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PETROVIETNAM DOMESTIC EXPLORATION PRODUCTION OPERATING COMPANY LIMITED DAI HUNG GAS GATHERING PROJECT PROJECT PHASE

PETROVIETNAM DOMESTIC EXPLORATION PRODUCTION OPERATING COMPANY LIMITED

DAI HUNG GAS GATHERING PROJECT

PROJECT

PHASE

DETAILED ENGINEERING DESIGN

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

A

23/05/14

Issued for Review

Rev.

Date

Description

PVE

VSP

Approval

PVEP POC

Approval

CA

Approval

Description PVE VSP Approval PVEP POC Approval CA Approval EpCI CONTRACTOR ( VIETSOVPETRO JOINT VENTURE )

EpCI CONTRACTOR

(VIETSOVPETRO JOINT VENTURE)

Document Number:

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

Number of pages: 57

(including the cover page)

PROJECT

   

DAI HUNG GAS GATHERING PROJECT

 

PHASE

   

DETAILED ENGINEERING DESIGN

 
 

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

   

Issued for

             

A

23/05/14

 

Review

N.T.K.Ngoc

V.T.Quan

D.T.Dung

V.V.Hung

     

Prepared

Checked

EM

PM

Discipline

Team

SPMB

Rev.

Date

 

Description

by

by

Leader

 

Sub-Contractor

 

EpCI Contractor

  EpCI CONTRACTOR (VIETSOVPETRO JOINT VENTURE)  
 

EpCI CONTRACTOR (VIETSOVPETRO JOINT VENTURE)

 
  Document Number:  
 

Document Number:

 
 

PV ENGINEERING J.S.C

   

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

REVISION LOG

Revision

No.

Date

Section

Revision Description

23/05/14

A

All

Issued For Review

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

CONTRACTOR’S Responsibility

14

2.2

Operation and Design Life

15

2.3

CONTRACTOR’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

24. DOCUMENTATION

55

25. GUARANTEES

56

26. PROTECTIVE COATING

56

27. TRAINING (OPTION)

57

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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:

Dai Hung Gas Gathering Project as show in figure 1 below: Figure 1: Block Diagram Dai

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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)

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE
 

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

MDR

Manufacturer’s 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

Test measurements

Speed governing

ISO 3046-3 Part 3

ISO 3046-4 Part 4

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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, 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 ½” Through NPS

24”

ASME B16.9

Factory-Made Wrought Butt-Welding Fittings.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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,

applicable)

British

Standards,

CENELEC,

ISO,

NEMA.

(as

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

CONTRACTOR’S 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 CONTRACTOR’s documents or inspection by the CLIENT shall not relieve the CONTRACTOR of any of these responsibilities.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 CONTRACTOR’s Exceptions

The CONTRACTOR Exceptions to this specification, project data sheets and other project documents including the codes and standards agreed upon and

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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:

Max. Relative Humidity

Wind Speed:

Maximum

Design Wind Speed

Salinity 35%

100%

34.2 m/s (3 sec gust)

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: 400V±10% 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 PACKAGE and CLIENT’s 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 CONTRACTOR’s UCP and CLIENT’s 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

Installation and Hook-up works for PACKAGE in CLIENT’s site.

6.

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 CLIENT’s 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 CONTRACTOR’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 compressor’s 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 heavy- duty Gas Engine starting and shall be supplied in a fully charged condition and complete with copper links. The battery shall be positioned

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 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 charger unit.

CONTRACTOR shall carry out industry standard testing for the battery and charger as per CONTRACTOR’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 μm 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), inter- connection 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 CONTRACTOR’s 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 CONTRACTOR’s recommendations and shall never exceed 91°C (195°F) for continuous operation. The oil temperature should never exceed 107°C (225°F) for short

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

term operation (one hour or less) during an overload condition. The crankcase oil temperature shall be maintained at a differential of 6°C to 12°C (10°F to 20°F) above jacket water temperature under any conditions using jacket water cooling.

The crankcase oil temperature shall be maintained at a differential of 6°C to 9°C (10°F to 15°F) 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 engine’s 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 CLIENT’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

aluminium coated for corrosion protection. Alternatively, stainless steel may be used.

7.9 Insulation

Thermal blankets shall be installed where surface temperatures exceed 60°C for personnel protection.

Ceramic fiber silicone treated glass cloth, covered with a 316L stainless steel knitted mesh good to 1260°C (2300°F) 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 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).

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

7.12 Ignition System

Engine CONTRACTOR’s 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 CONTRACTOR’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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. Anti- vibration 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 m³ 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 cm² of relief valve free lift area per m³ of crankcase volume.

Dipsticks and/or filler caps shall be effectively secured against ejection following a crankcase explosion.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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

150ºC.

Compressor maximum vibrations of cylinders shall be as per manufacturer’s 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 manufacture’s 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 manufacturer’s 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 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.

vent and drain routed outside the package

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.

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

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 -29ºC 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

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

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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 EEx’d’ 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 Ex’d’ 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 CLIENT’s 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 Ex”d” and Ex”e” 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 CLIENT’s requirements and the safe and correct operation of the CONTRACTOR’s engine/compressor package and

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CONTRACTOR provided auxiliary packages.

The package’s 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 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. 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 CLIENT’s 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 plant’s main Distributed control system (DCS) and the main ESD System located in the plant’s 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 CLIENT’s 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 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 CONTRACTOR’s scope. Appropriate logic within CONTRACTOR’s UCP PLCs shall be implemented to undertake necessary control and shutdown actions in the event of fire or gas detection. Inputs into CONTRACTOR’s UCP PLC from CLIENT’s 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.

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

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Remote access from computer to the UCP PLC via the Manufacturer’s 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 CONTRACTOR’s 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.

CONTRACTOR’s 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

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 CLIENT’S FGS. All areas within the compressor skid shall be protected by CONTRACTOR’S 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:

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

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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:

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.

11.

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-

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

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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

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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, CLIENT’s 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.

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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:

CONTRACTOR’s 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)

14. 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

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specifications.

15. QUALITY CONTROL PROGRAM

The CONTRACTOR shall have a complete and comprehensive quality control program.

The CONTRACTOR’s 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 CONTRACTOR’s 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 CONTRACTOR’s quality control standards.

17. CONTROL FUNCTIONAL TEST

All control panels inclusive of remote control panels and local control panels shall be functional tested at manufacturer’s shop. CONTRACTOR shall submit the test procedures for the CLIENT’s approval.

18. MECHANICAL RUN TESTS

A compressor mechanical running test shall be performed at the compressor

manufacturer’s 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 manufacturer’s 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE RECIPROCATING COMPRESSOR PACKAGE

least 1-1/2 times the maximum allowable working pressure for ½ 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.