MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
TABLE OF CONTENTS
1.0
PURPOSE ………………………………………………………………………………..
4
2.0
CODES, STANDARDS, AND SPECIFICATIONS …………………………………….
4
3.0
DESIGN ……………………………………………………………………………………
5
3.1
Air Compressor …………………………………………………………………….
3.1.1
Compressor Air Intake Filters and Silencer…………………………….
3.1.2
Inter/After Coolers……………………………………………………….
3.1.3
Drivers…………………………………………………………………….
3.1.4
Reduction Gears and Belt Drives………………………………………
3.1.5
Coupling and Guards……………………………………………………
5
5
5
5
6
6
3.2
Air Dryer …………………………………………………………………………….
7
3.2.1
3.2.2
3.2.3
Dryer Adsorbed Towers ………………………………………………..
Dryer Pre-filter/After Filter………………………………………………
Dryer Inter/After Coolers………………………………………………..
7
7
8
Instrumentation and Controls ……………………………………………………..
8
3.3
3.3.1
3.3.2
3.3.3
Interface …………………………………………………………………. 9
Compressor Control/Sequencing System……………………………. 10
Air Dryer Controls ………………………………………………………. 10
3.4
Skid………………………………………………………………………………….. 11
3.5
Balancing and Vibration…………………………………………………………… 11
3.6
Piping ……………………………………………………………………………….. 11
3.7
Painting……………………………………………………………………………… 12
3.8
Insulation and Cladding …………………………………………………………… 12
3.9
Noise………………………………………………………………………………… 12
4.0
MATERIAL ……………………………………………………………………………….. 12
5.0
MANUFACTURING ……………………………………………………………………… 12
6.0
INSPECTION AND TESTING…………………………………………………………… 12
7.0
PREPARATION FOR SHIPMENT……………………………………………………… 13
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MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
AIR COMPRESSOR SPECIFICATION
1.0 PURPOSE
The purpose of this specification is to define the minimum technical requirement for the
design, supply, manufacture, and testing of a skid mounted air compressor / dryer
package for MULTI PURPOSE REACTOR PLANT PROJECT at Batam – Indonesia.
2.0 CODES, STANDARDS AND SPECIFICATIONS
The current version, complete with the latest amendments of the following laws,
statutory regulations, codes, standards and specifications shall from part of and shall
be read in conjunction with this specification.
Indonesian Law
Statutory Regulations
American Society of Mechanical Engineers (ASME)
ASME
Section II
Section V
Section VIII, Div 1
Section IX
Boiler and Pressure Vessel Code
Materials
Non Destructive Examination
Pressure Vessel
Welding and Brazing Qualification
ASME B1.20.1
ASME B16.11
ASME B19.1
ASME B16.5
ASME B31.3
ASME B36.10
Pipe Threads
Forged Steel Fittings Socket Welding and Threaded
Safety Standard for Air Compressor System
Pipe Flanges and Flanged Fittings
Process Piping
Welded and Seamless Wrought steel Pipe
AWS D 1.1
Structural Welding Code
National Fire Protection Association (NFPA)
NFPA 70
National Electrical Code 70, Article 500 “Hazardous
Location”
American Petroleum Institute (API)
API – RP – 520 Part I/II
Sizing and Installation of Pressure Relieving device in
Refineries
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MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
API – RP – 550
API – 619
Installation of Refinery Instrument & Control System
Rotary Type Positive Displacement Compressors for
Petroleum, Chemical and Gas Industry Services
NEC / NEMA National Electrical Code / National Electrical Manufacturer’s Association
3.0 DESIGN
The air compressor / dryer package shall be designed and constructed for both a
minimum service life of 20 years and at least one year uninterruptible continuous
service.
No proto-type equipment or equipment with less than three (3) years of proven
experience shall be used.
3.1
Air Compressor
The air compressor shall be twin screw non-lubricated type.
All deviations to API 619 shall be stated.
The capacity control of the compressor shall steeples. The turndown shall be to
at least 20% of the rated capacity.
The capacity control requirements shall be as nominated on the compressor data
sheet.
3.1.1
Compressor Air Intake Filters and Silencer
The air compressor intake shall have a dry type air filter with provision for
replaceable cartridge. The filter shall be capable of removing 97%
particles of size 1 micron and above. The filter shall have a weather cap.
3.1.2
Inter / After Cooler
Inter / after coolers shall be air cooled. Inter / after coolers shall cool the
air at the final discharge location to within a maximum of 15 °F of the
specified ambient air temperature.
Inter / after cooler shall have knockout pots and automatic liquid
condensate removal traps.
3.1.3
Drivers
The drive motors shall comply with compressor specification. The driver
shall be suitable for the hazardous area classification stated on the data
sheet.
Page 5 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
The driver rating shall be at least 110% of the guaranteed power demand
for the rated conditions indicated in the data sheet.
The driver starting torque shall be at least 15 percent greater than driven
equipment starting torque requirements. The driver shall be able to
develop adequate starting torque to start compressor against relief valve
set pressure under the worst combination of the specified ambient and
utility conditions without margins.
The compressor and driver starting torque shall be torsion ally compatible.
The driver and driven equipment torque-speed curves shall be prepared
for submission to COMPANY. The starting requirement torque
requirement and time required to attain full speed shall be agreed with
COMPANY.
The starting requirement at reduced voltage shall be stated on the
compressor data sheet.
3.1.4
Reduction gears and Belt drives
The gear unit shall be rated for the maximum horsepower capability of the
electric motor.
Where the maximum torque occurs at other than the rated speed, this
torque and the corresponding speed shall be allowed for in the gear
design.
The gear unit shall be designed to with stand safely any transient torsion
loads imposed during start-up, reacceleration after a power interruption
and mal-operation.
The drive train including driver, gear, couplings and other drive
transmission devices used shall be free of any torsion ally critical speeds
within the specified operating range.
Where a belt transmission is used, the driver shall be provided with slide
rails to facilitate belt tension adjustment.
3.1.5
Coupling and Guards
All couplings shall be flexible spacer type.
The coupling shall be enable removal of compressor rotor, without
disturbing driver, gearbox, other transmission devices and without
disconnecting the compressor piping.
The coupling design shall prevent the spacer from flying out in case of
failure of flexible elements.
The coupling guards shall be non-sparkle materials.
Page 6 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
3.2
Air Dryer
The dryer type shall be regenerative desiccant with capabilities of supplying dry
air while regenerating.
Each dryer train shall be provided with inlet and outlet isolation valves. These
valves shall be facilities maintenance and outlet check valves shall prevent
reverse flow to the dryer train on standby. The dryer train changeover shall be
occur automatically without air supply interruption.
Within each dryer the tower changeover from drying to regeneration shall be via
non-lubricated four way valves. Each valve shall be complete with a discharge
muffler.
The depressurization of the vessel during regenerative cycles shall not result in
blow-out or fragmentation of the desiccants.
In case of timer failure or failure of pneumatic actuator, there shall be a provision
for manual dryer operation.
The regeneration cycle shall be fully automatic. The depressurization and
regeneration shall be through a common vent header. The air silencer discharge
noise level shall comply with COMPANY Specification.
The air outlet pressure dew point temperature shall be nominated on the dryer
data sheet A dew point indicator shall be located at each dryer train outlet. There
shall be a provision for dew point indication on the local control panel.
The desiccant type will be stated on the data sheet. The desiccant quantity
calculation basis shall be prepared for submission to COMPANY. The actual
desiccant quantity calculation basis shall be prepared for submission to
COMPANY. The actual desiccant quantity supplied shall be 20% more than the
calculated quantity required.
3.2.1
Dryer Absorber Towers
Each dryer train shall have two desiccant filled towers.
The towers shall be designed as per ASME Sec. VIII Div.1.
The desiccant tower design shall permit desiccant replacement and
removal without dismantling the connected pipe work.
The desiccant life shall be for min. 1 year.
3.2.2
Dryer Pre-filter / After-filter
A pre-filter which shall be located upstream of each dryer shall protect the
desiccant material from contamination.
Page 7 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
An after-filter shall prevent desiccant carry over and maintain the required
instrument air quality. The filtration efficiency shall be stated on the data
sheet.
The filters shall have a differential pressure gauge.
The pre-filter shall have an automatic drain trap, isolation and bypass
valves. The after-filter shall be provided with isolation and bypass valves.
3.2.3
Dryer Inter / After Coolers
Where required, the dryer inter/after coolers shall be manufactures
standard.
3.3
Instrumentation and Controls
All instrumentation, control and electrical system shall comply with COMPANY
specification and shall be suitable for the area classification stated on the data
sheet. Minimum rating for instrumentation shall be Class I, Group D, Div.2
All local instruments necessary for standard operational requirements such as
pressure, temperature, level gauges, etc, shall be part of the compressor dryer
package.
All shutdown initiators shall be electronic “smart” transmitters. Switches shall not
be used for shutdown purposes. Transmitter employed for shutdown shall neither
be used in monitoring loop nor in control loop.
All instrument and transmitter shall be weather proof to NEMA-4X.
All controls shall designed to operate in fail-safe mode.
All transmitters and field devices operating on electric supply shall be powered
from local control panel.
Intrinsically Safe (IS) circuits shall not be utilized.
All cabling shall be in rigid galvanized steel conduit. Wire transmissions shall be
identified with cable numbers that correspond to the package electrical schematic
and wiring diagrams.
Cabling, tubing and all interconnections within the skid shall be completed prior to
shipment.
Tubing shall be a installed tray with the skid.
All analogue control signals to or from COMPANY’s Plant Control system shall be
4 – 20 mA and all digital signal shall be via voltage free contacts.
Page 8 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
The Local Control panel shall be pre-wired, PLC based, free standing and shall
be suitable for outdoor installation. The compressor and dryer controls including
motor starters shall be housed in a single panel. The local control panel
enclosure shall be weather proof to NEMA 4X. the enclosure shall be suitable for
the hazard area classification stated in data sheet.
The panel construction, material, earthling etc. shall be as specified in
COMPANY specification.
All the alarm circuits shall be grouped into a single group and terminated with dry
contacts. The alarms shall be indicated as “first-out” on the local panel.
The height of the panel, including 100 mm plinth, shall be 2200 mm. the width
shall nor exceed 2000 mm. the panel shall be designed for bottom entry type.
The gland plate shall be removable.
Lifting lugs shall be provided on the panel. Load calculations to prove adequacy
of such lugs shall be prepared for submission to COMPANY.
3.3.1
Interface
The local control panel shall have provision for interfacing with the plants
main control system.
ESD signal from Plants Main Control System shall initiate the compressor
shut down.
Each signal shall be hardwired and will be identified in the compressor
data sheet. Pre-wired suitability identified terminals shall be located in the
local control panel. The terminals shall be clearly labeled for COMPANY’s
connection to the main plant control system.
The control panel shall provide the following interface signals.
For Compressor Packages :
• Common Alarm (potential free contacts).
• Local / Remote selector (potential free contacts).
• Status signals for each unit.
• Air pressure.
• Run Time (Hrs).
• Lube Oil Pressure.
• Lube Oil Temperature.
For Dryer Package
• Unit Shutdown (potential free contacts).
• Common Alarm (potential free contacts).
• Unit Tripped (potential free contacts).
• Dew Point Indication (4-20 mA) input.
Page 9 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
3.3.2
Compressor Control / Sequencing System
Each compressor will start in an unloaded condition. Each compressor
shall be able to be selected for lead/lag duty without interrupting system
operation.
All control and monitoring functions shall be from local control panel.
The compressor controls shall include the following switches/push buttons
and lamps:
Push Buttons/Switches
• Lead/standby mode for each compressor selector switch.
• Remote/auto/manual selection for compressor sequencing selector
switch.
• Automatic/manual loading of compressor selector switch.
• Start push button.
• Emergency stop push button.
• Acknowledge push button.
• Reset push button.
• Lamp Test push button.
Indication Lamps
• Unit running.
• Unit tripped.
• Unit ready to start.
The compressor controls shall have protection for the following:
• Inlet filters differential pressure high.
• Inter/after Cooler outlet temperature high.
• Differential pressure across the compressor high.
The detail list of alarms and trips shall be on the data sheet.
3.3.3
Air Dryer Control
The four way valves required for switching from one tower to another and
for switching drying to regeneration shall be provided with limit switches
shall be used to indicate the tower status i.e. under regeneration or online.
The control panel shall have dew point indication.
The dryer controls shall have the following protection.
• Pre filter/After filter differential pressure high.
• Absorber tower differential pressure high.
• High dew point at the dryer outlet.
• Inter/After cooler outlet temperature high (for heated dryer).
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MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
•
3.4
________________________________
Air Compressor Specification
Heater outlet temperature high (for heated dryer).
Skid
Unless otherwise specified on data sheet, all equipment in air compressor/dryer
package shall be mounted at separate skid. The skid design shall comply with
COMPANY Specification.
The base plates shall be stiff enough to resist permanent deformation from
bending and twisting due to handling and shall be designed to keep excessive
forces and deflections from being transmitted to the equipment.
The base plate shall be stiff enough in all directions to ensure that factory set
alignments are maintained at all times during design operation.
The base plates shall meet the following requirements:
3.5
•
No component of the unit (or accessories) may overhang the drained base
plate area except the motor conduit box.
•
The base plate shall have a full metal deck complete with provisions for
draining to a 1 inch NPT drain located at the base plate edge.
Balancing and Vibration
The power supply shall be 380 V AC, 50 Hz, three phase, 3 wire. The control
power shall be 220 V AC, 50 Hz UPS. Further distribution and / or conversion to
other voltages shall be done in the local control panel.
Instrument / Utility Air connection shall be at single termination point.
3.6
Piping
All piping shall be designed in accordance with the latest edition of ASME-B31.3
and COMPANY specification.
The extent piping inside package and specific piping requirements will be
nominated on the compressor and dryer data sheets. All piping shall be
fabricated in accordance with COMPANY specification.
Piping and tubing shall be securely fastened to minimize vibration and prevent
breakage during shipment and operation.
Welded fittings shall be used to maximum extent. Welded tees and reducing weld
tees shall be used for branch connections. Screwed piping shall not be used for
hydrocarbon service.
Page 11 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
Bolting shall conform to ASME B31.3. Stud bolts shall be ASTM-A-193 Grade B7.
Nuts shall be ASTM-A-194 Grade 2H unless the service is classified as low
temperature.
All drains, including casing drains, shall be piped to skid edge and terminated
with a flanged valve.
All vents shall have no pocketing, and shall be piped to a single vapor disposal
point located at skid edge.
3.7
Painting
Each equipment item shall be painted in accordance with COMPANY
Specification or as stated on the compressor and dryer data sheets. The surface
preparation and painting/coating shall be done only after satisfactory completion
of the inspection and testing of the package/equipment.
3.8
Insulation
Insulation and cladding shall be as stated on the compressor and dryer data
sheet. All insulation shall be in accordance with COMPANY Specification.
3.9
Noise
The noise limit for this package shall be as stated on the data sheet, and should
be measured at 1 meter from the skid in a free field (open air) environment.
Comprehensive noise data on the equipment shall be provided. The overall level
specified is the maximum cumulative emission from all noise sources on the
package.
Noise test reports shall be prepare for submission to COMPANY.
4.0 MATERIAL
Any additional specific requirements shall be as stated on the compressor and dryer
data sheet.
5.0 MANUFACTURING
Any additional specific requirements shall be as stated on the compressor and dryer
data sheet.
Page 12 of 13
MULTI PURPOSE REACTOR PLANT
BATAM – INDONESIA
________________________________
Air Compressor Specification
6.0 INSPECTION AND TESTING
Inspection and testing shall be as stated on the compressor and dryer data sheet.
Compressor mechanical run and performance test shall be as per API 619. The test
program shall be fully detailed and prepared fur submission to COMPANY.
Hydro test of compressor casing and pressure parts, pressure vessels and piping shall
comply with ASME Codes.
Instrument and control functions, loading and unloading, alarms and shutdowns shall
be tested.
The following dryer tests shall be carried out:
• Functional / Operational Test.
• Performance Test.
• Hydrostatic Test.
• Noise Test.
The Factory Acceptance Test (FAT) procedures shall be fully detailed and prepared for
submission to COMPANY.
The package functional testing procedure shall be fully detailed and prepared for
submission to COMPANY. Witnessed, functional and performance test for each
package shall be carried out at the package manufacture’s work prior to final
inspection. The tests shall include compressor performance test and mechanical run
test of compressor with motor and auxiliaries.
A full performance test of the assembled package at the Manufacture’s works shall
verify compliance with the requirements of the data sheet and the specifications.
The following will be verified:
•
•
The loop testing of all instruments and control circuit has been done.
The continuity test of all electrical & earthling circuit has been done.
7.0 PREPARATION FOR SHIPMENT
Unless specified otherwise the equipment and accessories will be shipped as one
complete installation assembly.
Additional requirements shall be stated on the compressor data sheet.
Page 13 of 13