Process Reciprocating Compressors (API 618) : Functional Specification
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brahim amiraProcess Reciprocating Compressors (API 618) : Functional Specification
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brahim amiraeni spa
exploration & production division
FUNCTIONAL SPECIFICATION
Process Reciprocating Compressors (API 618)
03022.MAC.MEC.FUN
Rev. 4 – February 2014
ENGINEERING COMPANY STANDARD
This document is property of Eni S.p.A. Exploration & Production Division.
It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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REVISION HISTORY
Rev.0 First issue
Rev.1 April 1989
Rev.2 July 1990
General revision
Rev.3 July 1996
Italian version
Rev.4 49 sheets plus 3 attachments (data sheets)
February 2014
General revision.
New and customized requirements are set in addition to those defined by the reference standard
API 618 “Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services” for
the purchase of reciprocating compressor packages for process gas service.
Changed code from SPC to FUN.
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Contents
1. INTRODUCTION............................................................................................................................ 6
1.1 Scope..................................................................................................................................... 6
1.2 Terms and Definitions............................................................................................................ 6
1.3 Glossary................................................................................................................................. 7
1.4 Units of Measurement ........................................................................................................... 7
1.5 Statutory Requirements......................................................................................................... 7
1.6 Contractor’s Responsibilities ................................................................................................. 7
1.7 Service life ............................................................................................................................. 8
1.8 Sub-suppliers List .................................................................................................................. 8
1.9 Language............................................................................................................................... 8
2. CODES, STANDARDS AND REGULATIONS............................................................................... 9
2.1 Project Specifications ............................................................................................................ 9
2.2 Industry Codes and Standards .............................................................................................. 9
Specification for belt drives. Endless wedge belts, endless V-belts, banded wedge belts, banded
V-belts and their corresponding pulleys......................................................................................... 9
2.3 Company General Specifications ........................................................................................ 11
2.4 Company Data Sheets ........................................................................................................ 11
2.5 Responsibility....................................................................................................................... 11
2.6 Deviations and Exclusions................................................................................................... 12
3. SCOPE OF SUPPLY.................................................................................................................... 13
3.1 Compressor Package .......................................................................................................... 13
3.2 Battery Limits ....................................................................................................................... 14
3.3 Exclusions of Supply ........................................................................................................... 15
3.4 Supply Options .................................................................................................................... 15
4. HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS ................................................ 16
4.1 Health, Safety and Environmental Regulations................................................................... 16
4.2 Area Classification............................................................................................................... 16
4.3 Noise Control ....................................................................................................................... 16
5. QUALITY ...................................................................................................................................... 17
5.1 Quality Management System .............................................................................................. 17
5.2 Project Quality Control Plan ................................................................................................ 17
6. BASIC DESIGN............................................................................................................................ 18
6.1 General ................................................................................................................................ 18
6.2 Bolting.................................................................................................................................. 19
6.3 Calculating Cold Run-out..................................................................................................... 19
6.4 Allowable Speeds ................................................................................................................ 20
6.5 Allowable Discharge Gas Temperature............................................................................... 20
6.6 Rod and Gas Loads............................................................................................................. 21
6.7 Critical Speeds..................................................................................................................... 21
6.8 Compressor Cylinders ......................................................................................................... 22
6.9 Valves and Unloaders ......................................................................................................... 23
6.10 Piston, Piston Rods and Piston Rings................................................................................. 24
6.11 Crankcases, Crankshafts, Connecting Rods, Bearings and Crossheads........................... 25
6.12 Distance Pieces ................................................................................................................... 25
6.13 Packing Cases and Pressure Packing ................................................................................ 26
6.14 Lubrication ........................................................................................................................... 26
6.15 Materials .............................................................................................................................. 27
6.16 Welding and NDE ................................................................................................................ 28
6.17 Nameplates & Rotational Arrows......................................................................................... 28
7. ACCESSORIES ........................................................................................................................... 30
7.1 Drivers ................................................................................................................................. 30
7.1.1 Steam and Gas Turbines................................................................................................ 30
7.1.2 Electrical Motors and VSD’s ............................................................................................ 30
7.1.3 Reciprocating Engines..................................................................................................... 31
7.2 Coupling and Guards........................................................................................................... 31
7.3 Reduction Gears.................................................................................................................. 31
7.4 Belt Drives ........................................................................................................................... 31
7.5 Barring Device ..................................................................................................................... 32
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7.6 Mounting Plates ................................................................................................................... 32
7.7 Electrical Motors and Auxiliary Equipment .......................................................................... 33
7.8 Instrumentation and Control ................................................................................................ 33
7.8.1 General ............................................................................................................................ 33
7.8.2 Control Systems .............................................................................................................. 33
7.8.3 Instrumentation ................................................................................................................ 34
7.9 Piping and Appurtenances .................................................................................................. 34
7.10 Valves .................................................................................................................................. 35
7.11 Intercoolers, Aftercoolers and Separators........................................................................... 35
7.12 Air Intake filters .................................................................................................................... 36
7.13 Pulsation and Vibration Control ........................................................................................... 36
7.14 Painting and Coating ........................................................................................................... 37
7.15 Enclosure............................................................................................................................. 37
7.16 Thermal Protection .............................................................................................................. 38
7.17 Earthing System .................................................................................................................. 39
7.18 Special Tools ....................................................................................................................... 39
7.19 Spare Parts.......................................................................................................................... 40
7.20 Assembly Degree ................................................................................................................ 40
8. OPERABILITY AND MAINTAINABILITY ..................................................................................... 41
9. INSPECTIONS AND TESTS........................................................................................................ 42
9.1 General ................................................................................................................................ 42
9.2 Inspections........................................................................................................................... 42
9.3 Tests .................................................................................................................................... 42
9.3.1 Mechanical Running Test ................................................................................................ 42
9.3.2 Performance test ............................................................................................................. 43
9.3.3 Other test ......................................................................................................................... 43
10. PRESERVATION, STORAGE, PACKING AND TRANSPORT ................................................... 44
11. WARRANTY AND GUARANTEES .............................................................................................. 45
11.1 Warranty .............................................................................................................................. 45
11.2 Performance Guarantees .................................................................................................... 45
12. CONTRACTOR’S DOCUMENTATION........................................................................................ 46
12.1 Tender Documentation ........................................................................................................ 46
12.2 Contract Documentation...................................................................................................... 46
13. SPECIAL REQUIREMENTS ........................................................................................................ 47
13.1 Sour Gas Service ................................................................................................................ 47
13.2 Offshore & Marine Installations ........................................................................................... 47
13.2.1 Vessel Installations...................................................................................................... 47
13.2.2 Weight Control ............................................................................................................. 47
13.3 Desert Installations .............................................................................................................. 48
13.3.1 Enclosure..................................................................................................................... 48
13.4 Arctic Installations................................................................................................................ 48
13.4.1 Materials ...................................................................................................................... 48
13.4.2 Enclosure..................................................................................................................... 48
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1. INTRODUCTION
1.1 Scope
This standard specifies requirements and gives recommendations for process reciprocating
compressors, based on “Reciprocating Compressors for Petroleum, Chemical and Gas
Industry Services” API Standard 618 5th edition, December 2007; ERRATA 1, November
2009; ERRATA 2, July 2010.
This standard amends and supplements various clauses of API 618. Furthermore, it
summarizes (highlights) some important clauses of API 618.
With respect to API 618, paragraphs are marked as follows:
clause added to API618
clause that modifies API 618
y clause that makes a decision, as required by API 618
9 clause that summarizes the corresponding API 618 clause
When input by Company is required for the specific Project, it is marked as follows: (Í).
1.2 Terms and Definitions
The “Company” is the party that initiates the project and ultimately pays for its design and
construction. The Company will generally specify the technical requirements.
The “Contractor” is the party that carries out all or part of the design, engineering,
procurement, installation, and commissioning or management of a project or operation of
a facility. The Company may sometimes undertake all or part of the duties of the
Contractor, e.g. when the Company awards the Contract directly to the Manufacturer.
The “Manufacturer” is the party that manufactures the compressor and performs the
design, engineering, procurement, installation, commissioning and management of the
compressor package, procuring other components from Sub-suppliers.
The “Sub-supplier” is the party that manufactures or supplies equipment and services to
perform the duties specified by the Manufacturer, typically sub-systems and components
of the main equipment.
The contractual structure may be one of the following:
o Company → (EPC) Contractor → Manufacturer → Sub-suppliers, or
o Company → (EPC) Contractor=Manufacturer → Sub-suppliers
The “compressor” comprises the main machine and its auxiliary equipment (lube, seal,
control etc.).
The “compressor package” (briefly, the “package”), in addition to the compressor,
comprises: the driver, the coupling, the separators, the cooler(s), all the valves,
instrumentation and the interconnecting piping that form a complete and self-sufficient
unit that needs process gas, utility fluids and electrical power to operate.
The “Project”, as related to requirements, indicates those set by the Company in the
specific Project documentation.
The word “shall” indicates a requirement.
The word “should” indicates a recommendation.
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1.3 Glossary
ADL administrative delay time
BOP balance of plant
CCPS compressor control & protection system
CCR central control room
CMMS computerized maintenance management system
CoG center of gravity
DCS distributed control system
EOH equivalent operating hours
LCR local control room
LDT logistic delay time
MDT mean down time
MMS machine monitoring system
MTBF mean operating time between failures
MTBO mean time between overhauls
MTTF mean time to failure
MTTO mean time to overhaul
MTTR mean time to recovery
PMI positive material identification
RPM revolutions per minute
SIL safety integrity level
SPL sound pressure level
VSD variable speed drive
1.4 Units of Measurement
The SI system of units and dimensions is used in this Standard. Any data or drawings
related to equipment supplied to this Specification shall use the SI system. The U.S.
Customary system may be employed for piping components dimensions (inches).
Pressure shall be relative and it shall be expressed in bar(g).
1.5 Statutory Requirements
Contractor shall fully comply with the legislation of the Country where the equipment
package is installed.
The Equipment supplied to this Specification adheres to the International Standards
referenced in Section 2.2 and the Company Specifications in Section 0. The Contractor’s
proposal should list other Codes and Standards to which equipment is designed and
built.
1.6 Contractor’s Responsibilities
This Specification is primarily intended to define the minimum requirements and does not
relieve the Contractor of its responsibility for the design, performance and safe operation
of the whole package.
The Contractor shall be responsible for the design, performance, guarantees, co-
ordination, manufacture, inspection, testing, preservation and packaging of the entire
compressor package, in accordance with the requirements of this General Specification
and Project Specifications and Data Sheets. This shall include as a minimum:
o provision of documentation;
o control and co-ordination of Manufacturer and Sub-suppliers;
o compliance with Statutory Requirements, Codes and Standards;
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o identification of all technical exceptions and deviations from this General
Specification, Project Specifications and all referenced Industry Codes and
Standards;
o consideration of equipment design and shipping arrangements for ease of delivery to
the site;
o provision of all necessary design certification.
The Contractor shall assure that the Manufacturer and all Sub-suppliers comply with the
requirements of this Specification and all reference Standards.
1.7 Service life
9 The equipment (including auxiliaries) covered by this specification shall be designed and
constructed for a minimum service life of 20 years and at least three years of
uninterrupted operation.
1.8 Sub-suppliers List
The Supplier (Compressor Manufacturer) shall submit to Company (Contractor) for
approval a qualified Sub-supplier list with relevant references and experience with similar
application. Such list shall be subject to the Company’s approval.
Any deviation from such list, for whatever reason, shall be notified to the Company
before the relevant suborder.
Suborders to Sub-suppliers not included in the qualified Sub-Supplier list shall not be
placed without the written approval of the Company.
1.9 Language
All drawings, data sheets, reports, manuals, correspondence and any other written
information shall be in the English language.
The nameplates shall be in the English language only.
Safety signs and indications (label, tags, etc.) at site shall be both in the English
language and in the local language, as required in the Project Specification (Í).
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2. CODES, STANDARDS AND REGULATIONS
The Codes, Standards and Regulations listed below shall be applicable. Unless
specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2.1 Project Specifications
Additional requirements, defined in the Project Specifications and Procedures (Í), shall
be adhered to by the Contractor.
2.2 Industry Codes and Standards
API Std 510 Pressure Vessel Inspector Certification Examination
API Std 618 Reciprocating Compressors for Petroleum, Chemical and Gas Industry
Services
API Std 613 Special Purpose Gear Units for Petroleum, Chemical and Gas Industry
API Std 614 Lubrication, Shaft-sealing, and Control-oil Systems and Auxiliaries for
Petroleum, Chemical and Gas Industry Services
API Std 661 Air-Cooled Heat Exchangers for General Refinery Service
API Std 670 Machinery Protection Systems
API Std 671 Special Purpose Coupling for Petroleum, Chemical and Gas Industry
Services
API 1B Oil Field V-belting
API 11P Packaged Reciprocating Compressors for Oil and Gas Production Services
API RP 686 RP for Machinery Installation & Installation Design
ASME V, VIII, IX Boiler and Pressure Vessel Code
ASME PTC 10-1997 Performance Test Code on Compressors and Exhausters
ASME B19.3 Safety Standard for Compressors for Process Industry
ASME B16 series Standards for Piping
ASME B31.3 Process Piping
ASTM Standards for Materials, Welding and Test Methods
NACE MR0175 Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
EN 287 Approval testing of welders; fusion welding
EN 288 Specification and qualification of welding procedures for metallic materials
ISO 1813 Belt drives - V-ribbed belts, joined V-belts and V-belts including wide
section belts and hexagonal belts - Electrical conductivity of antistatic belts:
Characteristics and methods of test
ISO 1940 - 1 Mechanical vibration -- Balance quality requirements for rotors in a constant
(rigid) state - Part 1: Specification and Verification of Balance Tolerances
ISO 8068 Lubricants, industrial oils and related products (class L) -- Family T
(Turbines) -- Specification for lubricating oils for turbines
ISO 9606 Approval testing of welders - fusion welding
ISO 9956 Specification and approval of welding procedures for metallic materials
ISO 10474 Steel and steel products - inspection documents
IEC 60079 series Electrical Apparatus for Explosive Gas Atmospheres
BS 903 part A16 Physical testing of rubber Determination of the effect of liquids
BS 3790 Specification for belt drives. Endless wedge belts, endless V-belts, banded
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wedge belts, banded V-belts and their corresponding pulleys
IEC 60034 series Rotating Electrical Machines
97/23/EC (PED) Pressure Equipment Directive
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2.3 Company General Specifications
03023.MAC.MEC.FUN Reciprocating Internal Combustion Engines
03591.MAC.MEC.FUN Steam Turbines (API 612)
03774.MAC.MEC.FUN Gas Turbines (API 616)
05497.VAR.ELE.STD Construction Methods for Electrical Material for Tropical Climates
(Tropicalization)
05882.COO.MEC.PRG 2 Years Operation Spare Parts for Mechanical Equipment and Machines
06778.ICO.ELE.STD Skid or Package Units - Typical Earthing Details
07423.PKG.GEN.SDS Inspection and Test of Package Supplies
08957.CMP.STA.STD Control Valves
08968.CMP.STA.STD Safety Valves
15801.PIP.MEC.SDS Manual Valves
20000.VAR.PAI.FUN Protective Coating, Galvanizing and Metalizing for internal and external
Surfaces of Offshore and Onshore Structures and related Components
20150.PKG.STA.FUN Instrumentation Automation Plants Included in Rotary Machine Package
20167.EQP.ELE.FUN Asynchronous Motors
20178.EQP.ELE.FUN Low Voltage Variable Speed Electric Drives
20179.EQP.ELE.FUN Medium and High Power Variable Speed Electric Drive
20182.COO.GEN.SDS Spare Parts
20185.COO.GEN.SDS Handling and Protection of Materials and Equipment
20186.COO.GEN.SDS Weight Control System
20187.COO.GEN.SDS Weight Control System for Engineering
20193.VAR.SAF.SDS Selection of Sensors and Gas and Fire Detection Criteria
20220.PKG.ETI.SDS Prefabricated Cabins for Electric Machinery and Equipment
2.4 Company Data Sheets
MOD.MEC.COA.001 Process Reciprocating Compressor Technical Data Sheets (TDS)
MOD.MEC.COA.101 Process Reciprocating Compressor Inspection & Test Data Sheets
(IDS)
MOD.MEC.COA.201 Process Reciprocating Compressor Required Document Data
Sheets (DDS)
2.5 Responsibility
Supplier is responsible for the design and engineering, the total mechanical and
aerodynamic performance, guarantee of the entire compressor unit and associated
auxiliary units, and compliance with the requirements set forth in this specification and
with applicable laws and regulation.
Nothing in this specification shall relieve the Supplier of the responsibility for performing
additional analysis tests, standard inspections and other activities that he considers
necessary to ensure the product, the equipment and workmanship are satisfactory for
the service intended, or as may be required by common usage or good practice.
Deviation to the requirements of this specification may be proposed by the Supplier,
providing are submitted to Company for approval, with the support of proper
documentation during the bidding phase.
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2.6 Deviations and Exclusions
The Contractor shall identify and list all deviations and exclusions to the Company
requirements.
Unless deviations and exclusions are explicitly signaled by the Contractor in its Proposal
and agreed upon with the Company, the Contractor’s supply shall be considered fully
compliant with all the Company requirements.
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3. SCOPE OF SUPPLY
3.1 Compressor Package
The Compressor Package configuration for the envisaged service, including the
definition of the Contractor’s battery limits, shall be defined by the Company (Í) and
endorsed by the Contractor.
The supply shall comprise, but shall not be limited to:
• compressor;
• driver (electric motor or gas turbine or steam turbine or engine);
• variable speed drive system (electrical or hydro-mechanical), if variable speed is
required for process qualification or during compressor starting;
• static frequency converter, if needed by constant speed compressor;
• soft-start equipment, if needed by constant speed compressor during starting phase;
• motor control center (MCC)
• UPS and battery systems (if required)
• load gear (speed-increasing/reducing gear);
• load coupling w/ guard;
• coupling mounting tools, if coupling is hydraulic type;
• Separator(s);
• Inter/aftercooler(s);
• shutdown valves;
• blowdown valve;
• flare valve;
• pressure relief valves;
• discharge check valve(s);
• suction throttle valve w/ actuator, if compressor is controlled by throttling;
• all interconnecting piping;
• suction temporary strainer;
• casing connections mating flange & gasket;
• enclosure, complete with:
access doors;
removable acoustic panels;
structural steel frame;
penetrating elements for cabling and piping;
HVAC system (main/stand-by fan, inlet duct, filter, outlet ducts);
fire & gas detection system;
fire extinguishing system (fixed);
hand-held CO2 fire extinguishers;
normal lighting system (AC) and emergency/safety lighting system (DC);
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platforms, catwalks, ladders and stairs.
• vibration monitoring system;
• bearing temperature monitoring system;
• control and protection instrumentation;
• control and protection system;
• load gear monitoring system;
• lube oil system;
• seal oil system (separated from lube system);
• buffer gas system;
• fugitive emissions recovery system;
• baseplate w/ accessories;
• anchor bolts
• foundation templates, embedded pieces, etc.;
• grounding connections on-skid;
• special tools required for disassembly and maintenance, if applicable;
• maintenance lifting system, if required (Í);
• other lifting equipment (shackles, lugs, beams, jackscrews, etc.), if necessary;
• surface preparation and coating/painting;
• nameplates;
• compressor breakout spools;
• commissioning & start-up spare parts.
3.2 Battery Limits
Battery limits depend on the specific configuration and, as such, should be defined at
Project level (Í). However, typical battery limits are:
o main process inlet shutdown valve (included);
o main process discharge shutdown valve (included);
o separators condensate drain valve (excluded);
o baseplate drains;
o baseplate: anchor bolts to be embedded in the concrete foundation or 3-point mount
gimbals;
o compressor casing(s) drains;
o lube/hydraulic oil: filling, vents, drains;
o instrument air supply;
o electrical:
junction boxes on baseplate for instrumentation;
terminal boxes on electric motors and heaters;
earthing connections on baseplate;
unit control system (compressor package) junction boxes;
VSD terminals, if provided.
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3.3 Exclusions of Supply
Typical exclusions are:
o multi-pair cables, optical fiber cables, and other cables from package junction boxes
to DCS;
o civil works and foundations for each skid;
o connections to the primary grounding system.
3.4 Supply Options
Optional items will be defined by the Project documentation, but the following may be
required:
o spare parts for 2-year operation (Í);
o capital spare parts (Í);
o supervision for site installation, commissioning and start-up (Í);
o training of personnel (Í).
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4. HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS
4.1 Health, Safety and Environmental Regulations
The Supplier shall be responsible for ensuring that the goods and services supplied meet
all applicable regulations on health, safety and environmental issues.
The equipment shall be designed to operate safely and satisfactorily in all expected
combinations of process, utilities, climates and environmental conditions including start-
up, shutdown, part load operation, and emergency cases, while retaining the overall
system security, reliability and availability.
4.2 Area Classification
Electrical equipment protection level shall be appropriate to the hazardous area
classification of the compressor package installation, as specified in
MOD.MEC.COA.001 (Í).
4.3 Noise Control
Limiting and attenuation of the sound pressure level (SPL) of all equipment furnished
shall be the responsibility of the Contractor. The equipment furnished by the Contractor
shall conform to the maximum allowable sound pressure level specified by the
Company in MOD.MEC.COA.001 (Í). In order to determine compliance, the
Contractor shall provide both maximum sound pressure and sound power level data per
octave band for each principal component supplied.
The sound pressure level of the equipment shall be submitted with the proposal and it
shall be guaranteed by the Contractor. Reference is made to Section 11.2 “Performance
Guarantees” below. The Vendor shall indicate what special silencing measures, if any,
are proposed in order to meet the specified levels.
For outdoor installations or when the noise level produced by the unenclosed equipment
is above the required level, a full acoustical enclosure, housing the compressor, its
auxiliaries and the driven equipment, may be provided. Reference is made to Section
7.15 “Enclosure”.
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5. QUALITY
5.1 Quality Management System
The Contractor’s proposed quality management system shall be certified as in
compliance with the ISO 9001 Standard. The Contractor’s Quality Management System
Certification shall be valid for design, engineering, project management, manufacturing,
maintenance and service of the compressor package.
A non-numbered copy of the Contractor’s Quality Management System Manual shall be
submitted with the Proposal.
In the event that the quality management system of the Contractor’s first tier Sub-
Suppliers is not certified as in compliance with the ISO 9001 Standard, the Contractor’s
shall submit to the Company the sub-supplier’s quality management system for approval,
before issuing any suborder to that Sub-Supplier.
5.2 Project Quality Control Plan
The Contractor shall issue a dedicated Quality Control Plan (QCP) including the tests
and inspections envisaged on all the equipment during fabrication. The QCP shall
provide for the planned and systematic control of all quality-related activities performed
during design/development, production, installation or servicing (as appropriate to the
given system).
The QCP shall be subject to the Company’s review and approval during the bidding
phase and the Company will request, at its own discretion, progress and technical audit
reports throughout the duration of the Contract.
All materials shall be inspected and tested in accordance with the applicable Codes and
the Project Inspection Data Sheets. The Contractor shall issue a plan for the tests to be
performed in its own and its Sub-Suppliers’ shops on raw, semi-manufactured and
finished materials in order to verify the compliance of the materials with the required
chemical, physical and mechanical characteristics.
The QCP shall include the procedures, inspections, tests, check points (R, W, H) for all
the critical phases of engineering, manufacturing, tests, preparation for shipment.
For each check point the Contractor shall indicate:
o Applicable Procedures;
o Acceptance criteria;
o Attendance of Parties (as per MOD.MEC.COA.101).
Reference is made to Section 9 “Inspections and Tests” below.
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6. BASIC DESIGN
6.1 General
Compressor ratings shall not exceed the limits of the Manufacturer’s design and shall be
within the Manufacturer’s actual experience. Only equipment that has proven its
reliability in similar service are acceptable. A reference of at least 3 units of the same
type and size and with an accumulated experience of 25,000 hours of operation is
required. Equipment that does not have an accumulated experience of 25000 hours is
considered prototype. If the Vendor proposes to supply prototype equipment then the
quotation shall clearly state that the offered equipment is a prototype and it shall be
accompanied by sufficient data for the Company to thoroughly investigate its suitability
for the intended duty and, in case, to accept it.
Unless otherwise specified, the compressor shall be horizontal and double-acting. Multi-
cylinder units shall be of balanced opposed design.
y The Company shall specify the equipment’s normal operating point and all other
applicable operating points such as start up, loading and unloading, regeneration, etc..
The Contractor shall confirm the compressor’s performance and mechanical capabilities
at the specified operating points (including valve selections). Unless otherwise agreed
by the Company, negative tolerances on capacity shall not apply to any specified
operating points.
Unless otherwise specified in the data/requisition sheets, liquid-cooling systems for lube
oil, cylinders and piston rod packing shall be designed for the following conditions on the
coolant side: Fouling factor on the coolant side: 0.25 m2.K/kW. Provision shall be made
for complete venting and draining of the liquid cooling system.
All equipment shall be designed to run safely to the relief valve setting including
accumulation .
Reciprocating compressors should normally be specified for constant-speed operation in
order to avoid excitation of torsional, acoustic, and/or mechanical resonances. When
variable-speed drivers are used, all equipment shall be designed to run safely
throughout the operating speed range, up to and including the trip speed. For variable-
speed drives, a list of undesirable running speeds shall be furnished to the purchaser by
the vendor. The occurrence of undesirable speeds in the operating range shall be
minimized. The application of variable speed drive systems (VSDSs) requires the
approval of the Company.
All electrical components and installations shall be suitable for the area classification,
gas grouping and temperature classes specified by the Company in the data/requisition
sheets.
The power required by the compressor at the normal operating point shall not exceed
the stated power by more than 3%. ( NOTE: this power tolerance refers to the required
power at Manufacturer's rated capacity.
The combined performance of the compressor and its driver under all operating
conditions shall be responsibility of the Vendor. The combined unit (or complete
package, if applicable) shall perform as well on its permanent foundation as it did on the
Manufacturer’s test stand.
The unit and its auxiliaries shall be suitable for start-up, operation and periods of
idleness under the specified environmental conditions. These conditions shall include
whether the installation is indoors (heated or unheated) or outdoors (with or without a
roof), maximum and minimum temperatures, unusual humidity, and dusty or corrosive
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conditions. The degree of winterization and/or tropicalization (e.g., allowances for
insulation) shall be mutually agreed upon by the Company and the Contractor. For
compressors installed in unheated areas, entirely or partly exposed to the environmental
conditions, the following minimum requirements shall be provided for:
(i) Dust-tight and watertight enclosure of the crankcase and distance pieces, vented and
purged when required.
(ii) If winterizing is required, the heating facilities should include crankcase, oil lines,
lubricators and cooling liquid piping, drains, vents, and instruments.
(iii) Complete drainage facilities of all cooling liquid spaces and lines.
y An intercooler shall be provided between each compression stage.
y An after-cooler shall be provided.
y A separator shall be provided upstream of the compressor and after each cooler.
y If feasible, the compressor body(ies), the load gear and the e-motor shall be mounted
on a single-lift skid. As a minimum, the skid shall contain the compressor body(ies) and
the load gear. The other packages shall be mounted on skid as far as possible.
The complete compressor unit shall be able to withstand the effects of a fully loaded
shutdown of the unit against the safety relief valve set pressure, including accumulation.
In the case of an electrical motor driver (either fixed or variable speed), the complete unit
shall be able to withstand the effects of a 2-phase short circuit. The complete unit shall
be capable of a restart with full opposite residual voltage.
The method of compressor control shall be proposed by the Contractor and approved
by the Company among:
Suction throttling
Valve unloaders
Clearance pockets
Speed variation
Cooled bypass from discharge to suction
For the purpose of establishing the total cost of ownership over the design life of the
equipment, the Contractor shall provide reliability and life cycle data, such as:
• Mean Time Between Failures (MTBF);
• Mean Time to Repair (MTTR);
• Mean Time Between Overhauls (MTBO);
• Mean Time to Overhaul (MTTO);
6.2 Bolting
Details of threading shall conform to ISO 261, ISO 262, ISO 724, and ISO 965 or ASME
B1.1. Cap screws shall not be used. Cadmium and Zinc plated studs, bolts, and nuts
shall not be used.
6.3 Calculating Cold Run-out
9 For horizontal compressors, the Contractor shall calculate the vertical cold runout,
including rod sag and submit these values, in conjunction with assumptions used, to
Company before the shop bar-over test. The shop-measured horizontal and vertical cold
rod runout shall be inside tolerances as stated by API 618 Standard. For non-horizontal
cylinders, the procedures and tolerances for runout measurements shall be agreed
upon between the Company and Contractor.
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6.4 Allowable Speeds
Process Compressors.
For process compressors (except in case of natural gas conveyance) rotation
speeds and corresponding average piston speeds shall be limited to the
following values:
o Maximum allowable speed of rotation shall be 800 rpm
o Maximum allowable average piston speed shall be 4.6 m/s.
Natural Gas Compressors
In natural gas compressors namely in those utilized for booster gas, gas
gathering, gas lift and gas reinjection service, the rotating speed and the
average piston speed shall not exceed the following limits:
Delivery Pressure Max. average piston Max. rotating
(bar abs) speed (m/s) speed (rpm)
< 70 5.3 1000
100 5.2 900
150 5.1 800
200 4.9 700
280 4.8 (*) 600
> 280 4.6 (*) 500
(*) piston/plunger stroke > 250 mm
For intermediate pressures the limits shall be obtained by linear
interpolation.
6.5 Allowable Discharge Gas Temperature
9 In General, unless otherwise specified and agreed, the maximum predicted discharge
temperature shall not exceed 150ºC. This temperature limit applies to all specified
operating and load conditions. The Contractor shall provide the Company with both the
predicted and adiabatic discharge temperature rise.
Special consideration shall be given to services (such as high-pressure hydrogen or
applications requiring non-lubricated cylinders) where temperature limitations should be
lower. Predicted discharge temperatures shall not exceed 135ºC hydrogen rich services
(molar mass less than or equal to 12).
For Natural Gas applications the max actual gas temperature at cylinder delivery shall
not exceed the following limit:
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Operating Pressure
Temperature at delivery (°C)
(bar abs)
< 70 150
150 135
370 120
For intermediate pressures the temperature limits shall be obtained by linear
interpolation.
Higher speeds and/or temperature can be allowed only if (when) referenced
and with Company approval
Each cylinder shall have its own dedicated temperature measuring point for alarm, and
a dedicated temperature measuring point for trip purposes. These temperature
measuring points shall be located in the nozzle neck between the cylinder discharge
flange and the pulsation bottle, but as close as possible to the discharge valves on the
cylinder. Each measuring point shall have its own thermowell.
6.6 Rod and Gas Loads
The combined rod load is defined as the algebraic sum of gas load and inertia force on
the crosshead pin. It shall not exceed the Manufacturer’s maximum allowable
continuous combined rod loading for the compressor running gear at any operating load
step. These combined rod loads shall be calculated on the basis of the set-point
pressure of the discharge relief valve including the allowed accumulation of each stage
and the minimum suction pressure corresponding to each load step.
In the proposal the basis for the Manufacturer's figure shall be provided, including
details of related critical stress areas.
The combined rod loads at normal operating conditions shall also be less than or equal
to 80% of the vendor's maximum allowable combined rod loads for the selected
compressor frame.
The gas loading shall not exceed the manufacturer’s maximum allowable continuous
gas loading for the compressor static frame components (cylinders, heads, distance
pieces, crosshead guides, crankcase, and bolting) at any specified operating load step.
These gas loads shall be calculated on the basis of the set-point pressure of the
discharge relief valve of each stage and of the lowest specified suction pressure
corresponding to each load step. The gas loads at normal operating conditions shall
also be less than or equal to 80% of the vendor's maximum allowable gas loads for the
selected compressor frame.
9 The compressor shall be capable of handling short duration excursions of operation
involving a load increase up to 10% above the maximum allowable continuous
combined rod load and/or maximum allowable continuous gas load. These excursions
shall be limited to a duration of less than 30 seconds and a frequency of no more than
twice in a given 24-hour period.
6.7 Critical Speeds
9 The compressor vendor shall perform the necessary lateral and torsional studies to
demonstrate the elimination of any lateral or torsional vibrations that may hinder the
operation of the complete unit within the specified operating speed range in any
specified loading step. The Contractor shall provide copies of the studies and shall
inform the Company of all critical speeds from zero to trip speed or synchronous speed
that occur during acceleration or deceleration.
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For compressor units involving either a VSDS, a motor driver, a geared motor driver or
turbine driver, the Vendor shall perform a torsional analysis of the complete
compressor/(gear)/driver system. Torsional natural frequencies of the complete driver-
compressor system (including couplings and any gear unit) shall not be within 10% of
any operating shaft speed and within 5% of any multiple of operating shaft speed in the
rotating system up to and including the tenth multiple. For motor-driven compressors,
torsional natural frequencies shall be separated from the first and second multiples of
the electrical power frequency by 10% and 5% respectively. If these separation margins
cannot be met, the Vendor shall perform an additional response analysis in order to
prove that the stress levels at resonance conditions are within well proven limits of the
Manufacturer. Additionally, for compressors with a VSDS, the Vendor shall perform a
response analysis of the rotating system during all possible resonance conditions which
may occur during run-up and within the complete operating speed range. All possible
excitation frequencies and consequent torques shall be considered.
In every response analysis the resulting stresses in the relevant components shall be
calculated using a maximum modal damping of 1%. (Modal damping is defined as the
damping ratio between the total combined structural and material damping and the
critical damping of the system under consideration).
In strength calculations the Manufacturer shall give due consideration to the combined
effect of static stresses, alternating bending and torsional stresses as well as the effect
of stress raisers, such as stress concentration factors and notch sensitivities. The
Manufacturer shall indicate the most highly stressed locations in the system and the
safety factor applied at these locations. Safety factors shall be clearly defined.
6.8 Compressor Cylinders
The MAWP shall be at least equal to the specified relief valve setting plus allowed over
pressure.
Unless otherwise specified in the data/requisition sheet, horizontal cylinders shall be
provided, which shall have top suction and bottom discharge. When vertical cylinders
are specifically allowed, e.g. for dry gases, these shall be designed so that complete
drainage of the cylinder is possible.
Step piston or tandem cylinder arrangements are not permitted.
All cylinders shall be supplied with replaceable liners, In addition, the cylinder shall be
thick enough to provide for re-boring to a total of 3.0 mm (1/8 in.) increase over the
original diameter. The increase in piston diameter shall not affect the cylinder maximum
allowable working pressure, the maximum allowable continuous gas load, or the
maximum allowable continuous combined rod load.
9 Cylinder supports shall be designed to avoid misalignment and resulting excessive rod
runout during the warm-up period and at actual operating temperature.
Each cylinder shall have a replaceable dry-type liner, not contacted by the coolant.
Liners shall be at least 9.5 mm (3/8 in.) thick for piston diameters up to and including
250 mm (10”). For piston diameters larger than 250 mm (10”), the minimum liner
thickness shall be 12.5 mm (1/2”). Liners shall be secured to prevent axial movement or
rotation. The liner fit to the cylinder bore shall be designed to enhance heat transfer and
diensional stability.
Note: Non-contacting vertical labyrinth type pistons do not necessarily need a placeable
liner.
The cylinder bore diameter shall not exceed 800 mm (32.50 inches). Larger diameter
bores will be considered only with review and approval of the Company.
The Compressor Cylinder shall be designed to mount (1) case mounted accelerometer
to it on a non-gasketed surface. The location of each cylinder accelerometer shall be
easily accessible in the field. The mounting shall be on a “FLAT” Boss cast into the main
part of the cylinder. The boss shall be drilled and tapped to accept an accelerometer
acceptable to the Company.
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9 Cylinders shall have cooling provisions according to the conditions of the following
services:
Static-filled coolant system
Atmospheric Thermosyphon coolant Systems
Forced – liquid coolant system.
Where Cooling Jacket System is selected, the arrangement shall be such that failure of
a gasket or other seal does not result in leakage of coolant into the cylinder or gas into
the cooling system. When cooling of cylinder heads is provided, separate non-
interconnecting jackets are required for cylinder bodies and cylinder heads. Cooling
water jackets for once-through systems shall have removable covers of ample
dimension for cleaning purpose.
When specified in the data/requisition sheet, a self-contained, closed loop jacket coolant
system shall be furnished.
Pumps in Cooling Jacket System shall be centrifugal pumps unless other types are
approved in the data/requisition sheet. Centrifugal Pumps shall be in accordance with
ASME B73 .
9 All openings or nozzles for piping connections on cylinders shall be DN 20 (3/4 NPS) or
larger and shall be in accordance with ISO 6708.
9 All connections shall be flanged or machined and studded, except where threaded
connections are permitted. All connections shall be suitable for the maximum allowable
working pressure of the cylinder.
9 Flanges shall conform to ISO 7005-1 or 7005-2 or ASME B16.1, B16.5, B16.42 or
B16.47 Series B as applicable.
9 Cast iron flanges shall be flat faced and conform to the dimensional requirements of ISO
7005-2 or ASME B16.1 or l6.42.
9 Steel flanges shall conform to the dimensional requirements of IS0 7005-1, ASME B16.5
or ASME B16.47.
9 Non-ferrous flanges shall conform to mutually agreed upon standards such as ISO 7005-
3.
6.9 Valves and Unloaders
Valve and unloader designs shall be suitable for operation with all gases specified. Each
individual unloading device shall be provided with a visual indication of its position and
its load condition (loaded or unloaded). Non-metallic (e.g. PEEK, engineered polymers)
plate, process poppet or ring type valves shall be supplied unless there is evidence of
unsatisfactory experience. Engineered polymers shall not contain any re-grind or re-
processed polymer. In addition, Unloaders are to operate at minimum available air
pressure value stated on the datasheet. Other valve designs will be considered only with
the Company approval.
Valve seat to cylinder gaskets shall be of soft iron or steel and of solid rectangular
design. Metal-jacketed gaskets shall not be used. The proposed type and material of
gaskets shall be subject to the approval of the Company.
y The vendor shall conduct a computer study of the valve dynamics to optimize the valve
sealing element motion during the opening and closing phase. The study shall also
include a valve dynamic response analysis of the valve component’s reactions to the
piping and compressor cylinder gas passage induced pulsations. The study shall include
a review of all operating gas densities and load conditions. “Unless otherwise specified”
the vendor shall submit a written valve dynamics report to the Company.
y If cylinder valve unloading is specified, the type of unloader provided (valve depressor or
plug-type) shall be mutually agreed upon. Valve assembly lifters shall not be used.
When valve depressors are used for capacity control, all inlet valves of the cylinder end
involved shall be so equipped where possible. Use of less than a full complement of
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suction valve depressors requires the Company’s approval. Capacity unloading
hierarchy shall be as follows:
o a. Cooled bypass / Recycle Piping. Unless otherwise stated on the data sheet,
machine shall be capable of starting with operating suction pressure on each stage.
Vendor shall advise the maximum pressure drop across the recycle start up valves.
o b. Plug or Port unloaders. Unloaders shall be pneumatically operated unless
otherwise specified on the data/requisition sheet. When unloaders are required on
cylinders that do not require a full complement of suction valves, plug type unloaders
shall be installed on the extra suction ports. Minimum number of valve unloader
steps shall be provided to maximize compressor reliability. Unloaders shall be
designed so indication of the loading state is clearly visible.
o c. Finger type unloader shall not be used, unless approved by the Company.
o d. O-rings with nitrogen purge shall be used to seal the unloader stem. Nitrogen
purge ports shall be provided for all selections.
The Vendor shall provide the Company with a system of properly sequenced unloader
operation.
y Unloaders shall be pneumatically actuated and shall be air-to-load. Individual hand-
operated unloaders or manual overrides on actuated unloaders are not permitted.
Remotely controlled unloaders shall be designed by the vendor in such a manner that
the correct sequence of operation between stages and cylinder ends is achieved.
Unloader actuator shall be sized to operate on minimum air pressure stated on the
datasheet without any plate fluttering, while in operation.
9 Unloaders shall be designed so that the operating fluid used for unloading cannot mix
with the gases being compressed, even in the event of failure of the diaphragm or
another sealing component.
6.10 Piston, Piston Rods and Piston Rings
9 Pistons that are removable from the rod shall be attached to the rod by a shoulder and
nut(s) design or a multi-through-bolt design. Other proven attachment methods may be
used, and in such cases they shall be noted by the Contractor in the proposal.
Piston rods shall be connected to the crosshead by (a) a direct connection, where the
rod is threaded into the crosshead, or (b) an indirect connection, where the the rod is not
threaded into the crosshead. Other proven attachment methods may be used, and in
such cases they shall be noted by the Contractor in the proposal. Hydraulic tightening
methods are required for all piston rod to crosshead connections.
Hollow pistons (single piece or multi-piece) shall be continuously self-venting. Vent
holes shall be located at the bottom of the piston. Spring-loaded relief plugs shall not be
used. Aluminium pistons shall have a wear resistant coating on the piston ring and the
rider ring landing.
y If specified, wear bands shall be of single- or multi-piece construction designed to
prevent underside pressurization (acting similarly to a piston ring). Pistons shall be
segmented if so required on account of the material of the selected wear (rider) band. A
Finite Element Analysis (FEA) is required for all piston designs where prior experience
with the identical piston in similar or more severe service cannot be demonstrated. The
methodology and results of the analysis are subject to Company’s approval. Piston ring
carriers supplied with multi-piece pistons shall be made of wear resistant material. Non-
metallic rings and wear bands (rider bands) shall be provided on all machines. Piston
and ring selections made shall be backed up with supportive evidence of successful
application in similar duty. Piston ring and wear band material selection, material
configuration and arrangement on the piston shall be based on a five-year continuous
operating period. Piston contour design shall be subject to these requirements. The
compressor Vendor shall submit to the Company a copy of the written selection report
made by the prospective ring suppliers. Selections made shall be backed up with
supportive evidence of successful application in similar duty. Rider bands in horizontal
cylinders shall have a maximum unit loading of 0.4 bar (5.4 psi) for lubricated or non-
lubricated cylinders.
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9 Unless otherwise specified, all piston rods, regardless of base material, shall be coated
with a wear resistant material. The material and surface treatment of piston rods shall be
chosen to maximize rod and pressure packing life and shall be proposed by the
Contractor for the Company’s acceptance.
6.11 Crankcases, Crankshafts, Connecting Rods, Bearings and
Crossheads
9 For compressors above 150 kW, crankshafts shall be forged in one piece and shall be
heat-treated and machined on all working surfaces and fits. The use of removable
counterweights is acceptable. For compressors equal to or less than 150 kW , ductile
iron is acceptable for crankshafts.
9 For compressors above 150 kW , replaceable, precision-bored shell (sleeve) crankpin
bearings and main bearings shall be used. For compressors equal to or less than 150
kW, tapered roller type bearings are acceptable for main bearings. Cylindrical, roller, or
ball type bearings may be used only with the Company’s approval.
9 For compressors above 150 kW, connecting rods shall be forged steel with removable
caps. For compressors equal to or less than 150 kW, ductile iron, steel plate, or cast
steel connecting rods are acceptable.
9 For compressors above 150 kW, crossheads shall be made of steel. For compressors
equal to or less than 150 kW , ductile iron is acceptable for crossheads.
9 If specified, the crankcase shall be provided with relief devices to protect against rapid
pressure rise. These devices shall incorporate downward-directed apertures (away from
the operator’s face), a flame-arresting mechanism, and a rapid closure device to
minimize reverse flow.
The crankcase shall have at least one top mounted vent connection and shall be
provided with a provision for a nitrogen sweep on the crankcase. A crankcase that has
more than four throws shall have at least two top mounted vent connections and shall be
provided with provisions for nitrogen sweep of the crankcase.
6.12 Distance Pieces
The Company shall specify the type of distance piece to be supplied. The Types are
listed as follows:
Type A—short, single-compartment distance piece used only for lubricated
service when oil carry-over (at the wiper packing and cylinder pressure
packing) is acceptable;
Type B—long single-compartment distance piece used for non-lubricated
service or for lubricated service where oil carryover is not acceptable.
Type C—long/long two-compartment distance piece designed to contain
flammable, hazardous, or toxic gases.
Type D—long/short two-compartment distance piece designed to contain
flammable, hazardous, or toxic gases.
Unless otherwise stated in the data/requisition sheet, the following type of distance
piece is required:
a) For air, nitrogen Type B.
b) “For very toxic service:” Type C or D.
c) For all other gases in lubricated service: Type B, provided that pressure
packing is purged with Nitrogen.
Note: Type D distance pieces is preferred to Type C if there is sufficient
room to replace the pressure packing without removing the piston rod.
Otherwise, Type C distance pieces shall be used.
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y Each distance piece compartment shall be provided with the following connections:
a. top vent connection at least DN 40 (NPT 11/2);
b. bottom drain connection;
c. if specified, a purge or vacuum connection;
d. a packing vent connection below the rod to facilitate liquid draining of the
packing case;
e. when required, packing lubrication;
f. where packing case cooling is required or specified, inlet and outlet
connections on the distance piece suitably arranged to facilitate draining and
venting.
See Figure G-3. See Annex I for vent and purge system schematics (API
Standard 618.
6.13 Packing Cases and Pressure Packing
y All oil-wiper packing, intermediate partition packing, and cylinder pressure packing, shall
be segmental rings with garter springs of a nickel chromium alloy (such as Inconel 600
or X750). If specified, shields shall be provided in the crosshead housings over the oil
return drains from the wiper-packing stuffing boxes to prevent splash flooding. Pressure
and wiper packing shall be filled Teflon or PEEK segmented rings. Metallic "backup"
rings can be used if necessary to prevent extrusion of the non-metallic ring.
For flammable, hazardous, toxic, or wet gas service, the pressure packing case shall be
provided with a common vent and drain, below the piston rod, piped by the Contractor to
the lower portion of the distance piece. See API Standard 618 Annex G. Packing case
vent and drain piping and fittings shall be of AISI 316 L stainless steel if compatible with
the process medium. Connections shall be minimum 1" NPT.
6.14 Lubrication
In addition to the requirements of ISO 10438-1 and ISO 10438-3 or API 614, the
following requirements apply to compressor lube oil systems:
The frame lubrication system shall be a pressurized system. The crankcase oil sump
temperature shall not exceed 70 °C (160 °F). Cooling coils shall not be used in
crankcases or oil reservoirs.
9 The basic oil system, shall contain, as a minimum, the following components:
reservoir—typically the compressor crankcase;
main oil pump (rotary internal screw or gear type)— which may be shaft-
driven or motor driven;
auxiliary pump, driven by an electric motor;
single cooler;
dual filters with a full flow transfer valve differential pressure indicator;
heater—when required;
pressure relief valve for each pump;
single regulator for control of delivered oil pressure (separate from relief
valves);
single regulator for oil temperature control;
valves—material shall be carbon steel with stainless steel trim;
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oil piping—shall be stainless steel pipe and fittings (with the exception of
cast-in-frame lines or passages); or stainless steel tubing and fittings
Unless otherwise specified, the vendor shall supply a divider-block mechanical lubricator
system for the compressor cylinder and packing lubrication.
Between oil filter and oil cooler a valved and flanged oil sampling connection shall be
provided.
Unless otherwise specified, cylinder lubricators shall be driven by two 100% redundant
electric motors. Each compressor cylinder packing box shall have at least two
lubricating points, in addition to the cylinder lubrication requirements. Unless the
Manufacturer has better experience and suggests otherwise, lubricating points within
the packing box shall be located on the upper side of the piston rod and at each end of
the packing assembly. Lubricators shall be suitable for outdoor installation.
6.15 Materials
9 Unless otherwise specified by the Company, the materials of construction shall be
selected by the manufacturer based on the operating and site environmental conditions
specified.
y The presence of any corrosive agents (including trace quantities) in the motive and
process fluids and in the site environment, including constituents that can cause stress
corrosion cracking, shall be specified by the Company (Í).
Note 1: Typical agents of concern are hydrogen sulfide, amines, chlorides, cyanide,
fluoride, naphthenic acid and polythionic acid.
Note 2: If chlorides are present in the process gas stream to any extent, extreme care
must be taken with the selection of materials in contact with the process gas. Caution
should be given to components of aluminum and austenitic stainless steel.
9 Copper and copper alloys shall not be used for parts of compressors or auxiliaries in
contact with corrosive gas or with gases capable of forming explosive copper
compounds.
9 Low-carbon steels can be notch sensitive and susceptible to brittle fracture at ambient or
lower temperatures. Therefore, only fully killed, normalized steels made to fine-grain
practice are acceptable. The use of steel made to a coarse austenitic grain size practice
(such as ASTM A 515) shall be avoided.
Material selection for auxiliary equipment, piping and instrumentation shall be in
accordance with API Std 618, Company requirements set in MOD.MEC.COA.001 (Í)
and suitable for the service and the site environmental conditions.
The Contractor shall specify within the bid all proposed materials, including
interconnecting pipework, and instrumentation.
The final material selection shall be subject to the Company approval.
All materials used shall be new and shall meet the requirements of the applicable Codes
and fabrication Standards.
Construction materials shall be identified according to ASTM-DIN Standard. Proprietary
or non-standard identification of materials shall be complemented by standard
identification.
Grey cast iron shall not be used.
Asbestos shall not be used in any part of the package.
Stainless steel shall be used for the lube and control oil piping.
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6.16 Welding and NDE
Welding & Welders shall be qualified according to ASME IX or EN 287. Welding
Procedures (WPS) and Welding Procedure Qualification Records (PQR) shall be
submitted to COMPANY for approval, prior to commencement of welding.
The Welding inspection and Non Destructive Examination Plan shall be mutually agreed
by the Contractor and the Company.
Welding inspection for the purpose of acceptance shall be performed after any post weld
heat treatment. Radiographic, ultrasonic, magnetic particle and dye penetrant
examination shall be performed by operators having an internationally recognized
qualification according to the acceptance criteria mutually agreed.
The reference Standard for non destructive examination shall be ASME V.
6.17 Nameplates & Rotational Arrows
9 A nameplate shall be securely attached at a visible location on the compressor frame, on
each compressor cylinder, and on any major piece of auxiliary equipment.
9 Rotation arrows shall be cast in or attached to each major item of rotating equipment at a
readily visible location.
9 Nameplates and rotation arrows (if attached) shall be of austenitic stainless steel or
nickel-copper (UNS N04400 alloy). Attachment pins shall be of the same material.
Welding is not permitted.
The following data, as a minimum, shall be clearly stamped or engraved on the frame.
Units used on the nameplates shall correspond to those used on the datasheets:
Project tag number;
year of manufacture;
Manufacturer’s name;
serial number;
rated speed;
stroke.
The following data, as a minimum, shall be clearly stamped or engraved on compressor
cylinders. Units used on the nameplates shall correspond to those used on the
datasheets:
Project tag number;
year of manufacture;
Manufacturer’s name;
serial number;
bore, stroke, model number;
Rated capacity;
Rated power;
Maximum allowable working pressure;
Minimum and maximum allowable working temperature;
Maximum continuous speed;
Cold piston end-clearance setting for each end;
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Hydrostatic test pressure.
The following data, as a minimum, shall be clearly stamped on the nameplate of any
major piece of auxiliary equipment:
Project tag number, if any;
year of manufacture;
Manufacturer’s name;
serial number;
model;
Nameplates shall be positioned to be clear of equipment surface or insulation by 40mm
and in such a way that they can be easily read, wherever possible from grade, adjacent
to a man-way or from an access platform.
Any additional information required by the Contractor or by the Company shall be defined
during the detail engineering phase.
The Contractor shall reference the Project equipment and instrumentation tag numbers
in its technical documentation. The Company will provide the tag numbers during the
detail engineering phase.
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7. ACCESSORIES
7.1 Drivers
y Unless otherwise specified, the compressor vendor shall furnish the driver and power
transmission equipment. The type of driver shall be as specified by the Company (Í).
The type of driver and drive system shall be as specified in the data/requisition sheet.
Driver shall operate under the utility and site conditions specified by the Company. The
full flow relief condition at the discharge (see ) and normal conditions at the suction shall
be taken into account when sizing the driver.
9 The driver shall be capable of driving the compressor with all stages at full flow and
discharging at the relevant relief valve set pressure.
9 The driver shall be sized to accept any specified (Í) process variations such as changes
in the pressure, temperature, or properties of the fluids handled and plant start-up
conditions.
The compressor Manufacturer shall be responsible for the performance of the
driver/compressor unit.
The Company shall specify (Í) anticipated process variations that can affect the sizing
of the driver (such as changes in the pressure, temperature or properties of the fluid
handled, as well as special plant start-up conditions). The driver shall be sized for all
process conditions stated on the data sheet with a 10 % margin and shall be capable of
operating at the relief conditions.
The Company shall specify (Í) the starting conditions for the driven equipment. The
starting procedure shall be agreed by the Company and the Contractor. The driver’s
starting-torque capabilities shall exceed the speed-torque requirements of the driven
equipment from zero to operating speed. The unit shall be suitable for starting with the
compressor at the maximum specified suction pressure with a bypass line (from the
discharge to the suction line) open, or with the compressor unloaded. The driver shall be
suitable for torque fluctuation at any degree of unloading.
NOTE: The bypass line pressure drop needs to be mutually agreed upon prior to
purchase of the driver.
7.1.1 STEAM AND GAS TURBINES
y Steam turbine drives shall conform to Company Standard 03591.MAC.MEC.FUN
“Steam Turbines (API 612). The turbine power rating shall be not less than 110% of the
power required (including power transmission losses) for the relieving operation
mentioned in 7.1, with the specified normal steam conditions. In addition, the turbine
continuous power rating shall be no less than 120% of the greatest power required,
(including any power transmission losses) when operating at any of the specified
operating conditions with the specified normal steam conditions.
Gas turbine drives shall conform to Company Standard 03774.MAC.MEC.FUN “Gas
Turbines (API 616)”. The gas turbine drive shall be sized for a maximum continuous
load (also known as base load) of not less than 110% of the maximum power required
by the machine train, when operating at any of the specified operating conditions, under
specified fuel conditions and site ambient conditions. The power margin should take
into account the gas turbine aging and the compressor aging and fouling.
7.1.2 ELECTRICAL MOTORS AND VSD’S
Electric motor drives shall conform to Company Standard 20167.EQP.ELE.FUN
“Asynchronous Motors”. The motor rating, inclusive of service factor, shall be not less
than 105% of the power required (including power transmission losses) for the relieving
operation specified in 7.1. In addition the electric motor rating, exclusive of service factor
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shall be not less than 110% of the greatest power required (including gear and coupling
losses) for any of the specified compressor operating conditions. The power margin
should take into account the compressor aging and fouling.
9 The electric motor’s starting-torque requirements shall be met at 80% of the normal
voltage, and the motor shall accelerate to full speed within 15 s or other period of time
agreed by the Company and the Contractor), during which time the electrical system
voltage will recover to normal voltage levels.
The electric variable speed drive, if provided, shall conform to Company Standards
20179.EQP.ELE.FUN “Medium and High Power Variable Speed Electric Drive” or
20178.EQP.ELE.FUN “Low Voltage Variable Speed Electric Drives”.
Electrical equipment protection level shall be appropriate to the hazardous area
classification of the package installation.
o When such equipment are foreseen power and control cables between equipment as
VSD, static frequency converter or Soft starter and electrical motor are not included
in the supply. Neverthless the supplier have to furnish sizing and technical
characteristic of the cables.
7.1.3 RECIPROCATING ENGINES
Diesel and gas engine drives shall conform to Company Standard
03023.MAC.MEC.FUN “Reciprocating Internal Combustion Engines”.
7.2 Coupling and Guards
9 Unless otherwise specified, a flexible coupling shall be supplied. The coupling shall be
of the all-steel, non-lubricated, flexible membrane, torsionally-rigid, spacer-type. For low
speed applications, couplings may be of the elastomeric type where necessary to avoid
torsional resonance problems. The coupling type, manufacturer, model, and mounting
arrangement shall be mutually agreed upon by the Company and the Vendor of the
driver and driven equipment.
9 If specified, the coupling or couplings shall be special purpose couplings conforming to
ISO 10441 or API 671. Coupling mountings shall conform to ISO 10441 or API 671.
9 Guards shall be provided by the vendor for each coupling, auxiliary drive coupling and
all moving parts which might be hazardous to personnel. Guards shall comply with
specified applicable safety codes.
7.3 Reduction Gears
Reduction gears shall be in accordance with the specifications identified in the data
sheets.
Reduction gears, which require forced feed lubrication, shall be integrated with the
compressor oil system unless the selected lubricating oils of compressor and gear do
not match. The system shall be arranged to prevent starting unless oil pressure has
reached the minimum permissible level.
7.4 Belt Drives
Belt drives can only be used for equipment of 150 kW (200 hp) or less and require
Company approval.
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If V-belts and tooth belts are provided they shall be oil resistant conforming to BS 903
part A16 and antistatic in accordance with either BS 3790, ISO 1813 or API 1B.
7.5 Barring Device
The compressor shall be fitted with barring gear that is either manual, electrical or
pneumatic.
Manual barring may be achieved by turning the flywheel, provided that the
arrangement is such that the barring tool cannot be retained.
The barring device shall be designed so that gas forces acting on the pistons cannot
cause the compressor either to accelerate or to rotate in the reverse rotation.
With the barring device engaged it shall not be possible to start the compressor.
7.6 Mounting Plates
Unless otherwise specified, the compressor shall be mounted on sole plates. The
design and method of installation on the foundation shall be mutually agreed upon.
The vendor shall furnish stainless steel shim packs between the drive equipment feet
and the mounting plates. The alignment shims shall be in accordance with API 686,
Chapter 7, and shall straddle the hold-down bolts and vertical jackscrews and be at
least 5 mm (1/4 in.) larger on all sides than the equipment feet. No more than three
shims shall be used at any location.
If a baseplate is required, it shall contain the compressor, drive motor, pulsation vessels,
lube system, purge panel and vent header. If possible, all associated piping shall be
mounted on the baseplate, including suction, interstage and discharge piping, gas
coolers, ricycle valve and jacket water system (when specified). A baseplate shall be a
single fabricated steel unit, unless the Company and the Contractor mutually agree that
it may be fabricated in multiple sections. Multiple-section baseplates shall have
machined and doweled mating surfaces to ensure accurate field reassembly, and
provisions for a sufficient number of optical leveling targets to record and repeat the
required level in the field.
If the compressor driver can be re-aligned after initial installation, removable vertical and
horizontal driver alignment jackscrews shall be provided.
Lugs holding these do not interfere with the installation or removal of the drive
equipment and shims. Jackscrews shall be plated for rust-resistance (cadmium or
other), and shall be placed in locations that do not interfere with removal of alignment
shims. Motor shims shall be full bearing. Each alignment support point shall include a
minimum of a ground 3mm (1/8 inch) solid stainless steel spacer and 1.5mm (1/16 inch)
total various thickness stainless steel shim
stock.
Baseplates shall be prepared by commercially abrasive blasting all grout contacting
surfaces and shall precoat these surfaces with a inorganic zinc silicate.
The Contractor shall submit drawings and calculations of the proposed baseplate design
for Company approval, before commencement of fabrication.
The baseplate shall be designed to meet allowable stress and deflection considering
transportation, lifting and operating loads.
Floor plates shall have drain holes (min 16mm dia) at low points to prevent the
accumulation of rainwater.
Anchor bolts for all equipment shall be supplied by the Contractor and they shall be
selected according to the site and operating conditions.
Equipment mounting pads shall be machined flat and parallel after welding to baseplate
supports. To prevent distortion, the machining of mounting pads shall be deferred until
welding on the support base in close proximity to the mounting pads has been
completed.
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The baseplate shall have vertical jacking screws along the main longitudinal members
with maximum intervals not exceeding 1500 mm. Anchor bolts holes shall be located in
the same reinforced area as the jacking screws.
The baseplate shall be equipped with pad-type lifting eyes to accommodate a four point
lift so that the complete package, including all equipments and accessories, can be lifted
with a single hook.
Two grounding bosses shall be supplied, one at each opposite end of the baseplate.
Vertical lift should be assumed for the design of the pad-eyes.
7.7 Electrical Motors and Auxiliary Equipment
Auxiliary electrical motors shall conform to Company Standard 20167.EQP.ELE.FUN
“Asynchronous Motors”.
Electrical equipment protection level shall be appropriate to the hazardous area
classification of the package installation.
When Motor control center (MCC) and/or UPS and battery system are included in the
extent of supply the following standard shall be followed:
o 20161.EQP.ELE.FUN “Low Voltage Switchgear And Control gear Assemblies (Up To
1000 V A.C 1500 D.C)”
o 20162.EQP.ELE.FUN “Ac & Dc Uninterruptible Power Supply Systems And D.C.
Back-Up Power Supply Systems”
o 20163.EQP.ELE.FUN “Electrical Storage Batteries For Stationary System”
7.8 Instrumentation and Control
7.8.1 General
y The Contractor shall provide the compressor control and safety system in conformance
with Company Standard 20150.PKG.STA.FUN “Instrumentation & Automation Plants
included in Rotary Machine Package” and unless otherwise specified in conformance
with API 614 Standards.
y The controls and instrumentation shall be adequate for controlling the compressor
safely and efficiently at the operating conditions specified in data/requisition sheet.
7.8.2 Control Systems
9 The compressor can be controlled on the basis of inlet pressure, discharge pressure,
flow, or some combination of these parameters. This can be accomplished by suction
throttling, valve unloaders, clearance pockets, speed variation, or a cooled bypass from
discharge to suction. The control system can be mechanical, pneumatic, hydraulic,
electric or electronic, or any combination thereof.
Contractor will provide the compressor control on the basis of the following as specified
by the Company(Í):
a. the type of control system (manual, automatic or programmable);
b. the control signal;
c. the control range;
d. the process sensing lines handling flammable, toxic, corrosive or high-temperature
fluids that require transduced signals to the instrumentation;
e. the source of the control signal and its sensitivity and range;
f. equipment to be furnished (by the Company);
g. speed of response required.
y The unloading arrangement for start-up and shutdown shall be stated on the data
sheets and shall be agreed by the Contractor and the Company. If specified, automatic
loading-delay interlock shall be provided to prevent automatic loaded starting. If
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specified, automatic immediate unloading shall be supplied to permit re-acceleration of
the motor after a temporary electric power failure of an agreed maximum duration. The
Contractor and the Company shall agree on the modes and duration of unloaded and
partially loaded compressor operation. The Contractor shall be responsible for the
loading/unloading sequence.
y Capacity control for constant-speed units will normally be achieved by suction valve
unloading, clearance pockets, or bypass (internal-plug type or external) or a
combination of these methods. Step-less, reverse-flow capacity control acting on
suction valves shall be subject to Company’s approval. Control operation shall be either
automatic or manual as specified on the data sheet. Unless otherwise specified, five-
step unloading shall provide nominal capacities of 100%, 75%, 50%, 25% and 0%;
three-step unloading shall provide nominal capacities of 100%, 50% and 0%, and two-
step unloading shall provide capacities of 100% and 0%.
y Capacity control on variable-speed units is usually accomplished by speed control, but
this can be supplemented by one or more of the control methods above specified.
7.8.3 INSTRUMENTATION
The instrumentation shall conform to Company Standard 20150.PKG.STA.FUN
“Instrumentation & Automation Plants Included in Rotary Machine Package”.
y Unless compressor is specified to be controlled by means of a DCS system, an
instrument and control panel shall be provided for the compressor Package.
y The instruments on each panel shall be clearly visible to the operator from the driver
control point. Panels shall be completely assembled, requiring only connection to the
Purchaser’s external piping and wiring circuits.
y Locally mounted controls and instrumentation shall be designed for outdoor installation.
y If specified, a tachometer shall be provided for variable speed units.
y Pressure and temperature monitoring of each stage, shall be provided by Vendor.
y Packing or piston rod temperature indication, as recommended by the vendor, shall be
provided for cylinders operating at or above a gauge pressure of 35 bar and for all
cylinders with liquid cooled packing.
y Main bearing and/or valve temperature detectors shall be supplied. Details of the
monitoring requirements and auxiliary equipment to be furnished (thermocouples,
resistance temperature detectors (RTD), intrinsically safe systems, etc.) shall be jointly
agreed to by the Company and the Contractor.
y An alarm/shutdown system shall be provided. The alarm/shutdown system shall initiate
an alarm if any one of the specified parameters reaches an alarm point and shall
initiate shutdown of the equipment if any one of the specified parameters reaches the
shutdown point. The Contractor shall provide the alarms and trips, as agreed with the
Company.I
y instrumentation and controls shall be designed and manufactured for use in the area
classification (class, group and division or zone) specified by the Company (Í) and
shall comply with any local codes and regulations.
All package instrumentation shall be wired to junction boxes at skid edges.
7.9 Piping and Appurtenances
9 Piping and installation shall first conform to the Company specifications. Unless
otherwise specified, in the absence of purchaser specifications, piping shall comply with
the requirements of API 614.
y The extent of process and auxiliary piping to be supplied by the vendor shall be as
specified by the Company.
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Auxiliary piping shall be in accordance with API 614. For the seal gas and lube oil
systems, piping classes shall be Manufacturer’s standard. Process gas piping, shall
comply with Company piping classes, which may be defined on a project basis.
All terminations up to and including 24” shall have flanges to ASME B16.5; flanges
greater than 24”shall be to ASME B16.47 Series A.
Gaskets shall conform to ASME B16.20/ASME B16.21.
All pipework shall be adequately supported and shall have sufficient flexibility to allow for
thermal expansion and contraction. Dissimilar metals shall have an effective insulating
barrier fitted in between the pipe and the steel support to avoid galvanic corrosion.
Threaded connections shall not be used unless where permitted by Company
requirements (Í).
Flange faces shall be installed plumb with respect to horizontal and vertical planes. All
steel pipe and fittings shall be free of scale, rust, weld flux, oil, grease and other foreign
materials. Interior welds of flanges and fittings shall be ground and finished to provide
smooth and matching bores.
No backing strips or rings shall be used.
All equipment shall have provision for drainage and venting. The minimum size of
drain/vent pipework and valves shall be 3/4”.
All drains and vents to atmosphere shall be fitted with blind flanges.
Drain piping shall be separate from relief valve discharge piping and they normally are
collected in a common header and routed to the edge of baseplate.
Where a piping system is connected to another piping system or to equipment of higher
design rating, the higher design rating shall prevail for all piping components up to and
including the first block valve in the system of the lower rating.
Piping termination points shall be grouped and supported at the edge of the baseplate.
The main piping connections shall be agreed between the Company and the Contractor.
Valves shall not be located on overhead pipe runs. Valves shall be preferably located on
horizontal pipe runs and, only when strictly necessary, on vertical pipe runs.
Threading of nuts and bolts shall be in accordance with ASME B1.1.
Piping and pipe supports shall be designed and arranged to allow heat tracing and/or
insulation. Any heat tracing and insulation shall be included in Vendor scope of supply (if
required).
Piping and pipe supports shall be designed to meet the requirements of vibrating and
pulsating service.
7.10 Valves
Valves shall conform to the Company Piping Classes and to the relevant standards:
08957.CMP.STA.STD “Control Valves”, 08968.CMP.STA.STD “Safety Valves”,
15801.PIP.MEC.SDS “Manual Valves”.
7.11 Intercoolers, Aftercoolers and Separators
If intercoolers, aftercoolers or separators are to be supplied, the extent of supply and
technical requirements shall be mutually agreed between Company and Contractor.
y If specified, the Contractor shall furnish an intercooler between each compression stage.
unless otherwise specified, intercoolers shall comply with API 614, Chapter 1 .
y If specified, aftercoolers shall be furnished by the Contractor. Unless otherwise
specified, aftercoolers shall comply with API 614, Chapter 1.
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Rupture discs are not allowed on the shell side of water cooled shell and tube
exchangers.
9 The choice of water on the tube or shell side of shell and tube heat exchangers shall be
agreed between the Contractor and the Company, with due consideration to pulsations,
pressure levels, corrosion and maintainability.
y If specified, liquid separation and collection facilities shall be provided upstream of the
compressor, and after every intercooler.
y When specified (Í) the Separators shall be designed, manufactured and tested
according to PED.
Separators shall be supplied complete with instrumentation and safety valves.
y When specified (Í) After-coolers shall be designed, manufactured and tested according
to PED.
7.12 Air Intake filters
For air compressors taking suction from the atmosphere, a dry type air intake filter-
silencer suitable for outdoor mounting shall be provided by vendor, unless otherwise
specified. Intake filters shall be designed to suppress noise and have sufficient stiffness
to prevent filter and filter housing damage due to pulsation-induced vibration.
7.13 Pulsation and Vibration Control
9 In order to avoid problems with detrimental pulsation and vibration basic techniques
used are:
a. system design based on analysis of the interactive effects of pulsations and the
attenuation requirements for satisfactory levels of piping vibration, compressor
performance, valve life, and operation of equipment sensitive to flow pulsation;
b. utilization of pulsation suppression devices such as: pulsation filters and attenuators;
volume bottles, with or without internals; choke tubes; orifice systems; and selected
piping configurations;
c. mechanical restraint design; specifically including such things as: type, location, and
number of pipe and equipment clamps and supports.
The Manufacturer shall provide pulsation suppression devices at the suction and
discharge side of each cylinder. Cylinders operating in parallel may be connected to a
common suction and a common discharge pulsation suppression device. The
application of pulsation filters and attenuators with internal pulsation control devices
such as choke tubes, baffles, and orifices requires an acoustic simulation and analysis,
as well a stress evaluation to assure that components are designed to withstand
acoustic forces. This analysis can be performed by the compressor vendor or a third
party consultant. Intercoolers and/or aftercoolers shall not be used as pulsation
suppression device.
Unless otherwise specified, Table 6 of API Standard 618 shall be utilized to determine
the Design Approach. For applications above an absolute pressure of 350 bar (5000
psia), the Company and the Contractor shall agree on the criteria for pulsation
suppression. Unless otherwise specified, only Design Approach 1 or Design Approach 3
may be used.
y The Company shall specify (Í) if the analysis is to be performed by the vendor or a
third party. If a third party is selected to perform the analysis, the compressor vendor
shall provide the necessary information required for the third party vendor to complete
the analysis. Acoustical simulation and/or mechanical analysis may be performed by the
compressor supplier or an approved independent 3rd party contractor
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If the results of an acoustical simulation and/or the results of a mechanical response
analysis are such that modifications to the piping and/or pulsation suppression devices
are necessary, the following shall be used by the Manufacturer in making proposals for
modifications, in descending order of preference:
1) Increase of volume bottle and/or pipe volume (if still feasible at time when results
become available).
2) The application of orifices. The restriction orifice plates shall be tagged as instrument
flow orifice plates.
3) The application of other types of pulsation suppression devices. Each modification is
subject to the Company approval.
y As a minimum, pulsation suppression equipment shall be designed and fabricated in
accordance with the specified (Í) pressure vessel code.
9 Material selected by the Contractor shall be compatible with process gases being
handled.
Suction pulsation suppression devices shall be designed to prevent liquid being trapped
and shall not be equipped with internals for moisture removal. All suction piping shall be
sloped back toward the KO Drum to prevent liquid accumulation in the machine suction
bottles.
9 If specified, the suction pulsation suppression device(s) shall include a final moisture
removal section as an integral part of the vessel.
9 Intercoolers and/or aftercoolers shall not be used as pulsation suppression devices.
7.14 Painting and Coating
Painting and coating of equipment shall comply with Company Standard
20000.VAR.PAI.FUN “Protective Coating, Galvanizing and Metalizing for internal and
external Surfaces of Offshore and Onshore Structures and related Components”.
Manufacturer’s standard painting system may be proposed as an alternative, but shall be
subject to Company’s review and approval.
The Compressor Package items shall be completely shop painted (including auxiliaries
and electric/instrument panels).
7.15 Enclosure
For indoor installations, a small enclosure around the compressor, without worker
access, may be used. To this configuration, the following clauses do not apply.
When the compressor package is envisaged for outdoor installation and when a full
enclosure is required it shall be built for all-weather conditions, and it shall be designed
to simplify maintenance and provide acoustical and thermal insulation.
The enclosure shall be ventilated to extract the heat generated by the compressor and its
auxiliaries, and to dilute the concentration of flammable vapors that may accumulate
within the enclosure. When different compartments separate the enclosure, each shall be
ventilated.
The enclosure shall be ventilated with forced-draught (thus maintaining a pressure above
atmospheric pressure). When the surrounding area is classified, gas and smoke
detectors shall be installed at the ventilation air inlet, so that a unit emergency shutdown
can be initiated. Only when the surrounding area is safe, may induced-draught
configurations (indoor pressure below the atmospheric pressure) be proposed by the
Contractor and they shall be subject to the Company approval. 2x100% duty ventilation
fans shall be installed. Ventilation air shall be filtered.
Enclosure inlet vents shall be equipped with self-cleaning updraft filters to remove dust
and sand (especially in desert environments), although the risk formation of dust cake
shall be assessed. The exhaust vents shall equipped with back draft dampers to prevent
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dust ingress when the unit is not running. For forced-draught designs, ventilation air shall
be taken from the inlet filter house downstream the filters.
Both the inlet and the outlet ventilation openings shall be equipped with a silencer.
The ventilation system shall be fully automatic and controlled by the compressor control
system.
The enclosure walls and roof shall be made of a structural steel frame and panels,
treated for sound attenuation and thermal insulation, removable for maintenance. The
access doors shall be industrial grade/self-closing type with panic bars. Penetration
elements for cabling and piping shall be provided.
The enclosure shall be equipped with an internal maintenance trolley rail.
A fire & gas detection system shall be provided as per 20150.PKG.STA.FUN
“Instrumentation & Automation Plants included in Rotary Machine Package” and
20193.VAR.SAF.SDS “Selection of Sensors and Gas and Fire Detection Criteria”. Flame
detectors, compensated rate of heat rise fire detectors, flammable gas detectors, smoke
optical detectors, F&G control panel with capability to test the detection system integrity
shall be provided.
A fixed total saturation fire extinguishing system shall be provided, using a clean agent
(e.g., Inergen), to prevent combustion without compromising the safety of any worker
present in the enclosure. CO2 as an extinguishing agent shall not be used, due to safety
hazards.
The extinguishing system shall be actuated:
o automatically (by the fire detection system),
o manually, with a push button in the electrical cabin,
o manually, with a mechanical switch on the outside of the enclosure.
A test valve shall be installed downstream of the release valves of each release
mechanism.
To ensure the safety of operation and maintenance personnel:
o alarm lights shall be provided on the outside of the enclosure and on the F&G control
panel to indicate: extinguishant system normal, extinguishant release and
extinguishant electrically isolated;
o acoustic and visual alarms shall be installed within the enclosure to signal
extinguishant release;
o a two-position switch shall be provided on the outside of the enclosure and on the
F&G control panel to inhibit or allow automatic release of the extinguishant;
o if the enclosure is entered by personnel without first inhibiting the automatic release
of extinguishant, an acoustic alarm will be fired and annunciated on the F&G control
panel.
Optical alarms for fire, gas and smoke in the plant shall be provided inside the enclosure.
Internal lighting, emergency lighting, small power outlets and the grounding system shall
be provided.
Where required by the ambient conditions, the enclosure shall be complete with an anti-
condensation heating system.
Electrical and control equipment shall be housed in separate cabins, as per
20220.PKG.ETI.SDS “Prefabricated Cabins for Electric Machinery and Equipment”.
7.16 Thermal Protection
Insulation for personnel protection shall be provided by the vendor. Compressor
casings normally accessible during operation shall be insulated and jacketed or
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provided with suitable lagging or guards so that no exposed surface in a personnel
access area exceeds a temperature of 60 °C. Jackets and insulation shall be designed
so that routine maintenance may take place without damage being done to the
insulation.
9 Where the application of insulation is not practical or interferes with unit design or
operation, barrier isolation such as an enclosure may be utilized (with the approval of
the purchaser) to protect personnel from excessive temperature. These barriers must be
readily removable for ease of maintenance or fitted with suitable access points.
All protections and shielding shall be easily removable.
All connections to electrical transmitters shall protrude through the protection. Cables
shall be installed outside the protection.
7.17 Earthing System
The package earthing system shall comply with Company Specification
06778.ICO.ELE.STD “Skid or Package Units - Typical Earthing Details”.
All electrical equipment supplied shall be bonded to the related skid.
Each skid shall be provided with two earthing bus bars for connecting to the main
earthing system.
All non-current carrying metalwork on the skid, which is not permanently welded to the
skid base, shall be bonded to the base using adequately sized earth cables.
Equipment anchor bolts shall not be used for earthing purposes.
All earthing connections shall be clearly identified on the General Arrangement Drawings
and the earthing terminals shall be in accordance with the International Standards and
Local Regulations.
7.18 Special Tools
9 When special tools and fixtures are needed to disassemble, assemble or maintain the
unit, they shall be included in the quotation and furnished as part of the initial supply of
the machine, together with complete instructions for their use. For multiple unit
installation, the quantities of special tools and fixtures shall be agreed by the Company
and the Contractor. These or similar special tools shall be used during shop assembly
and post-test disassembly of the equipment.
y Special tools for reciprocating compressors shall include, as a minimum:
a. mandrels for fitting solid wear bands on non-segmental pistons;
b. a lifting and lowering device for removal and insertion of valve assemblies with a
mass greater than 15 kg (33 lb);
c. a crosshead removal and installation tool;
d. sleeve/cone to enable piston rod to be passed through completely assembled
acking;
e. if specified, hydraulic tensioning tools.
f. Lifting devices for installation and removal of cylinders, distance pieces, cylinder
heads and distance piece covers (e.g. lifting eyes, spreader bars, etc..) with
appropriate lift plans for maintenance of all components.
9 When special tools are provided, they shall be packaged in separate, rugged metal
box or boxes and marked “special tools for (tag/item number).” Each tool shall be
stamped or tagged to indicate its intended use.
9 The equipment “Installation, Operation and Maintenance Manual” shall include a list of
special tools and any special drawings or instruction on how to use such tools.
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7.19 Spare Parts
Spare parts for the compressor and all furnished auxiliaries shall meet all the criteria of
this specification. Spare parts shall be available for purchase and manufacturing
drawings shall be retained by the Manufacturer during the compressor life as a
minimum.
The selection of spare parts, with the purpose of ensuring operation continuity, shall
take into consideration the following aspects:
o equipment criticality;
o mean time to failure (MTTF), for non-repairable items;
o mean operating time between failures (MTBF), for repairable items;
o mean down time (MDT, LDT, ADL), for repairable items
o ambient and service conditions
o plant operating life
The Contractor shall provide in the proposal the recommended spare parts split in the
following lists:
o start-up & commissioning spare parts, as firm proposal;
o 2-year operating spare parts, as option;
o capital spare parts, as option.
The Contractor shall submit in its proposal the Spare Parts Forms fully filled-in; each item
shall be priced separately.
After Contract Award, the Contractor shall submit the Company SPIL Forms.
All spare parts supplied by Contractor shall be new, wrapped and packed in such a way
as to be preserved in their original condition under normal operating conditions of
extended storage. These parts shall be tagged and coded so that later identification as to
intended usage can be made.
Spare parts and relevant technical documentation are described in Company Standard
20182.COO.GEN.SDS “Spare Parts”.
2-year operation spare parts shall be selected in accordance with Company Standard
05882.COO.MEC.PRG “2 Years Operation Spare Parts for Mechanical Equipment and
Machines”.
7.20 Assembly Degree
The compressor package shall be shop assembled on the baseplate and other skids, if
applicable, or prefabricated to the maximum possible extent to minimize assembly at
site.
A preliminary alignment, baseplate drilling and coupling installations shall be done at
shop.
All auxiliary piping shall be completely assembled within skid limits and, if necessary,
prefabricated at shop and installed at site.
All the spools of the interconnecting piping shall be clearly identified.
Finish coats, where required, shall be applied at the workshop. Required insulation and
cladding shall be completed at the workshop.
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8. OPERABILITY AND MAINTAINABILITY
The Contractor shall provide full details for maintaining the package. Due consideration
shall be given to the ease of access to all the items, during operation and maintenance,
when designing the layout of the package. Access shall be provided to all equipment and
any area requiring maintenance. The equipment shall be designed so that maintenance
can be carried out with the minimum special facilities/tools. All equipment and piping
shall be neatly arranged on the skid in such a way that they do not obstruct maintenance
operations. The Contractor shall work closely with the Company to ensure that the most
maintenance-effective layout is achieved for the package.
All major equipment items shall be supported on stainless steel shims at each mounting
point, to facilitate re-alignment at a later stage. No tapered shims are allowed. Sufficient
quantity of pre-cut shims shall be provided loose for site commissioning.
The Contractor shall provide in the proposal maintenance lifting requirements for the
equipment, and shall advise suitable methods (runway beam, overhead travelling crane,
etc.). The Contractor shall provide all the maintenance documentation (see Section 12.2
“Contract Documentation”) and analysis necessary to manage the maintenance activities
and the data to populate the Company CMMS.
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exploration & production division
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9. INSPECTIONS AND TESTS
9.1 General
Inspections & tests shall be in accordance with Company Standard
07423.PKG.GEN.SDS “Inspection and Test of Package Supplies”.
9 Acceptance of shop tests does not constitute a waiver of requirements to meet field
performance under specified operations conditions, nor does inspection relieve the
Contractor of his responsibilities.
9.2 Inspections
y The Inspection & Test Plan shall be agreed between the Company and the Contractor
as to the type and extent of inspections and tests to be carried out on the supply. The
Company shall specify the type of inspections and the Company attendance in the
MOD.MEC.COA.101 “Process Reciprocating Compressor Inspection & Test Data
Sheets (IDS)”.(Í)
y Positive material identification (PMI) test methods are intended to identify alloy
materials and are not intended to establish the exact conformance of a material to an
alloy specification. PMI is used to verify that the specified materials are used in the
manufacturing, fabrication and assembly of components.
y Mill test reports, material composition certificates, visual stamps, or markings shall not
be considered as substitutes for PMI testing.
y Unless specified otherwise by the Company or legislative requirements, nondestructive
examination (NDE) of materials shall be in accordance with ASME Section V and PED.
9.3 Tests
The Company shall specify the type of tests and the Company attendance in
MOD.MEC.COA.101 “Process Reciprocating Compressor Inspection & Test Data Sheets
(IDS)”.(Í)
9.3.1 MECHANICAL RUNNING TEST
9 All compressors, drivers, and gear units shall be shop tested in accordance with the
vendor’s standard.
y The shop test of the compressor shall comprise a 4-hour unloaded running test.
y If specified, packaged units, including integral auxiliary system packages, shall undergo
a 4-hour mechanical running test prior to shipment. The test shall prove mechanical
operation of all auxiliary equipment, as well as the compressor, reduction gear, if any,
and driver as a complete unit. The compressor need not be pressure-loaded for this
test. The procedure for this running test shall be agreed upon by the Company and the
vendor.
y Auxiliary equipment not integral with the unit, such as auxiliary oil pumps, oil coolers,
filters, intercoolers and aftercoolers need not be used for any compressor shop tests
unless specified. Auxiliary system consoles shall receive both an operational test and a
4-hour mechanical running test prior to shipment. The procedure for this running test
shall be as agreed upon by the Company and the vendor.
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Rev. 4 February 2014
exploration & production division
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9.3.2 PERFORMANCE TEST
y If specified, the compressor shall be subject to a performance test in accordance with
ISO 1217 or the applicable ASME power test code. Unless otherwise specified,
performance testing is not required
9.3.3 OTHER TEST
9 A bar-over test of the frame and cylinders shall be made in the vendor’s shop to verify
piston end clearances and rod runout. The final bar-over test shall be performed with all
compressor cylinder valves in place to demonstrate no piston interference. Vertical and
horizontal piston-rod runout (cold) at packing case flanges shall also be measured during
this test . Bar-over test results shall become a part of the purchaser’s records
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Rev. 4 February 2014
exploration & production division
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10. PRESERVATION, STORAGE, PACKING AND TRANSPORT
Preparation for shipment shall conform to Company standard 20185.COO.GEN.SDS
“Handling and Protection of Materials and Equipment”.
Packing shall comply with Company Specification 05883.VAR.GEN.SPC “Packing for the
Dispatching of Material and Equipments”.
As a minimum, the Contractor shall:
o prepare the supply for shipment and deliver to nominated delivery point;
o furnish internal and external shipping braces required to prevent damage or
movement during transportation;
o furnish all the crates with relevant Packing List and Shipping Documentation;
o provide shipping, installation, operation and maintenance weights and centre of
gravity;
The Contractor shall provide Storage and Maintenance Procedures for Company's
review and approval, which shall include, as a minimum, the following subjects:
o weather protection;
o equipment storage maintenance;
o periodical inspection;
o periodical maintenance;
o notice required for equipment usage;
o corrosion protection and application of temporary coatings;
o storage conditions including temperature range and humidity.
The inspections indicated in MOD.MEC.COA.101 “Process Reciprocating Compressor
Inspection & Test Data Sheets (IDS).
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exploration & production division
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11. WARRANTY AND GUARANTEES
11.1 Warranty
All equipment and component parts shall be warranted by the Contractor against
defective material, design, and workmanship for one year after being placed in service
(but not more than 18 months after date of shipment).
If any performance deficiencies or defect occur during the guarantee and warranty period
, the Contractor shall make any necessary alterations, repairs and replacements free of
charge, free on board factory. Field labor charges, if any shall be subject to negotiation
between the Company and the Contractor.
11.2 Performance Guarantees
9 As stated in 6.1 Company shall specify the equipment’s normal operating point and all
other applicable operating points such as start up, loading and unloading, regeneration,
etc.. The Contractor shall confirm the compressor’s performance and mechanical
capabilities at the specified operating points (including valve selections). Unless
otherwise agreed by the Purchaser, negative tolerances on capacity shall not apply to
any specified operating points.
9 The “normal operating point” is defined by the purchaser and is normally the minimum
capacity at the specified pressures and temperatures required to meet the process
conditions with no negative tolerance permitted (this is typically the process flow sheet
material balance capacity). The sizing of the compressor must take into account all
specified operating conditions, and the manufacturer’s
standard tolerances so that the resulting full-load capacity will never be less than the
capacity at the certified operating point.
9 Sound pressure level at 1 m from equipment or acoustical enclosure shall be
guaranteed.
eni spa 03022.MAC.MEC.FUN
Rev. 4 February 2014
exploration & production division
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12. CONTRACTOR’S DOCUMENTATION
12.1 Tender Documentation
The Company shall specify the technical documents to be provided by the Contractor
during the tendering phase in the MOD.MEC.COA.201 “Process Reciprocating
Compressors Required Document Data Sheets (DDS)”.(Í).
For gas turbine driven compressors, gas turbine documentation shall be as per
03774.MAC.MEC.FUN “Gas Turbines (API 616)”; steam turbine documentation shall
conform to 03591.MAC.MEC.FUN “Steam Turbines (API 612)”.
12.2 Contract Documentation
The Company shall specify the technical documents to be provided by the Contractor
during the execution phase in the MOD.MEC.COA.201 “Process Reciprocating
Compressors Required Document Data Sheets (DDS)”.(Í)
The Contractor shall prepare the as-built revision for each document (drawings,
specifications, procedures, data sheets etc.) modified during field installation.
For gas turbine driven compressors, gas turbine documentation shall be as per
03774.MAC.MEC.FUN “Gas Turbines (API 616)”; steam turbine documentation shall
conform to 03591.MAC.MEC.FUN “Steam Turbines (API 612)”.
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Rev. 4 February 2014
exploration & production division
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13. SPECIAL REQUIREMENTS
13.1 Sour Gas Service
Materials exposed to a sour environment (wet H2S) as defined by NACE MR0175,
including trace quantities, shall be in accordance with the requirements of that
standard. Ferrous materials not covered by NACE MR0175 shall not have a yield
strength exceeding 620 N/mm2 (90,000 psi), nor a hardness exceeding Rockwell C 22.
Components that are fabricated by welding shall be postweld heat treated, if required,
so that both the welds and heat-affected zones meet the yield strength and hardness
requirements.
Material inspections shall include the hardness test.
13.2 Offshore & Marine Installations
The compressor is in an “offshore environment” when it is installed at sea, at an
elevation higher than 30.5m. A “marine environment” is an installation at sea, below
30.5m elevation.
13.2.1 VESSEL INSTALLATIONS
Compressor packages installed on vessels or floating platforms shall be capable of
withstanding the vessel movements and inclinations specified by the Company (Í) while
in operation.
The functionality and safety of the seal-oil and lube-oil systems shall not be jeopardized
by vessel/platform motions and inclinations.
y The bottom of the baseplate shall have machined mounting pads. These pads shall be
machined in a single plane after the baseplate is fabricated.
The baseplate shall be designed to minimize weight but it shall be stiff enough not to
have adverse effects either on the equipment alignment or the equipment dynamic
behavior. The manufacturer shall perform a static and dynamic structural analysis to
demonstrate the suitability of the baseplate design.
The baseplate shall be supported on a 3-point mount with gimbals, to isolate the train
from deck movements.
All connecting pipework shall be anchored to the baseplate to prevent misalignment
caused by vessel movements.
13.2.2 WEIGHT CONTROL
Among proposal documentation, an estimate of the CoG and the total installed weight of
each compressor skid and off-skid equipment shall be supplied, with an upper tolerance
of 10% or 10 kg, whichever is greater.
The Contractor shall implement a weight monitoring program as per Company
Specifications 20186.COO.GEN.SDS “Weight Control System” and
20187.COO.GEN.SDS “Weight Control System for Engineering”. The Company shall be
notified of any deviation of more than 10% or 10kg, whichever is greater, from the weight
estimate supplied in the proposal.
The Contractor shall verify the weight of all components and auxiliaries, after
fabrication/assembly in the Manufacturer’s workshop or after reception from Sub-
suppliers.
A General Arrangement Drawing shall be provided, showing the weight and centre of
gravity of each skid and interconnecting components (piping, valves etc.) that are part of
the package, both dry and operating (including fluids and lubricants).
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exploration & production division
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When all the weights and CoG’s of significant components have been verified, the
Contractor shall issue the final revision of the General Arrangement Drawing with
weights and CoG’s one month before shipment of the package.
13.3 Desert Installations
The desert is classified as an area with dry and hot climate. Large amount of dust is
present and there is little vegetation. Sand storms are common.
13.3.1 ENCLOSURE
Enclosure inlet vents shall be equipped with self-cleaning updraft filters to remove dust
and sand. The exhaust vents shall equipped with back draft dampers to prevent dust
ingress when unit is not running.
Protections against dust and sand ingress shall be provided considering sand storms of
an intensity appropriate to the location.
Ventilation shall be forced-draught type (indoor pressure above atmospheric pressure).
Induced-draught ventilation shall not be used, due to the risk of sand and dust ingress
from leakages in the enclosure.
Proper grounding of the enclosure shall be provided to account for the high electrostatic
charges due to particle impact during a sand storm.
13.4 Arctic Installations
The arctic environment is characterized by freezing weather (below 0°C) for an extended
period of time.
13.4.1 MATERIALS
Low-carbon steels can be notch sensitive and susceptible to brittle fracture at ambient or
lower temperatures. Therefore, only fully killed, normalized steels made to fine-grain
practice are acceptable.
Material inspections shall include the Charpy impact test, (see Section 9.2 “Inspections”).
13.4.2 ENCLOSURE
For outdoor installations, the enclosure shall be provided with heating, air conditioning
and ventilation systems.
The design of the enclosure ventilation system shall consider a “cold soak” condition,
with the unit not operating and determine what components will require heating and to
what level to be able to start the unit. During operation, which components will continue
to require heating, how much radiated heat is available from the compressor, lube
system and driver.
The design of the control system of the enclosure ventilation shall allow for alteration of
the sequencing of operations due to the temperature and length of the lines involved.
Enclosure inlet ducting or any intake plenum abutting a heated space shall be insulated.
For stand-by units, the enclosure ambient temperature may be required by Company to
be maintained notwithstanding the outdoor conditions (Î).
Provision shall be made for start-up from a “cold soak” condition by:
o selecting a suitable lube oil
o sizing the oil tank heater;
o pre-lubing or circulation of oil through the compressor;
Low temperature conditions occur when compressor is purged prior to start up.
The oil cooler, sized for full load operation at the highest summer ambient, shall be by-
passed in cold ambient temperatures. Care shall be taken in the system design so that
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Rev. 4 February 2014
exploration & production division
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when the oil temperature rises to normal operating level a sudden oil by-pass shutoff is
prevented.
Because of the 24-hour winter darkness, ample lighting shall be provided inside the
enclosure.
In the enclosure, sufficient room for personnel wearing bulky outer winter clothing to
move around equipment shall be provided. The enclosure shall also be equipped with a
vestibule with space to stow cold weather outer clothing.
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