GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED ...MECH)-PRO6... · GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED ... given in Section VIII Division I of the ASME

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED 50,000 MTPA PAC PROJECT

SECTION 6 ANNEXURE 4.2 DESIGN PHILOSOPHY FOR MACHINARY

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PART A – DESIGN PHILOSOPHY FOR CENTRIFUGAL PUMPS

IN GENERAL, API 610, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING CENTRIFUGAL PUMPS. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

0.0 INTRODUCTION 0.1 Intention 0.1.1 This specification is intended to supplement API Standard 610, Centrifugal

Pumps for general Refinery Services, latest edition which forms a part of this specification.

0.2 Vendor Qualification All pumps shall be supplied by vendors qualified by experience to

manufacture the proposed units. To qualify, a vendor must be able to produce a reference list of pumps built & supplied by them for similar services.

0.3 Besides codes & standards, Contractor shall follow National Laws &

Regulations together with Local By Laws for the state, including statutory requirement as applicable. Further, Contractor shall specifically note that any applicable local mandatory code / statutory requirement, if any, shall be informed later on.

During detail engineering, Contractor shall submit the specification sheet

indicating the make / manufacturer, efficiency, NPSHa, NPSHr, Suction specific speed, min cont. flow, Mech Seal flushing plan, lubrication detail. Performance Curves and GA & CS Drgs are also required to be submitted along with the Reference list for supply of similar duty machine.

1. GENERAL 1.1 SCOPE This specification, together with the latest edition of API 610, covers the

minimum requirement for the design, materials, fabrication, shop inspection & Testing of centrifugal pumps for hydrocarbons, chemicals and water services to be used for Feed Stock Conversion Project and procured by the Contractor appointed for the Project.

1.2 REFERENCE This specification shall be used in conjunction with the:

Process Data sheets as per the Process Licensor. Any other Special Requirements laid down by the Process Licensor.

2. BASIC DESIGN 2.1 GENERAL 2.1.1 The balancing piston shall not be used to balance axial thrust in multistage



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pumps which handle the liquid containing solid or erosive particles. 2.1.2 The NPSH required for the pumps shall not be greater than the following,

whichever is the smaller: a) NPSH Required < / = 0.85 X NPSH Available b) NPSH required < / = NPSH Available – 1 Mtr. 2.1.3 The head / capacity curve for the pump shall continuously rise fro the

specified capacity point to the shutoff point. When parallel operation is specified, the head rise for one and two stage

pumps shall be preferably 10-20 % of the head at rated capacity. This percentage may be reduced for multistage pumps (three or more stages) to

avoid excessive shutoff head. 2.1.4 The best efficiency point for the furnished impeller should be between the

rated point and normal point. When this is impractical, the rated point shall be to the left of Best Efficiency Point.

2.1.5 The maximum allowable sound level (pump & driver combined) is 85 dB(A) 1

m apart from the equipment surface, unless otherwise specified. 2.2 PRESSURE CASINGS & IMPELLERS 2.2.1 The stress used in design for any given material shall not exceed the values

given in Section VIII Division I of the ASME Boiler & Pressure Vessel Code. For the cast material, the factor specified in the code shall be applied.

2.2.2 All threads shall be metric screws except: 1) Unified inch screw threads for anchor bolts / nuts and ANSI standard flanges. 2) NPT threads for pipes. 2.3 Nozzles and Pressure Casing connections 2.3.1 Openings for nominal pipe sizes of 1 ¼”, 3 ½”, 5, 7 and 9 inches shall not be

used. 2.3.2 Openings for nominal pipe sizes of 2 ½” inches shall not be used unless

approved by the purchaser. 2.3.3 Gage connections shall not be furnished unless otherwise specified. 2.4 Impellers shall be single piece castings. Fabricated impellers shall not be

used. 2.6 SEALS 2.6.1 Pump manufacturer shall be responsible for adequate design and installation

of a mechanical seal and its auxiliaries such as circulation, injection, quenching & cooling facilities.

2.6.2 Built in Mechanical Seal shall not be used.



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2.6.3 Cooling or any other connection, if not in use, shall be plugged off if no liquid injection is required.

2.6.4 Mechanical Seals shall be as per API 682, Latest Edition. 2.7 Assembled rotors of pumps running at 1400 RPM or Over shall be

dynamically balanced. 2.8 MATERIALS Generally, the material of Construction shall be as per the Process Licensor’s

recommendations. However, API Guideline may be adopted to the extent applicable.

Use of equivalent & superior material may be selected & shall be furnished with the offer along with the chemical composition.

2.8.1 When materials of only main parts (such as casing, impeller, shaft, etc.) are

specified on the data sheet, the vendor shall specify other materials on the data sheet in the proposal.

2.8.2 Materials shall be identified in the proposal with the applicable material

standard number including the material grade. 2.8.3 The vendor shall inform the purchaser of the need to repair before repair

welding is carried out. In any case, details of repairs shall be recorded & reported to the purchaser in

writing. 2.8.4 For CW Pumps the MOC shall be with ASTM A216WCB Casing / SS Impeller. 2.8.5 3 mm AIR lining shall be carried out for all pumps base frame & foundation

shall carried out. 2.8.6 For any pumps cast iron materials are not allowed. It should be minimum Cast

steel. Base frame in cast iron is also not acceptable. 2.8.7 All pumps shall be provided with jacking bolts (6 Nos ) for the Alignment of

pumps with motor. 2.8.8 For motor mounting, body threaded bolt is not acceptable. Motor mounting

shall be with studs with two nuts. 2.8.9 Speed of the all acid service pumps, erosive service pumps, vertical pumps of

any service shall be with maximum 1500 RPM. 2.9 NAME PLATE The name plate shall be stamped with the following information in English: 1) Purchaser’s item number 2) Pump Serial Number 3) Rated Capacity in M^3 per Hr 4) Differential Head in Meter 5) Casing Hydrostatic Test Pressure in Bar 6) Speed in RPM



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7) Bearing Manufacturer’s identification number 8) Date of Manufacture 9) Name of Manufacturer 3.0 DRIVERS 3.1 Unless otherwise specified, the electric motors shall have power rating to

cover following required Horse Power, whichever is higher. The required horsepower at the rated capacity for rated diameter impeller

including the service factor shown in table below: HP Requirement Percentage of Horsepower Requirement 20 KW and less 125 % Above 20 KW and below 75 KW 115 % 75 KW and above 110 % 3.2 Unless otherwise specified, couplings shall be of steel, and of gear type OR

Flexible type. 3.3 Removable coupling guards made of non sparking materials shall be supplied

& they shall cover rotating parts to within 13 MM of stationary housings & will be of rigid construction.

4.0 INSPECTION AND TESTING Inspection & Testing items, including the extent of witnessing or observation is

specified in INSPECTION PHILOSOPHY FOR MACHINARY, Part F-1 & Part F-2 of this Annexure.



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PART B – DESIGN PHILOSOPHY FOR CENTRIFUGAL COMPRESSORS

IN GENERAL, API 617, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING CENTRIFUGAL COMPRESSOR. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

1.0 General Vendor Qualification Compressors shall be supplied by vendors qualified by experience to

manufacture the proposed units. To qualify, a vendor must be able to produce a reference list of Compressors built & supplied by them for similar services and at least, 5 of them should be in operation since minimum 3 years of successful operation.

For Synthesis Gas, Natural Gas Service, Process Air compressor, the offered

Compressors should not have geared / integrally geared drive. Synthesis Gas compressors , Co2 Compressor , Natural Gas compressor or any Hazardous gas compressor , for the sealing , Bi directional double tandem Dry Gas seal with berior seal is to be used.

INTEGRALLY GEARED COMPRESSOR CAN BE USED ONLY FOR UTILITY

SERVICE. FOR THE PROCESS SERVICE INTEGRALLY GEARED COMPRESSORS ARE NOT ALLOWED..

Besides codes & standards, Contractor shall follow National Laws &


1.1 Scope

This specification covers the minimum requirements for Centrifugal compre-ssors and their accessories.

Compressors shall be in accordance with API standard 617, (LATEST EDITION), but with the following changes (additions, deletions, modifications, substitutions, etc. as noted in parenthesis for each item.

Item numbers used below are the API-617 paragraph numbers. Compliance with this specification does not relieve the manufacturer or the

vendor of the responsibility for furnishing equipment of proper design and construction and fully suitable for all specified operating conditions.

All equipment supplied shall be finished machined. On site only pure

assembly work is acceptable. Piping not completely prefabricated is to be marked on Piping Arrangement Drawing (s). All ''Spare components are to be machined at Vendors' shop with suitable tolerances in order to allow replacement without any re matching.



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During detail engineering for Compressors & Blowers, Contractor shall also submit the following details: i) Surge limit, polytrophic efficiency, Head coefficient, Flow coefficient, Mach No. for nor / rated point. ii) Speed nor. / rated, 1st / 2nd lateral critical and tensional critical. iii) Casing Design pressure / temperature. iv) Model No. Impeller no., diameter. v) End Seal – type / make , Coupling type/make / rating. vi) Gas cooler – Heat duty, surface area provided, Design pressure / temperature. vii) Separator – Design pressure / temperature, Hold up capacity, Moisture content at outlet. viii) Gear – Type / make , rating, service factor. ix) Utilities consumption. x) MOC of compressor, gear, coupling, gas cooler, separator etc. xi) Sealing system details. xii) Lube oil system details. The Performance Curve and Reference list for supply of similar duty machines

also to be submitted. Refer Technical Deviations to ITB. Except for the clause where specific

deviations have been indicated, all other clauses, standards, specifications shall be as per ITB conditions only. Deviations shall be reviewed and approved by the owner. Please confirm.

1.2 Alternative Design For alternative proposals refer to 6.1 of API-617. 1.3 Conflicting Requirements: All conflicts between the requirements of this philosophy, other specifications,

code, standards, purchase order, drawings and data sheets shall be referred to the purchaser for clarification before proceeding with the design or manufacturing of the affected part.

Where the vendor wants to deviate from any of the information given in the

a.m. documents, he must ask for the written approval by the purchaser. The deviations have to be listed in order sequence of the document related to

and the reasons for deviating shall be given. It shall clearly be understood that lack of a list of deviations will imply, that

equipment offered is in complete accordance with the specifications and the documents mentioned therein.

1.4 EOT REQUIREMENTS For Compressor House, EOT Crane of the required capacity, to the nearest

multiple of 5.0 MT but minimum 15.0 MT capacity shall be installed. SECTION 2 - BASIC DESIGN: 2.1 General: 2.1.1 (Add) Process gas compressors will be run-in on air or Nitrogen in



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the field (run-in on air means a mechanical test run in the field where compressor is priming and discharging to atmosphere). Compressor vendor shall propose procedure for run in on air or Nitrogen (flows, discharge pressures and temperatures, speed, horsepower requirement, necessity of bleed connections, safety screens, etc.) and shall provide performance curves and temperature limitations, etc. for this operation. If specified in the spec. Data sheet, process gas compressors will be operated for several weeks on air for pre-start-up equipment drying.

The machines sets and their auxiliaries shall be supplied by vendor’s qualified

by experience in manufacturing the units proposed. Vendor has to inform the purchaser in writing where major parts

will be manufactured. The vendor must inform the purchaser about his licenser. (Add) Compressor intended for parallel operation shall have suitable head-

capacity characteristics. The surge limit at p/p = const, is to be guaranteed with a tolerance of 5%

based on the figure given in the proposal. (% of guarantee flow). 2.1.7 (Add) Reference is made to Chapter 3.0 in "Scope of Supply".

2.1.10 (Mod) The compressor and its auxiliary shall be suitable for outdoor

installation (without roof) if not stated otherwise in the data sheet. All equipment supplied must be suitable for start-up and for operation at min.

ambient site temperature as indicated in the specification data sheets. Compressor, Drivers & Utilities auxiliary equipment must be suitable for the

specified operating conditions & shall be designed and constructed for continuous full load duty (at least 3 years of service).

2.1.11 (Mod) The compressor installation shall conform to API Standard

615. Vendor shall furnish noise emission data for the quoted machine with his proposal, per API 615.

2.1.12 (Add) A flushing and drain system shall be furnished if specified.

Flanged casing connections for injection and drainage at each impeller shall be provided.

The spray nozzles to individual impellers and the shut-off valves are of the compressor MFR's supply.

2.1.13 (Mod) Equipment vendor shall furnish compressor and auxiliary

equipment in accordance to local rules or regulations that will apply. Vendor might ask purchaser for assistance to list applicable rules or regulations.

2.1.14 (Add) For inter stage coolers, oil coolers, after cooler, pulsation dampeners,



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other equipment, Design Philosophy as per Annexure 4.1 Part A & B shall be followed. For Inspection of the same, Annexure 4.9 part A, B & C shall be followed. For piping, Annexure 4.4 shall be followed.

Compressor LUBE OIL / SEAL OIL SYSTEM Lubrication systems shall consist of 2 oil pumps (1 Running + 1 standby) with

suction strainer, a supply and return system, an oil cooler (when required), 2 full-flow filters (1 Running + 1 Standby), LO tanks with level instruments and other necessary instruments. This is over & above Main Oil Pump ( shaft driven).

For seal oil system also, above philosophy shall govern with de gassing tank. There shall be an overhead Lube Oil system and emergency lube oil system

for the compressor / turbine train. For turbine driven compressor, over and above LO / SO system, Control Oil

System shall follow the philosophy as described above. Lube Oil & Control Oil may have common system, depending upon design. However, emergency & seal oil shall individual system. Overhead LO system shall be in addition to emergency (having emergency power connection) LO system. For screw pumps: body shall be CS and internals shall be SS. For valves, body shall be CS and trim shall be SS. Filter body shall be CS and internals shall be SS. Pipes, fittings and flanges shall be SS. Main oil tank, Run down tank shall be SS. Oil cooler tubes shall be seam less In SS material and shell can be CS. Pump suction strainers body shall be CS and internals shall be SS.

For single shaft centrifugal compressor, main & aux. oil pumps ( 1 Running + 1 stand by ) are required. Accumulators will be required for pump switchover. Emergency oil pump is required for steam turbine Plus Compressors. Rundown tank is required for turbine driven centrifugal compressors. For Integrally geared compressor: Shaft driven main oil pump and motor driven aux. oil pump (1 Running + 1 stand by) are required. Run down tank is not required. Accumulators are required for steam turbine driven compressors.

2.2 Casings 2.2.1 (Add) The casing and all pressure containing parts shall be at least

suitable for operation at the most severe conditions of coincident and temperature expected with the specified operating and test condition.

2.2.3 (Mod) The vendor shall state in his proposal the limits (pressure,

temperature) for operation in relation to the selected casing material.



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2.4 CASING CONNECTIONS 2.4.1 (Mod) Inlet and outlet connections shall be flawed or machined and studded,

oriented as specified in the data sheets (see Technical Specification), and shall be suitable for the maximum stresses arising from any of the specified operating or test conditions, unless otherwise agreed to by the purchaser.

2.4.3 (Mod) Flanged connections shall be provided (not Jess than 3/4 ) for- Liquid

injection (if specified on the spec. Data sheet) other low points - Casing drains at the lowest point of each stage or a of horizontally split casings - Lube and seal oil - Flushing - Buffer gas/reference gas - Balance gas If flange thicknesses of casing connections deviate from those of the

applicable standard the actual flange thicknesses shall be shown on the outline drawing.

2.5 External Forces and Moments: 2.5.1 (Mod) Compressors shall be designed to withstand external forces and

moments at least equal to 2.0 times the values calculated in accordance with NEMA SM-23.

The allowable forces and moments have to be shown for each

nozzle on a drawing. 2.6 Rotating Elements: 2.6.5 (New) Plating of the shaft at the bearing surfaces and at the surfaces

under vibration probes is not acceptable. 2.6.10 (Add) Vendor has to give his limits for impeller tip speeds for the

various types of impellers quoted. If actual speeds are close to vendors limits, he has to prepare references.

Locally mounted pressure gauge to be provided to indicate the balancing

chamber pressure. Balance line sizing shall consider also noise generation due to high

gas velocities in the balance line. During mechanical run test in vendor's shop balance line(s) must

be installed. A weld specimen may be manufactured together with the impeller

to verify material and weld hardness after heat treatments and repair welding. Material and details of construction should be identical to the impeller in construction .



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2.7 Shaft Seals: 2.7.1 Shaft seals and oil supply system shall be designed to contain the

compressed gas with the compressor idle and internal gas pressure(s) equal to the casing design pressure(s) or settle out pressure if stated in the data sheets and to allow compressor start-up with gas pressures within the compressor casing(s) equal to the related casing design pressure(s) or settle out pressure.

2.7.3 Aluminum labyrinths are not acceptable.

2.8 Dynamics: 2.8.1.11(MOD) A composite torsional vibration analysis shall be performed for all

compressor driver units. For compressor units driven by electric motor through a gear box, both the compressor and gear motor to perform an independent torsional analysis.

The input and results of this analysis shall be submitted to the purchaser (see also para. 3.1 and 3.2 of this specification).

2.8.2.1 (Mod) Major parts of the rotating element, such as impellers and

balancing drums, shall be dynamically balanced, followed by a check of the assembled rotor at 100% operating speed.

2.9 Bearings and Bearing Housings: 2.9.1.1 (Add) Radial bearings are to be designed for short time reverse rotation. Thrust bearing loading shall not exceed 2800 kPa (400 psi) taking into

consideration maximum internal thrust and coupling lock-up based on driver rated horse power (or that portion of driver rated horsepower applicable to the compressor casing involved).

For drive through compressor casings both coupling lock-ups are to

be considered to act in the same direction. Radial and thrust bearings shall be designed for short lime reverse rotation

with lube oil supply in operation (caused by leakage of process non-return valves, etc.)

For turbine driven compressor units particular attention concerning bearing

design must be given to turbine turning gear speed, which may be very low. Compressor vendor shall coordinate with turbine vendor. 2.9.1.3 (Sub) Radial bearings shall be fitted with imbedded temperature

sensors to detect bearing metal surface temperature. Each radial bearing shall have thermocouple (s) embedded in the steel

backing of the babbit lining (either dual element, preferable if feasible, or 2 separate TC's) for temperature monitoring and alarm,,

Each tilting pad type thrust bearing (active side and inactive side of the bearing) shall be equipped with 2, preferably dual element type, thermocouples each 180 apart for temperature monitoring. The TC shall be at



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least 0.75 mm away from the babbit and the drilled hole shall not extend into the babbit material.

Vendor shall provide the TC's wired to a machine mounted junction box.

Thermocouple material shall be Iron-Constantan. Bearing housing shall be equipped within 1/2 inch connection between the

outer labyrinth and bearing for nitrogen or air purging. 2.9.2.1 (Mod) Hydrodynamic thrust bearings shall be of the babbitted steel-

backed multiple-segment type, designed for equal thrust capacity in both directions, short time reverse operation and arranged for continuously pressurized lubrication to each side.

2.9.2.8 (Sub) Thrust bearings shall be fitted with imbedded temperature

sensors to detect pad surface temperature. Please also refer 2.9.1.3. 2.9.3.1 (Add) Exception is allowed for applications where the gas suction

pressure is below atmospheric pressure and sealing is required. 2.10 The contact of lube oil with process gas is not permitted. 2.11 Materials: 2.11.1. General Generally, Material of construction shall be as per the Process Licensor’s

recommendations. However, API Guidelines may be adopted to the extent possible.

Material of Complete Lube Oil system shall be SS 304. This includes all items

coming in contact with Oil viz. piping, valves, strainers, filters, flanges, etc. MOC of tubes for LO Coolers, Inter & After Coolers shall be SS 304 minimum,

as specified in Clause 2.3.1 of Annexure 4.1. Tubes shall be seamless. 2.11.1.2 Materials shall be identified with ASTM Standards. Use of equivalent &

superior material may be selected & shall be furnished with the offer along with chemical composition.

2.11.2 Pressure containing parts: 2.11.2.1 (Mod) Major repair welding on casted casing is not allowed without approval

of the purchaser. Major repairs are defined as : welding having a depth exceeding 40 % of

wall thickness or exceeding an area of 65 cm^2. WPS/PQR for all casted casings must be submitted to the purchaser 4 weeks after order placement latest. Detailed information about post weld heat treatment has to be included.

In case of repair the vendor has to inform the purchaser immediately in detail

about the amount of repair work, the repair method and the place where the repair work shall be carried out.



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Purchaser reserves the right to reject the casting in case of a high amount of

cracks, holes or inclusions or other defects. 2.12 Name plates 2.12.3 (Add) The name plates shall also contain the contractor's item number. 2.12.4 (Add) Material of Complete Lube Oil system shall be SS 304. This includes all items coming in contact with Oil viz. piping, valves, strainers, filters, flanges,

etc. Oil Coolers shall have minimum SS 304 Tubes. SECTION-3: ACCESSORIES: 3.1 Drivers: 3.1.1 Drivers shall be sized and rated to develop at least 110% of the horsepower at

the maximum compressor operating conditions, including either gear or hydraulic coupling losses or both.

3.1.9 (New) Gears and coupling must be designed for at least rated motor

horsepower, or the maximum power plus 10 percent of compressor casings driven by gear in case where the gear is installed between the casings.

3.2 (New) Continuously lubricated / Non Lubricated gear type coupling with

spacer or diaphragm type with spacer may be used. All couplings and guards required for one train are furnished by the

compressor vendor. Gear couplings shall be designed to assure full tooth flushing and to prevent sludge retention.

The purchaser and vendor shall mutually agree upon the make,

type and supplier of the couplings. The driver coupling half shall be finished machined and shipped to the

driver manufacturer. Couplings whether hydraulically or mechanically fitted shall be designed for

removal and devices shall be provided by the vendor for the removal of this coupling.

Coupling guards to be provided with a breather cap. The maximum total coupling end float shall be 6mm and the total rotor end

float. The motor magnetic center shall be considered as the geometric center. The couplings and spacers shall be dynamically balanced independently from

the rotating assemblies to a tolerance suitable for the maximum allowable speed. The balancing quality shall be at least equal to g – 1.6.

The couplings hubs, sleeves, and spacer shall be match marked. Bolting shall



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be weight matched to permit random 'interchange without altering the balance. 3.3 Mounting Plates: 3.3.1 (Mod) The compressor shall be provided with a base plate. Supporting

compressor casing(s) 3.3.2.6 . DELETED 3.3.2.9 (Mod) Anchor belts shall be furnished by the vendor. 3.3.3.6 (Mod) Decking shall be provided on the top of the base plate covering all walk

and work areas. 3.4 Control & Instrumentation: 3.4.1.1 (Mod) The vendor will be responsible for train system control and ensuring

compatibility with the process control requirements. Vendor to furnish complete basic data for all instruments and controls within

the lube, seal and control systems of the compressor on a purchasers equipment and instrument list for rotating machinery.

(Substitute for the second sentence) Vendor to supply “only special

instruments related to the machine such as : - bearing oil temperature indicators. - two TC for each radial bearing (see para 2.9.1.3) - two TC for each side of tilting pad bearings (see para 2.9.1.3). - two TC for each tapered land thrust bearing - two vibration probes, connecting cables and proximitors for each radial bearing, (see para 3.4.5) - one axial displacement probe, connecting cable and proximitor for each shaft (see para3.4.5) - buffer gas control valve (see para 3.5.11) 3.4.3 Minimum Instrumentation ( Please also refer Instrumentation requirement

mentioned in the Instrument Volume) 3.4.3.1 (Add) Panel instruments will be supplied by the purchaser. 3.4.3.2 (Sub) Vendor to supply only instrument connections according to

purchaser specification. 3.4.3.4 The vendor to furnish all necessary local instrument connections for the

compressor, interconnecting piping and oil units. Instrument connection specification will be furnished by the purchaser. Minimum requirements are as per API 614/App. A or as per detailed

purchaser specification. Final instrumentation requirements and their location will be discussed and assigned after receipt of vendor's flow diagrams (LO/SO/CO/Buffer gas/flushing/drains, etc.)

Thermocouples to be provided as specified under 2.9.1.3 A differential pressure indicator and differential alarm switch to be installed by



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the purchaser if buffer gas is needed during start-up or other operating conditions. In any case, the connections for installation of these instruments are to be furnished by the compressor vendor.

3.4.5 Vibration and Position Detectors: 3.4.5.1 (Add) Vibration probes to be installed in the same plane for

compressor casings, gears and drivers of one compressor unit. Compressor vendor shall coordinate with driver vendor and gear unit supplier.

3.4.5.2 (Add) Total mechanical and electrical run out shall be not more than

0,5 mils, or 12,5 Micron. Shaft location of probe should be de gauzing prior to installation of rotor into

the compressor casing. 3.5 Auxiliary Piping: 3.5.1 (Supp) Auxiliary piping includes also all buffer gas, reference gas

and flushing lines and its mounted appurtenances. 3.5.2 (Mod) If not stated otherwise on the compressor datasheet, the

interconnecting piping between the base plate or the compressor unit and the sections described in API Standard 614, shall be provided by the compressor vendor.

3.5.4 (Add) The purchaser piping specification shall apply to all piping

mounted on either the compressor unit or the base plate or/and both.

3.5.6 (Sub) Inter stage gas or air piping furnished by the vendor shall

conform to purchasers piping specification. 3.5.9 (New) For internal piping such as balance lines, seal gas piping,

vent lines, oil piping or the like, at limits of supply flanges and other connections have to meet purchasers' standard.

3.5.10 (New) After fabrication oil and gas lines shall be thoroughly cleaned to remove

foreign materials, corrosion products and milled scale. Carbon steel oil lines shall be pickled, passivated and immediately coated with a rush inhibitor. S.S. lines will be pickled and passivated.

3.5.11 (New) Each compressor casing shall be provided with an automatic buffer gas

system incl. pressure differential control valve. For start-up operation an external buffer gas piping incl. Y-type strainer, non-return valve, shut off valve and blind flange shall be furnished. This applies also to inter stage diaphragm buffer system, if specified on the specification data sheet.

3.5.12 (new) The use of cast iron fittings and piping is not allowed. 3.6 (New) General information on scope of supply: Unless otherwise stated in the documents having priority to this Philosophy,

the following shall be included in the scope of supply (To be described in



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detailed in data sheet). 3.6.1 All drain and vent connections, equipped with double valves & Blinds. 3.6.2 Pipes of DN 50 or more prefabricated (with allowance + spare.) 3.6.3 Interconnecting piping shall be fitted and mounted to an extent reasonable for

easy transportation and installation of the machines with their auxiliaries to site.

3.6.4 Any part of vendors scope of supply has to be delivered to site in a condition,

which requires only normal erection work like alignment, fastening to foundation, connection to the plant network. Manufacturing at site is not allowed.

If equipment has to be completed at site because of transportation weights or dimensions this has to be stated in the proposal and requires the approval by the purchaser.

3.6.5 2 sets of all different types and sizes of gaskets, 1 set of springs for safety and

control valves. (This has to be specified in detail by the vendor. Commissioning spares & regular spare to be defined and listed down. Safety valve seats and orifice required.) Refer Spare Parts Philosophy.

3.6.6. All fixing material required for fastening the machines and their auxiliaries on

the foundation. Foundation bolts for compressors, gears, driver, lube oil console, piping support, inst. & tubing, alternators on concrete table foundation have to be bolts for through holes.

3.6.7 Special tools for maintenance and alignment shall include an

alignment device for each coupling and if required, special heating / hydraulic devices for tightening or loosening of casing bolts and the like. [Coupling, jack, Nitrogen filling device for pulsation, Rotor lifting bar/Special fixture for seal mounting / dismantling.

3.6.8 Sound cover boxes have to be equipped with inspection doors as far as

applicable and required for operating and servicing the compressor and the auxiliaries.

3.6.9 Wherever special flanges cannot be avoided at limits of supply, the vendor

has to supply counter flanges, gaskets, bolts and nuts. 3.6.10 Provisions for optical alignment have to be made at the compressors, base

frames, etc. SECTION-4 : INSPECTION AND TESTING 4.0 General Inspection & Testing shall be carried out in accordance with applicable

Inspection Philosophy as per Part – F-1 & Part F-3 of this Annexure. 4.4 Preparation for Shipment: 4.4.1.1 (Sub) Each unit shall be suitably prepared for the shipment specified in



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the Purchase order and for outdoor storage at the job site of at least one year in a manner requiring no disassembly prior to operation.

After all tests are completed and after inspection is made equipment shall be completely dry prior to any preparation of shipment. All exposed machined surfaces shall be thoroughly coated with suitable rust preventive.

All exterior parts of the units except machined surfaces, shall receive a shop coat of point. The interior surfaces shall be s| rayed or flushed with suitable rust preventive that is compatible with the normal charge oil and that can be removed by flushing with the normal oil or that can be removed by solvent flushing. Bearing and seal assemblies shall be fully protected from rusting and entry of moisture and dirt.

4.4.1.2 (Sub) If storage for more than one year is specified , the vendor shall include

all necessary coating and protections for this period and advise purchaser of method to remove the rust preventive.

4.4.1.3.5 (Add) Flange openings larger than 10 shall have steel covers

with 10mm thickness. 4.4.1.4 (Mod) The compressor shall be packed securely for domestic or export

shipment as specified to the purchase order. 4.5 Mechanical run test with shop lube oil system, however with job (ordered) driver

I,e with ordered motor / ordered turbine. The lube oil system will be functional tested. Job driver will be tested separately.

SECTION- 5 GUARANTEE AND WARRANTY.

5.1 Mechanical: 5.1.1.1 (Mod) All equipment and component / parts shall be warranted by the

vendor against defective materials, design and workmanship for 1 year after being placed in service.

These are minimum guarantee terms. The purchase order shall govern, when more conservative terms are specified.

5.2 Performance: 5.2.1 (Mod) The compressor shall be guaranteed for head, capacity and

satisfactory performance at all specified operating points and further shall be guaranteed for horsepower at the operating points marked in the Technical Specification.

5..2.1.1 (Sub)For variable-speed compressors, the head and capacity shall

be guaranteed with the understanding that the horsepower may vary according to the tolerances given in the Technical Specification.

The operating speeds specified in the proposal are not guaranteed, but if the

necessary speed to meet the guarantee figures exceeds the specified value, purchaser has to be informed about the activities planned by the vendor. Any modification shall be approved by the purchaser.



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For variable speed compressors the head, capacity and horsepower shall be guaranteed at the specified speed as listed below.

Head minus 0 percent plus 5 percent Capacity minus 0 percent horsepower plus 0 percent Where changes in specified speed are needed to meet head requirements,

the vendor shall adjust operating range and guarantees to be no closer to a critical or to the trip speed than the percentage in 1.5 and 2.17. Pressure levels at side, loads shall be guaranteed as indicated on the compressor data sheet.

5.2.1.4 (New) If the test run carried out at site shows that the compressor

cannot meet the guarantee figures, the costs for the test will be charged to the vendor.

5.2.1.5 (New) Purchaser reserves the right to deduct 0.5% from the price

of the complete compressor set, up to a maximum of 5% for every full percent that the power requirement of the compressor exceed the tolerance on the guarantee figures.

If the guarantee (figures) will be exceeded by 10% or more, the purchaser

may reject the complete set, if after a reasonable time vendors improvements to meet the guarantee figures have been ineffective.

SECTION-6 VENDOR'S DATA 6.1 Proposals: 6.1.1.14 (Add) Price for spare rotor mechanical test run shall be indicated

separately in the proposal. The "specific list of deviations" shall show the para numbers used in this

specification and the API standard 617. Only the comments and/or exceptions in this list will be considered by the purchaser. The vendor shall indicate all decisions he made for all paragraphs marked with an asterik that have not been commented herein.

Proposal must clearly show the extent of instrumentation included in the scope of supply and indicate individual prices for each kind of instrument (FG, FO,LC,LG, LI, LIC, LS, LT, PI, PDI, PS,' PDS, PC, TI, TS, TC, etc.) in order to allow ordering of additional instrumentation after release of main purchase order.

6.2.2 Drawings 6.2.2.3 Contractor shall submit Drawings as per Part G – 1 – Inspection Instruction to

Vendors 6.2.5 Manuals Contractor shall submit Manuals as per Part G – 1 – Inspection Instruction to

Vendors



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6.2.5.1 (Mod) The vendor shall provide written instructions (and cross-referenced list of all drawings) to enable the purchaser to install, operate and maintain .the complete equipment ordered.

The manuals have to be related to the special job in question and apply to

the date of the Technical Specification. Typical manuals are not acceptable, neither for the compressor nor the auxiliaries.

The information shall be compiled in manuals with title pages containing all

identifying data required in 6.2.1.2, index sheets containing section titles and complete lists, of enclosed reference drawings by title and drawing number.

6.2.7 Engineering Responsibility 6.2.7.1 (New) The compressor manufacturer shall have full responsibility for the entire

system, including compressor, driver, power transmissions and auxiliary equipment.

The engineering responsibility includes but is not limited to : a) Torsional analysis for the train b) Outline drawing completed for driver, base plate and or bolt location. c) Piping stress analysis, forces on nozzles, etc. d) Selection and rating of power transmission components, couplings,

guards, axial force. e) Lube control and seal system design including co-ordination of oil viscosity,

flow, pressure and temperature, heat to be removed. f) Equipment layout and base frame design. g) Common foundation and arrangement drawing for compressor and driver. h) Design of vibration and axial -displacement monitoring system. i) Obtaining engineering data for the train components and

to submit all necessary information to the purchaser. j) Power, speed, direction of rotation, shaft end dimensions,

distance between shaft end, axial and radial shaft moment, cold and hot alignment dimensions.

The compressor vendor shall solve all engineering problems relating

to the equipment including driver and shall keep the purchaser informed.



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PART C – DESIGN PHILOSOPHY FOR RECIPROCATING COMPRESSORS

IN GENERAL, API 618, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING RECIPROCATING COMPRESSOR. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

1 - INSTRUCTION 1.1 Intention This specification is intended to supplement API Standard 618, Reciprocating

Compressors for General Refinery Services, Fourth Edition – June 1995 which forms a part of this specification.

2 GENERAL 2.1 Vendor Qualification Compressors shall be supplied by vendors qualified by experience to

manufacture the proposed units. To qualify, a vendor must be able to produce a reference list of Compressors built & supplied by them for similar services and at least, 5 of them should be in operation since minimum 3 years of successful operation.

For Hydrogen & Natural Gas Service, The offered Compressors should be

directly coupled with Motor. Besides codes & standards, Contractor shall follow National Laws &


2.2 Scope This specification covers the minimum requirements for design, materials,

fabrication, shop inspection and tests of reciprocating compressor (including lubricated reciprocating compressors) for gases, to be used in Feed Stock Conversion Project & to be procured by the Contractor.

Compressors covered by this specification are moderate to low speed and in critical services. Also included are related lubricating systems, controls, instrumentations, intercoolers, after Coolers, pulsation suppression devices, and other auxiliary equipment.

Excluded are integral gas-engine-driven compressors, package high speed separable engine-driven reciprocating gas compressors, compressors with single-acting trunk-type (automotive-type) pistons that also serve as crossheads, and either utility or instrument air compressors that discharge at 9 kg/cm2G (8.6 bar effective) or below. Also excluded are gas engine and steam engine drivers.

2.3 This specification shall be used in conjunction with the related specification

and data. Except as excepted, modified or added by this specification or the subject

references, compressors shall conform to "API std 618 Reciprocating



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Compressors for General Refinery Services – Fourth Edition June 1995." 3. DESIGN 3.1 General 3 All electrical components and installations shall be suitable for the specified

electrical area classification and grouping as specified in the data sheet. When they are specified, the vendor shall submit certificates to the safety enforcement authority.

3.2 Allowable Speeds Compressors shall be conservatively rated at a speed not in excess of that

known by the manufacturer to result in low maintenance and trouble-free operation under the specified service conditions. The maximum acceptable average piston speed shall be 3 m/sec for non lubricating type.

3.3 Compressor Cylinders Step piston cylinder arrangement shall not be used. But single acting or tandem cylinder arrangement may be furnished with the

purchaser's approval. For such cylinder arrangements, adequate design considerations must be given to rod reversals.

3.4 Distance Pieces Distance pieces or compartments shall be equipped with gasketed solid Covers for toxic or flammable gas service. When specified, nitrogen purge connection shall be provided. 4. Compressor Frame Lubrication Lubrication systems shall consist of 2 oil pumps (1 Running + 1 standby) with

suction strainer, a supply and return system, an oil cooler (when required), 2 full-flow filters (1 Running + 1 Standby), and other necessary instruments.

1 No.of Emergency oil pump is also to be provided. 5. Materials All materials of construction in contact with process gases shall be compatible

with the gases handled. Unless otherwise specified, the corrosion allowance for carbon steel knockout pots shall be minimum of 1/8 inch (3.2 mm). The corrosion allowance for heat exchangers and alloy parts required for special services shall be agreed upon by the purchaser and the vendor.

Generally, material of construction shall be as per the Process Licensor’s

recommendations. However, API guidelines may be adopted to the extent possible.

Use of Equivalent or Superior material may be selected & shall be furnished with the offer along with the Chemical Composition.

Material of Complete Lube Oil system shall be SS 304. This includes all items

coming in contact with Oil viz. piping, valves, strainers, filters, flanges, etc. Oil Coolers will have minimum SS 304 tubes.

6 - ACCESSORIES



- 21 -

6.1 Drivers Motors shall conform to standards and codes specified by purchaser and

Electrical Design Philosophy. 6.2 Soleplates and Rails When soleplates, base plates or rails are required, they shall be provided by

the vendor. 6.3 Unless otherwise specified, anchor bolt will be supplied by the Contractor. 6.4 All equipments, such as gears and drivers, directly coupled to the compressor,

shall have Contractor provided stainless steel shims for location on top base plates or soleplates to assist in field alignment.

7 Controls and Instrumentation 7.1 Unless otherwise specified, controls and instrumentation shall conform, where

practical, with API Recommended Practice 550, API Standard 670, and API Standard 678.

7.2 Unless otherwise specified, control panels and gage boards shall be

completely piped and wired, requiring only connection to the purchaser's external piping and wiring circuits.

When more than one wiring point is required on a unit for control or

instrumentation, the wiring to each switch or instrument shall be provided from a single terminal box with terminal posts. The box shall be mounted on the unit (or its base, if any). Wiring shall be installed in metal conduits or enclosures. All leads and posts on terminal strips, switches, and instruments shall be tagged for identification.

8. Piping and Appurtenances 8.1 The vendor shall supply a complete lubricating oil piping system (with its

mounted appurtenances) if it is to be located within the confines of the unit base area, any assembly (console) base, or any packaged unit accessory. This piping shall terminate with flanged connections. Unless otherwise specified, the vendor shall provide all interconnecting piping.

8.2 All necessary piping, valves, fittings and wirings for all instrument panels and

all tubing for un loader controls including interconnecting tubing between the local panel and compressor shall be furnished. This piping shall be shop-fabricated and shop-mounted except for interconnecting piping.

8.3 Instrument- and control-air tubing shall be of 316 stainless steel tube. 8.4 Drain and Vent piping Drain-and-vent piping of Schedule 80 carbon steel less than 1 inch nominal size may be allowed if approved by the purchaser. 9 Inter coolers and After coolers



- 22 -

9.1 Water-cooler shell and tube intercoolers and after coolers shall be designed and constructed in accordance with TEMA Class R as specified in the data sheet. They shall be furnished in accordance with the provisions of the applied Pressure Vessel Code or Standard. When TEMA Class R is specified, the heat exchanger shall also be in accordance with API Standard 660.

MOC of tubes for LO Coolers, Inter & After Coolers shall be SS 304 minimum,

as specified in Clause 2.3.1 of Annexure 4.1. Tubes shall be seamless only. 9.2 Pulsation and Vibration Control Requirements When specified by the purchaser, all reciprocating process compressors shall

have a pulsation suppression device installed at the suction and discharge flanges of each compression stage.

9.3 As a minimum, pulsation suppression equipment shall be designed and fabricated in accordance with Pressure Vessel Code or Standard. 9.4 1-inch minimum external drain connection shall be provided where practical

for each compartment. Where drains are impracticable, circular notched openings in the bulkheads extending to the vessel wall may be used with the purchaser's approval. The effect of such drain openings on pulsation suppressor performance should be considered. Arrangement of internals shall ensure that liquids will flow to drain connections under all operating conditions.

9.6 When specified, flanged inspection openings, complete with blind flanged and

gaskets, shall be provided for access to each compartment. 9.7 Unless otherwise specified, the vendor shall supply a support system for the

pulsation suppressors. 10 Tools All compressors shall be provided with a suitable and safe manual barring

device for maintenance. 11 - PREPARATION FOR SHIPMENT Unless otherwise specified, the equipment components or surfaces subject to

corrosion shall be coated with the vendor's recommended rust preventative approved by the purchaser immediately after inspection.

Temporary rust preventatives shall be easily removable with common petroleum solvents. Equipment shall be closed promptly upon the purchaser's acceptance thereof.



- 23 -

PART D – DESIGN PHILOSOPHY FOR STEAM TURBINES

IN GENERAL, API 612, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING STEAM TURBINES. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

SECTION 1 - GENERAL Vendor Qualification Steam Turbines shall be supplied by vendors qualified by experience to

manufacture the proposed units. To qualify, a vendor must be able to produce a reference list of Turbines built & supplied by them for similar services and at least, 5 of them should be in operation since minimum 3 years of successful operation.

Besides codes & standards, Contractor shall follow National Laws &


1.1 Scope 1.1 (Add) This Philosophy covers the basic requirement for the design, fabrication

, inspection and testing of special purpose steam turbines. It is the purpose of this Philosophy to give supplementary information and to

state deviations or supplementary requirements to API 612 and the Technical Specification.

The numbering of the sections and chapters is the same as in API 612,

edition, June . The type of change - e.g. addition (Add), substitution (Sub) or modification

(Mod) - will be indicated in brackets for each chapter. For regulations or explanations which are not covered by API-standards, (New) chapters have been added.

Any part of API 612 not mentioned herein shall remain unchanged. 1.2.1 Alternative Design For alternative proposals refer to 6.1.1.9 of API-612 Where the vendor wants to deviate from any of the information given in the

a.m. documents, he must ask for the written approval by the purchaser. The deviations have to be listed in order sequence of the document related to

and the reasons for deviating shall be given.



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It shall clearly be understood that lack of any list of deviations will imply, that equipment supplied (offered) is in complete accordance with the specification and the documents mentioned therein.

SECTION 2 - BASIC DESIGN 2. 1 General 2.1.1 (Add) The turbine and its auxiliaries shall be supplied by vendors qualified by

experience in manufacturing the units proposed. The vendor must demonstrate that at the proposed manufacturing place at least five

units for comparable operating conditions have been fabricated and each of these units must have been satisfactorily in continuous operation on for at least three years.

Vendor has to inform the purchaser in writing where major parts will be

manufactured. The vendor must inform the purchaser about his licenser. a. (Mod.)Turbines and auxiliary equipment shall be suitable for the specified operating

conditions and shall be designed and constructed for/continuous, full load duty for a minimum of 16000 hrs of uninterrupted operation.

b.1 (Mod.) The turbine and auxiliary equipment shall be designed for outdoor

installation. c.2 (add.) The rated load shall be at least 110 % of the maximum operating load at any

of the specified operating conditions. Gear losses, if any, shall be added to the 110%. Rated speed is 105% of normal speed.

d. (add.) Vendor shall review and comment on the purchaser's piping and foundation

drawings. e. (add.) Steam strainer shall be a Y-type strainer with approximately 1/8 in. openings.

No additional integral strainer is required. f. (Add.) inlet nozzles shall be replaceable (not welded) into the steam chest.

Stationary blades shall be mounted in replaceable stator blade carriers. g. (Add) Repair welding need special approval by the purchaser. Welding procedure

and certificates for weld s approval shall be furnished. k. (add.) The electrical area classification will apply as stated, if not specified

otherwise in the data sheet or under utility data. l. (Add.) Turbines shall be suitable for washing at normal speed and 80 % load. The

vendor shall state in his proposal the washing procedure he recommends and indicate any special precaution required to avoid damage. Washing Connection Turbine may be suitable for water washing using saturated steam. No water spray nozzle at turbine casing., no washing system in L & T Scope. Washing procedure will be part of user manual. Provision on I/L line by permanent piping with block /



25

bleed arrangement, if agreed by Turbine Manufacturer . m. (Add.) Spare rotors and stationary blades and the stator blade carriers shall be

furnished for each unit. For duplicate machines only one spare rotor and one spare stator are required. 2.2 Casings b. (Add.) All welding joints on pressure casings shall be full penetration welding and

shall be 100 % radio graphed. c. (Mod.) A sentinel warning valve shall be installed on the exhaust casting of all

casings. The sentinel valve setting shall be as stated in table 1, if not specified otherwise in the material requisition. Relief (1 + 1) Valves shall be provided on Condenser.

g. (Add) Turbines with top exhaust shall be provided with a drain system, including

condensate traps for continuous drainage. 2.5 (Add) External Forces and Moments Turbines have to be designed to withstand external forces and moments at least

equal to 2.0 times the values calculated in accordance with NEMA SM-23. The allowable forces and moments have to be shown for each casing and each

nozzle on a drawing. 2.6 Rotating Elements 2.6.3 Blading 2.6.3.1 (Add) Vendor has to give his limits for blading stresses, calculated at 115% speed.

If actual stresses for the various rows are close to those limits, vendor has to prepare references. Kind of damping shall be verified.

2.7 Shaft Seals Carbon ring shaft seals are not permitted for any capacity of Turbine. Specific

approval is needed before contract. Automatic control if specified only. 2.8 Dynamics

2.8.1.9 Critical Speeds 2.8.1.9 ( Sub) The turbine vendor shall supply all necessary (New pt) information to the

vendor of the driven equipment for calculation of torsional and lateral vibration analysis. Turbine vendor shall perform an independent torsional analysis when the train includes a gear unit.

2.8.2 Vibration and Balance



26

Major parts of the rotating element, such as wheels (disks) and balancing drums, shall be dynamically balanced followed by a check of the assembled rotor at 100 % operating speed.

(New) The rotating element shall have multiple dynamic balances during assembly.

The maximum unbalance force at each journal at maximum continuous speed shall not exceed 10 percent of the rotor weight. Rotors with one single key way at coupling ends shall be balanced with a half key mounted.

(Exception) The turbine shall be arranged to permit shaft vibration measurements

adjacent to each bearing while the turbine is in service. (Substitute). Total mechanical and electrical run out shall not exceed more than 0.2

mils at the radial probe positions. Shaft location of probes should be degauzed prior to installation of rotor into the turbine casing. Plating of shafts in this area is not permitted.

(Mod.) The design shall include provision to facilitate field balancing. 2.9 Bearings and Bearing Housings 2.9.1 (Add) Radial bearings shall be fitted with embedded temperature

sensors to detect bearing metal surface temperature. 2.9.2.1 Hydrodynamic thrust bearings shall be of the babbitted, steel- backed multiple-

segment type, designed for equal thrust capacity in both directions, short time reverse operation and arranged for continuously pressurized lubrication to each side.

2.9.2.5 (New) Thrust bearings shall be fitted with imbedded temperature

sensors to detect pad surface temperatures. 2.9.3.5 (Mod) Bearing housings for machines with rated speeds above 5000 revolutions per

minute and fitted with sleeve type bearings shall be designed to accept tilting pad radial bearings without additional machining on bearing housing and shaft.

2.9.5 (Add) a. Radial bearings are to be designed for short time reverse rotation. b. (Mod) Thrust bearings are to be of the double acting multiple segment type with

load equalization suitable for short time reverse rotation. Selection of the thrust-bearings size shall include consideration of thrust loads from the turbine and the thrust required to slip the coupling based on an 0.25 friction factor. Reserve thrust bearing capability should permit operation with some degree of fouling. Thrust loadings shall not exceed 400 psig or 50% of the bearing manufacturer's rating, whatever is less. The thrust bearing shall be adjustable for axial positioning of the rotor and shall be located on the governor end of the turbine. The thrust collar, which revolves with the shaft, shall be replaceable.

f. (Mod.) Both bearing housings shall be designed to accommodate non-

contacting probe to measure shaft vibration. Probes shall be mounted 90 circumferentially apart. Provision for installation of one axial displacement probe at the thrust collar shall be provided.



27

g. (Add) Thermocouples shall be placed in 50% of the active and two thermocouples to be placed in the inactive side (one top, one bottom) of the thrust pads. The thermocouples shall be of Iron-constantan. The extension wire to be run into an outside terminal box supplied by the' vendor. The thermocouples shall be placed into the steel backing at the babbitt interface in the area of maximum oil film temperature.

h. (Add) The radial bearing housing or adjacent to the housing shall provide shaft

access for manual vibration measurements. i. (Add) Bearing housings shall be provided with a 1" vent connection provided with

the manufacturing standard breather cap or closed with a steel plug if no venting is necessary.

j. (Add) Grounding devices shall be provided on the shaft of condensing generator drive turbines.

k. (Add) Bearing housing shall have 1/2" connections for air purging. Lube Oil System 2.10.6 (New) All the oil lines be in stainless steel. This includes piping, fittings, flanges &

valves. All Oil Coolers shall have SS Tubes. 2.10.7 (New) Control oil shall be filtered. If filtered separately from the main oil stream,

dual, replaceable element, 25 micron filters with pressure differential indicator shall be provided.

2.11 Materials 2.11.1 General Generally, Materials of construction shall be as per the Process Licensor’s

recommendation. However, API guideline may be adopted to the extent possible. Use of equivalent & superior material may be selected & shall be furnished with the

offer along with chemical composition. 2.11.1.2 Materials shall be identified with their equivalent ASTM Material Designation with

its’ grade. 2.11.2 Turbine Part 2.11.2.2 Valve seats, plugs and stem shall be of stellited. The hardness of

mating seating surfaces shall be dissimilar. 2.11.3 Castings 2.11.3.3 (Mod) Major repair welding on casted casings is not allowed without the approval of

the purchaser. Major repairs are defined as: Welding, having a depth exceeding 40 % of wall thickness or exceeding an area of

65 cm^2. WPS/PQR for all casted casings must be submitted to the purchaser 4 weeks,

latest, after order placement. Detailed information about post, weld heat treatment has to be included.



28

In case of repair the vendor has to inform the purchaser immediately in detail about the amount of repair work, the repair method and the place where the repair work shall be carried out.

Purchaser reserves the right to reject the casting in case of a high amount of

cracks, holes or inclusions or other defects. Steel Castings shall be repaired in accordance with ASTM a 488. Due to atmospheric Ammonia, Copper or Copper alloy must not be employed for

any piece of equipment of the plant. 2.12 Nameplates 2.12.2 The nameplates shall also contain the contractor's item number. 3.0 3.1.1 COUPLING 3.1.1.1 (mod.) The driven half coupling shall be mounted by the turbine manufacturer. 3.1.1.2 (Add.) The coupling shall be mounted on the shaft with a taper fit and keyed in

place. 3.1.2.2 (Add.) Coupling guards shall be provided with a 1" minimum vent connection with

breather cap or steel plug. SECTION 3 - ACCESSORIES 3.2 Mounting Plates 3.2.2.5 (Mod) Anchor bolts shall be furnished by the vendor. 3.2.3.4 (New) Decking shall be provided on the top of the base plate covering all walk and

work areas. (Add) Horizontal positioning screws shall be supplied on base plates and sole plate

as required for alignment. 3.3 For screw pumps: body shall be CS and internals shall be SS. For valves, body shall be CS and trim shall be SS. Filter body shall be CS and internals shall be SS. Pipes, fittings and flanges shall be SS. Main oil tank, Run down tank shall be SS. Oil cooler tubes shall be Seamless SS and shell can be CS. Pump suction strainers body shall be CS and internals shall be SS. Accumulators are required for steam turbine driven compressors . Rundown tank is required for turbine driven centrifugal compressors. Emergency oil pump is required for steam turbine 3.4 Controls, Protective Devices, Instrumentation



29

3.4.2 Controls 3.4.2.6 (Add.) The governor shall be furnished with hand speed changer and actuator. The

actu control signal will be 3-15 psi for pneumatic instruments and 4 to 20 mA or 10 to 5mA for electronic instruments as specified in the data sheet.

3.4.2.8 (Mod.) Hand-operated nozzle valves are not permitted to meet the requirements of

Para. 6-C-2 (delivering rated power with min. inlet and maximum exhaust conditions) except when specifically requested by the data sheets.

3.4.3 Protective Devices 3.4.3.1 (Sub) A separate, hydraulically or medium operated trip valve has to be supplied

besides the control valves. It shall close by spring action and stop the turbine either upon over speeding, lube

oil pressure falling below a safe level, manual tripping or when actuated by hydraulic, pneumatic, solenoid or other required or specified protective devices.

The trip valve shall be designed for being reset with maximum inlet steam pressure on the line. Seating surfaces shall be of corrosion-resistant material. Renewable seats are required. Turbines with an exhaust pressure less than atmospheric, shall be equipped with a vacuum breaker. Detail of such a system shall be mutually agreed upon by the purchaser and vendor.

3-4.3.3 (Add) Turbines designs which provide for simultaneous closing of the emergency

valve and the governor controlled valves when tripped, are preferred. 3.4.3.7 (Add.) A turbine tripping device shall be provided in the filtered control oil circuit.

This device will receive signals from other protective devices in the turbine, driven equipment or process system. The loss of utilities in the automatic trip circuit shall not cause a shutdown.

3.4.3.0 (Add.) The hydraulic operated trip valve shall permit testing and exercise of the

valve during turbine operation. 3.4.4 Instrument Panel 3.4.4.1 An instrument panel shall be provided and shall include all panel-mounted

instruments for the turbine. The instruments on the panel shall be clearly visible to the operator from the turbine inlet valve, The instruments mounted on the panel shall include but not be limited to :

3.4.5 Other Instrumentation 3.4.5.1 (New) In any case vendor has to supply a local analog speed indicator. (Add.)

Thermometers shall not measure the mixture of radial and thrust bearing oil drainage. Thermocouples to be installed as specified under 15g.

3.4.5-2 New Pt. (Mod.) Switches and control devices shall be furnished and mounted by the

vendor, to actuate purchaser's alarm and shut-down system, as the following service (per table 2 — Alarm and shut-down system)



30

Alarm Shutdown 1) Overspeed trip operation x 2) High turbine extraction pressure X 3) High exhaust pressure x 4) High governor oil filter P x 5) High vibration levels x x (New Pt.) (Add.) Thermometers shall not measure the mixture of radial and thrust bearing oil

drainage. Thermocouples to be installed as specified under 2-9.5.g (New Pt.) (Mod.) The filter differential pressure gauge shall be a single unit connected to

inlet and outlet by a 3 way valve. The 3 way valves shall not permit the filter to be bypassed.

The turbine shall be provided with a non contracting probe and monitoring system. Two

vibration probes and proximitors are to be furnished for each radial bearing and one axial displacement probe and proximitors for installation on the thrust collar.

Two monitors are required for shaft vibration measurements and one for axial displacement indication. Monitors be equipped with "Zenner barriers". Only the connecting cable between Monitor and Proximitors are furnished by the purchaser.

3.5 Gland Vacuum System (Mod) Must be included, if required by turbine design. 3.6 Piping and Appurtenances 3.6.2.6 Material of Complete Lube Oil system shall be SS 304. This includes all items

coming in contact with Oil viz. piping, valves, strainers, filters, flanges, etc. Piping shall be as per Design Philosophy for Piping, Annexure 4.4 3.6.3 After fabrication oil lines shall be thoroughly cleaned. S.S. oil lines shall be pickled,

passivated and immediately coated with a rust inhibitor. 3.7 Insulating and Jacketing 3.7.1 The turbine and its internal steam piping (including flanges, valves etc.) shall be

insulated and jacketed. 3.11 General information to scope of supply Unless otherwise stated in the documents having priority to this Philosophy the

following shall be included in the scope of supply: 3.11.1 All drain and vent connections, equipped with double valves. End shall be Blinded. 3.11.2 Pipes of DN 50 or more shall be prefabricated. 3.11.3 Interconnecting piping shall be fitted and mounted to an extent reasonable

for easy transportation and installation of the machines with their auxiliaries on site.



31

3.11.4 Any part of vendors’ scope, of supply has to be delivered to site in a condition,

which requires only normal erection work like alignment, fastening to foundation, connection to the plant network. Manufacturing at site is not allowed. If equipment has to be completed at site because, of transportation weights or dimensions has to be stated in the proposal and shall be approved by the purchaser.

3.11.5 2 sets of all different typos and sizes of gaskets, 1 set of springs for safety and

control valves, governors etc. 3.11.6 All fixing material required for fastening the machines and their auxiliaries on the

foundation. Foundation bolts for turbines, gears, alternators on concrete table foundations shall have bolts for through holes.

3.11.7 Special tools for maintenance and alignment shall include an alignment device for

each coupling and if required special heating or hydraulic devices for tightening or loosening of casing bolts and the like.

3.11.8 Sound cover boxes have to be equipped with inspection doors as far as applicable

and required for operating and servicing the turbine, and the auxiliaries. 3.11.9 Wherever special flanges cannot be avoided at limits of supply, 1 the vendor has to

supply counter flanges, gaskets bolts and nuts. 3.11.10 Provisions for optical alignment have to be made at the turbine, base frame

etc. SECTION 4 - INSPECTION AND TESTING 4.1 General Inspection shall be carried out in accordance with Annexure Part F-1 & F-4 of this

specification. 4.2 Mechanical run test with shop lube oil system howver with ordered driver only.( i.e

motor / turbine shop driver/turbine. The lube oil system will be functional tested. Job driver will be tested separately.

SECTION 5 - GUARANTEE AND WARRANTY 5.1 Mechanical 5.1.1.1 All equipment and component parts shall be warranted by the vendor against

defective materials, design and workmanship for 1 year after being placed in service.

These are minimum guarantee terms. The purchase order shall govern, when more conservative terms are specified.

5.1.1.2 If any defects or mal performance occur during the guarantee period, the

vendor shall make all necessary alterations, repairs and replacement free of



32

charge, by the vendor. Field labor changes and traveling expenses to be paid by the vendor.

Performance 5.2.2 The steam rate at the normal point (or other point defined by specified horsepower,

speed and steam conditions) shall be guaranteed not to exceed the value state in the proposal (plus "0" percent) when tested in accordance with the latest edition of ASME PTC-6.

5.2.3 If the test run carried out at site shows that the turbine cannot meet the guarantee

figures, the costs for the test will be charged to the vendor. 5.2.4 Purchaser reserves the right to deduct 0,5% from the price of the complete

turbine set up to a maximum of 5%, for every full percent the tolerances on the steam rate guarantee are exceeded.

If the consumption exceeds the guarantee figure more than 10% the

purchaser may reject the complete turbine set, if after a reasonable time vendors improvements to meet the guarantee figures have been ineffective.

Engineering Responsibility

5.3.1 In case of a compressor drive, the engineering responsibility

is with the compressor manufacturer. In that case the turbine manufacturer has to cooperate closely with the

compressor manufacturer, to obtain engineering data for, but not limited to: a) Torsional analysis for the train. b) Selection and testing of power transmitting components, couplings, guards, axial

force. c) Piping stress analysis, forces on nozzles etc. d) Lube - control - and seal oil system design, including co-ordination of oil viscosity,

flow, pressure & temperature , heat . e) Equipment layout and base frame design. f) Common foundation and arrangement & sectional drawings. g) Design of vibration and axial displacement monitoring system. h) Obtaining engineering data for the train components and to submit to the purchaser, i) Power, speed, direction of rotation, shaft and dimensions, distance between shaft

end, Axial & radial shaft moments, Cold & hot alignment dimensions. 5.3.2 In case of a generator drive the engineering responsibility

is with the turbine manufacturer i.e the points 5.3.1 a)-g) have to be executed by the turbine manufacturer in close cooperation with the generator manufacturer.

In case of a synchronous motor/generator the torsional analysis has be carefully

extended to the influence of the oscillating moments with this kind of generators effecting the proper selection of couplings.

For synchronous and asynchronous generators the short circuit moments have to be taken into account as well.

6.0 DOCUMENTS Final Document submission shall be in accordance with Part F-1 of this



33

specification. 6.2.2 Drawings 6.2.2.3) The drawings furnished shall contain sufficient information in the contract language

and contract dimensions, that when combined with the manuals covered by 6.2.5, the purchaser may properly install, operate and maintain the ordered equipment. The requirements in APl-612 are the minimum.

6.2.5 Installations and Instruction Manuals 6.2.5.1 The vendor shall provide, written instructions and a cross referenced list of all

drawings to enable the purchaser to install, operate and maintain the complete equipment ordered. The manuals have to lie related to the special job in question and apply to the data of the technical Specification. Typical manuals are not acceptable, neither for the turbine nor the auxiliaries.

The information shall be compiled in manuals with title pages containing all

identifying data required in 6.2.1.2, index sheets containing section titles and complete lists of enclosed reference drawings by title and drawing number.



34

PART – E DESIGN PHILOSOPHY FOR BLOWERS

IN GENERAL, API 673, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING CENTRIGUGAL BLOWERS. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

1. GENERAL 1.1 Scope This specification, together with the Process & Mechanical Data sheets, covers the

requirements to be met by Vendor in the design, fabrication, inspection, testing, and supply of centrifugal blowers, drivers and power transmissions, and other auxiliary equipment.

1-2 Specific Job Requirements Specific Job Requirements which are attached to this specification cover

modifications to this specification. Customer's special or local requirements as well as specific job data pertinent to this specification. Where Specific Job Requirements are in contradiction to this specification, Specific Job Requirements shall govern.

1.3 Codes and Standards, and Legal Requirements 1.3.1 The latest edition of the codes and standards listed in Appendix, shall form a part of

this specification. 1.3.2 It shall be the responsibility of Vendor that all aspects of the design, fabrication,

inspection and testing conform to the requirements of the specified codes and standards, and legal requirements,

1.3.3 Where there are conflicts between purchaser's data sheets/specifications and the

specified codes and standards or legal requirements, such conflicts shall be promptly referred to purchaser.

1.3.4 Even, if overhang blower is acceptable as per standard

, Only between bearing supported blower is acceptable.

1.4 Purchaser's Data Sheets and Specifications 1.4.1 Purchaser will provide the data sheets which contain the basic process data and

specific requirements necessary for the basic and detailed design of each centrifugal blower.

1.4.2 The related Engineering Specification to supplement this specification is as follows: Part F1 & F6 of Annex 4.2 Inspection & Tests of Centrifugal Blowers 1.4.3 Where requirements on Purchaser's data sheets or specifications are not accepted

by Vendor, suggested alternatives shall promptly be referred to Purchaser for approval before proceeding with the work.

1.5 Vendor's Drawing and Documents 1.5.1 Vendor shall submit to Purchaser the drawings and documents as called for on



35

Purchaser's requisition sheets. 1.5.2 Purchaser's approval for such drawings and documents shall not relieve Vendor of

his responsibility to meet all requirements of the purchase order. 1.5.3 All drawings and documents shall give the name of Client (end user). Purchaser's

Job No., Item No., and the name of the commodity. 1.5.4 Unless otherwise specified, metric, Celsius and kilogram units shall be applied as

the measurement system as referred to Appendix . 2. DESIGN 2.1 Definition of Terms 2.1.1 Normal operating point is the point at which usual operation is expected and at

which optimum efficiency is desired. 2.1.2 Blower rated point is determined as follows: (1) The highest speed necessary to meet any specified operating conditions. (2) The highest capacity required by blower design to meet all operating points. 2.1.3 Normal speed is the speed corresponding to the requirements of the normal

operating point. 2.1.4 In any case blower should not be designed for more than 1200 RPM speed. I.e

Maximum allowable speed of any blower is 1200 RPM. 100% speed is the speed corresponding to the requirements of the blower rated point.

2.1.5 Maximum continuous speed is the upper limit of the operating speed blowers. For

variable speed blower, it shall be at least 105% of the speed of the blower rated point.

2.1.6 Trip speed for steam turbine drives shall be approximately 110% of the maximum

continuous speed. 2.1.7 Trip speed for gas turbine drives shall be approximately 105% of the maximum

continuous speed. 2.1.8 Operating speed range is the set limits on the speed governor to meet the range of

specified operating conditions. The speed range shall be 85 to 105% of the speed at the blower rated point, unless otherwise specified.

2.1.9 Rated horsepower shall be defined as the horsepower required at the specified operating condition demanding maximum horsepower including any gear losses. 2.2 General 2.2.1 Blowers shall be designed and constructed to meet the specified operating

conditions for continuous full load duty for at least three years of service except for the normal maintenance period.



36

2.2.2 Suction and discharge pressures specified on the data sheet are based on static pressures.

2.2.3 Unless otherwise specified, suction pressure stated on the data sheet shall be kept

at blower suction flange. Allowable pressure drop through suction filter shall be as stated in Par. 2.11.2.

2.2.4 Blowers, auxiliaries, and accessories shall be of a construction suitable for outdoor

unsheltered services, unless otherwise specified. 2.2.5 Unless otherwise notified, all blowers shall be so designed that the uninterrupted

service period is 8000 hours on the basis of 24 hours per day operation at the rated operating conditions.

2.2.6 Unless otherwise specified. Vendor shall be fully responsible for the entire blower

assembly including gears, drivers and auxiliaries and for the coordination of all components.

2.2.7 Vendor shall guarantee the blower performance, i.e. capacity, head, speed, and brake horsepower, at the specified blower rated point. Tolerances with respect to the performance characteristics at design speed and head shall be in accordance with requirements specified at in Part F6 of Annexure 4.2..

2.3 Design Pressure and Temperature 2.3.1 Design pressure of casing shall not be less than the maximum possible suction

pressure to be encountered plus the maximum differential pressure that the blower is able to develop when operating at the specified conditions of speed, specific gravity and operating temperature with the furnished impeller. In no case the above maximum suction pressure shall be less than the atmospheric pressure.

2.3.2 Blowers which will operate at temperature above 0°C up to 350"C shall be designed

for the maximum anticipated operating temperature plus 10°C. For the maximum anticipated operating temperature of 350°C and over, 20°C shall be added for design. Blowers which will operate at 0°C and below shall be designed for the minimum anticipated operating temperature.

2.4 Drivers and Power Transmissions 2.4.1 Motor drivers shall have horsepower ratings at least equal to the following percentage

of the blower rated point brake horsepower including any mechanical losses: Motor Rating Percent of Brake Horsepower 19 kW and less 125 % 22 kW to 75 kW 115 % 75 kW and over 110 % 2.4.2 For atmospheric air services, drivers shall be selected so as not to over-load at

minimum atmospheric temperature. 2.4.3 In case of handling high temperature air or light hydrocarbon gas of which specific



37

gravities are less than that of atmospheric air, drivers may be selected using the specified specific gravities on the operating conditions.

2.4.4 Turbine drivers shall have horsepower ratings equal to at least 110% of the blower

rated brake horsepower. 2.4.5 Gear units shall be sized and rated for at least equal to rated output of the driver. 2.4.6 In the case of direct drives, suitable flexible-type spacer type couplings shall be

used. Couplings shall be completely machined to a tolerance of not more than 0.025 mm on the radius and face to face.

2.4.7 Removable coupling guards made of aluminum ( non – sparking) shall be

furnished. 2.4.8 Couplings shall be the limit and float type if bearings of the driver are of sleeve type. 2.4.9 V-belt drives are not acceptable for any power rating. used, the V-belts shall be of

non-spark type. Flat belt shall not be used. Blowers and drivers shall be so arranged that the tension side of belt is lower. No V-belt drives shall be allowed for the blower with the brake horsepower of 120 kW and above.

2.4.10 Removable covers shall be provided on V-belt drives. In the case of outdoor

installation, belt covers shall be of closed type. 2.4.11 All moving parts shall be completely guarded. 2.5 Materials 2.5.1 Unless otherwise specified, materials shall be selected for the specified operating

conditions in accordance with Vendor's standard, unless otherwise specified. 2.5.2 All casting repairs shall be subject to the purchaser's approval prior to proceeding. 2.6 Casings and Nozzles 2.6.1 Casing shall be split so that rotating elements can be easily dismantled. 2.6.2 In case of handling gas including solids or crystals, or if so specified, casing shall be

provided with inspection holes. 2.6.3 Casing shall have drain connections or drain plugs at the bottom. 2.6.4 Inlet and outlet nozzles shall be generally of duct type flanges. Nozzle orientation

will be specified on the data sheets. 2.6.5 Screwed connections shall be generally used for 1/2 inch (13 nun) or smaller pipe

sizes, and shall be in accordance with JIS or ISO pipe threads. Flange connections shall be used for 3/4 inch (19 mm) or larger pipe sizes.

2.6.6 Cast iron flanges shall be flat-faced. 2.7 Auxiliary Piping 2.7.1 Cooling water piping and/or other auxiliary piping shall be furnished fully assembled



38

and installed on the blower, and shall be terminated with a flange to purchaser's piping seals.

2.7.2 Piping sizes shall be 3/8 inch minimum, except for mechanical 2.7.3 Piping sizes of 1-1/4 (32 ram), 3-1/2 (90 mm), 7 (175 mm) and 9 inches (225 mm)

shall not be used unless otherwise specified. 2.7.4 Corrosion allowance of piping shall be 1 nun minimum for carbon and low alloy

steel, and 0 mm for high alloy steel and nonferrous materials. 2.8 Impellers and Shafts 2.8.1 Impellers of cast materials shall be of one piece. Such impellers shall be machined

all over, except for internal fluid passages. 2.8.2 Impellers shall be fixed to the shaft employing key, in such a way that it never

becomes loose. 2.8.3 Shaft shall be of one piece and shall be provided with impellers and shaft sleeve, if

necessary, locked to the shaft. 2.8.4 Major parts of rotating elements shall be balanced statically and/or dynamically.

Peak-to-Peak amplitude of vibration measured on the bearing housing shall not exceed the following values:

Speed Peak-to-Peak Amplitude of Vibration (microns) 2000 rpm and less 63 micron 2001 rpm - 4000 rpm 50.8 micron 4001 rpm and over 38.1 micron 2.8.5 The first critical speed of rotor shall be higher than 120% of normal speed unless

specially approved by the Purchaser. 2.9 Shaft Seals 2.9.1 Shaft seals shall be of gland packings, labyrinths, mechanical seals, oc liquid seals,

and will be specified on the data sheets. 2.9.2 Shaft seals shall be designed so as to be disassembled and inspected without

disassembling the blower casing. 2.9.3 In the case of mechanical seals or liquid seals, the whole seal systems such as pumps,

coolers, filters, and piping shall be provided, when required. 2.9.4 Packings shall be removed for shipping after the shop test. 2.10 Bearings 2.10.1 Ball or roller bearings shall preferably be used for the usual services, and the

minimum calculated life shall be 17500 hours.



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2.10.2 Radial bearings shall be of precision sleeve type with renewable liners or shells. 2.10.3 Bearing lubrication system and cooling system, if required, shall be selected for the

service conditions, and shall be capable of operating continuously with the temperature at any bearing housing not exceeding 70°C or ambient temperature plus 40°C, whichever is lower.

2.10.4 Bearing housings shall be effectively sealed against any invasion of water or dust. 2.11 Baseplates 2.11.1 Baseplates shall preferably be common for directly coupled blowers. 2.11.2 Baseplates shall be of welded construction and shall have enough strength and

rigidity for operation, and be provided with grout holes. 2.11.3 Baseplates shall be of one body construction. Contact surfaces shall be machined

and holddown bolt holes shall fit exactly the machine or part of machine to be mounted thereon.

2.12 Air Filters 2.12.1 Suitable intake air filters and/or wire meshes shall be provided on suction. 2.12.2 Allowable pressure drops through filters shall be as follows:

Condition

Pressure Drop (mm Aq)

Cleaned Max. dirty

5 10

2.12.3 Special air filters when specified on the data sheet for the process, shall be

furnished by Vendor. 2.13 Dampers 2.13.1 When specified, dampers for the purpose of flow control shall be provided. 2.13.2 When manual control dampers are employed, the handle shall be able to be

operated by force less than 10 kg (9.8 N). 2.13.3 When specified, actuators shall be equipped on dampers. The kind of signal to

actuators will be stated on the data sheets 3. INSPECTION AND TESTS All centrifugal blowers shall be inspected and tested in accordance with the

Engineering Specification PART F-1 & F-6 of this Philosophy., unless otherwise specified.

4. MARKING, PAINTING AND SHIPPING



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4.1 Nameplates and Rotation Arrows 4.1.1 Nameplates and rotation arrows on centrifugal blowers and drivers shall be of 18-8

stainless steel or monel attached by pins of similar material and located for easy visibility.

4.1.2 The following data as a minimum shall be clearly stamped on the nameplates. Blowers TEC's Item No.

Gear Unit

Manufacturer's name Manufacturer's name Serial No. Serial No. Date of manufacture Date of Manufacture Size and type Size & Type Rated capacity (m^/h) Gear Ratio Rated head (itimAq.) Rated Input Speed Rated speed (rpm) Rated output speed Rated horse power (kW) Rated Horsepower. 4.2 Markings All materials shipped separately shall be properly tagged or marked with the Item

and Serial No. for which it is intended. 4.3 Painting 4.3.1 Unless otherwise specified, all external surfaces of ferric materials, except that all

exposed machined surfaces shall be thoroughly coated with a rust preventive, shall be painted with not less than one primer coat.

4.3.2 The interior of the centrifugal blowers shall be sprayed or flushed with a suitable

rust preventive. 4.3.3 Details of painting shall be as per Appendix-C. 5. PACKING AND SHIPPING 5.1 General Export packing and shipping shall conform to Purchaser's Shipping Instruction. 5.2 Packing and Preparation for Shipping 5.2.1 Vendor shall clean all components and preserve and protect them on the basis that

the equipment and all accessories will be stored unprotected, in the field for a minimum period of 6 months.

5.2.2 All openings shall be provided with substantial wooden or metal closures. 5.2.3 All tapped openings, not otherwise closed, shall be plugged. 5.2.4 All items shall be suitably packed, securely fastened and protected from damage

during shipment. 5.3 Shipping 5.3.1 Equipment shall not be transported to job site as deck cargo without prior

Purchaser's approval.



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5.3.2 Centrifugal blowers shall generally be shipped as assembled units, except for those with separate bearing pedestals.

5.3.3 No equipment shall be released for shipment from Vendor's shop until it has been approved by Purchaser.

PART G – DESIGN PHILOSOPHY FOR RECIPROCATING PUMPS

IN GENERAL, API 674, LATEST EDITION SHALL BE FOLLOWED FOR PROCURING RECIPROCATING PUMPS. DEVIATION TO THE STANDARD SHALL BE APPROVED BY OWNER.

0.0 INTRODUCTION 0.1 Intention 0.1.1 This specification is intended to supplement API Standard 674, Positive

Displacement Pumps: Reciprocating, latest edition which forms a part of this specification.

0.2 Vendor Qualification All pumps shall be supplied by vendors qualified by experience to manufacture the

proposed units. To qualify, a vendor must be able to produce a reference list of pumps built & supplied by them for similar services.

0.3 Besides codes & standards, Contractor shall follow National Laws & Regulations

together with Local By Laws for the state, including statutory requirement as applicable. Further, Contractor shall specifically note that any applicable local mandatory code / statutory requirement, if any, shall be informed later on.

1. GENERAL 1.1 SCOPE This specification, together with the latest edition of API 674, covers the minimum

requirement for the design, materials, fabrication, shop inspection & Testing of Reciprocating pumps for hydrocarbons, chemicals and water services to be used for Feed Stock Conversion Project and procured by the Contractor appointed for the Project.

1.2 REFERENCE This specification shall be used in conjunction with the: 1. Process Data sheets as per the Process Licensor. 2. Any other Special Requirements laid down by the Process Licensor. 2.0 BASIC DESIGN 2.1 GENERAL



42

2.1.1 Accessories to be supplied by the pump vendor shall be as specified in respective pump data sheets. Accessories required / recommended by vendor (other than those specified in pump specification sheet) for safe and efficient operation of the pump unit, shall be included in the pump vendor’s scope of supply and the same shall be identified in the bid separately with adequate justification.

2.1.2 Pumps shall have SI dimensions and comply with applicable ISO Standards, except

for piping connections which may be as per ASME Standards. 2.1.3 Rated speed of pump at input shaft of gear box drive shall be the full load speed of

motor. In case the driver is not in pump vendor’s scope, full load speed of the driver shall be furnished to the pump vendor along with other details, after order. Pump characteristics shall be guaranteed / tested with reference ton the full load speed of motor.

2.1.4 All threads and fasteners shall preferably be of ISO metric sizes. 2.1.5 Working platform shall be furnished, wherever necessary, for vertical pumps. 2.1.6 NPSHR shall be indicated by the vendor taking into account acceleration head.

For pumps handling volatile liquids, the NPSH required shall be determined and guaranteed after taking into account the heat generated at the glands.

2.1.7 Hollow pistons / plungers shall not be used. Repacking should be possible without

removing piston from the cylinder. 2.1.8 Valves and seats shall have a minimum hardness of 150 BHN if constructed of

carbon or low alloy steel and 225 BHN if of 13% Cr Steel. The difference in hardness between valves and seats shall be 50 BHN minimum.

2.1.9 For liquid end pressure containing parts like cylinders, valve chambers and suction

& discharge manifolds corrosion allowance shall not be less than 3.0 mm for carbon & low alloy steels.

2.1.10 Any water or steam jackets for liquid ends shall envelop liquid cylinders, stuffing

boxes and valve chambers. Jackets shall have threaded inlet and outlet connections and any other openings that may be required for cleaning the entire passage ways.

2.1.11 In case of multithrow pumps, sealing fluid or cooling water shall be controlled for

each cylinder. 2.1.12 Enclosed crank cases, gear units and similar mechanisms shall be sealed.

Removable covers shall be provided for inspection, cleaning and minor adjustments of parts.

2.1.13 Welding of piping and pressure containing parts upto 40 kg/cm2 pressure shall be

spot radiographed. For pressures above 40 kg/cm2 100% radiography, magnetic particle inspection or liquid penetrant inspection of welds is required.

2.1.14 Cooling water or steam piping shall have manifold. Purchaser will provide only one

external connection of each service. Scope of supply of piping shall be shown by vendor on the drawing to be submitted with the offer.



43

2.1.15 Pump vendors scope of process piping shall include complete piping from inlet header to pump(s) up to discharge header of pump(s).

PART F 1 - INSPECTION INSTRUCTIONS TO VENDORS

1. GENERAL 1.1 This instruction covers the general requirements for shop inspection and testing of

equipment and materials (GOODS) to be supplied by the Contractor. Contractor shall be responsible for inclusion of inspection requirements herein and requirements of applicable individual specification as contractual requirements of Sub vendors.

1.2 In addition to the general requirements contained in this specification, the

Contractor shall be responsible for all other inspection requirements as defined by documents included in or referenced by the Purchase Order, Requisition, Specification or Data sheets applicable to the Order.

1.3 GOODS for which no individual specification is issued can be inspected and tested

in accordance with this instruction and Contractor's standards approved by the Purchaser

1.4 All deviations from this instruction and related inspection specifications shall be

previously proposed to the Purchaser in writing and shall be approved by the Purchaser before placement of the order.

1.5 The word "specification(s)" used in this instruction and related inspection

specifications often collectively means all technical specifications, drawings, and other technical documents supplied b^ the Purchaser and also specifications and technical documents as may be agreed and/or made by the Contractor and the Purchaser.

2. DEFINITIONS Words used in this instruction and related inspection specifications shall have the

following meanings, unless the context requires otherwise : Test Report: Means the individual record or certificate for respective test or

inspection. QC Dossier: means the compiled document package consisting of prescribed

Purchaser's cover sheet for QC Dossier, Contractor's cover sheet, table of contents, Test Reports, and other necessary documents.

Purchaser: means Gujarat Narmada Valley Fertilizer Company limited Purchaser's Inspector: Means inspector(s) dispatched by the Purchaser or

inspector(s) of inspection agencies designated by the Purchaser.

Owner’s Inspector: Means one or combination of inspector(s) dispatched by the Owner and inspector(s) of the inspection agency (agencies) designated by the Owner.

Contractor: Means a supplier or manufacturer of GOODS. Sub vendor: Means an organization, company or individual under

contract to Contractor for the supply of material, equipment sub-assemblies or services necessary to the completion of Contractor’s scope of work.



44

3. CODES AND STANDARDS All codes and standards for the inspection of GOODS shall be in accordance with

those specified in section 6.1 of the ITB. 4. CLARIFICATION OF CONFLICTS If there is any conflict between the related specifications, codes and standards, the

Contractor shall immediately consult with the Purchaser in writing for clarification. Failure of Contractor to seek, in writing, clarification of conflicting requirements prior

to acceptance of the Purchase Order shall constitute obligation of Contractor to comply with all of the conflicting requirements at no additional cost, even to the extent that rework and/or retesting may be required.

5. RESPONSIBILITY FOR QUALITY 5.1 Inspection or non-inspection by the Purchaser shall not relieve the Contractor of its

obligation for quality control activities and guarantees for the workmanship or performance of the GOODS.

5.2 The Contractor shall be responsible for inspection and testing of the GOODS,

including parts and materials supplied by Sub vendors. 5.3 The Contractor shall carry out all inspections and testing specified in the purchase

documents. 5.4 All Contractor's fabrication documents, including, but not limited to, welding,

nondestructive examination, heat treatment, and major repair procedures, specified in the requisition shall be reviewed and approved by the Purchaser prior to start of fabrication.

6. PRE-INSPECTION MEETING The Purchaser may require holding a pre-inspection meeting(s) at Contractor

and/or Sub vendors to resolve questions concerning the compliance with the purchase documents, specifically inspection requirements and related specifications. Final inspection items shall also be defined at the meeting. Contractor shall arrange to provide the following documents for this meeting;

1) Copy (Copies) of Purchaser's requisitions, drawings, specifications of the latest

revision and other documents necessary for discussion at the meeting. 2) List of missing documents such as specifications referenced in the Purchaser's

requisition, but not received by the Contractor. 3) Questionnaire about Purchaser's documents. 4) Contractor's drawings, diagrams, and schedules. 5) Fabrication procedure 6) Inspection procedure including NDE procedure 7) Written welding documents 8) Major repair procedure 9) Sample of inspection record(s) for a similar jab previously done by the Contractor 10) Other documents considered necessary Contractor shall also arrange for meeting attendance by all Contractor

representatives necessary to achieve resolution of technical questions, schedules,



45

and inspection requirements. 7. WITNESS INSPECTION NOTICE 7.1 The Contractor shall notify the Purchaser of readiness for witness inspection in

writing at least 4 calendar weeks prior to the date when the GOODS will be ready for inspection.

The Contractor shall also inform the Purchaser of the definite witness inspection date and time at least 10 working days in advance of the date of the witness inspection.

7.2 Verbal inspection notice is not acceptable. Notice shall be sent to Purchaser by

Facsimile (telefax) OR e-MAIL. The inspection notice shall also include the map or the necessary information to reach Contractor's shop, if such information was not given in advance.

7.3 Work shall not proceed beyond "Inspection Hold Points" established by contract

correspondence, Specifications or Pre-Inspection Meeting without written authorization of Purchaser.

8. WITNESS INSPECTION Purchaser's and/or Owner's Inspector shall have free entry to those parts or areas

of manufacturing shops of the Contractor or its sub vendors where and when work, testing or inspection on the GOODS is being performed.

Access shall not be limited to "normal office hours" and escort shall not be required except when agreed for reasons of safety or proprietary work.

Where escort restriction is agreed, Contractor and/or Sub vendor shall make escort available during all hours of shop fabrication, testing or inspection.

8.2 Purchaser's and Owner's Inspector reserve the right to monitor, audit, and visit

plants or other inspection locations with or without prior notice to the Contractor or Sub vendor.

8.3 For inspection items designated for witness of Purchaser's and/or Owner's

inspector, but not designated as inspection hold points, Contractor may, at Contractor's cost and risk, elect to proceed with fabrication after completion of Contractor's in-house inspection, provided that the witness inspection is repeated for witness of the Purchaser's and/or Owner's inspector at time of next inspection visit.

8.4 The Contractor, when so requested, shall provide one additional copy of the latest

approved drawings for the use of Owner's Inspector prior to the start of inspection. 8.5 The Contractor shall furnish Purchaser's and/or Owner's Inspector with shop test

data, mill certificates, and other materials to verify that each GOODS meets the requirements of the applicable specifications. Free copy, telex, facsimile (tele - fax), and telephone service by the Contractor shall be made available to Purchaser's and/or Owner's Inspector.

8.6 Safety equipment and inspection tools as necessary to safely and expeditiously

demonstrate compliance with applicable specifications, as well as assistance from



46

Contractor's or Sub vendor's inspection representative shall be made available to Contractor's and/or Owner's Inspectors.

8.7 When requested by the Purchaser, the Contractor shall prepare the required

number of QC Dossier, its part, or other documents for Owner's Inspector by the requested date.

8.8 Nothing herein shall preclude Contractor's inspection or contracts representative

from accompanying Contractor's and/or Owner's Inspector to Sub vendor locations for inspection purpose.

9. RELEASE FOR SHIPMENT 9.1 Purchaser's Inspector will issue "Inspection Release Note" to the Contractor shortly

after the final inspection and review of QC Dossier prepared by the Contractor. 9.2 The Contractor shall not ship any GOODS without securing the Inspection Release

Note. 9.3 When the Contractor is permitted to ship on condition to perform the additional work

at the work site, the Contractor shall bear all costs and expenses incurred by such work.

(1) Special provision for storage or proper care (2) Repair and/or Inspection 10. DOCUMENTATION Incomplete, inaccurate or illegible documentation shall be the cause for rejection of

GOODS until such time as satisfactory rectification has been effected. 10.1 Documents to be Submitted All Contractor's inspection and test procedures, including, but not limited to,

welding, nondestructive examination, heat treatment, definition of major repairs, and major repair procedures, required for submittal in the requisition shall be reviewed and approved by the Purchaser prior to start of fabrication or prior to use, whichever is the earlier.

(1) The Contractor shall submit to the Purchaser 5 white copies for documents such as Contractor's shop inspection and test procedure and welding procedure specification as required.

Unless otherwise specified, all these documents shall be prepared in English. The Contractor will be requested to submit these documents prior to fabrication. (2) The Purchaser will need a maximum of fifteen (15) working days, excluding mailing

time, from the receipt of the Contractor document to study and accept or give alternative decisions.

10.2 Submittal of QC Dossier (1) The Contractor shall prepare QC Dossier in English and submit 5 white

copies to the Purchaser within seven (7) working days after completion of the final inspection of the GOODS.

(2) For details of QC Dossier preparation, refer to section 11 of this specification. 11. PREPARATION OF QC DOSSIER



47

11.1 Unit of Preparation (1) The QC Dossier of individual pressure vessels, heat exchangers, tanks, and towers

shall be prepared for each equipment. (2) The QC Dossier of unit or packaged items such as boiler units, compressor units,

etc. shall be prepared for each unit or package including subsidiary equipment and accessories.

(3) The QC Dossier of materials, pumps, valves, fittings, instruments, and electrical equipment, which are not included in (1) and (2) above, may be prepared for each order.

In case of partial shipment, the QC Dossier may be divided for each shipment. 11 .2 Forms To prepare the QC Dossier, the Contractor may use its standard forms. 11.3 Compilation (1) As far as possible, A4 (210mm X 297mm) or 8-1/2 in. x 11 in. size paper shall

be used for the test report sheet. For larger sizes, A3 ( 297 mm X 420 mm) may be used, folded to A4 size.

When thickness of the QC Dossier is too thick to compile in one package, it can be divided into two or more packages.

(2) Construction of QC Dossier As far as possible, Test Reports in the QC Dossier shall be in the following order : (a) List of material certificates with part Nos. and part names (b) Material certificates (c) Nondestructive examination records (d) Visual inspection certificates (e) Dimensional inspection records (f) PWHT chart and thermocouple location map (g) Hydrostatic test records, Leak test records (h) Running test records, Performance test records, Operation test records (i) Nameplate rubbing (j) Cross Sectional Drawings / GA Drawings / Fabrication Drawings, Tolerances for

precision parts, etc. (j ) Operation & Maintenance Instructions for machinery. 11.4 Signature Requirements (1) Each document in QC Dossier shall have the verification signature by the

Contractor. (2) Signature by Purchaser's Inspector When witness inspection or review of documents is done by Purchaser's Inspector,

each respective sheet of the QC Dossier shall bear either witness signature or review signature of Purchaser's Inspector.

(3) Each test report sheet shall have the following data or information in addition to signatures :

Test data and/or results Date of test Identification of components tested 11.5 SOFT COPIES



48

Apart from Hard Copies, Soft Copies as per following descriptions shall be submitted by the Contractor:

No. Of Copies: 2 Sets. Medium: CD – R of reputed make viz. SONY / SAMSUNG / MOSER BAER Formats: All Drawings shall be in AUTO CAD 2004. All reports shall be in .TIF Editable Format . 11.6 Measuring Units (1) In principle, measuring units on QC Dossier documents shall be metric unit

except English unit may be applied for pipe, fitting, flange, flange bolts/nuts, and rating.

(2) Units for mill certificates of raw materials may be in accordance with specified codes and standards applicable to such materials.

11.7 Retention of Test Report Contractor shall retain original sheets of Test Report for at least 5 years after

shipment of GOODS.

PART F-2 INSPECTION PHILOSOPHY FOR CENTRIFUGAL PUMPS

1. GENERAL This specification, together with "Inspection Instruction to

Vendors", PART F-1, covers the general requirements for the shop inspection and tests of centrifugal pumps including vertical turbine pumps , mixed flow pumps and axial flow pumps.



49

Besides codes & standards, CONTRACTORs shall follow 2

CODES AND STANDARDS

2.1 Only the latest editions of regulations, codes, and standards in force at the time of order placement shall be applied, unless otherwise specified.

2.2 The requirements in the following codes and standards form a part

of the requirements of this specification: (1) API Standard 610, Section 4, "Inspection, Testing and Preparation

for Shipment" of Centrifugal Pumps for General Refinery Services (2) National standards in regard to materials of the countries from

which the materials are supplied. These standards shall, however, be previously approved by the Purchaser.

(3) Other codes and standards specified in each individual specification.

3.

WITNESS INSPECTION

3.1 All pumps shall be subject to inspection, at the option of the Purchaser, under witness by the Purchaser or designated representative of the Purchaser at any reasonable time and place before, during, and after manufacture/fabrication.

3.2 Witness inspection and test agenda shall be in accordance with

Table 1. 3.3 The owner has the right of access to the Contractor's or Subvendor's

shops for inspection matters. If the Contractor received any instruction from the Owner's Inspector, the Contractor should report to the Purchaser before making any changes.

4. INSPECTION AND TEST AGENDA 4.1 Material Test 1) Materials shall be verified to conform to the specified material

requirements by mill test reports or material certificates. 2) Mill test reports or material certificates for such main parts as

casing, casing cover, impeller, shaft and for other specified parts shall be submitted.

3) For other parts than specified above, mill test reports or material



50

certificates for corrosion resistant austenitic stainless steel and higher grade material such as Hastelloy and Zirconium shall also be submitted.

4.2 Welding Test All welding of piping and pressure-containing parts, as well as any

repair to such parts, shall be carried out only by the qualified welders using qualified welding procedures in accordance with the ASME Code Section IX and/or authorized standard of the country by which the Contractor is governed.

4.3 Dimensional Inspection Overall dimensions, including connection locations, nozzle flange

dimensions, and anchor bolt layout and sizes shall be checked against certified dimensional outline drawings. Unless otherwise specified, tolerances shall be as follows:

(1) Location of suction and discharge nozzles: +5mm (±3/16") (2) Anchor bolt hole pitch: ±5mm (±3/16") (3) Flanges: According to the competent standard for flanges (4) Coupling deflection: Contractor's standard 4.4 Visual Inspection 1) Pumps, including auxiliary piping and accessaries, shall be visually

checked for workmanship. 2) No defects shall be visible on the surface. 3) Location of nameplate and data on the plate shall be checked for

correctness. 4) Rotation arrows shall be provided to show proper rotation. 4.5 Hydrostatic Test 1) Pressure-containing parts (including auxiliaries) shall be

hydrostatically tested in accordance with paragraph 4.3.2 of API 610.

2) Cooling passages and components, including jackets for bearings, stuffing boxes, pedestals, oil coolers, and so forth shall be hydrostatically tested at 150% of the design pressure but not lower than 8.0 kg/cm^G (115 psig).

3) Hydrostatic test pressure shall be maintained for a minimum of 30 minutes.

4.6 Balancing Test 1) Major rotating components such as impellers and balancing drums

shall be dynamically balanced. 2) For multistage pumps, the assembled rotor running around 3600

rpm or over shall be multiplane dynamically balanced.



51

3) The Contractor shall submit the unbalance limit of pumps for Purchaser's approval.

4) Dynamic Balancing shall be witnessed by Purchaser / Purchaser’s Inspector.

4.7 Mechanical Running Test 1) Prior to a performance test, pump's mechanical reliability shall be

checked by continuous running at or near rated speed and capacity for a minimum of one hour to stabilize the temperatare of bearings and lubricating oi1 .

2) During the mechanical running test, pumps shall operate with no undue heating of bearings or no display of unfavorable operation such as noise caused by cavitation.

3) The temperature of bearing parts shall not exceed 40°C (72°F) above the ambient temperature being measured on the surface of bearing casings, but shall not exceed 75°C (167°F) regardless of the ambient temperature.

4) All lube oil pressures, viscosities, and temperatures shall be within the range of operating values recommended in the Contractor's operating instructions for the specified unit being tested.

4.8 Vibration Measurement 1) During the performance test or the mechanical running test,

vibration on bearing housing perpendicular to the shaft shall be measured and recorded at rated speed +10% and capacity +10%.

2) Vibration shall not exceed the following velocity or displacement

values or specified in the respective API standards, whichever more restrictive:

Vibration, Vibration Velocity, Bearing Type Peak to Peak Peak (Unfiltered) _________________ ______________ _________________ Antifriction Bearings 63.5 Microns 7.6 MM / Sec (2.5 Mils) (0.3 inch / sec) Sleeve Bearings 50 Microns 10.2 MM/ Sec (2.0 Mils) (0.4 inch / sec) 4.9 Performance Test



52

1) Each pump shall be performance tested with water for sufficient period to obtain complete test data, including data for head, capacity, and power from shutoff to end of curve at constant speed in accordance with paragraph 4.3.3 of API 610.

2) Pumps, when operated at rated speed and rated capacity, shall be within the following tolerances of the guaranteed characteristics or the test equivalent on both regular and suppression tests:

Guarantee Point % Shutoff % Rated differential head: 0 to 152 m (0 to 500 ft) -2 +10 +5 -10 (*a) 153 to 305 m (501 to 1,000 ft) -2 +8 +3 -8 Over 305 m (1,000 ft) -2 +5 +2 -5 Rated efficiency ....... -0.5 point of efficiency Rated power ....... +4 (*b) NPSHR ................ + 0 * a If a rising head-capacity curve is specified, the negative tolerance

specified here shall be allowed only when the test curve still shows a rising characteristic.

* b Under any combination of the above rated differential head at

guarantee point. 3) Unless otherwise mutually agreed, each pump shall be tested at

the rated speed with a job motor. 4) When specified, NPSHR tests shall be carried out in accordance

with paragraph 4.3.4.1 of API 610. and also the followings: a) NPSHR tests shall be done in accordance with a vacuum tank

suppression test, when NPSHR is smaller than 1 meter or (NPSHA-NPSHR) is smaller than 1 meter.

b) NPSHR tests by suction valve throttling may be used, in the other case than the above 1).

c) A 37. Drop in head (first stage head on multistage pumps) shall be interpreted as indicating cavitations.

d) NPSH Test shall be witnessed by Purchaser / Purchaser’s Inspector.

4.10 Sound Level Test 1) When specified, the sound level test shall be measured during the

performance test at 1 meter apart from the pump surface.



53

2) The sound level shall not exceed 85 dB(A), unless otherwise specified.

4.11 Posttest Internal Inspection 1) After performance test is completed, casings and impellers shall

be dismantled to check the following: a) There shall be no galling, scoring, and other harmful effects on

casing, impeller, bushing, and shaft. b) Inner surfaces shall have no foreign objects. c) Gland packings and gaskets shall conform to the drawings. d) No rust shall appear on the surfaces if the anticorrosive treatment

is specified. e) Wearing surfaces shall be checked & recorded. f) Dismantling of Mechanical seal will be decided on case to case

basis. If not required, the same shall not be dismantled. g) In case of abnormal noise or temperatures, the same shall be

recorded & its cause shall be analyzed & eliminated. 2) For identical pumps, the posttest internal inspection can be

generally performed by sampling one pump. 3) For pumps with hydrodynamic bearings, the bearings shall be

removed and inspected for soundness after the performance test is completed.

4) After posttest internal inspection, the dismantled parts shall be appropriately reassembled for shipment.

4.12 Inspection of Auxiliary Equipment Auxiliary equipment such as lube oil unit, seal oil unit and control

panel, shall be inspected in accordance with applicable specifications at Contractor's or Subvendor's shop.

4.13 Heat run or standard abbreviated tests, as specified, to be

witnessed on electric motor drive. 4.14 Final inspection and dimensional check to be carried out on motor

drivers. 4.15 For steam turbine drivers, hydrostatic test on pressure parts to be

witnessed. 4.16 Running tests on steam turbines to be witnessed. 4.17 Final inspection and dimensional check on steam turbines to be

done.



54

5. DOCUMENT SUBMITTAL The documents prescribed in the following paragraphs shall be

submitted in accordance with "Inspection Instruction to Vendors", PART F-1 of this document.

5.1 Detailed Inspection and Test Procedure Unless otherwise specified, the Contractor shall submit Detailed

Inspection and Test Procedure for the Purchaser's approval within 12 weeks after the date of purchase order or 8 weeks in advance of the date of the first inspection, whichever is earlier.

The procedure shall cover at least the following items and shall

meet requirements of all inquiry and purchase documents, including related Contractor's and Purchaser's correspondence.

1) Inspection and test agenda 2) Specific test methods including test equipment 3) Acceptance criteria 4) Test report and test certificate to be submitted 5) List of measuring instruments for running test and performance

test 5.2 QC Dossier (Test and Inspection Reports) After final inspection, all test records and/or test certificates for

inspection and test given in Table 1 shall be issued as a form of QC Dossier.

TABLE 1 INSPECTION AND TEST AGENDA AND DOCUMENTS TO BE

ISSUED Inspection & Test Test Category Test Report Remarks Agenda Material Test R Reqd By Mill Test Report Dimensional Inspection W Reqd



55

Visual Inspection W Reqd NDT viz. RT, DP, etc R Reqd Hydrostatic Test R Reqd Balancing Test R Reqd Mechanical Run Test W Reqd Note – 2 Vibration Test W Reqd Note – 2 Performance Test W Reqd Note 2 & 3 Incl NPSH Test Sound Level Measurement W Reqd NOTE – 2 Post Test Internal Inspection W Reqd Note – 2 Inspection of Auxilary Eqpt W Reqd Motor Test R Reqd Note – 4 Note 1) W : Witness inspection and test R : Reviewing the manufacturing test report Test Category: Purchaser's inspection Note 2) Witness all pump for identical pumps, unless otherwise specified. Note 3) Performance curves showing head, rapacity, horsepower and

efficiency relationships shall be provided for all pump. Note 4) When motors are supplied together with pumps by the pump

manufacturer, motor test data by the motor manufacturer shall be included in QC Dossier.

PART F- 3 INSPECTION PHILOSOPHY FOR CENTRIFUGAL COMPRESSORS

1. GENERAL 1.1 Intent This specification covers the minimum requirement for the procedures of inspection

and tests to be carried out by Vendor, and the acceptance standards of Purchaser pertinent to such procedures.

1.2 Scope This specification shall apply to shop inspection and tests of Centrifugal

compressors fabricated in accordance with Part C of this Design Philosophy.



56

1.3 Specific Job Requirements Specific Job Requirements which are attached to this specification cover

modification to this specification, customer's special or local requirements as well as specific job data pertinent to this specification. Where Specific Job Requirements are in contradiction to this specification, Specific Job Requirements shall govern.

1.4 Specifications and Drawings 1.4.1 Inspection and tests shall be carried out based on Purchaser's specifications and

data sheets, and Vendor's drawings as approved by Purchaser. Such specifications, data sheets and drawings shall be of the latest.

1.4.2 Where the application of any item in this specification is considered impractical,

Vendor shall, prior to fabrication of compressors, prepare in detail an alternative inspection procedure and submit it to Purchaser for approval.

1.5 Witnessing 1.5.1 Purchaser will, as required, witness Vendor's inspection and tests, and review test

documents. 1.5.2 Witness (hereinafter referred to as Purchaser's inspector) shall mean inspectors of

Purchaser, his designated representative, customer and/or a third party. 1.5.3 Purchaser's inspector shall have free entry to Vendor's shop while work on the

equipment is being performed. 1.5.4 Vendor shall notify Purchaser sufficiently in advance of any inspection and test

operations to permit Purchaser's inspector to arrive at Vendor's shop. 1.5.5 Vendor shall, at the time of witnessing, give Purchase's inspector a copy of the

records of his own prior inspection and tests. This copy shall be in addition to the number specified in Purchaser's requisition sheets.

1.5.6 Witnessing by Purchaser's inspector shall in no way relieve Vendor of his

responsibility to meet the specifications. 2. INSPECTION AND TEST RECORDS 2.1 Submittal of Records Vendor shall submit to Purchaser the following records for each compressor: (1) Material mill test certificates and heat treatment records (2) Non-destructive examination (3) Dimensional inspection (4) Overspeed test (including subsequent inspection) (5) Dynamic balancing test (including gear units) (6) Hydrostatic test (7) Mechanical running test (8) Shaft seal test (9) Gas leak test (10) Performance test (11) Test of gear units and oil system



57

(12) Other inspection and test (where specified) 2.2 Additional Information Vendor shall provide the following information in the first part of all the records of

inspection and tests: (1) Name of Client (end user) (2) Purchaser's Job No., Item No. and Name of commodity (3) Manufacturer's name (4) Date of inspection and tests (5) Size and type of commodity 2.3 Certificate The certificate to verify that all inspection and tests as required have been

completely performed, shall be attached to the records of inspection and tests. This certificate, which shall be in compliance with Purchaser's specific form, shall be signed by Vendor and Purchaser after completion of the inspection and tests.

3. INSPECTION AND TEST ITEMS, PROCEDURES AND ACCEPTANCE

STANDARDS 3.1 Material Test 3.1.1 Material mill test certificates shall be checked for the following parts. The certificate

shall give the chemical compositions, mechanical properties, heat treatment, etc., and they shall meet the requirements of the specified material specifications.

(1) Compressors: Casings (including heads, suction and discharge nozzles and flanges), diaphragms,

shafts, shaft sleeves, impellers, gear couplings (coupling hubs, sleeves and spacers) , casing bolts & nuts

(2) Gear units: Gears, shafts, (3) Main and critical parts of auxiliary equipment: Degassing drums, seal oil drain traps, overhead tanks, seal oil pumps, and other

equipment (where specified) Remarks: Parts of cast iron material may be exempted from submitting certificate.

(excluding casings) 3.1.2 As for Type 315 and 316L stainless steel, examination of molybdenum detecting

shall be done. 3.1.3 The parts, joints and areas as listed in Table-1 shall be non-destructively examined

in accordance with Vendor's standards, except as mentioned below. (1) Techniques and acceptance standards of radiographic examination for welds shall conform to ASME Code Sec. VIII div. 1, UW-51. Remarks: All radiographic films shall be available for review by Purchaser's

inspector. (2) Magnetic-particle or liquid-penetrant examination shall be made at the time

specified in Table-1 and shall cover 100% of all accessible external and internal surfaces of parts or areas.

(3) Acceptance standards for welds on the pressure-retaining casings shall be in accordance with ASME Code Sec. VIII div. 1 Appendix VI for magnetic-particle and Appendix VIII for liquid-penetrant examination.

(4) Ultrasonic examination of forgings shall be performed after its final heat treatment.



58

Ultrasonic examination of welds shall be performed in accordance with ASME Code Sec. VIII div. 1 Appendix U.

(5) Gearing, pinion forging & main wheel forging or castings shall be inspected at forge shop or foundry. Fabricated gear cases shall be inspected at sub-suppliers’ works. Final inspection & dimensional check of gearing to be done at manufacturer’s works.

3.1.4 Repairs on the pressure-retaining castings shall be as follows: (1) Unacceptable imperfections found by magnetic-particle or liquid-penetrant

examination shall be removed and their complete removal shall be verified by additional examination

(2) Pressure-retaining castings shall not be repair-welded except that steel castings may be repaired by welding in accordance with ASTM specification for similar materials.

(3) Before repair-welding, Vendor shall make a sketch clearly showing the defects to be repaired by welding and trasmit it to Purchaser. On this sketch, extent and location of the defect, and details of repair procedure shall be indicated.

(4) After repairs by welding have been made, the finished surfaces of all repair welds shall be examined by magnetic-particle or liquid-penetrant method. In addition, major weld repairs shall be heat-treated, and shall be inspected by radiography as shown in Par. 3.1.3 (1).

3.1.5 Vendor shall verify that all heat treatment, such as stress relief or postweld heat

treatment have been correctly performed in his normal course or as a part of a repair procedure. All heat treatment records (time-temperature charts) shall be available for review by Purchaser's inspector.

3.2 Visual Inspection 3.2.1 Each pressure-retaining casting shall be subjected to visual inspection for all

surfaces, and shall be free from adhering sand, scale, cracks, hot tears or other similar casting defects.

3.2.2 After completion of welding, all welded joints shall be visually inspected and shall be

free from cracks, undercuts or other injurious welding defects. 3.2.3 All machined surfaces shall be carefully checked for finishing. 3.2.4 The casings shall be cleaned both on inside and outside. 3.2.5 During the shop run, checking for oil leaks shall be made. Any leaks shall be

corrected. 3.2.6 The following items shall be inspected in accordance with Vendor's drawings as

approved by Purchaser and Purchaser's data sheets. (1) Rotational direction of compressors, gear units and drivers (2) All name plates (3) Direction and orientation of nozzles (4) Auxiliary piping arrangement (5) Number of accessories and spare parts, etc. 3.3 Dimensional Inspection



59

3.3.1 Dimensional inspection records shall include the followings: (1) Dimensions of the baseplate, including the size and location of each anchor bolt

hole. (2) Clearances and dimensions necessary for maintenance or assembling. (3) Outline dimensions necessary for field connection or installation, including the size,

type and location of the flanges. 3.3.2 Tolerances for any of distances between the anchor bolt holes shall be ± mm,

unless otherwise specified. 3.3.3 The dimensions and type of each flange shall satisfy the applicable specification. 3.3.4 Actual wall thickness of the pressure-retaining compressor casings shall be

checked to meet the thickness requirements. 3.4 Over speed Test (Spin Test) 3.4.1 Each impeller shall be subjected to an over speed test at least for 3 minutes at the

following speed:

Driver

Minimum Test Speed

Motors

115% of synchronous speed

Variable speed units

115% of maximum continuous

speed

3.4.2 After the over speed test, each impeller shall be examined all over by means of

magnetic-particle or liquid-penetrant methods for cracks or other similar defects. 3.4.3 In addition to Par. 3.4.2, each impeller shall be dimensionally inspected for

deformation. 3.5 Balancing Test 3.5.1 Major parts of the compressor rotating element, such as impellers, balancing

drums, etc. shall be individually balanced statically and dynamically. 3.5.2 The compressor rotating element shall have multi plane dynamic balancing during

assembling as follows: (1) This shall be accomplished after the addition of not more than two major elements

to a flexible rotor. (2) A stiff rotor shall have a minimum of three balancing planes. (3) Balance corrections shall only be applied to the new elements. Previously balanced

elements shall not be altered. (4) Dynamic balancing of the rotor shall be checked after mounting of the coupling

hubs. (5) Results of final balancing of the assembled rotating element shall be reported. 3.5.3 The rotating element of gear units shall also be dynamically balanced. 3.6 Hydrostatic Test



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3.6.1 All pressure-retaining parts, including pressure-retaining components, pipings, and equipment in oil system shall be hydrostatically tested with water or light oil at the pressure specified on Purchaser's data sheets.

3.6.2 The test pressure shall be maintained for a minimum period of 30 minutes. There

shall be no evidence of leaking. 3.6.3 Pressure-retaining parts shall not be painted until the hydrostatic test is completed. 3.6.4 Parts which passed the hydrostatic tests shall be die-stamped with the test pressure

and date. 3.7 Mechanical Running Test 3.7.1 All compressors shall be subjected to a mechanical running test in the following

sequence: (1) Operate the compressor at speeds from zero to maximum continuous speed with

stepwise increment of 10% of it or 1000 r.p.m. and run the compressor at maximum continuous speed until the bearing temperature stabilizes.

(2) Increase the speed to 110% of maximum continuous speed and run the compressor for a minimum of 15 minutes.

(3) Run the compressor at maximum continuous speed for minimum of 4 hours. (4) Observe and log vibrations, temperatures, pressure, etc. at all speeds. 3.7.2 Compressor bodies arranged for tandem drive shall be string-tested together as a

unit. All gears supplied with compressors shall be run with the compressor unit during the mechanical running test. Vendor shall subject the gear to a minimum of 10% of gear rating to demonstrate satisfactory performance.

3.7.3 All contract shaft seals and bearings shall be installed in the compressor for the

mechanical running test. (See Par. 3.8 for the shaft seal test) 3.7.4 All contract vibration probes and detectors shall be in use during the mechanical

running test if vibration probes and detectors are provided by Vendor. 3.7.5 During the running tests, the mechanical operation of whole equipment shall be

satisfactory. The double-amplitude of vibration in any plane measured on the shaft adjacent to the bearing housing during operation at maximum continuous speed or any other specified operating speed, shall not exceed the following value or 50.8 y, whichever is less.

Double amplitude (>) = 25.4 x / 200° (Including runout) ^

Where, rpm: maximum continuous speed in revolution per minute 3.7.6 Oil lubrication and water cooling shall be satisfactory during the running tests. In

any case, bearing temperatures and return oil temperatures from bearings shall not exceed 75°C.

3.7.7 For flexible-shaft compressors, the actual first critical speed shall be determined

during the mechanical running test and it shall conform to the requirements specified in PART C of this philosophy.

3.7.8 When spare compressor rotors are ordered with compressors, each spare



61

compressor rotor shall also be subjected to a mechanical running test in accordance with the requirements of this specification.

3.7.9 After completion of the mechanical running tests, all compressors and gear units

shall be wholly dismantled for internal and dimensional inspection. 3.7.10 If replacement of bearings, seals or rotating parts, or any dismantling is required for

improvement of mechanical operation, the initial test will not be acceptable and the final shop test shall be run after such replacements or corrections are made.

3.8 Shaft Seal Test 3.8.1 The shaft seal test shall be carried out for the compressors provided with liquid-film

or mechanical-contact shaft seals. 3.8.2 The amount of seal oil drain (contaminated oil) from each seal, with approximate

design differential pressure stabilized, shall be measured during the 4 hours test required by Par. 3.7.

3.8.3 If the shaft seal test is not made under the condition provided in Par. 3.8.2, a static

shaft seal test after the mechanical running test may be made in accordance with the following procedure under Purchaser's approval.

(1) The compressor casing shall be pressurized with an inert gas to the maximum gas sealing pressure.

(2) The shaft shall be turned manually to check the fit of the seals. (3) The test shall be continued for a minimum period of 1 hour and the amount of seal

oil drain from each seal shall be measured. 3.8.4 The amount of seal oil drain from each seal (adjusted for the design condition) shall

not exceed Vendor's guaranteed value. Seal oil drain in excess of Vendor's guaranteed value means necessity of a full retest after corrections.

3.9 Gas Leak Test 3.9.1 After completion of the mechanical running test and before shipment, a leak test

shall be carried out for the compressor casings for toxic or flammable gas service. 3.9.2 The leak test shall be made in accordance with the following procedure. (1) The compressor casing shall be pressurized with an inert gas (or air) to the rated

discharge pressure and held at this pressure for a minimum of 30 minutes. (2) Checking for gas leaks shall be made by a soap-bubble method or other approved

methods. 3.10 Performance Test 3.10.1 When specified in Purchaser's requisition sheets, compressor shall be subjected to

a performance test in Vendor's shop. Gas conditions shall be as mutually agreed upon by Vendor and Purchaser.

3.10.2 Performance curves for capacity, discharge pressure, and brake horsepower shall

be developed at 100% speed. A minimum of 5 test readings shall be taken.



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3.10.3 Vendor shall submit to Purchaser the detailed description of the test procedure for approval.

3.11 Miscellaneous 3.11.1 During assembling of the oil system and prior to testing, each component and all

piping in oil system shall be cleaned to remove foreign materials, corrosion products and mill scale.

3.11.2 The completed oil system shall be subjected to a shop running test for operation,

sound level and cleanliness in accordance with API 614. 3.11.3 All gear units shall be run to check for vibration, bearing temperature, sound level,

tooth contact and overall mechanical operability at gear vendor's shop in accordance with API 613, except for running gear for minimum of 15 minutes at trip speed (110% of maximum continuous speed for variable speed drivers) and then for a period of 4 hours at maximum continuous speed. The journal and thrust bearings, and gear mesh shall be inspected after completion of the tests.

3.11.4 Details of auxiliary equipment inspection and tests not listed or defined in this specification shall be established by mutual agreement between Vendor and Purchaser.

Table 1. Application of Non-Destructive Examination

METHOD PART

RT

PT or MT

UT

Casings (1 )

(1) Butt-welded joints (2)

(1) Cast steel parts (7) (2) All welds (3) (7)

(1) Forged steel parts (2) Suction and discharge nozzle attachment welds

Impel lers

(1) Welds on built-up impellers (2) Each after the over speed test(4)

Shafts

-

All (7)

All

Casing bolts & nuts

-

All (5)

All (6)

Gear units

-

-

All gears and shafts

Remarks: Method of non-destructive examination is defined as follows:

RT: Radiographic examination MT: Magnetic-particle examination PT: Liquid-penetrant examination UT: Ultrasonic examination

Notes: (1) Fabricated casings shall cover the cases, heads, suction and discharge nozzles and



63

flanges.

(2) Butt-welded joints shall be completely radiographed.

(3) Attachment welds in joining pipings, lugs, etc. to the pressure-retaining casings shall also be examined.

(4) Refer to Par. 3.4

(5) Examination shall be performed on the finished components (after threading).

(6) Examination shall be performed before threading.

(7) Examination shall be carried out after the hydrostatic tests for the casings, and after finish machining for the machined areas.

4.1 In each instance the actual number of calendar days considered to be

sufficient advance notice shall be taken from the official order. 4.2 Shop inspection is required for all compressors. Material certification, shop test

data, radiographic plates, etc. to be sent to the purchaser if equipment is not inspected.

4.3 Vendor to provide at least fifteen calendar days notice to the purchaser prior to

shop inspection by the purchaser. Notes: Purchasers regulations for testing of centrifugal compressor govern. 4.4 For service temperature below 29 C material impact tests shall be made for all

stressed compressor parts. Repair of defeats need special approval by the purchaser.

4.5 Prior to manufacture of compressor casings vendor shall submit workshop drawings

in order to mutually agree upon extent of ultrasonic and radio-graphic testing on welds. '

4.6 The following information shall be given at least 4(four) weeks prior to test.. 1. Drawings of test arrangement. 2. Master copy of the opera ting instruction. , 3. Complete description of the test conditions such as : Medium to be used, gas

analysis, gas properties, speed, pressure ratio, inlet pressure and temperature, isolation of compressor, conditions of lube and seal system.

4. Complete description and technical data of the driver, gear, the instrumentation (type, range, number per measuring point, location etc.)



64

PART F- 4

INSPECTION PHILOSOPHY FOR RECIPROCATING COMPRESSORS

1. GENERAL 1.1 Intent This specification covers the minimum requirements for the procedures of inspection

and tests to be carried out by Vendor, and the acceptance standards of Purchaser pertinent to such procedures.

1.2 Scope 1.2.1 This specification applies to shop inspection and tests of reciprocating compressors

fabricated in accordance with Engineering Specification GB-104, Reciprocating Compressors for Process Gas Services.

1.2.2 Where requirements in this specification are not acceptable by Vendor, suggested

alternatives shall promptly be referred to Purchaser for approval before proceeding with the work.


modifications to this specification, customer's special or local requirements as well as specific job data pertinent to this specification. Where Specific Job Requirements are in contradiction to this specification, Specific Job Requirements shall govern.

1.4 Inspection by Purchaser 1.4.1 Purchaser and/or his designated representative shall have the right to witness

inspection and tests to be carried out by Vendor, and to review Vendor's data and records.

1.4.2 Purchaser's inspector shall have free entry to Vendor's shop while the work on or

testing of the equipment is being performed. 1.4.3 Vendor shall notify Purchaser sufficiently in advance of the witnessed inspection and

test operations to permit Purchaser's inspector to arrive at Vendor's shop. 1.4.4 The term "Purchaser's inspector" in this specification shall also include inspectors of

customer and/or his designated representative. 1.4.5 Inspection by Purchaser's inspector shall in no way relieve Vendor of his

responsibility to meet the requirements of the purchase order. 2. INSPECTION AND TEST RECORDS 2.1 Records and Data Required 2.1.1 The complete records, as outlined in Par. 2.1.2, of inspection and tests shall be

supplied by Vendor to Purchaser after completion of all inspection and tests.



65

2.1.2 The complete records shall include (where applicable): (1) Material certificates (2) Records or certificates of non-destructive examination (3) Dimensional inspection records (4) Certificates of hydrostatic tests (5) Records of turning inspection (6) Records of additional tests (7) Other records/data for auxiliary equipment (when required) 3. INSPECTION AND TEST ITEMS, PROCEDURES AND ACCEPTANCE

STANDARDS 3.1 General 3.1.1 Unless otherwise specified, all compressors, compressor parts and accessories shall

be inspected and tested in accordance with the corresponding paragraphs of this section.

3.1.2 Any additional testing requirement will be stated in Purchaser's requisition sheets

and/or data sheets. 3.1.3 Details of auxiliary equipment inspection and tests not listed or defined in this

specification shall be established by mutual agreement between Vendor and Purchaser.

3.1.4 The following tests/inspection will be witnessed by Purchaser's inspector. (1) Cylinder hydrostatic tests (2) Turning inspection (bar over) (3) All additional tests 3.2 Material Inspection 3.2.1 Material certificates shall be furnished for the following parts. The material

certificates shall state the results of chemical analysis and physical tests, and heat treatment (if any) given the materials.

(1) Compressors: Cylinders & cylinder covers, cylinder liners, pistons, piston rods*, crossheads,

connecting rods, crankshafts (2) Main and critical parts of: Gear units, relief valves, pulsation suppression devices, intercoolers, aftercoolers,

drain separators, etc. (3) Gearing, pinion forging & main wheel forging or castings shall be inspected at forge

shop or foundry. Fabricated gear cases shall be inspected at sub-suppliers’ works. Final inspection & dimensional check of gearing to be done at manufacturer’s works.

Remarks: (1) The hardness shall be measured and reported for the parts indicated

by an asterisk(*). (2) Material certificates are not required for the parts (excluding cylinders

and cylinder covers) made of cast iron materials. 3.2.2 The compressor critical parts as listed in the following table shall be examined by



66

either the magnetic-particle (MT) or liquid-penetrant (PT) method for surface soundness in accordance with Vendor's quality standards. Such surface examination shall cover all critical areas of the parts. For machined surfaces, final examination shall be carried out after finish machining

Parts MT or PT Cylinders & cylinder covers X (1) Piston rods X Connecting rods X Crankshafts X Remark: X - Required Note: (1) Surface examination shall be required for the cast steel or forged steel

parts. 3.2.3 Pressure-retaining castings shall be visually inspected for detection of defects. The

castings shall be free from adhering sand, scale, cracks, hot tears or other similar injurious casting defects.

3.2.4 Repairs and repair welds shall be subject to Purchaser's approval. 3.3 Visual and Dimensional Inspection 3.3.1 Welds shall be visually inspected after completion of the welding and shall be free

from cracks, excessive undercuts or other injurious welding defects. 3.3.2 Machined surfaces of the parts shall be carefully checked for finishing. 3.3.3 During the shop run, cases and oil systems shall be checked for oil and water leaks.

Necessary repairs shall be made. 3.3.4 Dimensional inspection shall comprise check on the followings during assembling or

upon completion. (1) Dimensions of baseplate, including the size and location of foundation bolt holes. (2) Clearances necessary for maintenance (3) Outline dimensions necessary for field installation, including the size, type and

location of the connections 3.3.5 Tolerance for any of distances between the foundation bolt holes shall be ±5 mm,

unless otherwise noted. 3.3.6 Completed unit shall be subjected to a visual inspection to check for: (1) Rotational direction (2) Nameplate description (3) Cleanliness (4) Auxiliary piping arrangement (5) Accessories, spare parts, etc. (6) Painting 3.4 Hydrostatic Test 3.4.1 All pressure-retaining parts (including auxiliaries) shall be hydrostatically tested with



67

liquid in accordance with the following: (1) Compressor cylinders shall be tested at a minimum of 1.5 times the maximum

allowable working pressure (or design pressure). (2) Cooling jackets shall be tested at a minimum of 1.5 times the specified cooling water

pressure, but not less than 8.0 kg/cm2G. (3) All other pressure-retaining parts (such as pressure vessels, filters, coolers, piping,

etc.) shall be tested at a minimum of 1.5 times their maximum allowable working pressure (design pressure) or in accordance with the applicable codes.

3.4.2 The test pressure shall be maintained for a minimum period of 30 minutes. There

shall be no evidence of leaking. 3.4.3 Pressure-retaining parts shall not be painted until the hydrostatic test is completed. 3.4.4 For parts which passed the hydrostatic tests, the test pressure and testing date shall

be die-stamped. 3.5 Turning Inspection (Bar Over) 3.5.1 All compressors shall be completely shop-assembled, and shall be manually barred

over to check runout and clearances. 3.5.2 Dimensional checks shall, as a minimum, be made and recorded as follows:

(1) Top and bottom clearances between the cylinder and piston (see A and B) Cylinder

A B

C1

C2

C1

C2

PISTON ROD



68

(2) Piston rod runout (see Cl and C2)

Piston rod runout in two radial directions through one complete revolution shall be measured on the piston rod adjacent to each cylinder packing case. Maximum total reading shall be determined.

(3) Crankshaft deflection (see D)

Distance between crank arms (D) shall be measured at every 90' through one complete revolution. The difference between maximum and minimum distances, which is defined as a crankshaft deflection, shall be determined.

3.6 Miscellaneous

3.6.1 During assembly of the unit, each component and all piping shall be cleaned to remove foreign materials, corrosion products and mill scale,

3.6.2 All gear units shall be run to check for vibration, bearing temperature, sound level, tooth contact and overall mechanical operability at gear vendor's shop. The journal and thrust bearings, and gear mesh shall be inspected after completion of the running test.

3.6.3 Relief valves shall be checked for proper operation and adjustment made as required.

3.7 (New) The following information shall be given at least

4 (four) weeks prior to test. 1. Drawing of test arrangement. 2. Master copy of the operating instruction. 3. Complete description of the test conditions. 4. Complete description and technical data of the auxiliaries like gear, the

instrumentation (type, range, number per measuring point, location etc), oil system.

3.8 Purchaser will witness the hydrostatic test, no load running test (performance test

if specified), dismantling of the turbine after running test. Contract vibration probes &. proximation shall be used for the

running test.

Crank arm (crank web)



69

PART F- 5 INSPECTION PHILOSOPHY FOR STEAM TURBINES

1. GENERAL 1.1 Intent This specification covers the minimum requirements for the procedures of

inspection and tests to be carried out by Vendor, and the acceptance standards of Purchaser pertinent to such procedures.

This specification shall apply to shop inspection and tests of steam turbines fabricated in accordance with Design Philosophy for Steam Turbine, Part D of this specification.


modification to this specification, customer's special or local requirements as well as specific job data pertinent to this specification. Where Specific Job Requirements are in contradiction to this specification, Specific Job Requirements shall govern.

1.4 Specifications and Drawings 1.4.1 Inspection and tests shall be carried out based on Purchaser's specifications and

data sheets, and Vendor's drawings as spproved by Purchaser. Such specifications, data sheets and drawings shall be of the latest.

1.4.2 Where the application of any item in this specification is considered impractical,

Vendor shall, prior to fabrication of turbines, prepare in detail an alternative inspection procedure and submit it to Purchaser for approval.

1.5 Witnessing 1.5.1 Purchaser will, as required, witness Vendor's inspection and tests, and review

test documents. 1.5.2 Witness (hereinafter referred to as Purchaser's inspector) shall mean inspectors

of Purchaser, his designated representative, customer and/or a third party. 1.5.3 Purchaser's inspector shall have free entry to Vendor's shop while work on the

equipment is being performed. 1.5.4 Vendor shall notify Purchaser sufficiently in advance of any inspection and test

operations to permit Purchaser's inspector to arrive at Vendor's shop. 1.5.5 Vendor shall, at the time of witnessing, give Purchaser's inspector a copy of the

records of his own prior inspection and tests. This copy shall be in addition to the number specified in Purchaser's requisition sheets.

1.5.6 Witnessing by Purchaser's inspector shall in no way relieve Vendor of his

responsibility to meet the specifications. 2. INSPECTION AND TEST RECORDS



70

2.1 Submittal of Records Vendor shall submit to Purchaser the following records for each turbine: (1) Material mill test certificates and heat treatment records (2) Non-destructive examination (3) Dimensional inspection (4) Overspeed test (including subsequent inspection) (5) Dynamic balancing test (including gear units) (6) Hydrostatic test (7) No-load running test (8) Test of gear units (9) Other inspection and tests (where specified) 2.2 Additional Information Vendor shall provide the following information in the first part of all the records of

inspection and tests: (1) Name of Client (end user) (2) Purchaser's Job No., Item No. and Name of commodity (3) Manufacturer's name (4) Date of inspection and tests (5) Size and type of commodity 2.3 Certificate The certificate to verify that all inspection and tests as required have been

completely performed, shall be attached to the records of inspection and tests. This certificate, which shall be in compliance with Purchaser's specific form, shall be signed by Vendor and Purchaser after completion of the inspection and tests.


STANDARDS 3.1 Material Test 3.1.1 Material mill test certificates shall be checked for the following parts. The

certificate shall give the chemical composition, mechanical properties, heat treatment, etc., and they shall meet the requirements of the specified material specifications.

(1) Special-purpose steam turbine: casings, shafts, wheels, nozzle rings, casing bolts & nuts, governor valves and

emergency valves (body & steam) (2) General-purpose steam turbines: casings, shafts, wheels (3) Gear Units: gears, shafts (4) Gearing, pinion forging & main wheel forging or castings shall be inspected at

forge shop or foundry. Fabricated gear cases shall be inspected at sub-suppliers’ works. Final inspection & dimensional check of gearing to be done at manufacturer’s works.

Remarks: (1) Parts of cast iron material may be exempted from the certificate. (2) Casing shall mean all parts subject to steam pressure.



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3.1.2 As for Type 316 and 316L Stainless Steel, examination for molybdenum

detection shall be done. 3.1.3 The parts, joints and areas as listed in Table-1 shall be non-destructively

examined in accordance with Vendor's standards, except as mentioned below. (1) Techniques and acceptance standards of radiographic examination for welds

shall conform to ASME Code Sec. VIII div. 1, UW-51. Remarks: All radiographic films shall be available for review by Purchaser's

inspector. (2) Magnetic-particle or liquid-penetrant examination shall be made at the time

specified in Table-1 and shall cover 100% of all accessible external and internal surfaces of parts or areas.

(3) Acceptance standards for welds on the pressure-retaining casings shall be in accordance with ASME Code Sec. VIII div. 1 Appendix VI for magnetic-particle and Appendix VIII for liquid-penetrant examination.

(4) Ultrasonic examination of forgings shall be performed after its final heat treatment.

3.1.4 Repairs on the pressure-retaining casings shall be as follows: (1) Unacceptable imperfections found by magnetic-particle or liquid-penetrant

examination shall be removed and their complete removal shall be verified by additional examination.

(2) Pressure-retaining castings shall not be repair-welded except that steel castings may be. repaired by welding in accordance with ASTM specification for similar materials.

(3) Before repair welding, Vendor shall make a sketch clearly showing the defects to be repaired by welding and transmitted it to Purchaser. On this sketch, extent and location of the defect, and details of repair procedure shall be indicated.

(4) After repairs by welding have been made, the finished surface of all repair welds shall be examined by magnetic-particle or liquid-penetrant method. In addition, major weld repairs shall be heat-treated, and shall be inspected by radiography as shown in Par. 3.1.3(1).

3.1.5 Vendor shall verify that all heat treatment, such as stress relief or postweld

heat treatment have been correctly performed in his normal course or as a part of a repair procedure. All heat treatment records shall be available for review by Purchaser's inspector.

3.2 Visual Inspection 3.2.1 Each pressure-retaining casting shall be subjected to visual inspection for all

surfaces and shall be free from adhering sand, scale, cracks, hot tears or other similar casting defects.

3.2.2 After completion of welding, all welded joints shall be visually inspected and

shall be free from cracks, undercuts or other injurious welding defects. 3.2.3 All machined surfaces shall be carefully checked for finishing. 3.2.4 The casings shall be cleaned both on inside and outside. 3.2.5 During the shop run, checking for oil leaks and steam tightness shall be made.

Any leaks shall be corrected.



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3.2.6 The following items shall be inspected in accordance with Vendor's drawings

as approved by Purchaser and Purchaser's data sheets. (1) Rotational direction of turbines and gear units (2) All nameplates (3) Direction and orientation of nozzles (4) Auxiliary piping arrangement (5) Numbers of accessories and spare parts, etc. 3.3 Dimensional Inspection 3.3.1 Dimensional inspection records shall include the following: (1) Dimensions of the baseplate, including the size and location of each anchor

bolt hole (2) Clearances and dimensions necessary for maintenance or assembling (3) Outline dimensions necessary for field connection or installation, including the

size, type and location of the flanges 3.3.2 Tolerances for any of distances between the anchor bolt holes shall be ±5 mm,

unless otherwise specified. 3.3.3 The dimensions and type of each flange shall satisfy the applicable

specification. 3.3.4 Actual wall thickness of the pressure-retaining turbine casings shall be

checked to meet the thickness requirements. 3.4 Overspeed Test (Spin Test) 3.4.1 Each rotor of the special-purpose steam turbines shall be subjected to a

momentary overspeed test at 110% of the trip setting to verify the safety of the rotor.

3.4.2 After the overspeed test, each rotor shall be visually and dimensionally

inspected for deformation, cracks or other similar defects, and rebalanced. 3.5 Balancing Test 3.5.1 Major parts of the turbine rotating element, such as wheels, shafts, etc., shall

be individually statically balanced. 3.5.2 The turbine rotating element shall be dynamically balanced with coupling hubs

in place. 3.5.3 The rotating element of gear units shall also be dynamically balanced. 3.6 Hydrostatic Test 3.6.1 All pressure-retaining parts including pressure-retaining components, piping,

and equipment in oil system shall be hydrostatically tested with water or light oil at the pressure specified in Purchaser's data sheets.

3.6.2 The test pressure shall be maintained for a minimum period of 30 minutes.

There shall be no evidence of leaking. 3.6.3 Pressure-retaining parts shall not be painted until the hydrostatic test is



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completed. 3.6.4 Parts which passed the hydrostatic tests, shall be die stamped with the test

pressure and date. 3.7 No-Load Running Test 3.7.1 All turbines shall be subjected to a no-load running test with contract bearings

and seals in place as follows: (1) Steam conditions shall be as close to normal as practicable. (2) The no-load running test shall be conducted using an oil with the same viscosity

for the field operation. (3) Turbine speed shall be gradually increased except that the first critical speed

shall be passed as fast as practicable. (4) Vibration reading shall be taken at specified operating speeds, just below trip

speed, and through any observed critical speed. (See Par. 3.7.2 for Magnitude of vibration)

(5) Speed governor and any speed regulating device shall be tested for smooth performance over operating speed range, conformance to specified limits of regulation, no-load stability and response to control signal.

(6) Over speed governor and other trip mechanisms shall be checked at least three times and adjustment made as required.

(7) After bearing and lube oil temperatures have reached equilibrium, the turbine shall be run at maximum continuous speed for a minimum period of one hour without further undue rise in bearing and lube oil temperatures. (See Par. 3.7.3 for temperature limits)

3.7.2 During the running tests, the mechanical operation of all equipment shall be

satisfactory. The double-amplitude of vibration in any plane measured on the shaft adjacent to the bearing housing during operation at maximum continuous speed or any other specified operating speed shall not exceed the following limits.

(1) Special-purpose turbines:

Double-amplitude ( µ ) = 25.4 x (12000/rpm) ^ ½ OR Whichever is less (including run out)

50.8 µ,

(2) General-purpose steam turbines: Maximum Continuous Speed Double Amplitude N (rpm) ( µ ) N < / = 4,000 50.8 4,000 < N 38.1

GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED 50000 MTPA PAC PROJECT SECTION 6 ANNEXURE 4.2

DESIGN PHILOSOPHY FOR MACHINARY

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When the vibration cannot be measured on the shaft, the double-amplitude of vibration as measured on the bearing housing shall not exceed 50% of the above limits.

3.7.3 Oil lubrication and water cooling shall be satisfactory during the running tests. in any case, bearing temperatures and return oil temperatures from bearings shall not exceed the allowable limits as specified below:

Lubricating Type Allowable Limits Non-pressure* 70°C or ambient temperatures plus 40°C

whichever is less Pressure 75°C Note: * The temperature may be measured on the bearing housing. 3.7.4 For flexible shaft turbines, the first actual critical speed shall be determined

and shall conform to requirements specified in Design Philosophy for Turbines.

3.7.5 For turbine casings equipped with sentinel warning valve, the action of the

valve shall be ascertained at least three times with steam. 3.7.6 When spare turbine rotors are ordered with the turbines, each spare rotor

shall also be subjected to a no-load running test in accordance with the requirements of this specification.

3.7.7 After completion of the no-load running tests, all turbines shall be wholly

dismantled for internal and dimensional inspection. 3.7.8 If replacement of bearings, seals or rotating parts or any dismantling is

required for improvement of mechanical operation, the initial test will not be acceptable and the final shop test shall be run after such replacements or corrections are made.

3.7.9 No-load running test records shall include the followings: (1) Vibrations, temperatures and pressures of oil and steam (2) Performance test results of all control and protective devices (3) Axial thermal expansion in relation to casings and shafts (for special-

purpose steam turbines) 3.8 Miscellaneous 3.8.1 During assembly of the oil system, each component and all piping in oil

system shall be cleaned to remove foreign materials, corrosion products, and mill scale.

3.8.2 All gear units shall be run in gear vendor's shop at turbine speeds to check



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for vibration, bearing temperatures, sound level, tooth contact and overall mechanical operability. After completion of the running tests, the journal and thrust bearings and gear mesh shall be inspected.

3.8.3 Unless otherwise specified in Purchaser's requisition sheets, performance

tests shall not be required for the turbines. 3.8.4 Details of auxiliary equipment inspection and tests not listed or defined in this

specification shall be established by mutual agreement between Vendor and Purchaser.

Table 1 Application of Non-Destructive Examination METHOD PART

RT

PT or MT

UT

Special— Purpose Steam Turbines

(1) Cast steel parts (5) (2) All welds (2) (5)

Casings (Parts subject to steam pressure)

(1) Butt-welded Joints (1)

Shafts & wheels

-

All (5)

All

Casing bolts & nuts

All (3)

All (4)

General-Purpose Steam Turbines

_

All Shafts & wheels

-

Gear Units

_

—

All Shafts & gears

Remarks: Method of non-destructive examination is defined as follows: RT: Radiographic examination MT: Magnetic-particle examination PT: Liquid-penetrant examination UT: Ultrasonic examination Notes: (1) Butt-welded joints shall be completely radiographed. (2) All attachment welds in joining pipings, lugs, etc. to the pressure-retaining

casings shall also be examined. (3) Examination shall be performed on the finished components (after threading). (4) Examination shall be performed before threading. (5) Examination shall be carried out after the hydrostatic tests for the casings

and after finish machining for the machined areas. 3.9 The following information shall be given at least

4 (four) weeks prior to test. 1. Drawing of test arrangement. 2. Master copy of the operating instruction.



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3. Complete description of the test conditions. 4. Complete description and technical data of the auxiliaries like gear, the

instrumentation (type, range, number per measuring point, location etc), oil system.

3.10 Purchaser will witness the hydrostatic test, no load running test (performance test

if specified), dismantling of the turbine after running test. Contract vibration probes &. proximation shall be used for the

running test.

PART F- 6 INSPECTION PHILOSOPHY FOR BLOWERS

1. GENERAL 1.1 Intent This specification covers the minimum requirements for the procedures of

inspection and tests to be carried out by Vendor, and the acceptance standards of Purchaser pertinent to such procedures.

1.2 Scope 1.2.1 This specification applies to shop inspection and tests of centrifugal blowers

fabricated in accordance with Design Philosophy of Blowers Part E of this specifications.

1.2.2 Where requirements in this specification are not acceptable by Vendor,

suggested alternatives shall promptly be referred to Purchaser for approval before proceeding with the work.


modifications to this specification, customer's special or local requirements as well as specific job data pertinent to this specification. Where Specific Job Requirements are in contradiction to this specification, Specific Job Requirements shall govern.

1.4 Inspection by Purchaser 1.4.1 Purchaser and/or his designated representative shall have the right to witness

inspection and tests to be performed by Vendor, and to review Vendor's records and data.

1.4.2 Purchaser's inspector shall have free entry to Vendor's shop while work on or

testing of the equipment is being performed. 1.4.3 Vendor shall notify Purchaser sufficiently in advance of the witnessed inspection

and test operations to permit Purchaser's inspector to arrive at Vendor's shop. 1.4.4 The term "Purchaser's inspector" in this specification shall also include inspectors

of customer and/or his designated representative.



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1.4.5 Inspection by Purchaser's inspector shall in no way relieve Vendor of his

responsibility to meet all requirements of the purchase order. 1.4.6 For fabricated impellers, welding procedure and welders’ qualification shall be

established and impellers shall be inspected before assembly for Impeller over speed, NDT after over speed & dimensional inspection.

2. INSPECTION AND TEST RECORDS 2.1 Records and Data Required 2.1.1 The complete records, as outlined in Par. 2.1.2, of inspection and tests shall be

supplied by Vendor to Purchaser after completion of all inspection and tests. 2.1.2 The complete records shall include (where applicable): (1) Material certificates (2) Dimensional inspection records (3) Certificates of hydrostatic tests (4) Performance test records 3. INSPECTION AND TEST ITEMS, PROCEDURES AND ACCEPTANCE

STANDARDS 3.1 General 3.1.1 Unless otherwise specified, all blowers, blower parts and accessories shall be

inspected and tested in accordance with the corresponding paragraphs of this section.

3.1.2 Performance tests, and dismantling inspection following final running tests when

required will be witnessed by Purchaser's inspector. 3.2 Material Inspection 3.2.1 Material certificates shall be furnished for the following parts of alloy steel or

special material construction. The material certificates shall state the results of chemical analysis and physical tests, and heat treatment (if any) given the materials.

(1) Casings (2) Impellers (3) Shafts 3.2.2 Pressure-retaining castings shall be visually inspected for detection of defects.

The castings shall be free from adhering sand, scale, cracks, hot tears or other similar injurious casting defects.

3.3 Visual and Dimensional Inspection 3.3.1 Welds shall be visually inspected after completion of the welding and shall be

free from cracks, excessive undercuts or other injurious welding defects.



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3.3.2 Machined surfaces of the parts shall be carefully checked for finishing. 3.3.3 During the shop run, casings and oil systems shall be checked for oil leaks and

air tightness. Necessary repairs shall be made. 3.3.4 Dimensional inspection shall comprise check on the followings during assembling

or upon completion. (1) Dimensions of baseplate, including the size and location of foundation bolt holes (2) Running clearances necessary for maintenance, such as clearances at

mouthrings, etc. (3) Outline dimensions necessary for field installation, including the size, type and

location of the connections 3.3.5 Tolerance for any of distances between the foundation bolt holes shall be ±5 mm,

unless otherwise noted. 3.3.6 Completed unit shall be subjected to a visual inspection to check for: (1) Rotational direction (2) Nameplate description (3) Cleanliness (4) Auxiliary piping arrangement (5) Accessories, spare parts, etc. (6) Fainting 3.4 Balancing Test Major parts of the rotating element shall be balanced statically and/or

dynamically. 3.5 Hydrostatic Test 3.5.1 The blower cast casings shall be hydrostatically tested with water at a minimum

of 1.5 times the casing design pressure, but not less than 2.0 3.5.2 The test pressure shall be maintained for a minimum period of 30 minutes. There

shall be no evidence of leaking. 3.5.3 Pressure-retaining parts shall not be painted until the hydrostatic test is

completed. 3.5.4 For parts which passed the hydrostatic tests, the test pressure and testing date

shall be die-stamped. 3.6 Performance Test 3.6.1 Unless otherwise specified, all blowers shall be subjected to a performance test at

rated speed as follows. 3.6.1.2 The complete records shall include (where applicable): (1) Material certificates (2) Dimensional inspection records (3) Certificates of hydrostatic tests (4) Performance test records



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STANDARDS 3.1 General 3.1.1 Unless otherwise specified, all blowers, blower parts and accessories shall be

inspected and tested in accordance with the corresponding paragraphs of this section.

3.1.2 Performance tests, and dismantling inspection following final running tests when

required will be witnessed by Purchaser's inspector. 3.2 Material Inspection 3.2.1 Material certificates shall be furnished for the following parts of alloy steel or

special material construction. The material certificates shall state the results of chemical analysis and physical tests, and heat treatment (if any) given the materials.

(1) Casings (2) Impellers (3) Shafts 3.2.2 Pressure-retaining castings shall be visually inspected for detection of defects.

The castings shall be free from adhering sand, scale/ cracks, hot tears or other similar injurious casting defects.

3.3 Visual and Dimensional Inspection 3.3.1 Welds shall be visually inspected after completion of the welding and shall be

free from cracks, excessive undercuts or other injurious welding defects. 3.3.2 Machined surfaces of the parts shall be carefully checked for finishing. 3.3.3 During the shop run, casings and oil systems shall be checked for oil leaks and

air tightness. Necessary repairs shall be made. 3.3.4 Dimensional inspection shall comprise check on the followings during assembling

or upon completion. (1) Blowers shall be operated over a sufficient range of flow to obtain the reasonable

performance curves. Test data readings shall be taken at a minimum of 5 points, including shut-off (or surging limit) and maximum flow.

(2) Blowers provided with the damper shall be tested to verify adequate flow control over the specified control range.

(3) Blowers shall be run at rated conditions for the purpose of mechanical checking for a minimum duration of 1 hour.

3.6.2 When the blower cannot be operated at rated speed for reasons of testing facility,

tests may be done at a speed different from rated speed within ±20%. 3.6.3 In general, the gas used during the tests shall be air.



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3.6.4 The contract mechanical seals shall be installed in the blower during the tests and checked for tightness.

3.6.5 The contract driver shall not be used for shop tests if there is any possibility of

serious overload. In this case testing driver of which efficiency values are known shall be used for the tests.

3.6.6 Test results shall be converted to speed and specific weight at rated conditions. 3.6.7 The tolerances with respect to the performance characteristics at rated speed

and rated capacity shall be as follows: (1) Head : -0%

(2) Brake horsepower: Drivers

Driver Ratings (kW)

Tolerance (%)

Motors

19 and less

+10

22 to 55

+6

75 and more

+4

Turbines

-

+4

3.6.8 Vibration measurements shall be made during the running test. (Results shall be

recorded at rated conditions.) The peak-to-peak amplitude of vibration in any plane measured on the bearing housings shall not exceed the following limits.

3.6.9 Oil lubricating and water cooling shall be satisfactory during the tests. The bearing

temperatures shall be measured until they reach almost constant value, and they shall not exceed the allowable limits as specified below:

Lubricating Type

Allowable Limits

Non-pressure (^)

70°C or ambient temperature plus 40°C, whichever is less

Pressure (2)

70°C

Rated Speed (rpm)

Vibration Peak-to-Peak (Vm)

2000 and less

63.5

2001 to 4000

50.8

4001 and more

38.1



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Notes (1) The temperatures may be measured on the bearing housings. (2) Temperatures of return oil (drain oil) from the bearings shall also be

measured. 3.6.10 Noise measurements shall be made all around the blower during the running test

with a calibrated sound level meter. The microphone shall be located at the distance of 1.0 m from the nearest surface of the blower casing, and at the height of about 1.0 ra above the floor.

3.6.11 After completion of the running test, sleeve type bearings and mechanical seals

shall be removed, inspected and re-assembled in the blower. 3.6.12 If dismantling is necessitated because of some corrections, such as improvement

of mechanical or performance deficiencies, the initial tests will not be acceptable and the final shop tests shall be run after such corrections are made.

3.6.13 Test records shall include the followings: (1) Test curves and data such as capacity, head, efficiency/ brake horsepower and

speed (2) Vibration, bearing temperature and noise readings



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PART F- 7 INSPECTION PHILOSOPHY FOR RECIPROCATING PUMPS

1. GENERAL This specification, together with "Inspection Instruction to Vendors", PART F-1,

covers the general requirements for the shop inspection and tests of Reciprocating pumps.

Besides codes & standards, CONTRACTORs shall follow 2

CODES AND STANDARDS

2.1 Only the latest editions of regulations, codes, and standards in force at the time of order placement shall be applied, unless otherwise specified.

2.2 The requirements in the following codes and standards form a part of the

requirements of this specification: (1) API Standard 674, 2nd Edition, 1995, Section 4, "Inspection, Testing and

Preparation for Shipment" of Centrifugal Pumps for General Refinery Services (2) National standards in regard to materials of the countries from which the

materials are supplied. These standards shall, however, be previously approved by the Purchaser.

(3) Other codes and standards specified in each individual specification.

3.0 INSPECTION, TESTING AND PREPARATION OF SHIPMENT: 3.1 (4.1.1) Purchaser’s inspector shall witness the inspections and tests as below: a) Visual inspection. b) Dimensional inspection.

c) Non destructive examination (magnetic particle / dye penetrant / ultrasonic / radiography etc. where specified.)

d) Hydrostatic test. e) Performance test. f) Dismantling inspection. g) Inspection & testing of auxiliaries. h) Direction of rotation with respect to drive. i) Visual & dimensional inspection of spares. A minimum of ten days advance notice shall be given to purchaser’s inspector. 3.2 (4.1.2) Check list duly signed by both vendor’s and purchaser’s inspector shall be

submitted. 3.3 (4.2.1.1.a) Add: Material certificates for at least the following items shall be

submitted. a) Cylinder b) Crank shaft c) Piston / Plunger d) Connecting rod & piston rod. e) Cylinder liner (if any) f) Valves & valve seats g) Stuffing box h) Dampeners



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Material certificates shall indicate. a) Chemical analysis b) Physical properties c) Heat treatment details, if any 3.4 (4.2.1.1.d) Final assembly maintenance and running clearances shall be indicated

in maintenance manuals. 3.5 (4.2.1.3) & (4.2.2.1) a. For pumps of horse power 75 KW or more, shaft, gear, piston rods, connecting

rods, plungers, valves, valve sheets and cylinder (including liner, if any) shall be subjected to ultrasonic examination prior to matching.

b. Butt welded casting of pressure casing shall be radiographed. c. Repair welded casting cross heads & gudgeon pins shall be examined by means

of magnetic particle / dye penetrant methods. d. Non destructive testing of heat exchangers and pressure vessels shall be as per

relevant material specification standards. 3.6 (4.2.3.3) Requirement of this clause shall be complied with unless waived by

purchaser’s inspector. 3.7 (4.2.3.4) Requirement of this clause may be mutually agreed upon by the vendor’s

and purchaser’s inspector. 3.8 (4.3.1.4) Tests as per this clause shall be performed on the pump. 3.9 (4.3.4.1) Performance testing may be carried out in accordance with ASME PTC

7.1 instead of Hydraulic Institute Standards. 3.10 (4.3.4.3) Requirement of this clause shall be mutually agreed upon by the

purchaser and vendor depending upon the test facilities available. 3.11 (4.3.6) Refer pump specification sheets. 3.12 All auxiliary pressure vessels and heat exchangers shall be inspected and tested

in accordance with specified requirements of the applicable codes / standards. 3.13 All accessories i.e gear box, coupling, torque converter (if required), etc. shall be

inspected and tested as per the applicable codes / standards. 3.14 Instruments and control panels shall be tested and inspected as per the applicable

instrument specifications. 3.15 Electric motor drivers shall be tested and inspected as per the respective motor

specification sheet and the applicable engineering standard specified. 3.16 Acceptance of shop test shall not absolve the vendor of his responsibility in any

way. 3.17 (4.4.8) To the extent possible fit up and assembly of machine mounted piping,

intercoolers, etc. shall be completed in the vendors shop.



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CONTENTS PART H – ROTATING MACHINARY DOCUMENTATION SCHEDULE

SECTION NUMBER

DESCRIPTION

A PUMP B COMPRESSOR C TURBINE D FAN / BLOWER



- 86 -

SL. No.

Name of Document With Bid

Delivery Time in Weeks from placement of Letter of Intent (LOI)

Y/N For approval/

Information

For information

Final / approved/

As-built

A) PUMP

1.0 List of drawings / documents including drawing number, revision number, description and approval status N 4 - 8

2.0 Detailed manufacturing programme (Time bar chart )

Y 4 - -

3.0 Certified dimensional outline drawing

N 4 - 8

4.0 Cross sectional drawing and bill of material

N 4 - 8

5.0 Shaft seal drawing and bill of material

N 4 - 8

6.0 Shaft coupling assembly drawing and bill of materials including allowable misalignment clearances, shaft bores & key ways dimensions with tolerances and the style of coupling guard

N 4 - 8

7.0 Primary & auxiliary sealing schematic and bill of materials including seal fluid, fluid flows, pressure pipe and valve sizes, instrumentation, orifice sizes, and piping arrangement drawings

N 4 - 8

8.0 Cooling or heating schematic and bill of materials including cooling & heating media, fluid flows, pressure, pipe and valve sizes, instrumentation, orifice sizes and piping arrangement drawings

N 4 - 8

9.0 Lube oil schematic and bill of materials

Y 4 - 8

10.0 Lube oil system arrangement drawing including sizes, rating and location of all customer connections N 4 - 8

11.0 Lube oil component drawings data

N 4 - 8

12.0 Electrical and instrumentation schematics, wiring diagrams and bill of materials N 4 - 8

13.0 Electrical and instrumentation arrangement drawing and list of components N 4 - 8

14.0 Performance curves

Y 4 - 8

15.0 Pump specification sheet with complete details in proforma enclosed with enquiry / order Y 4 - 8

16.0 Certified foundation assembly drawing of pump with driver & all accessories mounted on base plate with load diagram for foundation design (In case of motor being procured by purchaser, motor frame details will be supplied to vendor within 4 weeks.)

Y 4 - 8

17.0 Engineering flow diagram showing: - Lubrication & sealing lines - Flushing / washing lines - Cooling / steam lines

N 4 - 8

18.0 Reference list for pumps supplied in past for similar duty conditions. Reference list shall contain complete address of user, user’s purchase order number, brief

Y - - -



- 87 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

specifications and date of commissioning

19.0 Lube oil schedule

N - - 8

20.0 Automatic recirculation valve assembly drawing, sectional drawing with bill of material Y 4 - 8

21.0 Quality Assurance Plan. Y 4 - -

22.0 Material test certificates and Inspection & performance test report along with dispatch clearance certificates from inspector

N - - 8

23.0 Instruction manuals describing installation, operation and maintenance procedures N - - 8

24.0 Spare parts recommendations and price list Y - - 8

25.0 Parts catalogue complete with reference drawing nos. and sketches etc. Y - - 8



- 88 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

B) COMPRESSOR

1.0 List of drawings / documents including drawing number, revision number, description and approval status N 4 - 8

2.0 Detailed manufacturing programme (Time bar chart )

Y 4 - 8

3.0 Specification sheet complete filled in proforma enclosed with enquiry/order. Y 4 - 8

4.0 Equipment layout with main overall dimensions including those required for foundations and piping design for compressor and auxiliaries. (This layout shall include the driven equipment and its auxiliaries).

N 4 - 8

5.0 Performance curves for Centrifugal compressor :

i) For turbine driven compressor, Discharge pressure, Brake horse power, Polytropic head and Efficiency Vs Inlet capacity (from surge point to 115 % of rated capacity) of the compressor at specified inlet pressure, temp. and mol. wt. of the gas and at 80, 90, 100 and 105 % speed for each stage and for overall compressor

Y 4 - 8

ii) For constant speed motor driven compressors Discharge pressure , Brake horse power , Polytropic head and Efficiency Vs Inlet capacity ( from surge point to 115 % of rated capacity ) of the compressor at specified inlet pressure, temp. and mol. wt of the gas for each stage and for overall compressor

Y 4 - 8

iii) Torque Vs Speed curve for the compressors.

Y - 4 8

6.0 Performance Curve

Y 4 - 8

7.0 i) Calculation of the lateral critical speeds of the

compressors. ii) Calculation of the torsional critical speeds. Analytical

report for torsional vibration of whole set. iii) Thrust loading curves for each casing / barrel for

various operating conditions. iv) Response curve of deflection Vs RPM for varying

amount of imbalance. v) Torsional critical response curve

N - 8 8

8.0 Overall dimensional drawing with all main dimensions, size and location of piping connections for compressors and its auxiliaries.

Y 6 - 8

9.0 Cross sectional drgs. Of the compressor showing details of construction including sealing details, bearing etc. With part no., description and material of construction.

Y 6 - 8

10.0 Coupling drawings

N - 6 8

11.0 Seal assembly drawings & Bill of material

N - 6 8



- 89 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

12.0 Lube oil Pumps a) Specification sheet b) Performance curve c) Cross Sectional drawing

Y Y N

4 4 -

8 8 8

13.0 Certified foundation scope drawing of the compressor with driver and all accessories resting on the foundation and control panel. In the event of motor not in the scope of supply of vendor the motor frame dimensions shall be supplied by the purchaser later). Direction and magnitude of all unbalanced forces, couples and centre of gravity along with direction of rotation shall also be mentioned

N 4 - 8

14.0 a) Engineering flow diagram indicating all instruments, valves, etc. marked with battery limit of supply of : - Process Gas lines - Cooling Water lines - Lubricating Oil lines - Condensate drain and vent lines The above drawings shall identify all components by size, pressure rating and material b) Material balance for gas, lube & seal oil.

Y 4 - 8

15.0 Piping layout plan and elevation drawings for gas, cooling water and utility lines, lube and seal oil lines etc.

N 4 - 8

16.0 Driver : Selection details a) Speed - torque diagram b) GD2 of the rotating masses of the compressor

referred to the motor speed

Y - 6 8

17.0 a) Piping isometrics for gas pipes DN>20, piping

manifold and all oil lines. b) Flexibility analysis for gas lines.

N - - 8

18.0 Piping support location drgs. With forces, moments and movements for gas pipes and with weights for all lines. N 4 - 8

19.0 Certified allowable forces, moments, movements, stresses for compressor nozzles. N 4 - 8

20.0 Bill of Material for Piping and supports.

N 4 - 8

21.0 Bill of Material for insulation for Pipings.

N 4 - 8

22.0 Bill of quantity for Painting for piping, equipments and auxiliaries. N 4 - 8

23.0 Thermal calculation for heat exchangers, Mechanical calculation and fabrication drawings for heat exchangers and Pressure vessels.

N 6 - 8

24.0 Inspection and Test Procedure.

N - - 8

25.0 Quality Assurance Plan.

Y 4 - -

26.0 Inspection and test reports, material test certificates, radiographic reports duly approved by specified inspecting authority, certificates for compressors, heat exchangers, pressure vessels, pipings, valves,

N - - 8



- 90 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

instruments and other auxiliaries.



- 91 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

27.0 Lubrication schedule

N - - 8

28.0 Instruction manual for erection, installation, operation and maintenance of compressor and its accessories (important clearances to be maintained should be clearly specified.).

N - - 8

29.0 Recommended list of spares for two years trouble free operation Y - - -

30.0 List of special tools

Y - 6 8

31.0 Installation list of similar machines shall also include the following : a) Client, location and year of installation b) Drive c) Model No. and type of compressor d) Duty condition of the compressor e) Speed and KW rating

Y - - -

C) TURBINE

1.0 List of drawings / documents including drawing number, revision number, description and approval status

N 4 - 8

2.0 Detailed manufacturing programme (Time bar chart ) Y 4 - 8

3.0 Specification sheet with complete details in proforma enclosed with enquiry/order Y 4 - 8

4.0 Equipment layout with main overall dimensions including those required for foundations and piping design for Turbine and auxiliaries.

Y 4 - 8

5.0 Performance curves for steam turbine : a) steam consumption versus Kw ( for various

extraction rate in case of extraction turbine) b) overall efficiency vs. load curve c) steam consumption correction curves d) curve showing variation of exhaust

temperature with inlet flow (i.e.under various loads) : - for change in live steam pressure

- for change in live steam temperature - for change in speed from governor set point

speed to max. continuous speed - for change in cooling water inlet

temperature from 25°C to 35°C

Y - 6 8

6.0 Thrust loading curves of each casing / barrel for various operating conditions N - 6 8

7.0 Overall dimensional drawing with all main dimensions, size and location of piping connections for turbine and its auxiliaries.

N 4 - 8

8.0 Cross sectional drawings of the turbine showing details of construction including governor, inlet trip and control valves sealing details, bearing details etc. With part no., description and mat of const

N 4 - 8



- 92 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

9.0 Description of governing system

N - 4 8

10.0 Blading plan for turbine

N - 4 8

11.0 Coupling drawings

N - 4 8

12.0 a) Engineering Flow diagram indicating all the

Instruments with limit of supply of steam and condensate lines, lube and control oil lines, Flushing and washing line and cooling water lines.

b) Material balance for steam condensate, lube & control oil.

N 4 - 8

13.0 Certified civil scope drawings for foundation of steam turbine and all auxiliaries. N 4 - 8

14.0 Piping layout plan, elevation and support drawings for steam and condensate lines, lube and control oil lines, gland sealing steam lines, flushing and washing lines.

N 4 - 8

15.0 a) Piping isometrics for steam pipes for DN>20,

piping manifold and all oil lines b) Flexibility analysis for steam lines

N 4 - 8

16.0 Piping support location drgs. With forces, moments and movements for steam and condensate pipes and with weights for all lines

N 4 - 8

17.0 Certified allowable forces, moments, movements, stresses for turbine nozzles. N - 4 8

18.0 Calculation of the lateral critical speeds of the turbines, Campbell diagram and Goodman diagram. N - 4 8

19.0 Bill of materials for piping and supports.

N 4 - 8

20.0 Bill of materials for insulation for piping.

N 4 - 8

21.0 Bill of quantity for painting for piping, equipments and auxiliaries. N 4 - 8

22.0 Thermal calculation for heat exchangers, Mechanical calculation and fabrication drawings for heat exchangers and pressure vessels.

N 6 - 8

23.0 Instruction and Maintenance manual for erection & maintenance of turbine and its accessories (important clearances to be maintained should be clearly specified.).

N - - 8

24.0 Cross sectional drawings of the Barring gear.

N - 4 8


N - - 8

26.0 Inspection and Test Procedure.

N - - 8

27.0 Quality Assurance Plan.

N 4 - 8



- 93 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built

28.0 Inspection and test reports, material test certificates, radiographic reports duly approved by specified inspecting authority.

N - - 8

29.0 Reference list for Turbines supplied in past for similar duty conditions. Reference list shall contain complete address of user, user’s purchase order number, brief specifications and date of commissioning.

Y - - -

30.0 Spare parts recommendations and price list

Y - - 8

31.0 Parts catalogue complete with reference drawing nos. and sketches etc. Y - - 8

D) FANS/BLOWER

1.0 Specification sheets completely filled in PDIL proforma. Y 4 - 8

2.0 Characteristic Curves - Performance curves, showing discharge pressure, capacity, and brake horse power at the inlet specified conditions (Pressure, capacity, temperature, molecular weight).

Y 4 - 8

3.0 Spare parts list

Y - - 8

4.0 Details of Lubrication and sealing system

Y - - 8

5.0 Data for selection of motor :

Y - - 8

a) Type

b) HP absorbed at duty point

c) RPM

d) Recommended HP

e) Max. starting torque as % NRT

f)GD2 figure for rotating mass of the Fan / Blower

g) Speed vs. Torque for the Fan / Blower

6.0 General Arrangement Drawing with all main dimensions, size and location of connections for ducting with all horizontal & vertical clearance necessary for installation and disassembly.

Y 4 - 8

7.0 Cross sectional drawing of fan with parts list

Y 4 - 8

8.0 Instruction manual for erection, installation operation and maintenance of fan and its N - - 8



- 94 -

SL. No.



Y/N For approval/

Information

For information

Final / approved/

As-built accessories (Important clearances to be maintained should be clearly specified).

9.0 Q.A.P and Test procedure

N 4 - 8


N - - 8

11.0 Reference list indicating duty condition, location, year of installation, name of client etc.

Y - - -

12.0 GA drawing with all details & dims. Including fan, drive, motor Y 4 - 8

13.0 Description of capacity control with details Y - - 8