sp for cng compressor_rev 00.pdf

HỒ SƠ DỰ THẦU: THIẾT KẾ - CUNG CẤP THIẾT BỊ CÔNG NGHỆ VÀ THI CÔNG XÂY DỰNG CÔNG

TRÌNH (EPC) DỰ ÁN: HỆ THỐNG PHÂN PHỐI KHÍ THẤP ÁP

CHO KHU CÔNG NGHIỆP TIỀN HẢI - THÁI BÌNH

SPECIFICATION FOR CNG COMPRESSOR

00 29/05/2014 Issued for Bidding VTL PCD

Rev. Date Status Prepared by Checked by Approved by

HỒ SƠ DỰ THẦU: THIẾT KẾ - CUNG CẤP THIẾT BỊ CÔNG NGHỆ VÀ THI CÔNG XÂY DỰNG CÔNG TRÌNH (EPC)

DỰ ÁN: HỆ THỐNG PHÂN PHỐI KHÍ THẤP ÁP CHO KHU CÔNG NGHIỆP TIỀN HẢI - THÁI BÌNH

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TABLE OF CONTENTS

1. PROJECT OVERVIEW .................................................................................................................... 4

2. PURPOSE .......................................................................................................................................... 4

3. ABBREVIATIONS ........................................................................................................................... 4

4. CODES AND STANDARDS ........................................................................................................... 5

5. ENVIRONMENTAL DATA ............................................................................................................ 5

6. GENERAL PACKAGE REQUIREMENTS ..................................................................................... 8

6.1 COMPRESSOR PACKAGE PERFORMANCE CURVES .................................................................... 8 6.2 DRAWINGS.............................................................................................................................. 8 6.3 PACKAGE INSTALLATION ........................................................................................................ 8

7. COMPRESSOR ................................................................................................................................. 8

7.1 GENERAL ................................................................................................................................ 8 7.2 ALLOWABLE DISCHARGE TEMPERATURE ............................................................................... 9 7.3 CRITICAL SPEEDS ................................................................................................................... 9 7.4 COMPRESSOR CYLINDERS ....................................................................................................... 9 7.5 PISTONS, PISTON RODS, AND PISTON RINGS ........................................................................ 10 7.6 CRANKSHAFTS, CONNECTING RODS, BEARINGS AND CROSSHEADS .................................... 10 7.7 DISTANCE PIECES ................................................................................................................. 10 7.8 PACKING CASE AND PRESSURE PACKING .............................................................................. 10

8. LUBRICATION .............................................................................................................................. 10

9. COOLING SYSTEM ...................................................................................................................... 11

9.1 GENERAL .............................................................................................................................. 11 9.2 COOLING FOR COMPRESSOR CYLINDERS .............................................................................. 12 9.3 INTER/AFTER GAS COOLERS ................................................................................................ 12

10. BASEPLATE................................................................................................................................... 12

11. PIPING AND APPURTENANCES ................................................................................................ 12

11.1 GENERAL .............................................................................................................................. 12 11.2 PIPINGS ................................................................................................................................. 13

12. MOUNTING ................................................................................................................................... 13

13. MATERIALS .................................................................................................................................. 13

14. PULSATION AND VIBRATION REQUIREMENTS .................................................................. 14

15. BELT DRIVER AND COUPLING ................................................................................................ 14



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16. INTER-STAGE DRUM AND INTER-STAGE COOLER............................................................. 14

17. PRESSURE VESSELS ................................................................................................................... 15

18. ELECTRICAL EQUIPMENTS ...................................................................................................... 15

19. INSTRUMENTATION ................................................................................................................... 15

19.1 GENERAL .............................................................................................................................. 15 19.2 CONTROLS AND INSTRUMENTATIONS ................................................................................... 17 19.3 DEVICES FOR LOCAL CONTROL ............................................................................................ 17 19.4 LOCAL CONTROL PANEL (LCP) ............................................................................................ 18

20. NOISE LEVELS.............................................................................................................................. 19

21. INSPECTION AND TESTING....................................................................................................... 19

22. PREPARATION FOR SHIPMENT ................................................................................................ 20

23. DOCUMENTATION ...................................................................................................................... 21

APPENDICES

APPENDIX A SCOPE OF SUPPLY

APPENDIX B SPECIFICATION, DATA SHEETS & P&ID’s APPENDIX C INSPECTION AND TEST REQUIREMENTS (ITR)



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1. PROJECT OVERVIEW

Petro Vietnam Gas Joint Stock Corporation (PVGas) is responsible for the development of Thai Binh- Ham Rong Gas Distribution and Gathering System Project to transport gas from Ham Rong field (Block 106), Thai Binh field (Block 102) and Other fields (Hong Long, Sapa Nam, Hong Ha- Block 103 & 107) to Tien Hai industrial zone in Thai Binh province in the north of Vietnam. The Sales Gas transported to onshore by the Thai Binh – Ham Rong Gas Distribution and Gathering System shall be transferred to Petro Vietnam Gas Distribution Joint Stock Company (PVGas D) who is responsible for its distribution to end-users. For this task, PVGas D is investing in a compressed natural gas (CNG) production plant (and a low pressure gas distribution pipeline network to deliver Sales Gas to the plant and to end-users in Tien Hai industrial zone and nearby). This PROJECT is called “Thai Binh Compressed Natural Gas Plant Project”.

2. PURPOSE

This specification defines the minimum requirements for CNG compressor package to be installed for the Thai Binh compressed natural gas plant project.

3. ABBREVIATIONS

EMDR Engineering Master Document Register

CNG Compressed natural gas

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society of Testing and Materials

BS British Standard

PCS Process Control System

F & G Fire and Gas

ESD Emergency Shutdown System

ICS Integrated Control System

DN Nominal Diameter

OD Outside Diameter

P&ID Piping and Instrument Diagram

SDV Shut Down Valve



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SIL Safety Integrity Level

SIS Safety Instrument System

LEL Lower Explosive Limit

4. CODES AND STANDARDS

In addition to the requirements of this specification and the referred or attached individual specification and data sheets together with the statutory requirements of the Vietnam Authorities, the general design, fabrication, assembling and testing of this compressor shall follow the the latest edition of international codes and standards including any addenda published for the edition listed, which shall form part of this specification. These shall include but not be limited to the following:

2.1.1 American Bearing Manufacturers Association (ABMA)

Standard No. Standard Title

ABMA 9 Load Rating and Fatigue Life for Ball Bearings

ABMA 11 Load Ratings and Fatigue Life for Roller Bearings

2.1.2 American Society of Mechanical Engineers (ASME)


ASME B16.5 Pipe Flanges and Flange Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard

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

ASME B16.11 Forged fittings Socket-Welding and Threaded

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

ASME B16.34 Valves Flanged, Threaded and Welding End

ASME B31.3 Process Piping

ASME Sect. V Non-destructive Examination

ASME Sect. VIII ASME Boiler and Pressure Vessel Code

ASME Sect. IX ASME-Welding and Brazing Qualifications

2.1.3 American Petroleum Institute (API)




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API 613 Special Purpose Gear Units for Petroleum, Chemical and Gas Industry Services

API 614 Lubrication, Shaft-Sealing and Control-Oil Systems and Auxiliaries for Petroleum, Chemical and Gas Industry Services

API 618 Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services

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

API 670 Machinery Protection Systems

API 671 Special Purpose Couplings for Petroleum, Chemical and Gas Industry Services

API 678 Accelerometer Based Vibration Monitoring System

API RP 684

Lateral Critical Speeds, Unbalance Response, Stability, Train Torsionals and Rotor Balancing

2.1.4 American Welding Society (AWS)


AWS D1.1 Structural Steel Welding Code

2.1.5 British Standards Institution (BS)


BS EN 10204 Metallic Products - Types of Inspection Documents

2.1.6 Engineering Equipment and Materials Users Association


EEMUA 140 Noise Procedures Specification

2.1.7 International Electrotechnical Commission (IEC)


IEC 60529 Classification of Degree of Protection Provided by Enclosures

IEC 60034 Rotating Electrical Machines



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IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere

2.1.8 Institute of Electrical and Electronics Engineers (IEEE)

2.1.9 International Organization for Standardization (ISO)


ISO 3046-1 Part 1: Standard Reference Conditions, Declarations of Power, Fuel and Lubricating Oil Consumptions and Test Methods

ISO 3046-3 Part 3 : Test Measurements

ISO 3046-4 Part 4 : Speed Governing

ISO 3046-5 Part 5 : Torsional Vibrations

ISO 3046-6 Part 6 : Overspeed Protection

ISO 3046-7 Part 7 : Codes for Engine Power

ISO 13631 Petroleum and Natural Gas Industries Packaged Reciprocating Gas Compressors

ISO 9001 Quality Assurance Systems

5. ENVIRONMENTAL DATA

The Vendor’s equipment or material shall comply with the following environmental data.

The extreme air temperature at Thai Binh and other sites will be: Maximum: 38°C Minimum: 04°C

The relative humidity at the Thai Binh and other sites will be: Mean Annual: 80-85% Maximum: 100% Minimum: 60%

The atmospheric conditions at these areas will contain industrial pollution and salt air.

Wind conditions: Max. Speed: 35 m/s measured at 10m above MSL, 1 in 50 years return.

Solar Radiation: Annual average of sunshine hours 2,375 Daily average 6.5 hrs/day



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Soil Conditions: High salinity adjacent to areas of tidal influence High acidity in sections of reclaimed mangrove areas with pH as low as 4 Temperature is nominally 23-24 °C

Lightning: Annual average of 126 lightning days/year

6. GENERAL PACKAGE REQUIREMENTS

6.1 Compressor package performance curves

Vendor shall provide the compressor package performance curves, which shall cover the range of operating conditions and design cases as specified in relevant data sheets.

6.2 Drawings

Vendor shall furnish plan and elevation drawings.

6.3 Package installation

The compressor package shall be fully enclosed, sealed to prevent entrance of dirt and water and installed outdoor. Provisions shall be made for proper venting, oil level indication and refilling.

7. COMPRESSOR

7.1 General

The design and fabrication of compressor shall comply with API 618 fifth edition 2007 unless otherwise stated in this specification.

The equipments, drivers and compressors shall be designed and constructed for a minimum service life of 30 years and at least three years of uninterrupted operation.

Compressors, drivers, auxiliary equipment, piping and appurtenances shall be designed and constructed for continuous, full-load duty at the specified operating conditions and shall be accessible for rapid and easy maintenance, particularly regarding the packing and valves.

The compressor shall be a heavy-duty machine of proven design, capable of unattended continuous duty operation under the maximum design and operating conditions specified in the attached data sheets.

The compressor shall be of non-lubricated type.

Compressors and drivers (including gear, pulley, and coupling, if any) shall be mechanically suitable to operate at both the design speed to the cylinder relief valve settings, and at full load emergency shutdown.

The Vendor shall be full responsibility for the engineering coordination of the compressor and drive train.



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High priority shall be given to the design of package to ensure adequate access for equipment removal and maintenance.

The major packaged equipment components will be installed in the minimum number of sections required. Each section shall be designed for a single point lift. Vendor shall include for spreader beams or lifting frames for lifting compressor package and cooling air console.

The equipment will be rigidly fixed to the support foundations via bolted connections.

The equipment shall comply with the hazardous area requirements, as stated on the data sheets.

The package design shall make provision for the following interfaces to the external facilities:

1. Process piping 2. Utility piping (eg. Instrument air, nitrogen purge gas) 3. Drain and vent pipework 4. Pressure relief valves 5. Electrical power supply cabling 6. Instrument/Cabling (Interface Junction Boxes)

7.2 Allowable Discharge Temperature

The rated discharge temperature from any cylinders, resulting from any specified service conditions, including part-load conditions, shall not exceed 135ºC (275ºF).

A high discharge temperature alarm and shutdown device shall be provided for each compressor cylinder.

7.3 Critical Speeds

The average piston speed shall not exceed 750 feet per minute. Regardless of the piston speed, the rotational speed shall not exceed 600 rpm.

For torsional analysis refer to item 6.7.2 page 13 API 618 5th (2007).

In addition, transient vibratory torques and stresses generated in all system components during an emergency shutdown shall be calculated. For this it should be assumed that there is insufficient time to vent down the system with the result that the machine decelerates whilst loaded. In the event that excessive stresses cannot be avoided, the Vendor shall propose the installation of a torque limiting drive release to prevent damage to the machine components.

7.4 Compressor Cylinders

The arrangement of valves and ports in horizontal cylinders shall be such as to ensure drainage of cylinders.

Maximum allowable working pressure shall exceed the rated discharge pressure by at least 10% or 1.7 bar (25 psi), whichever is greater.

All horizontal cylinders shall have top inlet and bottom discharge connections.



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Cylinders or liners shall have surface roughness not exceeding 0.1 µm ÷ 0.6 µm (4 µin ÷ 24 µin) Ra (arithmetic average roughness). The actual surface finish requirement is dependent on the choice of cylinder liner material, coatings, and operating conditions.

It should be screwed fittings on cylinders. Socket welded fittings shall not be permitted.

7.5 Pistons, Piston Rods, and Piston Rings

Piston-ring and wear band material shall be supplied by CPI (Compressor Products International). A system for monitoring piston wear band shall be included in the Vendor’s scope of supply. This shall include an accessory set for monitoring piston rod run out which includes probe, extension cable, system monitor and key phasor with each compressor train.

7.6 Crankshafts, Connecting Rods, Bearings and Crossheads

Crankcases shall be fitted with British International Combustion Engine Research Institution (BICERI) type relief valves and flame traps. The relief area shall not be less than 70 mm2/dm3 (3 in2/ft3) of crankcase volume.

Crankcase breathing devices shall be fitted with approved flame traps.

7.7 Distance Pieces

The outboard compartment (ie nearer the cylinder) shall be purged with nitrogen and shall be vented to a safe location. The inboard compartment shall also be vented to a safe location. Vendor’s scope of supply shall include all necessary instrumentation, purge gas piping, filters, pressure regulators, relief valves, orifices, isolation valves, vent/drain piping, liquid collection pots, etc. Packing failure detection shall be by means of temperature transmitter provided for each stage of compressor.

7.8 Packing Case and Pressure packing

All oil-wiper packing, intermediate partition packing, and cylinder pressure packing, shall be segmental rings with stainless steel garter springs.

The pressure packing case shall be provided with a common vent and drain, below the piston rod, piped by the Vendor to the lower portion of the distance piece. Packing vent piping inside of the distance piece shall be designed for the maximum allowable working pressure of the cylinder.

Packing cases shall be designed for liquid cooling with totally enclosed cooled cups. The vendor shall be responsible for determining and informing the Owner of minimum requirements such as flow, pressure, pressure drop, and temperature, as well as any filtration and corrosion protection criteria. The coolant pressure drop through the packing case shall not exceed 1.7 bar (25 psi). The Vendor shall supply a closed liquid cooling system, which shall be combined with the jacket air cooling system.

8. LUBRICATION

For compressors 150 kW (200 hp) and above, the frame lubrication system shall be a pressurized



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system. Splash lubrication systems may be used on horizontal compressors of 150 kW (200 hp), or less, with rolling element bearings. The crankcase oil temperature shall not exceed 70ºC (160ºF) for pressurized oil systems and 80ºC (180ºF) for splash systems. Cooling coils shall not be used in crankcases or oil reservoirs.

Each lubrication system shall include a reservoir in the crankcase, a manually operated pre-lube pump, a crankshaft driven oil pump with pressure relief valve, a single full flow oil filter (25 micron nominal rating), a pressure regulating valve, an oil cooler, and a reservoir level gauge. All internal and external oil piping required is to be provided, and is to be made of stainless steel piping or tubing. The instruments in the lubrication system shall contain as minimum the following components: pressure indicator, temperature indicator, level indicator, pressure transmitter for low pressure alarm and auxiliary pump start, pressure transmitter for low pressure shutdown, low frame oil level transmitter for alarm, filter high differential pressure transmitter for alarm.

The oil cooler shall be designed to TEMA requirements, and shall be able to maintain the lube oil supply temperature below 150°F.

An electric immersion heater having a watt density not exceeding 15 watts per square inch shall be provided for cold weather start-up.

9. COOLING SYSTEM

9.1 General

The cooling system for Compressor package shall be Air cooling system. The design of air cooling system should be according to API 661.

For air cooling system applied: An “On skid” air cooling console common for nine (09) machines shall be supplied, this console will consist:

• 100% duty fans (quantity to be advised by Vendor) • Common Antipyretic jacket • Other Auxiliary for completed skid.

When air coolers are used, they shall be in accordance with API standard 661, unless otherwise specified, air cooled heat exchanger used for intercoolers shall have automatic temperature control. This control may be accomplished by means of louvers, variable-speed fans, variable-pitch fans, bypass valves, or any combination of these. Proposed control system will be approved by Purchaser.

Caution: should be exercised in applying air-cooled heat exchanger because of their susceptibility to pulsation-induced vibration in system and structures.

Mechanical natural frequencies should not be coincident with pulsation frequencies in the heat exchanger systems.



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9.2 Cooling for Compressor Cylinders

Compressor cylinders shall be cooled by air cooler.

9.3 Inter/After Gas Coolers

Air-cooled Inter-stage and final-stage discharge coolers shall be provided which shall be limited the maximum gas temperature after the after cooler to 450C.

Cooler design shall be on the basis of 20% extra design based on the thermal duty.

10. BASEPLATE

When a baseplate is specified, major equipments to be mounted on it shall be as specified by the Purchaser. A baseplate shall be a single fabricated steel unit, unless the Purchaser and the Vendor mutually agree that it may be fabricated in multiple sections.

Design guidelines for structural skid design shall be furnished for Purchaser's review. The compressor along with its accessories such as motor, lube oil system, pulsation dampeners and Local Control Panel shall be mounted on baseplate. The baseplate shall be bolted-up to form an integral skid at site. The motor is able to be shipped separately but shall be mounted on baseplate at site.

Baseplates shall be designed and built to adequately support the weight of the compressor, motor and accessories and to avoid resonance with any possible excitation frequency. The baseplate shall be able to transmit all forces and moments generated by the compressor and motor to the foundation.

11. PIPING AND APPURTENANCES

11.1 General

All piping, fitting and valves containing process fluids shall be in accordance with Pipe, valve and fittings Specification and item 7.7 of API 618 (2007). For process piping the first instrument isolation block valve will be flanged, monoblock with screwed end connection to be used for tubing. Utility piping (water (if any)/ lube oil) first isolation valve can have screwed connection. Distance piece drain and vent connection on cylinders will be screwed. Refer to Piping Class Material Specification

Compressor cylinder drain connections will be terminated with flanged connection or others and they shall be specified by Vendor.

Nitrogen supply system will be Vendor’s standard design and supplied completely pre-assembled. Main piping will be carbon steel galvanized, instrument tubing will be stainless steel.

Package pipework connections for Purchaser tie-ins shall be flanged to ANSI B16.5, raised face, weld neck, flanges, terminating at the skid edge(s).

All equipment / piping RF facing shall be smooth finish with a roughness between Ra 3.2 and 6.3 μm.



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11.2 Pipings

Piping shall be prefabricated, and where possible, installed and supported on the compressor unit. Piping, tubing, or conduits shall be supported and protected to prevent damage from vibration, operation or maintenance. All equipment supplied and mounted on the compressor or compressor base by the Vendor shall be complete with interconnecting pipe, valves, and fittings. Low points where liquid can accumulate shall be avoided. Unavoidable low points shall be provided with drain valves. Piping shall be free of rust, slag, welding beads, and other foreign materials.

The materials and the construction of piping and connections to equipment shall conform to ANSI B31.3. Flanges shall conform to ANSI B16.1 or B16.5. No 1-1/4in, 2-1/2in, 3-1/2in, 5in, 7in, or 9-inch connections, pipe, valves, or fittings shall be used. When the required opening cannot be met on existing designs, the manufacturer shall furnish an adapter that meets the preceding requirements.

Pipe sizes 1-1/2 inches or smaller shall be schedule 80 minimum and may be flanged, welded, or screwed. Sizes 2 inches and larger shall be schedule 40 minimum, and with the exception of water piping and atmospheric vents, shall have welded or flanged connections. Where space does not permit the use of pipe, seamless steel tubing may be furnished with steel fittings.

Carbon steel piping shall be manufactured in accordance with ASTM A106 or A192.

Tubing shall be 1/2 inch, 3/4 inch and 1 inch ASTM A269 seamless stainless steel tubing and fittings with minimum wall thicknesses of 0.065 inch, 0.095 inch, and 0.109 inch, respectively.

12. MOUNTING

The compressor, driver, and all auxiliaries shall all be mounted on a common baseplate as a package.

Baseplates, soleplates, rails, or compressor parts to be grouted shall be drilled and tapped for leveling screws.

13. MATERIALS

General for material shall be followed item 6.15 of API 618 – 2007.

Unless specified by the purchaser, the materials of construction shall be selected by the manufacturer based on the operating and site environmental conditions specified.

The materials of construction for all major components shall be clearly stated in the Vendor's proposal. Materials shall be identified by reference to applicable international standards, including the material grade. Where international standards are not available, internationally recognized national standards (such as AISI or ASTM) or other standards may be used. When no such designation is available, the Vendor's material specification, giving physical properties, chemical composition, and test requirements shall be included in the proposal.

The Vendor shall specify the optional tests and inspection procedures required to ensure that



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materials selected are satisfactory for the service intended. Such tests and inspections shall be listed in the proposal.

Additional optional tests and inspections may be specified by the Purchaser.

14. PULSATION AND VIBRATION REQUIREMENTS

Vendor shall furnish all pulsation suppression devices. For pulsation and vibration control, design Approach 3 of API 618 shall be followed. Thermowell connections on pulsation suppression devices should be flanged and designed and supplied in accordance with Pipe, valve and fittings Specification or other connection methods shall be specified by Vendor and approved by Purchaser in the proposal.

Threaded connections on pulsation suppression devices are not permitted. No internals (ie, line chokes) shall be fitted in the pulsation suppresser devices.

15. BELT DRIVER AND COUPLING

Belt drives shall only be used for equipment of 150 kW (200 hp) or less and require purchaser approval. Belt drives up to 225 kW (300 hp) may be proposed for purchaser’s acceptance. Belt drive shall be integral multi-v belts. Belt drives shall be oil resistant. The drive service factor shall not be less than 1.75 based on the driver nameplate power rating.

The Vendor shall provide his standard for positive belt tensioning device on all belt drives.

Flange mounted motors shall be limited to 200 horsepower or lower.

The coupling shall be designed to enable replacement of component parts without moving the driver shaft or any other main drive component from the system. Tapped puller holes of adequate size shall be provided in each hub to facilitate removal.

High-speed couplings shall be machined to a tolerance of not more than 0.001-inch eccentricity on the diameter or on the perpendicularity of faces with the centerline. The total eccentricity of the bore shall be limited to 0.0005 inch. For couplings operating at 1,800 revolutions per minute or less, these tolerances may be doubled.

The WR2 provided on motor drives shall also limit current variations to a maximum of 66% of full load motor rated current in accordance with IEC 60034 or NEMA MG1.

16. INTER-STAGE DRUM AND INTER-STAGE COOLER

Vendor shall be advised the technology of inter-stage drum and inter-stage cooler. When stabilizers are used, each compressor supply shall include one inter-stage drum and one inter-stage cooler. This equipment shall be supplied complete with their instruments, electrical drives and accessories.

Intercoolers and after coolers required to meet the 300°F (150oC) limit shall be provided.

Intercoolers and after coolers shall have a moisture separator, automatic liquid trap, level gage,



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pressure gage, and a high liquid level alarm.

17. PRESSURE VESSELS

All pressure vessels including on the compressor skid shall be designed as per ASME VIII Div 1.

Internal corrosion allowance of pressure vessels shall be minimum 3 mm. All pressure vessels shall be fully 100% radio graphed as stated per ASME VIII Div 1 and the Pressure vessels shall be stamped by ASME Association.

18. ELECTRICAL EQUIPMENTS

Soft starter should be provided by Vendor in the Unit Control Panel.

Soft starters shall conform to the requirements of IEC 60947-4-2 and as minimum comprise of by pass contactor /Soft-starter unit, overload relay, indicating lamps and control and emergency stop push buttons. Besides, control cables between LCP (located in equipment room) and compressor will be supplied by Compressor Vendor.

The motors shall have continuous rating in accordance with IEC 600034-1 for site conditions as stated in Environmental Conditions in Section 5. The main LV motors for the stabilizer compressors shall be of low starting current type. The starting current when direct-on-line shall not be more than 5 times the full load current. The motor shall be capable of starting and running up the stabilizer compressor satisfactorily with a motor terminal voltage of 65% of nominal. Stator windings shall be equipped with three (3) embedded temperature detectors, wired to a motor mounted auxiliary terminal box. Bearing temperature indication shall be provided for motors >110 kW. Each sleeve bearing shall be provided with a pocket to suit a resistance thermometer to DIN PT 100 or RTD. Single phase 230V AC 50Hz space heaters shall be provided for electric motors rated 15 kW and above. The space heater shall be automatically switched off when the motor is running and switched on when the motor is stopped. Cable glands for the motors and auxilary shall be supplied by Vendor. For flame-proof motors, Ex’d’ cable glands type shall be applied.

All the motor and others auxilary as junction box, LCP shall be tested and certified for use in Zone 2 IIB T3 locations. The motors and auxilary shall be flameproof Ex-d or Ex-e type which is complied with IEC 60079.

Control and indication for motors shall be specified by Vendor in the proposal and approved by Purchaser.

Electrical enclosures shall be weather proof type IP 55 is minimum requirement. Blank plugs shall be fitted as required.

19. INSTRUMENTATION

19.1 General

All field instruments intrinsically safe type (EEx ia) suitable for hazardous area classification



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indicated and shall supply the necessary certification from the acceptable authorities (CENELEC/BASEEFA/PTB). Refer to General Specification for Instrumentation and Control System.

Vendor shall provide field transmitters only and switches with the exception of frame oil level indication. Temperature element (RTD) shall be provided with transmitter with the exception of RTD's required for valve temperature monitoring.

All necessary controls, instrumentation and precautions required to comply with the specified operational requirements shall be provided by Vendor.

Instrumentation on the Inter-stage drum will include level gauges and transmitter separate for control and shutdown. The gauges shall be magnetic type with integral transmitter. The material of construction shall be SS 316 with NACE compliance.

The instrument shall be a 2-wire transmitter with IP-66 enclosure and intrinsically safe to EEx ia IIB T3 certified by BASEEFA / PTB.

The level gauge / transmitter shall be subjected to the necessary tests such as hydrostatic pressure test, functional check etc

The control valves if any as identified shall meet the general requirements as specified here. The basis of sizing and sub Vendor's data shall be subject to Purchaser's approval. Control valves shall be globe type, cast body with flanged end connections to suit piping connections. The material of the body, bonnet, trim, gasket, bolts / nuts etc shall all be in compliance to Vendor’s standard.

Each control valve shall be supplied with the following accessories:

• Actuator ( shut-off differential pressure for the actuator shall be the design pressure of the system – shall be diaphragm actuator )

• “Smart Positioner”

• Air supply regulator

• Handwheel side-mounted

• Solenoid valve – E ex me type, 24 VDC.

All electrical components like the Positioner, solenoid valve etc shall be IP-66 and certified intrinsically safe to E ex ia IIB T3.

Control valves shall be provided with all the required testing such as hydrostatic test, leak test, stroke test, functional check etc. Vendor shall propose the tests to be carried out for purchaser’s approval.

Pressure safety valves and second stage discharge safety valves shall be procured by Vendor.

PSVs shall be designed to API-520 / 521 codes and the material of the body, bonnet, nozzle, seat, disc, spring, etc shall be in accordance with manufacturer’s standard to comply with Pipe, Valve and Fittings Specification: 111250-03-SPE-301.



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PSVs shall be full nozzle type, flanged connections, bolted bonnet. PSVs shall be subjected to the required tests – set pressure calibration, seat leak test, certification etc

19.2 Controls and Instrumentations

Control configuration and philosophy will be specified by Compressor Vendor. The Vendor shall provide sufficient instrumentation, indication, safety and control to monitor the package.

Automatic start, constant speed unloading systems, incorporating suction valve unloaders, shall be furnished by the Vendor. The control system shall completely unload the compressors for all starts.

Each compressor shall be furnished with its own control panel, containing visual and audible annunciators. A local control station shall be included on each compressor control panel to permit local starting and stopping.

Each compressor shall be provided with, but not limited to, the following panel mounted alarm and shutdown devices and separate annunciation points. All alarm and shutdown inputs shall be annunciated on a first out basis.

Vendor shall provide one Local Control Panel (LCP) which is located in equipment room, in a non hazardous area for each compressor package. The PLC shall be mounted on the LCP. LCP shall include interface module with ICS for monitoring.

In addition the package design shall make provision for the following interfaces with the plant system Pressure relief valves, Instrument/Cabling (Interface Junction Boxes).

19.3 Devices for Local Control

As a minimum the following devices at the compressor must include the following functions:

• Emergency Stop Push Button to directly trip compressor’s motor

• Compressor running lamp • Compressor shutdown lamp

• Auxiliary motors running lamp

• Common alarm lamp

• Load steps lamp

• Suction temperature gauges each cylinder

• Discharge temperature gauges each cylinder

• Suction pressure gauges each cylinder

• Discharge pressure gauges each cylinder

• Lube oil supply header pressure gauge (Frame oil)

• Lube oil supply header temperature gauge

• Bypass valve opening indicator



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• Horn

• The temperature, pressure for each stage.

Any 24V DC required to drive the lamps shall be provided from the LCP.

19.4 Local Control Panel (LCP)

The LCP shall be located indoors and shall contain the PLC, input/output modules etc. The LCP shall be connected to the instruments in the equipment skid(s) and shall control the Compressor and Auxiliaries Start/Stop, all the alarms and shut down functions necessary for the equipment protection. The LCP shall be provided with independent hard wired trip circuit logic which is separate from PLC.

Following minimum alarm and shut down functions are required. However Vendor may add more alarms/trips for safe operation of the compressor package, if deemed necessary.

Function Alarm Shut down

High discharge gas temperature (each cylinder)

X X

Low lube oil pressure X X

Low lube oil level X

High oil filter differential pressure X

Excessive frame vibration X X

High inter/after-cooler condensate level

X X

Jacket coolant system failure X

All Alarms and Shutdowns shall be through independent instruments. Following indications as a minimum is required in LCP. The same information will also be sent to ICS:

• Discharge process gas temperature of each stage

• Discharge pressure of each stage

• Suction process gas temperature of each stage • Suction process gas temperature of each stage at individual cylinder suction valve

• Discharge process gas temperature of each stage at individual cylinder discharge valve

• Suction pressure each cylinder

• Compressor vibration

• Compressor Motor bearing metal temperature



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• Compressor Motor current and KW (by Purchaser)

• Common alarm

• Unit tripped alarm

Interface signals between LCP and ICS shall be via an open protocol comply with Specification for instrumentation and control system. The data sent to ICS shall include all available package’s process data (e.g. Alarms, Analogue values, machine status, PLC watchdog Alarms etc).

All shut down and trip signals shall be hard wired from LCP to compressor. LCP shall provide suitable signal for interface to switchgear for start/ stop/running of each motor. LCP shall have provision for one (1) ESD Trip in each compressor.

Vendor shall also include provision for a communication card for interfacing between LCP and ICS.

In the event of equipment trip a “first out” facility shall be provided to identify the original fault. The Vendor shall furnish inter-stage and discharge air relief valves. Relief valves shall be set to operate at no more than maximum allowable working pressures, but not less than 110 percent of the rated discharge pressure or the rated pressure plus 25 psi, whichever is greater.

20. NOISE LEVELS

Noise levels at or beyond 1m from the machine (plus driver and ancillaries) surfaces, shall not exceed 85 dB, measured at 1.5 m above ground in a free field (open air) environment.

21. INSPECTION AND TESTING

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 Vendor shall comply with the detailed inspection requirements listed in the attached Testing and Inspection Requirements List (TIRL). This addition does not relieve the Vendor from performing other tests or inspections specified in the referenced standards.

All compressor cylinders, cooling jackets, pressure vessels, filters, and coolers shall be hydrostatically tested to minimum of 1.5 times maximum allowable working pressure or per applicable code.

Vendor's standard shop mechanical run and performance tests of compressors and accessories, such as coolers, control panels including control devices, shall be described in the proposal.

The compressor performance at rated operating conditions, i.e. capacity, pressure, and compression horsepower, remain within the following tolerances: % Rated



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Capacity -0 Discharge pressure -2 Normal hp +4

22. PREPARATION FOR SHIPMENT

The equipment preparation shall be suitable for a period of 6 months of outdoor storage.

The compressor, including cast-in passages and any piping and appurtenances furnished by or through the compressor Vendor, shall be mechanically or chemically cleaned to remove all dirt, chips, sand, oil, paint, pipe or mill scale, rust, weld rod, weld slag or beads, or other foreign objects.

Immediately upon completion of all tests and inspection, all exposed machined surfaces shall be cleaned and coated with a suitable rust preventive by the Vendor.

All exterior parts of the unit, except machined surfaces, shall receive a primer coat of heat and oil resistant paint. Surface preparation for painting shall be in strict accordance with the paint manufacturer's recommendations.

All internal surfaces with which oil comes in contact shall be carefully and adequately coated with a suitable oil soluble rust preventive.

Cylinders, heads, packing boxes, glands, packing, pistons, rods, crossheads and shoes, crosshead pins and bushings, and connecting rods (all or any of which are dismantled for the purpose of separate shipment) shall be slushed with heavy rust preventative, wrapped with waterproof sheeting and boxed in substantial crating to prevent damage in shipment or storage at the jobsite for at least six months.

All untapped openings shall be provided with 3/16-inch thick metal closures bolted in place with no less than four bolts with full rubber gaskets. All tapped openings normally plugged during service shall be plugged. All tapped openings disconnected for shipping purposes shall be dry fitted with solid, long-shank steel plugs. All connections, including those for instruments, instrument leads and lube oil shall be identified with a securely-attached metal tag indicating the type of connection, the instrument or the line description of the connecting piping.

Lifting, load-out, and handling instructions shall be securely attached to the exterior of the largest package in a well marked, weatherproof container. All special lifting devices and rigging shall be supplied with the unit. Upright position, lifting points, weight and dimensions shall be clearly marked on each package.

Major equipment components shall be securely bolted to substantial skids for shipment. Shaft couplings, if any, shall be disconnected, covered with grease and wrapped with waterproof sheeting to exclude dirt and moisture during transit and storage. Small, easily-damaged parts shall be removed, tagged, and adequately protected from damage during shipment.



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23. DOCUMENTATION

A detailed list of required documents is detailed on the Vendor Documentation Requirements List (SDRL).



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APPENDIX A

SCOPE OF SUPPLY

The following scope of supply covers the minimum technical requirements for the supply of the CNG Compressor packages for service at the CNG Plant for the Thai Binh CNG Plant Project, Thai Binh Province, Vietnam, including equipment, services and documentation as listed hereafter.

Spare parts for two years will be advised by Vendor in detail design.

ITEM N° DESCRIPTION

1. Nine (09) Compressor Packages, each as a minimum comprising:

1.1. Three stage Non-lubricated / Lubricated reciprocating compressor (CMP-211/21/31/41/51/61/71/81/91) as per specification and data sheets including:

1.1.1 Frame lube oil system complete with pumps, motors, TEMA “C” heat exchanger, filters, instruments, valves, machine mounted piping and external piping/support as required etc.

1.1.2 Buffer gas arrangement to minimize process gas leakage complete with filters, instruments, valves, piping etc as per API 618

1.1.3 “On skid” Cooling air system for packing integral with jacket cooling air system.

1.1.4 Compressor capacity control system for start/ stop is completed by receiver pressure and purchaser’s instruments.

1.1.5 Condition monitoring system

1.1.6 Necessary machine mounted instruments.

1.2 Compressor suction and discharge pulsation suppression devices including support, Acoustic simulation study and review of Purchaser’s piping arrangement.

1.3 All couplings for auxiliary equipment including non-sparking coupling guard.

1.4 Equipment baseplate (including support structure) will be on the same baseplate with compressor and motor with earthing boss.



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1.5 Low voltage electric motors for compressor mounted on baseplate, complete with all auxiliaries and accessories as per data sheet and specification (motor able to be shipped separately but shall be installed on the baseplate at site).

1.6 Local Control Panel mounted on the compressor skid

1.7 Soft starter which is built in LCP

1.8 All necessary piping , valves, fittings, wiring within the skid

2.0 All necessary instrumentation, controls and junction boxes within the skid with termination for Purchaser’s connection as required.

3.0 Unit Control Panel (for machine protection) supplied loose for mounting in instrument control room

4.0 Explosive – proof internal lighting

5.0 Gas leak detection system.

6.0 Inter-stage knock-out drums in SS 316L (Vendor to confirm) construction with complete instrumentation supplied loose, one for each compressor train.

7.0 Inter-stage process gas coolers, fin-fan type, designed and manufactured to API 661, supplied loose for purchaser’s mounting, one for each compressor train.

8.0 Inter-stage drum instrumentation Integral Level gauge with transmitters

9.0 Suction / discharge strainers, Inlet gas particulate filters remove 98.5% of 0.5 µm size solids. Discharge gas coalescing filters remove 99.995% of 0.5 µm liquid aerosol.

10.0 Control valves supplied loose (Vendor to advise)

11.0 Safety valves and final stage safety valves supplied loose

12.0 Lifting equipment (slings and spreader bar, certified)

13.0 09 units: Ground CNG storage including all accessories such as isolation valves, pressure gauges, safety valves, saddles, base frame etc…

14.0 09 flexible hoses 4” flanged ends ANSI 300# (for suction connections) (VTA)



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15.0 09 flexible hoses 1” NPT, class 3000# (for discharge connections) (VTA)

16.0 Inspection and testing as specified.

17.0 Third party Inspection and Approval

18.0 Surface preparation and painting

19.0 Long term preservation and packing, preparation for transport

20.0 Supervision of installation and commissioning (Separate quotation)

21.0 Recommended spare parts for start up and commissioning

22.0 All special tools and tackles for operation , installation and maintenance purposes

23.0 Necessary platforms/ladders for regular monitoring & maintenance of skid components

24.0 Documentation, drawings, manuals etc as detailed in SDRL.

25.0 3.1 Certifications



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APPENDIX B

SPECIFICATION, DATA SHEETS & P&ID’s The following project documents are applicable to the design of the equipment package:

DOCUMENT NUMBER TITLE

Data Sheet For CNG Compressor

P&ID - CNG Station

Piping Class Material Specification

General Specification for Instrumentation and Control system



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APPENDIX C INSPECTION AND TEST REQUIREMENTS

(THIS SECTION SHALL BE READ IN CONJUCTION WITH VENDOR'S) INSPECTION AND TEST REQUIREMENTS

Legend:

S: Review by Purchaser or Purchaser’s representative at Vendor

/manufacturer’s Works of activity

C: Confirm documents have been approved by Purchaser prior to commencement of activity.

M: Monitor activity.

W%: Witness inspection; %= percentage of activity to be witnessed (Vendor shall notify Purchaser per POQR, but may proceed without attendance or waiver by Purchaser)

H: Hold point (Vendor shall notify Purchaser per POQR and shall not proceed past a Hold Point without attendance or formal waiver issued by Purchaser)

Note 1– Vendor shall, as a minimum, include all activities identified below in the Inspection & Test Plan(s) and identify relevant activities from design through fabrication, testing and delivery.

Note 2 – Vendor is responsible for ensuring that these requirements are included, where appropriate, in Sub-Vendor Inspection & Test Plans and verify that all sub-Vendor documents are approved prior to commencing activity.

Note 3 – These requirements shall be read in conjunction with the package specific SDRL and POQR.

Note 4 – The below requirements identify the levels of involvement that the Purchaser’s inspection personnel and / or IVB may undertake to verify completion of relevant activity (ies).

Act. No. Activity description Purchaser Remark

(A) GENERAL

1 Kick off meeting / Post award Quality Clarification meeting H

The venue and timing of this meeting to be advised

2 Verify approval of Sub-Vendor list C

3 Verify approval of material origin and manufacture origin C



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4 Verify approval of design documents and drawings C

5 Verify approval of procedures (Like WPS/PQR, PWHT, NDE, Repair, Testing, Painting, Packaging, Shipping etc) C

6 Welder & NDE Personnel qualification records and welding consumable certificates. C

7 Calibration certificates for measuring and test equipment. S

8 Pre-production / inspection meeting H

The venue of this meeting shall be at the point of manufacture. Timing shall be decided during kick off meeting

9 Compliance audit against quality plan during manufacture M

10 Monitoring of Vendor’s / Sub –Vendor quality on a regular visit basis. M

11 Monitoring of material traceability, certification type, check of sour service requirements like hardness, impact etc M/S

12 Trouble shooting to works as necessary M

13 Material Verification / Review of material certificates S

14 Lifting attachment / equipment check and certification (calculation / proof load test) M/S

Third party certification is required.

(B) COMPRESSOR/LUBE OIL SYSTEM/COOLING AIR SYSTEM:

15 Material Inspection

15.1 10% radiography of seam / butt welds W



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15.2 100% MT/PT of all welds /attachments to pressure casing W MT or PT to be dependent on materials

15.3 100% MT/PT of all welds / attachments of piping or other than pressure casing W

15.4 10% radiography / UT of critical areas of pressure castings / forging W

15.5 100% UT of main nozzle welds W

16 Hardness test/ test report W/S

17 Minimum assembly check: W

17.1 Correct fitting of valves, valve unloaders together with their free operation with the springs in the housing W

17.2 When balance weights are fitted, these should fit tightly with no side clearance on the horns W

17.3 Bearing clearance check and record W

17.4 Check of Piston diameter, liner diameter, and other wearing dimensions and record W

17.5 Check of piston end clearances (bump clearance) and record W

17.6 Alignment check and record W

17.7 Cooling Air console assembly check (Verify system for control, issue and installation of correct components and parts)

17.8 Lube oil console assembly check (Verify system for control, issue and installation of correct components and parts)

17.9 Packing cooling console assembly check, if applicable (Verify system for control, issue and installation of correct components and parts)

18 Testing

18.1 Vendor standard shop test M

18.2 Cylinder hydrostatic test H

18.3 Cylinder jacket air hydrostatic test H



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18.4 Cylinder pneumatic test M

18.5 Compressor no load run test (minimum 4 hours at maximum speed) H

18.6 Bar over to check rod run out W

18.7 Performance test (ASME PTC 9) H

18.8 Crank case sump leak test W

18.9 Lube oil, packing cooling system console functional cleanliness and hydrostatic test. H

18.10 Cooling Air console functional, cleanliness and hydrostatic test. H

18.11 All Pumps performance and hydrostatic test. M

18.12 Static and dynamic balancing of major rotating components. M

18.13 Gear/Gear box tests as per spec/code (If applicable). W

18.14 Other tests M

19 Minimum disassembly check

19.1 Compressor dismantling to allow inspection of bores, piston rods, big ends and main bearings after running test. W

20 NDT/ Hardness inspection and acceptance of welds W/M/S

21 Painting / protective coating M

22 Name plate / project tagging W

23 Visual and dimensional inspection including final alignment check W

24 Inspection release certificate S

25 Manufacture’s data report/ Vendor data requirement list (Verify completion) S

(C) ELECTRIC MOTOR

26 Review completed data sheets C

27 Visual Inspection W

28 Dimensional check W

29 High Pot Test W



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30 Insulation Test W 31 Load test W 32 Starting / Running Test W

33 Lock Rotor test W

34 Integrated System test W

35 Inspection & test reports S (D) INSTRUMENTS / PANEL

36 Visual Inspection S

37 Verify Instrument models, instrument ranges, set points etc as per specification. S

38 Verify Hazardous area suitability of electrical components and Instruments C

39 Check Power supply as specified. Panel energize test S

40 Verify functional requirements of the panel operation of pushbuttons, lights etc. S

41 Verify logic operation of the panel. Verify PLC software- ladder logic / listing. Software validation. W

42 Verify interface with ICS. Verify Input / Output C

43 Verify package instruments, transmitters, switches-calibration records, functional checks. S

44 Stroke test control valves S

45 Verify shutdown valves / on-off valves operation. S

46 Verify installation-tubing/fitting leak test S

47 Safety valve set point test, leakage test S

48 Check Ingress rating of Instruments, panel, components S

49 Verify Instruments with isolation valve manifold. S

(E) PRESSURE VESSELS

50 Review of approved documents

50.1 Pulsation calculation, sizing of vessels. C



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50.2 Mechanical Calculation C Third party design review

50.3 Fabrication drawing and bill of materials C

50.4 Weld repair criteria and procedure C

51 Physical verification

51.1 NDT, Hardness Inspection and acceptance for welds W/M/S

51.2 Dimensional inspection and hydrostatic test H

51.3 Surface preparation and shop painting, DFT check M

51.4 Name plate / project tagging M

51.5 Issue of final shop inspection certificate S

51.6 As built shop drawings, QA/QC Dossiers, MDR etc S

(F) PIPING / VALVES / FITTINGS

52 Raw material receiving Inspection and documentation S

53 100% PMI examination W Only for SS body valves, pipes and fittings

54 FABRICATION

54.1 Verify approval of fabrication drawing/valve GA drawing/documents/calculation C

54.2 Fit up dimension check M

54.3 Welding M

54.4 NDE, Acceptance of welds M

54.5 Weld repairs W

54.6 100% Dimensional check / Visual Inspection / Heat identification W

55 100% Hydrostatic Pressure test for piping / valve body / valve seat leakage test W/S

56 Surface preparation / Painting inspection / thickness test certificates M/S

57 Marking (Line / tag no, size, pressure rating etc) M



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58 Install piping, valves on skid M

59 Line check including pipe support adequacy check/ bolting and gasket check M

60 Shop inspection / certification S

61 Inspection report S

(G) STRUCTURAL SKID

62 Approval of structural design calculation C

63 Radiography of butt weld (VTA) W

64 100% UT of pad eyes / lifting lugs H

65 Other NDT S

66 Surface preparation and shop painting, DFT check M

67 Dimensional inspection S (H) ASSEMBLED COMPRESSOR PACKAGE

68 Verify that all specified and required components of the package have been checked for correctness and tested for proper function.

S

69

Verify review of purchase order requirements and determination that all have been met or those deviations are documented by non conformances and design deviation request.

S

70

Fabrication/Assembly inspection: Performance and documentation of inspections on assembled package. Check package overall dimension and interface point location.

S

71

Welding Inspection: Verify that all required welding inspections on skid, piping, assembly & lifting equipment has been performed and documented. Verify repairs complete and re-inspected.

M/S

72

Package Electrical / Instrumentation Installation: Verify that electrical wiring and component installation has been inspected for safety, function & workmanship. Verify that components meet the area classification where installed.

S/C



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73 Complete unit string no load mechanical and operational test (4 hour min) H

74 Noise test H

75 Package weight: Verify that complete package is weighed and documented. S

76 Verify all issued non conformances and design deviation request have been resolved and closed. S

77 Final inspection H

78 Handling, preservation, packaging and transport S