National Oil Corporation: Rev Date Description Checked Approved
National Oil Corporation: Rev Date Description Checked Approved
National Oil Corporation: Rev Date Description Checked Approved
GES K.05
INDEX
1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 5
2.0 DEFINITIONS 6
2.1 Technical 6
2.2 Contractual 6
3.0 DESIGN 6
4.0 MATERIALS 16
5.0 INSPECTION 17
5.1 Procedures 17
5.2 Scope 18
5.3 Nameplates 18
6.0 TESTING 18
7.0 DOCUMENTATION 20
7.1 Introduction 20
7.2 Schedules, Reports and Co-ordination Meeting 20
7.3 Drawings and Data Requirements 21
7.4 Proposal Data 21
7.5 Contract Data 22
7.6 Final Records, Documents and Manuals 24
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 3 of 25
(API 11P) Rev 0 1999
1.1 Introduction
1.1.1 This specification applies to packaged, skid-mounted, reciprocating compressor units used in oilfield
production services and is based on API Specification 11P. The compressors covered by this standard are
higher speed (above 600rpm) with lubricated cylinders.
(a) Reciprocating compressors for refineries which are moderate to low speed with either lubricated
or nonlubricated cylinders and based on API standard 618. These compressors are covered by
GES K.03.
(b) Utility or instrument air compressors discharging at less than 125 psig (860 kPag) and limited to
25 hp size. These are covered by GES K.07.
(c) Compressors with single-acting trunk-type pistons that also serve as crossheads.
(a) This format relates to API 11P. GES K.03 is based on API 618.
(b) API 618 is specified for use in refinery service whereas this specification is generally used for
compressors in oil and gas production services.
1.1.3 This specification gives the minimum requirements for the design, fabrication, material selection,
inspection, testing, documentation and preparation for shipment for packaged reciprocating compressors.
Also included are the related drivers, lubricating systems, controls, instrumentation, intercoolers,
aftercoolers, pulsation suppression devices and other auxiliary equipment, and control panel.
1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.
1.1.5 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
Codes and Standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification from the Owner before proceeding with the work. As a general principle, the most stringent
specification shall apply.
1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.
The following NOC Specifications are an integral part of this specification and any exceptions shall be
approved in advance by the Owner.
GES A.04 Noise Level Criteria and Noise Control of Mechanical Equipment
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 5 of 25
(API 11P) Rev 0 1999
GES K.07 Reciprocating Plant and Instrument Air Compressors (API 680)
GES M.05 Lubrication, Shaft Sealing and Control Oil Systems for Rotary Equipment (API 614)
The technical data supplied by the Owner for the equipment is provided on the API 11P Data Sheets which
are attached at the end of this specification.
The Vendor/Contractor shall complete the Data Sheets with the remaining information and submit them
with his proposal. Prior to shipment, the Vendor/Contactor shall submit a complete set of "As-Built" Data
Sheets as part of the final documentation.
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 6 of 25
(API 11P) Rev 0 1999
2.0 DEFINITIONS
2.1 Technical
The technical terms used in this specification are as defined in Paragraph 1.10 of API 11P (2nd Edition).
2.2 Contractual
Owner
The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
Vendor
Contractor
Sub-contractor
A company awarded a contract by a contractor to do part of the work awarded to the Contractor.
Inspection Authority
The organisation representing the Owner or Contractor that verifies that the equipment and facilities have
been designed, constructed, inspected and tested in accordance with the requirements of this specification
and the Purchase Order/Contract.
Inspector
Qualified individual representing the Owner, Contractor or assigned Inspection Authority, who verifies that
the equipment and facilities have been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.
3.0 DESIGN
3.1.1 The design shall comply with this specification and the following Codes and Standards:
API 11P Packaged Reciprocating Compressors for Oil and Gas Production Services.
MR-01-75 Sulphide Stress Corrosion Resistant Metallic Materials for Oil Field Equipment. (NACE
standard)
Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order should be used.
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 7 of 25
(API 11P) Rev 0 1999
The following paragraph numbers refer to API 11P, Second Edition, November 1989, which is a part of
this General Engineering Specification.
In API 11P, paragraphs are marked with a bullet (•) this indicates that the Owner has to make a decision or
provide information. Where possible, these decisions have been made. Such paragraphs are marked "*" in
this specification.
All requirements specified in this specification are additions to those of API 11P unless otherwise stated.
Paragraph numbers in this specification which do not appear in API 11P are new paragraphs.
SECTION 1 - GENERAL
The Vendor/Contractor shall supply the compressor, driver, pulsation bottles, lube oil system, air cooling
system, gas inlet and interstage scrubbers, interconnecting piping, baseplate, operating platforms and
ladders and all auxiliaries. The Vendor/Contractor has the responsibility for the overall design and
performance of all equipment included as part of the package.
The compressor unit shall be designed for safe, reliable, continuous, unattended operation at all the
operating conditions specified in the Data Sheets.
1.3 * Compressor Package Performance Curves - Compressor package performance curves shall cover the
range of operating conditions indicated by the Owner. Any limitations such as rod load, available driver
horsepower, additional clearance required to meet the range of operating conditions, etc. shall be marked
on the performance curves.
1.4 Package Arrangement - Access and spacings shall be submitted for approval by the Owner.
1.5 * Drawings - The Vendor/Contractor shall supply data and drawings as specified in Section 7.3 of this
specification.
1.6 Sound Pressure Level - GES A.04 shall be complied with. The sound pressure level, measured at 3.3ft
(1m) from the surface of the equipment, shall not exceed 85 dB(A).
1.7 Electrical Location Classification - Unless specified otherwise, the area classification for electrical
equipment shall be Class 1, Division 2, Group D Hazardous Area.
1.9 Torsional Analysis - Delete the paragraph and replace by: The compressor Vendor/Contractor shall
assume unit responsibility for the entire train consisting of the compressor, driver, power transmission and
associated auxiliary equipment. This includes, but is not limited to, the following:
The unit shall be free of any objectionable torsional critical speeds within the specified operating range.
The Vendor/Contractor shall state at what speed transition occurs through any critical speed in accelerating
to the operating range. When torsional criticals are within 10% of the running speed, then torsional
alternating stress should be less than +/- 3500 psi (+/- 24.1 MPa). With clearance pockets or suction valve
unloaders in operation, there shall be no harmful vibration or excessive frame loading for any unloading
combination within the operating range.
The compressor Vendor/Contractor shall resolve all design and engineering problems related to the
equipment. Corrective measures shall minimise the use of restrictive orifice chokes. Any system or
equipment changes which are required as a result of the above analyses shall be to the
Vendor's/Contractor's account.
SECTION 2 - COMPRESSOR
2.1.4 * Forces and Couples - Delete this paragraph and replace by: The Vendor/Contractor shall supply values
for the unbalanced primary and secondary forces and couples in the horizontal and vertical planes for the
quoted compressor. The resultant of the secondary forces and the couples produced by these forces shall be
minimised.
2.2 * Maximum Allowable Speeds - Compressors shall not operate over 1200 rpm nor shall piston speeds
exceed 1033 ft/min (5.25 m/s).
2.4.2 Piston Rod Load Reversal - For all specified operating load conditions, the axial component of the
combined rod loading shall reverse for a duration of not less than 15 degrees of crank angle, and the
magnitude of the peak combined reversed load shall be at least 3% of the actual combined load in the
opposite direction.
2.5.1.1 Cylinder Maximum Allowable Working Pressure - Delete the first paragraph and replace by: The
maximum allowable working pressure shall exceed the rated discharge pressure by at least 10 percent or 50
pounds per square inch (345 kPa), whichever is the greater. The maximum allowable working pressure
shall be at least equal to the specified relief valve setting.
2.5.2.3 Cylinder Bolting - Add at the end of the paragraph: Tapped holes for studs or cap screws shall not be any
deeper than required for proper engagement of threads, and shall not penetrate the corrosion allowance of
pressure retaining components.
2.5.3.2*Indicator Connections - Each cylinder end shall be provided with threaded and plugged pressure taps into
the head end and crank end.
2.6.1 Inlet Valve Average Gas Velocity - Add the following before the “Notes”
a) The average gas velocity, V, shall be less than 7,500 ft/min. (38 m/sec.).
2.6.6 Valve Material - Add new paragraph: Where temperature and pressure conditions permit, valve plates
shall be thermoplastic.
2.7.5 Piston Rod Threads - Piston rods shall be furnished with rolled threads subject to stress not exceeding a
maximum of 8000 psi (55 MPa). This shall be calculated on the basis of area at the thread roots and relief
valve set pressure.
2.7.7 Surface Finish - Add new paragraph: Surface finish of the rod shall be according to Table 1.
2.8.5 Weights - Add new paragraphs: The weights of all reciprocating components shall be permanently marked
thereon. These weights shall also be recorded in the data book.
2.9.1 * Design - Delete this paragraph and replace by: Type ‘3’ two compartment distance pieces shall be supplied
on compressors handling gases containing more than 1,000 ppm H2S. All other process compressors shall
be supplied with type ‘2’ extra long distance pieces. For the sour gas service, materials complying to
NACE standards shall be used for process wetted parts.
2.9.3 * Explosion Relief Doors - Explosion relief doors shall be installed on the compressor frame or distance
piece(s) if space permits.
2.11.2 Gauges and Connections - Delete this paragraph and replace with: The crankcase oil reservoir shall be
flanged, gasketed and bolted for oil tight, dust free operation. It shall be fitted with an accessible drain
valve and an oil - level sight glass. The maximum and minimum operating levels of the sight glass shall be
indicated.
2.11.4 Pressurized Systems - Add the following paragraph: In addition, the pressurized frame lubrication system
shall include a low pressure shutdown switch and all other necessary instruments. Drain connections shall
be piped to the edge of the skid.
2.11.6* Oil Level Control - A storage tank of 80 US gallons (300 litres) minimum capacity with a level gauge and
low level alarm at 20 US gallons (80 litres) shall be supplied. Automatic refill accessories shall be
included.
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 10 of 25
(API 11P) Rev 0 1999
2.11.7* Lube Oil Heater - A thermostatically controlled electrical immersion heater shall be provided for heating
the charge capacity of the oil prior to start-up. The heating device shall have sufficient capacity to heat the
oil in the reservoir from the specified minimum site ambient temperature to 80°F (27°C) within 4 hours. A
maximum of 73 Btu/ft2h (23kW/m2) is allowed.
2.12.1* Cylinder Lubrication - Line filters, lube meter and fault indicators shall be provided for block
distribution systems.
2.12.2.1*Oil Level Control - A storage tank of 80 US gallons (300 litres) or 200 hrs at normal expected demand
whichever is greater, with a level gauge shall be furnished.
2.14.3 V-Belt Drives - Delete this section and replace by: Belt drives shall not be used.
2.14.5 Guards - Add at the end of the paragraph: Openings provided in flywheel guards for barring over shall be
covered by a hinged or sliding door.
3.2.2.2*Clearance Pockets - Variable capacity clearance pockets are preferred, except for sour service.
3.2.3.1*Start-up Bypass Unloading for start-up shall be provided by means of a manual bypass valve from
discharge to suction.
3.2.6 Control Flexibility - Add new paragraph: The compressor shall provide adequate flexibility in control to
permit operation over the entire range of operation specified on the Data Sheets.
4.2.4* Air Filters - Replace the first paragraph with: The Vendor/Contractor shall supply an air intake filter
suitable for the environmental conditions stated in the Data Sheets. The Vendor/Contractor shall fully
describe the air filtration system in his proposal and describe how the filtration system protects the engine
against the site conditions, for example, blowing sand. Air shall not be taken from inside enclosed
buildings.
4.2.5.3 Insulation and/or Guarding - Hot metal surfaces located within 1 ft. (300mm) horizontally or 7ft. (2.1m)
vertically of a normal access, walkway, or work area shall be insulated if required to maintain surface
temperatures at less than 150°F (65°C).
4.2.10* Oil Level Control - A crankcase oil level control device shall be supplied by the Vendor. A storage tank
of 80 US gallons (300 litres) minimum capacity with a level gauge shall be supplied.
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PACKAGED RECIPROCATING COMPRESSOR UNITS Page 11 of 25
(API 11P) Rev 0 1999
4.2.10.1 Lube Oil Heater - Add new paragraph: As detailed in Section 2.11.7.
4.2.13* Crankcase Explosion Door(s) - Crankcase explosion relief doors shall be supplied on the engine
crankcase.
4.3 Electric Motors - Electric motors shall conform with GES L.11, motors over 1500hp (1120 kW) shall also
conform with GES L.12.
5.1 General - Delete this paragraph and replace by: Air cooled heat exchangers shall be supplied in
accordance with GES E.04 and shall be of the forced draft design.
5.3.12* Sight Flow and Temperature Indicators - Sight flow and temperature indicators shall be supplied
before and after the coolers.
5.3.5* Gas Cooling - Gas intercoolers and aftercoolers shall be designed for 100% recycle duty. They shall be
supplied by the Vendor/Contractor and mounted separately.
1. Ambient temperature = 125°F (52°C) or the ambient temperature stated on the Data Sheets
5. Aftercoolers shall be designed for a 20°F (11°C) approach to ambient or a maximum process
temperature of 145°F (63°C) out or such temperature stated on the Data Sheets.
5.6.1 Cooler Air Flow - Add at the end of the paragraph: Air intakes shall be located away from heat sources.
5.6.4 Tube Material - Tubes shall be seamless stainless steel with aluminium fins
5.6.6* Air Flow Control - Delete this paragraph and replace by: Mechanical fan drives for the coolers are
preferred. Automatic variable pitch blades shall be provided.
6.1.5 Connection Size - Threaded and socket welded couplings shall only be used for connections NPS 1½ and
less. For connections NPS 2 and larger, only welded connections are acceptable. Threaded connections
shall be seal welded as specified in paragraph 7.8. Threaded connections shall not be used in sour service.
6.1.7 Radiography - Add new paragraph. All welds in sour service are subject to NACE MR-01-75
classification and shall be 100% radiographed and stress relieved.
6.1.8 Large Vessels - Add new paragraph. A manway, minimum internal diameter 20" (500mm) and NPS 2
vent, drain and purge connections shall be installed on all vessels 36" (900mm) diameter and larger. All
drain, vent and purge points shall be fitted with a globe valve and a blind flange.
6.2.6* Diameter - Suction scrubbers shall be Service Class "C", K=0.18. Interstage scrubbers without
sidestreams shall be Service Class "B", K=0.25.
6.3.1 * Pulsation Control - Delete this paragraph and replace by: Pulsation and vibration control shall be to
Design Approach 3, refer to API 618, API 11P and NACE MR-01-75 3.9.2. Pulsation dampeners shall be
guaranteed for a maximum residual peak-to-peak pulsating pressure of 1% of average absolute pressure at
the point of connection to plant piping. The Vendor/Contractor is responsible for conducting a pulsation
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 12 of 25
(API 11P) Rev 0 1999
study of the piping system supplied with the compressor to ensure that the piping and dampener design will
effectively minimize gas pulsations within the system, which shall not exceed the limits specified in API
618.
6.3.3 Drains - Drains with elbows are not allowed. Drains shall point straight down.
6.3.5* Code - Delete this paragraph and replace by: As a minimum, pulsation suppression equipment shall be
designed and fabricated in accordance with Section VIII, Div.1, of the ASME Boiler and Pressure Vessel
Code and NOC specification GES V.01. Pulsation suppressors shall be stamped with the ASME Code
symbol and registered with the National Board of Boiler and Pressure Vessel Inspectors. Design pressure
shall be 50 psi (345 kPa) or 10%, whichever is greater, higher than the maximum operating pressure.
Design temperature shall be 50°F (28°C) higher than the maximum operating temperature and a minimum
of 200°F (93°C).
6.3.7* Reinforced Connections - Delete this paragraph and replace by: Flanged connections shall have
mechanical reinforcement in the form of weld pads or saddles at least equal to the cutaway area. Credit
shall not be taken for the nozzle wall in the design of reinforcement pads around openings in the vessels.
Nozzles shall have wall thickness equivalent to extra strong pipe as a minimum.
6.3.8 Insulation and/or Guarding - Hot metal surfaces located within 1 ft. (300mm) horizontally or 7 ft.
(2.1m) vertically of a normal access, walkway, or work area shall be insulated if required to maintain
surface temperatures at less than 150°F (65°C).
6.3.9 Flanged Connections - Add the following paragraph: All pulsation suppressor connections shall be
flanged. Suction and discharge nozzles shall be gusseted in two planes.
6.3.10 Instrument Connections - Thermowell connection shall be provided for the cylinder nozzle of each
suction and discharge pulsation suppressor. Additional nozzles for the pressure indication and alarms
(low/high alarms/trips) shall be considered. Also, one pressure connection shall be provided on each
pulsation suppressor.
7.1.1 Codes - Add the following paragraphs: All pressure piping shall be designed to 50 psi (345 kPa) or 10%,
whichever is greater, higher pressure than the maximum operating pressure of the piping and tested to 1.5
times this design pressure for minimum 4 hours. Design temperature shall be 50°F (28°C) above maximum
operating temperature but no less than 200°F (93°C). The piping design shall also comply with GES P.01
and GES P.02.
A corrosion allowance of 1/16" (1.5mm) shall be provided on all pressure piping for sweet gas and at least of
1
/8" (3mm) for sour gas service if carbon steel is used.
7.1.4.1 Threaded Connections - Delete this paragraph and replace by: Threaded and socket welded connections
only shall be used for connections NPS 1½ and less. For NPS 2 and larger, only welded connections are
acceptable. All threaded connections in process gas and fuel gas service shall be minimum Sch.160 wall
thickness. Threaded connections shall not be used in sour service.
7.1.5* Drawings - Drawings shall be submitted to the Owner for review prior to pipe fabrication. Approval by
the Owner does not relieve the Vendor/Contractor of any of his responsibilities under this specification.
10) Interstage piping shall be securely anchored to structural steel skid, overhead interstage piping is
not permissible. All such piping shall be brought vertically to skid level and anchored in
horizontal plane.
11) Where disassembly is required for maintenance, forged steel unions or flanges shall be provided in
the lines.
(12) All Owner terminating piping connections shall be flanged, or in the case of screwed piping, shall
be fitted with a screwed coupling.
7.6 Threaded Fittings - When the corrosion allowance is _" (3mm), ANSI class 6000 fittings shall be used
for NPS 1 and NPS 3/4.
7.8 * Sealing - Threaded piping joints shall be seal welded in flammable or toxic service. Where disassembly is
required for maintenance, unions or flanges shall be provided.
7.15 * Start-Up Screen - The Vendor shall supply start-up screens at each Owner inlet connection. The
Vendor/Contractor shall also supply the removable spool piece(s) that allow removal and re-installation of
the temporary start-up screen(s).
7.16.2* Material - Delete the first sentence and replace by: All pressurised lubricating oil lines and fittings (with
the exception of cast-in-frame lines or passages) shall be made of 300 series stainless steel conforming to
ASTM 269 TP316L.
7.17.1* Coolant Piping - Coolant piping shall be supplied by the Vendor/Contractor. Flanged connections shall
be provided.
7.18.2 Connections - Add at the end of the paragraph: Each common connection shall have a vent valve.
7.20.1 Required Relief Valves - Add at the end of the paragraph: The Vendor/Contractor shall supply all relief
valves that are to be installed on the equipment or in the piping that the Vendor/Contractor is supplying.
Relief valves shall be flanged on the inlet and outlet.
7.23 Insulation and/or Guarding - Hot metal surfaces located within 1 ft. (300mm) horizontally or 7 ft. (2.1m)
vertically of a normal access, walkway, or work area shall be insulated if required to maintain surface
temperatures at less than 150°F (65°C).
8.1 Codes - Delete this paragraph and replace by: All electrical installations on the packaged unit shall
conform to GES L.28. The area classification for electrical equipment shall be Class 1, Division 2, Group
D Hazardous Area unless otherwise stated in the Data Sheets.
9.1* General - Delete this paragraph and replace by: The compressor unit shall be completely instrumented to
satisfy all necessary surveillance, control and safety functions. All controls shall be designed using a "Fail
Safe" design for unattended operation. The control panel and the compressor unit instrumentation shall be
in accordance with GES J.13 and GES J.14.
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 14 of 25
(API 11P) Rev 0 1999
9.2 Instrument and Control Panel - Delete this paragraph and replace by: A local panel shall be provided for
each compressor unit. This panel shall be in accordance with GES J.13. The panel shall include, but not be
limited to, the following:
The Vendor/Contractor shall include an annunciated alarm point for all unit shutdowns except vibration.
9.2.1 Panel Construction - Panel shall be suitable for the area classification specified and be ingress protected to
IP55 as a minimum
9.2.2* Panel Mounting - Delete the first sentence and replace by: Control and instrument panels shall be free
standing, floor mounted and off skid.
9.3.2.1 Required Temperature Indicators - Delete this paragraph and replace by: Temperature indicators shall
be provided as indicated in the following table as a minimum:
Local Panel
Mounted Mounted
9.3.3* Pressure Measurement - Liquid filled gauges shall be supplied in locations subject to vibration.
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9.3.3.2 Required Pressure Gauges - Delete this paragraph and replace by: Pressure indicators shall be provided as
indicated in the following table as a minimum:
Local Panel
Mounted Mounted
10.2.1* Specified Shutdown. Alarms and Annunciators - Delete the last sentence and replace by: The
annunciator panel shall contain 20 percent spare annunciation windows for Owner's use.
10.3 Required shutdowns - Delete this paragraph and replace by: The following alarm and shutdown devices
shall be provided in the local panel:
Alarm Shutdown
1. Prime Mover
Engine:
Motor:
2. Compressor:
GENERAL ENGINEERING SPECIFICATION GES K.05
PACKAGED RECIPROCATING COMPRESSOR UNITS Page 16 of 25
(API 11P) Rev 0 1999
Alarm Shutdown
3. Others:
SECTION 11 - SKIDS
11.2.6 Screws and Bolts - Jacks and screws for alignment purposes shall be provided on the driver. Adjustment
capability in lateral, axial and vertical directions shall be provided.
11.2.10 Oil/Water Collection - Add new paragraph: The skid shall be so designed to prevent oil and/or water
collecting underneath the compressor and driver, or between the skid and concrete.
11.5 Dowelling - Add new paragraph: After alignment, drivers shall be dowelled to the baseplate.
11.6 Drainage - Add new paragraph: All horizontal compressor bases should extend beyond the equipment and
be equipped with a drainage channel at outside perimeter which is provided with a NPS 1 minimum pipe
drain directed to a cup drain at one end of the base.
12.1 Surface Preparation - Delete this paragraph and replace by: Surface preparation and painting shall be in
accordance with GES X.01 and X.02 using a paint system which complies with GES X.03. The factory
coating of electrical equipment and instruments shall be in accordance with GES X.06.
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(API 11P) Rev 0 1999
4.0 MATERIALS
The Vendor/Contractor shall provide materials in accordance with paragraph 2.13 of API 11P, as amended
below. In addition, for compressors handling corrosive gases, hydrogen sulphide and carbon dioxide,
materials shall be in accordance with Section 15 of API 11P and NACE standard MR-01-75.
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(API 11P) Rev 0 1999
CYLINDER PRESSURE
RELIEF VALVE MATERIAL
SETTING
psig MPag
≤ 1000 ≤ 69 Cast Iron, Cast Steel or Forged Steel
1000 to 2500 6.9 to 17.2 Cast or Forged Steel
> 2500 > 17.2 Forged Steel
2.13.1.5 Packing and Piston Ring Material - Add new paragraph: Packing material shall be
filled fluorocarbon. Where cylinders are not lubricated, temperature and pressure permit,
wear bands and piston rings shall be filled with fluorocarbon.
2.13.4.2 * Inspection Codes - Delete this paragraph and replace by: The Vendor/Contractor shall
submit with his proposal a detailed Inspection and Test Plan. This plan shall show all
radiographic, ultrasonic, magnetic particle or liquid penetrant inspections which are
required or specified. Radiography shall be in accordance with Section VIII, Division 1,
UW-52, of the ASME Code; ultrasonic inspection shall be in accordance with Section
VIII, Division 1, Appendix 12, of the ASME Code; magnetic particle inspection shall be
in accordance with Section VIII, Division 1, Appendix 6, of the ASME Code; and liquid
penetrant inspection shall be in accordance with Section VIII, Division 1, Appendix 8, of
the ASME Code. Forged parts shall be ultrasonically inspected in accordance with
ASTM A-503, unless specified otherwise on the Data Sheet.
5.0 INSPECTION
5.1 Procedures
5.1.1 All items of plant and equipment referenced within this specification shall be subject to inspection by the
Owner or the Inspection Authority.
All inspection requirements shall be incorporated in the Quality Control Plan which shall be submitted by
the Vendor/Contractor with his proposal for review by the Owner.
5.1.2 Inspection shall be in accordance with the latest edition of API 11P, and this specification. All inspection
activities to be performed, including any special requirements, shall be agreed with the Owner and shall be
incorporated within the agreed Quality Control Plan.
5.1.3 All operators of NDT equipment shall have thorough knowledge of the operation of the equipment to be
used and shall hold an appropriate certificate of competence, which is to be agreed by the Owner. All NDT
procedures and qualifications shall be subject to approval by the Owner.
5.1.4 The Vendor/Contractor shall furnish the Inspector with all reasonable facilities, to satisfy himself that the
equipment is fabricated and tested in accordance with the relevant codes and this specification.
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(API 11P) Rev 0 1999
5.1.5 Any approvals given by the Owner's Inspector and/or the Inspection Authority do not relieve the
Vendor/Contractor of any responsibility regarding guarantees, workmanship or compliance with the code
and this specification.
5.2 Scope
The inspection scope shall comply with API 11P, Sections 13.1 and 13.2 as amended below:
General
13.1.2 Purchaser Participation - Delete the first sentence and replace by:. All inspection activities to be
performed, including any special requirements, shall be agreed with the Owner and shall be incorporated
within the agreed Quality Control Plan provided by the Vendor/Contractor.
13.2 Inspection
(a) The Vendor/Contractor shall propose the parts to be examined and the type of examination
required, for the approval of the Owner.
(b) The radiographic and other inspection of materials shall be carried out as specified below:
13.2.5 Oil Flushing - Add new paragraph: On completion of shop erection, the frame lubricating system shall be
flushed with hot oil [180°F (82°C)] for at least 8 hours, using an oil rate at least equal to that of the main oil
pump at design speed. On completion of this flush, the Vendor/Contractor shall demonstrate to the Owner
that the system is clean and free from sand, weld beads, slag or cuttings of a size larger than the filter
opening.
5.3 Nameplates
6.0 TESTING
i) cylinder,
ii) cylinder cooling jackets and packing cases,
iii) piping, pressure vessels, filters and other pressure retaining components.
The pressure tests shall be carried out in the presence of the Owner's Inspector.
c) Mechanical Running Tests - 4 hour mechanical running test prior to shipment to prove the
mechanical operation of the compressor, driver, accessory equipment, instruments and control
system as a complete unit. The compressor does not have to be pressure loaded for this test. This
test shall be witnessed by the Owner.
The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.
Test Procedures shall comply with API 11P, Section 13.3 and Section 13.4 as detailed below:
13.4.1 Compressor and Prime Mover - Add at the end: Prior to placement of order, the adequacy of the
Vendor's/Contractor's standard test shall be evaluated by the Owner on the basis of the ultimate location of
the equipment, the nature of the service and the Vendors/Contractors previous performance. Specific test
procedures shall be established as required, to ensure trouble-free operation of the equipment after
permanent installation.
13.4.4 Compressor Dismantling - Add new paragraph: Dismantling of the compressor for inspection after
testing is required.
- cylinder walls,
- cross-head guides,
- piston rods and packing,
- valves,
- main bearings.
- cross-head clearance,
- piston clearance,
- rod run-out.
13.5.4.6 Loose Parts - Add new paragraph: All interstage piping, lube oil and suction piping shall be pickled, sand
blasted and sprayed with Shell Ensis oil and sealed for storage and transportation.
13.5.4.8 Shipment - Add new paragraph. The equipment shall be crated for export shipment by sea. Shipment as
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13.5.4.9 Storage - Add new paragraph. The probable storage period will be specified in the order /enquiry and
will extend from the time of despatch to the time of unpacking at site. If the storage period is not stated, a
minimum period of 24 months shall be assumed.
13.5.4.10 Air Coolers - Add new paragraph. The top of forced draft air cooler tube bundles shall be covered with
5
/16" (8mm) minimum thickness plywood prior to shipment to prevent damage to fins. Motor rotor shall be
locked (with an appropriate warning label attached) to protect the bearing from brinelling during road
transportation to site.
a) The manufacturer's physical and chemical certification of steel pressure parts and forgings.
b) Certification for magnetic particle, dye penetrant, radiographic and ultrasonic examination.
d) A record of shop test data (which the Vendor/Contractor shall maintain for at least 5 years after
the date of shipment). The Vendor/Contractor shall supply certified copies of test data to the
Owner before shipment.
The Vendor/Contractor shall carry out at site a fully pressurised performance test on the installed
compressor/driver package. The Owner shall witness and approve the results of these tests.
6.5 Startup
6.5.1 The Vendor/Contractor shall be responsible for complete startup until unit is accepted as operational by the
Owner. The Vendor/Contractor shall be responsible for the supply of competent servicemen for the
duration of the checking, startup and run-in period.
6.5.2 The Vendor/Contractor shall supply for start-up, all lubricating fluids, including oil, grease and coolants as
required by the unit. The Vendor/Contractor shall recommend amount and type of lubrication and cooling
fluids for subsequent operation.
7.0 DOCUMENTATION
7.1 Introduction
7.1.1 This section covers the documentation requirements for design, materials, inspection, testing, installation
and operation of the equipment.
7.1.2 The detailed document list is specified in Section 7.3 below and is attached to the Purchase Order/Contract.
7.2.1 The Vendor/Contractor shall supply with his proposal, a schedule showing submission of all documents for
review and approval, proposed Sub-Contractors and material procurement and a production/fabrication
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programme.
7.2.2 The Vendor/Contractor shall submit with his proposal a Quality Control Plan for the contract.
7.2.3 After the Purchase Order/Contract award, monthly reports on design, material procurement and production
progress shall be submitted to the Owner.
7.2.4 A co-ordination meeting shall be held within six weeks of the placement of the Purchase Order/Contract.
a) A drawing schedule giving the dates by which the Vendor/Contractor will supply the drawings
and data requested by the Owner (see 7.3 above).
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b) Copies of the Owner's Data Sheets complete with the Vendor's/Contractor's information required
for the proposal.
c) Utility requirements such as steam, water, electricity, air, gas and lube oil, including the quantity
of lubricating oil required at supply pressure, the heat load to be removed by the oil, and auxiliary
driver ratings and net loads. Approximate data shall be clearly identified as such. This
information shall be entered on the data sheets.
d) Net maximum operating weights, maximum shipping and erection weights with identification of
the item, and maximum normal maintenance weight with identification of the item. These data
shall be stated individually where separate shipments, packages, or assemblies are involved.
Approximate data shall be clearly identified as such. These data shall be entered on the Data
Sheets where applicable.
e) For a compressor with variable speed drive, the minimum speed at which the unit may be operated
continuously with the proposed lubrication system.
f) Typical outline and arrangement drawings. Auxiliary system schematic diagrams shall be marked
to show which portions of the system are integral with or mounted on the major equipment, and
which are separate.
g) Typical cross-sectional drawings and literature to fully describe details of the offering(s).
h) A specific statement that the system and all its components are in strict accordance with this
standard. If the system and components are not in strict accordance, the Vendor/Contractor shall
include a specific list that details and explains each deviation.
j) A priced spare parts list for commissioning spares, two years operating spares and capital spares.
m) The Vendor's/Contractor's recommendation based on specified site data, of all the special
protection required by the compressor, the auxiliaries and the driver for startup, operation and
idleness.
o) A full description of the tests specified in 6.1.2, 6.1.3 and 6.4 above.
7.5.1 The documents shall be submitted for approval/review to the Owner and to the Inspection Authority within
the periods agreed between the Owner and Vendor/Contractor. It shall be the responsibility of the
Vendor/Contractor to ensure that the production schedule takes into account documentation submission
periods, plus a three week approval review period by the Owner and/or the Inspection Authority. The
Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.
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7.5.2 The following information shall be provided on the drawings (typical drawings are not acceptable):
c) The weight of each assembly, of the heaviest piece of equipment that must be handled for erection,
and of significant items to be handled for maintenance.
d) All principal dimensions, including those required for the Owner's foundation, piping design,
maintenance clearances, and dismantling clearances.
e) The direction and magnitude of unbalanced forces and couples, and location of the centre of
gravity.
g) The size, type, location and identification of all Owner's connections including vents, drains,
lubricating oil, conduits, and instruments. (The Vendor's/Contractor's plugged connections shall
be identified).
h) When applicable, the make, size and type of couplings, and the location of guards and their
coverage.
l) The amount of and the specifications for the lubricating oil required (in the operating manual).
m) The maximum allowable crankshaft web deflections (in the operating manual).
7.5.3 The Vendor/Contractor shall supply schematic diagrams of each system in his scope of supply, as well as
outline (general arrangement) drawings, bills of material and specifications for the components. Pulsation
suppressor fabrication drawings describing weld details, internal construction, and internal and external
drain details shall be submitted to the Owner for review.
7.5.4 The Vendor/Contractor shall supply cross-sectional or assembly-type drawings specifically made for all
equipment furnished, showing all parts, running fits, clearances, crankshaft web deflections, and balancing
data required for erection or maintenance.
7.5.5 The Vendor/Contractor shall submit performance curves or tables of brake horsepower (kilowatts) and
capacity versus suction pressure with parameters of discharge pressure, showing the effects of unloading
devices, as mutually agreed between the Vendor/Contractor and the Owner.
7.5.6 Combined rod load data for each operating condition shall be submitted to the Owner for review.
7.5.7 For electric motor drivers the curves of starting speed versus torque shall be furnished for the compressor,
for the motor at rated voltage, and for the motor at the specified voltage reduction. The curve sheet shall
also state separately the inertia (WK2) of the motor alone and the resultant WK2 of the driven equipment
plus the calculated time for acceleration to full speed at the specified voltage. All curves shall be scaled in
finite values. Percentages are not acceptable.
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Prior to shipment, the Vendor/Contractor shall submit to the Owner, two (2) copies of the Data Books. It
shall contain the following:
Six (6) copies of the Installation Operating and Maintenance Manuals shall be provided which shall include
but not be limited to:
(i) Percent compressor cylinder clearance with different pocket arrangements, for head and
crank ends of each cylinder,
(ii) Relative crank angle of compressor cylinder throws,
(iii) Serial number of cylinders and driving elements,
14. Temperature rise data,
15. Drawings of charts showing fits and clearances,
16. Crosshead load diagram or tabulated data.
7.6.3 The manuals shall be presented in A4 format and be securely bound in heavy duty 4-ring binders.
The Vendor/Contractor shall supply the Owner with one set of mylar original drawings and documents or
in an agreed electronic format.
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Surface preparation and painting shall be in accordance with GES X.01, GES X.02 and GES X.03. The
factory coating of electrical equipment and instruments shall be in accordance with GES X.06.
8.2 Spares
With his proposal, the Vendor/Contractor shall provide a priced list of capital, commissioning and two
years operating spares for review by the Owner.
8.3 Packing/Storage
This section describes the minimum requirement for the preservation and protection of compressor units
during the sea and land transportation and storage, prior to installation.
8.4 Shipping
The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Inspector.
8.5 Warranty
8.5.1 The Vendor/Contractor shall provide manufacturer's written guarantees of compressor and motor
performance. Curves of horsepower versus flow shall be provided with efficiency lines to cover the
operating range.
8.5.2 The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of 12 months after commissioning or 24 months from the date of delivery to site, whichever is the shorter
period, or for the period stipulated in the Purchase Order/Contract.
8.5.3 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
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