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N°P180060_TC
Version: (P180060_TC_00)
th
Date: Castel Maggiore - (Bologna),Italy,May 29 ,2018
www.AlkhorayefKuwait.com
Always available for any further information you may require, we remain
Sincerely yours
Page 2 / 18
1. REFERENCE DOCUMENTATION & INTRODUCTION TO THE DESIGN
This GEA Refrigeration Italy’s proposal has been prepared technically mainly in accordance to :
1) Your kind Request For Quotation (RFQ) received by E-Mail on May 07 th,2018.
2) Your Material Requisition (M.R.) – Doc. N° T17-ZA-01104_TS for Refrigeration Package –Rev. A and
also to the relevant attached applicable technical specifications received by E-Mail on May 07 th,2018.
3) Your additional technical information and comment received by E-Mail on May 17th,2018 to the GEA
request of technical clarifications (relevant to the use of butane as refrigerant fluid).
We have based our offer on using GEA Refrigeration Italy S.p.A. Engineering Procedures. These are based
on Petro-Chemical Industry standards and norms.
We believe that these standards will provide a package that will meet the demanding requirements of the site
conditions while offering a commercially competitive solution.
We inform you that in this first offer phase GEA will provide only the attached MAIN deviation list and
comments.
The complete and the GEA’s Detailed Deviation List and comments to the Specifications will follow at later
stage and / or eventually will be defined together at a later date at an eventual technical meeting.
But in any case, in this offer you can only find the deviations list and comments for as follow:
1) API 619 for the proposed lubricated butane bare screw compressors.
2) API 619 & 614 comments & deviations for the proposed lube oil system for the lubricated butane
screw compressors.
4) API 676 for the lube oil pumps (dedicated to only the specific manufacturers proposed by GEA that are
Pompe Cucchi or Ultra Pompe).
(*) Note : Please refer also to all the exclusions proposed in this offer.
Page 3 / 18
2. BRIEF DESCRIPTION OF THE SCOPE OF SUPPLY.
The GEA Refrigeration Italy scope of supply, subject of the present offer, consists of n°1 Refrigeration
Package Unit that in accordance to your request and to your specifications it is sized for the total
maximum / design cooling duty- refrigeration capacity of : 5.200 kW.
The above mentioned Refrigerating System proposed by GEA according to your request and
specifications is operating with Butane mix as refrigerant gas (70% n-Butane + 30% i-Butane)
The Refrigeration Unit (as per attached GEA PFD-Process Flow Diagram) will be sized to supply
°
Butane liquid refrigerant (sub-cooled) at a temperature of ~ 45,6 C approx. and with a pressure
of ~ 7,14 bar a to n°1 refrigerant flooded evaporator shell and tube type heat exchanger kettle-BKU
type or equivalent that in this first phase as per your request is not included in the GEA basic scope
of supply and quotation.
The above mentioned flooded evaporator with butane on shell side will be used as chiller of process fluid
on the tube side.
The Refrigeration Unit proposed by GEA will consists mainly of the following equipment :
No. 2 x 50% (Working-operating) identical butane oil flooded-lubricated screw compressors units ;
No. 2 x 50% (Working-operating) Medium Voltage electric motors for screw compressors drive;
No. 1 lubricating oil system with oil cooling system and auxiliaries in common to the two butane lubricated
screw compressors ; the lube oil system dedicated to the butane screw compressors is manly complete
with n°1 lube oil separator, n°1 oil cooler S & T cooled with butane thermosiphon type,
n°2 oil pumps , dual oil filters and strainers ,piping ,etc.);
No. 1 x 100% Working-operating butane condenser heat exchanger air cooled type;
No. 1 x 100% Working-operating butane liquid accumulator-receiver ; the above mentioned refrigerant
liquid receiver proposed by GEA in this first basic budget offer-price it is sized according to the GEA
experience in similar applications for a standard of hold up time and has not been sized in order to
contain all refrigerant charge of the whole system;
No. 1 x 100% Working-operating butane superheater shell and tube type heat exchanger that will be
installed on suction and in common to the two screw compressors;
No. 1 x 100% Working-operating butane suction drum-Knock Out Drum (K.O.D.), vertical type ,that will
be installed on suction and in common to the two screw compressors and used to prevent possible
butane refrigerant liquid on the compressors suction from the refrigerant flooded evaporator heat
exchanger / chiller of process fluid.
No. 1 set of LGB - Local Gauge Board suitable for classified area;
No. 1 remote U.C.P.-Unit Control Panel complete with PLC in common to the 2 compressors, suitable to be
installed in control room safe area;
No. 1 set of piping up to the skids edges, valves and controls;
No. 1 set of special tools for the screw compressor.
For more details relevant also to temperature , pressure, etc. please see and refer also to our attached
PFD-Preliminary Process Flow Diagram and related sheet for reference; the flow rates indicated in this
diagram are referred to max. capacity of the refrigeration system.
We have considered in this first phase that all the above mentioned main equipment (butane KOD, butane
compressors & relevant lubricating oil system, butane air cooler condenser, butane liquid receiver and butane
superheater) will be installed - located at Client’s charge at grade at zero elevation as per attached GEA
preliminary Plant Foot Print drawing.
The heat exchanger / butane evaporator used as chiller of process fluid we have considered that will be
installed – located at Client’s charge at grade at zero elevation at a max. distance of 10 -15 m. approx. from
the refrigerant KOD & two refrigerant screw compressors and from the refrigerant superheater .
Page 4 / 18
3. TECHNICAL DATA.
Type of compressors : screw, oil flooded;
Brand of the compressors : Howden or GEA ;
Compressors number : N°2 x 50%;
Speed of compressors : 1.480 rpm(direct coupled to electric motor);
Power supply
V/ph/Hz 3.300 / 3 / 50 MV el. mot. driver for compr.
V/ph/Hz 440/3/50 LV el. mot.driver / El. Heaters
V/ph/Hz 120/1/50 instruments, auxiliary circuit,
solenoid valves.
Executions/protection for :
Electric motors drivers : Ex-d;
Instruments : Ex-d;
Junction boxes : Ex-e;
Page 5 / 18
4. TECHNICAL DESCRIPTION
Note : For other conditions please see & refer to the attached GEA PFD-Process Flow Diagram Drawing .
Page 6 / 18
2) No.1 OIL CIRCUIT in common to the n° 2 x 50% refrigerant screw compressors
Oil piping.
Material : CS-Carbon Steel up-stream filters and in
SS-Stainless Steel down-stream filters.
Double oil filters.
Material casing : stainless steel;
Design temperature : - 29 /+120°C;
Degree of filtration : 20 µm.
Valves.
Body/internal : CS-Carbon Steel /S.S.- Stainless Steel;
No. 2 electric lube pumps for oil circulation(N°1 operating and n°1 as stand by).
Each pump is complete with internal safety valve, electric driver with coupling and with
non-sparking guard.
Casing material : cast iron;
Pump type : gear/screw;
No. 1 suction strainer in CS, cleanable type on each oil pump suction line;
3) No.2 SETS OF AUX. SEAL FLUSH-GAS SYSTEMS, for Butane screw compressors (n°1 for each
compressor) dedicated to the double mechanical shaft seal wet/dry Plan 72.
4) No.2 COUPLINGS for the butane screw compressors and the relevant MV electric motors drivers,
(n°1 for each compressor)flexible type, with non-sparking protection guard.
5) No. 2 M.V. ELECTRIC MOTORS for Butane screw compressors drivers (n°1 for each compressor)
at 4 poles ,at 3.300 V / 3 ph / 50 Hz with a fixed speed of ~1.480 rpm , suitable for classified area
and each with an installed power of 1.200 kW ; each a.m. proposed MV electric motor is complete of
standard manufacturer bearings (antifriction rolling-ball type or equivalent ) and with standard
manufacturer lubrication system (grease).
Page 7 / 18
6) No.1 REFRIGERANT CONDENSER
Refrigerant type : Mix Butane;
Type : Air Cooler;
Design / test pressure on butane side : 15 /code - bar G;
Design temperature on butane side : - 29 /+120 °C.
Tubes material : CS-Carbon Steel with Aluminium fins;
Nr. of fans : total 10.
Design air dry bulb ambient temperature
for the sizing of the air cooler : 51,1°C
Butane Condensing pressure (saturated) : ~ 7,24 bar a
Note 1):The air condenser is controlled by mean of VFD (out of GEA scope of supply)
installed on 50% of the fan motors. VFD are installed by client in MCC room (Safe Area).
Page 8 / 18
7) No.1 REFRIGERANT KO DRUM ON COMPRESSORS SUCTION
Refrigerant type : Mix Butane;
Type: : vertical;
All materials : CS-Carbon Steel;
Design/test pressure : 15 / code- bar G;
Design temperature : - 29 /+120 °C;
Page 9 / 18
10) No.1 SET OF LOCAL GAUGE BOARDS to run the unit from the field, installed on the compressors
skids and each complete of:
a) Junction boxes with:
Start/stop push buttons;
Interface terminal board;
Manual/automatic capacity control selector switch;
Signal lamps for: alarm & shut down, capacity control, heating and solenoids;
Ammeter for main motor;
Horn alarm.
Execution of the junction boxes : Ex-e
Page 10 / 18
Follow from previous Point 10
ON THE KO DRUM
pressure 1 gauge X
pressure 1 transmitter H
liquid level 1 gauge X
liquid level 2 transmitter H HH
ON THE SUPERHEATER
pressure 1 gauge X
temperature 1 gauge X
11) ELECTRICAL WIRING between the instruments and the junction boxes on the racks.
12) NOISE HOODS jacket type on the bare compressors, if necessary to respect 85 dB(A).
13) PAINTING of all the equipment included in GEA Refrigeration Italy ’s scope of supply as per
project specification.
14) TESTS NOT WITNESSED for all the equipment included in GEA Refrigeration Italy ’s scope
16) No.1 SET OF LIFTING DEVICE & METALLIC LIFTING BEAMS (spreader bar etc.) necessary
Page 11 / 18
17) No.1 SET OF EARTH LUGS-LIFTING LUGS AND GROUNDING LUGS for the equipment
included in GEA Refrigeration Italy’s scope of supply ;
18) No.1 SET OF NECESSARY METALLIC STAIRWAYS, LADDERS, GRATING AND PLATFORMS
for the above various equipment and skids included in GEA Refrigeration Italy ’s scope of
supply, supplied prefabricated and loose suitable to be installed on site at Client ‘s charge.
19) No.1 SET OF COMMISSIONING SPARE PARTS according to the attached GEA’s standard
manufacturer list ;
20) No.1 SET OF NAME PLATES for all the equipment included in GEA Refrigeration Italy’s scope
of supply ;
21) No. 1 SET OF INTERNAL PIPING UP TO THE SKIDS EDGES, VALVES AND CONTROLS;
22) No. 1 REMOTE U.C.P.-UNIT CONTROL PANEL COMPLETE WITH PLC in common to the 2 compressors,
the control system will be supplied loose-free standing and is suitable to be installed remote in your
Control Room and used for the control of the complete refrigeration system .
23) TRANSPORT & DELIVERY of all the material included in GEA Refrigeration Italy scope of supply
up to F.O.B. as indicated in the attached GEA Sales Conditions according to the ICC Incoterms
2010 latest edition ;
24) PACKING of all the material included in GEA Refrigeration Italy scope of supply ; the packing it is
seaworthy type and suitable for shipping and realized according to the UNI 9151.
The seaworthy packing it is certificated (FAO ISPM-15).
25) ENGINEERING: detailed engineering, drawings and sketches, operating manual and inspection book
for the complete scope of supply.
Page 12 / 18
5. PRELIMINARY (main) ELECTRICAL CONSUMPTION
Note (1) : The value of the absorbed power is the Max. & relevant to each compressor at 100% load
At partial load the absorbed power value for each compressor is ~ 1.080 kW /each
Note (3) : Utilities consumption relevant to the Double shaft seal for screw compressors will be defined
at a later stage.
Note (5) : Turndown requested in the spec. for the whole refrigeration package : 30% - 100%
In this first budget offer phase for your information please see to the attached GEA preliminary PFD –
Doc. N° P180060_GPFA_00
Page 13 / 18
7. EXCLUSIONS
General
Ex.G1 Any item of scope not mentioned in this section.
Ex.G2 Standards or other codes not mentioned in this offer.
Ex.G3 Documentation not mentioned in this offer.
Ex.G4 Non-standard documentation, testing or certification for proprietary items.
Ex.G5 Attendance to meetings outside GEA premises.
Ex.G6 Inspection visits by GEA except where marked “W” in our ITP.
Ex.G7 Unloading and / or positioning of skids at site.
Ex.G8 Civil engineering.
Ex.G9 Site Installation.
Ex.G10 Site Supervision (see pricing for daily rates).
Ex.G11 Commissioning (see pricing for daily rates).
Ex.G12 Service and maintenance contracts (available as option).
Ex.G13 Spare parts other than specified in our offer.
Ex.G14 Customer format P&ID check when redrawn from GEA P&ID.
Ex.G15 Oil Flushing and Oil for Oil Flushing.
Ex.G16 Any additional requirement generated during HAZOP, SIL, FMECA or SIL studies.
Ex.G17 Third part approval & inspection.
Ex.G18 Full material traceability for pipework.
Ex.G19 Third part approval & inspection.
Ex.G20 Applicable taxes, fees or permits.
Ex.G21 Vacuum test.
Ex.G22 N°1 butane hot gas by-pass system 0-20% for the refrigeration package.
Ex.G23 3D modelling with PDMS, PDM or PDS for the whole refrigeration package.
Ex.G24 N°1 Butane flooded evaporator shell and tube type heat exchanger kettle-BKU type or
equivalent used as chiller of process fluid and complete with instrument ,valves etc.
Ex.G25 Transport and delivery from F.O.B. as indicated in the attached GEA Sales Conditions
up to the site in Kuwait.
Electrical
Ex.E1 LV and HV cabling, cabling glands and /or Isolation Switches.
Ex.E2 Wiring between skids and/or to remote panel.
Ex.E3 Motor or heater switchgear, MCC’s, Starter panels, Power Panels.
Ex.E4 VFD for the Air Cooler fans electric motors.
Ex.E5 Ammeters.
Ex.E6 Lighting and small power.
Ex.E7 ESPB’s.
Ex.E8 Trace Heating.
Instrumentation
Ex.I1 MMS (e.g. Bently Nevada), DCS or ESD Systems.
Ex.I2 Emergency Blowdown valves.
Ex.I3 Bursting Discs or locking devices for PSV's.
Ex.I4 Balanced bellow relief valves.
Ex.I5 SIL studies for control systems.
Ex.I6 Instrument cabling from junction boxes to DCS / ESD or any remote location outside
individual skid limits.
Ex.I7 HAZOP / LOPA / FMECA studies.
Ex.I8 1oo2 or 2oo3 Voting.
Ex.I9 Wake calculations for thermowells.
Page 14 / 18
7. EXCLUSIONS (follow from previous page)
Mechanical
Ex.M1 “String” tests or skid performance tests.
Ex.M2 Compressors performance tests other than mechanical run test.
Ex.M3 First charge of butane refrigerant and oil.
Ex.M4 Passive fire protection.
Ex.M5 Thermal insulation and heat tracing.
Ex.M6 Steel structures other than the skid base frames.
Ex.M7 Maintenance platforms / ladders except where stated in section one.
Ex.M8 Vibration mounts.
Ex.M9 Lock devices for locked open or locked closed valves.
Ex.M10 Vacuum pumps, oil charging pumps or refrigerant pump-out units.
Ex.M11 Foundation bolts and anchor bolts for the skids and equipment.
Ex.M12 Piping or pipe supports between specified skids or outside the skid limits.
Ex.M13 Pipe stress analysis within skid limits.
Ex.M14 Fire safe valves, leak detection, gas/fire alarms.
Ex.M15 Underslung/Drip pan maintenance platforms.
Ex.M16 Shop assembly and trial run of the air condensers.
Ex.M17 Bolting and gaskets for flange to piping connections (client interface points).
Page 15 / 18
8. BUDGET PRICES
THE VALUE OF THE PROPOSAL IS BASED ON GEA ASSUMPTIONS, IN CASE OF VARIATION GEA
RESERVE THE RIGHTS TO CONFIRM THE PRICE.
1.
DAILY RATE FOR SITE / FIELD SERVICES ,TESTS, AND FIELD For the daily rate tariff
SUPERVISION ON SHORE IN KUWAIT please refer to the relevant
GEA attachment
“P180060_DR_2018”.
2. Excise duty. Excluded
Note : For the Terms and Conditions please see relevant attachment “P180060_STC_00”with the
GEA standard Terms of Sale.
The terms of the Technical Documents and Standard Terms of Sale as attached, shall be
deemed incorporated mutatis mutandis into this document in so far as the same do not
conflict with the terms of this document.
Always available for any further information you may require, we remain
Sincerely yours,
Giuseppe Falsiroli
Page 16 / 18
9. GEA ATTACHMENTS LIST
2) P180060_LI_DEV_API 619_& API 614_GEA COMMENTS-LIST FOR THE LUBE OIL SYSTEM FOR THE
LUBRICATED BARE SCREW COMPRESSORS.
4a) P180060_LI_DEV_API 676_00 FOR OIL PUMPS_(relevant to a specific manufacturer Pompe Cucchi
proposed by GEA).
4b) P180060_LI_DEV_API 676_00 FOR OIL PUMPS_(relevant to a specific manufacturer Ultra pompe proposed
by GEA).
9) P180060_GEA_EJECTOR_00
Page 17 / 18
10. GEA REFERENCES
GEA Refrigeration Italy S.p.A. has experience in supply similar unit to KOC. This is the main reference:
Client : Petrofac
Project : GC-32 NEW GATHERING CENTER FOR SEK
Equipment : Refrigeration Packages 0032-A6-Z-1501/2501/3501
GEA Refrigeration’s ref. : 01230
Page 18 / 18