Chevron Compressor

SAFETY INSTRUCTION SHEETS

Abstract

This section provides a general description of Safety Instruction Sheets, guidelines that apply to all
equipment, general information on mechanical equipment, and guidelines for preparing the Compressor
SIS's.

CONTENTS

SECTION I GENERAL GUIDELINES...........................................................................................2

SECTION II GUIDELINES APPLYING TO ALL EQUIPMENT..................................................4

SECTION III GUIDELINES APPLYING TO ALL MECHANICAL EQUIPMENT......................7

SECTION IV GUIDELINES FOR PREPARING THE CENTRIFUGAL

COMPRESSOR SIS ................................................................................................... 11

SECTION V GUIDELINES FOR PREPARING THE RECIPROCATING

COMPRESSOR SIS ................................................................................................... 13

SAFETY INSTRUCTION SHEETS:

EF-793 CENTRIFUGAL COMPRESSOR

EF-794 RECIPROCATING COMPRESSOR

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SECTION I
GENERAL GUIDELINES

The following are instructions for the preparation of Safety Instruction Sheets and recommendations for
their approval, issue, and distribution.

1. Safety Instruction Sheets summarize pertinent equipment data; designate safe operating limits of
the equipment; describe precautions necessary for continued safe operation; establish limiting
conditions of pressure, temperature, thickness, corrosion, speed, etc.; specify routine tests; and
reference sources of additional information necessary to operate, repair, and maintain the
equipment. The information provided helps to direct engineers to the sources of information used
to document the sheets and to information required for reevaluation of equipment design in the
event of changes in the operating requirements. Operators must be provided with concise operating
limits and inspectors with factual data on minimum thickness, corrosion allowance, test pressures,
and relief valve settings.

2. The Project Engineer is responsible for preparation of Safety Instruction Sheets. His signature and
that of the Operating Representative are required before the sheets are issued.

3. Plant operators need the Safety Instruction Sheets before the equipment is released for service.
Whenever possible, approved sheets in final form should be issued by that time. In the event that
the sheets are incomplete, a preliminary issue of the available data may be necessary. If a
preliminary issue is necessary, it should be approved by the Project Engineer and Operating
Representative and clearly marked as preliminary.

4. Safety Instruction Sheets may be issued as part of both the Inspection Record Books and the
Equipment Manuals. Distribution is outlined in the Project Instructions for each project or in the
design contract specifications.

5. Data presented on the safety instruction sheets are taken from initial design sheet forms, drawings,
design notes, inspectors' and manufacturers' data reports, vendor prints, and similar sources. It is
essential that all information given be accurate and representative of the equipment as
actually built.

6. Safety Instruction Sheets in use are as follows:

Form Use

EF-786 Columns and Vessels

EF-787 Shell and Tube and Double Pipe Heat Exchanger
EF-788 Air Cooled Heat Exchanger
EF-789 Fired Heater
EF-790 Centrifugal Pump
EF-791 Reciprocating Pump (Motor, Engine or Turbine)
EF-792 Reciprocating Pump (Direct Acting Steam Driven)

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EF-793 Centrifugal Compressor

EF-794 Reciprocating Compressor
EF-795 Piping
EF-796 Critical Piping

7. To avoid repetition, the general hazards inherent in the various types of equipment and the
precautions, inspections, and tests necessary for safe operation have been listed in Section II,
Guidelines Applying to All Equipment, and Section III, Guidelines Applying to All Mechanical
Equipment. Any applicable items should be incorporated with the appropriate SIS.

8. Any special hazards, inspections, or tests that are not covered by Sections II and III, should also be
noted on the SIS.

9. Safety Instruction Sheets are arranged by equipment groups in the following order:

a. Columns
b. Vessels
c. Heat Exchangers
d. Fired Heaters
e. Pumps
f. Compressors
g. Piping

10. The entire set of Safety Instruction Sheets for each plant or unit should be given one drawing
number. This number should be in the project drawing number series.

11. For those making up Safety Instruction Sheets for the first time, the following suggestions may be
helpful. Experience has shown that the least backtracking and recalculation will be needed if the
vessel sheets are made up first, then the pump, heat exchanger, furnace, and piping sheets, in that
order. In the average plant, the data accumulated for vessels will be advantageously referred to in
making up the pump sheets. Then both the vessel and pump sheets will be used in the preparation
of the remaining data. Safety Instruction Sheets should be started early in a project by the
design engineers responsible for the equipment. This will minimize the amount of backtracking
required to complete the sheets as the project nears completion.

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SECTION II
GUIDELINES APPLYING TO ALL EQUIPMENT

The Safety Instruction Sheets cite the hazards that are inherent in the operation and maintenance of
equipment and give recommendations for avoiding hazards and for inspections and tests.

Hazards

The general hazards to be considered in the operation of all process plant equipment include:

1. Unsafe condition due to defects existing in equipment as built or as repaired.

2. Rupture or unsafe condition of equipment due to excessive operating pressure, temperatures,

dynamic load, material thickness, or other conditions beyond the established safe limits.

3. Unsafe condition resulting from corrosion (internal or external) that reduces material thickness to
below the minimum allowable limit. Such corrosion may be general or localized, internal or
external. It may result from normal process conditions, areas of turbulence or high velocities,
failures at linings, leaks, inadequate neutralization, chemical cleaning, etc.

4. Embrittlement, cracking, and other deterioration resulting from hydrogen attack or graphitization if
metal temperatures exceed safe limits for the alloy, by temper embrittlement for some alloys or, by
stress corrosion cracking or caustic embrittlement, particularly if not post-weld heat treated.

5. Fatigue failures, particularly at supports, attachments, and connections, caused by vibration or

other cyclic loadings including those resulted from thermal or pressure stress.

6. Reduction of strength, ductility, toughness, and/or setting up of high residual stress as a result of
improper welding or heating operations. This is particularly applicable to alloy or higher strength
materials.

7. Unsafe condition or failure due to thermal stress caused by process thermal excursions, by failure
of internal insulation, or by exceeding established limiting rate of temperature change (°F/hr), or
temperature gradients (°F/inch) during heating, cooling, or operating cycles.

8. Excessive strain or failure (particularly at equipment connections) due to heating of lines or

equipment above design temperature for which expansion provisions is made.

9. Unsafe condition or failure of reciprocating or rotating machines, or motors due to operation at

speeds or loads in excess of design limits or operation at critical intermediate speeds.

10. Failure, plugging, settings too high, inadequacy or blocking-off of pressure relieving equipment.
Failure of control equipment resulting in excessive pressure, temperature or volume.

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11. Excessive pressure caused by thermal expansion of liquid ("sun pressure") in filled equipment or
freezing of contained water, especially at drains.

12. Damage to equipment caused by testing at pressures in excess of established limits, testing at too
low a temperature, or from excess loading due to weight of testing medium.

13. Release of hot flammable, poisonous, or corrosive gases or liquids due to failure of equipment from
cause such as rupture, cracking, draining, venting or opening equipment, or leakage as covered in
14 below.

14. Leakage at threaded, riveted, or gasketed joints or at packing glands of pumps, compressors,
valves, level controls and instruments.

15. Possible hazards associated with opening of relief valves, particularly where discharge is not to be
a closed system.

16. Explosive mixtures in equipment caused by improper purging or the failure of control valves,
motor operated valves, cycle timers, etc.

17. Collapse of towers, columns, stacks, tanks, supports, etc., under wind or earthquake loading due to
corrosion below minimum safe thickness, corrosive leakage, excessive temperatures, inadequate
provision for thermal expansion, binding of thermal expansion features, excessive external
pressure, fire exposure, or deterioration of foundations, supports, or guys.

18. Collapse of equipment due to external pressure (vacuum) loading in excess of design limits of
pressure, thickness, or excessive out-of-roundness (buckles or bulges).

19. Shock loading of equipment as by sudden stoppage of flow (water hammer), internal explosions, or
external loads. This is applicable to cast iron equipment, equipment in low temperature service, or
equipment with marginal toughness.

20. Violent pressure surges resulting from admitting, trapping, or pocketing of water or light products
in hot equipment or equipment to be heated.

21. Chemical reactions, either inherent in the process or accidental, causing excessive pressure,
temperatures, or corrosion.

22. Sudden release of LPG causing auto-refrigeration and resulting loss of metal toughness at low
temperature.

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Pressure Tests

Pressure tests may be divided into two categories: "strength tests" and "field tests for tightness."

For strength tests, the test pressure shall be determined, with consideration of thinning due to corrosion, in
accordance with the applicable company requirements for new equipment tests.

1. Code test all equipment after any major repair affecting the strength of the equipment, except
where approval is obtained to waive such a test based upon factors such as additional
nondestructive examination and/or superior design details.

2. Test certain equipment, such as fired heater coils, at specified intervals as called for in the
Equipment Inspection Schedules or as specifically recommended in the Safety Instruction Sheets.

3. The test pressure for field tightness tests of equipment shall be as given in the Safety Instruction
Sheets.

4. Hydrostatic testing procedure should conform to PIM-MS-3541, Field Hydrostatic Testing of

Piping Systems, or as given on special Hydrostatic Test Schedules prepared for particular
installations.

5. Obtain appropriate Engineering Division approval before applying any pneumatic test.

6. Do not apply pressure tests without adequate protection against brittle fracture. Secure
Engineering guidance when in doubt. See the Pressure Vessel Manual for information on brittle
fracture.

7. Actual code tests applied during shop fabrication or field construction are given on the Safety
Instruction Sheets or on Hydrostatic Test Schedules prepared to cover initial testing.

8. Remove, test, and reset safety or relief valves protecting the equipment at frequencies given in the
Equipment Inspection Schedule for the plant or, in lieu of such a schedule, as recommended on the
Safety Instruction Sheets.

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SECTION III
GUIDELINES APPLYING TO ALL MECHANICAL EQUIPMENT

Hazards

The hazards to mechanical equipment include:

I. Those hazards listed in the General Instructions Applying to All Equipment that apply to
Mechanical equipment.

2. Excessive pressure: in pumps caused by discharge shutoff, excessive suction pressure, or excessive
speed, particularly in series operation of pumps or in testing; in compressor cylinders caused by
discharge shutoff, excessive intake pressure, or blocked-off jacket water circulation; and in turbine
cases caused by a closed exhaust.

3. Shock and/or excessive pressure: in reciprocating pumps and engines due to wet stream or failure
to drain before starting, particularly in flywheel engines; in reciprocating compressors from liquid
entrained in gas entering cylinders; and water hammer from rapid closing of discharge valve.

4. Distortion or failure of parts and damage to bearings caused by overloading, for example,
operating machines or motors in excess of design capacity or speed or abnormally low compressor
intake capacity.

5. Damage to turbine or compressor blading caused by: water in steam, liquids in gas, erosion by
solids, excessive temperatures, corrosion during shutdown periods; blade deposits sloughing off
during idle periods resulting in rotor unbalance, especially in high speed machines; and
operation with blading in resonance.

6. Excessive speeds caused by: malfunctioning or failure of governors, speed controllers, or

overspeed trips or failure of couplings resulting in runaway and "explosion" of driver, flywheel, or
driven machine.

7. Excessive vibration leading to fatigue failure of parts and of connected lines - especially small
threaded connections - caused by inadequate bracing or foundation, loose foundation bolts, poor
alignment, or improper balancing of rotating elements.

8. Excessive temperatures of fluids handled causing: distortion or failure of cases or parts due to
reduced strength of the material above the design temperature limit; reduced clearances or running
fits leading to excessive wear or seizing; irregular expansion and misalignment leading to vibration,
interference, bearing, mechanical seal, or packing failure, or shearing of dowels or anchor bolts;
deterioration and excessive scaling in water jackets and cooling systems. Steaming out equipment
that normally operates at lower temperature may cause expansion strains or pump flanges, frame
castings, etc., resulting in failure or misalignment.

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9. Excessive temperatures not due to process heat caused by mechanical difficulties such as:
interference of loose parts of misalignment, overloading bearings, presence of foreign material,
failure of cooling systems, and loss or contamination of lubricant to bearings.

10. Thermal shocks leading to: mechanical seal failure and cracking of case parts - particularly
irregularly shaped castings and cast iron parts - due to sudden temperature changes, as in too rapid
starting from cold or in cutting-in standby units, or too rapid cyclic changes.

11. Overheating and scoring or seizing of close clearance parts: in centrifugal or rotary pumps if
operated on other than the designated fluid or at insufficient throughput; and excessive
recirculation from discharge to suction without cooling.

12. Excessive temperatures in motors leading to damage to windings and possible fire hazard caused
by improper bearing adjustment or lubrication, overloads, shorting, or obstruction of ventilation.
Motor overloads may result from pumps such as those designed for low gravity stocks being
operated on higher gravity stocks.

13. Corrosion or damage to insulation and shorting of motor windings by: moisture, chemical leakage,
dirt, excessive lubrication, or abrasive material carried in ventilating air circulated through
motor.

14. Direct release of hot, flammable, corrosive, or poisonous liquids or gases in the event of: threaded
or gasketed joint leakage, packing or mechanical seal leakage, or actual failure of case or
connections.

15. Source of ignition hazards such as a dragging gland follower on pumps, electrostatic charges on
belts, gas engine or turbine exhausts; and explosion hazards in gas engine crankcases and starting
air systems.

16. Overpressure and rupture of lube oil or hydraulic governor systems because of: plugged line, filter
or screen in system with inadequate pressure relief, or maladjusted or malfunctioning relief valve or
pressure reducing valve.

17. Failure of mechanical seal resulting from stoppage of flushing fluid because of vaporization,
plugged line, or insufficient seal cavity pressure.

Recommendations for Avoiding Hazards

1. Consider the appropriate hazards given in the General Guidelines Applying to All Equipment.

2. Provide for adequate "running in," and close observation in initial operation for strains, vibration,
misalignment, bearing temperature, packing gland adjustment, functioning of sealing, cooling and
lubricating systems, and of governors and overspeed trips. Take precautions against foreign
material entering wearing parts and bearings.

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3. Maintain close attention in service to functioning and condition of all instruments, regulating
equipment, governors, automatic cutouts, protective devices, and relief valves which serve to
control operating conditions within safe limits. Make sure that lube oil and hydraulic governor
systems are protected against overpressure resulting from maladjustment of pressure
reducing devices or from plugged line or filter.

4. Avoid losing suction or sudden shutoff against pumps, particularly positive displacement types.
Check series or tandem combinations to prevent excessive pressure on the second pump.

5. Bleed steam supply lines and drains on pumps, engines, and turbines. Open exhaust valves before
admitting live steam. Warm up any hot service equipment slowly when putting it in operation.
Hand rotate hot oil pumps through at least one full turn before starting driver.

6. Follow safe practices for operation and lubrication of equipment as given in the Manufacturer's
Instruction Manuals. Additional information is included in the General Machinery Manual.

7. Pay particular attention to gland adjustment, cooling water, or oil circulation to glands and
bearings, mechanical seals, jacket water circulation, and bearing lubrication systems.

8. Keep cooling air passages in motors clean and free from obstructions. Do not operate motors
without specified fuses or overload protection devices. Guard against damage to motor
insulation where motor is installed in an atmosphere laden with excessive moisture, dust, or
abrasive material such as catalyst fines.

9. Chemically clean bladed rotor when unit is to remain idle long enough for deposits to slough
off and unbalance the element. This is especially important with high-speed machinery.

10. Turn over standby units at regular intervals as specified in Operating Procedures. Frequently
check functioning of steam traps on standby units.

11. Observe requirements of State Safety Orders for Engines and Mechanical Power Transmission
relative to guarding, clearances, and access and ventilation in pump and compressor rooms.

Inspections and Tests

1. Refer to General Safety Instructions Applying to All Equipment.

2. Regular periodic tests and inspections of all protective devices, including test and resetting of relief
valves. Relief valve set pressures to be given on the Safety Instruction Sheets. Differentiate
between safety (or relief) valves and pressure reducing (or control) valves on lube oil and
hydraulic governor systems. Safety valves are registered and have specified set pressure.
Pressure reducing or control valves normally have to be set or adjusted in place to suit
equipment conditions as they vary from time to time.

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3. Regular inspection and servicing by machine and electric shops in accordance with manufacturer's
and department or district maintenance schedules. Have Electrical Inspector check any explosion-
proof motor that is opened before closing the case.

4. Inspection of critical units for corrosion or materials by Equipment Inspectors whenever opened for
maintenance, or as specifically called for in the Safety Instruction Sheets or the Equipment
Inspection Schedule for the plant.

5. Test equipment to test pressure given on the Safety Instruction Sheets after any major repair
affecting the strength of the equipment.

6. Consult the Engineering Division for proper test pressure and procedure in event of any question
on pressure testing.

7. Be sure equipment is adequately oiled and oil reservoirs are maintained at proper levels.
Check lubricators at frequent intervals. Confirm satisfactory operation of all auxiliary systems
at frequent intervals.

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SECTION IV
GUIDELINES FOR PREPARING THE CENTRIFUGAL COMPRESSOR SIS

This guideline provides an explanation of what information is required on the Centrifugal Compressor
Safety Instruction Sheet, EF-793.

SUBJECT DISCUSSION

Service Use name of the associated vessel as given on the process

design flow diagram or the P&ID

Equipment Number This number may be required and assigned for accounting
purposes. When not available, leave space blank to be filled in
later.

Test Pressure New Manufacturer's shop casing test pressure (usually 1.5 times the
maximum case design pressure).

Materials Wherever possible, note ASTM specification and grade. When

these are not known, enter carbon steel, cast iron, 18-8 SS, etc.,
as appropriate.

Frequency of Starts Allowable For motors above 100 HP, note any limitation on frequency of
starts to prevent overheating.

Type of Lubrication Note whether oil mist, forced feed, or other type of lubrication.

Maximum Safe Speed Manufacturer's recommended maximum safe operating speed.

Minimum Lube Oil Pressure Pertains to forced feed lubrication systems. This should be the
manufacturer's recommendation for the absolute minimum
pressure which will not result in damage to any lubed parts. It
should correspond to oil pressure trip setting. If oil pressure
trip switch is not used, the minimum lube oil pressure should be
specified as 10% higher than manufacturer's recommendation.

Surge Limit Minimum capacity at rated speed below which the compressor
is unstable. This is called "surge," a condition in which the
compressor fails to meet the pressure of the system into which
it is discharging. This causes a cycle of flow reversals as the
compressor alternately delivers gas and the system returns it.
This minimum flow can be obtained from manufacturer's
performance curve.

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SUBJECT DISCUSSION

Critical Speed List critical speeds of compressor and turbine and turbine
driver, if provided. Indicate any special startup requirements
when critical speeds fall below the normal operating speed.

Additional Safety Precautions Note any additional compressor or turbine driver limitations
associated with abnormal process conditions such as
regeneration, refrigeration service, etc. Consider speed-torque
limits of both compressor and turbine driver.

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SECTION V
GUIDELINES FOR PREPARING THE RECIPROCATING COMPRESSOR SIS

This guideline provides an explanation of the information required on the Reciprocating Compressor Safety
Instruction Sheet, EF-794.

SUBJECT DISCUSSION

Service Use name of the associated vessel as given on the process

design flow diagram or the P&ID.

Equipment Number This number may be required and assigned for accounting
purposes. When not available, leave space blank to be filled
in later.

Power Cylinder Applicable only to integral engine-compressor machines.

Materials Whenever possible, note ASTM specification and grade.

When these are not known, enter carbon steel, cast iron
nodular iron, 18-8 SS, etc., as appropriate.

Maximum Allowable Continuous This is the limiting force that a manufacturer will permit on
Rod Load the compressor piston rod, crosshead assembly, connecting
rod, and crankshaft under any condition of continuous
operation.

Manufacturer Maximum Allowable This is the maximum continuous pressure capability of the
Working Pressure on Cylinder cylinder as determined by the manufacturer.

Cylinder Minimum Suction Pressure This is normally the minimum pressure at which the cylinder
can operate, without exceeding the maximum allowable rod
loading, when the discharge pressure is equal to the MAWP
(usually the discharge relief valve set pressure).

Maximum Safe Operating Speed RPM Pertains only to variable speed motor, engine or turbine
drivers.

Minimum Allowable Speed Pertains only to variable speed motor engine or turbine
drivers. This is normally set by lubrication requirements.

Overspeed Trip Setting Pertains only to engine or turbine drivers.

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SUBJECT DISCUSSION

Minimum Lube Oil Pressure This should be manufacturer's recommendation for absolute
minimum which will not damage any lubed parts and should
correspond to oil pressure trip setting. If oil pressure trip
switch is not used, the minimum lube oil pressure be specified
as 20% higher than the manufacturer's recommendation.

Relief Valves Number, set pressure, and location. The PSV between the
cylinder discharge and the first downstream block valve must
be set at or below the maximum allowable working pressure.

Maximum Allowable Discharge This is the maximum continuous temperature of the discharge
Temperature gas as determined by the manufacturer for the cylinder design,
including valve and trim materials.

Prohibited Load Modes Where an operator can unload ends of individual cylinders,
there may be some unloading modes which could result in
excessive rod loads or in excessive temperature rise in the
compressed gas. Engineering should consult with the
manufacturer to determine these possibilities and specify any
prohibited modes on the SIS.

Additional Safety Precautions Note any special precautions such as use of special fire
resistant lube oils in starting air compressors, etc.

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