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Onshore Engineering & Construction

Rotating - Inspection Hand Book (Rev.0) Supplier Quality Management System (SQMS) PEC-QU-GDE-X-13240 Quality Department This document is an uncontrolled copy when prin Shakkeeb Arsalan Vaikileri 12-Nov-2017

Contents Introduction .................................................................................8 Purpose and Scope .....................................................................9 Intended Use...............................................................................9 Reference Documents and their Precedence .............................9 Responsibilities of Assigned Inspectors....................................10 Pre-Inspection Meeting (PIM) ...................................................10 Confirm Document Approval Status..........................................10 Material Receiving Inspection ...................................................11 In Process Inspections..............................................................14 Inspections Specific to Weld Overlays......................................17 NCR Management ....................................................................18 Outstanding Works List Management .......................................19 Final Inspection & Inspection Release......................................20 Product Description and Specific Inspection Checklists ...........21 Pumps.......................................................................................21 Centrifugal (Roto-Dynamic) Pumps ..........................................22 Centrifugal Pumps .....................................................................24 Axial Flow Pump .......................................................................38 Multistage Centrifugal Pumps ...................................................40 Rotary Pumps ...........................................................................49 Shop Inspection and Testing Activities ......................................51 Material Inspection....................................................................51 Visual Inspection.......................................................................52

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Non Destructive Examination....................................................52 Static and Dynamic Balance Test  .............................................52 Hydro-Static Test .......................................................................53 Assembly Inspection .................................................................53 Performance Test......................................................................54 Acceptance Criteria...................................................................54 NPSHR Test..............................................................................55 Mechanical Running Test..........................................................56 Acceptance Criteria...................................................................57 String Test for Pumps ................................................................58 Dismantling Inspection..............................................................59 Dimensional and Final Assembly Inspection.............................59 Pump Installation Checks ..........................................................60 Pump Checks............................................................................60 General Checks ........................................................................64 Supplier Quality Assessment Checklist for Pumps-Centrifugal ....................................................................65 Supplier Quality Assessment Checklist for Pumps - Positive Displacement ............................................................................70 Centrifugal Compressors ..........................................................75 Impellers....................................................................................76 Rotor Assembly.........................................................................76 Casings .....................................................................................76 Lube Oil System ........................................................................77

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Dry Seal System .......................................................................77 Seal Gas System ......................................................................77 Separation Gas System ............................................................79 Hydrostatic Testing....................................................................79 Shaft Coupling ...........................................................................80 Bearings....................................................................................80 Preliminary Alignment ...............................................................80 Start System ..............................................................................80 Direct-Drive AC Start System ....................................................80 Functional Description ...............................................................81 Starter Motor .............................................................................81 Variable Frequency Drive (VFD) ...............................................81 Power Wiring.............................................................................82 Fuel System ..............................................................................82 Operation of Fuel System .........................................................83 Lubrication System ....................................................................83 Gas Turbine-Driven Main Lube Oil Pump .................................84 DC Motor-Driven Backup Lube Oil Pump .................................84 Duplex Lube Oil Filter System ...................................................85 Lube Oil Vent Coalescer ...........................................................85 Lube Oil Vent Flame Arrestor....................................................85 Lube Oil Cooler .........................................................................85 Lube Oil Immersion Tank Heater ...............................................85 Control and Monitoring..............................................................86

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Gas Compressor Surge Detection System ...............................87 Anti-Surge Control .....................................................................87 Compressor Vibration and Temperature Monitoring  .................89 Compressor Performance Map Display ....................................89 Enclosure ..................................................................................90 Inlet and Exhaust Ventilation Silencers.....................................90 Enclosure High Temperature Alarm ..........................................91 Pressurization System ..............................................................91 Lighting......................................................................................91 Sound Attenuation.....................................................................91 Exterior Connections.................................................................91 Fire and Gas Detection System ................................................92 Dual Fan Ventilation..................................................................93 Barrier Filter...............................................................................93 Standby Lighting .......................................................................93 Door Open Alarm ......................................................................93 CO2 Fire Suppression System ..................................................94 CO2 Isolation Valve Software....................................................94 Air Inlet System.........................................................................94 Self-Cleaning Barrier Type Air Filter..........................................95 Fixed Height Leg Kit ..................................................................95 Air Inlet Silencer........................................................................95 Exhaust System ........................................................................95 Turbine Exhaust Silencer..........................................................96

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Testing.......................................................................................96 Acceptance Testing...................................................................97 Compressor Testing ..................................................................97 Dynamic Test .............................................................................98 Preservation..............................................................................99 Impeller ...................................................................................102 Diffuser....................................................................................104 Conventional Designs .............................................................105 Lube and Seal Oil / Seal Gas Systems...................................110 Seal System............................................................................ 111 Controls System......................................................................112 Testing Activities......................................................................113 Axial Compressor....................................................................115 Dry Gas Seals.........................................................................120 Rotor Balancing .......................................................................125 Rotor Rigidity...........................................................................127 Balancing Machines................................................................127 Supplier Quality Assessment Checklist for Compressors - Centrifugal ......................................................130 Supplier Quality Assessment Checklist for Compressors - Reciprocating ..................................................137 Gas Turbines...........................................................................144 Compressor.............................................................................146 Combustor...............................................................................146

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Turbine....................................................................................147 Output Shaft & Gearbox..........................................................147 Exhaust ..................................................................................147 Advantages of Gas Turbine Engines .......................................150 Disadvantages of Gas Turbine Engines..................................151 Typical Key Highlights of any Turbine Package ......................151 Compressor .............................................................................151 Gas Turbine Engine ................................................................152 Baseplate ...............................................................................153 Start System ...........................................................................153 Gears, Couplings and Guards ................................................153 Lubricating Oil System ...........................................................153 Gas Fuel System ....................................................................154 Acoustic Enclosure .................................................................154 Acoustic Enclosure Ventilation System...................................155 Gas Detection System ............................................................155 Fire Protection System ............................................................155 Fire Extinguisher ....................................................................155 Combustion Air Inlet System...................................................156 Combustion Exhaust System..................................................156 Package Electrical Systems....................................................156 Package Auxiliaries.................................................................157 Control System........................................................................157 Turbo-Machinery Applications.................................................158

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Testing .....................................................................................159 Gas Turbine Testing ................................................................159 Compressor Testing ................................................................159 Suppliers Assistance During Commissioning ..........................163 Description of the Inspection and Testing Program .................166 Supplier Quality Assessment Checklist for Turbines – Combustion Gas ....................................................179 Preservation............................................................................186 Lessons Learned .....................................................................190

WARNING: The information in this handbook is intended only as a guide to provide general information of Quality Control and Inspections in this extremely complex field of Rotating Equipments. This information does not intend to cover all the issues that may arise in the design, selection, manufacturing, installation, inspection & testing of Rotating Equipments. Under no circumstances can the information contained in this handbook be used as an alternative to the relevant standards, project specification or the equipment certification/approval documentation. Received Date: ....................................... Name & Signature: ..................................

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Introduction This hand book is intended to assist in the training, development and enhancement of Petrofac Rotating Equipment Quality Control Personnel. •• Provide useful quality control guidelines, technical information, instructions and referable data to assist Quality Control personnel in ensuring a consistent Quality of Supplier works on all OEC projects. •• The reference text and materials included in this hand book shall only be used to supplement and/or clarify common good engineering practices on projects and to provide understanding of certain project requirements. •• This hand book should not be used to clarify or replace established codes, standards, procedures or specific project engineering design documents or requirements. •• Included in this hand book is information relative to minimum inspection and testing methods information for industrial projects. •• The text and information was derived from industry standard publications, industrial manufacturer’s catalogues or publications and conventional good engineering and installation practices.

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Purpose & Scope This guideline hand book describes the Petrofac OEC Project requirements, methods and expected “Basic Practices” for the performance of QA/QC by Supplier and/or shop based Inspectors. It provides guidance to inspection personnel involved in the Inspection and QC of equipment and material procured by Petrofac. It provides details of the requirements for assignment, planning, communications, interventions, reporting, release and the roles and responsibilities of inspectors, inspection agencies and project personnel. Intended Use This document is intended to be used by QA/QC Engineers and QC Inspectors assigned to the project and other relevant project QA/QC personnel as a reference document to provide guidelines in the implementation of the QA/QC requirements of the project procedures and specifications. This document also identifies expectations with respect to “Basic Practices” to be followed by inspectors when performing Inspection, Surveillance and review. Wherever the title “Inspector” is used in this handbook, it shall be treated as applicable to RI, TPI, TPC, QC Inspector & QA/ QC Engineer. Reference Documents and their Precedence Documents shall be applied in the following order: •• Project Specifications. •• Applicable Code. •• Current Document.

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Responsibilities of Assigned Inspectors •• •• •• •• •• •• •• ••

Pre-Inspection Meeting (PIM). Confirm Document Approval Status. Material Receiving Inspection. In Process Inspections. Inspections Specific to Weld Overlays. NCR Management. Outstanding Works List Management. Final Inspection & Inspection Release. Pre-Inspection Meeting (PIM)

PIM shall be conducted when ITP has been reviewed and at the minimum, approved with comments. Inspector shall conduct PIM where assigned by Package QA/QC Engineer. Standard PIM agenda shall be supplied as part of Supplier Quality Requirements Form (SQRF). Package QA/QC Engineer shall review adequacy of PIM agenda and update with vendor specific issues for discussion during PIM. Where advised by Package QA/QC Engineer, Inspector shall also conduct meeting at Sub-vendors locations. Confirm Document Approval Status Prior to performing inspections, Inspector shall verify the SDRL for applicable QC Procedures, Inspection & Test Plan & relevant detailed design documents. Inspector shall confirm that required documents are approved prior to performing inspection. Inspector shall also verify the SDRL and ensure that latest revision of document is used for inspection and testing.

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Material Receiving Inspection Inspector shall perform material receiving inspections along with vendor representatives with specific attention to following points: ● Verify dimensions, including their tolerances as per design document. Verify surface roughness, where indicated on the drawings. ● Review and if acceptable, sign and stamp material test certificate after internal review / acceptance by the vendor. Confirm that certification type (EN ISO 10204 Certification Types) is as per the project quality requirements / project specifications. ● Material grade for casing, auxiliary piping system, bearing housing, skid, entire seal system etc., shafts and impeller parts, gear units are in compliance with ISO 10474 / EN 10204 3.1 certificate. ● Confirm that pressure containing castings of carbon steel is furnished as per material and project specification. ● Confirm that serial number is clearly and permanently marked on the casing. ● Verify that casing and other castings involved in the package are sound, free from porosity, hot tears, shrink holes, blow holes, cracks, scale, blisters and similar injurious defects. ● Casing is cleaned by appropriate method and mould parting fins, gates and risers removed and those spots ground flush. ● Verify that impeller is made from a single piece casting or as specified in material specification.

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● Verify that cast impellers are 100% radiographed and accepted as comparing with reference radiographs of ASTM/ ISO and as per ITP. ● Verify that castings are not repaired by peening, plugging, burning in or impregnating. ● Verify that identification markings are available on all the materials and traceable to their quality certification and documentation. ● Verify that all pressure retaining steels are subject to impact test in case specified MDMT is below -30°C and results are compliant with applicable code and P.O. technical requirements. ● Verify that rotating assemblies / sub-assemblies are supplied and marked with rotation arrow. The rotation arrow is either cast in or attached (SS or Ni-Cu alloy or equivalent) to each major item of rotating equipment at a readily visible location. ● Verify that other materials and/or components like forgings, pipes, tubing, fittings, skid base structural materials, valves, instrumentation, alarms and control system items etc. are free from any irregularities, defects, discontinuities, physical damages, corrosion (internal and external) etc. and conform to required dimensions and configuration. ● Verify that MTCs / certification / functional test reports of instrumentation (such as temperature gauge, thermo wells, pressure gauges, pressure transducers, vibration and position detectors, solenoid valves, relief valves, flow indicators etc.) comply with the specification / data-sheet requirements. ● Verify that instruments are supplied with their valid calibration certificates.

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● Verify that certification / functional test reports of driver unit are available and exhibit compliance with specified requirements. ● Verify that the motors and electrical components area classification is as per P.O. technical requirements. ● Confirm that ultrasonic testing reports of shafts, MP/RT for the pump casing, NDE reports for the casing weld joints, RT reports for the piping weld joints, NDE reports for the skids as per project requirements are available and meets acceptance criteria. (The applicability for various NDE shall be as per approved ITP). ● Verify fasteners (excluding and headless set screws) have material grade and manufacturing identification symbols applied to one end of studs 10 mm in diameter and larger and to the head of bolts 6 mm in diameter and larger. ● All carbon steel hot formed components have been normalized after forming, unless those parts were formed within the normalizing temperature range. ● The tolerances of flange dimensions are in compliance with ANSI B16.5 for size up to 24 inch and ANSI B16.47 for more than 24 inch. ● Spot checking of nozzle dimensions, location and orientation is done. ● Flange surface roughness and hardness requirement shall be as per project requirement. ● Verify one of the contacting faces of jackscrews, provided to facilitate casing disassembly, is relieved (counter bored or recessed).

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● Verify that threaded holes use in pressure parts is minimized and in pressure sections of casings metal, metal equal in thickness to at least half the nominal bolt or stud diameter, plus the allowance for corrosion, is left around and below the bottom of drilled and threaded holes. ● Verify that vent and drain connections are provided except for self-venting equipments. ● Verify that impeller is keyed to the shaft. Pinning of impeller to the shaft is not allowed. ● Verify shaft is machined and finished throughout the length so that the Total Indicated Run-out (TIR) does not exceed API requirement. ● Carry out cleanliness inspection of the equipment and all piping and appurtenances before assembly. In Process Inspections Inspector shall perform in process inspections along with vendor representatives in accordance with ITP requirements. Routine daily surveillance shall be performed for items indicated as surveillance inspections. Following are few examples of routine in-process and surveillance inspections: ● NDE (MPI/DPI/RT/UT) for all major components (like pump casings, pipe attachments, base frame, auxiliary pipe work etc.) are as per approved ITP. ● PMI for all wetted parts as applicable for SS & Alloy steels. ● All connection to the pressure casing shall be full penetration welds.

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● All piping weld shall be butt weld, screw connection is allowed for instrument connection only when allowed by project specification. ● Welding/NDE operator qualification records. ● PWHT records for specific parts. ● Copies of calibration certificates of instruments used for all test instruments. ● Pickling and Passivation of all SS piping in accordance with ASTM A 380. ● All welding surfaces thoroughly cleaned of scale, rust oil or foreign bodies, before welding. ● Hardness is limited to 248HV10 for CS material for sour service and in line with NACE. For SS, the hardness shall be limited to 22 HRC. ● All acceptance NDE is carried out after PWHT where required. ● All welding is free from unacceptable indications/discontinuities. ● All Flange faces and other machined surfaces suitably protected during PWHT. ● Temporary rolling support provided during PWHT to take care of thermal expansion. ● Consumable color coding is checked. ● Confirm that direction of rotation is as per approved drawing. ● The clearance between impeller and wear rings is checked by the assembler before rotor assembly. ● Verify that arrangement of the equipment including piping and auxiliaries are provided with adequate clearance areas and

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safe access for operation and maintenance, as per applicable drawing. ● Verify that bolting for pressure casing conforms to Project specifications and applicable code requirements including threading. ● Verify that adequate clearances are provided at all bolting locations to permit use of socket or box spanners. ● Confirm that external hexagonal bolting is applied; fasteners are not less than 12 mm diameter. Metric fine and UNF threads are not used. ● The eccentricity of shaft and the outside diameter of the mounted shaft sleeve carefully measured and recorded. ● Verify that the minimum running clearances comply within the ranges specified in applicable code. ● Alignment of motor, coupling and turbo machinery shall be checked. ● Lifting beam load test to be witnessed as 150% SWL. ● Skid welding shall be checked, skid dimension, bulking, position of lifting lugs, earthling lugs shall be checked. ● Verify that casing openings for nozzles and pressure casing connections are of standard pipe sizes and in compliance with approved detailed drawings. ● Verify that suction and discharge nozzles are flanged and comply with design rating and dimensional requirements; full faced or spot faced on the back and designed for through bolting. ● After completion of assembly, outline dimensions checked

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against the approved outline drawing and confirmed within the acceptable tolerances as agreed upon. ● Verify that pumps operating above 3600 r/min and absorbing more than 300 KW (400 hp) per stage are conforming to clearance requirements and any special construction features provided in approved detailed drawings. ● Verify that cooling arrangement is as per P.O. requirements and compatible with coolant type, pressure and temperature specified in P.O. ● Confirm Jackets, if provided, have clean out connections arranged so that the entire passageway can be mechanically cleaned, flushed and drained. ● Verify that radially split casings have metal to metal fits with confined controlled compression gaskets such as an O-ring or spiral wound type. Inspections Specific to Weld Overlays Inspector shall pay special attention to weld overlay that may be required on internal surface of casings, pipes, nozzles, vessels etc. Following shall be confirmed during welding overlay activity: ● Confirm application of correct welding procedure. Verify welding parameters, welding consumables types. ● Confirm that welding operators / welders are qualified to perform overlay welding. ● Confirm that parent metal surface is cleaned of any mill scale and bright metal is exposed prior to performing weld overlay activity. This is necessary to ensure complete fusion between overlay and parent metal.

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● Confirm that overlay has been applied on complete surface required to be overlaid. ● Confirm that thickness and overlap of weld overlay is as per Welding procedure / detailed drawings / specifications / Mechanical data sheet. ● Make sure that weld overlay chemistry is checked by chemical analysis by taking metal sample from overlay. Confirm that chemical analysis result complies with required overlay chemistry. ● Perform PMI on weld overlay surface (no. of spots as per project specification or at least one per Sq. m). ● Perform required NDE on overlay surface as per project specification / ITP. Recommended to perform PT on completed weld overlay surface followed by UT for overlay disbandment. ● For the areas with limited accessibility, it is recommended that appropriate template should be used to ensure that correct thickness of overlay has been applied and achieved. ● Make sure that fabrication / manufacturing / assembly sequence is planned in a way that overlay quality and dimensions are confirmed prior to assembly (Before overlaid surface is hidden and becomes inaccessible). NCR Management ● Nonconformity is any condition which does not comply with the applicable rules of the Code or other specified requirements. Nonconformities must be corrected before the

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completed component can be considered to comply with the Code. Example of Non-conformities shall include, but need not be limited to: Materials and Parts found to be deviating from specified requirements during in-process examination.  Weld material used not meeting specification requirements.  Repairs to materials.  Un-calibrated equipment used in measurements and tests.  Time-temperature chart of completed heat treatment, deviating from specified requirements. • Petrofac Quality Control inspector shall raise NCR if he finds any deviations to the requirements during his regular surveillance inspection of the manufacturing process. Manufacturer shall analyse root cause analysis of nonconformance in order to eliminate the cause and prevent reoccurrence. Petrofac Inspector shall verify the disposition and effectiveness of corrective action taken. ● A log of NCR’s raised shall be maintained to ensure that they are closed after necessary corrective action and within agreed time frame. Correction of Non-conformity and management shall be done according to the Quality Control Manual procedure of the Manufacturer. Outstanding Works List Management All the points of Punch List / OWL shall be closed with the Corrective actions detail and shall be available in the Inspection Dossier.

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Final Inspection & Inspection Release ● Complete final Inspection and report any punch list which required to be corrected within the scope of vendor. ● Final Visual Inspection carries out and conform the final condition of equipment and packing & shipping mark shall be done according to the approved procedure. ● Refer the Inspection Check List, review and verify all the inspection stages with relevant inspection test reports as necessary. ● Ensure that all NCR’s if any initiated shall be closed. ● Any DCN was raised during the manufacturing, shall be incorporated into the As-Built Drawing. ● Deviation during the manufacturing which shall be approved by the customer. ● Review Inspection Dossier / MRB / SQRL which shall comply according to the Approved Index MDR or Approved ITP. ● Handover all the relevant documentation to the Project QC to issue the Inspection Release Note. ● All inspection Measuring and testing equipment shall maintain a current calibration status that is traceable back to the national standards at all times ● When a Non-conformance is noted during production the Inspector shall ensure to quarantine the material and an NCR shall be raised. Rejected material shall be removed from the production area and shifted to dedicated quarantine area. ● Visual inspection and sampling will be done in the fabricating shop and in the field by the Engineer to confirm the material

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supplied and the fabrication has been done as specified on the Drawings, in this Specification and in the Special Provisions. The Contractor shall supply material specimens for testing when requested by the Engineer. ● The vendor shall provide full facilities for the unencumbered inspection of material, workmanship and all parts of the work at all stages of the work by the Engineer in the shop, in storage facilities and in the field. ● The RI shall be allowed free access to the work. The Engineer will perform non-destructive testing of the works, destructive testing of samples obtained of materials to be incorporated into the work and any other additional inspection at his discretion. Product Description and Specific Inspection Checklists Pumps A pump is a device that moves fluids by mechanical action. Pumps can be classified into three major groups according to the method they use to move the fluid: direct lift, displacement and gravity pumps. Pumps operate by mechanism (typically reciprocating or rotary) and consume energy to perform mechanical work by moving the fluid. Pumps are driven by many energy sources, including electric motors, engines. Pumps may be placed in one of the two general categories, Dynamic pressure pumps (roto-dynamic pump) - centrifugal

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pump, jet pump, propeller and turbine. It is pump in which the dynamic motion of a fluid is increased by pump action. Positive displacement pump-Piston plunger, gear, lobe, vane, screw etc. It causes a fluid to move by trapping a fixed amount of it then forcing (displacing) that trapped volume into the discharge pipe. Centrifugal (Roto-dynamic) Pumps A rotodynamic pump is a device where mechanical energy is transferred from the rotor to the fluid by the principle of fluid motion through it. The energy of the fluid can be sensed from the pressure and velocity of the fluid at the delivery end of the pump. Centrifugal Pumps are classified into three general categories: CENTRIFUGAL PUMPS

RADIAL FLOW

MIXED FLOW

AXIAL FLOW

Radial Flow - a centrifugal pump in which the pressure is developed wholly by centrifugal force. Mixed Flow - a centrifugal pump in which the pressure is developed partly by centrifugal force and partly by the lift of the vanes of the impeller on the liquid. Axial Flow - a centrifugal pump in which the pressure is developed by the propelling or lifting action of the vanes of the impeller on the liquid.

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Positive Displacement Pumps are classified into two general categories and then subdivided into four/five categories each. POSITIVE DISPLACEMENT PUMPS

SINGLE ROTOR

MULTIPLE ROTOR

VANE PISTON FLEXIBLE MEMBER SINGLE SCREW PROGRESSING CAVITY 

GEAR LOBE CIRCUMFERENTIAL PISTON MULTIPLE SCREW

Single Rotor •• VANE - The vane(s) may be blades, buckets, rollers or slippers which cooperate with a dam to draw fluid into and out of the pump chamber. •• PISTON - Fluid is drawn in and out of the pump chamber by a piston(s) reciprocating within a cylinder(s) and operating port valves. •• FLEXIBLE MEMBER - Pumping and sealing depends on the elasticity of a flexible member(s) which may be a tube, vane or a liner. •• SINGLE SCREW - Fluid is carried between rotor screw threads as they mesh with internal threads on the stator. •• Progressing Cavity - Fluid is carried between a rotor and flexible stator.

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Multiple Rotor •• GEAR - Fluid is carried between gear teeth and is expelled by the meshing of the gears which cooperate to provide continuous sealing between the pump inlet and outlet. •• LOBE - Fluid is carried between rotor lobes which cooperate to provide continuous sealing between the pump inlet and outlet. •• CIRCUMFERENTIAL PISTON - Fluid is carried in spaces between piston surfaces not requiring contacts between rotor surfaces. •• MULTIPLE SCREW - Fluid is carried between rotor screw threads as they mesh. Centrifugal Pumps Centrifugal pumps are used to transport liquids/fluids by the conversion of the rotational kinetic energy to the hydro dynamics energy of the liquid flow. The centrifugal pump, by its principle, is converse of the Francis turbine. The flow is radially outward and the hence the fluid gains in centrifugal head while flowing through it. In a simple case, the fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser or volute chamber (casing), from where it exits. Because of certain inherent advantages, such as compactness, smooth and uniform flow, low initial cost and high efficiency even at low heads, centrifugal pumps are used in almost all pumping systems. Centrifugal pumps are also classified as horizontal or vertical, depending on the position of the pump shaft. Impellers used in

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centrifugal pumps may be classified as single-suction or doublesuction, depending on the way in which liquid enters the eye of the impeller. Construction The casing for the liquid end of a pump with a single-suction impeller is made with an end plate that can be removed for inspection and repair of the pump. A pump with a double-suction impeller is generally made so one-half of the casing may be lifted without disturbing the pump. Since an impeller rotates at high speed, it must be carefully machined to minimize friction. An impeller must be balanced to avoid vibration. A close radial clearance must be maintained between the outer hub of the impeller and that part of the pump casing in which the hub rotates. The purpose of this is to minimize leakage from the discharge side of the pump casing to the suction side.

Components of Centrifugal Pump

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Centrifugal Pump in assembly

The simplest form of a centrifugal pump is shown below. It consists of three important parts: (i) the rotor, usually called as impeller, (ii) the volute casing and (iii) the diffuser ring. The impeller is a rotating solid disc with curved blades standing out vertically from the face of the disc. The impeller may be single sided or double sided. A double sided impeller has a relatively small flow capacity.

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A centrifugal pump

The tips of the blades are sometimes covered by another flat disc to give shrouded blades, otherwise the blade tips are left open and the casing of the pump itself forms the solid outer wall of the blade passages. The advantage of the shrouded blade is that flow is prevented from leaking across the blade tips from one passage to another.

(a) Single sided impeller

(b) Double sided impeller

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(c) Shrouded Impeller Types of Impellers in a Centrifugal Pump

While converting the mechanical energy from a motor into an energy of a moving fluid, a portion of the energy goes into kinetic energy of the fluid motion and some into potential energy represented by fluid pressure (Hydraulic head) or by lifting the fluid against gravity, to a higher altitude. The outlet pressure is a reflection of the pressure that applies the centripetal force that curves the path of the water to move circularly inside the pump. On the other hand, the statement that the “outward force generated within the wheel is to be understood as being produced entirely by the medium of centrifugal force” is best understood in terms of centrifugal force as a fictional force in the frame of reference of the rotating impeller; the actual forces on the water are inward or centripetal, since that is the direction of force need to make the water move in circles. This force is supplied by a pressure gradient that is set up by the rotation, where the pressure at the outside, at the wall of the volute, can be taken as a reactive centrifugal force.

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Liquid Flow Path Inside a centrifugal pump

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A centrifugal pump has main components under two groups: I. A rotating component comprised of an impeller and a shaft. II. A stationary component comprised of a casing, casing cover and bearings. The general components, both stationary and rotary, are depicted in the below figure. The main components are discussed in brief below shows these parts on a photograph of a pump in the field.

Centrifugal pump in in running plant

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Stationary Components Casing - Casings are generally of two types: volute and circular. Volute casings build a higher head; circular casings are used for low head and high capacity. A volute is a curved funnel increasing in area to the discharge port as shown in the below figure. As the area of the crosssection increases, the volute reduces the speed of the liquid and increases the pressure of the liquid. Circular casing have stationary diffusion vanes surrounding the impeller periphery that convert velocity energy to pressure energy. Conventionally, the diffusers are applied to multi-stage pumps. The casings can be designed either as solid casings or split casings. Solid casing implies a design in which the entire casing including the discharge nozzle is all contained in one casting or fabricated piece. A split casing implies two or more parts are fastened together. When the casing parts are divided by horizontal plane, the casing is described as horizontally split or axially split casing. When the split is in a vertical plane perpendicular to the rotation axis, the casing is described as vertically split or radially split casing. Casing Wear rings act as the seal between the casing and the impeller. Suction and Discharge Nozzle The suction and discharge nozzles are part of the casings itself. They commonly have the following configurations.

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End suction/Top discharge - The suction nozzle is located at the end of and concentric to, the shaft while the discharge nozzle is located at the top of the case perpendicular to the shaft. This pump is always of an overhung type and typically has lower NPSHr because the liquid feeds directly into the impeller eye. Top suction/ Top discharge nozzle - The suction and discharge nozzles are located at the top of the case perpendicular to the shaft. This pump can either be an overhung type or betweenbearing type but is always a radially split case pump. Rotating Components Impeller The impeller is the main rotating part that provides the centrifugal acceleration to the fluid. The impellers are fitted inside the casings. They are often classified in many ways. Based on major direction of flow in reference to the axis of rotation, •• Radial flow. •• Axial flow. •• Mixed flow. Based on suction type, •• Single-suction: Liquid inlet on one side. •• Double-suction: Liquid inlet to the impeller symmetrically from both sides.

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Centrifugal pump impellers. A. Single-suction. B. Double-suction

Based on mechanical construction, ● Closed: Shrouds or sidewall enclosing the vanes. ● Open: No shrouds or wall to enclose the vanes. ● Semi-open or vortex type. Closed impellers require wear rings and these wear rings present another maintenance problem. Open and semi-open impellers are less likely to clog, but need manual adjustment to the volute or back-plate to get the proper impeller setting and prevent internal re-circulation. Vortex pump impellers are great for solids and “stringy” materials but they are up to 50% less efficient than conventional designs. The number of impellers determines the number of stages of the pump. A single stage pump has one impeller only and is best for low head service. A two-stage pump has two impellers in series for medium head service. A multi-stage pump has three or more impellers in series for high head service.

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Wear Rings Wear ring provides an easily and economically renewable leakage joint between the impeller and the casing clearance becomes too large the pump efficiency will be lowered causing heat and vibration problems. Manufacturers demand for disassembling the pump to check the wear ring clearance and replace the rings when this clearance doubles. Shaft The basic purpose of a centrifugal pump shaft is to transmit the torques encountered when starting and during operation while supporting the impeller and other rotating parts. It must do this job with a deflection less than the minimum clearance between the rotating and stationary parts. Shaft Sleeve Pump shafts are usually protected from erosion, corrosion and wear at the seal chambers, leakage joints, internal bearings and in the waterways by renewable sleeves. Unless otherwise specified, a shaft sleeve of wear, corrosion and erosion resistant material shall be provided to protect the shaft. The sleeve shall be sealed at one end. The shaft sleeve assembly shall extend beyond the outer face of the seal gland plate. (Leakage between the shaft and the sleeve should not be confused with leakage through the mechanical seal). Coupling Couplings can compensate for axial growth of the shaft and transmit torque to the impeller. Shaft couplings can be broadly classified into two groups: rigid and flexible. Rigid couplings are

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used in applications where there is absolutely no possibility or room for any misalignment. Flexible shaft couplings are more prone to selection, installation and maintenance errors. Flexible shaft couplings can be divided into two basic groups: elastomeric and non-elastomeric. ● Elastomeric couplings use either rubber or polymer elements to achieve flexibility. These elements can either be in shear or in compression. Tire and rubber sleeve designs are elastomer in shear couplings; jaw and pin and bushing designs are elastomer in compression couplings. ● Non-elastomeric couplings use metallic elements to obtain flexibility. These can be one of two types: lubricated or nonlubricated. Lubricated designs accommodate misalignment by the sliding action of their components, hence the need for lubrication. The non-lubricated designs accommodate misalignment through flexing. Gear, grid and chain couplings are examples of non-elastomeric, lubricated couplings. Disc and diaphragm couplings are non-elastomeric and non-lubricated. Auxiliary Components Auxiliary components generally include the following piping systems for the following services, ● Seal flushing, cooling, quenching systems. ● Seal drains and vents. ● Bearing lubrication, cooling systems. ● Seal chamber or stuffing box cooling, heating systems. ● Pump pedestal cooling systems.

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Pumping System and the Net Head Developed by a Pump The pumping implies to convey liquid from a low to a high reservoir. Such a pumping system, in general, is shown below. At any point in the system, the elevation or potential head is measured from a fixed reference datum line. The total head at any point comprises pressure head, velocity head and elevation head. For the lower reservoir, the total head at the free surface is HA and is equal to the elevation of the free surface above the datum line since the velocity and static pressure at A are zero. Similarly the total head at the free surface in the higher reservoir is (HA + HS) and is equal to the elevation of the free surface of the reservoir above the reference datum. The variation of total head as the liquid flows through the system is shown in the next diagram. The liquid enters the intake pipe causing a head loss hin for which the total energy line drops to point B corresponding to a location just after the entrance to intake pipe. The total head at B can be written as. HB = HA – hin As the fluid flows from the intake to the inlet flange of the pump at elevation z1 the total head drops further to the point C due to pipe friction and other losses equivalent to hf1. The fluid then enters the pump and gains energy imparted by the moving rotor of the pump. This raises the total head of the fluid to a point D at the pump outlet. In course of flow from the pump outlet to the upper reservoir, friction and other losses account for a total head loss or hf2 down to a point E . At E an exit loss he occurs when the liquid enters

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the upper reservoir, bringing the total heat at point F to that at the free surface of the upper reservoir. If the total heads are measured at the inlet and outlet flanges respectively, as done in a standard pump test, then (refer to the below figures for detials).

A general pumping system

Change of head in a pumping system

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Axial Flow Pump The axial flow or propeller pump is the converse of axial flow turbine. The impeller consists of a central boss with a number of blades mounted on it. The impeller rotates within a cylindrical casing with fine clearance between the blade tips and the casing walls. Fluid particles, in course of their flow through the pump, do not change their radial locations. The inlet guide vanes are provided to properly direct the fluid to the rotor. The outlet guide vanes are provided to eliminate the whirling component of velocity at discharge. The usual number of impeller blades lies between 2 and 8, with a hub diameter to impeller diameter ratio of 0.3 to 0.6. The below figure shows an axial flow pump. The flow is the same at inlet and outlet. An axial flow pumps develops low head but have high capacity. The maximum head for such pump is of the order of 20 m.

A propeller or an Axial flow pump

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Vanned Diffuser A vanned diffuser, as shown in below figure, converts the outlet kinetic energy from impeller to pressure energy of the fluid in a shorter length and with a higher efficiency. This is very advantageous where the size of the pump is important. A ring of diffuser vanes surrounds the impeller at the outlet. The fluid leaving the impeller first flows through a vaneless space before entering the diffuser vanes. The divergence angle of the diffuser passage is of the order of 8-10° which ensures no boundary layer separation. The optimum number of vanes are fixed by a compromise between the diffusion and the frictional loss. The greater the number of vanes, the better is the diffusion (rise in static pressure by the reduction in flow velocity) but greater is the frictional loss. The number of diffuser vanes should have no common factor with the number of impeller vanes to prevent resonant vibration.

A vanned diffuser of a centrifugal pump

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Multistage Centrifugal Pumps A centrifugal pump containing two or more impellers is called a multistage centrifugal pump. The impellers may be mounted on the same shaft or on different shafts. For higher pressures at the outlet impellers can be connected in series. For higher flow output impellers can be connected in parallel. There are two types of arrangements. ● Multistage centrifugal pump for high heads or impellers in series. For developing a high head a number of impellers are mounted in series or on the same. ● Multistage centrifugal pump for high discharge or impellers in parallel. The fluid from suction pipe enters the 1st impellers at inlet and discharged at outlet with increased pressure. The fluid then from 1st impeller taken to inlet of the 2nd impeller with the help of connecting pipe. So at outlet of 2nd impeller pressure of water will be more.  Some difficulties faced in centrifugal pumps are as follows, •• Cavitation—the net positive suction head (NPSH) of the system is too low for the selected pump •• Wear of the Impeller—can be worsened by suspended solids •• Corrosion inside the pump caused by the fluid properties •• Overheating due to low flow •• Leakage along rotating shaft •• Lack of prime—centrifugal pumps must be filled (with the fluid to be pumped) in order to operate •• Surge

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Cavitation Cavitation is defined as the process of formation and disappearance of the vapor phase of a liquid when it is subjected to reduced and subsequently increased pressures. The formation of cavities is a process analogous to boiling in a liquid, although it is the result of pressure reduction rather than heat addition. Cavitation is a thermodynamic change of state with mass transfer from liquid to vapor phase and vice versa (bubble formation & collapse). Cavitation causes following problems, •• Performance loss (head drop). •• Material damage (cavitation erosion). •• Vibrations. •• Noise. •• Vapor lock (if suction pressure drops below break-off value).

Typical cavitation damages

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Understanding Centrifugal Pump Performance Curves The capacity and pressure needs of any system can be defined with the help of a graph called a system curve. Similarly the capacity vs. pressure variation graph for a particular pump defines its characteristic pump performance curve. The pump suppliers try to match the system curve supplied by the user with a pump curve that satisfies these needs as closely as possible. A pumping system operates where the pump curve and the system resistance curve intersect. The intersection of the two curves defines the operating point of both pump and process. However, it is impossible for one operating point to meet all desired operating conditions. For example, when the discharge valve is throttled, the system resistance curve shift left and so does the operating point.

Typical system and pump performance curves

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Developing a Pump performance Curve A pump’s performance is shown in its characteristics performance curve where its capacity i.e. flow rate is plotted against its developed head. The pump performance curve also shows its efficiency (BEP), required input power (in BHP), NPSHr, speed (in RPM) and other information such as pump size and type, impeller size, etc. This curve is plotted for a constant speed (rpm) and a given impeller diameter (or series of diameters). It is generated by tests performed by the pump manufacturer. Pump curves are based on a specific gravity of 1.0. Other specific gravities must be considered by the user. A centrifugal pump works under its maximum efficiency conditions. However when the pump is run at conditions different from design conditions, it performs differently. Therefore to predict the behavior of the pump under varying conditions of speeds, heads, discharges or powers, tests are usually conducted. So characteristic curves of centrifugal pumps are defined as those curves which are plotted from the results of a number of tests on the centrifugal pump. Performance characteristics of a pump fall into following categories, Main characteristic curves - The main characteristic curves of a centrifugal pump consist of a variation of head (Hm), power and discharge with respect to speed. For plotting curves of manometric head versus speed, discharge is kept constant. For plotting curves of discharge versus speed, manometric head (Hm) is kept constant and for plotting the curves between power and speed the manometric head and discharge are kept constant.

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Operating characteristic curves - The curves plotted from the results of a number of tests on a pump while running at its design speed are referred as characteristic curves. The curves indicate the rotation between efficiency, power and head with respect to discharge. These are plotted for only one speed. Constant efficiency or Muschel curves - The constant curves are also called the ISO-efficiency curves; depict the performance of a pump over its entire range of operation. Data for plotting these curves is obtained from main characteristic curves i.e. Efficiency Vs. Q and H Vs. Q. Constant head and constant discharge curves - The performance of a variable speed pump for which the speed constantly varies can be determined by these curves. Mechanical Seals Mechanical seals are rapidly replacing conventional packing as the means of controlling leakage on centrifugal pumps. Pumps fitted with mechanical seals eliminate the problem of excessive stuffing box leakage, which can result in pump and motor bearing failures and motor winding failures. Where mechanical shaft seals are used, the design ensures that positive liquid pressure is supplied to the seal faces under all conditions of operation and that there is adequate circulation of the liquid at the seal faces to minimize the deposit of foreign matter on the seal parts. One type of mechanical seal is shown in the below figure. Spring pressure keeps the rotating seal face snug against the stationary seal face. The rotating seal and all of the assembly below it are affixed to the pump shaft. The stationary seal face is held stationary by the seal gland and packing ring. A static seal is

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formed between the two seal faces and the sleeve. System pressure within the pump assists the spring in keeping the rotating seal face tight against the stationary seal face. The type of material used for the seal face depends on the service of the pump. When a seal wears out, it is simply replaced. Following precautions are required, when performing maintenance on mechanical seals: Do not touch new seals on the sealing face because body acid and grease can cause the seal face to prematurely pit and fail. Replace mechanical seals when the seal is removed for any reason or when the leakage rate cannot be tolerated.

Mechanical Seal

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Wearing Rings The clearance between the impeller and the casing wearing ring must be maintained as directed by the manufacturer. When clearances exceed the specified amount, the casing wearing ring must be replaced. It requires the complete disassembly of the pump. All necessary information on disassembly of the unit, dimensions of the wearing rings and reassembly of the pump is in the manufacturer’s technical manual. Failure to replace casing wearing ring when the allowable clearance is exceeded results in a decrease of pump capacity and efficiency. If a pump has to be disassembled because of some internal trouble, the wearing ring must  be checked for clearance. Measure the outside diameter of the impeller hub with an outside micrometer and the inside diameter of the casing wearing ring with an inside micrometer; the difference between the two diameters is the actual wearing ring diametric clearance. By checking the actual wearing ring clearance with the maximum allowable clearance, you can decide whether to renew the ring before reassembling the pump. These may need only a slight amount of machining before they can be installed. The new rotor can be installed and the old rotor sent to a repair activity for overhaul. Overhauling a rotor includes renewing the wearing rings, bearings and shaft sleeve. Inducer A special axial flow pumping device, an inducer provides significant improvement in suction performance by reducing pump NPSHR. This results in a reduced suction barrel length and a more compact, less expensive installation. A special inducer design reduces the backflow and guarantees troublefree operation over a wide flow range.

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Inducer

Typical Items Under Centrifugal Pump Skid Following are the typical key highlights of any pump skid, the requirements may vary from client to client. •• Reinforced Motor Stand ensures rigid structural design. •• Screen type Non-sparking Coupling Guard provides safety while allowing visual inspection of coupling and mechanical seal areas. •• Stiff Shaft Design ensures stable operation under all service conditions. •• Discharge Head, with in-line flanges in any required rating, incorporates all gauge, vent and drain connections. •• Inside Drain Line permits complete draining of suction barrel. •• Low Suction Velocity Can Design results in optimum hydraulic

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••

•• ••

••

•• •• ••

inlet conditions at suction bowl inlet Centerline Aligned and Flanged Columns ensure total indicator readings well within API 610 limits. API 682 compliant Mechanical Seal Chamber accommodates all cartridge mounted seal designs, including: single and dual pressurized or unpressurized liquid; and gas designs Engineered gas coffer dam seal system available for cryogenic services. Guide Bushing and Bearing Material selected to meet fluid requirements. Casing and Impeller Wear Rings, with a minimum 50 Brinell hardness difference between them, prevent galling, allow economical retention of operating efficiency and maintain mechanical stability. Flanged Spacer Type Coupling permits easy maintenance of thrust bearings and mechanical seals without disturbing or removing driver. Separate Axial Thrust Bearing Assembly designed to withstand total hydraulic thrust and rotor weight. Self-contained oil lubricated, anti-friction bearings for standard applications. Tilting pad thrust bearings for high horsepower or high thrust applications. Sound Level Measurement

Noise level shall be measured at 1.5 meters above the bottom surface of the skid at a distance of 1 meter from the edge of the skid. (6) point of measurement is required as follows, 1. Pump end of the skid.

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2. Diesel end of the skid. 3. two readings on both sides of the skid, one at pump end and one at the motor end. After completion of noise tests with pump running, shut-off pump and record the background noise. This must be deducted from the values recorded with engine running if outside the limits for “Corrections for Background Sound”. Noise levels will be weighted using the A scaling factors. The data will be provided with the test report along with the calibration sound level meter. Vibration Measurement Vibration readings will be recorded at two locations on the pump, 1. Inboard bearing housing (vertical and horizontal readings). 2. Outboard bearing housing (vertical, horizontal and axial readings). A digital printout of the vibration analysis will be printed and provided with the test report along with the calibration for the vibration analyzer. This report is provided to insure that the pump has no mechanical problems. Actual field vibration results will be within the limits of Hydraulic Institute vibration standards (HI 9.6.4-2000). Rotary Pumps Among this group are the gear pump, the screw pump and the moving vane pump. Unlike the centrifugal pump, the rotary pump is a positive- displacement pump. For each revolution of the pump, a fixed volume of fluid is moved regardless of the resistance against which the pump is pushing. Any blockage in the system

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could quickly cause damage to the pump or a rupture of the system. Always make sure that the system is properly aligned so a complete flow path exists for fluid flow. Also, because of their positive displacement feature, rotary pumps require a relief valve to protect the pump and piping system. The relief valve lifts at a preset pressure and returns the system liquid either to the suction side of the pump or back to the supply tank or sump. Rotary pumps are also different from centrifugal pumps in that they are essentially self-priming.  A rotary pump operates within limits with the pump located above the source of supply. A good example of the principle that makes rotary pumps self-priming is the simple drinking straw. As you suck on the straw, you lower the air pressure inside the straw. Atmospheric pressure on the surface of the liquid surrounding the straw is therefore greater and forces the liquid up the straw. The same conditions basically exist for the gear and screw pump to prime itself.

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Above figure shows a gear pump located above the tank. The tank must be vented to allow air into the tank to provide atmospheric pressure on the surface of the liquid. To lower the pressure on the suction side of the pump, the clearances between the pump parts must be close enough to pump air.   When the pump starts, the air is pumped through the discharge side of the pump and creates the low-pressure area on the suction side, which allows the atmospheric pressure to force the liquid up the pipe to the pump. To operate properly, the piping leading to the pump must have no leaks or it will draw in air and can lose its prime. Rotary pumps are useful for pumping oil and other heavy viscous liquids. In the engine room, rotary pumps are used for handling lube oil and fuel oil and are suitable for handling liquids over a wide range of viscosities. Rotary pumps are designed with very small clearances between rotating parts and stationary parts to minimize leakage (slippage) from the discharge side back to the suction side. Rotary pumps are designed to operate at relatively slow speeds to maintain these clearances; operation at higher speeds causes erosion and excessive wear, which result in increased clearances with a subsequent decrease in pumping capacity. Classification of rotary pumps is generally based on the types of rotating element. Shop Inspection and Testing Activities This Inspection and test procedure shall be carried out at the time of acceptance of the raw materials, during the manufacturing process, the shop test and prior to shipment. Material Inspection The materials shall be checked to conform to the materials for their specification and GA drawing.

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Visual Inspection All surfaces of materials shall be inspected visually and confirmed to be free of adhering sand, cracks and hot tears. Other surface discontinuities shall be judged and accepted in accordance with MSS SP-55. Non Destructive Examination Liquid Penetrate Examination - Parts shall be performed Liquid Penetrate Examination after machining in accordance with ASME Sec-8 Div-1 App.7 & 8. ● Applicable Parts : Machined area for Casing, Impeller and Shaft. Ultra-Sonic Examination - Shaft shall be performed Ultrasonic Examination after rough machining in accordance with ASME SA388. Static and Dynamic Balance Test Static and Dynamic balance test shall be performed in such a way that the impeller and test bar are assembled to make up a rotating unit. The single plane or two plane balancing method shall be employed for impeller with test bar. Correction of the residual unbalance weight shall be performed by grinding from the impeller shroud. Adjustment will be continued until the value of unbalance comes within that of tolerance. Impeller with test bar shall be dynamically balanced at 300 rpm to 1000 rpm as shown below,

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The allowable balance quality in plane of correction shall be within 2.5 mm/s in accordance with ISO-1940-1. Hydro-static Test Each pressure containing parts shall be hydrostatically tested before painting and after machining. The pressure parts shall be hydrostatically tested in accordance with approved data sheet. All Pressure casing components shall be hydrostatically tested with liquid at a minimum of 1.5 times the maximum allowable working pressure. The duration times of the test shall be minimum 30 min. Hydrostatic test shall be performed according to API 610. The clean water shall be used for the test. The chloride content of liquids used to test austenitic stainless steel material shall be not exceed 50 mg/kg. Assembly Inspection Clearance measurement - Prior to rotor assembly, the clearance between impeller wear ring and case wear ring shall be measured. The values of clearance must be within the limitation specified in Para-5.7.4 and Table 5 of API 610.

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Rotor Run-Out Measurement - In addition to the clearance measurement, the eccentricity of shaft and impeller wear ring shall be checked. The values of run-out (TIR = Total Indicator Readings) must be within the following limitation. PUMP TYPE

ON SHAFT

ON IMPELLER

Horizontal

Maximum 0.025 mm

Maximum 0.05 mm

Performance Test Test method and calculation of performance test and capacity measuring method shall be as per API 610. The fresh water of the ambient temperature which is less than 65 Degree C shall be used for the shop test. Five point measuring shall be applied as per following, ● Shut-off, Minimum flow, Middle flow, Rated Flow, Maximum allowable flow (120% of BEP). The purchaser’s motor shall be used for the shop test as applicable. If the performance and mechanical running test were carried with shop motor, it requires necessary purchaser’s approval. When the rated point is closed to minimum flow, other test point may be changed to over flow point against the rated flow. Witness Inspection is applied to one pump out of identical models. Acceptance Criteria When operated at rated speed and rated capacity, pumps shall be within the following tolerances of the guaranteed characteristics per API 610,Table-14.

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•• The negative tolerance specified here shall be allowed only if the test curve still shows a rising characteristic. •• If it is necessary to dismantle any pump after the shop test for sole purpose of machining impellers to meet the tolerance on differential head, no retest will be required unless the reduction in diameter exceeds 5 percent of the original diameter. •• The diameter of the impeller at the shop test, together with the final diameter of the impeller, shall be recorded on a certified shop test curve sheet showing the operating characteristics after the diameter of the impeller has been reduced. NPSHr Test When specified, the pump shall be tested for NPSH. At rated speed and with NPSHa equal to quoted NPSHR, the pump capacity shall be within three percent of the non cavitating capacity. NPSHr is determined at cavitation noise starting point by the choking a suction-line valve. a. The pump is run at constant rate of flow and speed with suction condition varied to produce capitation. b. NPSHr test shall be performed only one pump per each pump type c. NPShr test shall be carried out when the difference of NPSHa and NPSHr is less than 0.6 m. d. A suction valve throttling test method and A vacuum suppression test method shall be employed. e. 3% drop in head shall be defined as NPSHr. If the drop in head should be less than 3% at the test with minimum suction head which will be obtained at the test facilities.

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f. NPSH of this test shall be regarded as NPSHr. g. NPSHr data shall be taken at the 3 flow points as follows, - Minimum continuous flow - Rated flow - Max. flow Acceptance Criteria - The tested NPSHr data shall be less than NPSHr specified on pump data sheet at the rated flow point. Also, the head drop in total head shall be less than 3 percent at the rated flow point. MECHANICAL RUNNING TEST During the shop performance test, the following mechanical running conditions shall be observed. until the bearing temperature being stabilized. Minimum Running Test Time is 1 hour at rated flow. a. Vibration Check - During the performance test, vibration shall be measured at ±10% of rated flow on bearing housing. - Fast Fourier Transform (FFT) spectrum measurement shall be made at ±10% of rated flow. - FFT Measurement location shall be horizontal direction, 1 point for overhung pumps, 1 point (X or Y direction) for vertical pumps and 2 point (each bearing housing) for between bearing pumps. The position of the vibration measurement points for horizontal and vertical pumps is shown below,

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Vibration measurement points for horizontal and vertical pumps

b. Noise Level Check

The noise level including motor noise and back ground noise shall be measured at 1m from the equipment surface and 1.5m above the ground and at rated flow.

c. Bearing Temperature Check

Bearing temperature shall be measured on bearing housing at rated flow. (Min Running time : 1hr) Mechanical seal leakage During the shop performance and mechanical running test, mechanical seal leakage shall be checked. Acceptance Criteria

a. Vibration measurement - Reference only at shop test. - The maximum vibration level measured must lie at rated flow. - The limit value / range specified for the guaranteed point

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refers to plant operation. - The maximum value measured during the acceptance test cannot serve as evidence for guarantee purpose because of the test set-up conditions. - For pumps running above 3600rpm or absorb more than 300kw per stage, refer to API610 Fig.29. - Maximum vibration value : API 610 table-8. b. Noise level: Reference only.

The noise level measured in shop will be greatly affected by noise generated from shop testing facilities, such as control valves & bending piping. Therefore, the measured values at the shop test are reference only. Noise level shall not exceed 85dB(A) at 1 mtr from the pump at site.

c. Bearing Temperature. - Temperature Rise : Max 39°C. - Max allowable temperature : Max. 82°C. d. Mechanical seal leakage. - No leakage. String Test for Pumps Tests typically include a full mechanical run, a full hook-up and functional test on all aspects of the package including startup, simulated emergency shut-down, variable speed operation etc. Tests may have to be carried out with new clearances on the driven equipment and also with artificially enlarged clearances (to 2x new) so that behavior at end-of-life can also be assessed.

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Dismantling Inspection After completion of the specified performance and mechanical running test, the pump shall be dismantled in order to check and cleaning the following internal parts. ● Impellers ● Shafts ● Wearing Parts ● Casing Dismantle Inspection shall be applied if abnormal noise or temperature rise is detected during the running test The parts and components shall be confirmed that there are no harmful defects such as heavy scratches and scorings. The antifriction bearing shall be checked if undue heating is observed. After dismantling inspection was completed, the pump shall be assembled finally. Dimensional and Final Assembly Inspection After completion of pump assembly, outline dimensions shall be checked against the specified approved outline drawing and shall be confirmed within the following tolerances. Nozzle location and foundationa. Suction nozzle to discharge Nozzle: +5mm ~ -5mm b. Nozzle to Anchor Bolt Hole: +5mm ~ -5mm c. Nozzle Height: +5mm ~ -5mm d. Anchor bolts hole pitch: +3mm ~ -3mm

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Flange dimensionsa. The tolerance of flange dimension shall be compliance with ASME B 16.5. Pump Installation Checks Pre-installation checks are as follows, 1. Correct seal and all the parts needed for the replacement. 2.  Refer to the pump drawing to hand with installation dimensions or the seal manufacturer’s drawing. 3. The pump stuffing box is clean. 4. On split casing pumps the gasket does not extend into the stuffing box. 5. The shaft is free of scratches and burrs, threads are taped and keyways are filled flush with the shaft surface to prevent seal elastomers from being cut on the keyway edge (a dummy wooden key insert is ideal). 6. All the seal parts are in their protective coatings at this stage. Pump Checks ● Shaft Run-out: Shafts get bent. The spinning impeller has unequal loading on in causing the shaft to deflect away from the volute throat. Constant deflection causes weakness and can lead to a permanent offset of the shaft leading to shaft run out. Shaft run out is bad for seals. It causes them to flex twice on every revolution of the shaft. At high enough speeds this can cause a vibration in the seal which allows the seal faces to OPEN.

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So, look into the dark recesses of your lockers and pull out the Dial Test Indicator (DTI) or Clock Gauge that lurks there, unloved & unused and check the shaft of your pump for any damaging shaft deflections. Single stage overhung pumps should be checked near the seal running position but multi stage pumps should be checked at suitable intervals along the shaft as well as at the seal running position.

The run out should not exceed 0.002 inches or 0.05 mm. ● Shaft Sleeve Concentricity: Check the shaft for run-out and because the seal elastomer has a tendency to wear a fret ring on the shaft a shaft sleeve is fitted to protect the shaft. When a new shaft sleeve is fitted and this should be with every new seal, it is a good idea to re-run the shaft run-out check to ensure that the sleeve is concentric with the shaft.

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The run out should not exceed 0.002 inches or 0.05 m. Axial Shaft Movement: Set up your DTI to measure the amount of axial movement of the shaft. The amount will vary according to the type of pump, its bearing configuration and the type of thrust bearing in use. Essentially there are four types of thrust bearings •• Deep groove ball bearings. •• Roller bearings. •• Thrust pad bearings, usually made of white metal bearing surfaces. •• Balance piston thrust absorbing arrangement. This type is often found on high pressure multi-stage water pumps where the hydraulic forces are partially balanced by the impellers and controlled leakage past a balance piston provides the final stage of rotating unit positioning. The basic principle is that the shaft should be set to its running position before attempting to fit the seal.  In the case of cartridge seals, the seal cover plate should be fixed to the pump casing, the shaft positioned and then the seal locking screws tightened to the shaft.  Non cartridge types need to have a datum mark scribed onto the shaft relative to the seal plate position and then the fitting dimension marked from this point. A note about fitting position - It is not good practice to fit a new seal by looking at the old set-screw marks and then lining up on them.  If you want good seal performance then start out right; measure the distance required, don’t take short cuts. The last

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seal could have been fitted incorrectly, perhaps causing the rebuild that is now necessary. Seal Housing Square-ness - The seal stationary must be fitted at 90 degrees to the axis of the shaft.  Failing to achieve this will cause the seal head to move to take up any misalignment.  This movement offers an opportunity for the seal faces to open and for the ingress of dirt particles.  If you are changing out packing and up-grading your equipment to a mechanical seal you need to pay close attention to setting the seal housing closing plate in the correct position.  The basic check is as shown in the diagram.

It is also wise to check the bore of the seal housing at this point for concentricity with the shaft.  Put the sensing tip of the Dial Indicator inside the bore on the wall of the seal housing and rotate the shaft.  A small amount of misalignment is permitted but the important thing is to check that the seal body cannot touch the seal housing wall at any point of its rotation.

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General Checks While the pump unit is in the shop for maintenance take the opportunity to ensure that the cooling water jacket is clear of debris, that any other cooling water arrangement is cleared of any obstruction.  Orifice plates controlling the flow of water to a seal housing should be checked dimensionally correct.  A seal starved of its ration of cooling water will be very unforgiving and cause you lots of grief in a short time. This kind of fault is very difficult to diagnose for the average engineer. Even the best have trouble with this one, too!  So check it out now while the doing is easy. Bearings need to be replaced if they have been running with any pump leakage around. Moisture ingress into a bearing dramatically reduces a bearing’s useful life. If you are changing out soft packing for a mechanical seal replace the bearings on the unit too.  The leakage from the packing gland is more than enough to damage the bearings. Check the impeller for cavitation damage indicating a system problem that might go un-noticed during normal running conditions. Cavitation can cause vibration in the pump shaft which will affect the seal’s performance.

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Supplier Quality Assessment Checklist for Pumps - Centrifugal PEC-QU-FRM-X-11407 Rev 0

PROJECT NO:

SPECIFICATIONS/ CODES/STANDARDS

INSPECTION CATEGORY

A Pre-Inspection Meeting, SCA, Audits, Stage Wise Inspections, Hold / Witness, Final Inspection INSPECTION ACTIONS:

1 Physical Inspection / Verification 2  Verify Document Status 3 Review / Endorse test reports & certificates No

1

2 3 4 5 6

QC Inspection Activities Pre-Inspection Meeting Specification/Data Sheets Drawings QCP/ITP Welding Procedure Specification Welder Qualification Record

A 1 2 3

Comments

Inspector Remarks

Country of origin, language requirements, service after sales, special tools, spare parts

O

O O O

Verify approval Verify record

O

Verify approval

O

Verify record

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No 7 8 9

QC Inspection Activities

A 1 2 3

Welding Repair Procedures NDE Procedure Specification NDE Personnel Qualification Records

10 Material Certification

Comments

O

Verify approval

O

Verify approval

O

Verify record

O

Review, Stamp & Endorse

Inspector Remarks

Material Verification/ 11 Traceability for all the O components below 12 Components/Parts Inspection (Visual/ 13 Dimensional): 14 Casing, Cover 15 Impellers

O

O

O

O

O O

Shaft, Mechanical 16 seals & bearings

O

Impeller Ring, Casing 17 Ring, Wearing rings/ clearances

O

18 Boltings

O

19 Couplings, Coupling Guard 20 Drivers (motors) 21 Accumulator

O O O

(with ASME stamping data )

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No 22 23 24 25 26 27 28 29 30 31 32 33

34

A Comments 1 2 3 Pressure Relief Valves O Pipes & Tubing (Flushing/Seal system, O Drain) Positive Material O O Identification Fabrication & O Assembly Inspection: Base plate for Flatness, O Straightness Visual/dimensional of O assembly Welding Inspection O Non-Destructive Examination (Casting, O O Forging, pressure piping welds) Piping & Tubing O Inspection Lubrication System and Drain system O Inspection Cooling System O Inspection Heat Treatment Certificate & Heat For major repair of O Treatment Chart for casing Castings/Casing Instrumentation items (Temperature, O Verify ATEX Pressure, Vibration, Positioner probes) QC Inspection Activities

Inspector Remarks

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QC Inspection Activities 35 Testing: 36 Test procedures

A 1 2 3

37

Hydrostatic test

O

38

NPSH test

O

39

Performance/ running test

O

40

Test reports/test certificates

No

O

O

42 Cleaning/Drying

O

Pickling and passivation in case of 43 O stainless steel overlay/ seal system welds 44

Painting/Protective Coating

O

46 Project Tagging

O

Final Inspection with photographic survey

48

Supplier Certificate of Compliance

49

Accessibility check and operability check

Including Noise level, vibration O measurement, Complete unit test as applicable As required by P.O./ codes/specs Strip test & retest on seal leakage as applicable

O

O

45 Nameplates 47

Inspector Remarks

Verify approval

OO

41 Post-Test Inspection

Comments

Rubbing/Photograph

O O

Certified to NACE MR01-75 (if required)

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QC Inspection Activities

No 50

Preservation checks (Piping etc.)

A 1 2 3 O

Manufacturing Record 51 Book including all subsupplier’s components 52

Preparation for Shipment

53 IRN

Comments

Inspector Remarks

O OO Spare parts requirements, as applicable

O O

NOTE: The activities and corresponding inspection listed on this guide are the minimum requirement by Petrofac. The assigned Inspector should comply with and follow the approved QCP / ITP’s, Project Specifications. Tick the activity inspected / verified and sign below with details. Sign & Date:.......................................................................... Vendor & Location:................................................................ Name of Inspector:................................................................ P.O #:..................................................................................... Remarks : ............................................................................. Origin

Distribution

Audit / SCA

Corporate

Vendor verification Group / Project Engineer / PMI

Corporate & Projects

Resident Inspector / Third Party Inspector

Projects

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Supplier Quality Assessment Checklist for Pumps - Positive Displacement PEC-QU-FRM-X-11408 Rev 0

PROJECT NO:

SPECIFICATIONS/ CODES/STANDARDS

INSPECTION CATEGORY

A Pre-Inspection Meeting, SCA, Audits, Stage Wise Inspections, Hold / Witness, Final Inspection INSPECTION ACTIONS:

1 Physical Inspection / Verification 2  Verify Document Status 3 Review / Endorse test reports & certificates No.

QC Inspection Activities

Pre-Inspection 1 Meeting

2 3 4 5 6

Specification/Data Sheets Drawings QCP/ITP Manufacturing Sequence procedure and flow diagram Welding Procedures Specification

A 1 2 3

Comments

Inspector Remarks

Country of origin, language requirements, service after sales, special tools, spare parts

O

O O O

Verify approval Verify record

O

Verify approval

O

Verify approval

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No. 7

QC Inspection Activities Welder Qualification Record

Welding Repair Procedures 9 NDE Procedures 8

A 1 2 3

Comments

O

Verify record and List of Welder personnel for applied for the job

O

Verify approval

Inspector Remarks

O

Verify approval Verify record and List O of NDE personnel for applied for the job Review, Stamp & Material Certification OO Endorse Verify against Bill of Materials in all Material Verification / O drawing (Mechanical, Traceability Instrumentation, Electrical) Components/Parts Inspection: Casing/cylinder O Rotor and Shaft O Piston and Piston Rod O Bearings/seals O Fittings & flanges O Valves & seats O Verify ATEX Drivers O certification, Routine and Type certificates Couplings O Base plate and drain valves

NDE Personnel 10 Qualification Record 11

12

13 14 15 16 17 18 19 20 21 22

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No.

QC Inspection Activities

23 Packing and liners

A 1 2 3 O

Instrumentation (control valve, tubing, TT,PDT,PT, PSV, 24 O Pressure Gauges, Flow Indicators and solenoid valves etc.) 25 26 27 28 29 30 31

Lubrication System Inspection Auxiliary Piping Inspection Welding Inspection Non-Destructive Examination: 100% RT welds in pressure piping Testing: Test procedures

Comments

Inspector Remarks

O

O O O O O O

Verify approval For casing in sour or cold service

32 Hardness/ charpy test O Hydrostatic test/NPSH O test Mechanical running 34 O test 33

35 Performance Test 36

Test reports/test certificates

O

Noise level, Vibration etc., O

Strip test as necessitated

O

As required by P.O./ codes/specs

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No.

37

38 39 40 41

QC Inspection Activities

A 1 2 3

Dimensional Inspection (for base plate flatness, distortion and lifting O points) specifically at mating ends/interface site hook ups. Drying/Cleaning O Pickling and passivation (of all O welds) Painting/Protective O Coating Project Tagging O

42 Final Inspection

O

Certificate of Compliance Photographic surveillance of complete equipment 44 for all parts and as whole assembly (before insulation and packing) Manufacturing Record 45 Books 43

Preparation for Shipment

Inspector Remarks

O

Verify record for passivity

Verify as per PID, GA drawing Certified to NACE MROO 01-75 (if required)

O

O Verify material and workmanship

46 Insulation 47

Comments

O

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No.

A 1 2 3

QC Inspection Activities

Photographic survey 48 after shipment preparation 49 Preservation check 50 IRN

O O

Spare parts (Capital spares such as rotors, piston and 51 O commissioning spares including gaskets, Bolts, etc.)

Comments

Inspector Remarks

O O Verify records, O Dimensional check, Interchangeability

NOTE: The activities and corresponding inspection listed on this guide are the minimum requirement by Petrofac. The assigned Inspector should comply with and follow the approved QCP / ITP’s, Project Specifications. Tick the activity inspected / verified and sign below with details. Sign & Date:.......................................................................... Vendor & Location:................................................................ Name of Inspector:................................................................ P.O #:..................................................................................... Remarks : ............................................................................. Origin

Distribution

Audit / SCA

Corporate

Vendor verification Group / Project Engineer / PMI

Corporate & Projects

Resident Inspector / Third Party Inspector

Projects

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Centrifugal Compressors Centrifugal Gas Compressor The compressor skid includes the centrifugal compressor mounted on a structural steel matching base that, when bolted to the driver skid, forms a continuous base plate on which all the required subsystems are installed. The skid is complete and includes all the necessary accessories, auxiliary and control systems for functional operation. Gas Compressors Gas compressors are typically designed to achieve a minimum of three years of continuous full-load duty between inspections and major components are designed for 20 years of continuous operation. Many features commonly used in compressor designs conform to API 617. Standard features include: •• Vertically split barrel-type construction. •• Tilt-pad journal bearings. •• Self-aligning tilt-pad thrust bearings. •• Rigid modular rotor construction. •• Rotor trim balancing. •• Overcompensating balance piston. •• Radial vibration measurement. •• Thrust bearing temperature sensors.

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Impellers Compressor impellers are designed to conservative stress levels. All impellers are suitable for sour gas. applications. Each impeller, after machining, is proof tested to 115% of its maximum mechanical speed. Rotor Assembly The rotor assembly consists of stub shafts, impellers, a center bolt and, if required, rotor spacers to maintain a constant bearing span. These components are individually balanced and are rabbet-fit to each other for concentric alignment. Torque is transmitted through dowel pins. The entire assembly is clamped together with the center bolt. Impellers that can be used in a “restaged” rotor are easily salvaged and downtime can be minimized. Reusing old impellers, instead of purchasing new ones to match new operating conditions, enhances the economic feasibility of restaging to maintain optimum compressor performance and the lowest possible operating costs. Casings The pressure-containing outer casing of a gas compressor is an assembly of three major components: the suction and discharge end caps, which contain the bearing and seal assemblies and the center body, which holds the rotor and stator assemblies. This is considered a vertically split “barrel” design. The end caps contain all the service ports for oil and gas supply and discharge.

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Lube Oil System The gas turbine and gas compressor can have a common lube oil system if they are from the same manufacturer. Dry Seal System The dry seal system consists of the seal gas and separation gas systems. The seal system maintains a barrier between the process gas and the compressor bearings. The separation gas system maintains a barrier between the compressor bearing lube oil and the dry gas seals. Seal Gas System The seal gas system consists of a primary and secondary gas face seal to prevent the escape of process gas from each shaft end. The primary dry seal takes the full pressure drop. It is used to provide the main sealing function. The secondary or backup seal acts as an emergency barrier between the process gas and the atmosphere and operates at a zero pressure differential. Typical seal gas supply flow is 1.34 to 3.35 Nm3/min (50 to 125 scfm) at 689 kPag (100 psig) above maximum suction pressure, depending on the compressor model and suction pressure. The seal gas flow rates are metered by maintaining a constant pressure drop across a flow-limiting orifice in each seal gas supply line to each compressor seal capsule. Differential pressure switches provide low flow alarm and shutdown functions. The seal gas supply flow is higher than the primary seal leakage. The majority of the seal gas flow travels past the compressor shaft labyrinth seals and into the compressor case. This ensures

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the dry seal cavity is flushed with clean dry gas and that the dry seal operates in a clean environment. The on skid duplex seal gas coalescing filters are designed for typical clean transmission pipeline conditions. If larger particle or liquid loads are expected, a larger off-skid filtration system with a high pressure external seal gas supply is recommended. Leakage past the primary dry seals is measured by monitoring the pressure drop across an orifice run. Pressure switches provide high leakage flow alarms and shutdowns. Primary and secondary seal vent lines must be vented by the customer to a safe location. Dry Gas Seal System Pressure Rating - The seal gas system will be designed to a maximum pressure of 1500 psig at 250°F. External Seal Gas Source for Dry Seal System - Customers provide an acceptable external seal gas source. A driven skid service connection is provided for the supply of dry, clean, sweet seal gas from an external source. This supply is required during all phases of compressor pressurization and/or lube oil pump operation, including pre and post lubricating oil systems. This feature includes an on skid seal gas shutoff valve and associated control components. Seal gas flow rates and supply pressure requirements are generally listed in the manufacturer. Service connection for buffer air for the outboard air seals will also be provided in the skid. The nominal flow rate is 0.134 Nm3/min (5 scfm) per compressor and this air supply must be maintained during all phases of compressor pressurization, dry seal vent pressurization and/or lube pump operation.

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Separation Gas System A circumferential buffer air or nitrogen circumferential-segmented split-ring type seal provides a barrier between the compressor bearing lube oil and the dry gas seals. It is the most outboard component of the complete seal assembly. Air flows between the seal rings and the compressor stub shaft. Separation gas flowing past the outboard seal mixes with lubricating oil and drains to the lube oil reservoir. Air flowing past the inboard seal is vented through the secondary seal gas/buffer air vent. The separation gas source may be clean dry shop air, instrument air or nitrogen and must be supplied by the customer. The system includes a hand valve for maintenance, a coalescing filter, a differential pressure regulator and pressure switches and gauges to monitor the separation gas differential pressure. The system forms a positive separation between the lube oil and the dry seal. Flame arrestors are supplied for the primary and secondary vents. Leakage seal gas and separation gas must be piped away by the customer to selected safe areas. Hydrostatic Testing Hydrostatic pressure testing of all compressor casings and end caps is done per API 617 for 30 minutes at 1.5 times the maximum casing design pressure, regardless of application. Test water is treated with a wetting agent to allow better penetration of possible casing defects. After the hydro and final magnetic particle test, the casing is steam cleaned and bead blasted for surface preparation. Afterwards, it is sent for painting.

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Shaft Coupling Typically the shaft interconnect is by dry coupling. Bearings Journal bearings - The journal bearings are of the tilting pad type with forced lubrication. Pressurized oil flows in the bearings radially and passes through holes to lubricate pads and blocks. It is then laterally discharged. Bearings pads are made of steel, internally lined with white metal. The pads can swing inside the shell to enable maximum damping of radial vibration of the rotor. Thrust bearing - The thrust bearing, assembled on the bearings support (suction side), is a double acting self-equalizing tilting pad type. It is designed to absorb the residual axial thrust operating on the rotor that is not completely balanced by the balance drum. The standard design allows installing either flooded or directed oil lubrication bearing. Preliminary Alignment The whole drive train is aligned preliminarily at the factory to simplify final field alignment. Start System The start system provides torque to initiate engine rotation and to assist the engine to reach a self-sustaining speed. The start system consists of a direct-drive AC starter motor driven by a solid-state variable frequency drive (VFD). Direct-Drive AC Start System: The direct-drive AC (DAC) start system consists of a squirrel cage, three-phase, AC-induction

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motor with a solid state variable frequency drive (VFD). The starter motor is mounted directly on the gas turbine accessory drive gearbox. The VFD regulates voltage and frequency to the starter motor for engine rotation as commanded by the control system. Functional Description: To begin gas turbine rotation, the VFD initially provides low-frequency AC power to the starter motor. The VFD gradually increases the speed of the starter motor until the gas turbine reaches purging speed. When purging is completed, the control system activates the fuel system. The speed of the starter motor is gradually increased until the gas turbine reaches starter dropout speed. The VFD then de-energizes the starter motor and the motor clutch assembly is disengaged. Starter Motor: The starter motor provides high breakaway starting torque and acceleration from standstill to starter dropout speed. The motor is a standard frame size and is constructed to be explosion proof and flameproof. The motor includes an integral over-temperature protection thermostat connected to the control system for hazardous area motor certification and protection. Separate cable/conduit entry points are provided for power connections, thermal protection wiring and the space heater wiring. Starting power is transferred to the gas turbine via the reduction-drive gearbox and over-running clutch and shaft assembly. Variable Frequency Drive (VFD): The VFD is a motor speed controller that provides pulse-width modulated power with variable frequency and voltage to the starter motor. Controlled by the control system, the VFD regulates voltage and frequency to

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the starter motor to control engine speed from standstill to starter dropout speed. The system is capable of performing up to six start attempts per hour, as well as extended purge cycles for heat recovery unit applications and engine wash cycles. The VFD cabinet is designed for installation in a non-hazardous location. Power Wiring: The start system, requires customer-furnished, three-phase AC input. Additional three-phase AC power wiring is required to connect the VFD to the starter motor. A start contactor is not required for VFD operation. Fuel System The fuel system, in conjunction with the control system, includes all necessary components to control ignition and fuel flow during all modes of operation. Conventional Combustion System - Conventional combustion system use fuel injectors equally spaced around the combustor to inject fuel into the combustion chamber. The fuel injected into the combustion chamber is controlled during starting and steady state operation to maintain stable combustion. The fuel system includes, •• Supply pressure transmitter. •• Pilot air operated primary gas fuel shutoff valve. •• Pilot air operated secondary gas fuel shutoff valve. •• Pilot air operated gas vent valve. •• Electrically operated fuel control valve.

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Torch with shutoff valve and pressure regulators •• Main fuel manifold. •• Fuel injectors. Operation of Fuel system The gas fuel pressure supplied to the turbine skid must meet minimum and maximum pressure and flow requirements. If the gas fuel pressure is too high or too low, the control system will prevent turbine operation. Pneumatically actuated primary and secondary gas fuel shutoff valves are controlled using pilot air pressure. For each valve, pilot air pressure is admitted to and exhausted from a pneumatic actuator through a solenoid valve. Fail-safe operation ensures both valves will close in case pilot air pressure is lost. The gas fuel control valve is powered by integrated DC motor-driven actuators. Integrated actuator electronics provide precise, closed-loop valve control based on position command inputs versus position feedback outputs. Both valves are fast acting and provide fuel metering for light-off, acceleration, full load and load transient conditions. Fail-safe operation ensures both valves will close in case the command signal or control power is lost. During the start sequence prior to ignition, the control system will verify gas pressure and perform a gas valve check to ensure proper operation of all gas fuel valves. The gas fuel control valve material will be aluminum. Lubrication System The lubrication system circulates oil under pressure to the gas turbine and driven equipment. Lube oil is supplied from the lube oil tank located in the driver skid.

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The lubrication system incorporates the following components, •• Oil tank. •• •• •• •• •• •• •• •• ••

Oil tank heater. Lube oil (customer furnished). Gas turbine driven main lube oil pump. AC Motor-driven pre/post lube oil pump. DC Motor-driven backup lube oil pump. VDC Step starter. Duplex lube oil filter system with replaceable elements. Oil level, pressure and temperature indications. Pressure and temperature regulators.

•• Strainers. •• Oil tank vent separator. •• Oil tank vent flame trap. •• Carbon Steel oil tank and tank covers. •• Carbon Steel filter system. Gas Turbine-Driven Main Lube Oil Pump: The main lube oil pump is mounted on an integral accessory drive gearbox. This positive-displacement pump provides lube oil pressure for normal operation. DC Motor-Driven Backup Lube Oil Pump: The backup lube oil pump provides lube oil pressure for post lube cooling of the gas turbine and driven equipment bearings in the event the pre/ post lube oil pump fails. It provides lube oil pressure during a gas turbine roll down in the event the main lube oil pump and pre/post

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lube oil pump have both failed. The backup lube oil pump also provides lube oil pressure during an emergency condition such as a fire, control system failure, emergency stop or if a turbine over speed is detected by the backup system. Duplex Lube Oil Filter System: The Carbon Steel duplex lube oil filter system is supplied with a filter transfer valve and filter differential pressure indication with alarm. The transfer valve allows a filter transfer to be performed while the gas turbine is running. The lube oil filter system is contained completely within the driver skid. Unless specifically referenced in this proposal, the interconnect piping between the skid edge and the off-skid oil cooler is not provided. Lube Oil Vent Coalescer: An off-skid lube oil vent coalescer is provided to remove oil vapor from the lube oil tank vent airflow. The coalesce drains trapped oil vapor back to the lube oil tank and allows the remaining vent airflow to exhaust to the atmosphere. A tank overpressure alarm and shutdown are also included. Unless specifically referenced in this proposal, the lube oil vent coalescer is loose shipped for off-skid installation by others. Lube Oil Vent Flame Arrestor: The lube oil vent flame arrestor prevents an ignition source from entering the lube oil tank. Unless specifically referenced in this proposal, the flame arrestor is loose shipped for off-skid installation by others. Lube Oil Cooler: Lube oil coolers are provided for the exchange of thermal heat carried by lube oil. Lube Oil Immersion Tank Heater: The lube oil tank immersion heater ensures the lube oil tank temperature is adequate for

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starting in cold conditions. The tank heater also facilitates a short lube oil temperature warm up period after a cold start. Unless specifically referenced in this proposal, electrical supply contactors are not included. Control and Monitoring Compressor flow control is included in the unit control system to regulate turbine power to maintain a preset flow. For suction flow control, control logic for local and remote, single-unit, setpoint adjustment, flow element sizing (for user-supplied element) and loose-shipped suction pressure and flow transmitters are included for installation by purchaser. Purchaser-supplied pressure sensing line must be connected at a distance of at least 5 ±1 pipe diameters upstream of the compressor suction and downstream of the suction inlet screen or other flow resistances, with provisions to ensure no liquids get trapped in the lines. The user-supplied flow element must be separate from any other flow control element, such as surge control and be located outside the recycle control loop. For discharge flow control, control logic for local and remote, single-unit, set-point adjustment, flow element sizing (for user-supplied element) and loose-shipped discharge pressure and flow transmitters are included for installation by purchaser. Purchaser-supplied pressure sensing lines must be connected at a distance of at least 5 ±1 pipe diameters downstream of the compressor discharge and upstream of the discharge scrubber, coolers or other flow resistances, with provisions to ensure no liquids get trapped in the lines. The user-supplied flow element must be separate from any other flow control element, such as surge control and be located outside the recycle control loop.

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Gas Compressor Surge Detection System The integral surge detection system detects gas compressor discharge pressure pulsations and will alarm and if necessary initiate a gas turbine shutdown if pulsations exceed a preset value within a predetermined time period. Anti-Surge Control Surge at a given gas compressor speed is caused by excessive head across the gas compressor (isentropic head) for a given suction flow rate. Therefore, surge in the gas compressor may be controlled by decreasing the head across the gas compressor and/or by increasing the flow rate of the gas to the suction side of the gas compressor. The anti-surge control system prevents surge by modulating a surge control (bypass) valve to lower head and increase suction flow. A typical system consists of pressure and temperature transmitters on the gas compressor suction and discharge lines, a flow differential pressure transmitter across the suction flow meter, an algorithm in the control system and a surge control valve with corresponding accessories to keep the gas compressor from going into surge. Fast stop valves are also included to protect the compressor in the event of a sudden turbine shutdown. Anti-Surge Recycle Valve: A complete and functionally tested assembly will be provided, shipped separately for field installation by others. The assembly includes the valve and the following features, •• Spring-return, diaphragm-type, pneumatic actuator

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•• Position transmitter with valve fully open and fully close relay outputs. •• Pressure regulator. •• solenoid valve. •• Electro-pneumatic valve positioner. •• actuator pressure port. •• Carbon steel body. Successful operation of the anti-surge control system is dependent on correct valve selection. The following anti-surge recycle valve has been selected based on the application data available at the time of this proposal. Anti-surge valves are provided with approximately 100% overcapacity (2 x surge flow at the same head). If this overcapacity is insufficient to ensure surge avoidance during a shutdown, additional valves (hot bypass) may be required. This valve is sized for optimum controllability during normal operation and can handle a maximum discharge volume to avoid compressor surge during a fast stop shutdown. If the actual discharge system volume exceeds this value, an additional valve will be required. The discharge system volume is defined as the pipe volume bounded by the compressor discharge flange, the discharge check valve (if installed), the anti-surge and vent valves: and also the gas cooler volume (if installed). Globe style valves are typically not provided with noise attenuating trims for surge control service as they are susceptible to clogging. If recycle is anticipated as part of normal operation and noise limitation is necessary, we recommend an additional capacity control valve.

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The proposed valve will not ensure 3 MW, expander/generator set and steam turbine generator sets) .For identical units in the same service, only one part load string test is required. Performance and Mechanical Run Test-Aerodynamic performance is proven through open or closed-loop testing to confirm achievement of the contract efficiency, head and flow of the compressor at specified design and operating points. Full-load and full pressure is done to comply with Type 1 and Type 2 testing to ASME PTC 10 standards. The finished unit receives a final mechanical running test that includes a check of oil flows and vibration levels throughout the specified speed range. A static gas seal test confirms that all components will satisfactorily contain gas at the system’s rated pressure. After the mechanical running test, the following shall be inspected. •• The bearings, •• Hydraulic and mechanical seals (if installed during the test) •• Couplings (it is preferred that contract couplings be used.) If any modifications are required in order to improve mechanical operation, the initial test is not acceptable and shall be repeated. The spare rotor shall also be tested. It is preferred that a functional test be done after the successful completion of the mechanical running test. For packaged units this can be done at the vendor’s shop. This shall include the following •• The anti-surge and control systems

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•• Flanged joints shall be inspected for leaks •• Hydraulic seal performance shall be checked •• Vibrations levels shall be recorded Axial Compressor

Overview of Axial Centrifugal Compressor

The gas in an axial compressor flows in an axial direction through a series of rotating (rotor) blades and stationary (stator) vanes that are concentric with the axis of rotation. Unlike a turbine, which also employs rotor blades and stator vanes the flow path of an axial compressor decreases in cross-sectional area in the direction of flow. This reduces the volume of air as compression progresses from stage to stage.

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Upon entering the first set of rotating blades, the air, which is flowing in a general axial direction is deflected in the direction of rotation. The air is arrested and turned as it is passed on to a set of stator vanes. Following that it is picked up by another set of rotating blades and soon through the compressor. Air pressure increases each time it passes through a set of rotors and stators. The rotor blades increase the air velocity. When air velocity increases, the ram pressure of air passing through a rotor stage also increases. This increase in velocity and pressure is somewhat but not entirely nullified by diffusion. When air is forced past the thick sections of the rotor blades static pressure also increases. The larger area at the rear of the blades (due to its airfoil shape) acts as a diffuser. In the stators velocity decreases while static pressure increases. As air velocity decreases, the pressure due to velocity or ram that has just been gained in Passing through preceding rotor stage decreases somewhat; however, the total pressure is the sum of static pressure and pressure due to ram. Successive increases and decreases in velocity as air leaves the compressor are usually only slightly greater than the velocity of the air at the entrance to the compressor. As the pressure is built up by successive sets of rotors and stators, less and less volume is required. Thus, the volume within the compressor is gradually decreased. At the exit of the compressor, a diffuser section adds the final stage to the compression process by again decreasing velocity and increasing static pressure just before the air enters the engine burner section. Normally, the temperature change caused by diffusion is not significant by itself. The temperature rise which causes air to get

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hotter and hotter as it continues through the compressor, is the result of the work being done on the air by the compressor rotors. Heating of the air occurs because of the compression process and because some of the mechanical energy of the rotor is converted to heat energy. Because airflow in an axial compressor is generally diffusing it is very unstable. High efficiency is maintained only at very small rates of diffusion. Compared to a turbine, quite a number of compressor stages are needed to keep the diffusion rate small through each individual stage. Also, the permissible turning angles of the blades are considerably smaller than those which can be used in turbines. These are the reasons why an axial compressor must have many more stages than the turbine which drives it. In addition, more blades and consequently more stages are needed because the compressor, in contrast to a turbine, is endeavoring to push air in a direction that it does not want to go in. Axial-flow compressor casings not only support stator vanes and provide the outer wall of the axial paths the air follows but also provide the means for extracting compressor air for various purposes. The stator and compressor cases show great differences in design and construction. Some compressor cases have variable stator vanes as an additional feature. Others compressor cases have fixed stators. Stator vanes may be either solid or hollow and mayor may not be connected at their tips by a shroud. The shroud serves two purposes. It provides support for the longer stator vanes located in the forward stages of the compressor and it provides the absolutely necessary air seal between rotating and stationary parts. Some manufacturers

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use split compressor cases while others favor a weldment, which forms a continuous case. The advantage of the split case is that the compressor and stator blades are readily available for inspection or maintenance. On the other hand the continuous case offers simplicity and strength since it requires no vertical or horizontal parting surface. Both the case and the rotor are very highly stressed parts. Since the compressor turns at very high speeds the discs must be able to withstand very high centrifugal forces. In addition the blades must resist bending loads and high temperatures. When the compressor is constructed each stage is balanced as a unit. The compressor case in most instances is one of the principal structural, load-bearing members of the engine. It may be constructed of aluminum steel or magnesium. Clearances between rotor blades and the outer case are very important to maintain high efficiency. Because of this, some manufacturers use a “wear fit” design between the blade and outer case. Some companies design blades with knife-edge tips that wear away to form their own clearances as they expand from the heat generated by air compression. Other companies coat the inner surface of the compressor case with a soft material (Teflon) that can be worn away without damaging the blade. Rotor discs that are joined together by tie bolts use serration splines or curve coupling teeth to prevent the discs from turning in relation to each other. Another method of joining rotor discs is at their rims. Axial-flow compressors have the following advantages, •• High peak efficiency.

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•• Small frontal area forgiven airflow. •• Straight-through flow, allowing high ram efficiency. •• Increased pressure rise due to increased number of stages with negligible losses. •• They have the following disadvantages: •• Good efficiency over narrow rotational speed range. •• Difficulty of manufacture and high cost. •• Relatively high weight. •• High starting power requirements (this has been partially overcome by split compressors). Reciprocating compressor has advantages below compare to other compressor type. •• Simple structure. •• Flexibility in wide range of application. •• Applicable for any composition of gases because of positive displacement type. •• Possible to discharge high pressure at a comparatively low mass flow rates. •• Easy and instantaneously capacity control. •• High efficiency at part or full load operation. Centrifugal compressors have the following advantages, •• High pressure rise per stage. •• Efficiency over wide rotational speed range. •• Simplicity of manufacture with resulting low cost. •• Low weight. •• Low starting power requirements.

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Dry Gas Seals Dry Gas Seals are also called Mechanical gas “no-contact”, “clearance self-adjusting” seals use process gas as working fluid. Each seal consists of a cylindrical cartridge which, during operation, has pressurized process gas at one end and atmospheric pressure at the other end. Inside there are two disks, a rotating one (made of tungsten carbides) integral with the shaft and a static one (made of graphite) integral with the casing, which has the possibility of axial floating. In static conditions, the seal is made by the contact between the even and lapped surfaces of the two disks which are kept pressed one against the other by a series of springs located behind the stator disk. This seal system does not use any circulating seal oil. Dry seals operate mechanically under the opposing force created by hydrodynamic grooves and static pressure. The dry gas seal system is essentially composed of five parts, •• Seal cartridges - usually supplied in tandem arrangement to provide emergency back-up of secondary seal ring. •• Buffer gas system - supplied filtered gas to the dry gas seal cartridge. The gas is usually taken from the compressor discharger from an intermediate stage, filtered in a 5 micron twin filter and injected via a PDCV into the primary seal cartridge. The PDCV maintains the buffer gas set pressure few mbars above the balancing drum pressure. The system consists of a 5 micron twin filter, DPCV, DP transmitter & controller and gages. •• Primary vent - designed to monitor the condition of the primary seal element. The system checks the DP across the adjustable

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orifice which controls the leakage flow. •• Secondary vent - designed to collect both the gas mixture coming from the secondary seal and from Air/N2 injection system. The secondary vent is passed to the atmosphere in order to avoid any backpressure in the seal system. •• Air/N2 injection system - prevents oil migration to the dry gas seals. The system consists of a PCV, a filter, a pressure gauge & a switch. Hydrodynamic grooves are etched into the surface of the rotating ring affixed to the compressor shaft. When the compressor is not rotating, the stationary ring in the seal housing is pressed against the rotating ring by springs. When the compressor shaft rotates at high speed, compressed gas has only one pathway to leak down the shaft and that is between the rotating and stationary rings. This gas is pumped between the rings by grooves in the rotating ring.

Dry Gas Seal

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The opposing force of high-pressure gas pumped between the rings and springs trying to push the rings together creates a very thin gap between the rings through which little gas can leak. While the compressor is operating, the rings are not in contact with each other and therefore, do not wear or need lubrication. O-rings seal the stationary rings in the seal case. Putting two or more of these dry seals together in series is called “tandem dry seals,” and is very effective in reducing gas leakage. This type of seal has less than one percent of the leakage of a wet seal system vented into the atmosphere and costs considerably less to operate.

Dry Gas Seals in Tandem

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Dry Gas Seals in Tandem

At compressor startup, even at minimum speed, the microgrooves on one part of the even surface of the rotating element make the gas pressure in the area between the two disks increase, changing the balance among the axial forces present and moving away the two rings. Even though the movement is micrometric, it is therefore enough to prevent rubbing and wear. During the dynamic operation, the disks move near or away in order to match the process changes and, therefore, ensure stable seal conditions. During shut down, when rotating speed is reduced, the two disks return to the contact position, ensuring again the seal with the stopped machine. Oil seal bushings were utilized for main compressor seals for higher-pressure natural gas applications. These seals used oil supplied at a pressure higher than the compressor suction pressure to ensure the volatile gas did not leak to the atmosphere. Today, oil film seals are typically only used for revamp and repair activities. Nearly 100% of new compressors sold in the oil and gas industry feature dry gas seals.

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Dry gas seals substantially reduce hydrocarbon emissions. At the same time, they significantly reduce operating costs and enhance compressor efficiency. Economic and environmental benefits of dry seals include, •• Gas Leak Rates - During normal operation, dry seals leak at a rate of 0.5 to 3 scfm across each seal (1 to 6 scfm for a two seal system), depending on the size of the seal and operating pressure. While this is equivalent to a wet seal’s leakage rate at the seal face, wet seals generate additional emissions during degassing of the circulating oil. Gas from the oil is usually vented to the atmosphere, bringing the total leakage rate for dual wet seals to between 40 and 200scfm, depending on the size and pressure of the compressor. •• Mechanically Simpler - Dry seals systems do not require elaborate oil circulation components and treatment facilities. •• Reduced Power Consumption - Because dry seals have no accessory oil circulation pumps and systems,they avoid “parasitic” equipment power losses. Wetsystems require 50 to 100 kW per hour, while dry seal systems need about 5 kW to power per hour. •• Improved Reliability - The highest percentage of downtime for a compressor using wet seals is due to seal system problems. Dry seals have fewer ancillary components, which translates to higher overall reliability and less compressor downtime. •• Lower Maintenance - Dry seal systems have lower maintenance costs than wet seals because they do not have moving parts associated with oil circulation(e.g., pumps, control valves, relief valves).

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•• Elimination of Oil Leakage from Wet Seals - Substituting dry seals for wet seals eliminates seal oil leakage into the pipeline, thus avoiding contamination of the gas and degradation of the pipeline. Rotor Balancing With the high cost of replacing damaged rotors, the industry requires that parts or sections of rotors that are changed must maintain an acceptable balance. The technique involves using dummy adjacent parts, for example balancing a compressor module with a dummy turbine module and replacing compressor and turbine blades without any further balance. The latest production methods reduce or eliminate the need for balancing in low speed applications, but with ever increasing speeds used on rotating machinery, dynamic balancing will be necessary. Unbalance exists in a rotor when the mass centre axis is different to its running centre axis. Practically all newly machined parts are non-symmetrical due to blow holes in castings, uneven number and position of bolt holes, parts fitted off-centre, machined diameters eccentric to the bearing locations etc. An unbalanced rotor, when rotating, wants to revolve around its mass centre axis. Because the bearings restrict this movement, the centrifugal force, due to the unbalance, causes the rotor to vibrate. This vibration causes wear to the bearings, creates unnecessary noise and in extreme cases disintegration of the rotor itself can be experienced. It is therefore necessary to reduce the unbalance to an acceptable limit.

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The units of unbalance are mass times radius, for example: a weight added to a certain position on the part being balanced would shift the mass axis into the running axis and therefore be in balance. The weight of correction multiplied by the applied radius will give an unbalance unit. For metric measurement the units will be gram-millimetres (g-mm) or for large rotors, gramcentimetres. This weight (mass) would be applied at a radius from the running centre at the light position. Types of Unbalance: There are three types of unbalance, •• Static unbalance - is where the mass axis is displaced only parallel to the shaft axis. The unbalance is corrected only in one axial plane. •• Couple unbalance - is where the mass axis intersects the running axis. For example: a disk that has swash run-out with no static unbalance. The unbalance is usually corrected in two planes. •• Dynamic unbalance - is where the mass axis is not coincidental with the rotational axis. This unbalance is usually a combination of static and couple unbalance and is corrected in two planes. Balancing limits - There are balance limits, just like machining limits, where the unbalance is acceptable. International and national standards are quoted for rotors, for example:. electrical armatures are balanced to grade 2.5. The grades are converted to unbalance units, depending on the rotational speed of the rotor as per ISO 1940 standards. Types of rotors - Rotors fall into two groups. One is where the rotor is rigid and does not deflect up to and including the operating

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speed. The other group comprises flexible rotors that “bow” up to the operating speed. The first deflection seen is a “skipping rope effect” which means the centre of the rotor at speed moves out from its rotational axis, causing high “static” unbalance. Rotor Rigidity There are a number of classifications of rotors, depending on flexibility, operating speed and other factors (ISO 5243). Class 1 is rigid rotors - this covers 90% of application. Class 2 is rotors that are not rigid or that have special characteristics of mass distribution but that can be balanced using a modified balancing technique (choice of correction planes is the key here). Class 3 and 4 are flexible rotors. Note some motors need to be balanced at specific speeds, at two speeds or even when hot. Thermal effect can cause distortion that in turn causes unbalance, which can cause more distortion. Methods of Correcting Unbalance Removal of material by drilling, milling etc from the heavy position on the component is used to correct the unbalance. Alternatively it can be corrected by adding material to the “light” position on the component by bolting or welding balance weights to reduce unbalance. Balancing Machines To identify the position and amount of unbalance, balancing machines are used by a rotor manufacture to correct any

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unbalance that exists. These machines are so sensitive that they can easily and accurately identify any mass axis 0.001mm off the running axis. One type of machine will only identify static unbalance. This is used for balancing disk shaped parts. Another type of machine will identify unbalances in two axial planes, e.g. for balancing a rotors whose length is proportionally greater than its diameter. These machines are available in versions that balance the rotor in either the horizontal or vertical axis. With the use of modern electronics, accuracy easily exceeds national and international standards. The set-up of the machine is very simple by just typing measurements into a computer. Balancing rigid rotors: Because unbalance exists in a component even when stationary, rigid rotors can be balanced at a low speed, just enough to produce a centrifugal force to register the unbalance. Balancing flexible rotors: This type of rotor is balanced at a low speed where the rotor does not flex. Correction for unbalance is made, then the speed is gradually increased and the unbalance is corrected in stages until the rotor’s operating speed is reached. The conclusion is that API standard demands a low residual unbalance level and with a smaller unbalance force load on the rotor’s bearings. ISO 1940 provides the classification of vibration in terms of G codes, G2.5 is a tighter tolerance than G6.3. Tighter not necessarily better, G2.5 means a vibration velocity of 2.5 mm/s under specified conditions. Unfortunately, it is the theoretical

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value assuming the rotor was spinning in free space so it does not relate to actual operating conditions. ISO 1940 uses a set of criteria to classify the acceptable vibration grade – a low speed marine diesel has a coarse grade while a high speed grinding spindle has a very tight grade. The tightest grades require balancing a rotor in its own bearings and under service conditions.

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Supplier Quality Assessment Checklist for Compressors - Centrifugal PEC-QU-FRM-X-11400 Rev 0

PROJECT NO:

SPECIFICATIONS/ CODES/STANDARDS

INSPECTION CATEGORY

A Pre-Inspection Meeting, SCA, Audits, Stage Wise Inspections, Hold / Witness, Final Inspection INSPECTION ACTIONS:

1 Physical Inspection / Verification 2  Verify Document Status 3 Review / Endorse test reports & certificates No.

QC Inspection Activities

A 1 2 3

Specification/Data Sheets

Inspector Remarks

Country of origin, language requirements, service after sales, special tools, spare parts

1 Pre-Inspection Meeting O

2

Comments

O

3 Drawings

O

Verify approval

4 QCP / ITP

O

Verify record

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No.

QC Inspection Activities

A 1 2 3

Comments

5

Welding Procedure Specifications

O

Verify approval

6

Welder Qualification Record

O

Verify record

7

Welding Repair Procedures

O

Verify approval

8 NDE Procedures

O

Verify approval

NDE Personnel 9 Qualification Records

O

Verify record

10 Material Certification

OO

Review, Stamp & Endorse

11

Material Verification / traceability

12

Components/Parts Inspection:

Inspector Remarks

O O

13 Casing

O

14 Shaft & shaft sleeves

O

15 Impellers

O

Bearing & bearing 16 housing

O

17 Shaft sealing

O

Inter-stage diaphragm & 18 O inlet guide vanes 19 Balance drum & line

O

20 Couplings

O

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No.

QC Inspection Activities

A 1 2 3

Pressure Piping (Lubrication, Process)

O

Structural Steel (Base frame, Lifting lugs, 22 Spreader Bar/Lifting Beam etc.)

O

Instrumentation & controls (Heat 23 Tracing, TT, PDT, PT, JB, Cabling, Tubing, Manifolds etc.)

O

Bought out Electrical 24 Items (Motors, JB, Cables)

O

Bulk Piping (Pipe/ 25 Fittings, Flanges, Gaskets, Boling)

O

21

26

Spare Parts (Gaskets, Bolting, Seal etc.)

O

27

Balancing of Rotating Elements

O

28

Over speed test of impellers

O

29

Low speed balancing of rotor

O

30 Degaussing of Rotor

O

Comments

Inspector Remarks

Static & dynamic balancing of impellers,

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No.

QC Inspection Activities

31

Mechanical and Electrical Run out

32

Mechanical Seal balancing test

A 1 2 3

Comments

Inspector Remarks

O

Lube Oil & Seal Gas Systems including 33 piping, pump, skid O structural, motor, cooler, tank etc.) 34 Inspection of Assembly:

O

Base plate for flatness, 35 straightness, distortion, O lifting points 36

Visual & dimensional inspection

O

37 Welding Inspection:

O

Welding material 38 verification

O

39 Joint preparation/fit-up

O

40

Visual/dimensional weldments

O

41

Non-Destructive Examinations

O

O

100% RT butt welds on casings and pressure 42 piping, Fabricated O instrument items, Fabricated air coilers

O

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No.

QC Inspection Activities

A 1 2 3

100% MT attachment 43 weld & welds on cover O and pressure welds 100% UT in case of 44 forgings shafts, casing, O cover, nozzle, impellor 45 Testing:

Comments

Inspector Remarks

O

O

Test procedures & Testing for Mechanical, Performance, String Verify approval & test, Assembly test for Witness the testing 46 Gear Unit, UCP and OOO as necessitated in Valves (For Shutdown/ PO/ITP Anti-surge valves, Manual valves, Lube Oil unit etc.)) 47 Hydrostatic test

O

O

48 Mechanical running test O

O

Instrumentation & Electrical test 50 Gas leak test 49

O

O

O

O Per P.O./Project O specs ( as applicable) As required by P.O./ O codes/specs

51 Hardness test 52

Test reports/test certificates

53 Post-Test Inspection

Noise level, Vibration etc.,

O

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QC Inspection Activities

No.

Nameplate & Rotation Arrows Painting/Protective 55 Coating 56 Cleaning/ Drying 54

A 1 2 3 O

Inspector Remarks

Rubbing/Photograph

O

O

O

Pickling and passivation 57 in case of stainless O steel overlay/welds 58

Final Inspection across PID, Layout with O detailed photographic survey

59

Accessibility check and O operability check

60

Preservation check (Rotors, Piping etc.)

O

O

O

Supplier Certificate of 61 Compliance Manufacturing Record 62 Books including all subsupplier’s components

O O

Preparation for Shipment (Packing arrangement inside 63 O boxes to avoid damage during transit, with photographic evidence) 64 IRN

Comments

Spare parts requirements and testing as per PO / ITP O

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NOTE: The activities and corresponding inspection listed on this guide are the minimum requirement by Petrofac. The assigned Inspector should comply with and follow the approved QCP / ITP’s, Project Specifications. Tick the activity inspected / verified and sign below with details. Sign & Date:.......................................................................... Vendor & Location:................................................................ Name of Inspector:................................................................ P.O #:..................................................................................... Remarks : ............................................................................. Origin

Distribution

Audit / SCA

Corporate

Vendor verification Group / Project Engineer / PMI

Corporate & Projects

Resident Inspector / Third Party Inspector

Projects

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Supplier Quality Assessment Checklist for Compressors – Reciprocating PEC-QU-FRM-X-11401 Rev 0

PROJECT NO:

SPECIFICATIONS/ CODES/STANDARDS

INSPECTION CATEGORY

A Pre-Inspection Meeting, SCA, Audits, Stage Wise Inspections, Hold / Witness, Final Inspection INSPECTION ACTIONS:

1 Physical Inspection / Verification 2  Verify Document Status 3 Review / Endorse test reports & certificates No

QC Inspection Activities

Pre-Inspection 1 Meeting

2

Specification/Data Sheets

A 1 2 3

Comments Country of origin, language requirements, service after sales, special tools, spare parts

O

O

3 Drawings

O

Verify approval

4 QCP/ITP

O

Verify record

Manufacturing 5 Sequence procedure and flow diagram

Inspector Remarks

Verify approval

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No

QC Inspection Activities

A 1 2 3

Comments

6

Welding Procedure Specifications

O

Verify approval

7

Welder Qualification Record

O

Verify record and List of Welder personnel for applied for the job

O

Verify approval

O

Verify approval

O

Verify record and List of NDE personnel for applied for the job

OO

Review, Stamp & Endorse

Welding Repair Procedures 9 NDE Procedures 8

10

NDE Personnel Qualification Records

11 Material Certification 12 13 14 15 16

Material Verification/ traceability Components/Parts Inspection: Casing/frame Shaft & shaft sealing Seal housing

O

O O O

17 Air/Oil coolers

O

18 Cylinders/liners

O

19

Pistons/piston rods/ run out

Inspector Remarks

Verify the records (material, Welding, NDE) from Sub-contractor Cylinder pneumatic test

O

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No 20

QC Inspection Activities Bearing & bearing housing

A 1 2 3

Inspector Remarks

O

21 Gaskets

O

22 Driver

O

23

Auxiliary piping & O associated gas piping

24

Shop fit up test for pulsation bottles

Instrumentation & controls (Control 25 valve, tubing, manifolds, TT, PDT, PT etc.)

Comments

Verify ATEX certification, Routine and Type certificates Verify the records (material, Welding, NDE) from Sub-contractor

O

O

Verify the records (material, Welding, NDE) from Sub-contractor (including Code stamping)

26 Oil/Gas Filters

Other Electrical 27 accessories (JB, O Heaters, Cables etc.) 28 UCP

O

Verity Factory Acceptance testing as per test procedure

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No

QC Inspection Activities

29

Lubrication System Inspection

A 1 2 3

Comments

Inspector Remarks

O

Cooling water console 30 O skid 31 Lube Oil pumps

O

32 Lube Oil Piping

O

33

Inspection of Assembly:

34

Base plate for flatness, distortion, Spreader Bar/Lifting Beam, lifting points

35

Structural supports and Gratings

36

Visual & dimensional O inspection

Verify the records (material, Welding, NDE) from Sub-contractor

37 Welding Inspection:

O O

38

Welding material verification

O

39

Joint preparation/ fit-up

O

40

Visual/dimensional weldments

O

Non-Destructive 41 Examinations

Verify the records (material, Welding, NDE) from Sub-contractor

O

O

O

42 Testing:

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No

43

44 45 46 47 48 49 50 51

QC Inspection Activities

A 1 2 3

Comments

Inspector Remarks

Test procedures (for Mechanical, Performance test, UCP, Valves (For O Verify approval Shutdown valves, Manual valves), Lube Oil functional etc.) Hydrostatic test/ O O cylinders & jackets Bar over test to check O rod run out Mechanical running O O test If necessitated by Performance test O O client / PO Hardness test O (as applicable) Instrumentation test O O Other tests (including O O Per P.O./Project specs PMI) Test reports/test As required by P.O./ O certificates codes/specs

Dimensional check of mating parts for out of flatness, ovality 52 (after Heat treatment) specifically at mating ends/interface site hook ups. 53 Nameplate

O

O

Rubbing/photograph

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No

QC Inspection Activities

54

Painting/Protective Coating

A 1 2 3

Comments

O

Pickling and 55 passivation (of all welds)

O

Verify record for passivity

56 Final Inspection

O

Verify as per PID, GA drawing, Layout drawing

Photographic surveillance of complete equipment 57 for all parts and as whole assembly (before insulation and packing) 58

O

Certified NACE MRO O 01-75 (if required)

Certificate of Compliance

59 Insulation 60

Manufacturing Record Books

61

Preparation for Shipment

Inspector Remarks

O

Verify material and workmanship

O O

Photographic survey 62 after shipment O preparation 63 Preservation check

O

O

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No

QC Inspection Activities

A 1 2 3

Comments

Inspector Remarks

64 Release for Shipment O Spare parts (Capital spares 65 and commissioning spares including gaskets, Bolts, etc.)

O

66 IRN

Verify records, O Dimensional check, Interchangeability O

NOTE: The activities and corresponding inspection listed on this guide are the minimum requirement by Petrofac. The assigned Inspector should comply with and follow the approved QCP / ITP’s, Project Specifications. Tick the activity inspected / verified and sign below with details. Sign & Date:.......................................................................... Vendor & Location:................................................................ Name of Inspector:................................................................ P.O #:..................................................................................... Remarks : ............................................................................. Origin

Distribution

Audit / SCA

Corporate

Vendor verification Group / Project Engineer / PMI

Corporate & Projects

Resident Inspector / Third Party Inspector

Projects

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Gas Turbines Gas Turbine Package A gas turbine, also called a combustion engine, which has an upstream rotating compressor coupled to a downstream turbine and a combustion chamber in-between. Energy is added to the gas stream in the combustor, where fuel is mixed with air and ignited. In the high pressure environment of the combustor, combustion of the fuel increases the temperature. The products of the combustion are forced into the turbine section. There, the high velocity and volume of the gas flow is directed through a nozzle over the turbine’s blades, spinning the turbine which powers the compressor and, for some turbines, drives their mechanical output. The energy given up to the turbine comes from the reduction in the temperature and pressure of the exhaust gas. As the gas turbine speeds up, it also causes the compressor to speed up forcing more air through the combustion chamber which in turn increases the burn rate of the fuel sending more high pressure hot gases into the gas turbine increasing its speed even more.

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Working of Gas Turbine

In a gas turbine, a pressurized gas spins the turbine. The engine produces its own pressurized gas and it does this by burning something like propane, natural gas, kerosene or jet fuel. The heat that comes from burning the fuel expands air and the highspeed rush of this hot air spins the turbine. This air is first drawn into the engine where it is compressed, mixed with fuel and ignited. The resulting hot gas expands at high velocity through a series of airfoil-shaped blades transferring energy created from combustion to turn an output shaft. The residual thermal energy in the hot exhaust gas can be harnessed for a variety of industrial processes.

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Typical outline of Gas Turbine Generator

The Gas Turbine Generators consists of following major parts, as shown in the below figure, Compressor: The compressor takes in outside air and then compacts and pressurizes the air molecules through a series of rotating and stationary compressor blades. Combustor: In the combustor, fuel is added to the pressurized air molecules and ignited. The heated molecules expand and move at high velocity into the turbine section.

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Turbine: The turbine converts the energy from the high velocity gas into useful rotational power though expansion of the heated compressed gas over a series of turbine rotor blades. Output Shaft & Gearbox: Rotational power from the turbine section is delivered to driven equipment through the output shaft via a speed reduction gearbox. Exhaust: The engine’s exhaust section directs the spent gas out of the turbine section and into the atmosphere.

EXHAUST TURBINE COMBUSTOR COMPRESSOR OUTPUT SHAFT & GEARBOX

Titan 130

Single Shaft Gas Turbine for Power Generation Applications

Typical Outline of the Gas Turbine

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Cutout showing Gas Turbine components

Energy can be extracted in the form of shaft power, compressed air or thrust or any combination of these and used to power aircraft, generators. Gas turbines also tend to use more fuel when they are idling and they prefer a constant rather than a fluctuating load. That makes gas turbines great for things like transcontinental jet aircraft and power plants, but explains why we can’t have under the hood of the car. In gas turbine, gases are first accelerated in either a centrifugal or axial compressor. These gases are then slowed using a diverging nozzle known as a diffuser; these processes increase

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the pressure and temperature of the flow. In an ideal system, this is isentropic. However, in practice, energy is lost to heat, due to friction and turbulence. Gases then pass from the diffuser to a combustion chamber or similar device, where heat is added. In an ideal system, this occurs at constant pressure (isobaric heat addition). As there is no change in pressure the specific volume of the gases increases. In practical situations this process is usually accompanied by a slight loss in pressure, due to friction. Finally, this larger volume of gases is expanded and accelerated by nozzle guide vanes before energy is extracted by a turbine. In practice this process is not isentropic as energy is once again lost to friction and turbulence. If the device has been designed to power a shaft as with an industrial generator, the exit pressure will be as close to the entry pressure as possible. In practice it is necessary that some pressure remains at the outlet in order to fully expel the exhaust gases. Gas Turbine Electric Power Generation

System showing the gas turbine driving an electrical power generator

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As a general rule, the smaller the engine, the higher the rotation rate of the shaft must be to maintain tip speed. Blade-tip speed determines the maximum pressure ratios that can be obtained by the turbine and the compressor. This, in turn, limits the maximum power and efficiency that can be obtained by the engine. In order for tip speed to remain constant, if the diameter of a rotor is reduced by half, the rotational speed must double. For example, large Jet engines operate around 10,000 rpm, while micro turbines spin as fast as 500,000 rpm. Gas turbines are less complex than internal combustion (piston type)engines. Simple turbines might have one moving part: the shaft/compressor/turbine/alternative-rotor assembly, not counting the fuel system. However, the required precision manufacturing for components and temperature resistant alloys necessary for high efficiency often make the construction of a simple turbine more complicated than piston engines. Advantages of Gas Turbine Engines •• Very high power-to-weight ratio, compared to reciprocating engines; •• Smaller than most reciprocating engines of the same power rating. •• Moves in one direction only, with far less vibration than a reciprocating engine. •• Fewer moving parts than reciprocating engines. •• Greater reliability, particularly in applications where sustained high power output is required. •• Waste heat is dissipated almost entirely in the exhaust. This

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results in a high temperature exhaust stream that is very usable for boiling water in a combined cycle or for cogeneration. •• Low operating pressures. •• High operation speeds. •• Low lubricating oil cost and consumption. •• Can run on a wide variety of fuels. •• Very low toxic emissions of CO and HC due to excess air, complete combustion and no “quench” of the flame on cold surfaces. Disadvantages of Gas Turbine Engines •• Cost is very high. •• Less efficient than reciprocating engines at idle speed. •• Longer startup than reciprocating engines. •• Less responsive to changes in power demand compared with reciprocating engines. •• Characteristic whine can be hard to suppress. Typical Key Highlights of any Turbine Package Following are the typical key highlights of any Turbine package, the requirements may vary from client to client. Compressor •• Turbo Compressor, in accordance with API 617. •• Compressor designed to suit specific duty. •• Vertically orientated nozzles. •• Tandem Dry gas shaft end seals.

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•• Dry Gas seal control panel. •• Shaft vibration and position monitoring probes wired to junction box for compressor. •• RTD bearing temperature probes wired up to junction box for compressors. •• Shop inspection and tests in accordance with Quality Assurance System. •• Driven unit bearings lube oil supply and drain piping system. •• Finish in accordance with standard. •• Compressor mounted on a single baseplate which is separate from gas turbine baseplate. Gas Turbine Engine •• Core Engine. •• Gas Generator. •• Air Inlet Casing. •• Compressor Rotor. •• Compressor Stator with Variable Guide Vanes. •• Centre Casing. •• Combustion System – Dry Low Emissions ( DLE ) or standard for gas & liquid fuels. •• Compressor Turbine Rotor. •• Compressor Turbine Stator. •• Power Turbine. •• Hot Gas Inter-duct. •• Power Turbine Rotor.

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•• Power Turbine Stator. •• Output Shaft Drive. •• Exhaust Outlet Casing. •• Engine Bearing Temperature Instrumentation. •• Engine Casing Accelerometer type Vibration Probe. •• Engine arranged for hot end drive. Baseplate •• Under base of fabricated carbon steel construction arranged for multi-point mounting. •• Mounting assemblies for the gas turbine core, gearbox and auxiliaries. •• Integral lubricating oil tank – carbon steel with stainless steel lining. Start System •• AC Electric Starter Motor – direct drive. Gears, Couplings and Guards •• Auxiliary gearbox, incorporating drives for start system and lub oil pump. Lubricating Oil System •• Gas turbine lubrication system utilizes mineral oil. •• Lubricating Oil System serving the turbine, gearbox and driven unit. •• Lubricating Oil Pump Main – Turbine Gearbox Driven. •• Lubricating Oil Pump Auxiliary – AC Motor Driven.

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•• Lubricating Oil Pump Emergency – DC Motor Driven. •• Lubricating oil tank immersion heaters. •• Duplex filter standards. •• Filter differential pressure transmitter. •• Lubricating oil system breather. •• Lubricating oil breather ducting in austenitic stainless steel. •• Lubricating oil breather oil mist eliminator. •• Lubricating oil breather flame trap. •• Lubricating Oil System Cooler, supplied loose; Air Blast Simplex Lubricating Oil Cooler suitable. Gas Fuel System •• Pilot fuel flow control valve with actuator. •• Main fuel flow control valve with actuator. •• Rapid-acting gas shut-off valves ( 2-off ). •• Temperature monitor. •• Trace heating and lagging (if required ). •• Gas fuel block and vent valves ( off-package ). •• Automatic changeover from gas to liquid on falling gas pressure. Acoustic Enclosure •• Acoustic enclosure, 85dBA, painted carbon steel, fitted over gas turbine and auxiliaries. •• Doors for personnel access. •• Integral lifting beam for maintenance. •• Internal lighting.

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Acoustic Enclosure Ventilation System •• Ventilation air inlet filter – carbon steel. •• Ventilation inlet and outlet dampers – carbon steel galvanized – air operated. •• Ventilation fan – 2 x 100% – AC electric motor driven. •• Ventilation air system – positive pressure. •• Ventilation air silencer – carbon steel galvanized. •• Ventilation air inlet and outlet ducting – carbon steel galvanized. •• Combined support for turbine enclosure ventilation and air intake system. Gas Detection System •• Gas Detectors (combustion inlet). •• Gas Detectors (vent inlet). •• Gas Detectors (vent outlet). Fire Protection System •• IR Flame Detectors. •• Heat Detectors. •• Single Sounder, Status Indicator (end of package). •• Single MAC (Manual Alarm Contact). Fire Extinguisher •• Twin shot CO2 fire protection system. •• Cylinders housed in a weatherproof cabinet. •• Extinguisher system distribution pipework and nozzles. •• Piping from cabinet to package.

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Combustion Air Inlet System •• Combustion air filter – automatic pulse clean type – painted carbon steel please refer to GA. •• Additional weather protection – insect screen. •• Combustion air silencer – painted carbon steel. •• Combustion air inlet ducting – painted carbon steel. •• Integral support for combustion air inlet system. •• Maintenance access platform and ladder – combustion and ventilation filters. Combustion Exhaust System •• Exhaust Stack with vertical orientation made of ferritic stainless steel. •• Exhaust Silencer with – ferritic stainless steel. •• Combustion Exhaust Ducting – ferritic stainless steel. •• Thermal insulation and cladding – personnel protection only. Package Electrical Systems •• Junction Box Stack on-package, suitable for a maximum cable run of 100 metres to the Unit •• Control Panel, comprising: •• Junction box – high energy igniters and AC devices. •• Junction box – engine DC devices. •• Junction box – DC power supplies. •• Junction box – turbine instrumentation. •• Junction box – proximitors.

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•• Junction box stack located at non-drive end of the package. •• Cabling on-package complete. •• Cable tray and fixings on-package – austenitic stainless steel. •• Earthing system for on-package items. •• Emergency stop push-buttons located on package. •• Local stop push-buttons for turbine AC motors. •• Batteries, lead-acid standard, sized to ensure a safe rundown of the turbine and driven unit in. •• An emergency. •• Battery cabinet manufactured from carbon steel, located offpackage. •• Battery charger. •• Distribution plate, junction box mounted, for turbine DC auxiliary supplies, located adjacent to. •• The battery charger. •• Cable and instrument identification to seller provided cable schedule and P & ID nomenclature. Package Auxiliaries •• Turbine compressor cleaning system for hot and cold wash •• Mobile water wash trolley with polypropylene tank. Control System •• Unit Control System. •• Control and monitoring of the package systems. •• Control system located off-package.

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•• Emergency stop function – on-package control panel mounted. •• Turbine Vibration displacement monitoring ( typically Bently Nevada system). •• Operator display language - English. •• Remote cabinet mounted PC, HMI, keyboard and mouse. •• Laptop PC and programming software for Control system configuration. Turbo-machinery Applications – Remote Monitoring System Provision for data collection and remote communication from site allowing access to the, following services:•• Connection via internet (customer supply).

broadband

ADSL

connection

•• Automatic recording of data values within the Control System. •• Analysis of events. •• Analysis of downtime. •• Predictive trending. •• Anomaly detection. •• Software updates. •• Accelerated troubleshooting support. •• Customer notification reports. •• Access to historic data.

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•• Fleet and unit performance overview. •• Driven unit monitoring. Testing Gas Turbine Testing •• Gas turbine frame and systems test. •• Gas turbine core engine test– gas fuel; full load against water brake. Compressor Testing •• Compressor Mechanical run test (for every casing in case of multiple trains). •• Compressor Performance Test (PTC 10 Type 2 for one casing in case of multiple trains). Following activities are typically taken care by the purchaser to interface with the GTG; •• First fill of lube oil. •• Off-package lube oil cooler supply and return piping. •• Off-package lube oil breather piping. •• Drains and/or vent piping from the gas turbine package to a remote point. •• Demineralized water supply and treatment. •• Off-package gas fuel piping. •• Off-package gas fuel demister assembly. •• Combustion air and ventilation air inlet arrangement other than specifically listed in the scope of supply.

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•• Support structure, hangers, brackets and personnel access for combustion inlet air and ventilation systems. •• Turbine exhaust system other than specifically listed in the scope of supply. •• Lube Oil breather supply and return pipe work. •• Site grounding. •• Lightning Protection. •• Off skid Cable trays, cleats and ducts for high voltage and low voltage cabling or cabling beyond the scope of supply. •• Off-package site electric cabling. •• DC Lighting. •• Off skid gas fuel block & bleed vent valve. •• Emissions monitoring equipment. •• Process interconnect piping. •• Anti-Surge Valve. •• Station Controls. •• Off package gas fuel system heat trace & insulation. •• Drain tanks. Following are the interface points (Termination Points) of the GTG, Driven Unit •• Compressor Suction and Discharge connections. •• Peripheral compressor casing and systems connections.

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Under Base •• Underside of mounting pads. •• Vent and drain outlets at edge of under base. •• Instrument air inlet flange for compressed air. Start System •• Terminal box – AC Starter Motor. Lubricating Oil System •• Terminal box – lube oil pump AC electric motor. •• Terminal box –air blast lube oil cooler fan AC electric motors. •• Oil filler cap – lube oil tank. •• Lube oil supply and return connections at underbase. •• Lube oil supply and return connections at lube oil cooler. Gas Fuel System •• Gas fuel inlet flange. •• Grounding stud on turbine underbase. •• Vent flange from space between fire safe shut off valves. •• Gas inlet and outlet connections on gas fuel block and vent valves. •• Compressed air inlet and outlet connections on gas fuel block and vent valves. •• Turbine junction box. Acoustic Enclosure Ventilation •• Ventilation fan electrical terminal boxes.

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Combustion Air Inlet Filter •• Inlet face of air filter •• Electrical connections for controls Control System Hardware •• Input terminals of unit control pane Industrial Gas Turbines are available with a Dry Low Emissions (DLE) combustion system, providing extremely low NOx levels with gas and liquid fuels and a full dual fuel capability. Rotors are contained in heavy duty casings which are horizontally and vertically split, allowing full site maintenance to be carried out. The package is very compact, providing a small footprint and a high power-to-weight ratio. The twin-shaft configuration provides excellent speed and load turndown characteristics to allow maximum flexibility of operation. For Pump applications - Gas turbine provides an ideal drive solution for pumping applications. These include crude oil and product transmission and water injection. Drive from the power turbine is usually via a speed reducing gearbox. The loadspeed characteristics of the gas turbine provides operators with maximum flexibility for flow turndown and pressure control. Compressor Applications - Gas Turbine provides the drive for the centrifugal compressors for gas injection, pipeline transmission and boosting, gas processing, refrigeration applications and a variety of other duties. Where required, the exhaust heat of the unit can be recovered for process provision, thus raising overall efficiency.

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Advantage of completely integrated gas compression package is that having benefit of common control and auxiliary systems. Critical Items: Critical items are generally of a proprietary design and are recommended to maximize equipment availability. Critical items typically include actuators, fuel control valves, pumps, probes, sensors, fuel injectors, power supplies, control system I/O modules, etc. Non-Critical Items: Non-critical items are usually more readily available and typically include transmitters, hoses, relays, solenoids, valves, pressure switches, pressure regulators, circuit breakers, lamps, diodes, capacitors, resistors, etc. Repair Kits/Components: Repair kits/components (as available and applicable) are typically used to repair or replace subsystem assemblies such as hydraulic pumps, fire control systems, pressure regulators, solenoids, valves, actuators, etc. Suppliers Assistance During Commissioning This supervisory assistance will help minimize unnecessary procedures and ensure that the equipment has been properly installed, interconnected with other equipment, calibrated and is operated in accordance with the client’s specifications and good engineering practices. This can improve equipment reliability and help reduce the potential for subsequent operational problems due to poor installation or operating practices. The equipment will also be tested statically and operationally dynamically to contractual requirements at the completion of the commissioning phase. The types of tasks that might be required during the commissioning and start-up phase are;

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Level Package and Plumbing Checks •• Verify that frame is level. •• Verify correct installation integrity and cleanliness of air inlet/ exhaust. •• Verify that lube, fuel and water connectors are clean and appropriate filters and strainers are in place. Alignment Checks •• Perform cold alignment of engine, gearbox, accessory gearbox and driven equipment as required. •• Verify alignment and spacing of exhaust silencer or waste heat recovery hardware as required. •• Verify alignment and spacing of recuperator or external combustor as required. •• Verify alignment and stress relief mounting methods for header pipe on driven equipment (gas compressors or liquid pumps packages). Oil System Checks •• Flush all lube oil lines and coolers. •• Inspect lube oil tanks. •• Verify installation of start-up filters as required. Verify Electrical Interconnect •• Battery and battery charger systems. •• AC connections to motors. •• Continuity check interconnect wiring. •• Remote supervisory control panels.

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MCC Check •• Verify motors operate correctly. •• Strip heaters. •• Verify chargers operate correctly. Static Tests/Calibration •• Check alarm/shutdown functions. •• Calibrate devices. •• Verify proper operation of remote supervisory panel (if applicable). •• Verify proper operation of condition monitor system as required (per contractual requirements). Operational Checks •• Verify normal start time and temperature and normal rundown •• Verify proper operation. •• Perform sound tests (per contractual requirements). •• Perform engine/package performance tests (per contractual requirements). •• Perform vibration analysis. Final Inspection/Wrap-Up •• Ensure all drawings are properly marked to indicate changes and updating procedures are under way to reflect the “asinstalled” condition. •• Ensure necessary operation, maintenance and repair manuals and start up information are onsite. •• Ensure any tools and parts not on-site during inventory check

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or used during installation are now onsite or en route. •• Direct efforts to coordinate the availability of personnel and equipment with the scheduled start-up date. Description of the Inspection and Testing Program A teleconference is normally conducted within one week after the receipt of order and is held between the Manufacturer Team and the Customer to review the project requirements. This meeting includes a review of the project timeline, key deliverables and data required from both Manufacturer and the Customer. The SDRL will be reviewed and document submittal dates agreed upon. The Kickoff Meeting (KOM) may be scheduled as early as four weeks after receipt of order. The objective of this meeting is to resolve and finalize any open items related to the Package scope of supply. This covers everything directly associated with the physical turbine package. This interface document will be discussed and this contains package dimensions, external connection points and other package details. Project inspection, test and quality assurance documentation requirements are identified through the project ITP. This information is communicated by the ITP throughout the organization. Prior to the commencement of the build of each package, a project-specific QC folder must be created. This QC folder remains with the package throughout the assembly cycle. It contains checklists and forms to verify that important assembly operations are performed and data are recorded. Respective Quality Engineers must perform audits to verify proper completion of package assembly activities and collection of data.

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At the completion of package assembly and prior to moving of the package to test, a pre-test audit is performed. This ensures that assembly has been satisfactorily completed and that project special requirements have been incorporated into the assembly up to that point. The Inspection and Test Plan (ITP) documents quality assurance, inspection and testing requirements and defines the level of customer or third-party involvement in the inspection process. It is the controlling Quality Control document for the project. Although ITP’s are project specific, their format has been standardized for similar applications. Typically a GTG package ITP will contain the following sections, Major activities related to, •• Baseplate •• Packaging Manifolds •• Control Console •• Gas Turbine •• Process Compressor •• Package Assembly •• Package Test •• Final Inspection The ITP is created based on information derived from the customer specification and from project co-ordination or kick-off meetings. ITP’s must be revision controlled.

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Testing Activities Testing activities will be carried out throughout the manufacturing cycle. Testing is conducted throughout the product manufacturing cycle. Major assemblies, including gas turbine engines, gas compressors, controls, generators and gearboxes have separate or combined tests performed on them to evaluate and confirm that they have individually met performance parameters. Some tests, as in the case of turbine engines, are conducted under load. Other tests are not, as in the case of gas compressors. Subassemblies, such as turbine nozzles, combustor liners, turbine cases, fuel manifolds, injectors, rotor blades, starters, pumps, compressor cases, etc. have individual component and subassembly tests performed for the same purpose. When these units are assembled into a package, additional tests are performed to validate that the entire package is functioning as intended. The assigned Package Engineer is responsible for all the tests required as per specifications are properly conducted. The test reports become part of the permanent test record. Some of the tests conducted and systems validated during the package test include fuel, lube start and seal system pressure checks. Lube system flushing is also required. Package testing comprises both static and dynamic tests. All of the major package systems are operated during testing. Critical safety/protective circuits, fire systems and devices are functionally tested. Depending on the particular application, certain tests (such as string test) will be carried out as per options defined at the outset of the contract.

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Final Inspection Following the completion of package testing, the package and console are moved to final preparation areas. If the package requires an acoustic enclosure, it is installed at this point. Prior to preparation for shipment, the complete package and console undergo a final inspection. If a final inspection by the Customer is required, the package is presented to the Customer at this time. Importance on Calibration The accuracy of Inspection Measuring and Test equipment used in the production process for product acceptance purposes must be controlled through a comprehensive calibration control program. Devices and instruments are calibrated using standards with accuracies traceable to the National Institute of Standards and Technology (NIST) or derived from a controlled measurement process employing a fundamental constant of nature. The frequency of calibration is established on the basis of stability, purpose and degree of usage. The initial interval will be assigned according to manufacturers’ recommendation or established from historical data. Intervals are adjusted as required to assure continued accuracy as evidenced by the results of preceding calibrations. Quality Overview and Receiving Inspection The extent of receiving inspection of incoming materials is established on the basis of the type of material being supplied and the suppliers’ historical performance. If material is found to be acceptable by receiving Inspection, inspection records are accepted. If material does not meet Customer requirements, the

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discrepancy is documented in the system and inspection records must show non-conformance and the material is forwarded to a secured quarantine area for further review and disposition. Generators GTG suppliers offer generators from a range of manufacturers. Customer can have the option to apply inspection at the manufacturer at the source, as required to fulfill project specific inspection requirements. Air Inlet and Exhaust Systems Generally GTG suppliers will source Air inlet and exhaust systems from limited number of sub-suppliers. GTG suppliers provides these vendors with engineering drawings and requires compliance with applicable engineering and procurement specifications, including painting specifications, welding specifications etc. Lube Oil Coolers Typically lube oil coolers are outsourced. Product Quality is documented through leak tests, in-process checklists, final inspection checklists, Lube oil flushing in compliance with API 614, ASME Code Stamping and U1A form and Material Test Reports. Lube Oil Filters Lube Oil filters are either manufactured by self or purchased from vendors depending on the product and application. All filter housings are ASME VIII code stamped.

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Skid Base and Manifolds Welding Procedure Specifications (WPS) applied during the baseplate, manifold and process piping fabrication cycles should have been qualified in accordance with the following codes: Structural: AWS D1.1 Steel - Structural Welding Code Manifolds: ASME B31.3 - Chemical Plant & Petroleum Refinery Piping Process piping: ASME Section IX - Boiler & Pressure Vessel Code WPS’s and Procedure Qualification Records (PQR’s). All the above documents should be available for Customer review. Certificates of Compliance are available upon request for lube oil tank leak test and coating and painting processes. Manifolds/ASME Pressure Vessels All piping systems (manifolds) will be manufactured and inspected per ASME B31.3 and Engineering Drawings. It is preferred that all piping is seamless and all welds and weld procedures are qualified to ASME Section IX. All pressurized manifolds must be hydro tested. NDE percentage is dictated by the customer specification or the reputed GTG suppliers generally apply five percent NDE on all manifolds are X-rayed per welder (which is not project specific). All welders shall be verified for qualification in accordance with ASME Section IX. Control Console Control console undergoes a variety of quality control processes during the manufacturing phase. Apart from a number of in-process inspections during the console build cycle, the

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completed control console is statically tested. Finally, the console is dynamically tested together with the turbo-machinery package during the package acceptance testing process. Following are details of the quality control processes: Gas Turbine Rotating Components Rotor blades are fabricated castings and forgings. All cast blades should be 100% radiographically examined. Turbine blades are fluorescent penetrant inspected for non-conformities. Compressor and turbine discs are manufactured from forgings. All compressor discs are checked for proper hardness. Discs are magnetic particle inspected or fluorescent penetrant inspected. All discs must be traceable. Bladed disc assemblies are dynamically balanced at the end of the process. Rotor Balance Rotor assemblies are dynamically balanced. Electrical and mechanical run out of bearing journals must be conducted on all engine models with proximity probes. Engine Assembly At the manufacturer location, Engines are assembled in special build pits. Critical dimensions and clearances are documented in the system. Assembly data and traceable component serial numbers must be recorded for each item. Engine Test Engines are tested in accordance with the applicable specification.

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Compressor and Combustor Cases Cases must be hydrostatically tested per engineering drawing requirements. Each part tested must be stamped with the mark to identify test completion. Cases must be heat treated per drawing. The entire case is given a wet magnetic particle test. Nonstainless steel cases are nickel-plated. Fuel Gas Manifold All manifold related manufacturing operations must be documented. Welders must be certified to ASME Section IX. All weld seams must pass three inspection tests - visual, fluorescent penetrant and hydro-test. All manifolds are hydrostatically tested at 1.5 times design pressure for 30 minutes. Gears and Gearbox For most of the generator applications, the reduction drive gears are manufactured and assembled at OEM’s Gear facility itself based on the models or Reduction gearboxes for mechanical and compressor drive applications are sourced from a number of outside suppliers. Interconnect Couplings Typically standardized couplings for compressor, mechanical and generator drive applications are being used. GTG manufacturer retains the design specification control for all out-sourced interconnect couplings. Driven Compressor Compressors are assembled and tested. Bearings and seals are generally procured from outside suppliers. Compressor center

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bodies and end caps are hydro-tested for 30 minutes at 1.5 times design pressure. Individual impellers are over-speed spin tested and dimensionally checked. Rotor balance and run out records must form the part of the documentation. Standard testing is conducted in accordance with the customer specification requirements. The test consists of an open loop test on ambient air, with the compressor being driven by a facility slave driver. The purpose of the test is to verify the position of the compressor surge line and speed lines, using air test equivalent compressor performance curves. Mechanical performance is verified and a nitrogen seal leak check is conducted. Enclosure Purchased hardware and components are processed through Receiving Inspection. Enclosure components are welded in accordance with the engineering and specification requirements (i.e. AWS). All Structural parts are manufactured as per Engineering Drawing and AWS D1.1. Welders are Qualified to AWS D1.1. The enclosure roof frame wiring and tubing systems are preassembled. The enclosure roof is then assembled to the Package base skid after the roof supports are installed. Side panels and doors are pre-assembled with the applicable hardware prior to installation. All final electrical runs are made and inspected. All panels and doors are installed and secured to the enclosure. Standard enclosure tests are conducted on all the applicable systems to ensure the systems operate within the parameters set in the Engineering Test specifications. Final visual inspection is accomplished prior to paint.

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Package Acceptance Test Typically production test facilities are arranged to provide for a three-part test program. Phase 1 utilizes simulation equipment to perform static testing of the control console and package systems to verify electrical and fluid system continuity and calibration prior to dynamic test preparation. Phase 2 consists of interconnecting the turbine package and control console in the pre-test area to undergo additional simulated systems tests of the total package and prepare the unit for interconnection with the test cell facilities. Phase 3 utilizes a real-time data acquisition system to collect raw digital and analog data from the turbine package. The unit is installed in the test cell where it is controlled and monitored by its own control console and the facility data acquisition system. Results are displayed in customary engineering forms and units. The gas turbine is tested on the package itself, using the generator as a load. Contract engine performance and package acceptance is based on the loaded package test. For generator applications and for all compressor and mechanical drive applications, the engines are performance tested on a facility test skid using a water brake dynamometer as the load source. The control and display equipment provides the capability to monitor and control the Packaging and test stimuli, to operate the unit under test and to measure and evaluate its performance.

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Specified test conditions are established by keying in calibration coefficients, constants and operation limits. The data are displayed on a video terminal, various parameters are selected for display and the system checks values and limits. Printouts are generated as needed. When performance levels have been achieved, the test technician initiates a command to capture all instrumented points, initiating automatic performance computations. The collected data become part of the permanent test record. Items typically not part of Package supplier are contract inlet and exhaust system ancillary equipment such as; filters, silencers and ducting, battery systems, oil coolers, package enclosure, ancillary skid, switchgear and any customer furnished hardware. For generator applications, packages are tested with the contract generator whenever possible. Acceptance Test Data Test Engineering and Project Management review acceptance test data prior to submittal to the purchaser. The test report provides test results and compares the results acceptance test specification requirements by means of calculations, graphs, strip charts and descriptions. Data must be provided for each turbine package. The acceptance test report generally includes the following type of data: Starting and control - A record of average starting time (zero speed to rated speed) and maximum turbine gas temperature reached during the start cycle.

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•• Turbine fuel consumption rates - A comparison of measured fuel consumption versus specified fuel consumption showing correlation of fuel consumption. •• Packaging output at the generator terminals. •• Turbine gas temperature at full load. •• Voltage and frequency transients (Generator set applications) Traces are provided showing voltage and frequency deviations during load application and removal. •• Operating values - A chart showing operating values of the following engine parameters from no load, with step increments, to full load is included: - Lubricating oil pressure, temperature and flows. - Turbine exhaust gas temperature. - Engine compressor discharge pressure. - Package vibration levels. Final Inspection Following completion of all assembly activities the package and console undergo a final inspection of mechanical and electrical integrity, paint quality, workmanship, etc., including: Package is cleaned and prepared for paint. Package is painted in accordance with the engineering specifications and any special Customer requirements. Final Inspections are made after paint to assure all systems are intact and sealed as required. The Shipping department prior to packaging for shipment inspects all loose-ship components and hardware. Any discrepancies are noted by the assigned

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Inspector and are resolved by the responsible department. Customer’s Final Inspection, if required is accomplished at this point. Package is prepared for shipment as required by Contract. All Hardware is boxed for shipment after inspection is completed. Package and all associated Hardware are shipped. Customer Inspection Within the manufacturing process, Customer’s Third Party Representative will be visiting the manufacturer’s facilities or sub-supplier facilities to observe elements of the manufacturing and testing process. In order to make appropriate provision and to ensure proper coordination, the extent of the Customers inprocess inspection or observation will be specified at the time of order. These requirements will then be reflected in the project ITP.

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Supplier Quality Assessment Checklist for Turbines – Combustion Gas PEC-QU-FRM-X-11409 Rev 0

PROJECT NO:

SPECIFICATIONS/ CODES/STANDARDS

INSPECTION CATEGORY

A Pre-Inspection Meeting, SCA, Audits, Stage Wise Inspections, Hold / Witness, Final Inspection INSPECTION ACTIONS:

1 Physical Inspection / Verification 2  Verify Document Status 3 Review / Endorse test reports & certificates No.

QC Inspection Activities

A 1 2 3

Specification/Data Sheets

O

3 Drawings

O

Verify approval

4 QCP/ITP

O

Verify record

O

Verify approval

Manufacturing Sequence procedure and flow diagram

Inspector Remarks

Country of origin, language requirements, service after sales, special tools, spare parts

1 Pre-Inspection Meeting O

2

Comments

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No.

QC Inspection Activities

A 1 2 3

Comments

5

Welding Procedure Specification

O

Verify approval

6

Welder Qualification Record

O

Verify record and List of Welder personnel for applied for the job

7

Welding Repair Procedures

O

Verify approval

O

Verify approval

NDE Personnel Qualification Record

O

Verify record and List of NDE personnel for applied for the job

10 Material Certification

O

Review, Stamp & Endorse

8 NDE Procedures 9

11

Material Verification/ Traceability

12

Components/Parts Inspection:

O

13 Casing

O

14 Rotor & shafts / clear

O

Wheels & blades / 15 clear

O

16 Seals / clear

O

Inspector Remarks

Verify full coverage against Bill of Materials in all drawing (Mechanical, Instrumentation, Electrical)

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No.

QC Inspection Activities

A 1 2 3

17 Bearings

O

18 Combustors

O

19 Gear drive units

O

Comments

Inspector Remarks

Load bearing members 20 O fabrication 21

Base plate for flatness, O straightness, distortion.

O

22

Lifting lugs, Spreader Bar/Lifting Beam

O

O

23 Other accessories

O

Control Oil & 24 Lubrication System Insp.

O

25

Turbine Insp. Separated Shaft

O

26

Turbine Insp. - Single & O Multiple Shaft

27 Fuel System Inspection O 28

Starter System Inspection

O

29

Auxiliary Piping & Tubing Inspection

O

Bulk Piping (Pipe/ Fittings, Flanges, Gaskets, Boling)

O

O Verify BOM

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No.

QC Inspection Activities

Electrical, 30 Instrumentation & Controls Inspection

A 1 2 3

Inspector Remarks

O

Instrumentation items (Thermowells, Control valves, Pressure regulators, Pressure transmitters, Flow transmitters, Pressure 31 Gauges orifice O plates, Temperature transmitters, solenoid valves, PSV, Instrument tubing, manifolds, compression fittings) 32

Electrical items (Fans, Cables, Motor, JB)

33

Alarms & Shutdown Inspection

34

Fire Protection System O Inspection

Verify full coverage against Bill of Materials in all O drawing (Mechanical, Instrumentation, Electrical)

O

35 Welding Inspection

O

36

Non-Destructive Examination:

O

37

100% RT butt weld joints of casing

O

38 Heat Treatment

Comments

O

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No.

QC Inspection Activities

A 1 2 3

Comments

Inspector Remarks

39 Testing: 40 Test procedures

O

Verify approval

Low speed balancing 41 O of rotor 42 43

Degaussing of Rotor O Mechanical and Electrical Runout

44 Hydrostatic test

O O

45 Pneumatic or gas test O 46

Mechanical running test

47 Performance test

48 Other tests

49

Internal insp. of casings when open

50

Test reports/test certificates

Noise level, Vibration etc.,API 616 (as applicable)

O

O

ASME PTC-22 Full load test on O gas generator including spares (as applicable)

O

Post test inspection, Complete Unit test, as applicable - Per P.O./Project specs

O OO

As required by P.O./ codes/specs

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No.

QC Inspection Activities

A 1 2 3

Comments

Inspector Remarks

Spare Parts (Gaskets, 51 Bolting and Rotors etc.) Pickling and 52 passivation (of all CRA welds) 53

Final Assembly Inspection

Verify record for passivity

O

Photographic surveillance of complete equipment 54 for all parts and as whole assembly (before packing) Verify across PID, 55 Layout with detailed photographic survey 56

Accessibility check and operability check

57

Preservation check (Rotors, Piping etc.)

58

Painting/Protective Coating

O

59

Nameplate/ Identification

O

Rubbing/Photograph

60 Drying/Cleaning

O

Supplier Certificate of 61 Compliance

O

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No.

QC Inspection Activities

62

Manufacturing Record Book including all sub-supplier’s components

63

Preparation for Shipment

64 Release for Shipment

A 1 2 3

Comments

Inspector Remarks

O

O

Spare parts witness (as applicable)

O

NOTE: The activities and corresponding inspection listed on this guide are the minimum requirement by Petrofac. The assigned Inspector should comply with and follow the approved QCP / ITP’s, Project Specifications. Tick the activity inspected / verified and sign below with details. Sign & Date:.......................................................................... Vendor & Location:................................................................ Name of Inspector:................................................................ P.O #:..................................................................................... Remarks : ............................................................................. Origin

Distribution

Audit / SCA

Corporate

Vendor verification Group / Project Engineer / PMI

Corporate & Projects

Resident Inspector / Third Party Inspector

Projects

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Preservation Preservation Of Rotating Equipments General •• Initial preservation and preservation after installation of all Rotating equipment shall be maintained as per Vendors Preservation procedures. •• All exposed shafts and polished surfaces shall be thoroughly cleaned and coated with Ensis Fluid grade S, T or V. or Equivalent. •• Periodic Rotation of Shafts as recommended by vendor. •• Manual rotation of shafts at weekly intervals is recommended. •• Rotation through a minimum of 5 complete turns is good practice. •• The position of the shaft at rest should be advanced by a 1/4 turn each time. •• Exposed metallic surfaces of any rotating equipment and its drivers, associated valves and auxiliaries shall be protected with suitable rust preventive oil as required. •• Internal Preservation of Rotating equipment shall be carried out as per vendor preservation procedure. •• Drivers (Turbine or Electric Motors) of the rotating equipment shall be preserved as per respective vendor’s preservation instructions.

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Preservation Of Centrifugal Pumps •• Seal/blind off suction and discharge connections suitably during storage stage. And after installation on foundation, ensure that suction and discharge is spaded off if provided with the gap for spading or spool shall be dropped off or isolation valves are closed to prevent debris from piping and display a Spading/Isolation Tag on the same. •• Rotate shaft every two weeks •• Ensure that bearing housings is lubricated or filled with lubricating or preservation oils recommended by vendors. •• Ensure oil Plug vents on bearing housing is closed. •• Ensure that opening of mechanical seals are plugged during storage stage •• For long term protection, fill the bearing housing with original lube oil or suitable preservation oil or also VCI concentrate can be added in lube oil for long term protection, if approved by vendor. (Preference should be given to Vendor’s recommendation) Preservation Of Reciprocating Pumps •• Seal/blind off suction and discharge connections suitably during storage stage. And after installation on foundation, ensure that suction and discharge is spaded off if provided with the gap for spading or spool shall be dropped off or isolation valves are closed to prevent debris from piping and display a Spading/Isolation Tag on the same. •• Fill all lubricators as recommended by vendor or by suitable preservation oil.

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•• Replace the covers and rotate the crankshaft through several revolutions by hand; •• Ensure that gear box crank case are filled with vendor recommended oil. •• Run oil pump if recommended by equipment vendor. •• For long term protection, fill the bearing housing with original lube oil or suitable preservation oil or also VCI concentrate can be added in lube oil for long term protection, if approved by vendor. (Preference should be given to Vendor’s recommendation). •• Apply suitable protective coatings or corrosion inhibitor spray on the exposed metallic surfaces of the pump. Preservation of Compressors and Blowers •• Seal/blind off suction and discharge connections suitably during storage stage. And after installation on foundation, ensure that suction and discharge is spaded off if provided with the gap for spading or spool shall be dropped off or isolation valves are closed to prevent debris from piping and display a Spading/Isolation Tag on the same. •• Gas side of the compressor or blower shall be internally preserved as per vendor preservation procedure ideally with Nitrogen interting and check periodically. •• Ensure that Oil sump and seal oil tank preserved with vendor recommended oil. •• Associated exchangers and receiver drum shall be internally preserved as per vendor recommendations, ideally with Nitrogen inerting and check periodically. •• Rotate shaft weekly simultaneously with the operation of the lubricating/seal oil system

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•• Apply suitable protective coatings on the exposed metallic surfaces of compressors and blowers. Preservation of Reciprocating Compressors •• Seal/blind off suction and discharge connections suitably during storage stage. And after installation on foundation, ensure that suction and discharge is spaded off and/or valves are closed to prevent debris from piping and display a Spading/ Isolation Tag on the same. •• Cylinder head and crank case shall be internally preserved as per vendor preservation procedure ideally with Nitrogen interting and check periodically. •• Ensure that Oil sump and seal oil tank with vendor recommended oil. •• Associated exchangers and receiver drum shall be internally preserved as per vendor recommendations, ideally with Nitrogen inerting and check periodically. •• Rotate shaft weekly simultaneously with the operation of the lubricating/seal oil system. •• Apply suitable protective coatings on the exposed metallic surfaces of the pump. •• For long term storage VSI concentrate shall be added to lubricating/seal oil and operate system weekly for about 30 minutes.

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Lessons Learned Root Cause & Recommendations

Equipment

Issue

Centrifugal Condensate Pump

Pump Suction and Discharge Heads - Defects (Blow holes) detected on the Receiver Can Mounting Flanges during Visual and MPI check after proof machining. PIL rejected the castings. Castings have been replaced by vendor.

Minimum NDT like RT, MPI for Carbon Steel Casting shall be done before Proof Machining which avoids delays. This shall be addressed in the ITP during review and discussed with vendors in the KOM.

Two types of ANSI Flanges in size 26” and above.

Vertical sump pump mounted on close drain vessel had pump mounting flange 30” diameter, # 150 rating.Pump flange was type A and vessel flange was type B as per ANSI B16.47. This had resulted in a major mismatch. Pump had to be completely disassembled. Pump mounting flange modified to suit vessel flange and then reassembled pump was installed.

ANSI flanges in size 26” and above are covered under two series namely Type A and Type B. it is important to specify flange series in addition to size and rating on all data sheets in order to avoid any mismatch.

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Equipment Mating flanges of High Pressure pumps

Issue The mating flanges for MOL pump suction and discharge nozzles were supplied by Petrofac. Pump Vendor drawings only specified the size, rating and face and did not specify any requirement of the schedule. The flanges were procured to match with the thickness of the suction / discharge piping class. It was later found that the flange on the Pump nozzles was thicker (Sch 160). The ID of the mating was flange was more than that of the pump nozzle flange which was objected by the pump vendor. The issue was later resolved as the impact on pump performance was considered to be negligible.

Root Cause & Recommendations It is preferable that pump vendor should provide mating flanges (“companion” flange) for critical pumps. If the flanges are to be procured by piping, complete details including the ID / thickness of the flange shall be provided by the pump vendor to avoid problems during commissioning.

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Equipment

Issue

Root Cause & Recommendations

Flange ID mismatch due to different schedules of piping/ Pump

MOL Pumps specified # 1500 RF flanges for suction and discharge. Matching flanges were procured of # 1500 RF to suit piping of schedule 80. As schedule of pump flanges were not mentioned, it was observed at site that the ID of pump flanges was smaller compared to matching flanges procured. On investigation, it was clarified by pump vendor that the flanges on pump are of schedule 160 to take care of nozzle loads. This information was no were mentioned on the drawing. Thus there was mismatch in IDs of flanges due to different schedules.

For procuring matching flanges, it is essential to specify nozzle/pipe schedule in addition to flange rating and nominal sizes. This is more essential for large dia piping (more than 6”) and higher pressure ratings.

Always check the preservation time for equipment

Many a times, preservation used for equipment, is for shorter duration than the time before which it will be installed on site

The preservation time for the equipment was shorter than the duration it will be installed for

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Onshore Engineering & Construction

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