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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 SCREW 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-007

Number of pages: 61

(including the cover page)

PROJECT

   

DAI HUNG GAS GATHERING PROJECT

 

PHASE

   

DETAILED ENGINEERING DESIGN

 
 

SPECIFICATION FOR GAS ENGINE SCREW 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-007

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

30

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

32

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

8.

GAS COMPRESSOR

33

8.1

General

33

8.2

Compressor

Performance

34

8.3

Compressor

Construction

35

8.3.1 Materials of Construction

35

8.3.2 Bearings

35

8.3.3 Compressor Rotor

35

8.3.4 Coupling and Guard

35

8.3.5 Casing

36

8.3.6 Shaft seals

36

8.3.7 Miscellaneous

36

8.4

Auxiliary Systems

37

8.4.1 Cooling Systems

37

8.4.2 Lubrication System

38

8.4.3 Gas Scrubbing and Filtration

39

8.5

Pulsation, Vibration Control and Analog Study

41

9.

TECHNICAL REQUIREMENTS FOR ELECTRICAL

41

10.

TECHNICAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL

43

10.1

General

Instrumentation Requirements

43

10.2

General Control Requirements

44

10.3

Unit Control Panel (UCP)

44

10.4

Interface with Platform PCS/SSD/FGS System

48

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

10.4.1 PCS

48

10.4.2 SSD

48

10.4.3 FGS

48

10.5

Vibration Monitoring

49

10.6

Bearing Temperature Monitoring System

49

11.

PIPING

50

11.1

Valves

50

11.2

Piping and Accessories

51

11.3

Welding and Weld Repairs

51

12.

UTILITIES &

TIE-INS

52

12.1

Utilities

52

12.2

Tie-Ins

52

13.

EQUIPMENT TAGGING AND NAMEPLATES

52

14.

INSPECTION AND TESTING

53

15.

QUALITY CONTROL PROGRAM

53

16.

PRODUCTION INSPECTION

53

17.

CONTROL FUNCTIONAL TEST

54

18.

MECHANICAL RUN TESTS

54

19.

PERFORMANCE/ FACTORY ACCEPTANCE TEST (FAT)

54

20.

FIELD TESTS

56

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

21.

CERTIFICATION

57

22.

SPARES AND SPECIAL TOOLS

58

22.1

Spare Parts

58

22.2

Special Tools

58

23.

PREPARATION FOR SHIPMENT

58

24.

DOCUMENTATION

59

25.

GUARANTEES

60

26.

PROTECTIVE COATING

61

27.

TRAINING (OPTION)

61

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

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

MDR

Manufacturer’s Data Report

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

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

ISO 3046-4 Part 4

ISO 3046-5 Part 5

Test measurements

Speed governing

Torsional vibrations

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

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 SCREW COMPRESSOR

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE SCREW 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-007

Datasheet for Screw 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 SCREW COMPRESSOR

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

Ambient Temperature:

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

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.

Fuel Gas System is designed to cater for the overall fuel requirement on BK

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

4.4

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.

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:

Screw 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 SCREW COMPRESSOR

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

control

Engine

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 SCREW COMPRESSOR

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

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 SCREW COMPRESSOR

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE SPECIFICATION FOR GAS ENGINE SCREW 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 term operation (one

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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.

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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

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:

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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).

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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.

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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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 gas engine driven, heavy-duty, rotating-type, positive displacement screw 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 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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).

The Contractor shall provide all equipment completely fabricated, assembled, and tested. The equipment shall be dismantled only to the extent necessary for inspection and practical shipping. If the compressor package components are to be mounted and/or tested at the Manufacturer’s plant, the Manufacturer shall provide and take responsibility for the following:

Coordination of arrangements for receipt, handling, and set up of compressor package components.

Testing of compressor package in accordance with applicable standards.

Preparation for shipment of the entire compressor package in accordance with applicable standards.

Coordination and cost for correction of compressor package problems discovered at the Manufacturer’s factory during test or assembly.

All control equipment for integral units shall be furnished.

IIB, T3

All equipment shall be rated for installation hazardous locations

The compressor, gas engine, and all accessories shall be completely factory assembled on a common, fabricated steel base and be ready for installation.

Internal piping shall be such that only single point connections for gas inlet, gas outlet, drains, vents, cooling system fill/makeup (if required), cooling water inlet and outlet (if available), and instrument air supply (if available) are necessary for the compressor package.

in

a

Zone 2, Group

8.2 Compressor Performance

The Contractor shall provide a complete capacity/ pressure control system. The compressor shall provide a constant discharge gas pressure at any gas flow rate and any suction pressure. The discharge pressure control system shall use

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

SPECIFICATION FOR GAS ENGINE SCREW COMPRESSOR PACKAGE

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

slide valves to adjust the flow rate due to suction pressure swings and capacity changes. In addition, a recirculation line may be used, as necessary, to supplement the slide valve, and to allow for fully unloaded compressor operation. Gas recirculation shall be to a point upstream of the inlet gas scrubber. The gas recirculation valve shall include a valve positioner with a position transmitter.

The control system shall include a manual override (local manual start and control).

The compressor shall operate without excessive vibration or noise.

8.3

Compressor Construction

The compressors shall be constructed as specified herein. The maximum allowable working pressure (MAWP) shall be at least 110% of or 25 psig greater than the maximum operating pressure, whichever is higher.

8.3.1

Materials of Construction

Materials of construction for the compressors and auxiliaries shall be the manufacturer's standard for the specified operating conditions unless otherwise specified in API Standard 619.

8.3.2

Bearings

Bearings shall be replaceable sleeve type or antifriction of the tapered or spherical roller type.

8.3.3

Compressor Rotor

The rotor assembly including thrust disk, balance piston (when applicable) and half key on shaft end shall be dynamically balanced with manufacturer's specified criteria and in accordance with Section 5.7.3.3 of API STD 619 prior to compressor assembly.

The rotor shaft shall be key way or keyless shaft end and manufactured from forged steel and shall be one (1) piece with helical rotor, statically and dynamically balanced to provide vibration free operation.

8.3.4

Coupling and Guard

When a torsional damping or resilient type coupling is required by analysis, the coupling shall be in accordance with API STD 671, Appendix B.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

The coupling connecting the compressor and drive motor shall be sized for all operating conditions. The drive coupling assembly shall be protected with a removable, non-sparking guard.

8.3.5 Casing

The main pressure casing shall be bolted and main casing split face shall use a metal-to-metal joint (such as O-ring) to avoid gas leakage due to high pressure. Gasketed joints are not acceptable.

A flat surface of an agreed size and location shall be provided on the casing as close as possible to the bearing locations for mounting of magnetic-based seismic vibration measuring equipment. See Section 5.9.8 of API STD 619 for further details.

8.3.6 Shaft seals

Gas leakage to the atmosphere is not permissible. The CONTRACTOR shall provide either a dual mechanical contact-type seal design with an independent seal fluid system (Section 5.6.4.2 of API STD 619) or a double or tandem self- acting dry gas seal in accordance with API STD 614 Chapters 1 and 4. See Section 5.6 of API STD 619 for further details.

The CONTRACTOR shall furnish complete seal support system, as described in Section 5.6.2 of API STD 619.

8.3.7 Miscellaneous

Name plate data shall be permanently etched, stamped, or embossed into the metal surface. Printing or painting data onto the nameplate is not permitted. The nameplate shall be in the English language.

An allowance for laser-based engine and coupling alignment shall be inherent in the design of the equipment base. Alignment shall be verified just prior to shipment and at site. All bolting shall be confirmed as tightened to the proper torque value.

Epoxy grout shall be used around all embedded items.

Compressor and engine mounting base shall be machined after all welding is completed so that all the machined mounting pads contacting with compressor and motor legs are within 0.005" of each other in parallel when measured on the milling machine.

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

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

0.2" - 0.25" thickness adjustable shims shall be installed under motor legs only. Compressor is fixed and adjustment shall be done by engine location. These shims shall be adjusted during cool conditions.

All machine mounted equipment, piping, and tubing shall be fitted and assembled in the Manufacturer’s shop.

8.4

Auxiliary Systems

As indicated, the gas compressor shall be supplied with cooling, lubrication, and gas scrubbing and filtration systems as specified herein.

8.4.1

Cooling Systems

The compressor shall be furnished with a complete cooling system.

The base scope shall include a fin fan/lube oil cooler suitable for ambient conditions. The system shall be designed to prevent the lube oil temperature from dropping below the start permissive while the compressor is off line.

The compressor cooling system shall be complete with pumps, strainers, isolation valves, sight flow indicators, flow control valves, surge tank, instrumentation, interconnecting pipe, and all other devices required for a complete system.

The compressor cooling system shall provide cooling for the lube oil coolers, recirculation coolers, inter stage (VTA) coolers, and after coolers, as required.

An after cooler shall be provided. If a multistage unit is provided, and if required by compressor design, the compressors shall be furnished with an intercooler for reducing the gas temperature. Intercoolers or after coolers shall be air cooled with electric motor driven fans.

Intercoolers shall be machine mounted with all interconnecting piping and accessories furnished in accordance with ASME B31.1. Intercoolers and inter stage equipment shall be shop mounted to check for proper fit and match marked prior to disassembly and shipment.

A recirculation gas cooler shall be supplied in the recirculation line. This cooler shall reduce the recirculated gas temperature to inlet conditions.

Lube oil coolers, intercoolers, after coolers, and recirculation coolers shall be mounted with the compressor as part of the skid mounted unit and arranged to allow space for installation and ease of maintenance.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

Inter stage (If required) coolers shall be provided with scrubbers, gauge glasses, automatic condensate traps, valves, thermal relief valves, and drain piping.

All gas cooler inlets and outlets shall be provided with thermometers.

8.4.2 Lubrication System

Each compressor shall be provided with a complete, force-feed, lube oil system designed to furnish all lubricating oil required for the compressor and the drive motor. The lubrication system shall be per API STD 619, and as specified herein.

Each lube oil system shall include the following:

The lube oil system shall be equipped with the alarms, indicators and

shutdowns

Dual flow filter assembly including 10-micron replaceable element and

differential pressure indicator and continuous flow transfer valve with

isolation valves to facilitate the replacement of a filter element while the

other filter is in use. The filters shall be located in an easily maintainable

place.

Temperature control valve.

Strainer.

System relief valve for full pressure lubrication to bearings and seals.

Thermal relief valves for blocked-in equipment (i.e. coolers and filters) in

accordance with Section 5.10.1.2 of API STD 619.

Control oil system for hydraulic cylinder for slide valve movement. It may

be common oil system with lube oil.

Positive displacement lube oil pumps shall be supplied in accordance with

API STD 614 as follows:

When a lube oil pump is not necessary in normal operation, the Manufacturer shall provide a motor driven pre-lube pump which has also automatic cut in function when lube oil supply pressure hits low alarm point. If the pre-lube pump starts and oil pressure continues to fall, the compressor shall automatically shut down.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

When a lube oil pump is necessary in normal operation, the Manufacturer shall provide two motor driven positive displacement pumps, one for main and another for stand-by. The stand-by pump shall be a 100% capacity pump and have automatic cut in function when lube oil supply pressure hits low alarm point. If the stand-by pump starts and oil pressure continues to fall, the compressor shall automatically shut down.

Isolation valves and break-out union for pump removal and maintenance

without draining system.

Initial oil fill with recommended lubricant (regular oil and flushing oil).

Compressor oil reservoir with level instrumentation.

Thermostatically controlled electric immersion heaters shall be provided to

maintain the minimum required lube oil reservoir temperature such that

each compressor can start immediately upon a start signal, with no lube oil

preheating required. Oil heaters shall be sized and configured to have a

maximum surface temperature of 400° F exposed to the oil. A low oil level

switch shall be provided to de-energize the oil heater.

The lube pump shall be located in an accessible location and shall be piped

with block valves, strainer and a downstream check valve, and appropriate

flanges for ease of break-out and to allow removal with minimal

compressor oil loss.

All piping and equipment supports shall be supplied. The piping shall be

butt-welded stainless steel seamless pipe downstream of filters, and

upstream of filters may be socket or butt-welded stainless steel or carbon

steel seamless pipe. All piping shall be pre-piped and base mounted and

shipped as a packaged assembly.

8.4.3 Gas Scrubbing and Filtration

Gas separation and scrubbing equipment for equipment protection shall be supplied for the compressor package to meet the exhaust gas requirements as defined below:

A gas scrubber shall be supplied for the compressor inlet. The scrubber may utilize mist demister pads or vanes to remove entrained liquid from the gas.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

The scrubber shall be designed and constructed in accordance with the ASME Pressure Vessel Code and shall have an ASME stamp.

The scrubber shall be provided with the following accessories:

External level controller for auto drain

High level shut-down switch

Level gauge

Thermal relief valve

Dump valve

Vent valve

Manual drain valve

The scrubber vessels shall be skirt or leg supported and vertical, with horizontal inlet and outlet connections.

Each vessel shall be provided with a gauge glass and angle type isolation valves. The gauge glasses shall have a minimum length of 12 inches (300 mm). The vessels shall be provided with an automatic drain valve for the discharge of liquids. All necessary controls for the drain valves shall be supplied. A flanged cleanout connection shall be provided for each vessel. A vent connection shall also be provided for each vessel.

A liquid filter/ separator or combination of bulk oil separators and coalescing oil separators shall be supplied for the compressor outlet. The filter/separators shall be a vane type line separator designed to remove entrained liquid from the gas. Coalescing filters shall be supplied, as necessary, to meet the exhaust gas purity requirements. The liquid separator and coalescing filters shall be designed and constructed in accordance with the ASME Pressure Vessel Code and shall have an ASME stamp. Bulk oil separator may be demister pad with vertical type coalescing element, and coalescing oil separator may be coalescing element type.

The separator and coalescing oil filter shall be provided with the following in accordance with Section 5.10.3.5.5 of API STD 619:

High-level/ low level alarm, set point, and switch (two level switches)

External level controller for auto drain, or drain line back to compressor oil

system.

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DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

Dump valve or drain line back to compressor oil system.

Level gauge

Vent valve

Thermal relief valve

Manual drain

Differential Pressure transmitter for oil coalescing element.

Electric heater for bulk oil separator

The separator vessels shall be skirt or leg supported and vertical, with horizontal inlet and outlet connections.

Each vessel shall be provided with a gauge glass and angle type isolation valves. The gauge glasses shall have a minimum length of 12 inches (300 mm). The vessels shall be provided with an automatic drain valve for the discharge of liquids. All necessary controls for the drain valves shall be supplied. A flanged cleanout connection shall be provided for each vessel. A vent connection shall also be provided for each vessel.

8.5 Pulsation, Vibration Control and Analog Study

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 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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 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.

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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 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

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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).

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:

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

DAI HUNG GAS GATHERING PROJECT DETAILED ENGINEERING DESIGN PHASE

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

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

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.

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

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

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

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%

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

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

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.

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.

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

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

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.