DHG PVE DD 3 ME SPC 006 - Spec For Gas Engine Reciprocating Compressor Package

PETROVIETNAM DOMESTIC EXPLORATION
PRODUCTION OPERATING COMPANY LIMITED

PROJECT
DAI HUNG GAS GATHERING PROJECT
PHASE
DETAILED ENGINEERING DESIGN
SPECIFICATION FOR GAS ENGINE

RECIPROCATING COMPRESSOR
PACKAGE
23/05/14
Issued for Review
Rev.
Date
Description
PVE
VSP
Approval
PVEP POC
Approval
CA
Approval
Document Number:
EpCI CONTRACTOR
DHG-PVE-DD-3-ME-SPC-006
(VIETSOVPETRO JOINT VENTURE)
Number of pages: 57
(including the cover page)
PROJECT
PHASE
DETAILED ENGINEERING DESIGN

RECIPROCATING COMPRESSOR
PACKAGE
23/05/14
Issued for
Review
Rev.
Date
Description
N.T.K.Ngoc
V.T.Quan
D.T.Dung
V.V.Hung
Prepared
by
Checked
by
EM
PM
Sub-Contractor
Discipline
Team
Leader
SPMB
EpCI Contractor
EpCI CONTRACTOR
(VIETSOVPETRO JOINT VENTURE)
Document Number:
PV ENGINEERING J.S.C
DHG-PVE-DD-3-ME-SPC-006

DETAILED ENGINEERING DESIGN PHASE

RECIPROCATING COMPRESSOR PACKAGE
REVISION LOG
Date
Revision
No.
Section
Revision Description
23/05/14
All
Issued For Review
Doc No: DHG-PVE-DD-3-ME-SPC-006
Rev. A
Page 3/57


TABLE OF CONTENTS
1.
INTRODUCTION ......................................................................................9
1.1
Project Overview .....................................................................................9
1.2
Purpose of Document ............................................................................ 10
1.3
Definitions and Abbreviations ................................................................. 10

1.3.1 Definitions ................................................................................. 10
1.3.2 Abbreviations ............................................................................ 11
1.4
Codes and Standards ............................................................................. 12
1.5
References ........................................................................................... 14
2.
GENERAL REQUIREMENTS ..................................................................... 14
2.1
CONTRACTORS Responsibility ................................................................ 14
2.2
Operation and Design Life ...................................................................... 15
2.3
CONTRACTORs Exceptions .................................................................... 15
2.4
Weight Control ...................................................................................... 16
3.
LOCATION AND ENVIRONMENTAL CONDITIONS ..................................... 16
4.
UTILITY DATA ...................................................................................... 17
4.1
Electrical ............................................................................................... 17
4.2
Instrument air:...................................................................................... 17
4.3
Fuel gas ............................................................................................... 17
4.4
Units .................................................................................................... 18
5.
SCOPE OF WORK & SUPPLY ................................................................... 18
Rev. A
Page 4/57


6.
DESIGN REQUIREMENTS ....................................................................... 21
7.
ENGINE AND AUXILIARIES..................................................................... 21
7.1
General ................................................................................................ 21
7.2
Intake Air System .................................................................................. 22
7.3
Starting System ..................................................................................... 23

7.3.1 Electric Starting System .............................................................. 23
7.3.2 Hydraulic Starting System ........................................................... 24
7.4
Fuel Gas Treatment Package .................................................................. 25
7.5
Lubrication System ................................................................................ 25
7.6
Cooling System ..................................................................................... 27
7.7
Governor .............................................................................................. 27
7.8
Engine Exhaust System .......................................................................... 28
7.9
Insulation ............................................................................................. 29
7.10 Engine Shutdown Devices ...................................................................... 29

7.11 Engine Instruments Panel ...................................................................... 29
7.12 Ignition System ..................................................................................... 31
7.13 Over-speed Protection ........................................................................... 31
7.14 Torsional Vibration ................................................................................ 31
7.15 Lateral Vibration and Vibration Suppression ............................................. 31
7.16 Shaft Couplings and Guards ................................................................... 32
7.17 Crankcase Explosion Relief ..................................................................... 32
7.18 Miscellaneous Requirements ................................................................... 33
Rev. A
Page 5/57


8.
GAS COMPRESSOR ................................................................................ 33
8.1
General ................................................................................................ 33
8.2
Allowable, Temperature and Vibration Levels ........................................... 34
8.3
Piston Rod, Bearings and Cross Heads .................................................... 34
8.4
Packing Cases and Pressure Packing (If Applicable) .................................. 34
8.5
Compressor Frame Lubrication ............................................................... 35
8.6
Distance Pieces (If Applicable) ................................................................ 35
8.7
Cylinder and Packing Lubrication ............................................................ 35
8.8
Cooling System ..................................................................................... 36
8.9
Separators & Oil Removal System ........................................................... 36
8.10 Pulsation, Vibration Control and Analog Study .......................................... 36

9.
TECHNICAL REQUIREMENTS FOR ELECTRICAL ........................................ 37
10.
TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL .... 38
10.1 General Instrumentation Requirements ................................................... 38

10.2 General Control Requirements ................................................................ 40
10.3 Unit Control Panel (UCP) ........................................................................ 40
10.4 Interface with Platform PCS/SSD/FGS System .......................................... 43
10.4.1 PCS ........................................................................................ 43
10.4.2 SSD ........................................................................................ 43
10.4.3 FGS ........................................................................................ 44
10.5 Vibration Monitoring .............................................................................. 44
10.6 Bearing Temperature Monitoring System ................................................. 45
Rev. A
Page 6/57


11.
PIPING ................................................................................................. 45
11.1 Valves .................................................................................................. 46

11.2 Piping and Accessories ........................................................................... 46
11.3 Welding and Weld Repairs ..................................................................... 47
12.
UTILITIES & TIE-INS ............................................................................. 47
12.1 Utilities ................................................................................................. 47

12.2 Tie-Ins ................................................................................................. 47
13.
EQUIPMENT TAGGING AND NAMEPLATES ............................................... 48
14.
INSPECTION AND TESTING ................................................................... 48
15.
QUALITY CONTROL PROGRAM ............................................................... 49
16.
PRODUCTION INSPECTION .................................................................... 49
17.
CONTROL FUNCTIONAL TEST ................................................................ 49
18.
MECHANICAL RUN TESTS ...................................................................... 49
19.
PERFORMANCE/ FACTORY ACCEPTANCE TEST (FAT) ............................... 50
20.
FIELD TESTS ........................................................................................ 52
21.
CERTIFICATION .................................................................................... 52
22.
SPARES AND SPECIAL TOOLS ................................................................ 53
22.1 Spare Parts ........................................................................................... 53

22.2 Special Tools ......................................................................................... 54
23.
PREPARATION FOR SHIPMENT ............................................................... 54
Rev. A
Page 7/57


24.
DOCUMENTATION ................................................................................. 55
25.
GUARANTEES........................................................................................ 56
26.
PROTECTIVE COATING .......................................................................... 56
27.
TRAINING (OPTION) ............................................................................. 57
Rev. A
Page 8/57


1.
INTRODUCTION
1.1
Project Overview
Dai Hung Field is located at Block 05-1a at North-West of Nam Con Son basin
within South-East continental shelf, Viet Nam, 260km far from Vung Tau
seashore. This field was discovered in 1988 by DH-1X.
In 2011, WHP-DH2 with existing system is operated to increase the capacity
of associated gas up to 1 MMSCMD. Besides the associated gas there is
considerable volume of natural gas located in bottom and middle of Mioxen
layer.
The overall Dai Hung Gas Gathering Project as show in figure 1 below:
Figure 1: Block Diagram Dai Hung Gas Gathering System

Modifying WHP-DH2 and installation pipeline between WHP-DH2 and BK-TNG
is to gather and transport 1.9 BMSCM of associated gas at outlet of HHP
Separator and Test Separator of WHP-DH2 to BK-TNG platform. Gas from
WHP-DH2 shall be transported to TEG skid on BK-TNG platform before being
routed to NCS2 gas pipeline phase 1.
Rev. A
Page 9/57


Preliminary configuration of Dai Hung Gas Gathering Project is as follows:
On WHP-DH2: Gas Cooler, Gas Scrubber, Gas Engine Generator, Corrosion
Inhibitor Injection Skid, Electrical System, Instrumentation System, Fuel
Gas System, Fire Fighting System, Telecommunication System and other
Utility Systems.
1.2
The 16 subsea gas pipeline (approximately 20 km) from existing 10 riser

at WHP-DH2 to BK-TNG Platform and 16 Y-Tee for future connection.
On BK-TNG Platform: 16 Riser, Slug Catcher, DH Gas Custody Metering

System, DH Gas Compressor Suction Scrubber, DH Gas Compressor
Package, DH Gas Compressor After Cooler, Fuel Gas System, Piping
System, Instrumentation System, Telecommunication System, Open/
Closed Drain System, and other Utility Systems.
Purpose of Document
This document, together with the project data sheets provided separately,
defines the minimum requirements for supply, engineering, mechanical
design, performance guarantee (where specified), materials, fabrication,
inspection, testing, certification, painting, preparation for shipment, packing,
forwarding, transport and documentation for the Gas Engine Reciprocating
Compressor Package to be installed as part of the Thien Ung Platform.
The CONTRACTOR shall ensure that all equipment and services supplied meet
the requirements of this specification, the project data sheets, codes and
standards and specifications specified herein, whether CONTRACTOR supplies
the equipment and services directly. CONTRACTOR shall supply the equipment
in line with the scope of supply as indicated in this specification.
1.3
Definitions and Abbreviations
1.3.1 Definitions
PROJECT
: Dai Hung Gas Gathering Project
CLIENT
: PetroVietnam
Domestic
Exploration
Production Operating Company Limited
(PVEP POC)
EpCI CONTRACTOR
VIETSOVPETRO JOINT VENTURE (VSP)
ENGINEERING SUB-CONTRACTOR
PetroVietnam Engineering Consultancy

Joint Stock Company (PVE)
Rev. A
Page 10/57


CONTRACTOR
Party,
which
supplies
material,
equipment and services to perform the
duties as specified by CLIENT in the
scope of supply
1.3.2 Abbreviations
FPU-DH1
Dai Hung 1 Floating Production Unit Platform
WHP-DH2
Dai Hung 2 Wellhead Platform
BK-TNG
Thien Ung Platform
MMSCMD
Million Metric Standard Cubic Meter Per Day
BMSCM
Billion Metric Standard Cubic Meter
CCR
Central Control Room
ESD
Emergency Shut-Down
FGS
Fire & Gas
HMI
Human Machine Interface
HSE
Health Safety and Environmental
ICSS
Integrated Control and Safety system
IOM
Installation Operation and Maintenance
ITP
Inspection and Test Plan
LV
Low Voltage
HV
High Voltage
VFD
Variable Frequency Drive
UPS
Uninterruptible Power Supply
AC
Alternating Current
DC
Directing Current
SGR
Switch Gear Room
RTD
Resistance Temperature Detector
IEC
International Electrical Commission
IP
Ingress Protection
MCC
Motor Control Centre
Rev. A
Page 11/57


1.4
MDR
Manufacturers Data Report
MPI
Magnetic Particle Inspection
NDT
Non-Destructive Testing
PWHT
Post Weld Heat Treatment
TBA
To Be Advised
VDRL
CONTRACTOR Data Requirements List
VDS
CONTRACTOR Data Schedule
FAT
Factory Acceptance Test
SAT
Site Acceptance Test
SSD
Safety Shut Down/ Safety Shut Down PLC
PPLC
Process Programable Logic controller
SIS
Safety Interated System
TEG
Triethylene Glycol Dehydration
PCS
Process Control System
APS
Abandon Platform Shutdown
LCP
Local Control Panel
UCP
Unit Control Panel
Codes and Standards

In addition to the requirements of this specification and the referred or
attached individual specification and data sheets together with the statutory
requirements of the Vietnam Authorities, the general design, fabrication,
assembling and testing of this package shall follow the indicated editions of
the following API standards and the latest edition of international codes and
standards including any addenda published for the edition listed, which shall
form part of this specification. These shall include but not be limited to the
following:
ISO 3046-1 Part 1
Standard reference conditions, declarations of power, fuel

and lubricating oil consumptions and test methods
ISO 3046-3 Part 3
Test measurements
ISO 3046-4 Part 4
Speed governing
Rev. A
Page 12/57


ISO 3046-5 Part 5
Torsional vibrations
ISO 3046-6 Part 6
Overspeed protection
ISO 3046-7 Part 7
Codes for engine power
ISO 13631
Petroleum and natural gas

reciprocating gas compressors
ISO 9001
Quality System - Model for Quality Assurance for Design

and Development, Production, Installation and Servicing.
ABMA 9
Load Rating and Fatigue Life for Ball Bearings
ABMA 11
Load Ratings and Fatigue Life for Roller Bearings
API 613
Special Purpose Gears Units for Petroleum, Chemical, and

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

Special-Purpose Applications
API 618
Reciprocating Compressors for Petroleum, Chemical and

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

Gas Industry Services.
API 670
Machinery Protection Systems
API 671
Special Purpose Couplings for Petroleum, Chemical and

Gas Industry Services.
API 678
Accelerometer Based Vibration Monitoring System
API RP 505
Recommended Practice for Classification of Locations for

Electrical Installations at Petroleum Facilities Classified as
Class I, Zone 0, Zone 1, and Zone 2.
API RP 684
Lateral Critical Speeds, Unbalance Response, Stability,

Train Torsionals and Rotor Balancing
OPC OLE
Process Control Standard, Version 1.0A
ASME B31.3
Chemical Plant and Petroleum Refinery Piping
ASME B16.5
Pipe Flanges and Flanged Fittings NPS Through NPS

24
ASME B16.9
Factory-Made Wrought Butt-Welding Fittings.
Rev. A
industries
Packaged
Page 13/57


1.5
ASME B16.20
Metallic Gaskets for Pipe Flanges (Ring-Joint, SpiralWound and Jacketed)
ASME Sec VIII
Rules for Construction of Pressure Vessels Div. 1 and Div.

2
ASME PTC 10
Performance Test Code on Compressors and Exhausters
AWS D1.1
Structural Welding Code.
ANSI
American National Standard Institute (as applicable)
Electrical Code
IEC, British Standards, CENELEC, ISO, NEMA. (as

applicable)
Instrument Code
ISA, API RP 551, IEC, NEMA (as applicable)
NFPA 12
CO2 Fire Extinguishing System.
OSHA
Occupational Safety and Health Act
NACE-MR0175
Petroleum and natural gas industries materials for use in

H2S-containing environments in oil and gas production.
UL
Underwriters Laboratories
References
DHG-PVE-DD-3-ME-DAS-005
Datasheet for Reciprocating Compressor
DHG-PVE-DD-3-ME-DAS-009
Datasheet for Gas Engine
1014-BKTNG-PR-PID-2023
PID DH Gas Compressor Package
In case of any conflict between this specification and the requirements of

other CLIENT specifications, industry standards, codes, regulations, data
sheets or drawings, the most stringent requirements shall apply with the
written approval of CLIENT.
2.
GENERAL REQUIREMENTS
2.1
CONTRACTORS Responsibility
The CONTRACTOR shall have full responsibility for design, selection of
materials, fabrication, Certification, testing, inspection and transportation of
PACKAGE based on relevant project documents. Review and approval of
CONTRACTORs documents or inspection by the CLIENT shall not relieve the
CONTRACTOR of any of these responsibilities.
Rev. A
Page 14/57


The Overall PACKAGE Responsibility shall be with the CONTRACTOR. That
responsibility shall include coordination of scope boundaries between
Compressor, Engine and Other Components of the PACKAGE. The
CONTRACTOR has responsibility shall be liable for filling any scope gaps
between the compressor, Engine and Other Components of the PACKAGE
being supplied. The responsibility includes, but not limited to, the following:
Transmission to CONTRACTOR of all contractual requirements.

Compliance of CONTRACTORs item to the applicable specification and
standards
Basic design definition of CONTRACTOR equipment or works and

technical coordination with CONTRACTOR.
Co-ordination and checking of CONTRACTORs drawings and documents

before submission to the CLIENT
Co-ordination with CONTRACTOR for inspection including notification to

the CLIENT
Co-ordination of expediting of all CONTRACTOR items such as

compressor, drive gas engine, motors, gas seals panel, oil cooler,
coupling, and etc.
Ensuring that the design of CONTRACTOR items are compatible with

each other equipment in all respects. In particular, they shall be
compatible dimensionally, in performance, in control and in vibration
characteristics such that a fully integrated unit is achieved.
The CONTRACTOR shall be responsible for commissioning works of his

equipment and ensuring all performance guarantees as detailed in this
specifications are met.
The CONTRACTOR shall give with the tender the list of expected
CONTRACTOR with referenced list.
2.2
Operation and Design Life

The equipment shall be designed for a minimum service life of 20 years with
an uninterrupted operation of 4 years.
2.3
CONTRACTORs Exceptions
The CONTRACTOR Exceptions to this specification, project data sheets and
other project documents including the codes and standards agreed upon and
Rev. A
Page 15/57


recorded in the Bid Clarification Meeting Minutes which are part of the
Purchase Order shall be applicable.
2.4
Weight Control
The CONTRACTOR shall exercise an active weight control system throughout
the design and fabrication.
The CONTRACTOR shall submit the weight data sheet attached with the data
sheets, which shall contain the following details:
Dry weight Installed weight excluding operating fluids, spares, tools

and temporary packing.
Lift weight Dry weight + Packing weight
Operating weight Dry weight + Weight of operating fluids
Test weight - Dry weight + Weight of test medium
Heaviest maintenance lifts weight
The location of the COG in the X, Y, and Z planes for each designated
weight Condition
Design calculations, lifting procedures and lift arrangement drawings shall be

reviewed and approved by the CLIENT and CA. Final weighing shall be
performed prior to preparation of shipment. Final weighing shall achieve an
overall accuracy of +3%.
3.
LOCATION AND ENVIRONMENTAL CONDITIONS

The equipment will be installed on an offshore platform in the south of the
coast of Vietnam.
Location: Out door, Zone 2, Gas Group IIA, Temperature Class T3 Hazardous
Area.
The area in which the Gas Engine Reciprocating Compressor Package is
designated as hazardous Zone 2 Area. All equipment installed within the
module shall be suitable for a Zone 2 Gas Group IIA, Temperature Class T3
Hazardous Area. However, in order to permit interchange of instrument, a
zone 1, gas group IIB and temperature rating T6 certification shall be
generally specified.
Electrical equipment supplied outdoors shall be protected to IP 56, while IP 42
protection shall be specified for equipment installed indoors.
Rev. A
Page 16/57


Ambient Temperature:
Extreme High Temperature
39.0 Deg C
Extreme Low Temperature
21.0 Deg C
Average Annual Temperature
27.1 Deg C
Design Ambient Temperature
35 Deg C
Environment:
Salt Laden:
Salinity 35%
Max. Relative Humidity
100%
Wind Speed:
Maximum
34.2 m/s (3 sec gust)
Design Wind Speed
34.2 m/s
The equipment will exposed to the weather without further protection.

4.
UTILITY DATA
4.1
Electrical
The following electrical power supplies shall be made available for use by the
CLIENT:
4.2
Normal Power supply: 400V10% AC, 3 phase, 4 wire, neutral solidly

earthed, 50 Hz 5%.
Non-UPS Power Supply: 230V 10%AC, 1 phase, 2 wire, neutral solidly

earthed, 50 Hz 5%.
UPS power supply: 230V 5%AC, 1 phase, 2 wire, neutral solidly

earthed, 50 Hz 2%.
Power supply: 24VDC 5% for Control system.
Instrument air:
7 barg (Norm), 5 barg (Min), 8 barg (Max) / 10 barg (Design).
4.3
Fuel gas
The fuel gas supply for operation of PACKAGE is taken from Fuel Gas System,
which is designed for high-pressure gaseous fuel of main Turbine generator
on platform. The system also supplies low-pressure fuel gas, purge gas,
blanket gas, etc.
Rev. A
Page 17/57


Fuel Gas System is designed to cater for the overall fuel requirement on BK
TNG platform. The system consists of Pre-heater, Pressure Control Valve,
Scrubber, Filter and Super heater. The normal fuel gas supply is dehydrated
gas from TEG Contactor with back-up fuel gas supply tapped from the
Production Separator gas outlet.
4.4
Units
SI units shall be used for the project with certain exceptions where oil-field
units are to be adopted. Pressure shall be indicated in bar, kpa and
temperature in degrees Celsius.
5.
SCOPE OF WORK & SUPPLY

The CONTRACTOR shall design and furnish all components and ancillary
equipment necessary to make compressor package complete, safe and ready
for trouble free operation. Equipment and services shall include but not be
limited to the following for PACKAGE:
Reciprocating gas compressor.
Gas Engine driver
Suction scrubber.
Outlet Cooler
Speed reduction gearbox (shall comply with API 613).
Couplings and coupling guards.
Lube oil system(s) complete with one 100% main oil pump, one 100%
auxiliary oil pump, emergency lube oil pumps, air fin cooler(s), and a
dual oil filters with change over valves. The main oil pump should be a
shaft driven as external power supply is not available.
Fuel gas treatment package
All on skid piping including valves, flanges and fittings with appropriate
supports.
Access for exhaust emission measurements.
Walkway, platform, ladders, handrails, safety cage, and non-skid grating

for safe access to all PACKAGER supplied equipment, instruments, valves,
and other devices requiring routine monitoring and maintenance.
Weather protection shed for Equipment.
Rev. A
Page 18/57


Structural skids with framework to support Engine, compressor, gear box

and ancillaries.
Air intake system, exhaust system, ventilation system and ancillaries with
intake silencers, exhaust silencers, exhaust ducts with motorized
dampers of heat recovery system, exhaust system thermal insulation,
shielding, cladding exhaust expansion joints, insect screens at all intakes,
and support structure.
Engine control system including all associated instrumentation and

cabling.
Compressor control system including Capacity/ Load sharing Controls,

Vibration &
Temperature Monitoring, etc. including all associated instrumentation

and cabling
Process yard valve control system.
Control panels and instrumentation including local gauge panel, local

compressor seal gas gauge panel as well as main microprocessor-based
control panel (UCP).
Shaft coupled AC alternator of adequate size to power to UCP and

auxiliary drivers on
DC control power supply unit including batteries, battery charger, DC

panel and all DC Cabling.
DC emergency lube oil pump system complete with pump, motor.
Temperature and vibration monitoring system.
Complete Instrumentation & Control Cabling
Fire & gas detection.
Package and equipment leveling and alignment devices.
Package and equipment lifting lugs and eyebolts.
Personnel protection insulation.
Commissioning parts.
Inspection and Tests Plan
Third Party Certificate for entire PACKAGE.
Rev. A
Page 19/57


Documentation for project
Commissioning activities (Supervision).
Training courses (Option).
Special Tools for engine & compressor (Option).
Spares for 2 years operation (Option).
Anchor bolts for package frame.
The CONTRACTOR shall include in his supply:
With the exception of process gas connections all piping and tubing
connections for interfacing with the CLIENT shall be brought to the edge
of each compressor flanges and terminated with a complete companion
ANSI flange or Swage lock bulkhead fitting.
The CONTRACTOR shall take technical support to CLIENT in:
Mechanical Interface drawings between

equipments such as inlet/outlet piping.
Interface drawings of Inlet system, Exhaust system, lubrication oil cooler

system.
Provide drawings of Interconnecting electrical cables/instrument cables,

between the PACKAGE and loosed items such as UCP, oil cooler, anti
surge.
Responsible for Technical support to CLIENT for PACKAGE interface

engineering.
Interface and successful communication between CONTRACTORs UCP

and CLIENTs DCS system shall be carried out.
Supply E&I cable list and interconnection for E&I wiring diagram.
PACKAGE
and
CLIENTs
EXCLUSION:
Interconnecting piping between PACKAGE to oil cooler and field piping.
Interconnecting electrical cables/instrument

PACKAGE and UCP/PCS/SIS/MCC.
UPS system for the UCP.
MCC.
Process Vessels.
Rev. A
cables,
between
the
Page 20/57


6.
Installation and Hook-up works for PACKAGE in CLIENTs site.
DESIGN REQUIREMENTS
The CONTRACTOR shall minimize the points and locations of interface and
locate them at the unit skid edge. Piping interface with the off-skid piping
shall be provided with isolation valves and flanges. Common service piping
such as drain, vent and utility piping shall be manifold to interface with the
off-skid piping where it is safe to do so. All instrumentation and control wiring
shall be wired to the junction boxes located at the skid edge for interface with
the off-skid wiring.
The compressor and gas engine shall be skid mounted and coupled together.
The acoustic panel enclosure shall be weatherproof and made of carbon steel
and coated as per paints specification. The enclosure shall be framed and
supported from the skid. The gas engine ancillary package including
combustion air intake system and the engine exhaust duct and silencer system
shall be provided with support framework for quick hook-up and for mounting
on top of the enclosure. Access ways and maintenance platforms shall be
provided where routine maintenance and operation checks are required. All
foundation requirements including for main skid, ancillary bases and support
frames shall be provided with details for CLIENTs review and approval.
All piping, wiring, and tubing within the CONTRACTOR supply shall be fully
supported by the CONTRACTOR. All terminations at which the off-skid lines
are to make connections shall be fully anchored on the CONTRACTOR side.
Foundations required for supports will be provided by an off-skid installer. Any
limitation on loads and movements imposed by the off-skid piping shall be
defined on the CONTRACTORs drawings.
The CONTRACTOR shall clearly indicate in his proposal all items covered by
this specification which are located off-skid and to specify dimensions,
weights and interface details required for installation and hook-up.
The CONTRACTOR shall fully define all piping, mechanical connections,
electrical wiring, instrumentation and control interfaces with size, schedule,
type, location, rating, design and operation ranges.
7.
ENGINE AND AUXILIARIES
7.1
General
The engine driver shall be a reciprocating internal combustion associated gas
Rev. A
Page 21/57


engine complying ISO 3046 or equal. The engine shall have a continuous
rating, de-rated for site conditions at the maximum air ambient, minimum fuel
gas pressure and all power transmission losses, at least equal to 110 percent
of the BHP required for continuous operation supplying the maximum
compressors demand specified.
The engine shall not have any torsional natural frequencies within 10 percent
of the first or second harmonic of the rotational frequency of any shaft in the
operating speed range.
Constant speed applications shall be considered to have an operating speed
range of 10 percent of rated speed.
The engine shall include replaceable cylinder liners of the wet sleeve type and
replaceable valve seat inserts. Combustion chambers shall be of the open
type. Connecting rods and crankshaft shall be of forged steel.
Engine drive for attached auxiliaries shall be gear, V-belt or chain type. V-belt
and chain drives shall be furnished with adjustable tensioning devices.
Bearings shall be manufacturer's standard. Shims shall not be used for any
bearing.
The engine shall be designed to minimize the requirement of special tools for
installation and maintenance. One set of such tools with a description and
instructions for their use shall be supplied.
7.2
Intake Air System

The engine shall be provided with one or more engine-mounted dry-type air
cleaners/ filters of sufficient capacity to protect the working parts of the
engine from dust, grit and moisture laden air.
The filter shall be fitted with a differential pressure indicator (Transmitter) to
show when the filter requires attention.
If the air filter is to be installed remotely from the engine, the CONTRACTOR
shall supply the filter loose. The pipework between the filter and the engine
shall be either stainless steel or marine grade aluminum with less than 3%
magnesium.
The CONTRACTOR shall recommend the size of the intake pipe between the
filter and the engine. CONTRACTOR shall ensure that the pipework does not
impose unacceptable strains on the engine. The CONTRACTOR shall supply a
flexible joint between the intake pipe and the engine.
Rev. A
Page 22/57


Unless absolutely essential, internal fasteners shall not be used downstream of
the air filter. Where unavoidable, internal fasteners shall be positively secured.
Intake pipes 250 mm or larger in diameter shall be fitted with a BICERI type
explosion relief valve with integral flame trap between the engine and the air
filter (or the silencer, if fitted).
All external connections from the engine shall terminate in flanges to ASME
B16.5.
An air intake silencer shall be provided if the air intake noise level exceeds
that permitted.
7.3
Starting System
CONTRACTOR shall supply complete starting system(s) as specified in the
generator gas engine data sheet. Two (2) independent starting systems shall
be required.
The Gas Engine shall be able to cold start at the minimum ambient conditions.
7.3.1 Electric Starting System
This is the main starting system for the Gas Engine. The system shall be
a 24 VDC electric starting system, with the battery, engine start controls
and battery charger located on the skid. The controls and charger shall
be suitable for the engine vibration and outdoors site conditions. The 24
VDC battery and charger shall also supply power to the Gas Engine
control system.
Cranking time and pause between starts shall be adjustable. The battery
charger shall automatically disconnect from the battery during engine
cranking. The starting current for the first start shall be provided by the
first set of batteries and the subsequent start by the next set of
batteries. Cranking logic shall be designed such that the starting circuit is
deactivated after six (6) unsuccessful consecutive start cycles. Further
starting shall be only possible from field control panel.
CLIENT shall provide one (1) 220 VAC feeder cable on cable gland for the
battery charger and anti-condensation heaters (< 3kW) during platform
normal operation.
The battery shall be sealed, maintenance free type suitable for heavyduty Gas Engine starting and shall be supplied in a fully charged
condition and complete with copper links. The battery shall be positioned
Rev. A
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such that possible leakage of electrolyte or emission of gaseous product,
if any will not cause damage to other equipment or adjacent cells. The
battery shall be mounted in a robust fibreglass box (suitably rated for
outdoor installation, IP56).
Two (2) x100% trains of battery starting system shall be provided. Each
battery train shall have efficient capacity for six (6) consecutive 15seconds start cycles.
The charger shall keep the battery in fully charged condition and supply
all auxiliary loads on the skid simultaneously. The charger shall also be
capable of float-charging the battery from fully discharged condition to
fully charged condition within eight (8) hours.
Automatically regulated output voltage of the battery charger shall be

maintained within plus or minus 1% for load changes from zero to full
load and line voltage variations of plus or minus 10% and frequency
variations of plus or minus 5%. An over-current limit shall be adjustable
and preset at 105% of rated output to prevent overloading of the
charger during the starting of the engine.
Both the positive and negative terminals and conductors of DC power

supply shall be isolated from earth.
All connections shall be made at terminal strips provided at the charger

unit.
CONTRACTOR shall carry out industry standard testing for the battery
and charger as per CONTRACTORs CLIENT approved procedure.
7.3.2 Hydraulic Starting System
Hydraulic starting system shall be complete with reservoir, shaft driven

charging pump, accumulators, hydraulic motor starter with pre-engaged
non-sparking pinion type, piping, valves, solenoid etc. as required.
The hydraulic electrical motor, if provided, shall be as per CLIENT

Specification,.
The engine driven pump shall be sized to completely charge the

accumulator in not more than 15 minutes when operating at design
speed. The CONTRACTOR shall describe the method of declutching
/disengaging the engine-driven pump once recharging is complete. The
power absorbed by the engine-driven pump shall be advised by the
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CONTRACTOR. A hand pump for recharging the accumulator shall also be
supplied.
Accumulator capacity shall be sufficient for a minimum of six (6) starts. Each
start attempt must be distinct and separate. If the engine fails to start within
the time required for 12 complete revolutions, the starting control system shall
abort the start.
7.4
Fuel Gas Treatment Package

CONTRACTOR shall provide complete fuel system comprising of but not
limited to Carburetion System, Vertical Separator / Filters, heater (VTA),
Interconnection piping, fittings, Solenoid actuated fuel shutoff valve, Solenoid
actuator fuel line vent valve, Fuel gas pressure regulator, Pressure Safety
Valve, Fuel Consumption Meter. Fuel gas will be used as a starting gas for the
gas engine(s) i.e. it will crank the engine.
For Fuel Gas properties, refer attached data sheet. CONTRACTOR shall
provide a complete on-skid fuel system. All necessary valves and regulators
shall be consistent with the pressure. Fisher gas regulators or equivalent with
steel bodies shall be provided for pressure reduction, if required. An
explosion-proof, all steel, solenoid type fuel valve shall be furnished and
installed in the fuel gas supply line on the engine. This valve shall be
automatically latched to start the engine and electrically tripped. The engine
shutdown devices shall be configured to electrically trip the engine by at least
closing the fuel valve.
The strainer shall be 200 m nominal, and shall act only as a guard filter. The
strainer shall be fitted with a drain valve.
A swing-type or wing-type non-return valve shall be provided to prevent
pressure surges from engine "spit back" disturbing the fuel system.
CONTRACTOR shall provide system with fuel filters (vertical separator), interconnection piping, fitting, solenoid actuated fuel shut off valve, fuel line vent
valve and fuel consumption meter.
7.5
Lubrication System
The lubrication system shall be a pressure-type system. It shall consist of, but
not be limited to Sump (wet type) with level indication, fill filter, vented and
valve drain, Circulation pumps (shaft driven) with pressure relief valve, Duplex
filters with replaceable cartridge elements, full flow transfer valve and
differential pressure gauge across filters, Cooling equipment with
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thermostatically controlled bypass valve, Valves for relief and pressure
regulation, Low Level Alarm Switch and Automatic shutdown devices.
The oil sump shall be integral with the engine and shall be large enough to
contain all the oil in the system when the engine and pumps are shutdown.
The minimum capacity shall be an amount of oil equal to the lubrication
pump's working capacity for a period of two minutes.
The filters for the lube oil system shall be sized to meet the engine
manufacturer's filtration requirement. The oil filter shall be equipped with a
differential pressure gauge, and a bypass valve to assure engine oil flow in the
event of filter plugging. All filters shall utilize replaceable elements.
If aluminum, micro-Babbitt or equivalent bearings are provided, a bypass filter
rated for five (5) micron nominal filtration or better shall be provided. This
bleed off filtration line shall be sized to filter the total oil capacity in 24 hours
or less. Filter casings and heads shall be suitable for operation at a pressure of
not less than 10 percent over the relief valve settings of the lube pumps.
Strainers (20 mesh) shall be provided in the lube oil pump suction header.
Internal relief valves in filters shall not be acceptable.
Crankcase shall be explosion proof.
Pre-lube and/or post-lube pumps shall be provided. Pre-lube pump drivers
shall operate on the same energy source as the engine starter.
The CONTRACTORs standard pre-lube pump shall operate as follows:
The pump shall run when automatically started by the engine control
panel.
The pump shall run when the lube-oil heater is energized and allowed by
the skid mounted ON/OFF selector switch.
The post-lube pump shall be locked out from running when the engine is
locked out manually.
The pump shall be inhibited from running when the engine is running.
The CONTRACTOR shall provide the recommended lubricant for start-up. The
start-up lubricants shall not be those used during testing.
The engine oil temperature shall not exceed CONTRACTORs
recommendations and shall never exceed 91C (195F) for continuous
operation. The oil temperature should never exceed 107C (225F) for short
Rev. A
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term operation (one hour or less) during an overload condition. The crankcase
oil temperature shall be maintained at a differential of 6C to 12C (10F to
20F) above jacket water temperature under any conditions using jacket
water cooling.
The crankcase oil temperature shall be maintained at a differential of 6C to
9C (10F to 15F) below jacket water temperature under any conditions
when an oil cooler with a separate cooling water system is provided.
The lube oil dip stick shall be calibrated for oil pan level with the engine
running and not running, to permit checking during normal operation and
when the engine is stopped.
7.6
Cooling System
The engines cooling system shall be furnished with a closed loop, jacket
cooling system and a centrifugal pump. The cooling system shall be sized for
the continuous maximum BHP load at the max. ambient temperature.
The cooling coolant heat exchanger shall be of the finned radiator type. The
radiator shall be mounted on the engine skid and shall have a tin or solder
coated core and shall have carbo zinc #11 on all exposed steel surfaces. The
material shall be suitable for operation in a moist air environment. Coolant
shall be compatible for operation within tropic locations as well. Radiator shall
be filled out and sealed prior to test running. The cooling system shall include
one (01) 1" stainless steel valve for external fill and one (01) 1" stainless steel
valve for draining. System shall also include pusher type, fan, four ply hoses,
pump with carbon seal and radiator fan guard.
Automatic thermostat control with bypass valves shall be provided to control
engine temperature. Bypass shall operate so that cooling medium flow shall
never be throttled. Expansion or surge tanks shall be integrally mounted.
Thermometers shall be installed in stainless steel thermowells at the inlet and
outlet connection of each cooling coolant circuit in the heat exchanger
(radiator). Thermometers shall be installed in such a way that they may be
easily read from ground level without having to climb up on the skid
assembly.
7.7
Governor
The governor supplied for engine speed regulation and load control shall be
electronic utilizing digital technology.
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The governor actuator shall be direct acting, UL Approved for use in Zone 2,
Group II. The actuator and magnetic pickup shall be mounted on the engine.
Controller stability shall be within + 3.0% at rated load. The maximum
deviation relative to the rated speed for the range between no load and full
load shall be 1/4 %.
The amount of droop shall be field adjustable from 0 to 10%. The governor
shall be provided with a droop reset control feature to maintain system
frequency to within 0.5% when in droop control.
The governor shall monitor the speed sensor for loss of speed signal, calling
for minimum fuel when signal loss is detected.
The governor shall have the following adjustments:
7.8
Rated speed
Idle Speed
Acceleration ramp time
Deceleration ramp time
Start fuel limit
Gain and reset
Actuator compensation
Load gain
Droop
Engine Exhaust System

A hospital grade, muffler with spark arresting capability shall be installed in
the exhaust system unless the pressure drop across the silencer raises engine
exhaust pressure to unacceptably high pressure, in which case, a lower grade
Maxim muffler may be used with CLIENTs approval.
Silencers with flange sizes over 15 cm (6 inches) shall be provided with an
inspection opening or draw out cover. The exhaust silencer shall attenuate the
engine exhaust to 85 dB(A) at 1 m unless otherwise specified.
Engine-mounted silencers shall be provided with a bellows-type, stainless steel
expansion joints.
All carbon steel piping, silencers etc. subjected to exhaust temperatures and
exposed to the atmosphere shall be blast cleaned and flame sprayed
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aluminium coated for corrosion protection. Alternatively, stainless steel may
be used.
7.9
Insulation
Thermal blankets shall be installed where surface temperatures exceed 60C
for personnel protection.
Ceramic fiber silicone treated glass cloth, covered with a 316L stainless steel
knitted mesh good to 1260C (2300F) shall be provided on the exhaust line.
A minimum of 2.5 to 4 cm (1 to 1-1/2 inch) calcium silicate covered with
aluminum shall be provided where rigid insulation is required, such as on
water lines.
7.10 Engine Shutdown Devices

Each engine shall be equipped, as a minimum, with the following safety
shutdown devices:
Low oil pressure pre-alarm and shutdown with time delay for starting
Low coolant level alarm and shutdown
High oil temperature alarm and shutdown
High coolant temperature alarm and shutdown
Engine vibration
High Cooler vibration alarm and shutdown
Over speed alarm and shutdown
Over crank start sequence shutdown
Manual lockout at skid
Fire & gas detectors
Red mushroom head Emergency Stop pushbutton located at the engine

skid and on the engine control panel face.
All shutdown and alarm switches shall be hermetically sealed whenever

possible and shall be UL listed, as a minimum, for Zone 2, Group II hazardous
locations.
7.11 Engine Instruments Panel
A package mounted powder paint coated sheet steel instrument panel for
engine shall be provided. Panel shall be located on the edge of the engine skid
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so that it may be viewed from outside skid and shall be mounted on isolation
mounts in such a way as to prevent vibration damage to instruments. The
following instruments shall be provided on the instrument panel as a
minimum:
Lube oil pressure gauge
Electronic (LCD) tachometer
Engine outlet coolant temperature gauge
Engine outlet oil temperature gauge
Engine oil filter differential pressure gauge
Intake manifold vacuum/pressure gauge
Fuel pressure gauge
Running hour meters
Fuel filter differential pressure gauge
Engine inlet coolant temperature gauge
Cooler outlet oil temperature gauge
Gauge for diesel engines with after cooling
Red maintained mushroom

hermetically sealed contacts
Frequency Meter
Voltage Mete / Load
head
emergency
stop
pushbutton,
Additional instruments required by the CONTRACTOR shall be provided.

Instrumentation shall conform, in general, with API STD 670.
Instrumentation and associated local panel monitor for vibration, axial position
and bearing temperature shall conform, in general, with API STD 670.
Gauges shall be provided with glycerin filled stainless steel cases with a
minimum 100 mm (4 in.) face, identification labels, including tab number, and
normal and maximum reading markers. Pressure gauges shall have 316L
stainless steel bourdon elements and 316L stainless steel cases.
Thermometers shall be mounted in 316L stainless steel wells. Gas-filled
thermometers shall have leads and shall be no longer than 3 meters (10 feet).
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7.12 Ignition System
Engine CONTRACTORs standard, shielded, low tension, capacitive discharge
ignition system shall be used.
All cables and harnesses shall be shielded with stainless steel braid. Primary
cables shall also be vinyl covered.
Ignition transformers shall be integral with the spark plugs eliminating the
need for separate spark plug wires.
Engine CONTRACTORs standard electronic ignition diagnostic system shall be
used.
7.13 Over-speed Protection
The engine shall be fitted with an over-speed protection device in accordance
with ISO 3046-6. This device shall shut down the engine by both earthing the
ignition and shutting off the fuel independently of the speed governor.
The over-speed protection device shall be manual reset only.
7.14 Torsional Vibration
The assessment and prevention of Torsional vibration in the engine and its
driving train shall be as specified in ISO 3046-5.
The CONTRACTOR shall provide all the necessary information regarding the
engine including to enable the Torsional vibration calculations.
Alternator drives shall be regarded as having a speed range of 90 to 110% of
synchronous speed for the Torsional analysis.
Use of torsionally flexible couplings and torsional dampers (separate from
those fitted as standard to the engine) for tuning the torsional critical speeds
shall require the approval of the consultant.
The CONTRACTOR shall advise the life of viscous type torsional dampers fitted
to the engine.
7.15 Lateral Vibration and Vibration Suppression
The CONTRACTOR shall provide the anticipated lateral vibration levels of the
engine relating to measurements made directly on the crankcase or main
frame of the engine, expressed both as a filtered response at each of the
major excitation frequencies and as unfiltered vibration with the engine
running at rated power and speed. The vibration information shall include the
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magnitude and direction of unbalanced primary and secondary unbalanced
forces and couples.
Suitable anti-vibration mounts shall be supplied to limit the engine vibrations
transmitted to the foundations or surroundings if a vibration analysis study
reveals that the package requires isolation from the supporting structure. Antivibration mounts shall be of totally enclosed design, suitable for the
environment, and have an isolation efficiency of at least 90% in respect of all
engine induced vibrations.
Unless otherwise dictated by the arrangement of the engine and the driven
equipment or by the lateral vibration analysis, any anti-vibration mounts
required shall be installed between the baseplate and the supporting
structure. The CONTRACTOR shall supply the anti-vibration mounts.
Full details, including drawings of the anti-vibration mounts shall be submitted
to the CLIENT together with the frequencies and magnitude of any
unbalanced forces and moments that will be transmitted through the supports
into the supporting structure.
7.16 Shaft Couplings and Guards
The CONTRACTOR shall supply shaft couplings between the engine and the
driven compressor.
All couplings shall be either flange bolted to shafts or be hydraulically fitted to
cylindrical or tapered shafts.
All couplings shall be of the non-lubricated type.
All moving parts shall be protected from human contact by suitable guards of
either sheet or mesh material. All such guards shall be non sparking.
Aluminum is not regarded as a non-sparking material & should be prohibited.
7.17 Crankcase Explosion Relief
Engines having a crankcase volume of over 0.6 m shall be provided with
crankcase explosion relief devices. Explosion relief valves of the BICERI design
or approved equal with integral flame traps shall be used. Sufficient relief
valves shall be installed to provide more than 115 cm of relief valve free lift
area per m of crankcase volume.
Dipsticks and/or filler caps shall be effectively secured against ejection
following a crankcase explosion.
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The crankcase breather shall be as small as possible and located to minimize
air inrush into the crankcase following an explosion.
7.18 Miscellaneous Requirements
Relief valves shall be provided as necessary for the fuel supply, engine
crankcase pressure and lube oil supply.
Governor setting controls shall be mounted on the governor.
The engine over-speed shutdown will be easily accessible and capable of
being manually tripped and reset with fuel pressure on the line. Trip
mechanism shall be spark proof and suitable for use in hazardous locations.
Trip device, valve, valve stem, packing and interconnecting linkage shall be of
suitable material and so designed that they may be expected to perform
satisfactorily under conditions of minimum lubrication, infrequent tripping and
outdoor installation.
Automatic safety stops shall be entirely independent of the speed governor.
They shall operate to ground the ignition, shut off the fuel and vent fuel from
the engine.
Interlocks shall be provided to override shutdown signals when starting the
engine.
Some means of positive fuel shut-off should be provided for emergency use.
Pressurized fuel should have another shut off valve, preferably automatic,
other than those in the carburetor or gas pressure regulator equipment.
8.
GAS COMPRESSOR
8.1
General
The Compressor shall meet all the technical requirements as specified in:
Data Sheets
Technical Specification
International Codes & Standards
Gas composition given in Data Sheets shall be used for Compressor sizing and
performance guarantee estimates. However compressor shall be suitable for
continuous operation with the indicated gas composition range and operating
parameters given in the data sheet.
CONTRACTOR offer shall be based on firm and final compressor models on
Rev. A
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which basis the offer shall be evaluated. CONTRACTOR shall take full
recognizance of this matter before submitting the bid.
Note that the pressures given on the data sheet are at the compressor
package battery limits, CONTRACTOR shall consider all pressure losses at
suction, inter stage (VTA) and discharge at the specified capacity for
compressor/engine and indicate the same on the data sheets. No venting of
the gas is allowed at any point during operation except PSV lines.
The compressor Driver shall be capable of running the compressor under
loaded condition with each stage pressurized to its respective specified
pressure and final pressure up to PSV set pressure.
Certificate shall be supplied from the CONTRACTOR assuring that components
and manufacturing techniques meet the requirements of NACE MR 0175
(Latest Revision).
8.2
Allowable, Temperature and Vibration Levels

The maximum discharge gas temperature for each stage shall be limited to
150C.
Compressor maximum vibrations of cylinders shall be as per manufacturers
standard .The CONTRACTOR shall provide for all structural support within the
package so that these levels can be achieved. The Compressor shall stop if
the vibration limit crosses as specified above or manufactures specified limit.
8.3
Piston Rod, Bearings and Cross Heads

The surface hardness of Rockwell C 50 minimum is required on piston rods in
the areas that pass through the packing if applicable.
Crosshead shall be as per manufacturers standard material and designs.
Adequate openings for removal of the crossheads shall be provided.
Piston rod and cross head pin loading at any specified operating condition
including the relief valve set condition shall not exceed 80% of the maximum
design rod load of the offered compressor. Rod loads shall have sufficient
reversals in direction for all specified operating conditions including PSV
Settings and part load operation if applicable.
8.4
Packing Cases and Pressure Packing (If Applicable)

All oil wiper intermediate gas cylinder pressure packing shall be segmental
rings with stainless steel garter springs. The pressure packing case shall be
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provided with a common vent and drain routed outside the package
enclosure.
Seamless steel tubing conforming to ASTM A-192 or series 300 SS tubing
conforming to ASTM A-269/DIN with minimum thickness as specified in Cl.
11.9 of ISO-13631 shall be used for vent piping.
Packing vent piping inside of the distance piece shall be designed for the
maximum allowable working pressure of the cylinder.
8.5
Compressor Frame Lubrication

Compressor frame lubrication shall be pressurized system with main oil pump
driven directly by the compressor shaft.
All lube oil piping after oil filter shall be 300 series stainless steel conforming
to ASTM A 269.
For inherent design, the CONTRACTOR shall submit lubrication process detail
along with the bid.
8.6
Distance Pieces (If Applicable)

Type-2 distance pieces as per ISO-13631 can be provided as per compressor
design requirement.
8.7
Cylinder and Packing Lubrication

Single plunger per point force feed mechanical lubricator or divider block
system shall provide lubrication to compressor cylinders.
Lubricators shall be driven by crankshaft and CONTRACTOR shall highlight any
pre lubrication requirements of the cylinders and the method of achieving the
same.
Lubricators shall have a sight flow indicator for lubrication points and a
stainless steel double ball check valve shall be provided at each lubrication
point.
Digital no flow switch shall be provided to stop the compressor in case of loss
of cylinder lubrication in all stages.
CONTRACTOR shall furnish along with their bids the details of the
recommended Lubricating oil type, International Grades & Specifications along
with their quantity and changing frequency/ schedule. The recommended oil
shall be compatible with gaskets, O rings, seals, packing, lubricating parts
and other parts coming into contact.
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For inherent design the CONTRACTOR shall submit write up along with
sketches explaining lubrication detail along with the bid.
8.8
Cooling System
The water-cooled cylinders offered by the CONTRACTOR shall conceive and
design the common or separate Compressor cylinder cooling water (CW)
system. CONTRACTOR shall submit the authentication from respective
equipment manufacturer for the same. The Cooling Water shall be cooled by
an air-cooled heat exchanger.
8.9
Separators & Oil Removal System

Carbon Steel separators at suction and inter-stage, mist extractors, auto drain
system (timer based) shall be provided for the capacity as required.
All pressure vessels shall be designed as per ASME VIII Div 1 latest edition.
The offered scrubber and mist removal shall restrict the oil level to < 5 ppm in
the discharge gas of compressor and the equipment shall be designed
accordingly.
All pressure vessels including pulsation dampers shall be fully (100 %)
radiographed as per ASME VIII UW (a)
Minimum design temperature for separators shall be -29C and minimum
design pressure shall be 42.2 barg.
Material of vessels, internal components and manufacturing techniques should
meet the requirements of NACE MR 0175 (Latest Revision).
8.10 Pulsation, Vibration Control and Analog Study

CONTRACTOR shall provide pulsation, suppression devices at each suction and
discharge of compressor cylinders.
The design of pulsation suppressing devices shall be based on the acoustic
and mechanical evaluation carried out as per relevant standard.
These devices must reduce pressure pulsation in piping within 3%. These
pulsation dampers shall be designed to limit pressure drop to 1%. The
minimum acceptable volume of pulsation suppression device shall be 10 times
the cylinder swept volume.
CONTRACTOR shall get the acoustic and mechanical evaluation study carried
out for compressor package (from inlet flange to discharge on skid edge Plus
200 ft piping) by a certified agency. The compressor CONTRACTOR shall be
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totally responsible for all the coordination with the agency carrying out the
study. CONTRACTOR shall submit acoustic and mechanical evaluation report
to CLIENT.
9.
TECHNICAL REQUIREMENTS FOR ELECTRICAL

The Gas Engine Compressor Package shall be designed for installation in a
Zone 2 Gas Group IIA, Temperature Class T3 Hazardous Area. All equipment
installed within the module shall be suitable for a Zone 2 Gas Group IIA,
Temperature Class T3 Hazardous Area. Electrical equipment supplied outdoors
shall be protected to IP 56, while IP 42 protection shall be specified for
equipment installed indoors.
The CONTRACTOR shall provide appropriately certified stainless steel
interfacing junction boxes for all power and control signals on each separate
equipment for GEC. Separate junction boxes shall be provided for power,
shut-down, fire and gas, control and I.S. circuit.
Electric motors shall be of the 3-phase, 50Hz cage induction, totally enclosed,
fan-cooled type and rated to start and accelerate the load with 80% voltage at
their terminals.
For EExd motors/enclosures, all cable gland entries shall be provided. A valid
Ex certificate shall be supplied for each Ex certified item (motor, enclosure,
junction box, cable gland, etc.)
Power supply for equipment such as circuit breaker shall be provided in Exd
explosion proof enclosure
All junction boxes shall be provided with 20% spare terminals so that all spare
cores of incoming cables can be terminated.
Separately installed equipments shall be suitably earthed by connection to the
platform deck via two earth M10 screwed bosses positioned on diagonally
opposite corners of the equipments.
Nameplates of electrical equipment shall be carried electrical classification
information.
Electrical power will be provided by the CLIENT at 400V AC, 3-phase 4 wires /
230V AC, 1-phase, 50Hz, neutral solidly earthed at source for lighting and
small power and 230V AC (UPS), 1-phase, 50Hz neutral earthed for UCP.
All AC electric motors, such as lube oil pumps, engine enclosure ventilating
fans, etc., shall be rated 400 volts AC, 3-phase, 50 Hz. All motors shall
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conform to relevant IEC standards.
CONTRACTOR shall provide lighting fixtures for inside the gas engine
enclosure and inlet air filter. A battery pack that will allow the fixture to
continue to operate after a power outage for approximately 90 minutes shall
be supplied in the fixture.
Power and control wiring within the GEC package shall be in accordance with
BS 7671 IEE Wiring regulations 17th edition, and Specification for Electrical
Requirement for Packaged Equipment.
Solenoid coils furnished by CONTRACTOR shall be rated 24 VDC unless
otherwise specified.
Motors, switches, etc. shall receive full tropical treatment for operation in
humid, salt-laden environment, including fungus-proofing for the interior
surfaces.
Shutdown and alarm circuits shall be normally energized. Electrical power for
alarm and shutdown purposes shall be connected to separate branch circuits
for connection to CLIENTs SSD.
A maximum of two (2) conductors per terminal shall be permitted and shall
not violate the Ex requirement. 10% spare terminals must be allowed on all
terminal strips.
Cable glands shall be dual certified explosion proof Exd and Exe type
nickel plated brass with ISO threads, as manufactured by Hawke or
equivalent.
Grounding cables shall be installed from each skid mounted equipment to the
package GEC steel frame unless it is directly welded to the GEC. Two
grounding bosses, M10, welded to the skid shall be provided.
10.
TECHNICAL
CONTROL
REQUIREMENTS
FOR
INSTRUMENTATION
AND
10.1 General Instrumentation Requirements

This section defines the minimum requirements for the design and integration,
testing of the package instrumentation, control and automation system.
It shall be the responsibility of the package CONTRACTORs to advise the
CLIENT should conflicts exist with the CLIENTs requirements and the safe and
correct operation of the CONTRACTORs engine/compressor package and
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CONTRACTOR provided auxiliary packages.
The packages controls systems which reside in the Unit Control Panel shall be
interfaced with the plant SSD, PCS, SCADA systems via Modbus or EtherNet IP
network.
The CONTRACTOR shall be responsible for interface and collaboration with the
SCADA system existing to implement all necessary monitoring functions
associated with the compressor package. The control functions for the
production process and utilities should be achievable from the Control Room
(CR) via the PCS, SSD system located in CR.
Direct operator interaction with the UCP shall be local start-up, control,
maintenance and commissioning. All monitoring functions, including alarm
handling, shall be performed via the UCP and SCADA system.
The CONTRACTOR shall provide all the field devices on the GEC. These field
devices shall be provided in accordance with the approved project data sheets
and specifications, which the CONTRACTOR shall prepare and submit for
approval by the CLIENT. The field devices shall be installed and wired to skidedge junction boxes by the CONTRACTOR, ready to be connected to the CR
by means of multi-core cables.
The CONTRACTOR shall be responsible to review selection of the special
cables used for machine protection system etc. between skid and UCP. The
CLIENT shall supply of all these skid-to-UCP special cables.
The Instrument Control & automation equipment and systems for the package
shall be designed and installed in accordance with the documents, drawings,
standards. Field devices shall be selected in accordance with List of Approved
Instrument CONTRACTORs & Equipment.
Field instruments shall be specified certification to zone 1, gas group IIB and
temperature rating T6 as minimum.
Any control equipment, which may create arcing/sparking, that requires to be
mounted on the skid shall be housed in Exd explosion proof enclosure.
The CONTRACTOR shall participate in CLIENTs Hazop and Risk Assessment.
CONTRACTOR shall provide SIL Classification, verification and Safety
requirement specification (SRS).
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10.2 General Control Requirements
The CONTRACTOR shall provide the engine - compressor control system for
full automatic/manual control of startup, stable operation, monitoring
operation, stop, alarm, and shutdown of the unit including process and utility
valves and instrumentation from a unit control panel (UCP) provided. The UCP
will be capable of communicating with the plants main Distributed control
system (DCS) and the main ESD System located in the plants Control Room
(CR).
Control system shall be capable of monitoring actual valve open and close
positions and detect out of sequence conditions of the suction SDV, discharge
SDV, anti-surge control valves, loading valves and blow down valves
10.3 Unit Control Panel (UCP)
The UCP shall include PLC based complete with hardwired indicators,
hardwired switches for starting, emergency s/d pushbutton, hardwired alarms,
UCP-HMI etc. UCP shall include but not limit to:
Programmable Logic Controller (PLC) based c/w panel mounted HMI

display
I/O Modules to interface field devices.
Redundant
Communication
modules
for
interfacing
with
platform
PCS/ESD.
Redundant Power Supply Units
Panel mounted digital display of all alarms and critical monitored

parameters.
Licensed Configuration Software for whole system including any required

license required for interfacing with CLIENTs PCS/ESD system.
Remote/Local/Auto/Manual Selector switches, push buttons, and digital

indicators.
Bearing vibration and temperature monitoring system.
Panel-mounted manual governor Raise / Lower speed shall be a springreturn to neutral switch, and not a pushbutton.
Furthermore, the UCP shall provide interposing relays, with 24 Volt DC

coils, which will receive signal from platform ESD
Rev. A
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Digital indicators panel mounted.

Gas compressor speed (dual scale %/rpm).
Engine speed (dual scale %/rpm).
Load Compressor Speed (dual scale % rpm).
Selector Switches for:

Mode (off / manual / auto / crank / wash)
Main lube oil pump (A/B)
Governor raise/lower (spring return to neutral)
Control Push Buttons:

Unit stop.
Unit start.
Emergency stop.
Lamp test.
Shutdown reset.
Acknowledge (with horn silence).
Emergency lube oil pump reset.
Status Lights:
Permissive to start.
Stand by lube oil pump running.
Unit-in sequence / running.
Stop (normal).
Stop (emergency).
Watchdog timer time-out shutdown.
Two spares.
Start Counter.
Running time
Rev. A
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The PLC based system functions shall include controls, sequential start-up/
shutdown, safeguarding functions and protection and fire / gas detection and
protection. The PLC system hardware and software minimum shall be SIL 2
certified (as per IEC 61508/61511) or equal. It shall include dual redundant
power supply modules as a minimum.
The Control system shall include anti-surge control, capacity/performance
control. Any Diagnostic software shall be installed on a PC based system.
The following spare capacity shall be provided as a minimum:
Networks and Communication Capacity: 40%
Installed I/O (per I/O type and per system): 20%
Processor Capacity for each part of the system: 30%
Operator Interface Capacity for each part of the system: 20%
Available physical space inside UCP (per system and per location): 20%
Power Supply Capacity: 30%
Field Cables, Junction Box size, UCP size, UCP termination spare, PLC I/O
cards, Channels and Rack Space: 20%
The CONTRACTOR shall be responsible for implementing all the control logics
in the PLC system. The CONTRACTOR shall furnish, to the CLIENT, detailed
logic diagrams with written descriptions for all control functions. In addition,
the CONTRACTOR shall provide detailed Cause and Effect Diagrams (CED)
depicting the operation of the engine/compressor control system.
The Fire and Gas control functions for skid shall be included in CONTRACTORs
scope. Appropriate logic within CONTRACTORs UCP PLCs shall be
implemented to undertake necessary control and shutdown actions in the
event of fire or gas detection. Inputs into CONTRACTORs UCP PLC from
CLIENTs SSD/FGS system will be digital (voltage free contact). CONTRACTOR
shall specify his input requirements for SSD / FGS control.
CONTRACTOR should supply a Compressor Performance Monitoring and
Engine Performance Monitoring, each of the performance monitoring system
shall be implemented on HMI in UCP.
The UCP HMI shall have graphics as required by the CONTRACTOR for the
control and monitoring of the compressor/engine package.
Rev. A
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Remote access from computer to the UCP PLC via the Manufacturers
dedicated card shall be provided by CONTRACTOR with respective software
and license to allow the CLIENT staff remote troubleshoots and performance
optimization activities. CONTRACTOR shall collaborate with The CLIENT to
provide this communications tie-in on the platform. This remote access
feature will not be left active by the CLIENT on a regular basis. Password
protection is also required. Remote modifications to logic or system set points
will not be allowed, these must be made on location and follow CLIENT
management of change procedures. A time based Auto log off facility shall
also be incorporated.
CONTRACTOR shall provide 02 laptops PC for programming and maintenance
of UCP, complete with all required software, hardware and all accessories
inclusive of cables, adapters, carrying case, etc to permit up-loading and
down-loading of data and programs to the UCP PLC. The Laptop shall be of
ultra-light weight, and be provided with Core 2 Duo Intel microprocessor as
minimum, OS-Windows latest version, 14 inch monitor, CD combo drive. All
software shall be provided with evergreen licenses.
10.4 Interface with Platform PCS/SSD/FGS System
10.4.1 PCS
Signals required by the UCP for compressor control purposes shall be hard
wired directly to the UCP by CLIENT.
CONTRACTOR shall provide interface of CONTRACTORs package PLC to
SCADA via Modbus protocol or EtherNet IP for remote status monitoring at
SCADA console. CONTRACTOR shall provide PLC memory map, node address
and other configuration details as required for configuration of this interface
by CONTRACTOR
10.4.2 SSD
SSD will provide hardwired permissive signals for control of
suction/discharge/Level shutdown valves, blow down valves and compressor
start-up. Signals which are used for compressor shutdown shall also be
hardwired directly to the UCP.
Suction/discharge/pressurization valves are controlled by both SSD and UCP.
CONTRACTORs package shall receive the hard wired signals as powered
Digital Outputs (24 VDC signals) from Platform SSD system. These signals
shall be identified during detail engineering.
Rev. A
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CONTRACTOR shall install high reliability interposing relays in their cabinet to
isolate SSD power supply from its own power supply.
The CONTRACTOR shall ensure that the field devices selected and installed for
each loop fulfill the required Safety Integrity Level (SIL) in terms of the level
of certification carried by the device and the configuration. Furthermore, it
shall be ensured that the classified SIL level can be met without requiring
proof-testing more frequently than during planned maintenance shutdowns.
The CONTRACTOR shall also provide the necessary MTBF and reliability
numbers as per IEC 61508/61511 and shall include the same in the
CONTRACTOR developed Safety Requirement Specification (SRS).
10.4.3 FGS
All areas outside the compressor skid will be monitored by CLIENTS FGS. All
areas within the compressor skid shall be protected by CONTRACTORS FGS
controller installed in UCP unit.
Minimum three IR hydrocarbon type detectors shall be provided by
CONTRACTOR for each of the following locations:
Air Intake
Skid itself
Vent area
Four flame (UV) and Four heat detectors inside the skid
CONTRACTOR shall provide necessary warning audible and visual alarm.
The CONTRACTOR shall provide and install a fire and gas detection system
CONTRACTOR shall prepare and submit F&G field devices specifications and
data sheets for approval by the CLIENT.
CONTRACTOR shall install interposing relays, if required, in their cabinets to
provide interfacing digital signals. High integrity relays shall be installed per
hazardous area classification. CONTRACTOR shall make provision for installing
End of Line (EOL) devices for line monitoring of loops by FGS.
10.5 Vibration Monitoring
CONTRACTOR shall furnish a vibration monitoring system for each compressor
package comprising the following, as a minimum:
Rev. A
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X-Y radial vibration adjacent to each gear and compressor journal

bearing.
Dual voting axial position monitors on gear and compressor.
Probes shall be complete with cables and proximities mounted in NEMA

4X enclosures.
Each vibration monitoring system shall be mounted within their respective UCP.
10.6 Bearing Temperature Monitoring System
A bearing temperature monitoring system shall be incorporated into the UCP
and shall include two embedded dual element RTDs (100 Ohm platinum)
temperature sensors as follows:
11.
Each compressor radial bearing.
Each gear radial bearing.
Each compressor active and inactive thrust bearing.
Each gear active and inactive thrust bearing.
One element from each RTD shall be monitored.
PIPING
All inlet and outlet piping shall terminate at the Package edge with an
appropriately rated flange and Tie in pipe support.
Piping shall be arranged in such a manner as to avoid tripping or overhead
problems. Piping or tubing of insufficient mechanical strength for standing on
or hanging from shall be protected from personnel traffic. All piping and
tubing shall be adequately supported.
Valves shall be installed as necessary to bypass and allow removal of
duplicated components for maintenance without shutting down or draining the
complete system.
Equipment shall be oriented within the Package to allow as much space as
possible between pieces of equipment to facilitate maintenance. Adequate
space shall be allowed for access to and maintenance of package components
without removing any major assembly.
The on-skid piping supply shall include all piping components, such as valves,
fittings, pipe shoes, springs, expansion bellow and all in-line items. The on-
Rev. A
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skid piping shall be installed prior to shipment (if required may be supplied
loose).
On-skid piping shall be fully assembled, tested and painted prior to shipment.
Materials of construction shall be selected to suit the fluid medium with which
it is in contact and shall be suitable for offshore service. The Contractor shall
identify each component part and the proposed material, including minimum
corrosion allowances etc.
Materials exposed to the fuel gas are to be considered sour as defined by
NACE MR 0175 and shall conform to the requirements of that standard.
Piping design shall be based on ASME Standard B31.3, Piping shall be suitably
insulated according to services. Application & selection of material for
insulation and weatherproofing shall be in accordance with the specs.
11.1
Valves
All valves contained in interconnecting piping between the compressor and
accessories shall be provided by the Contractor.
Valves shall be of the outside screw and yoke type, with bolted bonnets and
glands.
Block valves and root valves shall be of the welded bonnet type with bolted
glands for primary service ratings of 900 psig and above.
All valves 2 inch nominal pipe size and larger shall have raised face flange
connections. All root valves 1-1/2 inch nominal pipe size and smaller may have
socket welded end connections.
Ball valves should have Class VI shutoff in accordance with ANSI FCI 70-2 and
are required to be API 607 certified. Metal seated ball valves shall be used in
fuel gas applications.
Butterfly valves shall be Class VI shutoff in accordance with ANSI FCI 70-2
and are required to be API 607 certified.
Plug valves shall not be used.
The compressor shall be supplied with a full capacity pilot operated safety
relief valve.
11.2
Piping and Accessories

The Contractor shall provide all interconnecting piping and associated
supports between the compressor and accessories, and all skid mounted
Rev. A
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piping, supports, and accessories. All process piping and process equipment
external to the compressor skid will be provided by the Contractor, except as
indicated. Temporary start-up screens and spool pieces in the process piping
shall be provided by the Contractor.
The Contractor shall conduct an active acoustical simulation review to
determine the acoustical response of the process piping system based on
isometric drawings (provided by the Contractor) of all piping and
appurtenances. A mechanical review of the piping support system and piping
layout is also required.
Each utility such as air and cooling water supply and returns shall be
manifolded to a common header.
Piping shall be insulated to maintain a maximum surface temperature of
1400F (600C) for personnel protection.
11.3
Welding and Weld Repairs

For welds that will be inaccessible on completion of fabrication, the Contractor
shall submit proposed inspection methods and acceptance criteria for review
and approval by CLIENT.
For all weld repairs, CLIENTs inspector shall have the right to examine repair
areas to ensure removal of all defects prior to repair.
All pressure containing welds for process gas shall be 100 % radiographed.
Any welds which require repair as a result of the radiograph examination shall
be given another examination after the weld has been repaired to assure final
weld integrity.
12.
UTILITIES & TIE-INS
12.1 Utilities
Cooling water is not available as utility and the package shall be provided with
self sufficient cooling water system for Engine & Compressor, as required,
with makeup tank.
12.2 Tie-Ins
All the platform interface connections (i.e. Gas Inlet & Gas Outlet) shall be
brought out to the package edge. Gas inlet shall be terminated in nozzles with
isolation valves having flange connections and Gas outlet shall be terminated
through high-pressure full flow ball valves.
Rev. A
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All drains from different process equipments, distance piece and packing shall
be manifolded and terminated as single point for the platform interface duly
flanged with isolation valve. Drains should be through a common header and
discharge to be allowed in a pit to avoid spillage around compressor package.
13.
EQUIPMENT TAGGING AND NAMEPLATES

Each main item of equipment of the package (e.g. gas compressor, gearbox,
gas engine) shall have an easily visible nameplate. The following data shall be
clearly stamped or engraved on the name plate:
14.
CONTRACTORs name
Serial number
Size, type and model (If applicable)
Rated capacity (If applicable)
Rated power (If applicable)
Lateral critical speeds up to and including the next lateral above

maximum allowable speed (if applicable)
CLIENT item number or other reference.
Maximum allowable working pressure (if applicable)
Minimum and maximum allowable working temperature (if applicable)
Minimum operating speed (if applicable)
Maximum continuous speed (if applicable)
Trip speed (if applicable)
Hydrostatic test pressure (if applicable)
INSPECTION AND TESTING

All equipment supplied by the CONTRACTOR shall be subjected to inspection
by CLIENT, his authorized agents and other certifying authority if required. All
test certificates for materials used during fabrication shall be available prior to
final inspection. The CONTRACTOR shall coordinate with CLIENT or his
authorized agents and conduct the inspection in accordance with the
Inspection Requirements and Specified in the Tender Document.
Inspection by CLIENT does not relieve the CONTRACTOR of his responsibility
to carry out inspection and testing as required by codes, standards and
Rev. A
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specifications.
15.
QUALITY CONTROL PROGRAM

The CONTRACTOR shall have a complete and comprehensive quality control
program.
The CONTRACTORs quality control programs shall be submitted for approval
to CLIENT prior to manufacture of components.
The CONTRACTOR shall grant to CLIENT, or his designated representatives,
access to his and his sub-CONTRACTORs quality control program
documentation and facilities at all times during fabrication, manufacturing,
and testing phases.
16.
PRODUCTION INSPECTION
The CONTRACTORs manufacturing and production inspections shall consist of
his standard quality control program procedures plus the requirements of
Inspection included in the Tender Document.
During any inspection or test CLIENT or its designated representative, shall
have the right to reject any part of the work not in compliance with this
specification including all applicable specifications, tender requirements, or not
in compliance with the CONTRACTORs quality control standards.
17.
CONTROL FUNCTIONAL TEST

All control panels inclusive of remote control panels and local control panels
shall be functional tested at manufacturers shop. CONTRACTOR shall submit
the test procedures for the CLIENTs approval.
18.
MECHANICAL RUN TESTS

A compressor mechanical running test shall be performed at the compressor
manufacturers shop in accordance with ISO 13631.
Hydrostatic test of compressor package shall be performed in accordance with
Codes.
Gear box mechanical running test shall be performed at the gear box
manufacturers shop in accordance with API 613. A post test bearing
inspection shall be performed.
All parts of the engine and its auxiliaries which are subject to cooling water
pressure during operation shall undergo a witnessed hydrostatic test of at
Rev. A
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least 1-1/2 times the maximum allowable working pressure for hour
without leakage.
19.
PERFORMANCE/ FACTORY ACCEPTANCE TEST (FAT)

CONTRACTOR shall submit detailed inspection and test plan at least 8 weeks
prior to the proposed test date, for review and approval by the CLIENT. The
test shall include, but not be limited to, the following:
CONTRACTOR shall submit specific test agendas (procedures) to the

CLIENT for review and approval. All pertinent test conditions, procedures
and acceptance criteria should be clearly mentioned and should be
conformance to the purchase order and pertinent test codes. It is critical
that all aspects of the test be mutually agreed upon in writing in the form
of a final test agenda. This final test agenda must be completed prior to
the start of any testing program.
Auxiliary system shall have to receive a functional test and a four-hour

minimum mechanical running test prior to shipment.
The overall test shall be considered satisfactory when no abnormal

conditions occur during the operational phase. An abnormal condition is
defined as system instability, relief valves listing, alarm or shutdown
signals or any other condition that would require operator attention to
correct.
Allow a 10 percent maximum pressure accumulation above relief valve

set pressure. Verify relief valve set point by testing.
Complete a filter-cooler changeover without the system's delivery

pressure dropping to the automatic-start setting of the standby pump or
increasing to the high differential pressure alarm set point.
Determine correctness of switch action and settings for all safety

switches.
Determine correct response of all pressure control valves for all possible
transient conditions.
Observe operation of oil temperature control valve.
Verify the nameplates and ratings of relief valves.
Verify acceptable changeover of transfer valve and valve leakage.

Acceptable leakage is defined as leakage that does not increase filter oil
Rev. A
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level above drain line with drain valve open.
All instruments, temperature gauges pressure gauges, tachometers,

thermometers, pressure switches, temperature sensors etc., shall be
calibrated and certified, prior to commencement of the test. Calibrated
records shall be submitted to the CLIENT representative.
All bearings, crossheads, pistons and liner clearances, rod run out and
alignment reading, shall be recorded and submitted to the CLIENTs
representative before and after, the Mechanical Running Test.
CONTRACTOR shall provide the CLIENT with his proposed no-load test
procedures for review and approval. The compressor shall be run with
the valves installed, if possible.
All shutdown simulations shall be initiated at the source instrument and

not at the control panel. Each shutdown function shall be tested by
disconnecting pressure lines to simulate a shutdown signal. Level
switches shall be mutually tripped and other instrument switches
manually vented or pressure/temperature simulated. Panel display shall
indicate the correct annunciation on each shutdown.
A mechanical, no-load witnessed run test shall be carried out on the

complete compressor package unit, to ensure that the unit operates over
the specified speed range, without evidence of vibration, malfunction,
etc., and also to ensure the integrity of the alarm and shutdown features
of the unit. The witnessed mechanical no-load run shall include 4 hours
uninterrupted running at maximum duty compressor speed.
Vibration measurements shall be carried out on the compressor unit

during the mechanical running test. The vibration levels shall be within
limits.
Resonance of any skid mounted component shall be identified and

removed prior to release from CONTRACTOR works.
During the witnessed no-load test, all equipment including their controls,
cooling and lubrication system and emergency shutdown systems shall
be tested. All start stop alarm and speed control function shall be proved
during this test. To ensure satisfactory governing of the engine, the
CONTRACTOR shall partially load the compressor by running gas around
the recycle loop.
The engine shall be subjected to tests in accordance with ISO 3046-1.
Rev. A
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20.
The fuel for performance tests shall be as close as practicable to the

specified fuel in respect of heating value, Wobbe index and density.
The works performance test shall be conducted with coolant and intake
air temperatures adjusted to correspond with the maximum ambient
temperatures on site unless otherwise agreed by the consultant.
Compressor performance test shall be performed in accordance with

ASME Performance Test Code 10 Type 2 and ISO 13631.
FIELD TESTS
CONTRACTOR shall perform a field mechanical reliability test of Gas Engine
driven compressor package to demonstrate the mechanical integrity,
operability and controllability of the package. During the test sound levels
(dBA) and exhaust emission levels shall be measured. CONTRACTOR shall
develop the detail test procedure for CLIENT approval.
The minimum duration of the field test shall be 72 hours running at the
compressor site rated conditions. The complete set of data shall be taken, at
least, every four hours or any time the process conditions at the inlet have
changed. Adequate time, at least one hour should be taken to allow for the
process stabilization after the process conditions have changed or fluctuated.
CONTRACTOR shall submit detailed test specification, procedure and program
for test on completion to purchaser for approval at least 12 weeks prior to
start of commissioning. This shall include a detailed step by step procedure
and program with details of measurements to be taken and curves for
correcting departure from guarantee test conditions. CLIENT shall comment
within 04 weeks. The test procedure shall be mutually agreed prior to start of
tests on completion. Following completion of tests CONTRACTOR shall prepare
a performance test report for review and approval by CLIENT. Test reading
shall be recorded in a test protocol and signed by CONTRACTOR. CLIENT
representative shall also sign witnessed.
21.
CERTIFICATION
Unless otherwise specified in the job specification, data sheet, equipment and
material certification shall be in accordance with the relevant code and
standard.
Material certification traceability for machinery components shall be as
follows:
Rev. A
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Level 1 requirement to EN 10204-3.2 for normal assurance on pressure

containing part and mechanical critical component like shaft, impeller,
blades, seal..
Level 2 requirement to EN 10204-2.2 for non-critical items and nonpressure parts.
The CONTRACTOR shall obtain certification from Third Party Inspector(TPI)

for the design verification and compliance of the package including materials,
fabrication and testing as per material requisition. All costs for this certification
shall be borne by the contractor. CONTRACTOR shall nominate the TPI during
bid for CLIENT /Owners approval.
Third Party Inspection& Certificate:
The CONTRACTOR is required to obtain Third party certification of conformity
with requirement of applicable project specifications, international codes for
design, procurement, fabrication/Installation and FAT for Reciprocating
Compressor package from a certifying agency such as DNV, ABS, BV, GL,
Lloyds.
CONTRACTOR shall be responsible for co-ordination and supplying necessary
document/drawing to the agency directly for certification.
22.
SPARES AND SPECIAL TOOLS
22.1 Spare Parts

CONTRACTOR shall provide the recommended spare parts for the equipment
as follow:
Pre-commissioning, commissioning and start-up spare parts.
Recommended spare parts for two years operation (price shall be

separately quoted as an option).
All spare parts furnished by the CONTRACTOR shall be wrapped and packed
to preserve items as new condition under normal storage anticipated in
Vietnam. The same parts shall be properly tagged so that later identification
as to their intended usage will be facilitated.
All items supplied shall be packaged separately and clearly marked as Spare
Parts for Pre-commissioning, commissioning and start-up and Spare Parts
for two years operation and shipped with the equipment in accordance with
the instructions from CLIENT.
Rev. A
Page 53/57


Packing lists shall be furnished complete and in detail so that parts can be
handled without unpacking, if desired.
22.2 Special Tools
CONTRACTOR shall provide all special tools required for the site installation,
commissioning, and maintenance of the equipment package.
CONTRACTOR to provide detailed list of the special tools be supplied in the
bid.
If required, the CONTRACTOR shall supply one (1) set of special tools & lifting
gear for the erection and/or maintenance of the package including all ancillary
equipment.
Special tools & lifting gear means all such tools/spreader bars or lifting frame
complete with slings and shackles that are specific to the erection and/or
maintenance of the supplied equipment/package, and are normally not
expected to be available in a plant workshop, but without which it would be
difficult or time-consuming to perform the erect and/or maintenance of the
supplied equipment/package
23.
PREPARATION FOR SHIPMENT

Gas Engine driven compressor package sets shall be properly protected during
the time of shipment from the factory until installation at site including the
storage period at the factory and the site before installation. CLIENT shall
approve the release of the Gas Engine driven compressor package sets prior
to shipment.
CONTRACTOR shall be solely responsible for the adequacy of the preparation
of shipment and the equipment preservation provisions employed with respect
to material and application. The minimum requirements for export packing are
specified in the Tender Document. The CONTRACTOR shall submit his
preparation for shipment procedure and equipment preservation procedure for
the CLIENT approval.
Flanged openings shall be provided with metal closures at least 5 millimeters
thick, with synthetic rubber gaskets. At least four full-diameter bolts shall be
used for flanged openings, wire locked and tag sealed to prevent unauthorized
entry. Seal shall not be removed without CLIENT written approval and the
CONTRACTOR representative present.
Rev. A
Page 54/57


24.
DOCUMENTATION
The following data/information shall be provided after placement of order, as
a minimum:
All documents including Drawings, Technical Data and Performance

curves of Reciprocating Compressor.
Detailed Piping and Instrumentation Diagram (P&ID).
Process Flow Diagrams (PFD).
Sizes & specifications of all off- skid / interconnecting piping,

instruments, vessels and coolers / heat exchangers, etc outside
compressor package but necessarily required for the operation of the
package.
Skid assembly drawings.
Detailed layout drawings (skid/ piping/ wiring).
Equipment/instrument data sheets completed and filled.
PACKAGER/ CONTRACTOR's installation manuals.
Equipment Dossiers including inspection, certification & manufacturing

records.
Graphs of specific fuel consumption, power and torque vs. speed.
Required fuel gas quality, heating value, normal, maximum and minimum
fuel supply pressures.
Statements of lateral and Torsional critical speeds, Campbell diagrams for

critical speeds.
Operation and maintenance manuals.
Spare Parts lists for 2 years of operation.
Electrical single line diagrams, schematic/ control diagrams with starting

methodology.
Cause & effect diagram.
Logic diagrams / Operating & s/d scheme flow charting.
Cable schedules (Instrument & Power).
Junction Box wiring diagrams.
Complete instrument list/ Index (duly filled in).
Rev. A
Page 55/57


25.
Control system hardware and software manuals, installation and wiring

terminating details etc.
Printed application software configuration (Ladder logic or any other

format/type).
Control system architecture drawings.
F&G Detection System.
As built drawings.
GUARANTEES
The compressors shall be guaranteed for head, capacity, and satisfactory
mechanical performance (including vibration levels) at all specified operating
points. It shall also be guaranteed for horsepower at the operating point
designated as guaranteed. The polytropic head and capacity shall be
guaranteed with no positive tolerance on the shaft horsepower.
The gas engine shall be guaranteed for satisfactory mechanical performance
at all operating conditions specified on the data sheet and the range between
those points. The engine performance guarantee point shall be the site-rated
power with no negative tolerance and site rated speed required by the
compressor guarantee point at the fuel rate quoted with no positive tolerance.
The CONTRACTOR shall warrant all material and workmanship for 24 months
from the day of signing of Acceptance Test Protocol.
The CONTRACTOR shall guarantee the suitability of the materials of
construction for the duties required, even if the CLIENT has specified the type
and grade of material to be used.
The CONTRACTOR shall replace and install without cost to the CLIENT any
materials, supplies or equipment which fails under design conditions due to
defects in material or workmanship if the defect is observed within the
guarantee/warranty period.
26.
PROTECTIVE COATING
External preparation, priming and painting offshore application shall only be
carried out after all pressure tests have been satisfactorily completed.
Protective coating of equipment including internal lining (if any) shall be done
after hydro test.
Rev. A
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CONTRACTORs Specification for Painting and Preservation of unpainted
machined surfaces shall apply, however, a CLIENT approved painting and
preservation system shall be used.
The surface preparation and coating application shall in accordance with the
offshore requirements considering high amount of salt laden moisture.
27.
TRAINING (OPTION)
CLIENTs Personnel shall be trained at manufacturers facility in all aspects of
the operation and maintenance of the equipment:
Maintenance/repair and trouble shooting of gas engine.
Maintenance/repair and trouble shooting of reciprocating compressor.
The CONTRACTOR shall provide details of training proposals to CLIENT.
Rev. A
Page 57/57

DHG PVE DD 3 ME SPC 006 - Spec For Gas Engine Reciprocating Compressor Package

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DHG PVE DD 3 ME SPC 006 - Spec For Gas Engine Reciprocating Compressor Package

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PETROVIETNAM DOMESTIC EXPLORATION

PRODUCTION OPERATING COMPANY LIMITED

DAI HUNG GAS GATHERING PROJECT

DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINE

Issued for Review

(VIETSOVPETRO JOINT VENTURE)

DAI HUNG GAS GATHERING PROJECT

DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINE

DAI HUNG GAS GATHERING PROJECT

SPECIFICATION FOR GAS ENGINE

Issued For Review

Doc No: DHG-PVE-DD-3-ME-SPC-006

DAI HUNG GAS GATHERING PROJECT

SPECIFICATION FOR GAS ENGINE

Project Overview .....................................................................................9

Purpose of Document ............................................................................ 10

Definitions and Abbreviations ................................................................. 10

Codes and Standards ............................................................................. 12

GENERAL REQUIREMENTS ..................................................................... 14

CONTRACTORS Responsibility ................................................................ 14

Operation and Design Life ...................................................................... 15

CONTRACTORs Exceptions .................................................................... 15

Weight Control ...................................................................................... 16

LOCATION AND ENVIRONMENTAL CONDITIONS ..................................... 16

UTILITY DATA ...................................................................................... 17

Fuel gas ............................................................................................... 17

SCOPE OF WORK & SUPPLY ................................................................... 18

Doc No: DHG-PVE-DD-3-ME-SPC-006

DAI HUNG GAS GATHERING PROJECT

SPECIFICATION FOR GAS ENGINE

DESIGN REQUIREMENTS ....................................................................... 21

ENGINE AND AUXILIARIES..................................................................... 21

Intake Air System .................................................................................. 22

Starting System ..................................................................................... 23

Fuel Gas Treatment Package .................................................................. 25

Lubrication System ................................................................................ 25

Cooling System ..................................................................................... 27

Engine Exhaust System .......................................................................... 28

7.10 Engine Shutdown Devices ...................................................................... 29

DAI HUNG GAS GATHERING PROJECT

SPECIFICATION FOR GAS ENGINE

GAS COMPRESSOR ................................................................................ 33

Allowable, Temperature and Vibration Levels ........................................... 34

Piston Rod, Bearings and Cross Heads .................................................... 34

Packing Cases and Pressure Packing (If Applicable) .................................. 34

Compressor Frame Lubrication ............................................................... 35

Distance Pieces (If Applicable) ................................................................ 35

Cylinder and Packing Lubrication ............................................................ 35

Cooling System ..................................................................................... 36

Separators & Oil Removal System ........................................................... 36

8.10 Pulsation, Vibration Control and Analog Study .......................................... 36

TECHNICAL REQUIREMENTS FOR ELECTRICAL ........................................ 37

TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL .... 38

10.1 General Instrumentation Requirements ................................................... 38

DAI HUNG GAS GATHERING PROJECT

SPECIFICATION FOR GAS ENGINE

11.1 Valves .................................................................................................. 46

UTILITIES & TIE-INS ............................................................................. 47

12.1 Utilities ................................................................................................. 47

EQUIPMENT TAGGING AND NAMEPLATES ............................................... 48