1. SCOPE ………………………………………………2. GENERAL 3. ADDENDA The following section and section numbers
refer to PIP RESR001
Section 1 – Introduction ……………………………..
1.3 Definitions Section 2 – References
2.2 Industry Codes and Standards …..
Section 3 – General Section 4 – System Section 5 – Compressors …………………………..
5.2 Reciprocating Compressors 5.3 Rotary Compressors 5.4 Centrifugal Compressors ………….
Section 6 – Drivers 6.1 Electric Motors 6.2 Steam Turbines………………………..
Section 7 – Heat Exchangers 7.1 General 7.2 Shell and Tube………………………..7.5 Air Cooled Heat Exchanger
Section 8 – Vessels 8.1 General ………………………………….8.2 Receiver 8.3 Oil Separator (Rotary
Compressor Systems) 8.4 Oil Recovery Pots (Reciprocating
or Rotary Compressor)………………8.5 Suction Knockout Drum
8.6 Economizer (If Provided) Section 9 – Oil System ………………………………
9.1 General 9.4 Piping/Valves 9.6 Lubrication Systems Tests ………..
Section 11- System Instrumentation
and Control 11.1 Controls
Section 12 – Control Panel…………………………
13 Electrical ……………………………..13.1 General 13.2 Wiring and Terminations
14 Pipes, Valves and Fittings……..15 Pressure Relieving Devices 16 Insulation 17 Structural Steel Kids …………….. 18 Noise 19 Compressor Vibration and
Critical Speeds
20 Painting……………………………….21 Inspection
21.1 Vendor Quality Requirements 21.6 Material Inspection………………..
22 Testing and Preparation
for Shipment
1. Scope
Process Industry Practice (PIP) Practice RESR001, Packaged, Skid-Mounted Industrial Process
Refrigeration Systems, dated August 2000, is adopted as a SABIC Engineering Standard (SES) with the following addendum.
2. General
This standard may be used for refrigeration systems with either API or non-API compressors. API
compressors should be considered on larger capacity systems and all systems that use flammable or toxic refrigerants. Non-API compressors can be considered for units smaller than 1500 kW and for systems using non-flammable or non-toxic refrigerants. API systems shall use API equipment data sheets to describe the various components.
3. Addenda
The following section, subsection and paragraph numbers refer to PIP RESR001.
1. Introduction
Add the following new subsection:
1.3 Definitions
Hermetic Compressor.
A hermetic compressor has an electric motor and a compressor built into an
integral housing. The motor and compressor utilize a common shaft and bearings.
Observed.
SABIC shall be notified of the timing of the inspection or test; however, the inspection or test
shall be performed as scheduled, regardless of whether SABIC is present or not.
Open Compressor.
An open compressor requires an external driver and may be direct driven or driven
through a speed increasing gear.
Unit Responsibility.
Unit responsibility refers to the responsibility for coordinating the technical aspects of
the equipment and all auxiliary systems included in the scope of the order.
Witnessed.
A hold shall be applied to the production schedule, and the inspection or test shall only be
carried out with SABIC in attendance. For mechanical or performance tests, this shall require written
notification of a successful preliminary test.
2. References
2.1 Add the following paragraph:
The following documents are part of this addendum. The latest issues, amendments, and supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards
Substitute the following listed SABIC Engineering Standards (SES) for the PIP Practices listed in
RESR001.
E02-E02 Hazardous Area Classification
E06-S01 Induction Motors 150 kW (200 HP) and Below
E06-S02 Induction Motors 185 kW (250 HP) and Above
E19-S01 Packaged Equipment Electrical Requirements
G03-S01 Lubrication, Shaft Sealing, Control Oil Systems and Auxiliaries
G04-S01 Centrifugal Compressors for Process Services
G06-S01 General Purpose Steam Turbines
G06-S02 Special Purpose Steam Turbines
G07-S01 General Purpose Gears
G07-S02 Special Purpose Gears
G08-S01 Rotary Positive Displacement Compressors
G13-S01 Reciprocating Compressors for Process Service
Q01-E01 Pressure Vessels – General
Q01-F07 Pressure Vessels – Fabrication
Q01-F12 Skirt Type Supports, Vertical Vessels
Q01-F13 Steel Saddle Supports for Horizontal Vessels
Q01-F14 Vertical Vessels: Leg Supports
Q01-F15 Vessels: Nameplate and Stamping
Q01-F20 Davit for Outdoor Manhole covers
Q01-F27 Vessels: Manhole Cover Hinge Fabrication
Q01-F28 Allowable Fabrication Tolerances Horizontal and Vertical Pressure Vessels
Q01-F31 Demister Pad Assembly and Details
Q02-E01 Shell and Tube Heat Exchangers
Q02-E02 Air Cooled Heat Exchangers
Q02-F01 Shell and Tube Heat Exchanger Fabrication
Q02-X01 Shell and Tube Heat Exchanger Data Sheet
Q02-X02 Air Cooled Heat Exchanger Data Sheet
S20-G01 Equipment Noise Limits
X01-S03 Instrumentation for Packaged Equipment
2.2 Industry Codes and Standards
Add the following references:
American Society of Mechanical Engineers (ASME)
Section V, Nondestructive Examination
Section VIII Div 1
Section IX, Welding and Brazing Qualifications
B30.30 Below the Hook Lifting Design
American Society for Testing and Materials (ASTM)
E 94 Standard Guide for Radiographic Testing
E 125 Reference Photographs for Magnetic Particle Indications on Ferrous Castings
E 142 Standard Method for Controlling Quality of Radiographic Testing
E 709 Magnetic Particle Examination
Process Industry Practices (PIP)
VESSMO1 Specification for small Vessels and Heat Exchangers with Limited Design Conditions
Tubular Exchanger Manufacturers Association (TEMA)
Standards of the Tubular Exchanger Manufacturers Association
3. General
3.1 Substitute the paragraph as follows:
The refrigeration package vendor shall have unit responsibility for the compressor, drive train, condenser, chiller and all auxiliary equipment specified in this standard or the data sheets.
4. System
4.10 Substitute the paragraph as follows:
Electric motors, electrical components and electrical installations shall be suitable for the hazardous area
classification and groupings specified by SABIC on the data sheets, and shall conform to SES E02-E02 and NFPA 70.
5. Compressors
5.2 Reciprocating Compressors
5.2.6 Add the following sentence:
Compressors rated 18.65 kW or higher shall not be supplied with vibration isolation pads without specific
written approval by SABIC.
5.2.8 Substitute the paragraph as follows:
Open compressors shall utilize dry type disc or diaphragm couplings.
5.2.10 Add the following new paragraph:
Reciprocating compressors of the V-type or W-type specifically designed for refrigeration service may be used in sizes up to 187 kW. Balanced opposed industrial compressors designed in accordance with SES G13-S01 may be used in sizes up to 750 kW. Compressors designed in accordance with SES G13-S01 should be used when flammable or toxic refrigerants are used.
5.3 Rotary Compressors
5.3.7 Substitute the paragraph as follows:
Rotary compressors shall utilize dry type disc or diaphragm couplings.
Add the following new paragraphs:
5.3.8 Screw compressors designed for refrigeration service may be used in sizes up to 187 kW. Rotary screw compressors designed in accordance with SES G08-S01 may be used in sizes up to 3000 kW. Compressors designed in accordance with SES G08-S01 shall be used when flammable or toxic refrigerants are used.
5.3.9 For rotary oil flooded compressors, the lube oil specified shall not be miscible with the refrigerant over the entire operating pressure and temperature, to ensure that the lubricant is not diluted by the presence of the refrigerant.
5.4 Centrifugal Compressors
5.4.3 Substitute the paragraph as follows:
Gear boxes, if used, shall be designed and constructed in accordance with SES G07-S01 or G07-S02 as indicated on the data sheets.
5.4.4 Substitute the paragraph as follows:
Non-API centrifugal compressors specifically designed for refrigeration service may be used in sizes up to 3000 kW. Compressors that comply with SES G04-S01 shall be used for larger sizes, or for processes that utilize flammable or toxic refrigerants. Centrifugal compressors designed and constructed in accordance with SES G04-S01 may be used in sizes up to 35,000 kW.
(Comment: In units larger than 7500 kW, the size of the components tend to become so large that packaging the refrigeration unit may no longer be practical.)
5.4.5 Substitute the paragraph as follows:
Centrifugal compressors shall utilize dry type disc or diaphragm couplings.
5.4.6 Add the following new paragraph:
Centrifugal compressors shall be provided with individual casing stage drains terminated with a flange and valve.
6. Drivers
6.1 Electric Motors
Substitute the subsection with the following new paragraphs:
6.1.1 Electric motors in open drive systems shall be in accordance with SES E06-S01 or E06-S02, as
applicable. Motors for auxiliary equipment shall be in accordance with SES E06-S01.
6.1.2 Electric motors in hermetic drive systems are cooled by the suction gas passing through the
windings and shall be the vendor’s standard design for the application.
6.1.3 The motor nameplate rating, exclusive of service factor, shall be at least 110 percent of the greatest
power required, including gear and coupling losses, for any of the specified operating conditions.
6.1.4 Full load and starting current, system WR raise power 2 and motor curves showing speed/torque, speed/current,
and speed/power factor shall be provided for each compressor drive.
6.2 Steam Turbines
Substitute the subsection with the following new paragraphs:
6.2.1 Steam turbine drivers shall in accordance with SES G06-S01 or G06-S02 as specified on the data
sheets.
6.2.2 Steam turbine drivers shall be sized to continuously deliver the horsepower for all specified conditions
while operating at corresponding speed with specified steam conditions.
7. Heat Exchangers
7.1 General
7.1.1 Substitute the paragraph as follows:
System heat exchangers shall be designed and fabricated in accordance with SES Q02-E01, Q02-E02 and
Q02-F01, as applicable. Small exchangers that are within the scope of PIP VESSM001 may be designed
and fabricated to that specification.
7.2 Shell and Tube
7.2.1 Add the following sentence:
Inserts or integral fin tubes may only be used with specific written permission of SABIC.
7.2.3 Substitute the paragraph as follows:
SABIC will indicate design requirements in SES Q02-X01. Vendor shall submit a completed SES Q02-X01 with the proposal.
7.2.4 Substitute the paragraph as follows:
Marine water boxes shall be provided when specified in SES Q02-X01.
Add the following new subsection:
7.5 Air Cooled Heat Exchanger
7.5.1 Unless otherwise specified, air cooled heat exchangers shall comply with SES Q02-E02.
7.5.2 The scope of the air cooled heat exchanger shall include the supporting structure, maintenance
platforms and access ladders as indicated in SES Q02-X02.
7.5.3 Fan motor drives shall comply with SES E06-S01.
8. Vessels
8.1 General
Substitute the subsection as follows:
8.1.1 System vessels shall comply with SES Q01-E01, Q01-F07, Q01-F12, Q01-F13, Q01-F14 and
Q01-F28, as applicable. Small vessels within the scope of PIP VESSM001 may be designed and
fabricated in accordance with that specification.
8.1.2 Vessels shall be provided with manways consisting of a nozzle with a fully bolted blind flange cover
with a hinge or davit, as shown in SES Q01-F20 or Q01-F27.
8.1.3 Vessels shall be provided with nameplates in accordance with SES Q01-F15.
8.2 Receiver
8.2.2 Add the following sentence:
Vortex breakers shall comply with SES Q01-F18.
8.3 Oil Separator (Rotary Compressor Systems)
8.3.1 Substitute the paragraph as follows:
Mounting of the motor/compressor drive train on a horizontal oil separator shall be limited to drivers rated
less than 560 kW, unless otherwise approved by SABIC. If the driver is rated greater than 560 kW, then the
system shall be supplied with an independently supported drive train.
8.4 Oil Recovery Pots (Reciprocating or Rotary Compressor)
8.4.2 Substitute the paragraph as follows:
Recovery pots shall comply with 8.1.1.
8.5 Suction Knockout Drum
8.5.4 Add the following sentence:
Mesh pad demisters, when supplied, shall comply with SES Q01-F31.
8.5.8 Substitute the paragraph as follows:
Suction knockout drums shall comply with 8.1.1.
8.6 Economizer (If Provided)
8.6.6 Substitute the paragraph as follows:
Economizers shall comply with 8.1.1.
9. Oil System
9.1 General
9.1.2 Add the following sentence:
When specified on the data sheets, the oil system shall comply with SES G03-S01.
9.6 Lubrication Systems Tests
9.6.1 Add the following sentences:
Lubrication system functional and cleanliness tests shall comply with SES G03-S01 if specified on the
data sheets. Functional test of the lube system shall be done with the oil to be finally used in the service.
11. System Instrumentation and Control
Add the following new paragraph:
In addition to the requirements of this section, system instrumentation and control shall comply with SES X01-S03.
11.1 Controls
Substitute the sentence as follows:
11.1.5.1 Microprocessor control shall have a graphic display with SI units.
12. Control Panel
Add the following new paragraphs:
12.11 Control panels shall be provided with a sunshade, to allow viewing of the graphic display even in
conditions of bright sunlight.
12.12 Control panels shall be provided with rear opening doors for maintenance access.
13. Electrical
13.1 General
13.1.4 Add the following new paragraph:
Electric motors, electrical components and electrical installations shall be suitable for the hazardous area
classification specified by SABIC on the data sheets, and shall conform to SES E02-E02 and NFPA 70.
13.2 Wiring and Terminations
13.2.6 Add the following new paragraph:
The electrical components, installations, wiring and terminations shall comply with SES E19-S01.
14. Pipe, Valves and Fittings
14.1 Add the following sentence:
Specific SABIC piping material specifications may also be applied to fluorocarbon based refrigerant piping
within the vendor’s skid boundaries, to ensure that this piping matches off-skid piping furnished by others.
14.2 Add the following sentence:
Specific SABIC piping material specifications may also be applied to hydrocarbon or ammonia based
refrigerant piping within the vendor’s skid boundaries, to ensure that this piping matches off-skid piping
furnished by others.
15. Pressure Relieving Devices
15.5 Add the following new paragraph:
When specified on the data sheets, the vendor shall supply dual, 100 percent capacity relief valves with
upstream and downstream block valves to allow a relief valve to be serviced without shutting down the unit.
The upstream block valve may be a switching type valve, to ensure that one relief valve always remains in
service. The handles on the upstream and downstream valves shall clearly indicate whether the valve is
open or closed, and shall be suitable for carsealing or locking. Upstream and downstream 1 inch vent
valves shall be provided between the relief valve and the corresponding block valve.
16. Insulation
16.3 Substitute the paragraph as follows:
Vendor shall indicate on the system flow diagram which items shall be insulated.
16.4 Add the following new paragraph:
The vendor shall supply insulation supports, rings or clips on vessels or heat exchangers, if so noted on the data sheets.
17. Structural Steel Skids
17.6 Add the following sentence:
Spreader bars shall comply with ASME B30.30.
17.13 Add the following sentence:
Lifting lugs shall comply with ASME B30.30.
18. Noise
Add the following sentence:
Noise level shall not exceed 85 dBA at 1 m from the skid, and shall also comply with SES S20-G01.
20. Painting
20.9 Add the following new paragraph:
Paint selected for piping or equipment to be insulated shall be compatible with the type of insulation to be applied.
21. Inspection
21.1 Vendor Quality Requirements
21.1.1 Add the following sentences:
The minimum surveillance requirements for the package are outlined in the appendix to PIP RESR001. Specific requirements for observed and witnessed inspections and tests will be outlined in the requisition documents.
Add the following new subsection:
21.6 Material Inspection
When radiographic, ultrasonic, magnetic particle or liquid penetrant inspection of welds or materials is
required or specified, the criteria in 21.6.1 to 21.6.4 shall apply unless other criteria are specified by SABIC.
When specified, cast iron shall be inspected in accordance with 21.6.3 and 21.6.4. When specified, welds,
cast steel and wrought material shall be inspected in accordance with 21.6.1 to 21.6.4.
21.6.1 Radiography
21.6.1.1 Radiography shall be in accordance with ASTM E 94 and ASTM E 142.
21.6.1.2 The acceptance standard used for welded fabrications shall be ASME Section VIII, Division 1,
UW-51 (100 percent) and UW-52 (spot). The acceptance standard used for castings shall be
ASME Section VIII, Division 1, Appendix 7.
21.6.2 Ultrasonic Inspection
21.6.2.1 Ultrasonic inspection shall be in accordance with ASME Section V, Articles 5 and 23.
21.6.2.2 The acceptance standard used for welded fabrications shall be ASME Section VIII, Division 1, Appendix 12. The acceptance standard used for castings shall be ASME Section VIII, Division 1.
21.6.3 Magnetic Particle Inspection
21.6.3.1 Both wet and dry methods of magnetic particle inspection shall be in accordance with
ASTM E 709.
21.6.3.1 The acceptance standard used for welded fabrications shall be ASME Section VIII, Division 1,
Appendix 6 and Section V, Article 25. The acceptability of defects in castings shall be based on a
comparison with the photographs in ASTM E125. For each type of defect, the degree of severity shall not exceed the following limits:
21.6.4 Liquid Particle Inspection
21.6.4.1 Liquid particle inspection shall be in accordance with ASME Section V, Article 6.
21.6.4.2 The acceptance standard used for welded fabrications shall be ASME Section VIII, Division 1, Appendix 8 and Section V, Article 24. The acceptance standard used for castings shall be ASME Section VIII, Division 1.
22. Testing and Preparation for Shipment
22.1 Substitute the paragraph as follows:
SABIC shall be notified at least 15 working days in advance of any witnessed testing, including testing of parts or assemblies in sub-vendor’s facilities.
22.15 Add the following new paragraph:
Unless otherwise specified, the entire system shall be prepared for export shipment and storage for up to 6 months from the date of shipment. Vendor shall submit their standard procedures for preparation for shipment for review and approval by SABIC.