Design Basis for Rotating Equipments

Document DescriptionDoc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 1 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 Extended Basic Engineering for LOA Plant, Jhagadia, Gujarat Design Basis For Rotating Equipments Document No. 12-008-ME-DB-0002 0 Issued for Approval VPP Rev. No. Rev. Date Reason for Issue Prepared By Checked By Approved By Project Manager Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 2 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 CONTENTS Sr. No. Description Page No. 1 GENERAL 2 DESIGN PHILOSOPHY / CRITERIA – GENERAL 3 DESIGN CRITERIA / REQUIREMENTS – SPECIFIC APPLICATIONS Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 3 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 SECTION-1: GENERAL 1.1. SCOPE 1.1.1. This Design Basis covers the design criteria for the purpose of carrying out Engineering for Procurement of various rotating equipment required including requirements with regard to spare parts & special tools. This Engineering Design Basis shall be applied to engineering for procurement of Rotating Equipments for Process Packages of Lanxess LOA Plant, Jhagadia, Gujarat. 2.1.2. Electrical items, Instrumentation & Controls, Piping, Pressure Vessels, Mechanical Equipment, Heat exchangers etc. associated with rotating equipment shall comply with the design requirements as given in the respective specifications forming part of the bid package. 2.2. CONFLICTING REQUIREMENTS 2.2.1. In case of conflict between this 'Engineering Design Basis-Rotary Equipment' and other documents attached to the Material Requisition, the following order of precedence shall govern: a) Statutory Approvals b) Licensor's Datasheet / Equipment datasheets. c) Specific Job requirements of 'Material requisition'. d) Licensor's specifications and drawings e) Functional Block diagram f) P&ID’s g) Inspection & Test plans h) This Engineering. Design Basis-Rotating Equipment i) Job specifications (Instrumentation / Electrical) j) Other Engineering Design basis (Process, Electrical, Instrumentation, Heat Exchanger, Vessels k) Other Standard Specifications l) Codes and Standards 2.3. UNIT RESPONSIBILITY 2.3.1. In addition to the overall responsibility of the Contractor, the unit responsibility shall rest with the driven equipment manufacturer, who shall also be the SPRV (Single Point Responsibility Vendor) for the complete equipment unit including driver, driven equipment & all other associated auxiliary systems, instrumentation & controls etc. All Rotating Equipment drivers shall be procured, preferably from the respective driven equipment manufacturers, complete with all associated auxiliary systems Compliance with the technical requisition does not relieve VENDOR of the responsibility to furnish GOODS of proper design, mechanically suited to meet the operating guarantees at the specified service conditions. 2.4. UNITISATION 2.4.1. All rotating equipments shall be unitized with respective drivers at the driven equipment manufacturer's shop before dispatch to check fit up of equipment, alignment, location of bolt holes, interface locations / dimensions etc. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 4 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 SECTION-2: DESIGN PHILOSOPHY / CRITERIA – GENERAL 2.1. Selection of rotating equipment shall be based upon the following considerations: − Suitability for the specified range of duty conditions. − Standard models under supplier’s regular manufacturing range. − Proven track record in similar service as specified under acceptance criteria. − Optimum operating and maintenance costs. − Maximum inter-changeability of parts. Inter-changeability charts to be furnished by Contractors/ Vendors. − Ease of operation and maintenance. − Foreign vendor shall preferably have a license office in India. 2.2. For design aspects not specifically covered by data sheets, specifications, codes and standards or regulations, the design shall be based on good engineering practices. 2.3. Equipment supplier shall make all possible efforts to comply strictly with the requirements of this design basis. In case deviations are considered essential by the vendor (after exhausting all possible efforts), these shall be clearly brought out and consolidated under technical exception chapter at bidding stage. However, same shall be subject to Consultant / Owner’s approval. 2.4. The equipment supplier shall fill in Experience record formats completely indicating information on operating conditions and construction features of the vendors past supply in sufficient detail to evaluate proneness of the equipment proposed. 2.5. The supplier of equipment shall be selected from the approved list of vendors specified elsewhere in bid document. Equipment of proven design and performance shall only be considered. Equipment qualification criteria as specified in bid document for equipment and auxiliaries shall be followed. 2.6. The number of spare equipment to be installed shall be as per the equipment sparing philosophy in the Licensor’s process package, datasheets and specified in the bid. 2.7. Air compressors, Centrifugal fans, Internal combustion engines and gas turbines handling ambient air shall be sized on the basis of maximum site coincident ambient temperature and relative humidity. 2.8. Electrical items, instrumentation and controls, piping, pressure vessels, mechanical equipment, heat exchangers etc., associated with rotating equipment shall comply with the design requirements as given in the respective engineering documents enclosed in the bid package. 2.9. The ratings of drivers (electric motor / steam turbine / diesel engine) shall comply with the requirements specified individually for each driven equipment. All rotating equipments shall be driven by electric motor, turbine as a drive is not acceptable. 2.10. Equipment layout shall incorporate adequate maintenance platforms, support structures, hand rails, material handling facilities for operational access, inspection, erection and maintenance of equipment. 2.11. All electrical components and installations, instruments shall be suitable for the electrical area classification and grouping in which the equipment is installed. 2.12. Material exposed to sour environment as defined by NACE MR-0175 & 0103 shall be in accordance with requirements of the NACE standard. Ferrous materials not covered by NACE MR-0175 & 0103 shall be limited to yield strength not exceeding 90,000 psi and hardness not exceeding Rockwell C-22. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 5 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 2.13. Noise level of continuous operating equipment (for Driver + Driven equipment + Auxiliary) shall not exceed 85 dBA when measured at 1M distance from the equipment skid in any direction. For turbine driven equipment and equipment with rating above 500 kW this shall be reviewed based on case to case basis. Note: This requirement is not applicable for intermittent operation equipment such as firewater pump, engine driven emergency generator, high speed high speed integrally gear driven type of pumps etc.For safety relief valve vents the noise level shall be limited to 105 dBA at 5m distance. 2.14. Acoustic enclosures are not preferred. However, it may be provided for equipment such as gas turbines, rotary screw compressors, high speed integrally gear driven type of pumps, compressors and root blowers to meet the specified noise levels. Requirement of silencers at fan/blower/compressor suction, relief valve outlets shall be accordingly decided. 2.15. All compressor sheds shall be provided with adequately sized EOT crane, depending upon the maximum weight of one component to be handled for maintenance of the compressor and its driver. Electric motor driver shall be considered a single component for maintenance except for the single bearing motors where the motor rotor and stator shall be considered as individual components. 2.16. Maximum allowable working pressure and temperature of the equipment shall not be less than the design pressure and temperature specified in the data sheet or not less than those specified in specifications, codes and standards. 2.17. Spare rotors where supplied shall be boxed in a metal containers for vertical storage with adequate corrosion protection. Nitrogen purging shall be considered. 2.18. Unless otherwise specified, equipment shall be driven directly. 2.19. Compressors and drivers (including gear units and couplings if any) shall be designed to perform satisfactorily under specified start up conditions, part load operation, maximum differential pressure operation and relief valve set pressure and up to full speed including any design margin specified considering future requirements. This shall also include operating conditions envisaged during regeneration cycle of plant and as specified in respective equipment data sheets. 2.20. Couplings shall be of non-lubricated diaphragm / metallic flexible membrane type with spacer for all equipment. However, coupling shall conform to API 671 for all the equipment with speed greater than 3600 rpm and / or driver rating greater than 160 kW. All coupling guards shall be of non-sparking type. Couplings shall be dynamically balanced separately with match marked coupling bolts/coupling halves. All coupling models shall be selected for a minimum service factor of 1.5. 2.21. As a minimum Centrifugal compressors, centrifugal integrally geared compressors, special purpose steam turbines, special purpose gear units and multi stage centrifugal pumps with hydro dynamic bearings shall be provided with probes / detector and monitors in accordance with API standard 670 for measuring shaft radial vibration, axial position, and bearing temperatures. The drive motors of these equipments shall also be provided with probes for measuring winding temperature, bearing temperature and bearing vibrations (X and Y). Fan and pumps above 160 KW shall be provided with vibration monitoring system. Alarm (alert) and shutdown (danger) annunciation shall be provided for each of the monitored variables. This system shall comply with requirements specified in specification for instrumentation covered elsewhere in the Bid document. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 6 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 Separate keyphasors shall be provided for input and out shaft of gear box. 2.22. In case of oil coolers the oil side operating pressure shall be higher than waterside operating pressure. 2.23. Unless otherwise specified, oil coolers and cooling water console coolers shall be water cooled shell and tube with removable bundle. The design of such coolers as per TEMA ‘C’ is acceptable. Cooling water shall be on tube side. 2.24. Unless otherwise specified, coolers (inter cooler and after cooler) shall be water cooled shell and tube with water on tube side type with removable tube bundle. Design pressure of the low pressure side shall be two third of the design pressure of high pressure side as a minimum. 2.25. Unless otherwise specified the inter and after coolers shall be designed with following considerations: − The fouling resistance of 0.0004 hr m2-OC / kcal shall be considered for water side. − Tubes shall be preferably more than 20 mm (3/4”) or 25 mm (1”) outside diameter (OD). The minimum allowable tube wall thickness is 2.5 mm in case of carbon steel tube. Coolant velocity in tubes shall be at least 1.0 m/sec. 2.26. Unless otherwise specified, for centrifugal compressors and steam turbines the following shall be provided. − Portable lube oil drain pump. − Portable lube oil purifier for online purification with fine filter (1 micron) in return line / oil purification system. − Fuel storage / transfer pump (as applicable) 2.27. Electrical motor drivers as per (IEC / IS) shall be rated for continuous duty (duty type SI) whereas motor as per American standards shall be designed to operate at a service factor of 1.0. 2.28. The rated BKW considered as the basis for sizing of the drivers shall include the positive tolerance as permitted in the applicable code or as specified i.e. the margin of 10%, 15%, 25% etc. as applicable for driver sizing shall be kept over and above the (rated BKW + tolerance). 2.29. In case of bladder type pulsation suppression devices for reciprocating pumps / accumulators for oil systems, gas charging assembly kit shall be supplied one for each service. 2.30. All rotating equipment base plates shall have jacking provision for leveling and screws for alignment. Only stainless steel shims shall be used for equipment alignment. Number of shims shall be minimum having thickness less than 1mm, rest SS packer plates shall be used to minimize number of shims. 2.31. In case of compressors, non-skid decking covering all walk and work areas shall be provided on top of the base plates. 2.32. Thermal relief valves shall be provided for components that they may be blocked in by isolation valves (including any cooling water return circuit piping of a cooler or jacket). 2.33. In case of centrifugal compressors and steam turbines (special purpose), the lube oil system shall comply with API-614. 2.34. Bearing housings for pumps and fans with oil lubricated bearings shall be provided with bearing guard type shaft seals to prevent oil leakage or contamination. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 7 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 2.35. After completion of shop performance test, mechanical seals of pumps shall be removed and shall be reassembled at pump vendor’s works with recommended secondary packing. 2.36. The installed mechanical components like gland plates, sleeve, etc. shall be of seal vendor’s make only. In case pump manufacturer provides the same, the drawing shall be vetted by seal vendor. 2.37. Small Air-cooled heat exchangers shall be preferred than water-cooled heat exchangers. 2.38. All special tools and tackles including hydraulic equipment required for maintenance purpose for the rotary equipment should be provided along with main equipment. 2.39. All rotating equipment shall be packed for an storage period of 12 months. Preservation of rotating equipment shall be as per OISD standards. 2.40. INITIAL FILL: The initial fill of lubricants, sealing fluid and other consumables shall be supplied by equipment supplier. 2.41. INTERFACE: Equipment nozzles at Purchaser’s interface shall be as per piping specifications and sizes. In case non-standard sizes are unavoidable, companion flanges along with gaskets and fasteners shall be procured from the equipment vendor. 2.42. ERECTION OF EQUIPMENT: 2.42.1. Erection of all rotating equipment except shall be carried out by mechanical contractor under supervision of equipment vendor. 2.42.2. Suction and discharge piping of rotating equipment shall be free from any stress. The execution contractor shall measure the alignment of piping before and after tightening the flanges. 2.43. INSTALLATION CRITERIA: 2.43.1. Pumps All pumps shall be suitable for outdoor installation. No equipment shelter is envisaged. 2.43.2. Compressors All compressors shall be located under roof with side walls partially open and shall be suitable for outdoor installation. 2.43.3. Centrifugal compressors driven by steam turbine/electric motor All centrifugal compressors driven by steam turbine/ electric motor shall be installed on tabletop foundation and with antiskid mezzanine floor with adequate working platform all around and drop out facility for maintenance. Other associated auxiliaries such as lube oil system, surface condenser, condensate water pumps etc. shall be located on ground floor (i.e. on finished floor level). 2.43.4. Integrally geared packaged centrifugal compressors All integrally geared packaged centrifugal compressors shall be installed on ground floor (i.e. on finished floor level). 2.43.5. Reciprocating multi-stage / multi-cylinder compressors Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 8 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 Reciprocating compressors shall be so located that no trenches are required for volume/pulsation bottles. Large reciprocating multi-stage piping/auxiliary equipment can be installed on Mezzanine floor with its interstate piping/auxiliary equipment located on the ground floor. Skid mounted reciprocating compressors shall be located on finished floor level. 2.44. SPARES AND SPECIAL TOOLS 2.44.1. Commissioning spare Commissioning spare parts shall be procured along with the main equipment as per equipment manufacturer’s recommendations. The list of such recommended spares shall be obtained along with the offer. 2.44.2. Special tools/tackles Special tools/tackles shall be procured along with the main equipment as per equipment manufacturer’s recommendations. The list of such recommended special tools/tackles shall be obtained along with the offer. 2.44.3. Mandatory spares Only mandatory spares shall be procured along with the main equipment. Such spares shall be specified in the enquiry document and shall include only those spares, which are critical for equipment and require longer delivery periods, such as, spare rotors for compressors, multistage pumps and spare gas generator for gas turbines etc. 2.44.4. Spare parts for two years normal operation Recommended spare parts for two years normal operation along with unit prices shall be obtained from equipment manufacturer for client to order the same separately. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 9 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 SECTION-3: DESIGN CRITERIA / REQUIREMENTS – SPECIFIC APPLICATIONS 3.1. CENTRIFUGAL COMPRESSORS (PROCESS GAS SERVICES) 3.1.1. Equipment qualification criteria 3.1.1.1. The vendor for the complete unit shall be an established manufacturer of Centrifugal Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same. 3.1.1.2. The vendor shall have engineered, packaged, tested and supplied at least two identical or validly similar packages in terms of type of compressor, driver, sealing system, inlet volumetric capacity (Am3/hr) and driver rating (kW) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major O&M problem as on the date of issue of invitation to bid. 3.1.1.3. The vendor besides satisfying the requirements of Cl. no. 3.1.1.1 and 3.1.1.2 above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package including control system. 3.1.1.4. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical in frame size and identical or validly similar in terms of power rating, inlet and discharge pressures, inlet temperatures, actual inlet flow, process gas, induction/ extraction side streams, speed, number and materials, bearing span, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have been operating satisfactorily in the field for at least 8000 hours without any major problems as on the date of issue of invitation to bid. 3.1.2. The compressor shall be designed to deliver the rated head and rated capacity without negative tolerance and the BKW at the above condition shall be guaranteed with zero positive tolerance. 3.1.3. Riveted impellers are not acceptable. 3.1.4. Dry gas seal for process gas centrifugal compressors shall be of dual unpressurised tandem type with an intermediate labyrinth as per API 617. Dry gas seal shall be Bi- directional. 3.1.5. Mechanical contact type seals shall incorporate a suitable design feature to prevent process gas leakage when the compressor is pressurized and not running and the seal oil system is shut down. 3.1.6. Centrifugal compressors shall be provided with tilting pad type radial and thrust bearings. Thrust bearing shall be of multi segmented, self-equalising double acting type of proven make. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 10 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.1.7. The compressor vendor shall perform a composite torsion vibration analysis of the compressor-driver unit and shall be responsible for the satisfactory mechanical performance of the complete train. All necessary co-ordination required for the purpose shall be the responsibility of compressor supplier so that no resonances should occur during range of operation. 3.1.8. Unless otherwise specified in code, Gear units for the compressors having rated BKW up to 750 kW shall comply with API Standard 677 and for rated BKW above 750 kW, gear units shall comply with API Standard 613. 3.1.9. Minimum instrumentation and process controls shall be as specified in the data sheets/ job specification/ P & IDs/ engineering design basis and other documents referenced in the FEED Document and shall be supplied by the vendor. The vendor shall specify and provide any additional instrumentation and controls as deemed necessary for the smooth and safe operation of the unit under all specified operating conditions. The vendor shall review owner’s overall compressor control system for compatibility with the vendor furnished controls/ instrumentation with local and DCS operation as required. 3.1.10. The design, engineering, supply, installation, testing, commissioning of complete anti- surge control system shall be in vendor’s scope. The anti-surge control system furnished shall include all instruments viz. (flow, diff. pressure, suction pressure, discharge pressure, speed) transmitters, indicators, control valves, anti-surge controller and with all accessories as required for completion of anti surge loop. Transmitters shall be smart type. 3.1.11. Vendor shall provide strainer with spool pieces for each stage inlet. Each strainer shall be installed in the suction side of the compressor between block valve and compressor suction flange. 3.1.12. Straight piping of minimum 5D shall be provided at compressor inlet unless longer length is advised by compressor manufacturer or dictated by the measuring instruments or as required to meet requirements of performance test procedure. 3.1.13. The compressors along with their drivers shall be mounted on a common skid. In case splitting of base plate becomes essential due to transportation problems, the splitting of the base plate shall be so designed as to make a common base plate in the field by doweling and bolting. 3.1.14. Inspection And Testing 3.1.14.1. Material certificate for chemical and physical properties for the following components shall be provided. Casing, impeller, shaft, shaft sleeve, lube oil skid, anti-surge control valve 3.1.14.2. 100% Radiography shall be done in case of connections welded to pressure castings. In addition cast compressor casings shall be radio graphed in critical areas. (Critical areas are section having abrupt changes in thickness, neck areas). 3.1.14.3. Ultrasonic testing of shaft liquid penetrant and magnaflux test of Impellers shall be performed. 3.1.14.4. Dynamic balancing of each rotor (job and spare). Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 11 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.1.14.5. The following test shall be witnessed by the third party inspection agency: − Hydrostatic test. − Helium Pressure test (for casing of compressors handling gas containing 30% mole or higher of H 2 ). − Dynamic balancing of assembled job/ spare rotor with coupling hub assembled. − Impeller over speed test. − Mechanical run test (for main and spare rotor) − During the test apart from other API requirements, the following data shall be recorded – Vibration data at rated speed, start and shut down data in form of orbit, polar, cascade plots. − Gas leak test (After post test inspection). − Post test inspection after mechanical run test. − Performance test as per PTC-10. − Sound level test (during mechanical run test) − String test (including all auxiliaries) − Dry gas seal test. − Rated load, pressure and rated speed test 3.2. RECIPROCATING COMPRESSORS (PROCESS GAS SERVICES) 3.2.1. Equipment Qualification Criteria 3.2.1.1. The vendor for the complete unit shall be an established manufacturer of Reciprocating Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing, testing facilities for the same. 3.2.1.2. The vendor shall have engineered, packaged, tested and supplied at least two identical or validly similar packages in terms of type of equipment and driver, inlet volumetric capacity (am3/hr) and driver rating (kW) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major problem as on the date of issue of invitation to bid. 3.2.1.3. The vendor besides satisfying the requirements of Cl. 3.2.1.1 and 3.2.1.2 above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package. 3.2.1.4. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical in frame size and identical or validly similar in terms of frame rating, rod loadings, rotational speed / piston linear speed, inlet temperatures, actual inlet flow, process gas, cylinder sizes and pressure ratings, number of throws/ cylinders, number of stages, mechanical design, materials, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and atleast one of these units shall have successfully operated in the filed for atleast 8000 hours without any major problems as on the date of issue of invitation to bid. 3.2.2. Skid mounted compressor units, may be located under shed on grade level. Other compressors shall be located under shed at an elevation of 3.5 m with working structural platform all around within the compressor shed. Lube oil and cooling Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 12 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 water consoles (as applicable) shall be located underneath the platform. Enough headroom shall be made available for access and maintenance of all the equipment under the platform. 3.2.3. Reciprocating compressors shall be horizontally balanced opposed type (with equal no. of throws on each side). 3.2.4. Rotational speeds of reciprocating compressors in Hydrogen Service shall be limited to a maximum of 350 rpm. 3.2.5. Unless otherwise specified, the average linear piston speed for lubricated cylinders and non-lubricated cylinders shall not exceed 4 m/sec and 3.5 m/sec respectively. For `Bone Dry’ Nitrogen Service, the piston speed shall be limited to 2.5 m/sec. 3.2.6. Compressor shall be designed for any excess capacity as specified in data sheets to meet future requirements. In such a case, compressor shall be so selected that it is suitable for continuous, uninterrupted and safe operation at normal loads, which would be part load due to over design. 3.2.7. Air cooled / uncooled cylinders are not acceptable. 3.2.8. Compressor suction / discharge valves shall be of plate or port-plug type. Feather type (flexible plate) valves shall not be used. The design of valves shall be suitable for all operating conditions including start up, shut down and regeneration services. The same valve shall be designed for all operating gases and their corresponding molecular weights. 3.2.9. The maximum predicted discharge temperature shall be limited to 135oC for hydrogen rich services (molecular weight less than 12) and 150oC for other services. 3.2.10. The actual rod loading due to inertial forces of reciprocating masses alone shall not exceed the maximum allowable continuous rod load, in addition to requirements of API. 3.2.11. The compressor driver shall be capable to start the compressor under unloaded condition with maximum suction pressure as specified in the data sheet. 3.2.12. Unless otherwise specified, reciprocating compressor shall be driven by motor with diaphragm type coupling. It shall be compressor supplier’s responsibility to co- ordinate with drive manufacturer to ensure reliable design, alignment and operation of train. The necessary co-ordination shall be done as required for torsion analysis of train, selection of motor, matching of coupling, rod run out monitoring system with required pulsation dampeners. 3.2.13. Pulsation dampeners shall not have separate flanges mounted with studs. The flanges shall be integral part of volume bottle. 3.2.14. Reciprocating compressors shall be skid mounted packages up to a motor rating of 160 kW. Gearbox driven equipment arrangement may be considered for reciprocating compressor including diaphragm compressors up to 160 kW. Belt drive arrangement is not acceptable. 3.2.15. When pulsation study as per Approach 3 of API 618 is specified, Compressor vendor shall get the Pulsation study carried out by an agency, which has sufficient experience in carrying out similar studies. The vendor shall furnish sufficient data / reference in his bid to prove the capability of the proposed agency. The Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 13 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 compressor vendor shall be responsible for all co-ordination with the agency carrying out the study. In case of any malfunctioning in the compressor installation, which is caused by any errors in the acoustical and mechanical evaluation, the compressor vendor shall carry out a field survey to identify the cause of the problem and rectify the same. The complete recommendations of the acoustic and mechanical system response study for the compressor and the associated equipment and piping shall be implemented by the contractor prior to the mechanical completion. The drawings shall be suitably revised to incorporate the study recommendations on piping routing and supports. 3.2.16. Suction strainers along with piping spool pieces will be installed in compressor suction lines of each stage and shall be supplied by the vendor. These strainers will be positioned as close as possible to the cylinder inlets but in no event shall they be located downstream of the inlet pulsation suppression equipment. The design of piping system pulsation suppression equipment, suction strainer shall afford easy removal / reinsertion of these strainers without necessity of pipe springing. 3.2.17. Intercoolers and after-coolers shall be designed as per TEMA ‘R’ standard with integral or separate condensate separation and collection facilities, and shall include the following. 3.2.17.1. A drain system on the knock out vessel shall be with an automatic level control, isolating valves and a manual bypass around the control valve and emergency shut off valve acting when level in knockout vessel is low. 3.2.17.2. An armoured gauge glass (with isolating valves and blow down valve) on the collection pot. 3.2.17.3. Condensate pot shall be sized to provide minimum holding capacity for two hours and a 5 minute time span between high level alarm and trip based on expected maximum liquid condensation rate. 3.2.17.4. Separate connections and level transmitters for high level alarm and trip on the collection pot. 3.2.17.5. All internal parts of instruments, valves, strainer, etc. coming in contact with condensate shall be of stainless steel. 3.2.18. Pulsation suppresser connections shall be flanged. 3.2.19. Crankcase explosion relief device shall be furnished for all compressors, in process gas service. 3.2.20. Where automatic start feature of auxiliary oil pump is provided in case of failure of main oil pump an audio visual alarm shall be actuated simultaneously. 3.2.21. The compressor emergency shutdown instrumentation shall be provided electronic and with “first out” feature that will allow determination of the first alarm to trip in event that multiple alarms are activated. This feature shall include all trip initiators, including process trip inputs. Trip inputs shall be communicated to process control instrumentation for data logging. 3.2.22. Emergency transmitters shall have a cover to prevent accidental trips. 3.2.23. Drivers shall have rating as a minimum 110% of then maximum brake power (including transmission losses and + 3% tolerance) required under any of the specified compressor operating conditions or 5% higher than the power Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 14 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 required at the relief valve set pressure condition (including transmission losses) whichever is higher. 3.2.24. Inspection And Testing 3.2.24.1. Material certificate for Chemical and Physical properties of the following components shall be provided. 3.2.24.2. Cylinder and liner, Piston, Piston rod, Crank shaft, Connecting rod, Cross head, Crankcase, Valves, Heat exchangers, Pressure vessels, Bolts (Connecting rod and Main Bearing). 3.2.24.3. Ultrasonic testing of the following – Crank shaft, Piston rod, Pressure vessels. 3.2.24.3.1. Magnaflux testing / D. P. Testing of the following – Cross head, Connecting rod, Piston rod, Pressure vessels. 3.2.24.3.2. 100% X-ray examination for all the welded joints for Pipes, Vessels and Heat exchangers handling process gas. 3.2.24.3.3. Surface roughness and hardness check for the following: 3.2.24.3.4. Cylinder bore / Linear bore, Piston rod in packing area. Crank shaft journal and Crank pin. 3.2.24.4. The following tests shall be witnessed by the third party inspection agency : − Hydrostatic test (for all pressure containing parts and auxiliaries). − Leak proof test of crankcase and distance piece (24 hrs. with kerosene). − Checking of cylinder clearance and rod run out. − Mechanical run test (for 4 hours) with job auxiliaries. − Performance test as per PTC 9. − Stripping check and internal inspection: Main bearing drive end side, connecting rod bid end bearing (atleast 1 no.) piston assembly (1 no.) cylinder bore effective surface (all cylinder). − Static balancing of fly wheel. − Vibration level check (for record during mechanical run test). − Lube oil console, cylinder cooling circuit console run test at sub vendor works (as applicable). − Functional test of control panel (by simulation at sub vendor works). 3.3. PACKAGED INTEGRALLY GEARED CENTRIFUGAL AIR COMPRESSOR 3.3.1. Equipment Qualification Criteria 3.3.1.1. The vendor for the complete unit shall be an established manufacturer of Reciprocating Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same. 3.3.1.2. The vendor shall have engineered, manufactured, packaged, tested and supplied at least two identical or validly similar packages in terms of equipment and driver, inlet volumetric capacity (am3/hr) and driver rating (kW) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid. 3.3.1.3. The vendor besides satisfying the requirements of Cl. 3.3.1.1 and 3.3.1.2 above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 15 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.3.1.4. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. 3.3.1.5. Compressors shall be identical in frame size and identical or validly similar in terms of frame rating, rod loadings, rotational speed/ piston linear speed, inlet and discharge pressures, inlet temperatures, actual inlet flow, cylinder sizes and pressure ratings, number of throws/ cylinders, cylinder arrangement, number of stages, mechanical design, materials, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully operated in the field for at least 8000 hours without any major problems as on the date of issue of invitation to bid. 3.3.2. All metal parts of filters such as housing, filter elements, inlet silencer, supporting and fixing system of filter elements inside the housing including supports, stays, nuts, bolts etc., shall be type of 304 or 316 stainless steel. Complete piping from filter element to compressor inlet including any expansion joint shall be of type 304 or 316 stainless steel. 3.3.3. The orientation and location of intake shall be such as to minimize dust, heat ingress and free air flow shall be possible without any obstructions. The filter shall be located outside the compressor house at an elevation of approximately 6 m from grade minimum and shall take care of personnel protection. The filter construction shall have suitable provision for preventing water ingress into the filter due to rains and a bird screen. The filter shall have primary filter and secondary filter elements. 3.3.4. All interstate air piping up to suction of final stage casing inlet shall be of ASTM A312 type of 304 or 316 stainless steel. 3.3.5. Inspection and Testing 3.3.5.1. Material certificate for chemical and physical properties for the following components shall be provided: Casing, impeller, shaft, shaft sleeve, lube oil skid, anti-surge control valve. 3.3.5.2. The following tests shall be witnessed by the third party inspection agency: − Hydrostatic test (pressure containing parts and auxiliaries) − Combined mechanical and performance test (for main and spare rotor as applicable). − Impeller over speed test. − Check bearings and seals after test. − Functional tests of job lube oil system and job control panel at sub-vendor works. − Noise level test. − Typical test certificate of torsion vibration analysis of compressor, gear box and drive motor as total system to safeguard any resonances during range of operation. − Guide vane calibration check. − Gear contact pattern check before and after mechanical run test by blue matching. 3.3.6. The compression ratios shall be so adjusted that the adiabatic discharge temperature shall not exceed 170 °C and the actual discharge temperatures for any Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 16 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 specified operating condition, including part load conditions, shall not exceed 160 °C. 3.3.7. Drivers shall have rating as a minimum 110% of then maximum brake power (including transmission losses and + 3% tolerance) required under any of the specified compressor operating conditions or 5% higher than the power required at the relief valve set pressure condition (including transmission losses) whichever is higher. 3.3.8. Gear units, when used, shall be designed in accordance with AGMA 420 or an equivalent standard and shall have an AGMA service factor of not less than 2, based on the driver nameplate rating when the driver is electric motor. For other drives it shall be as recommended by the gear box manufacturer. 3.3.9. Provision shall be made for unloading the compressor at the time of start. The driver starting system shall be interlocked with the control circuit to protect against loaded start. On power supply cut-off or failure, the compressor shall be unloaded automatically. 3.3.10. Volume bottles shall be provided at the inlet and the outlet of each cylinder to limit the residual peak and peak pulsations to 2% at the line side nozzle of the volume bottle. In case pulsation study is conducted, the requirement of API 618 shall be applicable. These volume bottles shall be designed and fabricated in accordance with ASME Sec. VIII Div. I. Volume bottles shall not be used as cylinder supports. 3.3.11. Compressor crankshaft bearing system shall be suitable to take into account additional loads imposed due to motor rotor. It shall be compressor supplier’s responsibility to co-ordinate with drive manufacturer to ensure proper design, alignment and operation of train. The necessary co-ordination shall be done as required for torsion analysis of train, selection of motor, matching of coupling, etc. 3.3.12. Inspection And Testing As per Reciprocating Compressors (Except Helium pressure test which is not applicable). 3.3.13. All interstate air piping up to suction of final stage casing inlet shall be of ASTM A312 type of 304 or 316 stainless steel. 3.4. RECIPROCATING COMPRESSOR (UTILITY AND INSTRUMENT AIR) 3.4.1. Equipment Qualification Criteria 3.4.1.1. The vendor for the complete unit shall be an established manufacturer of Reciprocating Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same. 3.4.1.2. The vendor shall have engineered, manufactured, packaged, tested and supplied at least two identical or validly similar packages in terms of equipment and driver, inlet volumetric capacity (am3/hr) and driver rating (kW) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid. 3.4.1.3. The vendor besides satisfying the requirements of Cl. 3.4.1.1 and 3.4.1.2 above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 17 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.4.1.4. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. 3.4.1.5. All compressors shall be designed for unsheltered outdoor location. 3.4.1.6. Compressors shall be identical in frame size and identical or validly similar in terms of frame rating, rod loadings, rotational speed/ piston linear speed, inlet and discharge pressures, inlet temperatures, actual inlet flow, cylinder sizes and pressure ratings, number of throws/ cylinders, cylinder arrangement, number of stages, mechanical design, materials, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully operated in the field for at least 8000 hours without any major problems as on the date of issue of invitation to bid. 3.4.2. Compressors, drivers, auxiliary equipment, piping and other appurtenances shall be designed and constructed for continuous full load duty at the specified operating conditions for atleast 2 years and shall be accessible for rapid and easy maintenance, particularly with regard to cylinder packing and valves. The unit shall also be suitable for start up/part load conditions, maximum differential pressure conditions, operation at relief valve set pressure. Compressors shall be horizontal balance opposed type. Reciprocating compressors shall be used provided up to 60 kW motor rating max. Above 60 kW motor rating, compressors shall be screw type or centrifugal type. 3.4.3. Unless otherwise specified, the average linear piston speed for lubricated cylinders and non-lubricated cylinders shall not exceed 4 m/ sec and 3.5 m/sec respectively. 3.4.4. The compression ratios shall be so adjusted that the adiabatic discharge temperature shall not exceed 170 °C and the actual discharge temperatures for any specified operating condition, including part load conditions, shall not exceed 160 °C. 3.4.5. Drivers shall have rating as a minimum 110% of then maximum brake power(including transmission losses and + 3% tolerance) required under any of the specified compressor operating conditions or 5% higher than the power required at the relief valve set pressure condition (including transmission losses) whichever is higher. 3.4.6. Gear units, when used, shall be designed in accordance with AGMA 420 or an equivalent standard and shall have an AGMA service factor of not less than 2, based on the driver nameplate rating when the driver is electric motor. For other drives it shall be as recommended by the gear box manufacturer. 3.4.7. Provision shall be made for unloading the compressor at the time of start. The driver starting system shall be interlocked with the control circuit to protect against loaded start. On power supply cut-off or failure, the compressor shall be unloaded automatically. 3.4.8. Volume bottles shall be provided at the inlet and the outlet of each cylinder to limit the residual peak and peak pulsations to 2% at the line side nozzle of the volume bottle. In case pulsation study is conducted, the requirement of API 618 shall be applicable. These volume bottles shall be designed and fabricated in accordance with ASME Sec. VIII Div. I. Volume bottles shall not be used as cylinder supports. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 18 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.4.9. Compressor crankshaft bearing system shall be suitable to take into account additional loads imposed due to motor rotor. It shall be compressor supplier’s responsibility to co-ordinate with drive manufacturer to ensure proper design, alignment and operation of train. The necessary co-ordination shall be done as required for torsion analysis of train, selection of motor, matching of coupling, etc. 3.4.10. Inspection And Testing As per Reciprocating Compressors (Except Helium pressure test which is not applicable). 3.5. GENERAL PURPOSE STEAM TURBINES 3.5.1. Equipment Qualification Criteria 3.5.1.1. The Steam Turbines offered shall be from a regular and established manufacturer of general purpose Steam turbines having requisite design, engineering, manufacturing and testing facilities. 3.5.1.2. The Steam turbine model offered shall be from regular manufacturing range of the manufacturer. 3.5.1.3. Steam turbines shall be identical in frame size (Model number) and validly similar in power rating, rated speed, steam flow, steam inlet conditions, steam exhaust conditions, rotor dynamics, bearing span, mechanical design and materials as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully operated in the field for minimum 8000 hours without any major problem as on the date of issue of invitation to bid. 3.5.2. Turbine shall be preferably of multi-stage design. Single stage overhung design shall not be provided. 3.5.3. In case pressurized lube oil system is required the same shall be vendor’s proven system. Vendor shall provide proof for the same. 3.5.4. A sentinel valve shall be supplied on the turbine casing. 3.5.5. A relief valve shall be provided on the turbine exhaust side. 3.5.6. For turbine end shaft sealing, mechanical seal shall be provided. 3.5.7. Inspection and Testing 3.5.7.1. NDTs shall be carried out as per vendor’s standard quality plan. 3.5.7.2. Following test shall be witnessed by third party inspection agency : − Hydrostatic Test (All pressure parts and auxiliaries). − Mechanical run test. 3.6. CENTRIFUGAL PUMPS 3.6.1. Equipment Qualification Criteria 3.6.1.1. The vendor shall be an established centrifugal pump manufacturer having adequate engineering, manufacturing and testing facilities for pumps conforming to API 610, 10 th Edition Standard. 3.6.1.2. The pump model offered shall be from the existing regular manufacturing range of the vendor. The mechanical as well as the hydraulic performance (including NPSHR) for the complete range of operation of the offered model Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 19 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 shall have been established in the shop test. The offered pump model shall meet the following minimum service and manufacturing experience requirements: Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance (including NPSHR), Inlet low, Differential Head, Operating Pressure & Temperature, Pumping Liquid, Speed, Number & Type of Impellers, Mechanical Design, Materials, Bearing span (applicable for between bearing pumps), Column Length (applicable for vertically suspended pumps) etc. as compared to at least TWO UNITS of the proposed model designed, manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major problem as on the date of issue of inquiry. 3.6.1.3. The vendor should have engineered, packaged, tested (performance test, string test etc.) and supplied at least TWO identical or validly similar pumping units in terms of construction (axially or radially split), size of pumps (flow, head and power), lubrication system, sealing system and type of drive from the proposed shop in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major problem as on the date of issue of inquiry. 3.6.2. Two stage pumps shall be of between bearing types. 3.6.3. Inducers shall not be used except for Sundyne or equivalent type of pumps. 3.6.4. Pumps for high head, low flow duties (falling outside the range of two stage pumps without continuous bypass) shall be Sundyne or equivalent type. 3.6.5. Pumps where difference between NPSHA and NPSHR is less than 0.6 meter are not acceptable. The said NPSHR value shall correspond to the maximum value of NPSHR from rated flow down to the recommended minimum continuous stable flow specified by the vendor. In case higher margin is required, data sheet will govern. In case of pump operating at the end of curve, positive NPSH margin shall be available at the end of curve. 3.6.6. The maximum permissible running clearances shall not be less than twice the running clearances as specified in API610. 3.6.7. Impeller of multistage pumps shall also be positively locked against axial movement in the direction opposite to normal hydraulic thrust. 3.6.8. Mechanical Seal and relevant equipment and instruments for pumps shall conform to API —682,2 nd Edition Standard. Mechanical Seals shall be imported either in fully assembled condition OR the critical components shall be imported by Indian seal manufacturers from their respective principals and the seals shall be assembled and tested in the indigenous facilities of these seal manufacturers. Qualification test results of each seal shall be furnished during detail engineering for review. The type of mechanical seal shall be as defined in the datasheet/process package. 3.6.8.1. All Pumps shall be provided with cartridge type mechanical seals (Except, clean cold water service or for services such as vacuum residue bottoms where, due to catalyst fines in the product, gland packing have shown better results.) The type of mechanical seal (i.e., single or dual unpressurized / pressurized) shall be as defined in the bid package. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 20 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.6.8.2. Unless otherwise specified, mechanical seals shall conform to API Standard 682. 3.6.8.3. Seal Qualification tests (SQT) shall have been conducted on the proposed mechanical seal model(s). Related certificates shall be furnished during detailed engineering stage. 3.6.8.4. Mechanical seals (as per API Std. 682) shall be one of the following makes: Principals Indian Counterparts M/s John Crane John Crane Engineering Sealing System India Pvt. Ltd. M/s Flowserve Flowserve Sanmar Ltd. M/s Eagle Eagle / Burgmann M/s Burgmann Eagle / Burgmann 3.6.8.5. In case the offered mechanical seal is intended to be supplied by the Indian counterparts of the above manufacturers, following requirements shall be met: - For standard mechanical seals, for which SQT has been conducted by the principals, critical components such as Bellows, springs and Seal Faces shall be sourced from their principals. - For Engineered seals, the complete mechanical seal along with sleeve and gland plate shall be sourced from their principals. 3.6.8.6. Any seal offered under "Engineered Seal" category shall be subjected to following tests: "Four hour static test, four hour dynamic test and one hour cyclic test with test fluid selection as per. API 682 and test conditions shall be commensurate with the conditions expected during operation in normal as well as start-up/shut down conditions." Vendor shall develop test procedure and submit for review during detailed engineering. Related test certificates shall also be furnished as part of Inspection & Test record. 3.6.8.7. Tank mounted vertical pumps (process service) shall be provided with dry running vapour seals. In case of handling hazardous or toxic fluids this vapour seal shall be Nitrogen buffered. 3.6.9. Pumps for vacuum service or having operating temperature of 176°C and above shall be provided with stationary metal-bellows seals. 3.6.10. (a) Pumps handling non-congealing liquids at temperatures 200°C and above shall be provided with API seal flushing plan 23 or 32 where single mechanical seals are provided.(Plan 32 shall be as per sketch in annex. 1) (b) Cooler shall not be provided in seal flushing system where seal is flushed by congealing liquid. (c) For pumps provided with flushing Plan 21 and 23. Temperature Indicator shall be provided in the flushing line. (d) Seal Plans 52 (API-610) shall be as per sketch & specs. Enclosed in Annex - 2. (e) Column bottom and other hot congealing fluid pumps shall be provided with API Plan 32. (f) For congealing service, the stuffing box shall be jacketed with LP or MP steam to ensure fluid inside seal does not congeal. (g) In case of seal plan 53, plan 53B shall be supplied as per API 682 along with hand pump. (h) Plan 54 shall be as per sketch in annex. 3 Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 21 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.6.11. For all API cooling water piping plans a sight flow glass shall be provided in the outlet lines. 3.6.12. In case multi-stage pumps require forced feed lubrication system as per bid package requirements, the same shall meet following requirements: Bearing lubrication system as a minimum shall be as per API 610, with below - mentioned requirements. The system offered shall be proven for the offered pump model & suitable for the loads expected under any condition of operation. Following requirements for pressurized lubrication shall be met: a.) Each pump shall be provided with a separate tube oil system and shall be separate skid-mounted package, comprising of auxiliary lube-oil pump (motor driven), instruments and controls inclusive PCV. The skid shall be located adjacent to the main pump and driver skid. b.) L.O. reservoir and all lube oil piping, valves, fittings and flanges shall be of 316 stainless steel. Any tubing required shall be of 316 stainless steel with compression type fittings of like material. The minimum retention time for the reservoir sizing shall be 3 minutes based upon normal flow and total reservoir volume below the minimum operating level. Also the reservoir shall be sized to provide run down capacity of at least 10% more than the amount oil contained in all components, bearing housing and return oil piping of the L.O. system. c.) Lube oil system shall be designed to ensure supply of lube oil in the event of failure of lube oil supply system for the coast down time of equipment. Run down Tank has not been specified however in case the same is required for cost down requirements the same has to be provided. Vendor may propose alternate fail safe means to ensure supply during coast down period with necessary reference in vendor's quotation. d.) Auxiliary L.O. pump shall be in accordance with API 676 and duly filled in datasheets for these pumps shall be furnished for PMC's review and approval during detailed engineering. The main L.O. pump shall be shat driven. The pump capacity shall be based on maximum system usage plus a minimum margin of 10% & motor shall be rated to operate at lowest ambient viscosity at rated capacity. e.) Following witness test for each pump shall be carried out: - Lube Oil system cleanliness, Four hour run test, check control, changeover (filters) one & two pump operation at Lube oil system manufacturer's shop. f.) Except in case of shat driven pumps, if a positive displacement type of oil pump is supplied, a separate relief valve (not integral with the pump) shall be provided. The relief valve shall not be used for pressure regulation. If the type of pump is centrifugal then a non-return valve shall be provided at the discharge. Horizontal oil pumps shall not be installed on top of the oil reservoir. The oil side operating pressure shall be higher than the waterside operating pressure to prevent contamination of oil in case of cooler failure. Filters shall be equipped with continuous flow switch over valve and equalizing line. Oil system shall have drain rim or pan to catch oil spills. A thermal relief valve shall be provided on cooling water return line for oil coolers. 3.6.13. Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor equal to 1) not lower than API requirements , unless higher rating is dictated by Note 1 and/or Note 2: Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 22 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 Motor name plate rating up to 22 KW: To suit maximum BKW indicated on pump data sheet or 125% of rated pump BKW, whichever is higher. The electric motor shall be suitable for the electrical area classification specified elsewhere in data sheet. Note: 1. The motor nameplate rating for pumps under parallel operation or for pumps with auto start operation shall not be less than the max. BKW indicated on pump datasheet (maximum power at any point on pump performance curve from shutoff to end of the curve for the rated impeller) or shall have the specified margin as per this clause whichever is greater. The pump motors shall also be suitable for start- up under open discharge valve condition. 2. The motor nameplate rating for applications where the specific gravity of pumped fluid is less than 1.0 shall either be 100% of the BKW of pump at minimum continuous stable low with clean cold water of sp. gravity 1.0 or shall have the specified margin (as specified above) as per this clause, whichever is greater. 3.6.14. The balance line should be provided with instruments as a minimum (pressure gauge, Pressure transmitter, pressure safety valve, check valve) In case it is recommended to connect this balance line to suction vessel, quantity of flow being returned to suction vessel shall be indicated and shall be added to the rated flow of the pump. Correlation showing in the extent of wear to balance line flow shall also be provided. Balance line shall utilize flange joints, screwed connections are not allowed. 3.6.15. One set of special tools and tackles per item for up-to 3 nos. equipments per item and 2 sets of special tools and tackles per item for higher no of equipments per item shall be part of Vendor's scope. 3.6.16. In case of multistage pumps (Horizontal & Vertical) , if specified Vendor shall quote spare rotor as optional as per following: - For radially split pumps, one set of complete replaceable inner case element consisting of all rotating and hydraulic elements. And for Axially split pumps one set of complete rotor assembly dynamically balanced including balance drum. 3.6.17. For balancing axial thrust in multistage pumps, balance disk & combination of balance disc and balance drum shall not be used. 3.6.18. The coupling service factor shall not be less than 1.5 over the driver rating as a minimum. 3.6.19. Coupling guard shall be perforated and of non -sparking material .The guard shall be open at the bottom to permit manual shat rotation. The guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kg. The guard for pumps/motors should have proper and convenient arrangement for vibration readings. 3.6.20. INTERCHANGEABILITY: As far as possible pumps & mechanical seals and couplings shall be of identical make so that minimum levels of inventory can be maintained and maximum interchangeability/standardization can be achieved. 3.6.21. Whenever pump capacity control is through LIC or LIC/FIC cascade or has a fail closed control valve on pump discharge or process minimum capacity is less than pump MCF, necessary flow instruments in pump discharge along with pump bypass back to suction vessel with control valve for pump protection shall be Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 23 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 provided. However when continuous Bypass of pump MCF is envisaged bypass from pump discharge back to suction vessel with restriction orifice sized for pump MCF instead of control valve shall be provided. 3.6.22. Equipments along with the drivers and hydraulic power recovery turbine (if applicable) shall be procured from the respective driven equipment manufacturers as skid mounted units with all accessories, auxiliaries along with auxiliary piping. 3.6.23. Magnetic drain plug shall be provided for all centrifugal pumps bearing housings. 3.6.24. For seal flushing plans, piping material shall be of SS 316. For cooling water plans, piping material shall be A 106B. All piping connections shall be threaded I flanged. No ferrules / unions shall be provided in seal flushing lines. 3.6.25. All pumps shall be provided with plugged connection for oil mist lubrication for future use. All pumps shall be provided with bearing isolators. 3.6.26. Tolerances for guaranteed characteristics are, Rated head — Zero negative tolerance Shut of head — Zero negative tolerance. Positive tolerance permitted as long as SOH does not exceed 120% of rated head. NPSHR — Zero positive tolerance Rated BKW - Zero positive tolerance 3.6.27. For rated flow exceeding 1000m3/hr Between Bearing Pumps shall be offered. 3.6.28. Regions of double casings and horizontal multistage pumps (pump with 3 or more stages) that are subject to only suction pressure shall also be designed for MAWP. 3.6.29. Single casing ring suction pumps are not acceptable. 3.6.30. The pumps pressure casing shall be suitable to withstand twice the forces and moments in Table-4 applied simultaneously to the pump through each nozzle, plus internal pressure, without distortion that would impair upon. Vendor to note that above criteria shall be used for design of purchaser's associated system of pump and seal. 3.6.31. The vendor shall furnish the results of pipe load test data for proposed pump models along with their proposal indicating shat deflection at coupling end. In case of pipe load test has not been conducted in past, the vendor shall demonstrate the proposed pump models at their manufacturing shop within 4 months of placement of order. 3.6.32. Maximum numbers of stages allowed in multistage pumps are 10 (including both impellers, if two impellers are used for double suction pump.) 3.6.33. For Vertically suspended pumps, Bowls and columns shall be flanged and bolted. Multi piece vertical pump line shaft shall not be joined by threaded couplings. Pump thrust shall not be transferred to driver motor. Vertical pumps shall be provided with their own thrust bearing to carry rotor weight and pump generated axial forces. Thrust bearing shall be positively locked on the pump shat (shouldered shat) and the bearing housing. For self lubricated pumps, guide bushings shall be suitable for dry running during start up. For vertical pumps, not provided with non reverse rachet, vendor shall describe the precaution taken, to prevent damage due to Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 24 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 reverse rotation. Line shaft shall be furnished with hardened sleeves under the bearing. For vertical canned pumps, suction shall be supplied with a drain piped to surface. 3.6.34. Inspection and Testing (For Each Pump) 3.6.34.1. Material Certificates for the following are required: - Casing, Impeller & shat. 3.6.34.2. The material inspection requirement for pressure containing parts shall be as per the following inspection category: Category A: This category is applicable for carbon steel and cast iron for services with process design pressure up to 40 kg/cm²g and design temperature from 0 to 150°C. Inspection requirement: As per vendor's standard Quality Assurance Plan. Category B: This category is applicable for services within the design pressure and temperature range other than covered under category A above and category C below. Inspection requirement includes visual inspection and magnetic particle or liquid penetrate inspection of following components as a minimum: - Nozzle weld - Butt welds on pressure containing components - Fillet welds on pressure containing components. - Shaft Liquid penetrate inspection shall be performed only when specified magnetic particle inspection is not feasible. Category C: This category is applicable for services with process design pressure above 70 kg/cm²g or process design temperature below -29°C and above 300°C. Inspection includes all the requirements of Category B together with radiographic or ultrasonic inspection of - Nozzle weld - Butt welds on pressure containing components. Ultrasonic inspection shall be carried out when radiography is not feasible. 3.6.34.3. Inspection shall also include dimensional check of pump, driver and auxiliaries (if any) duly mounted on the base plate, in accordance with certified general assembly drawing. This will include all main pump dimensions, base plate dimensions, location of foundation bolt holes, size/position/rating of flanges, coupling guard arrangement, verification of the required material certificates and their traceability to the respective components. In addition, following checks shall also be carried out: - A measurement of the actual running clearances throughout the pump. - A check of the hardness of wear rings. - A check for good workmanship and finish throughout. 3.6.34.4. The following tests shall be witnessed by owner's inspecting agency for each pump: - Hydrostatic (For all pressure containing parts including auxiliaries) - Performance with string test (with 4 hour run test) Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 25 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 - NPSH (In case difference between NPSHA and NPSHR is less than or equal To 1.0m or when specified in the data sheet) - Dismantling inspection and reassembly are the running test, which shall include examination of mechanical seals, close clearance parts and measurement of running clearances. In case of multistage pumps having hydrodynamic bearings, the bearing shall be removed inspected and reassembled. Sound level test (During Performance Test). Dimensional check. Check for direction of rotation of pump & drivers. Unitization check in case of single / two stage pumps and complete unit test in multistage pumps. 3.7. CENTRIFUGAL PUMPS (WATER SERVICE) 3.7.1. Equipment Qualification Criteria 3.7.1.1. The pump vendor shall be an established centrifugal pump manufacturer having adequate engineering, manufacturing and testing facilities for Centrifugal Pumps (Water Service). 3.7.1.2. The pump model offered shall be from the existing regular manufacturing range of the pump manufacturer. The mechanical as well as the hydraulic performance (including NPSHR) for the complete range of operation of the offered model shall have been established in the shop test. The offered pump model shall meet the following minimum service and manufacturing experience requirements. Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance (including NPSHR), Inlet flow, Differential Head, Speed, Number & Type of Impellers, Mechanical Design, Materials, Bearing span (applicable for between bearing pumps), Column Length (applicable for vertically suspended pumps) etc., as compared to at least TWO UNITS of the proposed model manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major overhaul as on the date of issue of invitation to bid. 3.7.1.3. In case the exact past references for identical hydraulic performance, speed etc. are not available, the same can be established on the basis of past supplied identical or validly similar hydraulic design by use of similarity laws. 3.7.2. Pumps with constant speed drivers shall be capable of atleast 5 percent head increase at rated condition and pump rated speed by replacing with a new impeller or impellers. Offered impeller shall in no case be less than the minimum diameter impeller. 3.7.3. Horizontal pumps of the close-coupled, the two stage overhung, or the single stage double suction overhung, type shall not be furnished. 3.7.4. Pumps where difference between NPSHA and NPSHR is 0.6 meter or less are not acceptable. In case of pumps operating at end of curve, minimum 0.6m NPSHR margin shall be available for the region from minimum continuous stable flow to flow at end of performance curve. 3.7.5. Pumps that have stable head/capacity curves (continuous head rise to shut -off) are preferred for all applications and are required when parallel operation is specified. When parallel operation is specified, the head rise shall be at least 10 percent of the head at rated capacity. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 26 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.7.6. Vertical pumps & motors that could be damaged due to reverse rotation shall be provided with non-reverse ratchet or suitable device to prevent reverse rotation. 3.7.7. Impellers shall be cast as one piece. 3.7.8. Shaft shall be provided with sleeves under the seal. Sleeves shall be locked to the shaft. The material of sleeve shall be 12 percent chrome steel (hardened). Where the size of pump makes the use of shat sleeve impracticable, the shat shall be constructed of 12 percent chrome steel (hardened). For vertical pumps, shat material shall be 12 percent chrome steel. Manufacturer standard seals shall be provided for all water pumps except large capacity cooling water pumps. 3.7.9. The following vibration limits shall be applied at rated speed and at low of 10 percent of rated flow. 3.7.9.1. Horizontal pumps Unfiltered vibration velocity for horizontal pumps up to 3000 rpm with antifriction bearing or sleeve bearings when measured at the bearing housing in horizontal or vertical direction shall not exceed 4 mm/sec RMS. 3.7.9.2. Vertical Pumps Unfiltered vibration velocity for vertical pumps with antifriction and or sleeve bearings when measured at the top bearing housing of pump or top bearing housing of motor or mounting flange for measuring points up to 3 meters above the mounting base shall not exceed the following limit: Pumps greater than 1500 rpm (Peak to Peak) = 7 mm/sec RMS Pumps up to & including 1500 rpm (Peak to Peak) = 4 mm/sec RMS 3.7.10. Pumps for Fire Water Application shall also meet the following additional requirements: - Pumps shall be direct-coupled except in the case of engine -driven vertical turbine pumps wherein gear drives shall be used. - Pumps shall be capable of furnishing not less than 150 percent of rated capacity at a head not less than 65 percent of the rated head. Shut off head shall not exceed 120 percent of rated head in horizontal pumps and 140 percent in the case of vertical turbine pumps. - Difference between NPSHA and NPSHR at 150 percent of the duty point shall not be less than 0.5 meters. - For Diesel engine drivers, the net continuous site power available after considering the duration due to site condition and power losses, due to other parasitic loads and engine driven auxiliaries shall be higher of the following two values: (a) 20 percent in excess of the maximum BKW (including +4% tolerance) required to drive the pump at rated condition. (b) Maximum BKW rated impeller as indicated by the manufacturer in the pump data sheets. 3.7.11. Electrical motor drivers as per (IEC/IS) shall be rated for continuous duty (Duty type S1) whereas motor as per American Standards shall be designed to operate at a service factor of 1.0.Rating shall not be less than the following unless higher rating is dictated by the Note1. Motor Name plate Rating Motor MCR (% of Pump Rated BKW inclusive of +4% tolerances) Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 27 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 Less than 22 kW: To suit maximum BKW indicated on pump data sheet or 125% of_ rated pump BKW, whichever is higher 22 kW - 55 kW: 115% of rated pump BKW. Higher than 55 kW: 110% of rated pump BKW. Note: 1. The motor nameplate rating for pumps under parallel operation shall not be less than the max. BKW indicated on pump data sheet (the power at End of the curve for the rated impeller) or shall have the specified margin as per this clause whichever is greater. The pump motors shall also be suitable for start -up under open discharge valve condition. 3.7.11.1. INSPECTION AND TESTING Refer Centrifugal Pumps (Other than water service). 3.8. FANS (CENTRIFUGAL / F.D. / I.D. FANS - GENERAL REQUIREMENTS) 3.8.1. Equipment Qualification Criteria 3.8.1.1. The Vendor shall be an established centrifugal fan manufacturer having adequate engineering, manufacturing and testing facilities for the same. 3.8.1.2. The fan model offered shall be from the existing regular manufacturing range of the fan manufacturer. Centrifugal fan proposed shall be identical or validly similar in terms of impeller diameter, power rating, flow rates, differential pressure, operating pressure and temperature, gas handled, speed, mechanical design, bearing span, materials etc., as compared to at least 2 units designed, manufactured, tested and supplied from the proposed manufacturing plant at least 1 of these units shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid. 3.8.2. Fans, drivers and auxiliary equipment shall be designed and constructed for a service life of 20 years and at least two years of uninterrupted continuous full load operation at the specified operating conditions. 3.8.3. Fan and its auxiliaries shall be suitable for unsheltered outdoor installation. 3.8.4. The head capacity characteristic of the fan shall rise continuously from the maximum capacity to surge. The fan shall, without the use of a bypass, be suitable for stable operation at all capacities higher than the surge capacity shown. All characteristic curves shall be corrected for specified process gas and shall refer to the capacity at the normal intake conditions specified on the data sheets. 3.8.5. Unless otherwise specified, centrifugal fans shall be mechanically designed for a temperature at least 15 °C beyond the extreme temperature anticipated for the specified operating conditions. 3.8.6. A drain connection with block valve and blind flange shall be provided at the lowest point of the casing and inlet boxes. 3.8.7. Centrifugal fan blades shall be backward curved design. 3.8.8. The casing construction shall have provision (man ways / removable panels) to allow inspection and cleaning of impeller and casing internals. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 28 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.8.9. Impeller shall be of cast or fabricated and welded construction. Cast impellers, if offered, shall be of one piece construction, machined all over except on the internal fluid passages. 3.8.10. Impellers shall be positively locked to the shaft. 3.8.11. Unless otherwise specified, shaft seals shall be of the gland packing or labyrinth type. 3.8.12. Shaft seals shall be such as to permit removal for inspection and replacement without disturbing the shaft or bearings. 3.8.13. The complete rotor along with coupling half shall be dynamically balanced to grade 2.5 as per ISO 1940 prior to assembly. 3.8.14. The first lateral critical speed of the rotor shall be greater than 120% of the rated speed of the machine. 3.8.15. Antifriction bearings, if provided, shall be selected for a minimum L-10 life of 25,000 hours. 3.8.16. Journal type bearings when used shall have replaceable liners or shells, and shall be horizontally split. 3.8.17. Allowable vibration limits are as follows as per ISO 1940. Up to 1000 rpm – 60 microns peak to peak. 1000-1500 rpm – 40 microns peak to peak. 3.8.18. Damper or variable guide vane operating mechanism shall be of proven design and made of corrosion resistant metallurgy and self lubricated bearings compatible to operating temperatures. 3.8.19. Electrical motor drivers as per (IEC / IS) shall be rated for continuous duty (duty type SI) where as motor as per American standards shall be designed to operate at a service factor of 1.0. Rating shall not be less than the following units. Fan rated BKW Motor MCR (% of fan rated BkW Inclusive of positive tolerance. Less than 22 - 125% 22 to 55 - 115% Higher than 55 - 110% The motor rating shall also be adequate for operation of the fans at the minimum specified fluid temperature (specified in data sheet) at rated speed in un throttled conditions. 3.8.20. The steam turbine drivers shall be rated atleast 110% of the maximum anticipated BKW (inclusive of positive tolerance) of the fan including transmission losses if any. 3.8.21. Variation inflow shall be achieved by VFD driven motor for fans. 3.8.22. When the gas handled contains matter than tends itself to accumulation on the internal parts of centrifugal fan or that may cause wear, a provision shall be made for injecting one or more sprays into the centrifugal fan to prevent such effects. The cleaning system shall be designed steam / water as recommended by the vendor. Elements of blade cleaning system inside the centrifugal fan housing shall be made of corrosion resistant material and shall be adequately supported to resist damage due to vibration. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 29 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.8.23. Fan housings, shall be of cast or fabricated construction, suitably stiffened to avoid drumming, and shall be split to permit the removal of the impeller and the shaft without disturbing the bearing pedestals. In case of fabricated construction minimum plate thickness shall be 6.0mm and shall of butt welded construction with inspection doors. 3.8.24. Inspection And Testing 3.8.24.1. Material test certificate shall be furnished for casing, impeller, shaft and shaft sleeve. 3.8.24.2. Following NDT are required: - DP/MT for impeller weds. - Ultrasonic / DP for shaft. 3.8.24.3. Following tests shall be witnessed by the third party inspection agency: - No load running test for 4 hours. - Balancing test for impeller. - Vibration test at rated speed of motor alone and fan coupled with motor. - Performance test as per BS848/AMCA210/ASME PTC II 3.8.25. Forced Draft / Induced Draft Fans – Specific Requirement 3.8.25.1. Unless otherwise specified induced draft fans shall be mechanically designed for operation at least 56 0C (100 0F) above maximum flue gas temperature specified. 3.8.25.2. The rated speed of the forced draft / induced draft fan shall not exceed 1500 rpm. 3.8.25.3. FD fans shall be provided with aerofoil design type blades. Skin thickness shall be minimum 2.5mm for hollow shaped construction. ID fan blades shall be of single thickness and as a minimum 6.5mm thick. 3.8.25.4. Shaft sleeves shall be of SS316 in case of induced draft fans. 3.8.25.5. Bearing housings for ID fans shall be provided with cooling water jackets. 3.8.25.6. In case of ID fans, thermal barrier or cooling disc shall be provided on the shaft to reduce the heat soaking from fan casing to the bearings. 3.8.25.7. FD fans shall be supplied with an inlet trash screen, filters and rain hood of corrosion resistant material. 3.9. RECIPROCATING PUMP 3.9.1. Equipment Qualification Criteria 3.9.1.1. The pump vendor shall be an established positive displacement (reciprocating) pump manufacturer having adequate engineering, manufacturing and testing facilities for API 674 pumps. 3.9.1.2. The pump model offered shall be from the existing regular manufacturing range of the pump manufacturer. The offered pump model shall meet the following minimum service and manufacturing experience requirements. Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance, Inlet flow, Suction Pressure, Operating Pressure & Temperature, Pumping Liquid, Speed, Number & Type of Pump Heads (i.e. Simplex, Duplex, Triplex, Quintuplet etc.), Mechanical Design, Materials etc. as compared to at least TWO UNITS of the proposed model shall have been designed, manufactured, tested and supplied from the proposed manufacturing plant in Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 30 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid. 3.9.2. The Maximum Allowable Speed Ratings for Reciprocating Pumps shall not exceed Eighty percent (80%) of the values, indicated in Table 1 & Table 2 of API 674. 3.9.3. Pumps where difference between NPSHA (including estimated system acceleration head) and NPSHR is 0.6 meter or less are not acceptable. 3.9.4. For temperature above 150°C and/or viscosities above 200 cst, speeds shall not exceed Sixty percent (60%) of the speeds indicated in Table 1 & Table 2. 3.9.5. Electric motor drivers shall have a rating as specified in API, however the motor rating shall be adequate to start the pump at the specified maximum suction pressure. 3.9.6. Inspection and Testing 3.9.6.1. The following tests shall be witnessed by owner's inspecting agency: - Hydrostatic Tests - Performance test (including mechanical performance) for 4hours for pump along with job accessories. - NPSH test when difference between NPSHA including allowances for acceleration head & NPSHR is less than 2m. - Dismantling inspection of liquid end after performance test. - R.V. Test (R.V. Mfr.'s shop) 3.10. POSITIVE DISPLACEMENT PUMP CONTROLLED VOLUME 3.10.1. Equipment Qualification Criteria 3.10.1.1. The pump vendor shall be an established positive displacement (controlled volume) pump manufacturer having adequate engineering, manufacturing and testing facilities for API 675 pumps. The pump vendor shall be an established positive displacement (controlled volume) pump manufacturer having adequate engineering, manufacturing and testing facilities for API 675 pumps. 3.10.1.2. The pump model offered shall be from the existing regular manufacturing range of the pump manufacturer. The mechanical as well as the hydraulic performance for the complete range of operation of the offered model shall have been established in the shop test. The offered pump model shall meet the following minimum service and manufacturing experience requirements. Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance, Inlet low, Differential Pressure, Operating Pressure & Temperature, Pumping Liquid, Speed, Number & Type of Pump Heads (i.e. Simplex, Duplex, Triplex etc.), Mechanical Design, Materials etc. as compared to at least TWO UNITS of the proposed model which shall have been designed, manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major overhaul as on the date of issue of invitation to bid. 3.10.2. The pump low rate shall be adjustable over the range of 10% to 100% of rated capacity while the pump is running. 3.10.3. The pump speed shall not exceed 100 strokes per minute. 3.10.4. For both suction and discharge double check valves shall be furnished. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 31 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.10.5. For multi head pumps, ganging effect shall not be considered while sizing the driver. 3.10.6. Pulsation suppression shall be provided at the discharge of all metering pumps. When necessary Pulsation dampener shall be provided at suction to maintain adequate margin between NPSHA & NPSHR. 3.10.7. Pump unit complete with speed reducer, driver, suction pulsation dampner (if required or specified) & discharge pulsation dampner, suction and discharge manifold piping duly pre - fabricated for multi-head pumps, relief valves, instrumentation etc. shall be mounted on a common skid. 3.10.8. Inspection and Testing 3.10.8.1. Following test shall be witnessed by owner's inspecting agency: - Hydrostatic Test. - Performance Test. - Linearity and Repeatability. - Dismantling and Inspection after Test. - R.V. Test. - Diaphragm Rupture Detection. - NPSH test 3.11. CRYOGENIC PUMPS 3.11.1. Equipment Qualification Criteria 3.11.1.1. The vendor shall be an established Cryogenic pump manufacturer having adequate engineering, manufacturing and testing facilities for the same. 3.11.1.2. The pump model offered shall be from the existing regular manufacturing range of the vendor. The mechanical as well as the hydraulic performance (including NPSHR) for the complete range of operation of the offered model shall have been established in the shop test. The offered pump model shall meet the following minimum service and manufacturing experience requirements: Pumps shall be identical or validly similar in terms of Mechanical Design and Operating/Service conditions of Capacity. Differential Head, NPSHR, Temperature, Pressure and Power rating etc. as compared to at least TWO UNITS of the proposed model designed, manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major problem as on the date of issue of inquiry. 3.11.2. Following test shall be witnessed by owner's inspecting agency: - Hydrostatic Test. - Mechanical Run Test. - Performance Test. - Sound Level Test. 3.12. POSITIVE DISPLACEMENT (ROOTS TYPE) BLOWER 3.12.1. Equipment Qualification Criteria 3.12.1.1. The vendor for the complete unit shall be an established manufacturer of roots blowers having adequate engineering, manufacturing and testing facilities for the same. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 32 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.12.1.2. The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Blowers shall be identical or validly similar in terms of Type i .e. lubricated or non lubricated, Frame number, Frame rating, Rotational Speed, Inlet and discharge pressures, Inlet temperatures, Actual Inlet Flow, Process Gas, Mechanical Design, Type of Rotor, Rotor Dynamics, Materials etc. as compared to at least TWO units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least ONE of these units shall have successfully operated in the field for at least 8000 hrs without any major problems as on the date of issue of inquiry. 3.12.2. Inspection and Testing 3.12.2.1. The following test shall be witnessed by owner's inspecting agency: - Hydrostatic Test. - Performance test of the blower at manufacturer's works - Mechanical run test of the blower at manufacturer’s works - Noise Level Test. 3.12.2.2. The vendor shall also furnish material certificates for major components. 3.13. API 614 OIL SYSTEMS 3.13.1. All components external to the reservoir that retains oil under pressure shall be of steel components submerged in reservoir may be of cast iron. All piping including filters shall be in stainless steel. 3.13.2. The material of construction of main lube oil reservoir shall be decided as below. For smaller ratings (less than 2 MW) : Stainless Steel For higher ratings : Carbon Steel with protective coating (non peeling type) as recommended by manufacturer. 3.13.3. A lube oil overhead rundown tank (SS construction) shall be provided sized for the coast down time for normal lube oil flow rate. The main lube oil tank capacity shall take care of rundown flow from overhead tank. The main lube oil tank shall be provided with oil heater. 3.13.4. In case of gas turbine or steam turbine driver, an emergency oil pump driven by DC motor shall be provided sized for cool-off period. 3.13.5. The lube oil system shall be provided with two (1W+1S) coolers and two (1W+1S) filters with change over facility. 3.13.6. For lube oil and seal oil system, each system shall have two (1W+1S) motor driven lube oil pumps. The lube oil pumps shall preferably have flooded suction. In case this is not possible due to layout constraints then NPSH requirements of pump shall be taken care of. 3.13.7. In case of oil seals, degassing facility shall be provided. 3.13.8. Inspection and Testing 3.13.8.1. Following test shall be witnessed at lube oil system vendors works by the third party inspection agency: - Hydrostatic test of assembled oil system and all pressure containing parts and auxiliaries. - Cleanliness. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 33 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 - Four hour run, check control, changeovers (coolers / filters), one and two pump operations. 3.14. SPECIAL PURPOSE GEAR UNITS 3.14.1. In case of alternators gears shall be designed for short circuit condition of the alternator. 3.14.2. Gears shall be of double helical or herringbone type. 3.14.3. Inspection And Testing 3.14.3.1. Following test shall be witnessed at gear vendors works by the third party inspection agency: - Hardness verification - Contact check. - Bearing clearance. - Mechanical run test. - Vibration and noise test at full load. 3.15. SPECIAL PURPOSE STEAM TURBINES 3.15.1. Equipment Qualification Criteria 3.15.1.1. The steam turbines offered shall be from a regular and established manufacturer of special purpose steam turbines having requisite design, engineering, manufacturing and testing facilities. 3.15.1.2. The steam turbines shall be identical in frame size (model number) as well as number of controlled extractions / induction and validly similar in power rating, rated speed, steam flow, steam inlet conditions, steam extraction conditions, steam exhaust conditions, rotor dynamics, bearing span, mechanical design and materials as compared to at least 2 units designed, manufactured, tested and supplied form the proposed manufacturing plant at least one of these units shall have successfully operated in the field for minimum 8000 hours without any major O&M problem as on date of issue of invitation to bid. 3.15.2. Turbine shall be capable of following: 3.15.2.1. Delivering the rated power at its corresponding speed with coincident minimum specified steam inlet conditions, maximum specified steam exhaust conditions, and normal steam extraction / induction flows. 3.15.2.2. Unless otherwise specified delivering 80% of the rated power at its corresponding speed with coincident minimum specified steam inlet conditions, maximum specified steam exhaust condition and zero steam extraction / induction flows. 3.15.2.3. Continuous operation at rated power and speed with maximum specified steam inlet conditions and minimum or maximum specified steam exhaust condition and normal to maximum specified steam extraction / induction flows. 3.15.2.4. Continuous operation at the lowest speed at which maximum torque is required with minimum specified steam inlet conditions and maximum special exhaust conditions with normal to maximum steam extraction / induction flows. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 34 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.15.2.5. Operation with variations from rated steam conditions and steam purity limits as per NEMA SM23. 3.15.2.6. Operation uncoupled / no load operation for alternator sets with maximum specified steam inlet conditions. 3.15.3. Train internal analysis shall be performed as per requirements specified in API612. 3.15.4. Combined trip and throttle valve shall be provided. 3.15.5. Governor shall be electronic type, It shall confirm to NEMA Class D. 3.15.6. Turbine insulation and jacketing shall be supplied by the vendor. 3.15.7. Unless otherwise specified, turning device shall be driven by an electrical motor. A turning gear operating station with associated control features shall be provided and detailed out by the vendor with necessary safety interlocks. 3.15.8. Turbine with exhaust pressure less than atmospheric pressure shall be provided with an exhaust vacuum breaker actuated by the trip system. 3.15.9. Turbine shall be provided with rotor grounding brush near LP Stages. 3.15.10. Gland steam condensers shall be provided with condensate tank and pumps. Bearing cooling water shall be used for gland condensers and surface condensers. 3.15.11. Surface Condenser And Auxiliaries 3.15.11.1. A surface condenser shall be supplied by the vendor and mounted directly below the steam turbine in case of condensing steam turbine. 3.15.11.2. The surface condenser shall conform to Heat Exchange Institute Standards (HEI Std.) for Steam Surface Condensers. 3.15.11.3. The sizing criteria for surface condensers shall be based upon the steam flow corresponding to turbine rated power and corresponding steam rate at minimum steam inlet conditions and maximum exhaust conditions. Cleanliness factor of 0.6 shall be used for sizing. 3.15.11.4. The condenser shall be of horizontal surface type with internal or external air cooling section. Design shall provide for externally cutting water circulation from one half of the condenser while the other half remains in service. (surface condenser shall have water boxes of divided type to facilitate cleaning in one half of the condenser, keeping the other half in operation.) 3.15.11.5. Water box covers and water boxes shall be removable without disturbing the tube sheets or water piping. In case of steel or stainless steel tube sheets, the water boxes can be welded to the shell. Covers shall be hinged or provisions made for handling by use of davits. 3.15.11.6. Surface condenser shall be equipped with: 3.15.11.6.1. Atmospheric Relief Valves. 3.15.11.6.2. Main and stand by twin ejectors each with inter and after condensers with steam side relief valves and condensate drain traps. 3.15.11.6.3. Start up ejector (hogging ejector). Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 35 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.15.11.6.4. Accessories such as stop valves, strainers, piping for ejectors and traps. 3.15.11.6.5. Condensate Removal System including condensate pumps with drivers, instruments, controls, inter connecting piping, fittings and valves. The valves shall be suitable for vacuum service and shall prevent the leakage of air into the system. 3.15.11.7. Construction and details for Surface Condenser 3.15.11.7.1. Shell: All expansion joints either bellows or diaphragm type shall be supplied in the condenser shell. Suitable supporting lugs or feet shall be provided on the shell, also all necessary flange and coupling connections for exhaust steam inlet, atmospheric relief, air removal and miscellaneous trap returns, vents and absolute pressure indicator. 3.15.11.7.2. Water box: Flanged joint connections on water boxes shall have machined faces. Suitable hand holes or man holes shall be provided on the cover plates to permit easy access and inspection of tube ends. 3.15.11.7.3. Tubes: Tubes shall be rolled into tube sheets at both ends. Material of construction of tubes shall be Super duplex SS. 3.15.11.7.4. Tube Support Plates: The tube support plates shall provide adequate support and prevent tube vibrations. Holes for the tube shall be drilled and either chamfered or deburred. 3.15.11.7.5. Tube Sheets Tube sheets shall be bolted to the condenser shell independently of the water boxes except steel or stainless steel tube sheets may be welded to the shell. The tube sheet and covers of surface condenser shall be provided with sacrificial zinc anodes and painted with epoxy zinc phosphate as primer and two coats of epoxy paint as finish paint. 3.15.11.7.6. Hot well Condensate shall be collected in a hot well attached to the bottom of the condenser shell. The hot well shall include cylindrical drop-leg atleast 584.2 mm (23’) ID and 1066.8 mm (3’ – 6’) long. The drop leg shall be provide with 80 mm flanged connections on 812.8 mm (2’-8’) centers for level instruments. 3.15.11.7.7. Elevation of Condenser Normal level of condensate of the hot well shall be approximately 2.75 m (9’) above baseline or a minimum of 1.98 m (6’-6”) above centreline of condensate pump. 3.15.11.7.8. Miscellaneous Connections larger than 25 mm (1”) shall be flanged, faced and drilled to ANSI Clas150. 3.15.11.8. Construction and Details for Steam Jet Air Ejectors and Inter / After Condensers. Document Description Doc No. 12-008-ME-DB-0002 Rev. No. 00 Rev. Date 13/09/2012 Design Basis for Rotating Equipments Page No. 36 of 36 File Name: Design Basis For Rotating Equipments_10-008-ME-DB-0002_Rev - 0 3.15.11.8.1. Each element of Twin ejector shall be capable of maintaining condenser vacuum at rated capacity. 3.15.11.8.2. The inter/ after condensers shall be designed to use condensate from the main condenser as cooling medium. 3.15.11.9. Construction and Details for Atmospheric Relief Valve Atmospheric Relief Valve shall be sized for maximum non-condensing operation. Design shall incorporate a screw lift mechanism and provision for water sealing including a sight glass to indicate the seal water level. 3.15.12. Inspection and Testing 3.15.13. 1 Non-destructive test shall be carried out as per vendor’s standard quality plan. 3.15.13.1. The following tests shall be witnessed by the third party inspection agency: − Hydrostatic test (all pressure containing parts and auxiliaries) − Mechanical run test (main and spare motor) − Performance test as per PTC 6 − Complete unit test. − Post test inspection − Casing joint leak test. − Auxiliary equipment functional test following: − Inlet and trip valve, gland sealing system, gland vacuum system, lube oil system, turning gear. − Emergency over-speed trip system test. − Governor stability report. − Residual electrical and mechanical run out test.