MULTI PURPOSE REACTOR PLANT BATAM INDONESIA

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Air Compressor Specification

TABLE OF CONTENTS
1.0 2.0 3.0 PURPOSE .. CODES, STANDARDS, AND SPECIFICATIONS . DESIGN 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 Air Dryer . 3.2.1 3.2.2 3.2.3 3.3 Dryer Adsorbed Towers .. Dryer Pre-filter/After Filter Dryer Inter/After Coolers.. 4 4 5 5 5 5 5 6 6 7 7 7 8 8

3.2

Instrumentation and Controls .. 3.3.1 3.3.2 3.3.3

Interface . 9 Compressor Control/Sequencing System. 10 Air Dryer Controls . 10

3.4 3.5 3.6 3.7 3.8 3.9 4.0 5.0 6.0 7.0

Skid.. 11 Balancing and Vibration 11 Piping .. 11 Painting 12 Insulation and Cladding 12 Noise 12

MATERIAL .. 12 MANUFACTURING 12 INSPECTION AND TESTING 12 PREPARATION FOR SHIPMENT 13

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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 ASME B1.20.1 ASME B16.11 ASME B19.1 ASME B16.5 ASME B31.3 ASME B36.10 AWS D 1.1 Boiler and Pressure Vessel Code Materials Non Destructive Examination Pressure Vessel Welding and Brazing Qualification 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 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

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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 Manufacturers 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.

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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.

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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.

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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 COMPANYs Plant Control system shall be 4 20 mA and all digital signal shall be via voltage free contacts.

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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 COMPANYs 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.
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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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Air Compressor Specification

Heater outlet temperature high (for heated dryer).

3.4

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: 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.

3.5

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.
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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.

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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 manufactures 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 Manufactures 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.

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