp/Cv VALUE AT DISCHARGE. . ---- --p---...--.--.... - 0 PULSATION DAMPENERS .- 0 INLET TEMP (%I INOTE3): .... 50 50 0 INTERSTAGE P I P I N G & RELIEF VALVES .................................... . . . .- ............. 0 INLET PRESSURE. (BAR A ) : 1.013 1.013 0 SEPARATE MOISTURE SEPARATORS WITRAPS . ... . ..... . .-. .................. .... ....... . ................. MIN. PRESS BETWEEN STGS. (BAR) 0 INTER COOLERS: AIR-COOLED .... ..... ..... ........... ..... -- "

D ACTUAL OISCH TEMP. ('C) 0 AFTER COOLERS. ..... AIR-COOLED .---a

D DISCHARGE PRESS. (BARG) .. : .- ........................ COOLERS SHALL BE: ............

D Z @SUCTION ......... ... 0 PER MANUFACTURER'S STSNDARO

D Z @DISCHARGE 0 PER KOC STANDARD: KOC-MV-008 -" - ........... .... .... EXPECTED (CAPACITY TOLERANCE 3%. BHP TOLERANCE + 3 % ) 0 INSTRUMENT PANEL ........... . 0 WET ..---...-...........................................-.-.r ( k g t h r ) ........... . . D INLET (CORRECTED) ( N m / H I : ...... 3""""""-...3"""""" ...... ..3"""""".3""""""..3""""""3""""""......3""""""3""""""...3""""""-. ........ O INLET (CORRECTED) ( A m / H ) : ........................ .... ** RATED PER A P I (CAPACITY TOLERANCE . - O x 2 kW T O I U A N C E - d A D WEIGHTS AND DIMENSIONS

(DISCHARGE WET BASIS) ...n - 1 E T k g L h ~ --..- MAX. ERECTION -.. WEIGHT. k q : .,,

MAX. MAINTENANCE WEIGHT. k g : ..!J..LCO.CTE9., .... NM3!HN?iE,1.1..~ .............. 10IS.CHAr!~E.E.,W.F.T.,.B!!S!.S.~ ........

- Q B R A K . L k W l s l A G E - ToTALWT*,CESJEIVER&GEAR.- ... .... ~Q.~LOTAL~W~W!Y,.BE.~,~..~~OSSI~~ ~ L _ L _ L _ L _ L _ L _ L _ -APPROX2.-FCOORSPACL.).-.mn~..C..; Wwj H.1 .-

0 TOTAL kW REQUIRED BY DRIVE (WIGEAR LOSS INCLUDED): ROD REMOVAL DISTANCE. mn: CAPACITY CONTROL

TO PERMIT OPERATION 0 - 1 0 0 % AND 1 / 2 LOAD FOR LONG PERIODS

D AT AN INLET m 3 / h r ) . .......... - ... - 0 POCKETStVALVES OPEN*:

0 INLET PRESSL!RJ,J,BARA) :

0 DISCHARGE PEES. (BARA) :

0 ACTUAL DISCH. TEMP. (OC): --- ---- D BRAKE kWISTAG6:

0 TOTAL BRAKE, kW.

TO PERMIT OEPRATION: ---- 0 AT AN INLET ( m 3 / h r ) : -

9.POCKETS/VALS ... OPLNL- 0 INLET P R E S S m B A R A ) :

D DISCHARGE PRES. (BARA): -- 0 ACTUAL DISCH. TEMP. P C ) : - 0 BRAKE k W / S T A a :

CAPACITY CONTROL SHALL BE BY. % RATEO .... ~...~AE/~~L~...S~.EEOooTO~ ...... -.

0 PURCHASER'S BY -PASS

0 MFR. STANDARD AUTOMATIC CONTROL

0 STARTISTOP 0 ( 2 ) STEP 0 (3 ) STEP

0 ( 5 ) STEP 0 PILOTED BY REC. PRESS --.- 0 PILOTED BY PURCHSA ER'S INSTRUMENTATION

W/ : BARG A I R SIGNAL

0 CLEARANCE POCKETS: ..-- CYLINDER

0 FIXED 0 VARIABLE

0 MANUAL 0 PNEUMATIC 0 AUTOMATIC

0 SUCT. VALVE UNLOADERS. @ EACH CYLINDER .-

, TYPE: 0 PLUG 0 FINGER 0 -0 w4JAL 0 p N L w I L - ~ A U T ! T L C . " ........

.. ON AIRtPOWER FAILJRECOMPRESSOR 0 LOAD

--- * S - SUCTION VALVE UNLOAOERS, H - HEAD END. C = CRANK END. F = FIXED POCKET OPEN. V - VARIABLE POCKET OPEN

NOTES: 1 . ~ m ~ / h r @ 0 C. 1 A M . 2 . VENDOR TO F I L L I N ALL DATA & S U ! H X X .. .................... 3. MAXIMUMtMINIMUM AMBIENT TEMPERATURE.: 55O C I WNUS 3' C -.--..-..-.- * SEE A P I (NO NEGATIVE TOLERANCE. ETC. )

I I I I I No DATE REVISION I BY CHECKED I APPROVED

DOC. NO. KOC-ME-018 1 Page 3 2 of 38 I REV. 1

APPENDIX-1: DATA SHEETS FOR COMPRESSOR (2 OF 3)

ALTITUDE: L e s s t h a n 150m BAROMETER: AVG. 0 . 9 9 4 b a r a b s - DESIGN TEMP. . OC: 5 5 (SUMMER). -3 MIN. (WINTER)

DESIGN DRY BULB TEMP. OC: 50(AVERAGE). 8 0 (MAX.SOLAR) SUMMER

0 WINTERIZATION REQUIRED 0 TROPICALIZATION REQUIRED

UNUSUAL CONDITIONS: 0 OUST 0 FUMES --- 0 OTHER. SEE K K STD. NO. K K - G . 0 0 7

--- . EQUIPMENT SHALL BE SUITABLE FOR:

0 INDOORS 0 HEATED 0 UNHEATED ....... . - 0 OUTOOORS 0 UNDER ROOF 0 WITHOUT ROOF

0 ATTENDED OPERATION 0 UNATTENDED OPERATION ----------.-

0 AREA CLASS1 FICATION ZONE -NON HAZARDOUS -- .. COOLING WATER FOR COMP. CYLINDERS: ............................. - ......... 0 TYPE WATER. CLOSED C I R C U I T BY VENDOR

.... .... PRESS. BARG SUPPLY - RETURN M I N . : -. .. ........ TEMP OC SUPPLY: RETURN MAX.

INSPECTION AND SHOP TESTS

SHOP INSPECTION

MFR STANOARO SHOP TEST

VALVE LEAK TEST

CYL HYDRO TEST

HYDRO CYL WATER JKTS

CYL HELIUM LEAK TEST MWP

BAR OVER TO CHECK RUNOUT. ETC

MECH RUN TEST WISHOP ORIVER

MECH RUN TEST WIJOB ORIVER

AUK EQUIP OPER TEST

DISMANTLE-REASSMBLE INSPECTION

THIRD PARTY INSPECTION

REQUIRED

0 0 0 0 0 0 0

0

0 0 0 0

0

WITNESSED

0

0

0

0

0

0

0

0

0 0 0

0

0

PAINTING

0 MANUFACTURER ' S STANOARO

0 OTHER SPEC NO KOC-P-001

SHIPMENT

0 DOMESTIC 0 EXPORT 0 EXPORT BOXING REQD.

0 OUTDOOR STORAGE OVER 6 MONTHS

REMARKS :

I DATE: O U T I L I T Y CONSUMPTION

LOCKED FULL LOAC

ELECTRIC - H . P R o t o r Amps AMPS MAIN ORIVER

................... ENBE OIL PUMP I

.......................

.............................

.............. ............... .........................

....... TEAL POWER USAGE

...... ................ FRAME O I L HEATER ..... LUBRICATOR HEATER

..................... SPACE HEATER - .............. .............. ............. ?....---..... 1

/ WATTS: ! [VOLTS, i F Z :

ELECTRIC POWER FOR HEATERS:

VOLTS. 1 PHASE. 5 0 HERTZ

ALARMS AND SHUTDOWNS

COMP. MFR SHALL FURNISH SEPARATE ELEC CONTACTS FOR.

PRE -ALARM SHUTOOWN

LOW LUBE O I L PRESSURE 0 LOW MECH. LUBR. O I L LEVEL 0

HIGH COMP. J .W. TEMP: 0

HIGH LEVEL I N EACH MOIST. SEP. 0 0

HIGH GAS OISCH. TEMP. 0 LOW GAS SUCT. PRESS 0 0

HIGH VIBRATION 0 0 COMP. MAIN BEARINGS HIGH TEMP.

INTAKE FILTER DIFFENTIAL PRESSURE 0

REMOTE SHUTDOWN. ELEC. 0 PNEUMATIC 0 HYDR

PRE-ALARM CONTACTS SHALL: 0 OPEN 0 CLOSE TO SOUND ALARM

SHUTDOWN CONTACTS SHALL: 0 OPEN 0 CLOSE TO SHUTDOWN

0 CONTROL CURRENT: VOLTS: PHASE: HERTS: . ...

SWITCH ENCLOSURE: 0 EXP. PROOF 0 WEATHERPROOF

0 NEMA TYPE TO I P 6 5

TO CONFORM TO SPEC NO. :

1. VIBRATION MONITOR. MEASURING SENSORS SHALL - BE SUPPLIED PER INSTRUMENT DATA SHEET. - 2 . INSTRUMENT A I R COOLERS TO BE SUPPLIED AS PART OF COMPRESSOR PACAKGE.

0 INDICATES INFORMATION TO BE COMPLETE0 BY PURCHASER O BY MANUFACTURER

NO DATE REVISION BY CHECKED APPROVE0

/ ,

APPENDIX-1: DATA SHEETS FOR COMPRESSOR (3 OF 3)

REV BY CHECKED APPROVED DATE

ISSUED FOR QUOTATION

REVISION

APPENDIX-2: DATA SHEET FOR AIR DRYER

FOR: KUIJAIT O I L COMPANY U N I T : S I T E : KUWAIT

SERVICE: INSTRUMENT A I R DRYER N o . REQ'D 0 DRYER MANUFACTURER. MODEL NO.

OPERATION : 0 CONTINUOUS AREA CLASS1 FICATION : ___I____L________ ABSORPTION CYCLE: 0 INTERMITTENT ZONE: HOURS: MINUTES:

Nm /hr (NOTE 2 ) 0 NON-HAZARDOUS . ~.RATEP_.CAPACIT.,: REACTIVAT1E-CYCLE.: ....... 0 INLET PRESSURE. b a r g 0 HEATING: HOURS: MINUTES: 0 INLET TEMPERATURE: ' C ___ 0 REACTIVATION __ ......... _ HEATER POWER: - N / A COOLING: HOURS: - _. MINUTES: .... - _ ......,,., __ ..... _ _ OUTLET DEW PT @ L I N E PRESS. 7 . 0 b a r g : VOLTAGE: N / A PHASE: N I A FREQUENCY: N / A RE-PRESS: HOURS. MINUTES:

CONTROL POWER:

ECTRIC 0 STEAM 0 INTERNAL 0 EXTERNAL A U T O M A T I C D T l M E O C Y C L E

D PURGE CONTROL O PURGE FLOW IND. & C A L I B . CURVE 0 VISUAL MOISTURE INDICATOR 0 THERM. EXT. HEATER OISCH.

O ACTUAL bar AFTERFILTER MOUNTED: 0 YES 0 NO O NOISE LEVEL : dB(A) AT 1 rn FROM S K I D MOTOR MANUFACTURER:

0 TO COMPLY WITH SPEC: TYPE: MOTOR HP:

0 U N I T F L O O R S P A C E . m n : L : W: H : 0 KOC STANDARD: ...... -. -

- -

1 RPM CURRENT

0 U N I T OPERATING WEIGHT, kg 1 ----- - - - -- I VOLTAGE PHASE FREQUENCY

- I ENCLOSURE

I I APPLICABLE DOCUMENTS. NOTES: (1) VENDOR SHALL F I L L I N ALL DATA AND SUBMIT WITH PROPOSAL

( 2 ) THE'X~TED FLOW SHALL BE 120% OF ONE COMPRESSOR 0 KOC-ME-018

FLOW + 0 I S A RECOMMENDED PRACTICE 7 . 7

PURGE REQUIREMENTS. THE DEW POINT SHALL BE - 4 0 ' ~ (P 7 .0 BARG 0 INDICATES INFORMATION TO BE COMPLETED BY PURCHASER D BY MANUFACTURER I S A STD I S A . S 7 . 3

I I I I

I I I I I

No DATE REVISION BY CHECKRO APPROVEOD

.I DOC. NO. KOC-ME-018 I Page 35 of 38 I REV. 1

APPENDIX-3: AIR COMPRESSOR PACKAGE INSTRUMENTS & CONTROLS

Instrument & Location Local I Local Panel I Remote 1 Minimum Instruments for Each Plant and Instrument Air Compressor

F~rst Stage Discharge Pressure Indicator X lntercoolerlAftercooler Startistop Push Button X X lntercoolerlAftercooler High Vibration Switch X IntercoolerIAftercooler High Vibration Alarm and Shutdown X lntercoolerlAftercooler Running Light X lntercoolerlAftercooler Unit Alarm X F~rst Stage Discharge Water Separator Level X (Gauge) X (Switch) X (Alarm) First Stage Discharge Water Separator Temperature X Solenoid Valve & Mnfld on 1". Stg Disch Wtr Sep Drain Ln X S~ght Flow Indicator on First Stage Discharge Water Separator X

Low-Low Lube 011 Pressure X (Sw~tch) X (Alarm + Shutdown) Auxiliary Lube 011 Pump StartlStop Hand Switch X X Auxiliary Lube 011 Pump Runnlng L~ght X High Lube 011 Coolmg Water Temperature X (Switch) X Lube 011 Coolmg Water C~rculat~on Pump StartIStop Swltch X X Lube 011 Coolmg Water Clrc Pump Motor Running L~ght X (Sw~tch) X

Lube Oil Coollng Wtr C~rculat~on 3-way Temp Cont Valve X Low Flow - Lube 011 Cooling Water C~rculation X (Flow Mete) X (Alarm) H~gh Vlbratlon - Compressor Crankcase X (Switch) X (Alarm + Shutdown) High Temperature - Compressor Motor X (Sw~tch) Current lnd~cator - Compressor Motor X (Ind~cetor) StartlStop Sw~tch - Compressor Motor Common Trip Alarm - Compr Motor Common Fault Alarm - Compr. Motor Runnrng Light - Compressor Motor Common Alarm Conf~rmat~on - Motor Motor LocallOffIRemote Push Button Compressor StartIStop Push Button Auxhary Equipment Stadstop Push Button

Differential Press. - Air Dryer Inlet & Outlet Filters Dual Filter Transfer Valves - Dryer Inlet & Outlet Filters Pressure Relief Valves on Air Dryers Moisture Analyzer on Air Dryer Outlet

Pressure Indicator and Switch on Air Dryer Outlet

X X X

X X X

LEGEND: X = REQUIRED

X (Indicator + Switch)

X X X

X

X X (Alarm) X (Alarm) X (L~ght)

X

Minimum Instruments for Each Air Dryer Package Temp. lndicatmg Transmitter - Aw Dryer Inlet

X (H~gh Tamp Alarm)

X (High Moisture Alarm)

X I 1 X (Indicator & H ~ g h Alarm)

X (Unit Alarm)

X (High Moisture Alarm)

APPENDIX-4: DATA SHEET FOR NOISE

EQUIPMENT NUMBER: PREPARED BY: @ KUWAIT OIL COMPANY DATE: Octave Band SPL [dB(A)I at

Center Designated Location Frequency

KOC Vendor Guarantee Specifications

I I

Description of Designated Location: ... .. .......... . ... . ... ................. . .. . .. ... .... .. . ..... .,. ...,... ......,... . .. ,

SPL = Sound Pressure Level measured at 1 meter from the source. Supplier shall state the method used to obtain the specified values.

ISSUED FOR

REV BY CHECKED APPROVED DATE REVISION

DOC. NO. KOC-ME-018 I , Pape 37 of 38 I REV. 1

APPENDIX-5: DATA SHEET FQR INSPECTION & TESTING

EQUIPMENT NUMBER: PREPARED BY:

DATE: PROJECT DATA:

..................... 2. PROJECT TITLE: .... ----- 3. SHOP ORDER NUMBER: ---- - 4. ENGINEERING - REQUISITION NUMBER: ... .--------..-" .... 5. PURCHASE ORDER NUMBER: -- 6. SUPPLIER:

MATERIALS:

EXCEPTIONS & JUSTIFICATIONS:

INSPECTION AND TESTING: 1. MANUFACTURER'S SHOP INSPECTION: REQUIRED 0 NOT REQUIRED ........ . ........................ 2. SUPPLIER'S SHOP INSPECTION: 0 REQUIRED 0 NOT REQUIRED --., .... . .. .... .....................................................

3. KOC ... SHOP .... __- INSPECTION: 0 ...... REQUIRED ......... 0 NOT .. REQUIRED ... 4. PRE-INSPECTION .................................. MEETING: ......... .. . ..... 0 REQUIRED 0 NOT REQUIRED . 5. SUPPLIER'SIMANUFACTURER'S QA MANUAL: 0 APPROVAL ._. 0 INFORMATION ......... ..... .. ._____. __ .......................................... ...-. 6. INSPECTION & TEST PLAN: .... .......... APPROVAL 0 INFORMATION - .. . 7. PRODUCTION & INSPECTION SCHEDULE: APPROVAL 0 INFORMATION

_-_...p--.__-.--- __.(... ...

DOCUMENTATION: 1. COMPLETED DATA SHEETS AT ENQUIRY STAGE: 0 APPROVAL 0 INFORMATION

.. - - .

2. MANUFACTURING PROCEDURE: ____ 0 APPROVAL o INFORMATION .. .__.. ." . ...... ... .... .... 3. INSPECTION & TESTING PROCEDURES: 0 APPROVAL 0 INFORMATION .. _ .

4. SHOP REPAIR PROCEDURES: -" ---." APPROVAL 0 INFORMATION

--.-----,----..------~.-...--n - 5. COMPLETE BILL OF MATERIALS APPROVAL 0 INFORMATION

6. MATERIAL TEST CERTIFICATES: ----."-...-" 0 APPROVAL 0 INFORMATION - --------- -- .... 7. OPERATING & MAINTENANCE MANUALS: 0 APPROVAL 0 INFORMATION

8. 'AS-BUILT" DRAWINGS: --" .,, REQUIRED 0 NOT REQUIRED --- .-.-

9. PACKING. MARKING AND DOCUMENTATION: 0 REQUIRED 0 NOT REQUIRED

I ISSUED FOR QUOTATION

REV BY I CHECKED I APPROVED ( DATE I REV1 SlON

ACKNOWLEDGEMENT

The Standards Technical Committee (STC), consisting of the following personnel, has approved this Standard

Mr. Ali H. Baba (Standards Div.) Chairman Mr. Mohammad Emam (Insp.& Corr. Div.) Deputy Chairman Mr. S. Kumar (Standards Div.) Secretary/ Member Dr. Mohammad llyas (Standards Div.) Member Mr. Khalid S. AI-AIi (Maint. Proj. Div.) Member Mr. Henry S. Hill (Maint. Plng. Div.) Member Mr. Jassem Al-Quraini (PMD- North) Member

The draft of this Standard has been circulated to the KOC User Departments for their review and responses were received from the following: -

ENGINEERING GROUP PROD. & EXPORT OPNS. GROUP

Gen. Supdt. Engg. Services Gen. Supdt. Proj. Mgmt. (N&W)

Gen. Supdt. Proj. Mgmt. (S&E)

Gen. Supdt. Prod. Opns. (N&W)

MAJOR PROJECTS GROUP LOSS PREVENTION GROUP

Gen. Supdt. Engg. Projects (N&E) Gen. Supdt. Fire & Safety

MAINTENANCE GROUP INDUSTRIAL SERVICES GROUP

Gen. Supdt. Maint. Services. Gen. Supdt. Ahmadi Services Gen. Supdt. Transport & Plant

DRILLING OPNS. GROUP DIVIDED ZONE GROUP

Gen. Supdt. Drill. Engg. & Supp. Svcs. Supdt. Proj. Engg. & Facilities Div.

The Task Force ( TF- ME/ 01 ) comprising of the following members has prepared this "KOC Standard for Reciprocating Compressor and Dryer for Plant and Instrument Air Service ( Factory Assembled Package Unit ) ":

Mr. S. Henry Hill Maint. Plng. Div. Team Leader Tel. No. 61 602 Mr. Andre Macarian (Ex) Standards Div. MemberIAuthor Tel. No. 61 508 (Parsons secondee) Mr. Met Welke Insp.& Corr. Div. Member Tel. No. 61 365 Mr. M. A. lmadi Engg. Design Div. Member Tel. No. 61 102 Mr. S. Kumar Standards Div. Coordinator Tel. No. 6 1 407

KOC_ME_018

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Transcript of KOC_ME_018