DHG PVE DD 3 ME SPC 006_Spec for Gas Engine Reciprocating Compressor Package

8/10/2019 DHG PVE DD 3 ME SPC 006_Spec for Gas Engine Reciprocating Compressor Package

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PETROVIETNAM DOMESTIC EXPLORATIONPRODUCTION OPERATINGCOMPANY LIMITED

PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINERECIPROCATING COMPRESSOR

PACKAGE

A 23/05/14 Issued for Review

Rev. Date Description PVEVSP

ApprovalPVEP POCApproval

CAApproval

EpCI CONTRACTOR

(VIETSOVPETRO JOINT VENTURE)

Document Number:

DHG-PVE-DD-3-ME-SPC-006

Number of pages: 57

(including the cover page)


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PROJECT DAI HUNG GAS GATHERING PROJECT

PHASE DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINE

RECIPROCATING COMPRESSORPACKAGE

A 23/05/14Issued for

ReviewN.T.K.Ngoc V.T.Quan D.T.Dung V.V.Hung

Rev. Date Description

Prepared

by

Checked

by EM PM Discipline

Team

Leader SPMB

Sub-Contractor EpCI Contractor

EpCI CONTRACTOR(VIETSOVPETRO JOINT VENTURE)

PV ENGINEERING J.S.C

Document Number:

DHG-PVE-DD-3-ME-SPC-006


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DAI HUNG GAS GATHERING PROJECT

DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINERECIPROCATING COMPRESSOR PACKAGE

Doc No: DHG-PVE-DD-3-ME-SPC-006 Rev. A Page 3/57

REVISION LOG

Date

Revision

No. Section Revision Description

23/05/14 A All Issued For Review


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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


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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


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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


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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


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24. DOCUMENTATION ................................................................................. 55

25.

GUARANTEES ........................................................................................ 56

26.

PROTECTIVE COATING .......................................................................... 56

27. TRAINING (OPTION) ............................................................................. 57


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1.

INTRODUCTION

1.1

Project OverviewDai 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.


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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.

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.

1.2

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)


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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


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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

1.4 Codes and Standards

In addition to the requirements of this specification and the referred or

attached individual specification and data sheets together with the statutory

requirements of the Vietnam Authorities, the general design, fabrication,

assembling and testing of this 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


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ISO 3046-5 Part 5 Torsional vibrations

ISO 3046-6 Part 6 Overspeed protection

ISO 3046-7 Part 7 Codes for engine power

ISO 13631 Petroleum and natural gas industries Packaged

reciprocating gas compressors

ISO 9001 Quality 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, andGas 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.


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ASME B16.20 Metallic Gaskets for Pipe Flanges (Ring-Joint, Spiral-

Wound 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

1.5 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.


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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. TheCONTRACTOR 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


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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 anoverall 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.


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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:

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.

4.2

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.


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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 dehydratedgas 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 appropriatesupports.

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.


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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.


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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 companionANSI flange or Swage lock bulkhead fitting.

The CONTRACTOR shall take technical support to CLIENT in:

Mechanical Interface drawings between PACKAGE and CLIENTs

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.

EXCLUSION:

Interconnecting piping between PACKAGE to oil cooler and field piping.

Interconnecting electrical cables/instrument cables, between the

PACKAGE and UCP/PCS/SIS/MCC.

UPS system for the UCP.

MCC.

Process Vessels.


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Installation and Hook-up works for PACKAGE in CLIENTs site.

6.

DESIGN REQUIREMENTSThe 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 steeland 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 fullysupported 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


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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 percentof 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 andreplaceable 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.


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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 24VDC 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 heavy-

duty Gas Engine starting and shall be supplied in a fully charged

condition and complete with copper links. The battery shall be positioned


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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 foroutdoor installation, IP56).

Two (2) x100% trains of battery starting system shall be provided. Each

battery train shall have efficient capacity for six (6) consecutive 15-

seconds 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 chargerunit.

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 CLIENTSpecification,.

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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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 filterrated 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 driversshall 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


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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 jacketwater 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 SystemThe 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 includeone (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:

Rated speed

Idle Speed

Acceleration ramp time

Deceleration ramp time

Start fuel limit

Gain and reset

Actuator compensation

Load gain

Droop

7.8 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 aminimum:

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 head emergency stop pushbutton,hermetically sealed contacts

Frequency Meter

Voltage Mete / Load

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 theengine 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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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 performsatisfactorily 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


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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 componentsand 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 steelinterfacing 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 inhumid, 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 REQUIREMENTS FOR INSTRUMENTATION AND

CONTROL

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 alarmhandling, 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 skid-

edge 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. TheCLIENT 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 bemounted 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 spring-

return 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


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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


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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 2certified (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, detailedlogic 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.


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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 performanceoptimization 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 accessoriesinclusive 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 hardwired 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.


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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

FGSAll 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:


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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:

Documents

DHG PVE DD 3 ME SPC 006_Spec for Gas Engine Reciprocating Compressor Package