Spec For Comp

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

ThinkXperT

MC:

MATERIAL STANDARD SPECIFICATION FOR

CENTRIFUGAL COMPRESSOR

DE

EXT

CFL

A

Eng. Phase

Purpose Of Distribution (POD)

Purpose Of Issue (POI)

Owner's Action

01

21.07.2014

Certified Final

A.Asadian

A.Eskandari

A.Eskandari

A. Kadkhodaee

00

14.04.2014

Issued For Engineering

A.Asadian

A.Eskandari

A.Eskandari

A. Kadkhodaee

Rev.

Date

Description

Prepared by

Checked by

Approved by

Authorized by

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 1 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Internal Issue

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

Change Index During Formal Issues First Issue

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This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Reason of Latest Change

Page 2 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Index

Rev. : 01

MC:

ThinkXperT

Page

Introduction Definitions CHAPTER 1 General Requirements 1. General 1.1 Scope 1.2 Alternative Design 1.3 Conflicting Requirements 1.8 Complete Unit Responsibility

4 4 5 5 5 5 5 4 5

2.

Basic Design 2.1 General 2.2 Materials 2.3 Casing 2.5 Rotating Element 2.6 Dynamics 2.8 Shaft End Seals 2.10 Lubrication and Sealing Systems

5 5 6 7 8 9 10 11

3.

Accessories 3.1 Drivers 3.2 Couplings and Guards 3.3 Mounting Plates 3.4 Controls and Instrumentation 3.5 Piping and Appurtenances 3.6 Special Tools

11 11 11 12 13 14 14

4.

Inspection, Testing, And Preparation for Shipment 4.1 General 4.2 Inspection 4.3 Testing 4.4 Preparation for Shipment

14 14 15 16 17

Annex 1F

18

CHAPTER 2 Centrifugal and Axial Compressors 2. Basic Design 2.1 General 2.3 Casing 2.4 Guide Vanes, Stators, and Stationary Internals 2.7 Bearings and Bearings Housing

19 19 19 19 20 21 21

3. 4.

22 23

Accessories Inspection, Testing, and Preparation for Shipment

CHAPTER 3 Integrally Geared Compressors 2. Basic Design 2.1 General 2.7 Bearings and Bearings Housing

24 24 24 24 24

3.

Accessories

25

4.

Inspection, Testing, and Preparation for Shipment

25

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 3 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

INTRODUCTION ADDITIONAL ARRANGEMENT TO API 617 (Addition) th

The numbers and titles correspond to the API 617, 7 edition, July 2002, sections and paragraphs involved. For API 617 paragraphs not addressed in this specification, vendor shall adhere strictly to the requirements of API 617. The type of change e.g. addition, substitution, modification or deletion is indicated in brackets for each paragraph. For regulations or explanations that are not covered by API 617, new paragraphs have been added and are indicated with (New). DEFINITIONS The Purchaser is BUSHEHR Petrochemical Company (BUPC). The Contractor is Petrochemical Industries Design and Engineering Company (PIDEC). The Vendor/Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Inspector is a person from Purchaser’s permanent organization of Inspection/QC section and/or from the qualified Inspection agencies of the Purchaser.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 4 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

CHAPTER 1 GENERAL REQUIREMENTS 1.

GENERAL

1.1

SCOPE

1.1.2

(Addition) Equipment offered by vendor shall satisfy the following minimum service and manufacturing experience requirements: Compressors shall be identical or validly similar in power rating, speed, discharge pressure, suction capacity, process gas, mechanical design, materials and rotor dynamics as compared with at least two units produced at the proposed manufacturing plant. These units must have had at least two years’ satisfactory operation. As an alternative, vendor may show to the satisfaction of the Contractor/ Purchaser, that the equipment offered is comprised of components each of which individually satisfies the qualification requirements. Equipment manufactured under license, in addition to satisfying the above requirements shall also have the licensor's written guarantee. Corresponding requirements apply and shall also be satisfied by the driver, gear and auxiliary equipment.

1.2

ALTERNATIVE DESIGN (Modification) Unless otherwise specified, pipe, pipe threading and flanges shall be based on U.S. standards.

1.3

CONFLICTING REQUIREMENTS (Modification) In case of conflict between the various documents, their order of precedence is as follows: • • • • • •

Purchase Order & Deviations thereto Material Requisition& Data sheets This Specification Other General and/or Project Specifications Referenced Codes and Standards Vendor’s bid and Vendor’s drawings

Any conflicting requirements shall be called to the Contractor/Purchaser’s attention in writing for clarification before proceeding with manufacture of the affected parts. 1.8

COMPLETE UNIT RESPONSIBILITY (Modification) Compressors, gears, drivers and auxiliaries that make up a complete unit shall be ordered from one Manufacturer, usually the compressor Manufacturer. This Manufacturer shall be responsible for the design co-ordination and the satisfactory mechanical, aero- and thermo-dynamic performance integrity of the complete unit. Further, this Manufacturer shall warrant and guarantee all equipment and component parts as stipulated in the relevant specifications and purchase order.

2.

BASIC DESIGN

2.1

GENERAL

2.1.1.3 (Addition) The Manufacturer shall also state the ability of the compressor to operate at all other conditions specified in the data/requisition sheets.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 5 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216

MC: ThinkXperT (Modification) If not differently specified in the data sheet, compressors and auxiliaries shall be suitable for outdoor unprotected installation in the climatic zone specified in the Material Requisition.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

2.1.8

Bushehr Petrochemical Company (BUPC)

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

The vendor shall describe the winterizing extent, if any required, and provide all the necessary clips or supports for the insulation. Vendor shall also show on its drawings and P&I diagrams, items of equipment and piping, which require tracing and/or lagging. 2.1.9

(Substitution) The overall sound pressure level measured at 1m from machine side in any directions shall be limited to 85 dB(A). Provisions of silencers, acoustic insulation and/or noise hood may be required to meet the above required noise level. Noise data shall be provided at bid stage. Vendor shall submit the data of expected sound pressure level per each octave band (in Hz) to Contractor/Purchaser for his approval.

2.1.16 (Substitution) When on the data sheet it is indicated that the compressor will be used for alternate service, e.g. air drying at start-up, catalyst regeneration, etc., vendor shall provide the relevant performance curves and shall indicate on proposal data sheets any special requirements to operate safely, including uncoupling of part of the train, insertion of alternative seal, purging oil seals, etc. 2.1.17 (Addition) Vendor shall be responsible for determining the thermodynamic properties of the gases to be compressed based on the gas analysis data specified on the compressor data sheets. 2.1.18 (Addition) Asbestos and asbestos filling materials shall not be used. Non-asbestos gaskets and/or packing shall be used. 2.1.19 (Addition) Equipment exposed to the sunlight shall be designed for 85°C as a minimum. 2.1.20 (Addition) Each compressor train shall have its own auxiliaries (i.e. lube oil system, seal gas system, unit control panel etc.). Common auxiliary systems may be proposed as an option. 2.2

MATERIALS

2.2.1

General

2.2.1.1 (Modification) Corrosion allowance of 3 mm shall be considered for all carbon steel (including 0.5 Mo) parts, which are in contact with the process fluid. 2.2.1.2 (Modification) Materials of construction shall be as per ASTM/ASME standards. DIN, BS or any other well-known international materials as substituted materials to ASTM/ASME ones can be selected, if they are equivalent or superior to ASTM/ASME ones. The certification should be presented. For major components the Vendor shall provide details as chemical composition and mechanical properties in case of non-ASTM or non-ASME materials. 2.2.1.3 (Modification) Corrosion agent injection, if present in process gas stream, will be identified in the data sheets. 2.2.1.6 (Modification) In corrosive gas service (wet H2S, wet CO2, etc.) at least the first two impellers of each section shall be made of 13% Chr. or better material. This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 6 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

2.2.1.15 Low Temperature 2.2.1.15.1(Substitution) Vendor shall exercise caution in the selection of steel materials intended for service between -29°C (-20 °F) and 40°C (100 °F). For the selection of materials other than Austenitic Stainless Steel for service below -29°C (-20 °F), vendor shall require a Charpy V-notch impact test. Steels shall have an impact strength at the specified minimum design temperature sufficient to qualify under the minimum Charpy V-notch impact energy requirements of the ASME Code, section VlIl, division 1, paragraph UG-84. Paragraph UCS-66 of the Code shall be used to establish impact testing exceptions for Steels. Curve A shall be used for all Steel materials, including castings, which are not specifically listed for Curves B, C or D. Vendor shall state in his proposal when thickness is not covered by the Code. 2.3

CASING

2.3.1

Pressure-Containing Casings

2.3.1.10.1(Modification) Standard procedures for casting repairs shall be submitted to Purchaser for approval prior to starting the casting work. Unacceptable imperfections shall be removed and their complete removal shall be verified by additional examination. All the finished surfaces by repair welding shall be inspected according to the same quality standard that was applied to inspect the casting. The casting defect, which corresponds to any of the following items, shall be considered as a major defect: • Having leaked during hydrostatic test due to the defects • The depth of any cavity prepared for repair welding exceeds 20 % of the wall thickness or 25 mm (1 in.), whichever is smaller • Any cavity prepared for welding is greater than approx. 6500 mm2 {10 in2} in area. For the major defects, defect and repair maps shall be prepared and submitted to Purchaser for review and approval prior to starting the repair work. On these maps, the extent, the location of the defect and details of the repair procedure shall be indicated. Welding repairs of major defects for pressure-retaining castings shall be stress relieved, heat-treated after the welding and shall be radiography tested. 2.3.1.12 Material Inspection of Pressure-Containing Parts 2.3.1.12.1(Modification) Butt welded joints of pressure containing casings shall be 100% X-Ray examined. 2.3.2

Pressure Casing Connections

2.3.2.1 General 2.3.2.1.1 (Modification) All connections (process/auxiliaries) on casing shall be flanged. Machined and studded and threaded connections are not allowed. 2.3.2.1.3(Modification) All nozzles for piping connections on pressure casing shall be flanged. Threaded connections or seal welded are not allowed. 2.3.2.1.7 (Modification) Vent and drain connections shall be provided with valves. Drains shall be furnished on all casings, and drain lines shall be provided and brought out to edge of the baseplate and individually valved. This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 7 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT Drain valves shall be grouped and readily accessible from the operating floor level. Flanged valved vent and drain connections are acceptable for compressors with Molecular Weight > 10. For applications with Molecular Weight < 10, they shall be butt-welded.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

2.3.2.2 Main Process Connections 2.3.2.2.1(Modification) If not otherwise specified studded connections shall not be provided. Sufficient provision shall be made to permit isolating, relieving and purging of the compressor in case internal inspection or repair shall be incorporated. 2.3.2.2.2 (Substitution) Unless otherwise specified flanges smaller or equal than 24 inches shall conform to ASME B16.5. Flanges equal or larger than 26 inches shall conform to ASME B16.47 series B. Unless otherwise specified, on RF flanges the gasket contact surface shall have concentric or continuous spiral grooves, resulting in a roughness height within the range of 125 to 250 AARH in accordance with ASME B16.5 while on RTJ Flanges the range shall be 32-63 AARH. 2.3.2.2.12 (Addition) The vendor shall state the minimum runs of straight pipe required at the inlet, as well as any sidestream connections. 2.3.2.3 Auxiliary Connections 2.3.2.3.3(Substitution) Auxiliary connections shall be welded and flanged or machined and studded. Socket welded connections are not permitted where there is a possibility of crevice corrosion or in applications where there is a potential for cracking. Socket welded connections are not allowed on lube oil and dry gas seal connections. All welded connections shall be full penetration. Openings smaller than DN 25 (NPS 1) shall be reinforced. No casing connection shall be smaller than DN 20 (NPS ¾). 2.3.2.3.4.1 (Modification) Each pipe nipple shall be provided with a welding neck flange. Slip-on flanges are not allowed. 2.3.2.3.5 Requirements for Threaded Connections (Modification) Threaded openings shall not be used on compressor casing. 2.5

ROTATING ELEMENT

2.5.1

(Modification) If not otherwise specified the coupling shaft end shall be designed for hydraulically fitted coupling.

2.5.4

(Modification) Impeller stresses at the maximum continuous speed shall not exceed 70% of the material yield strength. The minimum and maximum material strength and the actual stress of each impeller @ maximum continuous speed shall be stated in the proposal.

2.5.5

(Modification) Replaceable thrust collars shall be hydraulically fitted and positively locked into position.

2.5.10 Impellers 2.5.10.1 (Modification) Cast and riveted impellers are not acceptable. Each impeller shall be marked with a unique identification number. This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 8 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

2.6

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

DYNAMICS

2.6.1.4 (Modification) For compressor trains having other than gas turbine drivers, the compressor vendor shall have the unit responsibility for the entire system consisting of compressor, driver, power transmission, and associated auxiliary equipment. For gas turbine driven compressors, the unit responsibility shall be assumed by the gas turbine vendor. 2.6.1.5 (Addition) Both torsional and lateral analyses are under the complete responsibility of the compressor vendor. This vendor shall furnish a copy of these analyses and of the related data for review and approval. 2.6.2

Lateral Analysis

2.6.2.6 (Modification) A train lateral analysis shall be performed for all compressors. 2.6.2.14(Modification) Delete from this clause the words: “When specified”. 2.6.2.15 (Addition) An additional plot of an unbalance sufficient to cause vibration amplitude at the probe locations of the vendor recommended alarm (alert) level at rated speed, showing the amplitude(s) at the seal locations along the shaft when the machine is operated through any resonance, including coast down from trip speed, shall be provided. In placing this weight, consideration shall be given to the location(s) most likely to experienced unbalances during normal operation (impeller deposits, etc.). 2.6.2.16 (Addition) Supplier shall carry out a rotor stability analysis considering all sources of destabilization, taking into account the highest density that can be encountered with the specified gas compositions. The calculated log decrement shall have a minimum positive value of 0.2 over the complete speed range. 2.6.7

Torsional Analysis

2.6.7.1 Unless otherwise specified, a torsional vibration analysis shall be performed for all the compressor units. 2.6.8

Vibration and Balancing

2.6.8.7 (Modification) Delete the words “when specified” In this clause. Add to this clause: When an operating speed balance is performed, the low speed balance shall be checked. This is done to provide a reference of residual unbalance and phase for future use in a low speed balance machine. 2.6.8.12(Addition) Unbalance of rotating assembly shall not be corrected by modification of the replaceable parts such as sleeves, coupling and thrust collar. 2.6.8.13 (Addition) Spare rotors ordered with compressors shall be balanced to the same degree as the main rotor.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 9 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

2.7.4

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

Bearing Housings

2.7.4.1 (Modification) Irrespective of the type of coupling or coupling guard, compressors shall have drive-end bearing housing shaft seals to prevent oil leakage toward coupling. 2.7.4.3 (Modification) All oil return lines shall be stainless steel made, type 304 or 316, and they shall be furnished with sight flow indicators. 2.8

SHAFT END SEALS

2.8.1.1 (Addition) If rapid de-pressurization is specified, the Manufacturer shall confirm that the shaft seals and the sealing system are suitable for this and describe the relevant design features. 2.8.4

Self Acting Dry Gas Seal

2.8.4.1 (Modification) For air compressors labyrinth seal shall be utilized. Self-acting dry gas seals shall be used for sealing systems when they are compatible with handling gas (toxic or flammable gases). Self-buffer gas of suitable temperature may be introduced from the compressor discharge or inter-stage. Unless otherwise specified, self-acting dry gas seals shall be of tandem arrangement with an outboard additional isolating seal (floating carbon ring, labyrinth or equivalent type) using nitrogen as separation gas. The design shall prevent process gas leakage into the lube oil system or oil leakage and migration into the seal face area. Proven materials of components shall be used for dry gas seals to guarantee run time of three year, minimum. A tandem seal with an internal labyrinth seal and inert gas buffer or a double pressurized seal shall be selected for toxic applications, and whenever required to reduce process gas emission to an absolute minimum. The expected and guaranteed consumption of buffer gas and separation gas shall be stated at proposal stage. Vendor shall check start-up, operating and shutdown conditions in design of dry gas sealing system. The source of buffer gas and separation gas shall be specified for all the above-mentioned conditions and submitted during the bid stage. Any compressor seal system shall have a buffer flow indicator. 2.8.4.4 (Modification) If suitable and referenced for the specified service, vendor shall propose seals of the bi-directional type.

01

2.8.4.5 (Addition) A stainless steel seal, buffer/barrier, purge and separation gas system, as applicable, including piping harness, filtering facilities, instrumentation and controls, shall be provided fully installed on compressor skid. Minimum requirements of API 614 (Edition 5) Chapter 4 shall apply.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 10 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

2.8.4.6 (Addition) The seal and/or buffer gas supply system shall include a twin filter of coalescing type with 2 μm absolute filtration. One condensate drain trap per coalescing filter shall be provided when condensate may be present at the coldest operating temperature. 2.8.4.7 (Addition) The separation gas supply system shall include a twin filter with 2 μm absolute

filtration.

2.8.4.8 (Addition) Operating conditions of the dry gas seals shall be monitored by individual leakage flow indicators on primary leakage lines. The abnormal leakage due to any failure of the primary seals shall be detected by differential pressure transmitters before and after a restriction orifice in the leakage piping or by other equivalent system. Alarm and trip contacts of the differential pressure or equivalent system shall be provided. 2.8.4.9 (Addition) Piping material for buffer gas system shall be stainless steel. 2.8.4.10 (Addition) Vendor shall clearly indicate in the proposal seals behavior in case of reverse rotation, specifying if they can work properly, if they can withstand reverse rotation without damage, if reverse rotation shall be avoided and/or if some limitations for reverse speed and time shall apply. 2.10

LUBRICATION AND SEALING SYSTEMS

2.10.4 (Addition) The vendor shall supply, with the certified drawings, a summary of the lubricants and hydraulic fluid requirements for all systems and equipment components in its scope of supply. The type, physical properties and required quantity of each fluid and grease shall be specified in sufficient detail to permit proper selection and procurement. 2.10.5 (Addition) Nozzle size of pressure vessels including heat exchangers shall be 3/4 inch as

minimum.

2.10.6 (Addition) Heat exchanger shall be designed to 110% of the normal duty as minimum. 2.10.7 (Addition) Lube oil piping shall be of 304 stainless steel, and prefabricated, shop-pickled and completely sealed for shipment. 3.

ACCESSORIES

3.1

DRIVERS

3.1.8

(Substitution) Speed increasers and reducers shall comply with API Std 613 edition 5. and shall be sized for the maximum power and speed of the driver under all specified operating and ambient conditions.

3.1.9

(Additions) Electric motors shall be designed, fabricated, inspected, and tested in accordance with the applicable specifications.

3.2

COUPLING AND GUARDS

3.2.2

(Modification) Couplings shall be of the flexible element (laminated disc or diaphragm) type, supplied by manufacturers approved by Contractor /Purchaser.

01

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 11 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT Unless otherwise specified coupling hubs shall be removable and non-keyed type (tapered bore, hydraulically fitted). Flexible elements shall be stainless steel made.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

3.2.7

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

(Modification) Coupling guards shall be supplied for all rotating parts. Guards shall be fully enclosed and of the spark-proof type. They shall be provided with a 2 inch minimum vent connection fitted with vendor’s standard breather, and a 2 inch minimum drain connection fitted with a steel pipe plug. Guards shall be substantially constructed and be sufficiently rigid to withstand deflection and distortion and prevent rubbing as a result of bodily contact.

3.3

MOUNTING PLATES

3.3.1

General

3.3.1.1 (Modification) If not otherwise specified equipment shall be furnished with a baseplate. 3.3.1.2.6 (Substitution) Anchor bolts, nuts and washers shall be designed by vendor. 3.3.1.2.10(Modification) Baseplate shall be furnished with: • • 3.3.2

Leveling jackscrews and associated leveling plates adjacent to each anchor bolt pocket. Spot subplates, shim packs and capscrews adjacent to each anchor bolt.

Baseplates

3.3.2.1 (Modification) Unless otherwise specified, the complete compressor unit, including gear and driver, shall be mounted on a single baseplate. Baseplate shall be extended (length and width) for the compressor and all accessories without overhang, except that motor driver conduit boxes, and removable oil drain header piping may extend beyond the base plate. If the use of multiple section baseplates are inevitable due to size, transportation, installation (lifting constraints), and/or plant lay-out consideration multiple-section baseplates shall have machined and doweled mating surfaces, to ensure accurate field assembly. 3.3.2.4 (Modification) Delete from this clause the words “When specified”. 3.3.2.4.1(Modification) Delete from this clause the words “When specified”. 3.3.2.6 (Modification) Delete from this clause the words “When specified”. 3.3.2.6.1 (Modification) Levelling pads or targets shall be provided. 3.3.2.10(Modification) Delete from this clause the words “When specified”. 3.3.2.12 (Addition) The baseplate shall be furnished with two earthing lugs situated diagonally opposite each other at either end of unit.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 12 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

3.3.2.13 (New) Auxiliary piping to compressor supplied by the Manufacturer shall allow removal of the entire machines or machine heads. 3.3.2.14 (New) The baseplate design and layout shall consider safety, operator and maintenance efficiencies, and cost effectiveness. Piping, conduit and other auxiliary equipment shall be routed to eliminate tripping hazards. Piping and conduit shall be routed downward from the compressor and driver into troughs below the deck level and through the side of the baseplate. Grating or decking shall cover these troughs. 3.4

CONTROL AND INSTRUMENTATION

3.4.1.1 (Modification) For instrumentation and control system refer to the General Specification for instruments supplied with packages. 3.4.1.6 (Addition) All instruments/systems shall be repairable by replacing defective parts. 3.4.1.7 (Addition) Highly descriptive trouble shooting instructions, covered in vendor standard maintenance manuals including sufficient information and data, shall be furnished to help easy fault location and isolation. 3.4.2

Control System

3.4.2.1 (Modification) If not otherwise specified, a complete and independent Unit Control Panel (UCP) shall be supplied by the vendor. As far as applicable it shall include also the following systems: • • • •

Anti-surge system Steam turbine governor system Overspeed shutdown system Vibration and temperature monitoring system

3.4.2.2 (Substitution) An antisurge system shall be provided by the vendor. The unit surge controller shall be fully programmable to implement standard and custom algorithm/surge line models. Anti surge system for each compressor shall be comprised as a minimum of: • • • •

Performance monitoring Anti-surge control Anstisurge control valves (at field) Flowmeters, pressure transmitter and temperature transmitter (at field)

3.4.2.3 (Addition) Electronic instruments equipping the package shall be smart type with HART protocol. Selected important information such as facility fault alarms and shutdown alarms shall be repeated to DCS through redundant serial interface (MODBUS RS-485). Dedicated controllers i.e, anti-surge controllers shall be also interfaced to DCS through direct serial interface (MODBUS RS-485) or via Unit Control Panel. 3.4.2.4 (Addition) For vibration, axial displacement and bearings temperature monitoring system, the system shall include a dedicated card for connection to expert prediction monitoring system.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 13 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

3.4.6

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

Electrical Systems

3.4.6.1 (Modification) For electrical scope of work refer to the applicable specifications. 3.5

PIPING AND APPURTENANCES

3.5.1.1 (Modification) When buffer gas is specified as being required, compressor supplier shall furnish all required controls, indicating and protective instrumentation and interconnecting piping for the system. The system shall be designed to accept the fluid at the supply conditions specified. As minimum, compressor supplier shall furnish a pre-piped harness per API 617. If the system is off-mounted from the compressor, it shall be furnished as a fully assembled skid-mounted module. 3.5.1.5 (Addition) Piping and equipment shall be designed and arranged for easy disassembling and maintenance. Cooling water supply and return line connection shall be flanged at the edge of baseplate. Isolation valves for cooling water supply and return lines will be provided by the vendor. 3.5.1.6 (Addition) Vendor shall provide for by-passing the bearings together with couplings, if applicable, during shop and field prestart-up oil flushing operations, without dismantling housings and guard. The external feed/drain lines on the housing(s) shall be designed with a blinded tee next to the housing (or a short removable flanged section) so that a temporary by-pass can be easily installed to the drain line(s) and the housing blinded. The temporary by-pass lines and housing blinds shall be included in the Special Tools provided by the vendor. 3.5.1.7 (Addition) In general connections, piping, valves and fittings of 1 ¼”, 2 ½”, 3 ½”, 5”, 7”, 9”, 22” and 26” shall not be used. In case their use is unavoidable, vendor shall provide reducer with bigger size other than listed above at Purchaser’s battery limit connection. Pipe sizes smaller than 1/2” shall not be used except for instrumentation and analysis. 3.5.3

Process Piping (Modification) Process piping is not generally part of the scope of supply. If process piping is part of the scope of supply, Process piping shall be in accordance with the applicable piping material specification.

3.6

SPECIAL TOOLS

3.6.1

(Modification) Vendor shall quote any special tools required for installation and/or maintenance of the compressor including the facilities for the flushing of the lube oil piping. For vertical split units, vendor shall quote, a cradle or similar device for compressor rotor and diaphragms removal.

4.

INSPECTION, TESTING, AND PREPARATION FOR SHIPMENT

4.1

GENERAL

4.1.4

(Substitution) Compressor Data Sheet and/or Scope of inspection, which are attached to the Material Requisition, shall be referred for the inspection items that will be witnessed or be observed by Purchaser and the items which shall be reported to Purchaser. When the third party inspectors are involved, it will be informed to Vendor.

4.1.7

(Modification) The vendor shall provide a quality control plan listing the program of inspection and testing, for Contractor /Purchaser review and agreement.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 14 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

4.1.8.

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

(Addition) The vendor shall submit to Purchaser the following records for each compressor: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Material mill test certificates and heat treatment records Non-destructive examination Dimensional inspection Impeller overspeed test (including subsequent inspection) Dynamic balancing test (including gear units, if any) Hydrostatic test Mechanical running test Shaft seal test Gas leak test Test of gear units, if any Control device function test, when applicable Calibration certificate for instrumentation Dry gas seal test, when applicable Lube oil system -

Leak test for lube oil tank Hydrostatic test for cooler and filter System leak test System function test System cleanliness Calibration certificate for instrumentation

(15) Other inspection and test (when specified) 4.2

INSPECTION

4.2.1.a (Modification) Material mill test certificates shall be checked for the following parts. The certificate shall give the chemical compositions, mechanical properties, heat treatment, etc., and they shall meet the requirements of the specified material specifications. (1) Compressors casings (including heads, suction and discharge nozzles and flanges) shafts, shaft sleeves, impellers and casing bolts & nuts (2) Pinions and gears of gear units (3) Seal oil drain traps and seal oil overhead tanks. 4.2.1.2.b (Modification) The applicable non-destructive examination shall be clarified by vendor, taking account of the Purchaser’s basic requirements as shown in Annex 1F. 4.2.1.5 (Modification) Hardness of parts, welds, and heat-affected zones shall be verified for H2S service. 4.2.1.6. (Addition) Measurement of the major dimensions shall be taken and they shall be checked with the certified outline drawings (approved by Contractor/Purchaser). The major dimensions refer to the following items: • • • • •

length, width and height of baseplates position and size of foundation bolts major nozzles size and position, rotational direction position of coupling flange-end and height of shaft center nameplates.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 15 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT The result shall be noted on the inspection certificate with the drawing no. and revision no. of the certified outline drawings, but detailed dimensional records are not required.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

4.2.1.7 (Addition) All the running clearances shall be inspected and be recorded. 4.2.1.8 (Addition) Each pressure-retaining casting shall be subjected to visual inspection for all surfaces, and shall be free from adhering sand, scale, cracks, hot tears or other similar casting defects in accordance with the related specification. 4.2.1.9 (Addition) Machined surfaces of nozzle flanges shall be visually inspected to confirm no harmful defects. 4.2.2.6 (Addition) Material certificates The Manufacturer shall furnish material certificates in accordance with BS EN 10204 (2004), of the type as specified in the table below: CERTIFICATION OF MATERIALS BY COMPRESSOR PART COMPONENT Certificate Type BS EN 10204 Pressure containing parts (casing, end head and 3.1 (see note 1) main process nozzles) Shaft/ Impellers 3.1 (see note 1) Shear rings 3.1 Internals - inner barrel, diaphragms, guide 3.1 channels, labyrinths, shaft sleeves, shaft seals Bolting 3.1 All other process and auxiliary piping, flanges 3.1 and connections NOTE 1: Positive material identification (PMI) shall be applied at the time of assembly to pressure containing parts, rotor shafts and impellers that are made of low-alloy steel, highalloy martensitic steel, ferritic or austenitic stainless steel, or nickel alloys. This shall be used to positively identify that the materials have the specified alloy composition. The method and procedures are subject to approval by the Purchaser.

4.3

TESTING

4.3.2.1 (Addition) Hydrostatic test shall be performed only after final machining of the subject component. 4.3.3

Overspeed test

4.3.3.1 Impeller Overspeed Test (Modification) Each impeller shall be subjected to an overspeed test at not less than 115 percent of maximum continuous speed for a minimum duration of 3 minutes. 4.3.6

Mechanical Running Test

4.3.6.1.5 (Substitution) During the mechanical running test, the lubricating oil and seal oil temperatures shall be held for a minimum period of 30 min at the temperature corresponding to the minimum allowable viscosity, and for 30 min at the temperature corresponding to the maximum allowable viscosity. Variable speed compressors shall be checked for correct rotor dynamic behavior through their full speed range during this temperature variation. Oil pressures and temperatures and bearing temperatures shall be measured throughout the test. 4.3.6.1.6 (Addition)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 16 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT The contract shaft seals and bearings shall be used for the compressor mechanical running test. Job couplings, Job gear unit, job dry gas seal unit and job lube oil unit shall be used for Mechanical Running Test with job Rotor.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

4.3.6.1.7 (Addition) All warning, protective, and control devices specified for use during the test shall be checked, calibrated, and adjustments shall be made as required. 4.3.6.2.1 (Substitution) All bearings shall be removed, inspected, and reassembled after the mechanical running test has been successfully completed. 4.3.6.2.2(Modification) Mechanical contact type or dry gas seals shall not be removed after a successful running test. 4.3.8.5 (Modification) Post-test inspection of compressor internals shall be carried out only after completion of first rotor’s mechanical running test, if spare rotor is purchased. In this case, the gas test shall be performed only after completion of 2 (second) rotor’s mechanical running test. So , test sequence will be as follows: 1) 2) 3)

Performance Test with Spare Rotor Mechanical Running Test with Spare Rotor Mechanical Running Test with job Rotor.

4.4

PREPARATION FOR SHIPMENT

4.4.3

(Modification) Prior to shipment, a final inspection shall be made by Purchaser’s representative to ensure that all instruments, tags, etc., are as specified. All items requiring this inspection are to be collected in a central area.

4.4.3.1 (Substitution) Exterior surfaces, except for machined surfaces, shall be coated with primer paint and finishing paint in accordance with the applicable painting specification. The paint shall not contain lead or chromates. Painting of exterior stainless steel surfaces, if required, will follow the applicable painting specification. 4.4.3.9 (Addition) Separately shipped parts and spare parts shall be prepared and packaged per Manufacturer standard preparation methods. Identification tags shall be attached to each part as well as to the outside of each box. Spare parts shall be crated separately from parts needed for initial installation. 4.4.3.10(Substitution) Unless otherwise specified, each individual spare rotor shall be crated in a metal container for transportation and storage. These containers shall be equipped with facilities for low pressure nitrogen blanketing. The identification attached to spare rotor containers shall include Manufacturer serial number, the Purchaser's equipment tag number, and the weight of the container, including the rotor. Crating, containers and storage shall be suitable for 12 years outdoor storage in the vertical position. 4.4.3.12(Addition) Exposed shaft ends shall be protected against physical damage. 4.4.4

(Modification) All connections, except suction and discharge flanges, shall be identified by metal tags attached by stainless steel wire or stenciled imprints stamped on each connection.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 17 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

4.4.7

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

ThinkXperT

MC:

(Addition) Export packing and shipping shall conform to Purchaser’s shipping procedure.

ANNEX 1F Application Table for Non-Destructive Examination RT: Radiographic inspection MT: Magnetic particle inspection Item 1

Applicable Parts

PT: Liquid penetrant inspection UT: Ultrasonic inspection RT

MT or PT

UT

–

MT or PT (1) (3)

UT (1)

100% RT

100% PT

(*)

RT

100% MT or PT

–

–

100% MT or PT (2) (3)

–

MT or PT

–

Pressure Casings: 1a

Raw Material

1b

Butt-Weld/ Full Penetration Weld Joints

1c

Other Type of Weld Joints

1d

Machined Surface

2

Repair of Cast Casing 2a

Defects removed surface (4)

2b

Repair welded surface of major defects (4)

RT

PT

(*)

2c

Repair welded surface of other defects (4)

–

MT or PT

–

(2)

3

Diaphragms

–

4

Impellers

–

5

Shafts

–

MT

(2)

UT (1)

6

Balance Drums

–

MT

(2)

UT (1)

7

Shaft Sleeves

–

MT or PT

MT or PT

MT after the over-speed test for accessible area of welds

(2)

– UT (1)

–

Butt weld joints / Full penetration weld joints 8

5% RT

100% of PT

On process gas auxiliary piping 9

Gear 9a

Rotating parts

9b

Gear and pinion teeth

10

Butt weld joints/ Full penetrant weld joints

11

Machined surface

MT or UT (5)

UT (1)

MT 100% RT

100% of PT

(*)

100% MT or PT (2)(3)

Notes: (1) Applicable for the raw materials as per raw material supplier’s standard procedure. (2) Applicable after the final machining (machined surface). (3) Applicable after the stress relief (when applicable) (4) Non-destructive examination is applicable only for defects and repaired area (5) For welded joints (*) UT in case RT is not practicable.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 18 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

CHAPTER 2 CENTRIFUGAL AND AXIAL COMPRESSORS 2. BASIC DESIGN 2.1 GENERAL 2.1.1.1 (Substitution) The sectional head-capacity characteristic curve shall rise continuously from the rated point to predicted surge. This rise shall be sufficient to result in an increase of the pressure ratio of at least 5% when operating at specified suction conditions. If guide vanes are provided, this requirement shall be met for each setting of adjustable inlet guide vanes or axial stator vanes. The gradient of the tangent of the compressor head capacity curve shall decrease continuously, never increase, and never become zero from stonewall capacity up to the surge point. The “stonewall” capacity is defined as the capacity where the decrease in polytropic head is 10% for an increase of 1% in inlet volume capacity. The stonewall capacity shall be at least 110% of the rated capacity at rated speed. The compressor Manufacturer shall confirm the suitability of the compressor to operate continuously at the stonewall point and any limitation on operating beyond the stonewall point. For the purpose of operational flexibility: •

The end-of-curve (EOC) capacity is defined as the capacity at rated speed where the polytropic head is 85% of the polytropic head at rated capacity. If applicable, the EOC capacity shall be stated in the data/requisition sheets.

•

The turn-down (TD) capacity is defined as the capacity at the control point for the surge at rated speed. The predicted surge capacity at rated speed shall be stated in the data/requisition sheets.

•

For identical compressors operating in parallel (if so stated in the data/requisition sheets), the respective heads at the same flow shall not differ by more than 2% from each other at any point on the curves.

•

The operating stability range of the compressor shall be at least 25% of the rated point flow.

The Vendor shall guarantee the followings compressor performances.

2.1.2

•

Capacity shall have zero negative tolerance at the normal operating point (certified point). This tolerance shall be inclusive of all test tolerances.

•

Head shall be within the range of 100%-105% of the normal operating point (certified point). This tolerance shall be inclusive of all test tolerances.

•

Horsepower based on measure head at normal operating point (certified point) shall not exceed 104% of the value at the specified normal operating point (certified point). If the power required at this point exceeds 104%, excess head may be removed by trimming an impeller at the Purchaser’s option.

(New)

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 19 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT Impeller flow coefficients shall be within the 0.01 to 0.12 range. Impeller designs with flow coefficients outside the above limits need adequate references and are normally only acceptable if adequate model testing has been done. The final acceptance of these deviations shall be subject to the Contractor /Purchaser's approval.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

Flow coefficient: ϕ = Q1 / (π/4 × D² × U)

Where

2.1.3

Q1 = inlet volume flow m³/s U = impeller tip speed m/s D = impeller diameter m

(New) Impeller stage head coefficients shall be within the 0.4 to 0.55 range Impeller designs with head coefficients outside the above limits need adequate references and are normally only acceptable if adequate model testing has been done. The final acceptance of these deviations shall be subject to the Contractor /Purchaser's approval. Head coefficient: ψ = Hp / (U² / 2) Where

2.1.4

Hp= impeller stage polytropic head kJ/kg U = impeller tip speed m/s

(New) Shaft length-to-diameter ratio L/D shall not exceed a factor of 10. Larger L/D ratios may be acceptable only if they are provided with adequate references and an initial stability analysis in the Manufacturer's proposal, which proves the log decrement to be in the stable region. Where:

L = compressor bearing span in m (ft) D = average shaft diameter under the impellers m (ft).

2.1.5

(New) Average impeller inlet Mach numbers shall be within the normal 0.85 limit. On a case-by case basis, subject to the Contractor/Purchaser's approval, higher numbers may be acceptable if computational fluid dynamics (CFD) results indicate that localized stalling at the impeller eye rim is minimal, and is not affected by the specified temperature and pressure variations in the impeller inlet. Transonic conditions shall not be accepted.

2.1.6

(New) Machine Mach numbers or impeller tip Mach numbers shall normally be within the 1.2 limit. Higher Machine Mach numbers will be accepted if the Manufacturer provides adequate references and corresponding CFD results for these designs.

2.3

CASING

2.3.1

Pressure Containing Casings

2.3.1.1 Pressure containing casings shall not be de-rated from their design MAWP and the applied hydrostatic test pressure shall be selected accordingly. 2.3.1.2 (Modification) Casing designed for more than one maximum allowable pressure level (Split-pressure-level casing) are not acceptable 2.3.1.5 (Modification) O-rings or ring grooves machined into the flange facing of an axially split casing joints are not acceptable.

2.3.2

Pressure Casing Connections

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 20 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT 2.3.2.2.2(New) The Manufacturer shall state in its proposal the actual and the maximum recommended gas velocities in each nozzle.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

2.3.2.3 Auxiliary Connections 2.3.2.3.1(Substitution) All casing openings for pipe connections shall be not smaller than NPS ¾ (DN 20) and shall be welded to the casing and flanged or, alternatively, machined and studded. All welded connections shall be full penetration butt welded. Openings smaller than NPS 1 (DN 25) may be self-reinforced branch fittings of the “weldolet” type. 2.3.2.3.2(Substitution) Auxiliary connections shall not be threaded. 2.3.4.1

(Substitution) The compressor shall be designed to withstand external forces and moments on each nozzle calculated per Equations 2.E-1a or 2.E-1b and 2.E-2 of Annex 2E. For each main process nozzle, the Manufacturer shall furnish in tabular format the following data: •

The maximum allowable forces and moments and combinations thereof for continuous operation including any transient conditions such as start-up and (emergency) shut-down

•

Expected nozzle movements due to thermal expansion between the cold static and normal full load operating conditions

•

Any expected movement in addition to the above as a result of transient conditions.

2.4

GUIDE VANES, STATORS, AND STATIONARY INTERNALS

2.4.5

(Substitute) The vendor shall confirm that the furnished diaphragms are suitable for the maximum potential differential pressure during any specified operating condition, as well as coast-down, shutdown, momentary surge, or settling out pressure.

2.4.11 (Addition) When the compressor is provided with diffuser vanes after impeller exit, it shall be free from any abnormal acoustic noise and vibration. Vendor shall verify the acceptable acoustic noise/vibration shop tests. No diffuser vanes are permitted for single stage compressors and at the exit of the last stage impeller of every compression section, i.e., just before discharge piping, for multistage compressors. Description of proposed vaned diffusers, if applicable (i.e. location within the compressor, number of vanes, passing frequencies) shall be submitted by vendor. 2.5.3.1 (Substitution) Centrifugal compressor shafts shall be made only of a single piece of forged and heat-treated steel. The shaft shall be forged as close as possible to the final dimensions and then suitably machined. Shafts shall not be made from hot rolled bar stock, but vacuum remelted bar may be considered on an individual basis subject to approval of the Purchaser. 2.5.4.3 (Substitution) Flow in the balance piston line(s) shall be measured. During the factory test, balance piston flow shall be monitored and recorded. 2.7 2.7.1

BEARINGS AND BEARINGS HOUSING General

2.7.1.3 (Addition) This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 21 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

MSS for Centrifugal Compressor

Bushehr Petrochemical Company (BUPC) Project No. :BU20

Project No. : 1216

MC: ThinkXperT Bearing metal temperature, as measured by the embedded RTD's, shall not exceed 110 °C under the worst combination of load conditions and at maximum specified oil inlet temperature. The maximum allowable temperature of the bearing metal temperature measured by RTD on the test stand shall be 105 °C.

PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

2.7.1.4 (Addition) Water jacket cooling shall not be used. 2.7.1.5 (Addition) 2 When the maximum operating bearing load exceeds 200 N/cm , it shall be subject to Contractor/Purchaser's approval. Vendor shall submit to Contractor/Purchaser the design figures with his standard criteria in this regard. 2.7.1.6 (Addition) Radial and thrust bearings shall be suitable for withstanding reverse rotation without damage. 2.7.2.1 (Addition) The bearing design shall ensure that they can only be installed correctly. Inboard and outboard bearings on one compressor body shall be identical, unless the vendor can provide details to demonstrate that this compromises the bearing design. The bearings shall be permanently marked as to their locations. 2.7.2.4 (Addition) The minimum turning speed has to be identified to avoid dry friction. The method of measuring the bearing clearances shall be clearly identified in the maintenance manuals. If required cylindrical gauges shall be delivered together with the compressor. 2.7.4.1 (Addition) In case a mist fan is not applied to the oil system the bearing housing shall be permanently sealed by a dry inert gas or air flow and needs design approval by Contractor/Purchaser. If a coupling hub is suited within the bearing housing the casing has to be equipped with sufficient breathing devices to enable heat transfer of air. 2.7.4.2 (Addition) Bearing housings, including bearing support members and oil retaining parts, shall be steel. 2.10.2 (Addition) Selection of the same oil type and viscosity grade for the complete machine train should be considered. 3.

ACCESSORIES

3.2.1

(New) The coupling shall be designed so that the full rated torque of the coupling, including a total service factor of 1.75, is transmitted by friction only and not by the coupling bolts shear load.

3.4.5

(Addition) The Manufacturer shall supply a list of alarms and/or shutdowns for the entire compressor train. The recommended setpoints for all these alarms and/or shutdowns shall be included. The list shall include, but not be limited to: • • • • • •

Radial bearing vibrations Radial and axial bearing temperatures Axial displacement of the rotor(s) Lube and control oil system parameters Oil seal or dry gas seal systems Operational process gas conditions limitations

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 22 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

3.4.7

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

Vibration, Position, and Bearing Temperature Detectors

01

3.4.7.2 (Modification) Vibration and axial-position monitors shall be supplied and calibrated in accordance with API 670 , edition 4.

01

3.4.7.4 (Modification) Bearing temperature monitors shall be supplied and calibrated in accordance with API 670, edition 4. 3.4.7.7 (New) All wire entries into the compressor casings or bearing housings shall be fully sealed against leakage into the environment and wiring conduits. 4.

INSPECTION, TESTING, AND PREPARATION FOR SHIPMENT

4.3.3

Optional Tests

4.3.3.1 Performance test 4.3.3.1.1 (Modification) Compressor’s Performance Test is required as per ASME PTC-10 1997, and shall remain having 01

the responsibility for combined performance of compressors and its drivers after installation at the site. This test shall be carried out at the Supplier’s workshop works prior to the delivery. This test shall simulate the individual operating cases as defined on the data sheets including normal and rated points. Purchaser could witness the above tests for five operating points (@ normal speed) including surge and overload. Compressor Manufacturer is responsible for combined performance test of compressor and its driver after installation of the compressor at site. The performance test shall also adequately demonstrate the compliance of the aerodynamic performance with the requirements of (2.1.1.1). For variable speed compressors, the surge line shall be established between minimum governor and maximum continuous speeds by means of additional points. 4.3.3.1.3(Addition) The speed required to achieve the specified performance and related tolerances shall be within ±5% of the originally stated 100% speed. 4.3.3.1.7(New) The contract seals shall be used during the performance test. 4.3.3.1.8(New) During performance testing the original internal clearances and tolerances shall be maintained. Increasing the clearances of the balance drum and/or other close clearance points with a subsequent performance correction is not permitted. 4.3.3.1.9(New) In the performance test procedure, the Manufacturer shall quantify all flows and correction factors for interstage losses, balance losses, and other such losses to be considered. The performance procedure including these calculations shall be subject to the Contractor/Purchaser's approval before the actual performance test.

This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 23 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

CHAPTER 3 INTEGRALLY GEARED COMPRESSORS 2.

BASIC DESIGN

2.1

GENERAL

2.1.1.1 (Substitution) The sectional head-capacity characteristic curve shall rise continuously from the rated point to predicted surge. This rise shall be sufficient to result in an increase of the pressure ratio of at least 5% when operating at specified suction conditions. If guide vanes are provided, this requirement shall be met for each setting of adjustable inlet guide vanes or axial stator vanes. The gradient of the tangent of the compressor head capacity curve shall decrease continuously, never increase, and never become zero from stonewall capacity up to the surge point. The “stonewall” capacity is defined as the capacity where the decrease in polytropic head is 10% for an increase of 1% in inlet volume capacity. The stonewall capacity shall be at least 110% of the rated capacity at rated speed. The compressor Manufacturer shall confirm the suitability of the compressor to operate continuously at the stonewall point and any limitation on operating beyond the stonewall point. For the purpose of operational flexibility: •

The end-of-curve (EOC) capacity is defined as the capacity at rated speed where the polytropic head is 85% of the polytropic head at rated capacity. If applicable, the EOC capacity shall be stated in the data/requisition sheets

•

The turn-down (TD) capacity is defined as the capacity at the control point for the surge at rated speed. The predicted surge capacity at rated speed shall be stated in the data/requisition sheets

•

For identical compressors operating in parallel (if so stated in the data/requisition sheets), the respective heads at the same flow shall not differ by more than 2% from each other at any point on the curves

•

The operating stability range of the compressor shall be at least 25% of the rated point flow.

The Vendor shall guarantee the followings compressor performances. •

Capacity shall have zero negative tolerance at the normal operating point (certified point). This tolerance shall be inclusive of all test tolerances.

•

Head shall be within the range of 100%-105% of the normal operating point (certified point). This tolerance shall be inclusive of all test tolerances.

•

Horsepower based on measure head at normal operating point (certified point) shall not exceed 104% of the value at the specified normal operating point (certified point). If the power required at this point exceeds 104%, excess head may be removed by trimming an impeller at the Purchaser’s option.

2.7

BEARINGS AND BEARINGS HOUSING

2.7.1

General

2.7.1.3.1 (Addition) Bearing metal temperature, as measured by the embedded RTD's, shall not exceed 110 °C under the worst combination of load conditions and at maximum specified oil inlet temperature. The maximum allowable temperature of the bearing metal temperature measured by RTD on the test stand shall be 105 °C. This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 24 of 25

BUSHEHR MEG PLANT

EPs Contractor:

Petrochemical Industries Design & Engineering Company (PIDEC)

Owner:

Bushehr Petrochemical Company (BUPC)

MSS for Centrifugal Compressor

Project No. :BU20

Project No. : 1216 PIDEC Doc. No.:1216-DE-00-RE-MSS-301

Owner Doc. No.: BU-20-D-000-MA-SPC-301

Rev. : 01

MC:

ThinkXperT

3.

ACCESSORIES

3.1

(ADDITION) Integrally geared compressors shall not be driven through the pinion shaft.

3.4.5

(Addition) The Manufacturer shall supply a list of alarms and/or shutdowns for the entire compressor train. The recommended set-points for all these alarms and/or shutdowns shall be included. The list shall include, but not be limited to: • • • •

3.4.7

Radial bearing vibrations Radial and axial bearing temperatures Axial displacement of the rotor(s) Lube and control oil system parameters

Vibration, Position, and Bearing Temperature Detectors

3.4.7.2 (Modification) Vibration and axial-position monitors shall be supplied and calibrated in accordance with API 670 edition 4.

01

01

01

3.4.7.3 (Modification) Bearing temperature monitors shall be supplied and calibrated in accordance with API 670 edition 4. 3.4.7.5 (Modification) Gearbox vibration monitors shall be supplied, installed and calibrated in accordance with API 670 edition 4. 3.4.7.8 (New) All wire entries into the compressor casings or bearing housings shall be fully sealed against leakage into the environment and wiring conduits. 4.

INSPECTION, TESTING, AND PREPARATION FOR SHIPMENT

4.3.3

Optional Tests

4.3.3.1 Performance test 4.3.3.1.1 (Modification) Compressor’s Performance Test is required as per ASME PTC-10 1997, and shall remain having

the responsibility for combined performance of compressors and its drivers after installation at the site. This test shall be carried out at the Supplier’s workshop works prior to the delivery. This test shall simulate the individual operating cases as defined on the data sheets including normal and rated points. Purchaser could witness the above tests for five operating points (@ normal speed) including surge and overload. Compressor Manufacturer is responsible for combined performance test of compressor and its driver after installation of the compressor at site. The performance test shall also adequately demonstrate the compliance of the aerodynamic performance with the requirements of (2.1.1.1). For variable speed compressors, the surge line shall be established between minimum governor and maximum continuous speeds by means of additional points. This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproduction or other use of the document in whole or parts is to be made without the prior consent of BUPC

Page 25 of 25