Spec (22 16 19.36 20) - Large Centrifugal Air Compressors (Over 500 HP).pdf

SECTION 22 16 19.36 20

LARGE CENTRIFUGAL AIR COMPRESSORS (OVER 500 HP)

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 2011 (2014B) Cylindrical Wormgearing Tolerance and Inspection Methods

ANSI/AGMA 2009 (2001B; R 2008) Bevel Gear Classification, Tolerances, and Inspection Methods

AMERICAN PETROLEUM INSTITUTE (API)

API Std 541 (2014; 5th Ed) Form-wound Squirrel Cage

Induction Motors-375kW (500 Horsepower) and Larger

API Std 672 (2004; Errata 2007; Errata 2010) Packaged, Integrally Geared Centrifugal Air

Compressors for Petroleum, Chemical, and

Gas Industry Services

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.20.1 (2013; R 2018) Pipe Threads, General

Purpose (Inch)

ASME B16.1 (2020) Gray Iron Pipe Flanges and Flanged

Fittings Classes 25, 125, and 250

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B40.100 (2022) Pressure Gauges and Gauge

Attachments

ASME BPVC SEC VIII D1 (2019) BPVC Section VIII-Rules for

Construction of Pressure Vessels Division 1

ASME PTC 10 (1997; R 2014) Performance Test Code on

Compressors and Exhausters

ASTM INTERNATIONAL (ASTM)

ASTM B111/B111M (2018) Standard Specification for Copper and Copper-Alloy Seamless Condenser Tubes and Ferrule Stock

SECTION 22 16 19.36 20 Page 1

ASTM B171/B171M (2012) Standard Specification for

Copper-Alloy Plate and Sheet for Pressure

Vessels, Condensers and Heat Exchangers

ASTM B209 (2014) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM C553 (2013; R 2019) Standard Specification for

Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications

ASTM E84 (2020) Standard Test Method for Surface

Burning Characteristics of Building

Materials

COMPRESSED GAS ASSOCIATION (CGA)

CGA G-7.1 (2011) Commodity Specification for Air;

5th Edition

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 112 (2017) Standard Test Procedure for

Polyphase Induction Motors and Generators

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 2151 (2004) Acoustics - Noise Test Code for

Compressors and Vacuum Pumps - Engineering

Method (Grade 2)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2021) Motors and Generators

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-A-3316 (1987; Rev C; Am 2 1990) Adhesives, Fire-Resistant, Thermal Insulation

MIL-PRF-17331 (2019; Rev L) Lubricating Oil, Steam

Turbine and Gear, Moderate Service

MIL-T-19646 (1990; Rev A; Notice 1 2021) Thermometer, Gas Actuated, Remote Reading

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.219 Mechanical Power Transmission Apparatus

1.2 SUBMITTALS

Government approval is required for all submittals prior to construction

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Submittal Register With Schedule

SECTION 22 16 19.36 20 Page 2

Quality Control Plan

SD-02 Shop Drawings

Certified Dimensional Overall Outline Drawing And List Of

Connections

Certified Dimensional Major Equipment Drawings

Cross-Sectional Drawings And Bills Of Materials

Foundation Loading Diagrams Including Dimensions Of Mountings And

Baseplates

Sealing Air System Schematics And Bill Of Materials

Lube Oil Schematic And Bills Of Materials

Lube Oil System Assembly And Arrangement Drawings

Electrical Schematics And Wiring Diagrams (Oil Heater And Motor

Heater)

Instrumentation And Control Schematics, Wiring Diagrams, And Bill

Of Materials

Instrumentation And Control Arrangement Drawings

Dimensional Drawings For All Major Auxiliary Equipment Or

Components

Installation Layout Showing The Ability To Fit In Space Allotted

SD-03 Product Data

Bleed Line Silencer

Tabulation Of Maximum Utility Requirements

ISA Data Sheets For All Instruments And Controls

Product Manuals, Installation Instructions And Calibration

Information For All Instruments And Controls

Compressor Controller Code

Control Parameters

Alert And Danger Alarm Settings Tabulation

Motor To Compressor Coupling Details Including Installation And

Maintenance Instructions

Motor dimensioned outline drawings with major and minor connections including:

Shaft End Details

Coupling Installation And Maintenance Instructions

SECTION 22 16 19.36 20 Page 3

Motor Terminal Box Details And Wiring Instructions

Motor Schematic wiring for:

Space Heaters

Vibration Monitoring

Temperature Sensors

Differential Current Transformers

Single Phase Instrumentation Current Transformer

Single Phase Instrumentation Potential Transformer

Motor Performance curves for:

Power Factor Versus Speed

Motor And Rotor Heating (I2/T)

Torque Versus Speed At Rated Voltage And At 90% Voltage

Current Versus Speed At Rated Voltage And At 90% Voltage

Expected Efficiency

Acceleration Time Curves

SD-05 Design Data

Curves And Envelope Showing Performance Characteristics Of

Pressure, Flow And Power At All Operating Conditions

Damped Unbalanced Response Analysis Per Api 672 (6.12.4)

Torsional Vibration Analysis Per Api 672 (6.12.5)

Detailed Startup Torque Curve Including Maximum Starting Time With

Critical Machine Speeds Noted

SD-06 Test Reports

Factory Test Procedures

Certified Factory Test Running Reports

Certified Hydrostatic Test Reports

Noise Data Sheets

SD-07 Certificates

Factory Testing Certification; G

Warranty; G

SECTION 22 16 19.36 20 Page 4

Material Safety Data Sheets

Pressure Vessel Certification Data

SD-08 Manufacturer's Instructions

Compressor Installation And Assembly Manual

Spare Parts Recommendations And Price List

Preservation, Packaging And Shipping Procedures

SD-10 Operation and Maintenance Data

Operating And Maintenance Manuals

Motor Installation, Maintenance, And Operating Instructions

SD-11 Closeout Submittals

Final As-Built of:

Certified Dimensional Overall Outline Drawing And List Of

Connections

Certified Dimensional Major Equipment Drawings

Cross-Sectional Drawings And Bills Of Materials

Foundation Loading Diagrams Including Dimensions Of Mountings And

Baseplates

Sealing Air System Schematics And Bill Of Materials

Lube Oil Schematic And Bills Of Materials

Lube Oil System Assembly And Arrangement Drawings

Electrical Schematics And Wiring Diagrams (Oil Heater And Motor

Heater)

Instrumentation And Control Schematics, Wiring Diagrams, And Bill

Of Materials

Instrumentation And Control Arrangement Drawings

Dimensional Drawings For All Major Auxiliary Equipment Or

Components

Installation Layout Showing The Ability To Fit In Space Allotted

Compressor Controller Code

Control Parameters

Alert And Danger Alarm Settings Tabulation

SECTION 22 16 19.36 20 Page 5

1.3 SUBMITTAL DESCRIPTIONS

1.3.1 Submittal Register With Schedule

Submittal register shall conform to section 01 33 00.

1.3.2 Quality Control Plan

Quality Control Plan shall provide detailed descriptions of the processes, procedures, personnel responsibilities and reporting provided to assure that the compressor is constructed to high quality material, manufacturing and assembly standards.

1.3.3 Shop Drawings

Shop drawings shall be provided in accordance with section 01 33 00.

Preliminary and final shop drawings shall be provided. Shop Drawings to be provided include:

a. Certified Dimensional Overall Outline Drawing And List Of Connections

b. Certified Dimensional Major Equipment Drawings

c. Cross-Sectional Drawings And Bills Of Materials

d. Foundation Loading Diagrams Including Dimensions Of Mountings And

Baseplates

e. Sealing Air System Schematics And Bill Of Materials

f. Lube Oil Schematic And Bills Of Materials

g. Lube Oil System Assembly And Arrangement Drawings

h. Electrical Schematics And Wiring Diagrams (Oil Heater And Motor Heater)

i. Instrumentation And Control Schematics, Wiring Diagrams, And Bill Of

Materials

j. Instrumentation And Control Arrangement Drawings

k. Dimensional Drawings For All Major Auxiliary Equipment Or Components

l. Installation Layout Showing The Ability To Fit In Space Allotted

1.3.4 Product Data

Provide the following product data:

a. Tabulation Of Maximum Utility Requirements

b. ISA Data Sheets For All Instruments And Controls

c. Product Manuals, Installation Instructions And Calibration Information

For All Instruments And Controls

d. Compressor Controller Code

e. Control Parameters

f. Alert And Danger Alarm Settings Tabulation

g. Motor To Compressor Coupling Details Including Installation And

Maintenance Instructions

h. Motor Dimensioned Outline Drawings With Major And Minor Connections

Including:

(1) Shaft End Details

(2) Coupling Installation And Maintenance Instructions

(3) Motor Terminal Box Details And Wiring Instructions

i. Motor schematic wiring for:

(1) Space Heaters

(2) Vibration monitoring

(3) Temperature sensors

(4) Differential current transformers

SECTION 22 16 19.36 20 Page 6

(5) Single phase instrumentation current transformer

(6) Single phase instrumentation potential transformer

j. Motor Performance curves for:

(1) Power factor versus speed

(2) Motor and rotor heating (I2/T)

(3) Torque versus speed at rated voltage and at 90% voltage

(4) Current versus speed at rated voltage and at 90% voltage

(5) Expected Efficiency

(6) Acceleration time curves

1.3.5 Design Data

Provide the following design data:

a. Curves and envelope showing performance characteristics of pressure, flow and power at all operating conditions

b. Damped unbalanced response analysis per API 672 (6.12.4)

c. Torsional vibration analysis per API 672 (6.12.5)

d. Detailed startup torque curve including maximum starting time with critical machine speeds noted

1.3.6 Test Reports

Test reports shall include logged data for factory running tests and shall include curves and envelope showing the as-built performance characteristics of pressure, flow and power at all operating conditions.

Provide the following test reports:

a. Certified Factory Test Running Reports

b. Certified Hydrostatic Test Reports

c. Noise Data Sheets

1.3.7 Certificates

a. Submit a Factory Testing Certification stating that the air compressor factory is equipped to perform all required factory tests.

b. Submit Material Safety Data Sheets.

c. Submit Pressure Vessel Certification Data.

d. Provide manufacturer's Warranty covering all aspects of quality and workmanship for the compressor for one year After finalization of commissioning. Warranties shall be available to cover delays in installation and extensions afetr commissioning.

1.3.8 Manufacturer's Instruction

Provide the following manufacturer's instructions:

a. Compressor Installation And Assembly Manual

b. Preservation, Packaging And Shipping Procedures

1.3.9 Operation and Maintenance Data

Operation and Maintenance data shall be provided in accordance with section

01 33 00. Data shall contain information required for maintenance and repair and shall contain no evidence that proprietary maintenance arrangements with the manufacturer/vendor will be necessary. Compressors which will require a proprietary maintenance arrangement with the

SECTION 22 16 19.36 20 Page 7 manufacturer/vendor shall require Government review and approval. The compressors may be disapproved if circumstances do not justify approval of compressors with limited maintenance availability. Provide the following:

a. Operating And Maintenance Manuals

b. Motor Installation, Maintenance, And Operating Instructions

1.4 QUALITY ASSURANCE

1.4.1 Qualifications of Field Supervisors

Submit the name and certified written resume of the engineer or technician, listing education, factory training and installation, start-up, and testing supervision experience for at least two projects involving compressors similar to those in this contract.

1.5 SAFETY

Construct all components of the unit in accordance with the requirements of

OSHA 29 CFR 1910.219. Requirements include shaft coupling guards, thermal insulation and jacketing with manufacturer's standard covering or aluminum sheet of all surfaces at 125 degrees F and higher within a height of 7 feet from floor level, and use of electrical safety devices. Thermal insulation, furnished by equipment manufacturer, shall conform to ASTM C553, Type I (flexible resilient), Class B-5 (up to 400 degrees F), 2 pcf nominal. Cement insulation to surface with MIL-A-3316, Class 2, adhesive and fasten with 16 gage wire bands at maximum 16 inches on center spacing.

Cover insulation with ASTM B209 sheet aluminum jacket. Thermal insulation and jacketing is also required for units with separate intercooler and aftercooler units.

1.6 SUPERVISION

The services of a qualified engineer or technician from the compressor manufacturer/vendor shall be provided to supervise installation, start-up, and performance testing of the compressor. After satisfactory installation of the equipment, the engineer or technician shall provide a signed certification that the equipment is installed in accordance with the manufacturer/vendor's recommendations.

1.7 DEFINITIONS

Conform to API Std 672

1.8 INSULATION

Thermal and acoustical insulation shall have flame spread rating not higher than 75, and smoke developed rating not higher than 150 when tested in accordance with ASTM E84.

1.9 OPERATING INSTRUCTIONS

Include pre-startup, start-up, operating, shutdown and emergency shutdown sequence instructions.

1.10 SITE ACCESSIBILITY

The installation location for each air compressor is accessed by a 16.5 ft long by 12 ft wide roof hatch. Each compressor must be capable of being

SECTION 22 16 19.36 20 Page 8 broken into components small enough to fit through the opening. The compressors shall be re-assembled by manufacturer/vendor's factory trained and authorized representative(s). Refer to drawings for site details and access location.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Materials and equipment complete with accessories shall be selected by the

Manufacturer/Vendor for performance compatibility.

2.2 AIR COMPRESSOR

The compressed air system will consist of two identical air compressors each with the design characteristics listed below. The air compressors shall be the packaged, integrally geared, centrifugal type. Include the electric motor driver, integral gears and cases, staged compressors, intercoolers and moisture separators, aftercoolers and moisture separators, seal air system instruments, controls, pressure lubrication system with prelubrication pump and shaft-driven lubrication pump, steel base and accessories. The aftercoolers may be mounted separately to meet the performance requirements.

2.2.1 Manufacturer's Certifications

The manufacturer shall certify that the air compressors proposed are of the same design, construction, and frame size, and of equal or not more than 10 percent smaller in capacity as compressors which have been in satisfactory continuous service for at least 2 years at not less than two locations.

Furnish the name of the owner, the address of the installation, and the name of a person at the installation who can be contacted for verification.

The manufacturer shall also certify that the factory is equipped to perform all required factory tests.

2.2.2 Nameplates

Secure a plate to each major component of equipment containing the manufacturer's name, address, type or style, model and serial number.

2.2.3 Guaranteed Performance

a. Net Compressed Air Output (All seal losses shall be considered internal and not included in the net output) (Minus zero plus 4 percent): 9,800

SCFM (ISA) / 12.5 LBM/SEC

b. Output Pressure Range Immediately Downstream of Aftercooler (Minus zero plus 4 percent): 250 - 500 psig

c. Output Air Maximum Temperature Downstream of Aftercooler: 100 degrees F

d. Inlet Air Pressure at First Stage: 14 psia

e. Inlet Air Temperature at First Stage: 0 - 95 degrees F

f. Inlet Air Filtration Efficiency: 99.9 percent of 0.5 micrometer size

g. Barometric Pressure: 14.3 psia

SECTION 22 16 19.36 20 Page 9

h. Relative Humidity: Ambient

i. Cooling Water Inlet Temperature: 95 degrees F

j. Total Cooling Water Flow Rate: As Required

k. Maximum Cooling Water Pressure Drop Through the Compressor and Any

Intercooler, Aftercooler, or Oil Cooler: 8 psi

l. Maximum Compressor Power Required: 4,000 hp

2.2.4 Additional Performance Requirements

2.2.4.1 Air Quality

Air at compressor intake will be considered breathing air quality conforming to CGA G-7.1, Type I, Grade D or better. Air compressors shall introduce no material, gases, or particles, or chemically alter any materials that will adversely affect or reduce the quality of the air passing through the unit.

2.2.4.2 Ambient and Inlet Conditions Operating Ranges

Allowing for rational engineering performance adjustments due to variations in ambient and inlet conditions, the compressor shall be designed, equipped, and furnished to be fully operational without abnormal wear throughout the entire range between and including the limits of the winter and summer design conditions specified.

a. Summer Design Conditions:

Inlet Air: 91 degrees F dry bulb and 75 degrees F wet bulb temperatures, 50 percent relative humidity

Inlet Cooling Water: 95 degrees F

Ambient Compressor Room Temperature: 100 degrees F

Barometric Pressure: 14.3 psia

b. Winter (Low Ambient) Design Conditions:

Inlet Air: 1 degrees F dry bulb and 0 degrees F wet bulb temperatures, 65 percent relative humidity

Inlet Cooling Water: 60 degrees F

Ambient Compressor Room Temperature: 80 degrees F

Barometric Pressure: 14.3 psia.

2.2.4.3 Critical Speeds

a. Resonances of structural support systems that are within the manufacturer’s scope of supply and that affect the rotor vibration amplitude shall not occur within the specified separation margins unless the resonances are critically damped. The effective stiffness of the structural support shall be considered in the analysis of the dynamics of the rotor-bearing-support system.

SECTION 22 16 19.36 20 Page 10

b. The manufacturer shall determine that the drive-train (turbine, gear, motor, and the like) critical speeds (rotor lateral, system torsional, blading modes, and the like) will not excite any critical speed of the machinery being supplied and that the entire train is suitable for the rated speed and any starting-speed detent (hold-point) requirements of the train. A list of all undesirable speeds from zero to trip shall be submitted for purchaser review and included in the instruction manual for purchaser guidance.

2.2.5 Electrical Service Conditions

2.2.5.1 Air Compressor Drive Motor

6,900 volts, 3 phase, 3 wire, 60 hertz electrical service.

2.2.5.2 Accessory electrical Service

See Table I.

TABLE I - COMPRESSOR ACCESSORY ELECTRICAL SERVICE SCHEDULE

Item Voltage Phase Frequency

Control Power 120 1 60 Hz

Accessory Power 460 3 60 Hz

Motor and Oil

Heaters

460 3 60 Hz

Aux Oil Pump 460 3 60 Hz

2.2.5.3 Control Power Uninteruptable Power Supply (UPS)

Provide uninterruptible power supplies (UPS) for control power as self contained devices suitable for installation and operation at the air compressor control hardware and sized to provide a minimum of 20 minutes of operation of the connected hardware. Equipment connected to the UPS must not be affected in any manner by a power outage of a duration less than the rated capacity of the UPS. Provide the UPS complete with all necessary power supplies, transformers, batteries, and accessories. Provide UPS which includes visual indication of normal power operation, UPS operation, abnormal operation and visual and audible indication of AC input loss and low battery power. Provide UL 1778 approved UPS.

2.2.6 Compressor Design Features

Compressor shall be multistage centrifugal, with a minimum of 4 centrifugal compression stages, designed for optimum flow and speed requirements to produce highest space efficiencies at highest compression ratio and lowest temperature and external noise level. Special attention shall be given to energy saving features in design and arrangement such as radial damper intake valve, long radius interstage piping, and low air velocities.

Equipment shall be designed for economical and rapid maintenance. Casing components bearing housings and other major parts shall be shouldered, dowelled, or designed with other provisions to facilitate accurate alignment or reassembly. Shaft seals and bearings shall be accessible for inspection or replacement with a minimum of disassembly.

SECTION 22 16 19.36 20 Page 11

2.2.6.1 Casings

Casing shall be cast iron, ductile iron, or cast steel. Casing stresses shall be within the limits allowed by ASME BPVC SEC VIII D1. Casings, supports, and baseplates shall be designed and fabricated to preclude excessive and injurious distortion from temperatures, pressures, and forces encountered in service conditions, including surge. Provide jackscrews, lifting lugs, eyebolts, guide dowels, and casing alignment dowels to facilitate disassembly and reassembly. When using jackscrews for parting contacting faces, relieve one of the faces by counterboring or recessing to prevent marring the face, which result in leaking or improper fit. Provide lifting lugs or eyebolts for removable portions of the casings. Flanged casing connections shall conform to ASME B16.1 or ASME B16.5. Threaded connections shall conform to ASME B1.20.1. Casing shall be split in a manner permitting direct access to impellers, shafts, and bearings.

Compressors shall be axial flow inlet. Gear cases shall be enclosed, accessible, force lubricated and designed with seals and slingers to keep oil out of air system.

2.2.6.2 Shafts

Shafts shall be of forged or rolled alloy steel and shall have a machined finish throughout their entire length. All rotating components shall be positively secured to shafts by approved mechanical means or interference shrink fits. No other material than the shaft steel shall be applied to the areas measured under the vibration proximity probes. No plating shall be applied to these areas.

2.2.6.3 Impellers

Impellers shall be of 400 series or 17-4 PH stainless steel, open or closed design, with backward leaning vanes, and of welded, milled, or cast construction.

2.2.6.4 Gears

Gears shall be of alloy steel, ANSI/AGMA 2009 and AGMA 2011 Quality Number

12 or better for both bull and pinion gears. Gears shall be hardened to

275 Brinell for bull gear and 320 Brinell for pinion, unless otherwise approved. Gears shall be ground to the required contours, checked for proper contact during assembly at the factory, and shall not require a break-in period in the field for proper operation. All gears shall be pressure lubricated.

2.2.6.5 Seals

Separate air and oil shaft seals shall be provided to confine air in the casing and prevent contamination of the air stream by lubricating oil.

Shafts seals shall be labyrinth type, carbon ring type, or a combination of the two types. Provide an air space vented to the atmosphere between the air and oil seals. Seals shall be suitable for all operating conditions including suction throttling, start-up, shutdown, and momentary surge.

Seal air may be utilized for the compressor. The seal air shall be self-supplied by the compressor during operation. A pressure switch shall be provided to disable lube oil pumping if seal air pressure is too low.

Seal air flow shall be measured by rotameters. The oil pressure shall be reduced by the oil pressure control system when seal air pressure is not

SECTION 22 16 19.36 20 Page 12 present.

2.2.6.6 Thrust Bearings

Axial impeller thrusts shall be absorbed by thrust bearings on the pinion or transferred to the bull gear shaft by conical rider-ring thrust collars.

Pinion thrust bearings shall be hydrodynamic (fluid film), multiple-segment type, tilted pad type, or other approved type, and shall be adequate to accommodate all operating conditions, including surging or stonewall operation. Bull gear thrust bearings shall be sized for equal thrust in both directions and shall be adequate for any axial loads transmitted through the driver coupling.

2.2.6.7 Radial Bearings

Radial bearings shall be hydrodynamic (fluid film), precision bored sleeve or pad type, designed for easy replacement by a split design or axially removable arrangement. High speed pinion bearings shall be anti-oil whip, tilting pad, tilted pad, or other approved type. Bearing design shall provide low vibration and sufficient damping at rated speed and all operating modes, including rated capacity and unloading down to 15 to 20 percent of unloaded power.

2.2.6.8 Inlet Guide Vanes

Inlet guide vanes shall be provided to regulate the airflow and pressure that enters a centrifugal compressor’s first stage of compression. The inlet guide vanes shall create a swirl direction in the incoming air that matches the spin direction of the first stage of compression. Provide guide vanes that, when fully closed, allow adequate air flow to prevent compressor surge. The inlet guide vanes shall be electropneumatically driven and shall be constructed of stainless steel. Actuators shall have a linear characteristic with 4-20mADC control signal and 4-20mADC position feedback.

2.2.6.9 Intercooler, Aftercoolers, and Oil Coolers

Intercoolers, aftercooler, and oil cooler shall include copper tubes conforming to ASTM B111/B111M in admiralty tube sheets conforming to

ASTM B171/B171M with plate fins and baffles for optimum cooling and fouling resistance using treated cooling tower water. Provide an intercooler between stages of compression and an aftercooler after the final stage of compression. The intercoolers and aftercooler may be integral or mounted separately. Intercoolers, aftercooler, and oil cooler shall be factory tested at 1.5 times operating pressure. Intercoolers and aftercooler shall be constructed in accordance with ASME BPVC SEC VIII D1, requirements and be ASME code stamped for 175 psig working pressure. Intercoolers and aftercooler shall be capable of one piece bundle removal. Each intercooler shall be equipped with an integral or direct connected moisture separator with pneumatically controlled automatic drainer valve assembly. Piping to drainer and drainer assemble shall be Class 600 stainless steel. Design intercoolers and aftercooler for 20 and 15 degrees F approach, respectively, and a fouling factor of 0.001 for both sides of exchanger;

however, the approach temperature used to size the coolers shall be reduced if required to meet aftercooler maximum air outlet temperature specified.

Nonstandard coolers shall be provided if required to meet the aftercooler maximum air outlet temperature requirement. All coolers shall be of counter-flow design. All coolers shall be provided with overpressure relief devices (OPD) to protect the water side from air leaks. OPDs shall

SECTION 22 16 19.36 20 Page 13 be provided with electronic remote monitoring devices for indication in the control system. Provide all coolers with a waterside wye strainer that includes a drain and drain valve.

2.2.6.10 Lubrication System

Include reservoir, shaft driven positive displacement pump, oil cooler, twin filter/strainer (readily replaceable cartridges while operating) and parallel piping and valving provisions to accommodate a separately driven prelube lubrication oil pump for start-up and standby. System shall be factory assembled and tested. The oil reservoir shall retain a minimum

3-minute oil supply. Lubricating oil shall conform to MIL-PRF-17331, Lubricant No. 2190-TEP or as recommended by compressor manufacturer. Oil cooler shall be designed for a fouling factor of 0.001 for both sides of exchanger. Pressure lubricate hydrodynamic bearings. Provide the oil sump with level indicator, level switch, drain and fill connections. Refer to section 2.2.7.6 for lube oil system control.

a. Prelubrication pump shall be sized by air compressor manufacturer for the requirements of the system, but shall meet the following requirements. Pump shall be positive displacement gear pump separately mounted with motor on a common base plate with drip lip and drain.

(1) Performance: Pump shall have separate safety valve bypass set at

25 psi above peak expected pressure.

(2) Materials shall be hardened steel gears and shaft, cast iron case, bronze bearings, mechanical seal.

(3) Flexible coupling with shaft guard shall be provided, except that these items are not required for a close-coupled pump.

(4) Motor shall be NEMA MG 1, Design A, Class B insulation, of open drip-proof type. Furnish combination type starter for motor.

b. Lube Oil Heater: Provide thermostatically controlled electric heater in lubrication oil sump of sufficient capacity to heat up and maintain manufacturer's recommended oil temperature when unit is cold at 50 degrees F ambient. Provide low oil level indicator with light for protection of heater.

c. Mist Eliminator: Provide a mist eliminator on the lube system atmospheric bleed sized to limit oil vapor in the bleed to 10ppm.

d. Lube Oil System Instrumentation: The lube oil system shall be provided with the following instrumentation.

(1) Oil pump pressure switch for each pump.

(2) Oil flow switch.

(3) Oil pressure switch at each compressor.

(4) Aux oil pump override control to allow operation after compressor shutdown for an adjustable operator selected duration. Provide

Hand-Off-Auto switch and contacts for remote indication of pump operation.

SECTION 22 16 19.36 20 Page 14

2.2.7 Compressor Controls

Provide a complete electronic control system for each compressor. Each compressor control system shall utilize one master programmable automation controller (PAC) for all functions and I/O interfaces. All instrumentation shall be connected to, monitored, and alarmed by this master controller.

All controlled devices shall be connected to and controlled by this master controller.

2.2.7.1 Control Functions

The controller shall control the compressor to meet pressure, flow and power setpoint requirements. The controller shall allow user input to modify the pressure, flow and power setpoints within the operational envelope of the compressor.

a. Pressure PID control shall use the main air pressure after the aftercooler as its process input with the last stage discharge pressure used as a fallback input.

b. Flow PID Control shall use the main air discharge flow after the aftercooler as its process input. A fallback input shall be provided.

This flow control loop shall act faster than the pressure control loop or the power control loop.

c. Operator hand control of the inlet and bleed valves shall be available.

d. Surge override PID control shall monitor the discharge pressure, discharge flow and motor power and override the pressure and flow control to keep the compressor from going below the surge line. This control shall be active during all normal automatic operations and when the inlet and bleed valves are in hand.

e. Stonewall override PID control shall monitor the motor power and override the pressure and flow control to keep the machine from going past the stonewall line. This control shall be active during all normal automatic operations and when the inlet and bleed valves are in hand.

f. Oil pressure PID control shall monitor both the main and auxiliary oil pump discharge pressures and shall control the pressures supplied to the bearings. Automatic switching between auxiliary to main pump and back shall be performed based upon operating conditions and oil pressure.

g. Oil temperature PID control shall monitor the lube oil temperature to the bearings at multiple places for redundancy, and control the temperature of the oil by controlling the oil cooler bypass and/or the oil cooler cooling water flow. The oil temperature control shall also operate the oil heater to maintain a minimum oil temperature.

- All PID controls shall redundant sensor inputs.

2.2.7.2 Control Enclosure and Termination

All compressor instrumentation shall be wired to a terminal enclosure before routing to the compressor's master PAC controller (facilitating a future replacement of the PAC when obsolete). The terminal enclosure may be within the primary control enclosure. All Compressor Controls shall conform to NEMA ICS 2 as selected by the compressor manufacturer. Control system

SECTION 22 16 19.36 20 Page 15 enclosure shall conform to NEMA ICS 6. Gasketed access doors shall be provided as required. The enclosure shall meet NEMA 12 requirements. The enclosure shall be fabricated of formed stretcher leveled sheet steel, reinforced, and assembled into a rigid unit. Controls shall be suitable for individual operation of the compressor or parallel operation with one or more other compressors.

2.2.7.3 Control Panel

Two control panels shall be provided where one is local at the compressor and one is located remotely in an adjacent building. The remote control panel shall mount into a standard 19-inch wide rack and be no taller than

15.75 inches (9 rack units). The control panels shall conform to NEMA ICS

6, package or frame mounted, factory designed, assembled, mounted and shall be provided complete with connections made to sensing points. Panels shall be factory finish painted. Both control panels shall include:

a. Electric and safety control work required, including either alarm annunciator or individual labeled pilot lights arranged in a group.

Panel shall contain alarm device with light and silencing.

b. Physical start and stop buttons (the latter with lockout feature), discharge air pressure gauge, load/unload control toggle, reset button, red stopped light and green unit running light. The local/remote control toggle shall be operable if control touchscreen and/or network connections are not available.

c. Manual override and adjustment of control valves.

d. Local / Remote toggle switch (local panel only) and a Remote indicator light (remote panel only).

e. A common alarm indication along with a method to acknowledge and reset the common alarm.

f. Self-diagnostics to check that the controller and all instruments are functioning properly.

g. Logging of the compressors cumulative operating time and total number of compressor starts.

h. Disconnect switch for control panel power (located behind the face of the panel ).

i. On/auto/standby switch for auxiliary oil pump.

j. Auxiliary pump running indicator.

k. A 12-inch diagonal minimum industrial HMI color touchscreen display.

The display shall show:

(1) All instrumentation and control parameters.

(2) Present operating mode of the compressor.

(3) Status of startup permissives tabulated.

(4) Status of pressure, flow, surge and stonewall automatic control.

SECTION 22 16 19.36 20 Page 16

(5) Status of auxiliary and main oil pumps and oil pressure control.

(6) Status of oil temperature control including cooler bypass, cooling water supply and oil heater control.

(7) Present alarm status including sensor tag, sensing level and alarm date/time.

(8) Historical alarm status including sensor tag, sensing level and alarm date/time.

(9) Real-time graphical indication of operation point within the operating envelope

2.2.7.4 Alarms Active and Historical

a. Alert alarms shall indicate a non-standard condition on the compressor.

These alarms shall have visual and audible annunciators. These alarms shall be logged.

b. Shutdown (danger) alarms shall indicate a hazardous condition that the compressor may be damaged if it continues. Danger alarms shut the compressor down. These alarms are logged.

2.2.7.5 Permissives

a. Startup permissives shall all be satisfied before the compressor is available to start. These control system inputs shall be from the compressor or from external indication. It is expected that the discharge isolation valve position, the cooling water supply, the motor starter and the motor breaker will be included as external indications as a minimum. Indication shall be made to show all permissives have been satisfied and the compressor is ready to start. Starting shall only occur by the operator pressing the start button locally or remotely.

b. Running permissives shall all be satisfied to keep the compressor running. The loss of any of these permissives shall cause a danger alarm and shall disable the run permissive shutting the machine down.

The stop button, any sensor or switch indicating danger and any applicable external indicators shall cause a loss of run permissive.

2.2.7.6 Compressor Startup and Shutdown

Compressor startup and shutdown shall be without surging. The compressor shall be controlled to an idle condition before loading and after unloading. This idle condition shall be at a minimum safe operating point for the compressor where all the stages are loaded and the vibration is minimal.

2.2.7.7 Customer Supervisory System Interface

The compressor's master control system will provide an Ethernet-based interface for customer connection to the customer's existing facility SCADA system. All analog and discrete instrumentation, all control output, all alarm, and all control functional parameters (e.g. surge curve and stonewall curve) data shall be accessible through this interface. All available data shall be fully described in a data definition provided by the manufacturer. All data shall be accessible via the OPC-UA protocol

SECTION 22 16 19.36 20 Page 17

(with secure connection options available). Modbus/TCP protocol may be substituted upon customer's approval.

2.2.7.8 Update/Refresh Rates of Data

Sufficient I/O, processing and communication hardware shall be provided to meet or exceed the following data update rates:

a. All Instrumentation for logging and alarming = 1 sample per second.

b. All Instrumentation and controls for closed loop feedback control = 10 samples per second.

2.2.7.9 Pressure Sensors

Pressure sensors shall be equivalent to Viatran model 34A for pressure and

374 for differential pressure. An isolation valve and calibration port shall be provided at each pressure sensor location. Pressure sensors are required in the following location at a minimum:

a. Air inlet and outlet of each stage of compression.

b. Upstream of inlet valve and downstream of aftercooler.

c. Cooling water supply and discharge at each cooler.

d. Discharge oil pressure at each lube oil pump, oil pressure at each bearing and differential pressure across all oil filters.

e. Surge detection/recognition sensor.

2.2.7.10 Temperature Sensors

Except for the main drive motor, all temperature sensors shall be T-type thermocouples. Temperature sensors for the main drive motor winding monitoring shall be 100ohm platinum or 10ohm copper 4-wire RTDs.

Temperature sensors in thermowells shall be the spring-loaded type in contact with the bottom of the well. Thermocouples shall be the ungrounded junction type. Temperature sensors are required in the following location at a minimum:

a. Air inlet and outlet of each stage of compression.

b. Upstream of inlet valve and downstream of aftercooler.

c. Cooling water supply and discharge at each cooler.

d. Discharge and inlet oil temperature at each oil cooler.

e. Motor windings with three sensors provided for each phase.

f. All bearings. The sensors shall be installed within the bearing housing into the babbit at the hot spot location. Two sensors shall be provided at each location for redundancy. Motor bearings may use indirect placement of bearing temperature.

2.2.7.11 Vibration Sensors and Balance

Vibration shall be monitored at both ends of the motor, the driveshaft of

SECTION 22 16 19.36 20 Page 18 every compression stage and every bullgear (if provided). Each vibration monitoring location shall be provided with 2 proximity-type probes mounted

90 degrees apart. Vibration probes shall not be mounted outside the case or bearing. Probe tracks shall be burnished in accordance with API 670.

Keyphasor probes shall be installed for all rotating shafts. Provide local vibration interfaces that provide both discrete alert and danger contacts and 100Hz continuous monitoring.

Bently-Nevada compatible vibration sensing, data gathering and processing equipment shall be utilized. Bently-Nevada Orbit 60 DAQ hardware (19-inch rack mountable) shall be utilized and shall provide a customer interface

(separate from that of the compressor's master controller) to integrate fully with customer's existing System 1 Evolution condition monitoring system.

a. Manufacturer’s standard balancing procedure shall be used.

b. When spare rotating elements are supplied, they shall be dynamically balanced to the same tolerances as the main rotating elements.

c. During the factory test of the machine as assembled with balanced rotors and operating at its rated speed, the peak-to-peak amplitude of unfiltered vibration, including runout, in any plane, measured on the pinion shaft adjacent and relative to each radial bearing shall not exceed the following value determined by Equation (1) below:

Equation (1) A = (12000/N)^(1/2)

A is the amplitude of unfiltered vibration, in µms (mil) true peak to peak

N is the rated speed, in revolutions per minute

d. Electrical and mechanical runout shall be determined and recorded by rolling the rotor in V blocks at the journal centerline while measuring runout with a non-contacting vibration probe, and with a dial indicator at the centerline of the probe location and one probe-tip diameter to either side.

e. Accurate records of electrical and mechanical runout for the full 360° at each probe location shall be included in the test report.

2.2.7.12 Flow Sensors

a. Discharge Compressed Air Flow: Provide an in-line body flow meter to measure the discharge air flow of the compressor. Flow meter shall provide +/- 1.0% accuracy. Flow meter shall provide SCFM (ISA) and lbm/sec flow units.

b. Bypass/Bleed Air Flow: Provide an in-line body flow meter to measure the discharge air flow of the compressor. Flow meter shall provide +/- 1.0% accuracy. Flow meter shall provide SCFM (ISA) and lbm/sec flow units.

c. Inlet Cooling Water Flow: Provide an in-line body liquid flow meter to measure the inlet cooling water flow to the compressor. Flow meter shall provide +/- 0.5% accuracy. Flow meter shall read in GPM.

2.2.7.13 Monitoring Instruments

Provide the following monitoring instruments in addition to the sensors

SECTION 22 16 19.36 20 Page 19 listed above. Pressure gauges shall conform to ASME B40.100, 4 1/2 inch, red marking pointer, single bourdon tube, brass case, black enamel finish.

Provide pressure gauges with a pressure snubber and a stainless steel barstock needle isolation valve. Thermometers shall be extended stainless steel sheathed bimetallic stem, 3 1/2 inch dial, and separable 4 inch stainless steel wells. Temperature measurements at inaccessible locations shall be made with remote reading thermometers conforming to MIL-T-19646, Class C separable well of Type 304 stainless steel. Select pressure and temperature gauge ranges to give a normal operating reading near the midpoint of the scale range.

a. Oil cooler inlet and outlet temperature gauges for oil.

b. Oil cooler inlet and outlet temperature gauges for water.

c. Lubrication oil pump discharge pressure gauge.

d. Compressor seal air pressure gauge, if applicable.

e. Inlet air filter differential pressure gauge with 8, zero, 8 inch water gauge. Provide selector valve, tubing, and tap to measure static gauge pressure downstream of each filter stage.

f. Pinion shaft vibration monitor readout.

g. Total running time readout (non-resettable).

h. Cooling water supply to compressor pressure gauge.

i. Cooling water return from compressor pressure gauge.

j. Interstage air pressure gauges for each interstage.

k. Compressed air pressure downstream of aftercooler pressure gauge.

l. Compressed air temperature downstream of aftercooler temperature gauge.

m. Interstage air temperature after intercooler of each stage temperature gauges.

n. Compressed air temperature at discharge of each stage of compression before cooling temperature gauges.

o. Compressor inlet air temperature gauge.

p. Cooling water to compressor temperature gauge.

q. Cooling water outlet temperature at outlet of each intercooler and aftercooler temperature gauges.

2.2.8 Electric Motors

Efficiency and losses shall be determined in accordance with IEEE 112.

Polyphase motors larger that 500 horsepower shall be tested in accordance with IEEE 112 with stray load loss determined by direct measurement or indirect measurement (test loss minus conventional loss).

The efficiency shall be identified on the motor nameplate by the caption

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NEMA Nominal efficiency or NEMA Nom eff.

2.2.8.1 Main Electric Drive Motor

Comply with the requirements of API Std 541.

The main drive motor for each compressor shall be an induction motor, 4,000 horsepower, with a service factor of 1.15. Size the motor so that the nameplate horsepower rating is not exceeded under the entire range of operating conditions specified (summer and winter). Motor shall be high efficiency delta wound type, rated not less than 95 percent based on

IEEE 112 testing and labeling. Electrical service will be as specified.

Motor shall be designed for reduced voltage starting at 80 percent of full voltage, allowing for characteristics of the connected load, and shall start without reducing the incoming line voltage more than 10 percent below normal. Provide nine (three per phase) 4-wire resistance temperature detectors (RTD) attached to or imbedded in motor winding . The motor shall meet the requirements of NEMA MG 1 with Class F insulation. Motor shall be drip proof. Motor design shall include acoustical covering and reduced noise air intake housing . Provide space heaters for protection of windings during motor shutdowns . Motor bearings shall be of the lubed sleeve type.

2.2.8.2 Motor Terminal Enclosure

Provide an electric motor terminal enclosure to protects the electrical connections of the compressor drive motor from external factors such as dust, moisture, corrosion, vibration, and mechanical damage.

a. Supply a drip-proof steel terminal box for housing the motor lead connections. Boxes must have adequate space to facilitate the installation and maintenance of cables and equipment including, but not limited to, surge arrestors, differential current transformers, single phase control power current transformers, single phase control power potential transformers. Boxes must also have adequate clearance and termination capability for up to three cables per phase. Boxes must have a bolted or hinged securable cover providing unrestricted access, be mounted on the motor frame, and have an auxiliary floor supporting structure, when required, supplied by the motor manufacturer. Conduit entrance must be from the bottom. Design the boxes to permit removal of motor supply leads when the motor is removed.

b. Bring leads out of the motor frame and provide with terminal lugs for connection to the motor supply wiring.

c. In the terminal box, provide a ground bus and means for external connection to the station grounding system when surge protection is provided.

2.2.8.3 Accessory and Related Equipment Motors

Motors less than 1/2 horsepower shall be single-phase induction motors and shall conform to NEMA MG 1. Motors over 1/2 horsepower shall be three-phase induction motors and shall conform to NEMA MG 1. Single-phase and three-phase motors shall have bimetallic disk thermostats attached to or imbedded in the motor winding. Motors shall have NEMA MG 1 Class B insulation.

SECTION 22 16 19.36 20 Page 21

2.2.9 Accessories

Required accessories include:

2.2.9.1 Control Valves

Blowoff bleed valve shall be capable of flowing the full capacity of the compressor. The valve shall have an equal percentage characteristic.

Actuators shall have a linear characteristic with 4-20mADC control for both signal and position feedback.

Valves (air and water) utilizing Polytetrafluoroethylene (PTFE) seats will not be permitted.

2.2.9.2 Drive Motor Coupling

Provide a maintenance free disc or diaphragm type flexible coupling between the drive motor and the compressor.

2.2.10 Bleed Line Silencer

Provide a bleed line silencer with each compressor as selected by compressor manufacturer/vendor to optimize noise attenuation measured at an elevation of 5 feet, and 10 feet horizontally from silencer.

2.3 SOURCE QUALITY CONTROL

2.3.1 Factory Test Procedures

The completely assembled air compressor package, including the actual contract drive motor, intercoolers, lubrication system, and control panel shall be subjected to performance tests, balance tests, and sound level and run-in tests. Unit shall comply with guarantee requirements applying engineering adjustments to guarantee conditions. Test shall be certified by the manufacturer/vendor. Test shall be run on the manufacturer's test stand using driver for this contract. Tests shall be in accordance with

ASME PTC 10 format. All accessory performance conditions shall be reported, including intercoolers, aftercoolers, and lubrication and control systems. The complete unit shall be factory tested with sound meters in accordance with ISO 2151. Location shall be one horizontal meter from unit at 1.5 meters above the floor. Test shall include readings at each octave band midpoint and the "A" scale. Results of test shall be included in the factory test report on the ISO 2151 format. Factory test data may be corrected to the levels of an equivalent background noise level of 60 dBA showing calculations for reference use.

Full-range performance tests shall indicate performance at:

a. Maximum rated flow, rating point, and blowoff conditions as specified in

2.2.3 - Guaranteed Performance.

b. Minimum rated flow determined by compressor turndown.

c. Minimum and maximum rated discharge pressure, rating point as specified in 2.2.3 - Guaranteed Performance.

d. Minumum and maximum power.

e. Sufficient data shall be gathered to provide a fully detailed operating

SECTION 22 16 19.36 20 Page 22 envelope of each compressor. Provide a detailed envelope with test documentation. The compressor control system shall be customized to conform to this envelope for surge and stonewall override control.

2.3.2 Supervision of Testing

System and components testing shall be conducted or supervised by either a designated authorized and factory trained representative of the compressor manufacturer supplying the unit or a registered Mechanical Engineer experienced in such work.

2.3.3 System Test

Testing of system shall conform to requirements outlined and shall be witnessed by the Contracting Officer or designated Contracting Officer

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