Attachment_1_-_Specifications_80GRC019Q0015.pdf

TECHNICAL SPECIFICATION FOR

ELECTRIC MOTOR DRIVEN

RECIPROCATING COMPRESSOR SYSTEM

National Aeronautics and Space Administration

NASA Glenn Research Center 21000 Brookpark Road Cleveland, OH 44135

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

ENGINEERING TECHNICAL SPECIFICATION

DATE: 07/11/2019

SUBJECT: COMPRESSOR SYSTEM FOR ETHYLENE GAS

1. SUMMARY

The Supplier shall provide all labor and materials to deliver one (1) electric-motor-driven ethylene gas compressor system.

The system shall include an ethylene gas compressor, drive motor, and all additional ancillary mechanical, electrical, structural, and control components necessary to comply with this specification.

2. SYSTEM OVERVIEW

A compressor system is required for upcoming tests at NASA’s Glenn Research Center in Cleveland, Ohio. The compressor system will be installed outdoors with no protection from the elements. The site elevation is around 760 ft. The ambient temperature range over which the compressor will be operated is 10 to 101℉. However, the compressor system may be exposed to a broader range of temperatures, -20oF to 120oF.

The service fluid utilized will be 100% ethylene. It will be operated 3 days per week, over two separate 10 calendar week periods (these periods could be separated by as much as 18 months. Residual condensation may be experienced on all flow surfaces). Each day it will be operated for up to four 10 minute periods, with each period separated by no less than an hour.

The compressor system will be fed from 480 VAC, 60 Hz, 3 Phase power, only.

The compressor system will be remotely operated. If lower voltages are required, the compressor system shall provide the necessary equipment to produce such power supplies.

2. SYSTEM OVERVIEW (CONT’D)

The ethylene will be supplied via a tube trailer. The trailer outlet will be connected to the compressor system inlet, with nothing but an isolation valve between the compressor system and ethylene supply trailer. The expected tube trailer supply pressure, depending on the temperature, will be between 560 and 2,110 psig. The maximum allowable tube trailer pressure is 2,400 psig. The compressor system will draw the ethylene fluid from the tube trailer.

Downstream of the compressor system, the ethylene system will be protected with a pressure relief valve set at 1,100 psig.

Ethylene is a unique fluid due to the fact that its critical temperature point, 48.6℉, is within typical ambient ranges. Therefor the ethylene pressure in the bulk delivery trailer will have significant fluctuation with the associated ambient temperature conditions. Depending on the ambient and particular process conditions, ethylene will transition into several different phase states. Adding complexity, the customer has stated there shall be no two-phase flow delivered to the final point of use. A phenomenon that poses an issue related to two-phase flow is the Joule-Thomson cooling effect caused by pressure drops through equipment and restrictions. Without careful design, an excessive pressure drop through a component could result in a large enough temperature drop that produces two-phase flow.

3 REQUIREMENTS

3.1 Design

3.1.1 Performance

3.1.1.1 The compressor system shall perform with an ethylene supply pressure from

250 to 2,110 psig.

3.1.1.1.1 The compressor system shall preclude the possibility of drawing a vacuum on the ethylene tube trailer.

3.1.1.2 The pressure at the ethylene compressor system outlet shall be 1000 psig with a pulsation tolerance less than ± 50 psig. The downstream ethylene system is protected by a pressure safety valve set at 1,100 psig.

3.1.1.3 The compressor system shall perform with an ethylene supply temperature from 10 to 101℉.

3.1.1.4 The temperature at the ethylene compressor system outlet shall be 235 to 250℉.

3.1.1.5 The compressor system shall be capable of ethylene flow rates from 0.8 to

5.8 pounds per second, without venting ethylene to atmosphere.

3.1.2 Compressor

3.1.2.1 The compressor shall be a non-lubricated design.

3.1.2.2 The compressor shall be air-cooled.

3.1.3 Piping & Pressure Vessels

3.1.3.1 Vessels shall be designed, built, and tested/inspected in accordance with

ASME Boiler and Pressure Vessel Code Section VIII, stamped accordingly, and registered with the National Board of Boiler and Pressure Vessel Inspectors.

3.1.3.2 Piping shall be designed, built, and tested/inspected in accordance with ASME B31.3 Process Piping for normal fluid service.

3.1.3.3 Any relief valves shall be ASME UV code stamped

3.1.3.3.1 Relief valve sizing and design shall be in accordance with API RP 520, API RP 521, API RP 526 and ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

3.1.4 Instrumentation

The system shall include the following instrumentation at minimum:

3.1.4.1 Redundant inlet gas temperature measurement

3.1.4.2 Redundant inlet gas pressure transducer

3.1.4.3 Redundant discharge gas temperature measurement

3.1.4.4 Redundant discharge gas pressure transducer

3.1.4.5 Redundant frame lube oil temperature measurement

3.1.4.6 Redundant compressor frame oil header pressure transducer

3.1.4.7 Inlet gas temperature gauge

3.1.4.8 Inlet gas pressure gauge

3.1.4.9 Discharge gas temperature gauge

3.1.4.10 Discharge gas pressure gauge

3.1.4.11 Frame lube oil temperature gauge

3.1.5 Structure

3.1.5.1 The compressor system components shall be packaged on a structural steel frame.

3.1.5.1.1 The frame shall have anchoring provisions suitably sized and reinforced to withstand the anticipated forces and moments that must be reacted into the foundation.

3.1.5.2 The as-delivered compressor system shall have provision for crane hoisting without need for any disassembly.

3.1.6 Electrical

3.1.6.1 The compressor shall be driven by an electric motor.

3.1.6.2 The compressor system shall include all electrical enclosures, power distribution panels, transformers, motor switchgear, and motor starters necessary for compressor system safe operation.

3.1.6.3 Motors, electrical components and electrical installations shall be suitable for service in a NFPA 70 Class 1 Division 2 Group C hazardous area.

3.1.6.4 All conductive components which are not intended to carry current shall be bonded and grounded.

3.1.6.5 The compressor system steel frame shall have provision for the attachment of a facility ground.

3.1.7 Controller

3.1.7.1 The system shall include a skid mounted PLC controller.

3.1.7.2 The system shall have an HMI that allows local display of system status, process variable readouts, and alarm/shutdown messages and related system diagnostics.

3.1.7.3 The compressor system controller communication protocol shall be Modbus

TCP/IP.

3.1.7.3.1 All system statuses, all process variable outputs, and all alarm/shutdown conditions shall be made available through Modbus

TCP/IP.

3.1.8 Safety

3.1.8.1 All moving parts shall be guarded to prevent contact with surrounding hardware and human contact.

3.1.8.2 Surfaces for which ethylene may come in contact under normal operating and leakage conditions shall be below 674℉.

3.1.8.3 Surface temperatures which may be subjected to human contact shall not exceed 110℉.

3.1.8.4 Appropriate safety signage shall be included (e.g. high voltage, high temperatures, rotating equipment, etc.).

3.2 Inspection & Test

3.2.1 Piping components shall be hydrostatically or pneumatically tested in accordance with AMSE B31.3, ensuring any reduction in allowable stress at design conditions is accounted for.

3.2.2 Pressure vessels shall be hydrostatically or pneumatically tested in accordance with AMSE B&PVC Sec VIII Division 1, ensuring any reduction in allowable stress at design conditions is accounted for.

3.2.2.1 The pressure tests shall be considered satisfactory when the measured pressure does not drop over a 30 minute period.

3.2.3 Piping component welding shall be performed and inspected by operators and procedures qualified in accordance with ASME B31.3.

3.2.4 Pressure vessel welding shall be performed and inspected by operators and procedures in accordance with ASME Boiler and Pressure Vessel Code, Section

IX.

3.2.5 The manufacturers’ standard non-load spin test shall be performed on the compressor.

3.2.6 The frame lube oil system run test shall be performed.

3.2.7 The controller shall be subject to a factory acceptance test (FAT) whereby nominal and off-nominal operational scenarios may be simulated to verify the controller logic works as intended.

3.2.8 The main driver motor shall be tested at the motor suppliers’ factory in accordance with NEMA MG-1 standards.

3.3 Miscellaneous

3.3.1 The compressor system shall NOT require grouting in place.

3.3.2 Final acceptance of the system shall be based on:

3.3.2.1 Based on successful commissioning of the equipment.

3.3.2.2 Supplier submittal of all deliverables.

3.3.3 The compressor system Supplier shall warrant the compressor system for a period of twelve (12) months after start up or 18 months after shipment, whichever occurs first.

3.3.3.1 During the warranty period, the compressor system Supplier shall furnish support, service, engineering, labor and materials necessary to correct deficiencies at no additional cost to NASA.

4. DELIVERABLES

The compressor system supplier shall provide:

• With their proposal:

o Any options/approaches which the compressor system supplier feels that the Government should consider to accelerate the delivery schedule, which can include deviations with this specification.

o Any options which the compressor system supplier feels that the Government should consider, along with accompanying rationale that will allow the Government to perform a proper assessment.

o Any exceptions taken to anything within this specification, and proposed alternatives with accompanying rationale that will allow the Government to perform a proper assessment.

o An itemization of life-limited components and recommended spares.

o A notional drawing of the proposed compressor system.

o Any information not explicitly mentioned herein, but that the compressor system supplier feels will assist NASA in evaluating their proposal.

• No later than 5 days after receipt of order:

o A kick-off meeting to be held at the system supplier’s facility.

Invitees to include NASA, system supplier, compressor manufacturer representative and long-lead item equipment manufacturer representatives per the supplier’s discretion.

• No later than 8 weeks after receipt of order:

o 480 VAC power supply and wiring (i.e. delta wye) requirements.

o Compressor system foundation requirements (e.g. – recommended size, static and operating loads to be imparted by compressor at the anchor points, anchor bolts size and layout, flatness, levelness, etc.).

o A preliminary general arrangement drawing(s) of compressor system.

o A preliminary piping schematic.

o Preliminary wiring and ladder logic diagrams o A preliminary listing of all alarm and shutdown conditions.

o A preliminary listing of all required permissives and interlocks necessary for compressor system operation.

4. DELIVERABLES (CONT’D)

• Prior to hot work:

o Welding:

A Welding Procedure Specification (WPS) per ASME B&PVC Section IX Article II QW-2001.1 for each weld joint type.

A Weld Procedure Qualification Record (PQR) per ASME B&PVC Section IX Article II QW-200.2 for each weld joint type.

Weld test reports from a 3rd party organization.

Proof of welder continuity.

o Brazing:

A Brazing Procedure Specification (BPS) per ASME B&PVC

Section IX Article XII QB-200.1 for each braze joint type.

A Braze Procedure Qualification Record (PQR) per ASME

B&PVC Section IX Article XII QB-200.2 for each braze joint type.

Braze test reports from a 3rd party organization.

Proof of brazer continuity.

o Material certifications for fillers and fluxes

• Throughout fabrication o The contractor shall submit digital photographs of progress every 2 weeks, starting from delivery of the first component.

The photographs shall be submitted to the NASA technical point of contact via the NASA Large File Transfer system.

• No later than 16 weeks prior to delivery:

o Craning instructions Special equipment required for craning (i.e. spreader bars).

o Installation instructions o Preliminary commissioning instructions.

• At delivery o Commissioning, operations and maintenance instructions/manual.

The manual shall include:

• Performance capabilities (e.g. – compressor performance curves, unsafe or undesirable operating speeds, etc.)

• Physical characteristics (e.g. – size and weight, power in, etc.)

• Preparation requirements for extended periods of disuse, as well as requirements for re-activation after a period of disuse.

o As-built 3-D STEP model of the compressor system (need not include internal features of components).

4. DELIVERABLES (CONT’D)

o As-built drawing (electronic format, PDF preferred):

assembly/general arrangement drawing, piping and instrument diagram (P&ID), and wiring and ladder logic diagrams o A final listing of all alarm and shutdown conditions.

o A final listing of all required permissives and interlocks necessary for compressor system operation.

o As-built parts list (electronic format, Microsoft Excel preferred), including but not limited to manufacturer, model number, serial number, pressure and temperature ratings, set pressures, materials of construction, etc.

o Catalog cuts for all components, including but not limited to: relief devices, pressure regulators, heat exchangers, pressure vessels, etc.

o Certified reports for all tests and inspections performed.

o Piping and pressure vessel material mill test reports.

o Pressure vessel U-1 forms.

o Pressure relief sizing scenarios and calculations.

o Pressure relief valve manufacturer’s certificate of conformance for pressure relief valves.

o Pressure relief valves manufacturer’s test reports.

o Piping stress analyses (including any flexibility analysis).

o Provide NIST traceable instrumentation calibration certificates valid for one year after time of delivery.

• At the start of commissioning o Labor to assist NASA personnel in the commissioning of the compressor system (NASA will provide notice at least 4 weeks prior to the start of commissioning).