JOB SPECIFICATION FOR

HP HYDROGEN COMPRESSOR
(ROTATING EQUIPMENT)
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JOB SPECIFICATION
FOR
HP HYDROGEN COMPRESSOR
(ROTATING EQUIPMENT)

Rishi Anukul Anukul

0 05/04/10 Issued for Bids
Bhardwaj Mandal Mandal
Rev. Prepared Checked Approved
Date Purpose
No by by by

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 JOB SPECIFICATION FOR
HP HYDROGEN COMPRESSOR
(ROTATING EQUIPMENT)
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1.0 GENERAL
1.1 Scope
This specification along with the equipment data sheets, design specification and scope of
work/supply describes the minimum requirements for design, manufacture, testing, supply &
supervision of erection and commissioning of “Diaphragm Type Positive Displacement
Compressors” for the ‘Offsites facilities’ .
.
1.2 Standards/Specifications
The design, construction, manufacture, supply and testing and other general requirements for
the “Diaphragm Type Positive Displacement Compressors” shall be strictly in accordance with
the Process datasheets, P&ID’s, equipment data sheets, this job specification, scope of
work/supply, Engineering design basis (Doc. No. ) and other referenced
codes, standards and recommended practices as applicable.
1.3 Conflicting Requirements
In case of case of conflict be this specification and other attached and/or referred specifications,
the following order of precedence shall govern:
(i) Process Data Sheets
(ii) Engineering Design basis
(iii) This Job Specification
(iv) EIL Equipment Data Sheets
(iv) API Standards
(v) Other Specifications
However, in case of any conflict, contractor/vendor shall bring out the same to the
notice of Owner/PMC. Owner/PMC’s decision shall be final.

2.0 SCOPE OF SUPPLY

2.1 Vendor shall furnish for the compressor package, all components and auxiliary equipments to
make a complete installation requiring only location in place and hooking up of wiring and
piping for operation and to make a complete and safe compressor package.
Compressor manufacturer's scope for each compressor package shall include but not limited to
the following:

- Reciprocating (Diaphragm) Compressors with electric motor drivers and other accessories /
auxiliaries comprising of

¾ Suction strainer with spool piece at compressor suction.

¾ All suction and discharge volume bottle/pulsation dampeners each stage
¾ Inter stage coolers and after coolers.
¾ Relief valves at discharge of each stage discharge.
¾ Non-return Valve, compressor discharge valve type at final discharge,
¾ Frame Lube oil System including all piping and fittings
¾ Cooling water system including all piping and fittings.
¾ All interconnecting piping for process gas& utility lines within the equipment skid
and as specified in P&ID’s.
¾ Diaphragms rupture detection system.
¾ All necessary hardware for automatic depressurising the gas before start-up/ after
shut-down
¾ Drive arrangement (through V –belt arrangement including pulleys, belts and non
sparking guards).
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(ROTATING EQUIPMENT)
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¾ Companion flanges with gaskets, fasteners for compressor interface connection.

¾ Common base plate for compressor, motor and auxiliaries.
¾ Guards for moving parts(Non sparking type)
¾ Flywheel
¾ Barring device(manufacturer’s standard)

- Instrumentation and control system as specified on various data sheets, specifications,

P & IDs, including Local control panel, Console gauge boards, etc.

- All electrical equipments ,controls, supply etc. as specified.

- All utility interconnections for the compressor package within compressor house.

- Interconnecting piping fittings, valves, instrumentation wirings and tubing’s as specified along-
with supports between auxiliary consoles and main equipment

- All inspections and testing as specified.

- Mandatory Spare Parts as per list attached elsewhere in the Bid Package.

- Spares for Erection & Commissioning/Start up.

- Special tools and tackles required for erection, site assembly and maintenance.

- All foundation and Anchor Bolts.

- Painting and preparation for shipment, packaging etc.

- All drawings and data required as per specified vendor data requirement.

2.2 For additional requirements refer process data sheet, P & IDs, equipment data sheets,
engineering design basis (Doc. No. ) and scope of work/supply (Doc. No.
6987-00-16-45-SW-01) as enclosed elsewhere in the Bid Package.
3.0 EQUIPMENT QUALIFICATION CRITERIA:
Refer Clause No. 2.5.1 of Engineering design basis (Doc. No )
4.0 BASIC DESIGN:
4.1 GENERAL
4.1.1 Compressors and drivers (including drive arrangement) shall be designed to perform
satisfactorily under the specified start-up conditions, part load/full load operation, and maximum
differential pressure operation including relief valve setting. Unless otherwise specified the
compressor vendor shall assume full responsibility to undertake:

i) Selection, sizing and rating of the transmission equipment between the compressor and the
driver.

ii) Stress Analysis of the piping and appurtenances from the intake filter/Inlet Flange at skid B/L
up-to the outlet flange of the final compression stage pulsation suppression
devices/separators/after-cooler/receivers as the case may be.

iii) Coordination of the work and resolution of any technical problems with the driver supplier.

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(ROTATING EQUIPMENT)
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4.1.2 Static O-rings shall be used on both Process gas side diaphragm and oil side diaphragm to
ensure high level of leak tightness.

4.1.3 Hydraulic Pistons shall be provided with replaceable piston rings.

4.1.4 The compressor shall be designed such as to limit the stress levels in the diaphragms and
ensure a minimum life of 2000 hours for the diaphragms.

4.1.5 The compressor along-with its driver, auxiliaries, accessories (including coolers), instruments
and local panel shall be supplied mounted on a common skid completely piped and wired.
Customer interface connections shall be terminated as under, at the skid battery limit for each
compressor.

- Main Process, Vent/Flare shall be provided with isolation valve & flange.
- Supply and/or return for each utility (Cooling water, Instrument air, N2)
- Instrument connections in junction boxes, as specified

4.1.6 All electrical components and installation shall be suitable for the area classification and
grouping specified in the equipment data sheets.

4.1.7 The maximum sound pressure level of the compressor package shall not exceed 88 dBA
measured at 1 meter from the equipment surface for recommended range of operation, unless
otherwise specified.

4.1.8 The compressor shall be provided with a suitable permanent suction strainer, in 5 to 10 micron
range or finer, as recommended by vendor which must be sized to minimise pressure drop. A
suction pressure gauge with snubber should be installed between this filter and suction
connection so that actual suction pressure at the compressor is indicated. This filter shall be
located as close as possible to the suction connection of the unit.

4.1.9 The shaft speed irregularity of the compressor shall not exceed the values specified below,
under any required operating conditions including relief valve set pressure as well as start-up.
The flywheel shall be suitably sized to meet this criterion:
- V-Belt : 1/80
- Direct drive : 1/100
- Driven thru gear unit : 1/100

4.2 COMPRESSOR HEADS

4.2.1 General

4.2.1.1 The maximum allowable working pressure of the head assembly shall exceed 110% of the
rated discharge pressure or specified relief valve set pressure or 1.7 kg/cm²g, whichever is
greater.

4.2.1.2 Heads shall be so arranged as to permit access to all wear components.

4.2.1.3 The Heads shall be provided with cooling passages to be cooled by forced water circulation.

4.2.1.4 The compressor cooling water circuit shall be designed to ensure that condensation does not
occur in the process cavity plates.

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(ROTATING EQUIPMENT)
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4.2.2 Compressor Head Cooling

4.2.2.1 The cooling system shall be so designed that the pressure drop across the compressor unit
with auxiliaries does not exceed 0.8 kg/cm².

4.2.2.2 The coolant jackets of heads shall be designed for a working pressure of not less than 8
kg/cm²g, and so sized that the coolant temperature rise across the cylinder does not exceed
5°C.

4.2.2.3 Coolant supply & return piping shall be provided at a single point at the skid edge by the
purchaser. Further distribution to various consumption points shall be in compressor vendor’s
scope.

4.2.2.4 Compressor vendor shall provide “Gate valve” at inlet and “Globe valve” at outlet of coolant
system.

4.2.2.5 The Coolant Outlet Line from each cooler and each head shall be fitted with a sight flow
indicator followed by a regulating globe valve. Series circuits shall have the necessary valved
bypasses to permit temperature control.

4.2.2.6 Coolant piping shall be so arranged that there is no possibility of air getting trapped. Where air
traps cannot be avoided, suitable vents shall be provided. Low points shall have drains. All
heads shall have coolant drain plugs.

4.2.2.7 All independent water circuits which can be isolated shall have a thermal relief valve to prevent
pressurization of pipes due to temperature changes.

4.3 ACCESS OPENINGS

4.3.1 Access openings of adequate size shall be provided on crosshead slide housing to permit
removal of piston rod to crosshead coupling.

4.4 COMPRESSOR FRAME LUBRICATION

4.4.1 Frame Lubrication system shall be as per the datasheet #

4.5 MATERIALS
4.5.1 The selection of suitable materials of construction shall be the responsibility of the vendor,
unless specific materials are indicated on the data sheet by the Purchaser.

4.5.2 Nodular Iron castings shall be produced in accordance with ASTM A395. Microstructure
examination and non-destructive testing shall be conducted.

4.5.3 Castings shall be free from shrinkage cracks, hot tears, blisters or other similar injurious
defects. The surfaces of castings shall be cleaned by shot blasting or sand blasting All mould
parting fins and the remains of gates and risers shall be removed and ground flush. Castings
shall be used in a suitable heat treated condition.

4.5.4 All welding of piping and fabricated pressure containing parts shall be in accordance with
written and qualified procedures and shall be performed by welders qualified in accordance with
ASME Boiler & Pressure Vessel Code-Section IX. Welding procedures shall be submitted to the
purchaser for his record.

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(ROTATING EQUIPMENT)
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4.5.5 All repair welding shall be carried out in accordance with procedures submitted to and approved
by the Purchaser prior to commencement of such welding. Weld repairs shall be inspected by a
suitable method after each layer of weld deposit to ensure that the weld metal is sound and free
from defects. Castings subjected to major weld repairs shall be stress relieved. Only weldable
grades of steel can be repaired by welding. Pressure containing parts of Cast Iron shall not be
repaired by welding.
4.6 DRIVERS
4.6.1 For motor driven units, the maximum continuous rating (MCR) (i.e. service factor equal to 1)
shall be a minimum of 110% of the greatest power (including transmission losses) required
under any of the specified compressor operating conditions or 5% higher than the power
required at the relief valve setting pressure condition (including transmission losses) whichever
value is greater. Vendor shall furnish along with the proposal the calculation to arrive at
compressor BKW and justify selection of Driver in line with the above.
4.7 COUPLINGS AND GUARDS
4.7.1 Compressor couplings shall be supplied by the Compressor Vendor.

4.7.2 Couplings shall be suitable for continuously transmitting the maximum torque and the maximum
torque fluctuations without distress or undue wear. They shall be suitable for emergency
shutdown of the unit, under full load.

4.7.3 Rigid couplings shall not be used.

4.7.4 Non-sparking guards as specified in the data sheets and extending to within 15mm of stationary
housing shall be provided on all exposed moving parts. Openings shall be provided on all
flywheel guards for barring over the machine and for access to any other part that may require
attention.

4.7.5 Guards shall be easily removable and shall be sufficiently rigid to withstand deflection and to
prevent rubbing as a result of bodily contact of 100 kgs.
4.8 REDUCTION GEARS
4.8.1 Gear units, when used, shall be designed, manufactured, tested & supplied in accordance with
API Std. 677 and the same shall have a minimum service factor as per Table-2 of API Std. 677.
4.9 BELT DRIVES
4.9.1 V-belt systems shall be equipped with a positive belt-tensioning device.

4.9.2 The drive service factor shall not be less than 1.75, based on the driver nameplate rating.

4.9.3 Belt materials shall be oil resistant and shall be compatible with the site conditions specified in
the inquiry documents. Unless otherwise specified, belts of static-conducting material shall be
provided.

4.9.4 The vendor shall supply both the driver and the driven end pulleys of the system and the
required number of V-belts. The suitability of mounting the pulley on the driver shaft shall

be ascertained by the Vendor in consultation with the driver manufacturer.

4.9.5 V-belt systems shall not be used for driver rating of 160 kW and above.

4.10 BASE PLATES

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HP HYDROGEN COMPRESSOR
(ROTATING EQUIPMENT)
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4.10.1 The equipment feet and the mating baseplate shall have machined surfaces.

4.10.2 The baseplate shall be fabricated with steel beams and sections and designed to support
compressor, drive train and auxiliaries. The arrangement of the package including piping,
coolers, controls shall provide adequate clearance areas and safe access for operation and
maintenance. Non-skid decking shall be provided on all walk areas. The skid shall have lifting
lugs for four (4) point lift and shall be supplied with foundation bolts and nuts. Slide rails
required for V-Belt driven motors shall be provided by the vendor, irrespective of whether or not
the driver falls within his scope of supply.

4.10.3 The mounting pads on the bottom of baseplate shall be in one plane to permit use of single
level foundation.
4.11 CONTROLS AND INSTRUMENTATION
4.11.1 General

4.11.1.1 Unless otherwise specified, compressor shall be started manually from the Local Control Panel
(LCP). Only those instruments required for local start-up shall be provided at the LCP. All trip
logic shall be executed through Contractor’s programmable logic controller (PLC). All alarms
shall be annunciated in Distributed Control System (DCS) or Main Control Room (MCR) Panel.
Common Alarm & Common Trip Alarm shall be annunciated at LCP. Locally mounted
instruments/Transmitters on the equipment skid shall be supplied by the compressor vendor.
Compressor vendor shall furnish logic write-up and logic diagrams for Contractor to implement
the logic in Purchaser’s PLC. Compressor shall have and Auto stop feature.

4.11.1.2 To ensure that the diaphragm remains in unloaded condition before start-up / after shut-down or
when the compressor is not in operation, vendor shall provide and include in his scope, all
necessary hardware for automatic de-pressurising the gas between the inlet & outlet isolation
valves, which shall be located at the skid battery limits. Details for such a scheme shall be
brought out in vendor’s proposal in the form of a P&ID and shall be explained in detail. All
battery limit isolation valves shall be in vendor’s scope and shall be of Tight Shut-off type.

4.11.1.3 The logic write-up for automatic de-pressurisation and automatic start-up/shut-down (if
specified) shall be submitted for Purchaser’s review & approval during detailed engineering.

4.11.1.4 Compressor vendor shall provide separate junction box for each type of signal (Analog, Digital,
Temperature) and fully wire the same up-to each instrument. Junction Box shall be supplied
with NPT threaded connection for further connection from junction box to Control room, by
others. All wiring within the skid, shall be running in galvanized Carbon Steel or PVC cable
trays.

4.11.1.5 Control panels shall be completely piped and terminated in bulk-head fittings and terminal
blocks requiring only connection to the Purchaser’s external piping and wiring circuits. When
more than one wiring point is required on a compressor, such wiring shall terminate in a
junction box mounted on the compressor. Control Panel shall be skid mounted.

4.11.2 Capacity Control

4.11.2.1 Capacity control of the compressor shall be achieved through a spill-back line with
Pneumatically actuated control valve. This control valve shall be controlled by electronic
Pressure controller configured in the DCS by Purchaser in MCR. The control valve shall have
isolation valves and a manual bypass through globe valve. The controller shall receive signal
from Pressure Transmitter located on the discharge line downstream of after-cooler within the
battery limits of vendor. The spill-back line shall connect discharge of compressor downstream
of after-cooler to suction of compressor upstream of suction KOD, all within the skid limits of the
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(ROTATING EQUIPMENT)
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compressor and shall be sized for 100% flow. To facilitate local start-up, the control valve on
the spill-back line shall have facility to operate through HIC, located at LCP. Local/Remote
selection switch shall be configured in the DCS by the Purchaser.

4.11.3 Instruments & Instruments Panel

4.11.3.1 As a minimum, the vendor shall provide the following instruments gauges on local gauge board:
- Compressor Inlet pressure & temperature, each stage
- Compressor Discharge pressure & temperature, each stage
- Compressor lube oil pressure & temperature
- C.W. Inlet pressure
- Differential pressure across suction strainer

4.11.3.2 In addition to instruments as specified in above, following are the minimum requirements for
Annunciation, Push Buttons and Switches on the LCP.
Item / Purpose Local Control Panel
1) Start/Stop Switch Yes
2) Ammeter Yes
3) Common Alarm Yes
4) Common Trip Alarm Yes
5) Alarm Acknowledgement P.B. and Reset P.B. Yes
6) Lamp Test P.B. Yes
7) Auxiliary Oil Pump running indication Yes

4.11.3.3 Alarms & Shutdowns :

Alarms and/or shut downs shall be provided for the following events at the Main Control Room
(Purchaser’s DCS).

Event Alarm Trip

Low Lube oil Pressure & Auxiliary pump start Yes
Low-Low Lube oil Pressure Yes Yes
Low Gas Inlet Pressure Yes
Low-Low Gas Inlet Pressure Yes Yes
High Gas discharge temperature Yes
High-High Gas discharge temperature Yes Yes
Diaphragm rupture detection (Each Head) Yes Yes
Cooling water - Low Flow Yes

4.11.3.4 Where a motor driven auxiliary oil pump is specified for the frame oil system, a suitable interlock
shall be provided to ensure that the main motor shall not start until after the auxiliary oil pump
has built up the requisite oil pressure.
Visual indication shall be provided to indicate when the auxiliary pump is operating. Stopping of
auxiliary oil pump shall be manual.

4.11.4 Relief Valves

4.11.4.1 Relief valves for all operating equipments shall meet the limiting requirements specified in API-
RP-520 Part I & II.

4.11.4.2 Unless otherwise specified, Relief valve setting shall be 110% of the rated discharge pressure
or 1.7 kg/cm²G, whichever is higher.
4.12 PIPING & APPURTENANCES
4.12.1 General
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(ROTATING EQUIPMENT)
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4.12.1.1 Piping within the skid shall be designed to provide proper flexibility and normal accessibility for
operation, maintenance and cleaning and shall be properly anchored to eliminate vibration and
damage.

4.12.1.2 Regardless of the scope of supply, the compressor vendor shall be responsible for assessing
the design and layout of the piping and appurtenances, from the suction strainer to outlet flange
of Pulsation Dampener, for excessive pulsation and harmful vibration. Based on his findings the
vendor shall be responsible for advising the purchaser of any modifications necessary to ensure
trouble-free operation.

4.12.2 Piping and Connections

4.12.2.1 The materials and construction of piping and its connections to the battery limit for purchaser’s
further connection shall conform to piping material specifications (PMS) attached with the
inquiry specification/order.

4.12.2.2 Cast iron or malleable iron pipe fittings shall not be used.

4.12.2.3 Carbon steel piping shall be in accordance with the piping material specifications (PMS)
attached with the inquiry specification/order.

4.12.2.4 Oil piping wherever threaded shall be seal welded without thread lubricants compound. Piping
material down stream of oil filter shall be of S.S. (except oil galleries in C.I. frames), (Oil piping
connected to CI frames shall not be seal welded).
4.13 INTER AND AFTER COOLERS
4.13.1 Unless otherwise specified, water cooled inter and after coolers shall be constructed and
designed in accordance with ASME Sec. VIII Div 1 and shall be manufacturer’s standard.

4.13.2 Unless otherwise specified, material of construction (MOC) of coolers shall be selected by
compressor manufacturer after due consideration to process gas and water properties indicated
elsewhere.
4.14 PULSATIONS AND VIBRATION CONTROL REQUIREMENTS
4.14.1 Pulsation suppression devices shall limit peak-to-peak pulsation levels at the line side of the
pulsation suppression device to a value as determined by the equation as under:

Pi (%) = 4.1 ÷ [Pline] 0.3333

where
Pi : Maximum allowable peak to peak pulsation level at any discrete frequency as a
percentage of average absolute pressure.
Pline : Average absolute line pressure in Bar, absolute.
These pulsation suppression devices shall be designed and fabricated in accordance with
ASME Sec. VIII Div. 1.
5.0 INSPECTION AND TESTING:
5.1 INSPECTION
5.1.1 The vendor shall furnish material test certificates for the following:
- Safety Valve
- Pulsation Suppression Devices

- Coolers
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HP HYDROGEN COMPRESSOR
(ROTATING EQUIPMENT)
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5.2 TESTING
5.2.1 General

5.2.1.1 The equipment shall be tested in accordance with 5.2.2.

5.2.1.2 Whenever the data sheets or specifications call for certain shop inspections and tests to be
witnessed, observed, or performed in presence of purchaser's representative, the vendor shall
provide a written notice of at least 30 days in advance to the Purchaser, prior to each inspection
or test. The vendor shall reconfirm the date seven days prior to the test date.

5.2.2 Testing For Assembled Equipment

The assembled equipment shall be subjected to tests in the vendors shop in accordance with
the following table. The requirements of vendor’s certificates and witnessing by the purchasers
inspector are stated in this table.

S.N Test Certificate required Witnessed by

from Vendor purchaser’s
Inspector
i) Mechanical running test (4 hours) Yes Yes
ii) Tests for instruments, controls and Yes ---
safety devices.
iii) Hydrostatic testing of pressure Yes Yes
vessels and Heat Exchangers
including Piping as per ASME Sec.
VIII.
iv) Helium Test (if applicable) Yes Yes

5.2.3 Hydrostatic and Leakage Tests

5.2.3.1 Hydrostatic Tests for all pressure containing parts, shall be carried out at a pressure of 1.5
times the maximum allowable working pressure. The test shall be maintained for a period of
time sufficient to permit a thorough examination of the parts, with a minimum period of 30
minutes.

5.2.3.2 The appropriate gas leakage test indicated by the following list shall be performed to ensure
that the components do not leak the process gas. The leakage test shall be conducted with the
components thoroughly dried and unpainted.

- Pressure containing parts, such as compressor heads handling gases with a maximum
molecular weight of 12 or gases containing more than 0.1 mole percent of H2S shall have a
pressure test with helium, performed at the MAWP. Leak detection shall be by the helium
probe or by submergence of the part in water. The water shall be at a higher temperature
than the nil-ductility transition temperature of the material being tested. The internal pressure
shall be maintained, while the part is submerged, at the maximum working pressure. The
amount of leakage must be zero (0).

- Cylinder heads handling gases other than those described above, shall have a gas leakage
test, as specified above except that the test gas shall be air or nitrogen.

5.2.4 Mechanical Running Test

5.2.4.1 The compressor shall be operated for 4 hours at rated speed.

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5.2.4.2 The following requirements shall be met before/during the mechanical running test is
performed.

(i) The contract valves and bearings shall be used in the machine.
(ii) All oil pressures, viscosities and temperatures shall be within the operating range of values
recommended by the manufacturer for the specific unit being tested.
(iii) All casing and oil system joints and connections shall be checked for tightness and any
leaks shall be corrected prior to test.

5.2.4.3 During the running test, the mechanical operation of all equipments being tested and test
instrumentation, shall be satisfactory.

5.2.4.4 Control systems shall be demonstrated to the extent practicable.

5.2.4.5 If replacement or modification of bearings, valves, or packing or dismantling of the machine to

replace or modify other parts is required to correct mechanical or performance deficiencies, the
initial test will not be acceptable, and the final shop tests shall be run after these replacements
or corrections are made.
6.0 SPARES AND SPECIAL TOOLS AND TACKLES
6.1 Refer Engineering Design Basis (Doc. No. - ) of Rotating Equipment.
6.2 The vendor shall furnish all special tools and gauges required for the installation and the
maintenance of each unit together with complete instructions for their use.
6.3 The compressor shall be provided with a suitable and safe barring device for maintenance.
7.0 DOCUMENTS, DATA & DRAWINGS
7.1 Refer Engineering Design Basis (Doc. No. ) of Rotating Equipment.

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