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Specification 17.09
07/07/15 1
SECTION
1.0 SCOPE
3.0 REQUIREMENTS
4.0 CHARACTERISTICS
4.1 Performance
4.2 Maintainability
5.1 Package
5.2 Driver
5.3 Diesel and Gas Engines
5.4 Electric Motors
5.5 V-belt Drives
6.0 COMPRESSORS
6.1 General
6.2 Reciprocating Compressors
6.3 Compressor Design
6.4 Compressor Ancillary Equipment
6.5 Air Receiver
6.6 Compressed Air Dryer System
6.6.1 General
6.6.2 Desiccant Towers
6.6.3 Controls, Indicators and Alarms
6.6.4 Prefilter System
6.6.5 Dry Air Filter System
6.7 Heat Exchangers
7.1 General
7.2 Carbon Steel Piping
SECTION
8.1 General
8.2 Safety
8.3 Bid Information
8.3.1 Compressors
8.3.2 Air Dryer
8.3.3 Air Filters
8.4 Documentation Requirements
9.1 Tests
9.2 Special Tests and Inspections
9.3 Quality Conformance Inspections
APPENDIX
ATTACHMENTS
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MAMTECH SERVICES LIMITED
Specification 17.09
P&ID
Flow Diagrams
Data Sheets
Engineering Specifications
These items shall include but are not limited to, the instrument air
package, drivers, auxiliary equipment, compressors, air receivers,
dryers, interconnecting piping and valves, electricals and
instrumentation and controls. For a specific instrument air system, this
specification shall be used in conjunction with the Technical
Requirements for that air system. Any exception to the requirements
shall be submitted in writing for resolution by Company.
2.1 Contractor shall consider the most recent standards and codes issued by
the associations and approved bodies listed in Appendix I as part of this
specification.
3.0 REQUIREMENTS
Drivers
Compressors
Dryers
Receiver
Control Panel
Auxiliary equipment necessary to complete the package
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MAMTECH SERVICES LIMITED
Specification 17.09
4.1 Performance
4.1.1 The instrument air package shall be suitable for the maximum rated
operating conditions specified in the Technical Requirements.
4.1.2 The instrument air package shall have a minimum service life of 20
years while operating in the specified environment.
4.2 Maintainability
4.2.1 The instrument air system shall be designed for ease of maintenance.
4.2.2 Removal of any major assembly shall not be required for periodic
maintenance or operator attention.
4.2.4 Critical items within the package shall be provided with installed spares
to ensure 100 percent functional availability of the instrument air
package.
5.1 Package
5.1.1 The instrument air package shall include drivers, compressors, dryers,
and auxiliary equipment as specified.
5.1.2 The instrument air package shall incorporate features that facilitate
connection between the package and the equipment associated with the
package such as additional storage capacity or cross-connection to the
instrument air system.
5.1.4 All instrument air package equipment shall be mounted on one skid.
5.1.6 Each piece of equipment within the package shall be provided with the
necessary lubrication system and fittings.
5.2 Driver
5.2.1 General
5.2.1.3 The design shall not include negative tolerance for capacity. The
maximum continuous horsepower (HP) shall be guaranteed by
Contractor.
5.3.1 Gas and diesel engines shall comply with the Company Technical
Requirements.
5.3.2 Air-cooled engines shall be compatible with available fuel systems and
rated to provide maximum continuous reliable power consistent with
fuel economy and ease of maintenance.
5.3.4 The fuel consumption of the driver shall be within 3 percent of the
stated values based upon a fuel analysis provided by Company. Fuel
consumption shall be in British thermal units per brake horsepower hour
(BTU/BHP-HR). Calculations shall be based on the lower heating value
of the fuel.
5.3.5 The engine rating shall exceed the maximum anticipated horsepower
requirements for site operating conditions.
5.4.2 Motors shall be 480 volt, three-phase, 60 hertz, totally enclosed, fan
cooled (TEFC) induction motors with double-extensions shafts for
mounting after cooler fans. Motors shall be furnished with space
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MAMTECH SERVICES LIMITED
Specification 17.09
5.5.1 Unless otherwise specified the prime mover power transmission to the
package compressors shall be a V-belt drive system.
5.5.2 Contractor shall supply all sheaves, belts, tensioning devices and belt
guards required for the driver. If multiple belts are required, Contractor
shall provide matched sets.
5.5.3 All belt drives shall be antistatic, oil-resistant material and shall be
conservatively sized and rated with a typical service factor of 1.5.
6.1 General
6.1.1 Each instrument air package shall include two (2) 100% compressors.
6.1.2 Under normal operating conditions, one compressor shall operate with
the other on standby.
6.3.1 Compressor cylinder(s) shall include integral fins for air cooling.
Water-cooled cylinders may be provided on compressors above 50 brake
horsepower (BHP) with written Company approval.
6.3.2 Unless otherwise specified, the unit shall include a distance piece long
enough to ensure that no section of the connecting rod in contact with
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MAMTECH SERVICES LIMITED
Specification 17.09
6.3.3 The piston rod shall be assembled with oil wiper rings.
6.3.5 Unless otherwise specified, the piston compression and rider rings shall
be teflon, or a teflon based material.
6.5.1 A dry air receiver shall be supplied with each instrument air package.
6.5.2 The air receiver shall be manufactured in accordance with the Company
Technical Requirements and ASME Section VIII, Division 1, Pressure
Vessel Code. Vessels shall be code stamped.
6.5.3 The air receiver shall be mounted vertically, unless otherwise specified,
or if the physical size exceeds the specified height limit.
6.6.1 General
6.6.1.1 The air dryer system shall be a twin tower, pressure swing, heatless
regeneration desiccant type provided in accordance with the Technical
Requirements.
6.6.1.3 The pressure loss across the total dryer system, including prefilters,
desiccant towers and dry air filters, shall not exceed 5 PSIG clean.
6.6.1.4 A dryer system shall ensure a minimum dew point depression of 50F
below the minimum service conditions specified in the Technical
Requirements.
6.6.1.5 The minimum design working pressure shall be 125 PSIG with a
minimum design pressure of 150 PSIG. Design temperature shall be
200oF minimum.
6.6.2.1 Each unit shall be provided with two (2) 100% vertical desiccant towers.
The towers shall be of the "upflow" design.
6.6.2.4 In addition to the initial fill of desiccant for the dryer towers, Contractor
shall also supply desiccant for one complete fill of both towers.
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MAMTECH SERVICES LIMITED
Specification 17.09
6.6.3.1 The control system, including valves, timers, purge flow indicators,
moisture indictor, and changeover failure alarm shall be incorporated
into the compressor package control panel.
6.6.3.3 The pressure and temperature indicators shall be locally mounted on the
desiccant towers.
6.6.4.1 The prefilter system shall consist of two parallel full-flow filters utilizing
oil vapor absorbing elements.
6.6.4.2 The prefilter system shall be fitted with associated changeover valving,
an automatic drain, and a differential pressure indicator.
6.6.4.3 The prefilter system shall prevent the carryover of oil and other
contaminants to the desiccant.
6.6.5.1 A dry air filter system similar to the prefilter system shall be installed
downstream of the dryers and upstream of the air receiver inlet.
6.6.5.2 The dry air filter system shall be designed for full-flow, duplex operation.
The filter system shall remove 99.9% of all particles 5 microns and
larger to prevent desiccant carryover into the receiver.
6.7.3 Heat exchangers shall be sized to cool the discharge air to within 20F of
ambient temperature.
6.7.4 Heat exchangers shall be in accordance with the minimum requirements
of TEMA Class C heat exchangers.
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MAMTECH SERVICES LIMITED
Specification 17.09
7.1 General
7.1.1 All interconnecting piping and fittings shall be installed within the limits
of the packaged skid.
7.1.3 Piping and tubing shall be firmly fixed in a neat and orderly
arrangement.
7.2.2 Pipe sizes 1-1/2 inch and smaller shall be schedule 80. The piping may
be flanged, welded, or screwed.
7.2.3 Pipe sizes 2 inches and larger as a minimum shall be schedule 40. With
the exception of water piping and atmospheric vents, piping 2 inches
and larger shall have welded or flanged connections.
7.3.1 Contractor shall provide all piping, tubing, valves and fittings required
for instruments and instrument panels.
7.3.2 Instrument connections and test points shall be minimum of 1/2 inch
size.
7.3.3 Pressure gauges and pressure switches shall be in accordance with the
Technical Requirements.
7.3.4 Remote mounted pressure instruments that measure the same pressure
may have common connections.
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MAMTECH SERVICES LIMITED
Specification 17.09
7.3.6 All pneumatic tubing and/or controls shall be installed with 316 stainless
steel tubing, fittings, and valves.
7.4 Connections
7.4.1 All piping runs shall contain sufficient union and flange connections to
enable individual devices such as check valves to be removed for
service. The union and flange connections shall be situated to ensure
minimum disturbance of piping and equipment during service.
7.4.3 All services shall terminate at the skid edge in a single connection.
Flanges shall be provided for all connections unless specified otherwise.
Connections shall be grouped in the same general area.
7.5.1 Threaded connections for oil and flammable services shall be seal
welded with the following requirements:
7.5.3 The seal weld shall consist of at least two passes. The throat of the
finished weld shall be a maximum of 3/8 inch, and the throat shall cover
all exposed threads.
7.6 Interconnections
7.6.1 The instrument air package shall be interconnected with the utility air
package. The interconnection shall provide utility air as a back-up for
the instrument air supply.
7.6.2 The tie-in point to the instrument air package shall be upstream of the
prefilter system.
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MAMTECH SERVICES LIMITED
Specification 17.09
7.6.4 The prefilter system, and the additional liquid removal systems if
provided, shall be within the instrument air package limits.
7.6.5 The utility air inlet connection shall terminate in a single flanged
connection at the edge of the instrument air package.
7.7 Electrical
7.7.2 Wiring shall be installed using Type MC cable in cable tray. Flexible
conduit is acceptable only if required for belt tensioning adjustment or
vibration isolation.
7.7.3 All electrical wiring shall be complete prior to testing and delivery.
Electrical connections for operation of the package shall consist of motor
power and space heater cables, motor control cables, and control panel
power input. If electrical power is required for the dryers, it shall be
derived from the control panel power input. Motor starters and motor
control relays shall be located in the MCC building, and will be provided
by others.
7.7.4 All electrical wiring shall include reference tags at the connection to the
electrical device and at the control panel or junction box. Motor power
cables shall be connected directly to motors. Motor control cables and
the control panel power cable shall terminate in a single interface
junction box.
7.7.5 All electric motors shall comply with Company Technical Requirements.
7.8.1 General
7.8.1.1 The package control system shall be electric. Provision shall be made
for both automatic and local manual operation.
7.8.1.2 All components and installation shall be suitable for the area
classification specified and shall comply with NEC Articles 500 and 501.
7.8.1.4 Controls and control panels shall be completely piped and wired, and
shall only require connection to platform piping and wiring circuits.
7.8.2.3 The panel shall be located on the skid and mounted in such a way as to
prevent damage from vibration.
7.8.2.4 If applicable, the panel shall be designed to close the main valve and
vent the engine fuel gas manifold during a shutdown.
7.8.2.6 The control panel shall be provided with the following for each
compressor as a minimum:
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MAMTECH SERVICES LIMITED
Specification 17.09
7.8.2.8 The control panel shall be provided with the following momentary
pushbutton switches for control power as a minimum:
Malfunction reset
Lamp test
7.8.2.9 In the hand position, the driver shall run regardless of the status of
control inputs. In the off position, the driver shall not run regardless of
the status of control inputs. In the auto position, the driver shall run
under the control of the package control panel.
7.8.3.1 The compressor control sequence shall have the following order:
c. If the pressure in the air receiver tank falls to 110 PSIG, the lead
compressor shall be brought on line and shall operate until pressure
reaches 125 PSIG. At this point, the compressor shall be unloaded
automatically by the constant speed control. The sequence shall be
repeated when the pressure falls to 110 PSIG.
7.8.3.3 The control system shall provide the following compressor operations:
7.9 Skid
7.9.3 Skid design shall permit single-point lift of the completed package. If
required for a single-point lift, Contractor shall provide a spreader bar or
lifting frame, complete with slings and shackles.
7.9.4 The skid shall be furnished with a drain pan to prevent contamination of
the surrounding area. The drain pan shall be sloped and provided with a
drain connection. The drain connection shall be suitable for easy
cleanout and disposal of the collected fluids.
7.9.5 The areas of the skid not directly under equipment shall be covered with
grating.
8.1 General
8.1.1 The instrument air system shall be provided with the identification and
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MAMTECH SERVICES LIMITED
Specification 17.09
8.1.3 All rotating equipment shall have arrows indicating the direction of
rotation. Rotation arrows shall be cast into the equipment or stamped
on stainless steel plates and mounted with stainless steel fasteners.
Manufacturer
Manufacturer's type
Serial number
Item or tag number
Size
Maximum allowable design conditions
Horsepower or kilowatt rating
Manufacturer
Manufacturer's type
Serial number
Item or tag number
Rated speeds
Trip speeds
Ambient ratings
Horsepower rating
8.1.7 Nameplates and tags shall be attached to equipment with stainless steel
screws or rivets. Adhesive shall not be acceptable. Tags may be
attached to items with stainless steel wire only if screws or rivets are
impractical.
8.2 Safety
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MAMTECH SERVICES LIMITED
Specification 17.09
8.2.2 Particular attention shall be given to ensure that all electrical equipment
and installations are suitable for the specified area classifications.
8.2.4 Relief valves shall be set to operate at no more than the maximum
stated design pressure, but not less than 110 percent of the compressor
discharge pressure.
8.2.5 Solid steel guards shall be provided to within 1/2 inch of stationary
housings adjacent to all moving parts. Moving parts include such
elements as drive belts, cooler fans, and extension shafts.
8.3.1 Compressors
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MAMTECH SERVICES LIMITED
Specification 17.09
The following specific information shall be supplied for the air dryer:
9.1 Tests
9.1.2 All compressors and engines shall receive the Contractor's standard
shop tests as a minimum.
9.1.3 Engines shall be factory tested and shall be run at rated speed and
horsepower for not less than one hour.
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MAMTECH SERVICES LIMITED
Specification 17.09
9.3.1 Contractor shall provide five days written notice to Company that the
equipment is complete, clean, and ready for inspection.
9.3.2 A check shall be made to ensure that the structural members comply
with the Technical Requirements.
9.3.4 Padeyes shall be checked as necessary for compliance with codes and
standards.
9.3.5 The dimensions of all components shall be checked for compliance with
the drawings and the Technical Requirements. Any components not
within the tolerances shall be brought to the attention of Company.
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MAMTECH SERVICES LIMITED
Specification 17.09
1. INDUSTRY ASSOCIATIONS
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MAMTECH SERVICES LIMITED
Specification 17.09
2. GOVERNMENT AGENCIES
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