1. SCOPE ………………………………………………………………………………..2. REFERENCES 3
3. DEFINITIONS 4
4. GENERAL ……………………………………………………………………………5. AIR COMPRESSOR
5.1 Casing 6
5.2 Rotors ……………………………………………………………………………..5.3 Gears 5.4 Bearings
5.5 Seals ………………………………………………………………………………6. ACCESSORIES
7. INSPECTION, TESTING AND PREPARATION FOR SHIPMENT 7.1 General …………………………………………………………………………..7.2 Inspection 7.3 Testing 7.4 Preparation for Shipment
1. Scope
This specification, along with the data sheets and referenced documents define the minimum
requirements for the performance, design, fabrication, testing, inspection and preparation for shipment of
packaged, skid mounted, rotary screw type air compressors typically used in utility or instrument air
services. This standard may also be used for packaged, skid mounted, rotary lobe air compressors.
Process type compressors are covered by SABIC Engineering Standard G09-S01 and are not considered
a part of this specification.
2. References
The latest edition of the following standards, codes or specifications in effect at the time of an award of a
purchase order by SABIC shall, to the extent specified herein, form a part of this specification.
ABMA (American Bearing Manufacturers Association)
Std-9 Load Ratings and Fatigue Life for Ball Bearings
Std-11 Load Ratings and Fatigue Life for Roller Bearings
Std-20 Metric Bearings Boundary Dimensions
AGMA (American Gear Manufacturers Association)
Practice for Enclosed Speed Reducers or Increasers Using Spur, Helical, Herringbone and Spiral Bevel
Gears
Practice for High Speed Helical and Herringbone Gear Units
ASME (American Society of Mechanical Engineers)
B1.20.1 Pipe Threads, General Purpose (Inch)
B16.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125 and 250
B16.5 Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24
B16.11 Forged Fittings, Socket Welded and Threaded
B16.42 Ductile Iron Pipe Flanges and Flanges Fittings
B31.3 Process Piping
BPVC Boiler and Pressure Vessel Code including:
Section V, Nondestructive Examination
Section VIII, Pressure Vessels
Section IX, Welding and Brazing Qualifications
ASTM (American Society for Testing and Materials)
A278M Standard Specification for Gray Iron Castings for Pressure Containing Parts up to 350 Degrees
Celsius
A395M Standard Specification for Ferritic Ductile Iron Pressure Retaining Castings for Use at Elevated
Temperatures
E94 Standard Guide for Radiographic Testing
E125 Reference Photographs for Magnetic Particle Indications on Ferrous Castings
E142 Standard Method for Controlling Quality of Radiographic Testing
E709 Magnetic Particle Examination
AWS (American Welding Society)
D1.1 Structural Welding Code – Steel
D14.6 Specification for Welding of Rotating Elements of Equipment
ISO (International Organization for Standardization)
Std 1000 SI Units and Recommendations for the Use of their Multiples and of Certain Other Units
NFPA (National Fire Protection Association)
National Electric Code
SABIC Engineering Standards (Saudi Basic Industries Corporation)
E02-E02 Hazardous Area Classification
E06-S01 Induction Motors 150 kW and Below
E06-S02 Induction Motors 185 kW and Above
E19-S01 Packaged Equipment Electrical Requirements
G03-S01 Lubrication, Shaft Sealing, Control Oil Systems and Auxiliaries
G06-S01 General Purpose Steam Turbines
G07-S01 General Purpose Gears
G20-E01 Installation of Rotating Machinery and Criteria for Installation Design
G22-S02 Specification for Skid Mounted Equipment
P01-E39 Auxiliary Piping for Mechanical Equipment
S20-G01 Equipment Noise Control
X01-S03 Instrumentation for Packaged Equipment
SSPC (Structural Steel Painting Council)
SP 6 Commercial Blast Cleaning
3. Definitions
Maximum allowable temperature: The maximum continuous temperature for which the manufacturer has
designed the equipment (or any part to which the term is referred) when handling the specific fluid at the
specified temperature.
Maximum allowable working pressure: The maximum continuous pressure for which the manufacturer has
designed the equipment (or any part to which the term is referred) when handling the specific fluid at the
specified temperature.
Maximum continuous speed (revolutions per minute): The speed of the power input rotor at least equal to
105 percent of the highest speed required by any of the specified operating conditions.
Normal operating point: The point at which usual operation is expected and optimum efficiency is desired.
This point is usually the point at which the vendor certified that performance is within the tolerances stated
in this engineering standard.
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.
SABIC: As used in this standard may refer to the Saudi Basic Industries Corporation, SABIC member
companies or SABIC’s designated representative.
Standard volume flow: The flow rate expressed in ISO standard conditions as normal cubic meters per
(Nm3/hr) at an absolute pressure of 101.3 kPa and a temperature of 0 °C .
Unit responsibility: The responsibility for coordinating the technical aspects of the equipment and all
auxiliary systems included in the scope of the order. It includes responsibility for reviewing such factors as
the power requirements, speed, rotation, general arrangement, couplings dynamics, noise, lubrication,
sealing system, material test reports, instrumentation, piping and testing of components.
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 requires written
notification of a successful preliminary test.
4. General
The vendor shall supply a positive displacement, water or air cooled, rotary screw or rotary lobe
compressor capable of delivering 100 percent oil free air. There shall be no lubricant within the
compressor chambers. The components of each compressor unit shall be delivered fully packaged,
mounted on a common baseplate and fully enclosed by a steel sound dampening enclosure.
The vendor shall provide, as a minimum, the equipment components listed below as a part of the complete
package to meet the specified operating conditions:
Rotary multi-stage compressor
Intercoolers and aftercoolers, each with moisture separator and automatic moisture removal
Dry type air inlet filter on the compressor inlet
Suction throttle valve, if required for capacity control
Unloading valve
Discharge check valve
Interstage and discharge relief valves
Inlet and discharge silencers
Driver
Coupling and guard
Lube oil system
Expansion joint on air discharge connection
Controls and instrumentation to maintain plant air system at a constant pressure
Control panel with specified indicators, alarm and shutdown annunciators
Baseplate
Unless otherwise specified, the compressors will be installed outdoors without a roof in Saudi Arabia.
Weather conditions in which the equipment must operate, including maximum and minimum temperatures,
unusual humidity, and dust problems will be shown on the data sheet. The unit and its auxiliaries shall be
suitable for operation in the specified conditions. The vendor shall list in the proposal any special
protection required.
The vendor shall assume unit responsibility for all equipment and all auxiliary systems included in the
scope of the order.
SABIC will specify the equipment’s normal operating point.
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 meet the requirements of
SABIC Engineering Standard E02-E02 and NFPA Bulletin Number 70.
All equipment shall be designed to permit rapid and economical maintenance. Major parts such as casing
components and bearing housings shall be designed (shouldered or cylindrically doweled) and
manufactured to ensure accurate alignment on reassembly.
Oil reservoirs and housings that enclose moving lubricated parts such as bearings, shaft seals, highly
polished parts, instruments and control elements shall be designed to minimize contamination by
moisture, dust and other foreign matter during periods of operation and idleness.
Spare parts for the machine and all auxiliaries shall meet all the criteria of this standard.
Unless otherwise specified, the equipment furnished by the vendor shall not exceed a noise level of 85
dBA measure at 1 meter when operated at the specified conditions. The complete installation shall conform
to the requirements of SABIC Engineering Standard S20-G01.
When tools and fixtures not commercially available are required to disassemble, assemble or maintain the
units, they shall be included in the quotation and furnished as part of the initial supply of the fan. For
multi-unit installations, SABIC and the vendor shall mutually agree upon the requirements for quantities of
special tools and fixtures.
5. Air Compressor
5.1 Casing
The compressor casing shall be a cast iron or cast steel for housing two screw or lobe type rotors. Any
permanent anti-corrosion coating applied to the internal surfaces of the casing shall be described in the
vendor’s proposal.
Inlet and outlet connections to the casing shall be flanged or machined and studded and suited for the
maximum allowable working pressure as defined in section 3 above.
Flanges shall conform to ASME B16.1, B16.5 or B16.42 as applicable.
Machined and studded connections shall conform to the facing and drilling requirements of ASME B16.1,
B16.5 or B16.42. Studs and nuts shall be furnished installed. The first 1-1/2 threads at both ends of each
stud shall be removed.
Casing openings for piping connections shall be at least NPS 1/2 and shall be flanged or machined and
studded. Where flanged or machined and studded openings are impractical, threaded openings in sizes
NPS ¾ through 1-1/2 are premissable.
Pipe threads shall be taper threads conforming to ASME B 1.20.1.
Openings for NPS 1-1/4, 2-1/2, 3-1/2, 5, 7 and 9 shall not be used.
Tapped openings not connected to piping shall be plugged with solid, round head steel plugs furnished in
accordance with ASME B16.11. As a minimum, these plugs shall meet the requirements of the casing.
Plugs that may later require removal shall be of corrosion resistant material. A lubricant that meets the
proper temperature shall be used on all threaded connections. Tape shall not be applied to threads of plugs
inserted into oil passages. Plastic plugs are not permitted.
5.2 Rotors
Rotors shall be of one piece steel construction. Internal cooling is not acceptable.
Rotor stiffness shall be adequate to prevent contact between the rotor bodies and the casing and between
gear timed rotor bodies at the most unfavorable specified conditions.
Any permanent anti-corrosion coating applied to the rotors shall be described in the vendor’s proposal.
5.3 Gears
Timing gears shall be fitted on the rotor shafts to maintain the rotors in correct position relative to each
other.
Timing gears shall be made of forged steel and shall be a minimum of AGMA Quality 7.
The meshing relationship between gear timed rotors shall be adjustable and the adjustment shall be
arranged for positive locking. The adjustment and locking provision shall be accessible with the rotors in
their bearings.
Gear boxes between the driver and the compressor or the bull gear and pinion gears used to drive multiple
stages of compression shall conform to the requirements of SABIC Engineering Standard G07-S01.
5.4 Bearings
Rotors shall be supported on each end by anti-friction type bearings. The bearings shall have a minimum
ABMA Standard 9 L10 life of 50,000 hours with continuous operation at normal conditions.
Except for the angular contact type, anti-friction bearings shall have a loose internal clearance fit
equivalent to ABMA Symbol 3 as defined in ABMA Standard 20. Single or double row bearings shall be of
the Conrad type (no filling slots).
Anti-friction bearing dmN factors shall not exceed the limits in the table below:
Anti-friction Bearing Limiting dmN Factors
5.5 Bearing Type
Splash Oil Lubricated
Pressure Oil Lubricated
Radial:
Single row ball bearings
450,000
500,000
Cylindrical roller bearings
Radial:
Tapered roller bearings
300,000
350,000
Spherical roller bearings
Thrust:
Single row ball bearings
200,000
350,000
Thrust:
Double row angular contact
250,000
300,000
Tapered roller bearings
230,000
250,000
Where:
dm = mean bearing diameter (d+D/2)
N = shaft speed (RPM)
5.5 Seals
Shaft seals shall be restricted ring type. The rings shall be made of carbon or other suitable material
mounted in retainers or spacers.
Oil seals shall be provided to prevent movement of lubricating oil into the compression chambers.
Dynamics
Rotors shall be of stiff shaft construction with the first actual lateral critical speed at least 120 percent of
the maximum allowable speed. A lateral critical analysis is not required unless otherwise specified.
The undamped torsional natural frequencies of the complete train shall be at least 10 percent above or 10
percent below any possible excitation frequency with the specified operating range from minimum to
maximum continuous speed.
Each rotor shall be individually dynamically balanced. The completely assembled rotating element,
including the shaft, shall be dynamically balanced.
The degree of balancing shall be such that the vibration levels measured during the shop test of the
assembled compressor shall not exceed the acceptance levels listed below. Velocity or acceleration
measurements shall be taken during shop testing to verify compliance.
Overall vibration at any speed within the operating range shall not exceed 8 mm/s RMS.
Discrete filtered frequency vibration at any speed within the operating range shall not exceed 5 mm/s RMS.
The increase in allowable vibration at speeds beyond operating speed but less than trip speed shall not
exceed 50 percent.
Materials
Materials of construction shall be the manufacturer’s standard for the specified operating conditions unless
otherwise noted on the data sheets or this standard. The metallurgy of all major components shall be
clearly stated in the vendor’s proposal.
Materials shall be identified in the proposal with their applicable ASTM, AISI, ASME or SAE numbers
including the material grade. Other international or national standards may be used if approved by the
purchaser.
Materials, casting factors and the quality of any welding shall be equal to those required by Section VIII,
Division 1 of the ASME Code. The manufacturer’s data report forms as specified in the code are not
required.
External parts that are subject to rotary or sliding motions (such as control linkage joints and adjusting
mechanisms) shall be of corrosion resistant materials suitable for the site environment.
Castings
Castings shall be sound and free from porosity, hot tears, shrink holes, blow holes, cracks, scale, blisters
and similar injurious defects. Surfaces of castings shall be cleaned by sandblasting, shotblasting, chemical
cleaning or any other standard method. Mold parting fins and remaings of gates and risers shall be
chipped, filed and ground smooth.
Welding
Welding of piping and pressure containing parts as well as any dissimilar metal welds and weld repairs
shall be performed and inspected by operators and procedures qualified in accordance with Section VIII,
Division 1 of the ASME Code.
Welding not covered by Section VIII, Division 1 of the ASME Code such as welding on baseplates or
control panels shall be performed in accordance with AWS D1.1.
Nameplates and Rotation Arrows
A nameplate shall be securely attached at a readily visible location on the equipment and on any other
major piece of auxiliary equipment.
Rotation arrows shall be cast in or attached to each major item of rotating equipment at a readily visible
location. Nameplates and rotation arrows (if attached) shall be type 300 stainless steel or a nickel-copper
alloy such as Monel. Attachment pins shall be of the same material. Welding is not permitted.
As a minimum, the following listed items shall be included on the nameplate. ISO units shall be shown.
Purchaser’s item number
Vendor’s name
Machine serial number
Design flow
Design discharge pressure
Power rating
Rotational speed
Maximum allowable working pressure
Maximum allowable temperature
Maximum allowable speed
6. Accessories
Drivers
Electric motor drivers shall conform to the requirements of SABIC Engineering Standard E06-S01 or
E06-S02 as applicable.
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.
Couplings and Guards
Couplings shall be dry type, spacer couplings and shall be supplied by the compressor vendor. Coupling
make may be specified by SABIC or mutually agreed upon by SABIC and fan vendor.
The coupling spacer length shall be sufficient to allow removal of the coupling hubs and allow
maintenance of adjacent bearings and seals without removal of the shaft or disturbing the equipment
alignment.
Each coupling shall have a coupling guard that sufficiently encloses the coupling and shafts to prevent any
personnel access to the danger zone during operation of the equipment train. The guard shall be readily
removable for inspection and maintenance of the coupling without disturbing the coupled machines.
Baseplate
The equipment feet and mating baseplate shall have machined surfaces.
Mounting pads shall be provided for all drive train components. The pads shall be larger than the foot of
the mounted equipment to allow leveling of the baseplate without removal of the equipment. The pads
shall be fully machined flat and parallel. Corresponding surfaces shall be in the same plane within 40
micrometers total variation between the pads. This requirement shall be met by supporting and clamping
the baseplate at the foundation bolt holes only.
The maximum surface roughness of the mounting pads shall be 3.2 micrometers or smoother.
The baseplate shall be supplied with leveling screws. Baseplates that are to be grouted shall have 50 mm
radius outside corners in the plan view. Mounting surfaces that are not to be grouted shall be coated with a
rust preventative immediately after machining.
Anchor bolt holes shall be drilled perpendicular to the mounting surfaces and spot faced to a diameter
three times that of the hole.
Anchor bolts will be furnished by SABIC.
Anchor bolts shall not be used to fasten machinery to the baseplate.
The vendor shall furnish stainless steel (AISI Standard Type 300) shim packs 3 mm to 6 mm thick under
the driver feet and the mounting pads. All shim packs shall straddle the hold-down bolts and vertical
jackscrews and be at least 5mm larger on all sides than the footprint of the equipment. Fasteners for
attaching the components to the baseplate and jackscrews for leveling the baseplate shall be supplied by
the vendor.
The baseplate shall be provided with lifting lugs for at least a four point lift. Lifting the baseplate complete
with all equipment mounted shall not permanently distort or otherwise damage the baseplate or the
machinery mounted on it.
The bottom of the baseplate between structural members shall be open. When the baseplate is installed on
a concrete foundation, accessibility shall be provided for grouting under all load carrying members.
The mounting pads on the bottom of the baseplate shall be in one plane to permit use of a single level
foundation.
The baseplate mounting pads shall be machined after the baseplate is fabricated.
Unless otherwise specified, the vendor shall commercially sand blast, in accordance with SSPC SP6, all
grout contact surfaces of the baseplate, and coat those surfaces with catalyzed epoxy primer. The epoxy
primer shall be compatible with epoxy grout.
Controls and Instrumentation
A microprocessor based control and instrumentation system suitable for outdoor installation in Saudi
Arabia shall be provided. The microprocessor shall be capable of communicating with the purchaser’s
distributed control system (DCS).
All conduit shall be designed and installed so that it can be easily removed without damage and located so
that it does not hamper removal of bearings, seals or equipment internals.
The compressor regulating system shall maintain a constant downstream air pressure as specified on the
equipment data sheets. The control system shall be integral to the compressor package and shall provide
circuits for loading delay at start-up and for idling delay at shut-off. The control system shall also provide for
automatic shut-off of the compressor during periods of low demand and excessive idling to conserve
energy.
The control panel shall be fully enclosed, NEMA 4X as a minimum, and shall have a display visible in
darkness or direct sunlight. The enclosure shall meet the specified hazardous area classification as shown
on the data sheets and conform to the requirements of SABIC Engineering Standard G20-E01.
The compressor shall include instrumentation to monitor the following variables, as a minimum:
Intercooler pressure
Discharge pressure
Oil pressure
Air intake filter pressure differential
Outlet air temperature (per stage)
Compressor running
Hour meter
Alarm annunciation for the following:
Low oil pressure
Low oil level in reservoir
High pressure differential at oil filters
High outlet air temperature (per stage)
High condensate level for intercooler and aftercooler traps
High intake air filter pressure differential
High vibration
Shut down annunciation for the following:
Low oil pressure
High oil temperature
High outlet air temperature (per stage)
High condensate level for intercooler and aftercooler traps
High vibration
Motor overload
Oil System
Bearings and bearing housings shall be arranged for hydrocarbon oil lubrication. The vendor shall provide
a pressurized oil system to supply oil at suitable pressure or pressures to all bearings, compressor timing
gears and the speed increasing gear, if supplied.
Pressure lubrication systems shall, as a minimum, consist of main and standby positive displacement oil
pumps with suction strainers, supply and return system, an oil cooler, twin full flow filters, a low lube oil
pressure shutdown switch and other necessary instruments.
The main oil pump shall be shaft driven. The standby oil pump shall be automatically controlled and driven
by an electric motor. The motor shall conform to the requirements of SABIC Engineering Standard
E06-S01.
Individual relief valves shall be provided for each positive displacement pump. These valves shall function
only to protect the pumps from overpressure.
A separate direct acting back pressure control valve with manual bypass shall be provided. The control
valve shall be designed to maintain system pressure with both pumps operating.
An oil cooler shall be provided to maintain the oil supply temperature at or below 60 °C. Shell and tube
coolers shall have water on the tube side. A removable bundle design is required for coolers with more
than 0.45 square meters of surface area. Removable bundle coolers shall be in accordance with TEMA C
and shall be constructed with a removable channel cover. A self contained, carbon steel, thermostatically
controlled, oil temperature control valve that bypasses oil for temperature control shall be provided.
Twin full flow filters with replaceable elements and filtration of 10 microns nominal or finer shall be
supplied. The filters shall be located downstream of the cooler and shall be supplied complete with a
separate or integral continuous flow transfer valve that provides tight shutoff to the idle filter. The system
shall be designed to permit cartridge replacement and repressurizing during operation.
A thermostatically controlled electric immersion heater with a sheath of AISI type 300 stainless steel shall
be provided the reservoir charge capacity of oil before start-up in cold weather. The heater shall sufficient
capacity to heat the oil from the specified minimum ambient temperature to the manufacturer’s required
start-up temperature within 12 hours. The watt density of the heater shall not exceed 2.0 watts per square
centimeter.
An oil reservoir of austenitic stainless steel or carbon steel, lined with the vendor’s standard coating, shall
be provided. The reservoir shall include:
A retention time of at least 3 minutes, based on normal flow at pump normal capacity and total volume
below the minimum operating level
An oil level indicator
A mounted low point drain valve
A temperature gauge
A removable cover plate for inspection and clean-out
Separate fill and vent connections
Inlet Air Filter / Silencer
The vendor shall provide a dry type, multi-stage, high efficiency air intake filter / silencer suitable for
mounting outdoors. This filter / silencer shall be provided with the following:
A differential pressure gauge and switch.
A design such that the first stage (pre-filter) elements may be changed while the unit is operating.
Weather hood or louvers
Clean pressure drop across the filter elements that does not exceed 5.0 millibar water gauge.
Removal of a minimum of 97 percent of particle sizes 0.025 mm or larger over the inlet capacity range.
Intercooler, Aftercooler and Condensate System
The vendor shall furnish an intercooler between each compression stage and, unless otherwise specified,
an aftercooler after the final compression stage
Intercoolers and aftercoolers shall be designed and constructed in accordance with Section VIII, Division 1
of the ASME Code.
Unless otherwise specified, intercoolers and aftercoolers shall be of the water cooled shell and tube type
with water on the tube side. A removable bundle design is required. Removable bundle cooler shall be in
accordance with TEMA Class C and shall be constructed with a removable channel cover. Tubes shall not
have an outside diameter of less than 15 mm and the tube wall thickness shall not be less than 1.25 mm.
Unless otherwise specified, cooler shells, channels and covers shall be of steel, tube sheets shall be of
brass and tubes shall be of inhibited admiralty. U-bend tubes are not permitted. Each cooler shall be sized
to accommodate the total cooling load. Vent and drain valves shall be included on the water side of coolers.
Unless otherwise approved by SABIC, intercoolers and aftercoolers shall be constructed and arranged to
allow removal of the tube bundles without dismantling piping or compressor components.
The vendor shall include details of any proposed air cooler in the proposal.
Unless otherwise specified, air cooled heat exchangers used for intercoolers shall have automatic
temperature control. This control may be accomplished by means of louvers, variable speed fans, variable
pitch fans, bypass valves or any combination of these. Proposed control systems will be approved by
SABIC.
Moisture separation shall be located between each intercooler and the following compression stage. The
condensate system shall have a v-notch gate valve or a SABIC approved drainer. Condensate piping shall
be stainless steel and shall be prefabricated as a part of the package although it may be removed for
shipping.
7. Inspection, Testing and Preparation For Shipment
7.1 General
SABIC will specify the extent of participation in the inspection and testing, including any witness or
observed points and the amount of advance notification required.
The vendor shall notify sub-vendors of SABIC’s inspection and testing requirements.
SABIC shall have entry to all vendor and sub-vendor’s plants where manufacturing, testing or inspection of
the equipment is in progress.
The vendor shall provide equipment for the specified inspection and tests.
7.2 Inspection
General
The vendor shall keep the following data available for at least 20 years for examination or reproduction by
SABIC upon request:
Material certificates of compliance for shafts, rotors, pinions and bull gears.
Test data to verify that the requirements of the specification have been met, such as hydro tests,
mechanical performance tests, and any optional tests specified by the purchaser.
Results of documented tests and inspections, including fully identified records of all heat treatment and
nondestructive examinations.
Final assembly maintenance and running clearances.
Pressure containing parts shall not be painted until the specified inspection of the parts is completed.
SABIC shall have access to the vendor’s quality program for review.
Material Inspection
General
Unless otherwise specified, the criteria in 7.2.2.2 through 7.2.2.5 shall apply when radiographic, ultrasonic,
magnetic particle or liquid penetrant inspection of welds or materials is required. Cast iron may be
inspected in accordance with 7.2.2.4 and 7.2.2.5. Welds, cast steel and wrought material may be
inspected in accordance with 7.2.2.2 through 7.2.2.5.
Radiography
Radiography shall be in accordance with ASTM E94 and ASTM E142.
The acceptance standard used for welded fabrications shall be Section VIII, Division 1, UW-51 (100
percent) and UW-52 (spot) of the ASME Code. The acceptance standard used for castings shall be
Section VIII, Division 1, Appendix 7 of the ASME Code.
Ultrasonic Inspection
Ultrasonic inspection shall be in accordance with Section V, Articles 5 and 23 of the ASME Code.
The acceptance standard used for welded fabrications shall be Section VIII, Division 1, Appendix 12 of the
ASME Code. The acceptance standard sued for castings shall be Section VIII, Division 1, Appendix of the
ASME Code.
Magnetic Particle Inspection
Both wet and dry methods of magnetic particle inspection shall be in accordance with ASTM E709.
The acceptance standard used for welded fabrications shall be Section VIII, Division 1, Appendix 6 and
Section V, Article 25 of the ASME Code. 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 limits specified below:
Type
Defect
Maximum
Severity Level
I
Linear discontinuity
1
II
Shrinkage
2
III
Inclusions
2
IV
Chills and Chaplets
1
V
Porosity
1
VI
Welds
1
Liquid Particle Inspection
Liquid particle inspection shall be in accordance with Section V, Article 6 of the ASME Code.
The acceptance standard used for welded fabrications shall be Section VIII, Division 1, Appendix 8 and
Section V, Article 24 of the ASME Code. The acceptance standard used for castings shall be Section VIII,
Division 1, Appendix of the ASME Code.
Mechanical Inspection
During assembly of the equipment and before testing, each component (including cast in passages of
these components) and all piping and appurtenances shall be cleaned chemically or by other appropriate
method to remove foreign materials, corrosion products and mill scale.
Any portion of the oil system furnished shall meet the cleanliness requirements of SABIC Engineering
Standard G03-S01.
SABIC will inspect for cleanliness the equipment and all piping and appurtenances furnished by or through
the vendor before heads are welded to vessels, openings in vessels or exchangers are closed or piping is
finally assembled.
The hardness of parts, welds and heat affected zones shall be verified as being within the allowable values
by testing. The method, extent, documentation and witnessing of the testing shall be mutually agreed upon
by SABIC and the vendor.
The vendor shall verify that dimensions of all rotating and stationary gas path components fall within the
drawing tolerances.
7.3 Testing
General
The package shall be tested in accordance with 7.3.2 through 7.3.3.
At least 6 weeks before the first scheduled running test, the vendor shall submit detailed procedures for the
mechanical running test and all specified optional tests to SABIC for review and comment.
The vendor shall notify SABIC not less than 15 working days before the date the equipment will be ready
for testing.
Hydrostatic Tests
Pressure containing parts (including auxiliaries) shall be tested hydrostatically with liquid at a minimum of
one and one-half times the maximum allowable working pressure but not less than 150 kPag. The test
liquid shall be at higher temperature than the nil-ductility transition temperature of the material being tested.
Where applicable, tests shall be in accordance with the ASME Code. In the event a discrepancy exists
between the code test pressure and the test pressure in this standard, the higher pressure shall govern.
Tests shall be maintained for a sufficient period of time to permit complete examination of parts under
pressure. The hydrostatic test shall be considered satisfactory when neither leaks nor seepage through the
casing or casing joint is observed for a minimum of 30 minutes. Large, heavy casings may require a longer
testing period to be agreed upon by SABIC and the vendor.
The chloride content of liquids use to test austenitic stainless steel materials shall not exceed 50 parts per
million. To prevent deposition of chlorides as a result of evaporative drying, all residual liquid shall be
removed from tested parts at the conclusion of the test.
Following hydrotest, the parts including the air intercoolers and aftercoolers shall be cleaned and dried to
prevent corrosion.
If approved by SABIC, hydrotest certificates shall be acceptable in lieu of witness testing of normally
stocked components.
Combined Mechanical and Performance Test
The combined mechanical and performance test of the package, including the lube oil system, bearings,
seal and vibration monitoring system, shall be conducted at rated operating speed for a continuous period
of 4 hours.
A minimum of five test points shall be recorded. Test points shall include Normal, Rated, relief valve set
point and unloaded conditions. Vibration readings shall be recorded at each test point.
All oil pressures, viscosities and temperatures shall be within the range of operating values recommended
in the vendor’s operating instructions for the specific unit being tested. Performance data shall be obtained
only after bearing and lube oil temperatures have stabilized.
The following requirements shall be met during the combined mechanical and performance test:
With the compressor operating at its rated discharge pressure, the delivered capacity at the tested, rated
operating point shall have zero negative tolerance when compared to rated capacity.
The required power at the tested rated operating point shall not exceed 104 percent of the value quoted
for the rated operating point.
Compressor vibration levels shall meet the criteria of 5.6.4.
If replacement or modification of bearings or seals is required to correct mechanical or performance
deficiencies, the initial test run will not be acceptable. The final shop tests shall be made after these
replacements are made.
7.4 Preparation for Shipment
Equipment shall be suitably prepared for the type of shipment specified, including blocking of the rotor
when necessary. Blocked rotors shall be identified by means of corrosion resistant tags attached with
stainless steel wire. The preparation shall be suitable for a period of 6 months outdoor storage from the
time of shipment, with no disassembly required before operation, except for bearing and seal inspections.
If storage is contemplated for longer periods, SABIC shall consult with the vendor regarding procedures to
be followed.
The vendor shall provide SABIC with the instructions necessary to preserve the integrity of the storage
preparation after the equipment arrives at the job site and before start-up.
Preparation for shipment shall be made after all testing and inspection of the equipment has been
accomplished and the equipment has been accomplished and the equipment has been approved by
SABIC. The preparations shall include as a minimum those listed below;
Exterior surfaces, except for machined surfaces, shall be given at least one coat of the manufacturer’s
standard paint. The paint shall not contain lead or chromates.
Exterior machined surfaces except for corrosion resistant material shall be coated with a suitable rust
preventative.
The interior of the equipment shall be clean; free from scale, welding spatter and foreign objects. The
interior shall be sprayed or flushed with a suitable rust preventative that can be removed with solvent.
Internal steel areas of bearing housings and carbon steel oil systems’ auxiliary equipment such as
reservoirs, vessels and piping shall be coated with a suitable oil soluble rust preventative.
All flanged auxiliary piping connections shall be provided with metal closures of 5 mm minimum thickness
with elastomer gaskets and at least four full diameter bolts. For studded openings, all nuts needed for the
intended service shall be used to secure closures. Each opening shall be car sealed so that the protective
cover cannot be removed without the seal being broken.
All threaded openings shall be provided with steel caps or long shank steel plugs. In no case shall
nonmetallic plugs be used.
All auxiliary piping connections that have been beveled for welding shall be provided with closures
designed to prevent entrance of foreign materials and damage to the bevel.
The center of gravity, the lifting points and the lifting lugs shall be clearly identified.
Equipment shall be identified with the item and serial numbers. All material shipped separately shall be
identified with securely affixed corrosion resistant metal tags indicating the item and serial number for
which it is intended.
One copy of the manufacturer’s standard installation instructions shall be packed and shipped with the
equipment.
8. Vendor’s Data
8.1 Proposals
The vendor’s proposal shall include the information listed below. The vendor shall include the time
schedule for transmission of drawings, curves and data.
Copies of SABIC’s data sheets with complete vendor’s information entered.
Complete performance curves to fully define the envelope of operations and the specific guarantee point.
Utility requirements such as steam, water, electricity, air and gas plus driver ratings and net loads.
Approximate data shall be defined clearly as such. This information shall be entered on the data sheets
where applicable.
Net and maximum operating weights, maximum erection weight with identification of the item. These data
shall be stated individually where separate shipments, packages or assemblies are involved. These data
shall be entered on the data sheets where applicable.
Preliminary outline and arrangement drawings and schematic diagrams.
Typical cross sectional drawings and literature to fully describe details of the offerings.
Details of shaft seals.
A specific statement that the system and all components are in strict accordance with SABIC’s
specifications. If not in strict accordance with the specifications, the vendor must include a specific list
detailing and explaining every deviation. Deviations may include alternative designs or systems equivalent
to and guaranteed for the specific duties.
An explicit statement of any deviations from the specified guarantee and warranty.
A statement of the fixed number of weeks to effect shipment after receipt of the order. A separate time shall
be stated for manifold shipment, as in the case of separate packages, assemblies or multiple units.
A statement of the vendor’s promised times after order placement for transmittal of the contract data. This
information shall be presented in the form of an explicit schedule.
A list of spare parts recommended for normal maintenance purposes. SABIC will specify any specific
requirements for long term storage.
An itemized list of the special tools included in the offering.
The tests and procedures for materials as required by this standard.
A statement of the rate for furnishing a competent erection supervisor, plus an estimate of the length of
time the erection supervisor’s services might be required under normal conditions.
An outline of necessary special weather and winterizing protection required by the fan, the auxiliaries and
the driver for start-up, operation and idleness. The vendor shall quote separately protective items he
proposes to furnish.
Contract Data
Drawings
SABIC shall state in the inquiry and in the order the number of prints required and the times within which
they are to be submitted by the vendor.
Review of the vendor’s drawings will be made promptly after receipt by SABIC. Such review does not
constitute permission to deviate from any requirements in the order unless specifically agreed upon in
writing. After the drawings have been reviewed, the vendor shall furnish copies in the quantity specified.
All drawings must be clearly legible.
Typical drawings are not acceptable. The following information shall be provided on the drawings:
SABIC’s order number on every drawing.
SABIC’s equipment number on every drawing.
The weight of each assembly of the heaviest piece of equipment that must be handled for erection and of
significant items that must be handled for maintenance.
All principal dimensions, including those required for SABIC’s foundation, piping design, maintenance
clearances and dismantling clearances.
The direction and magnitude of all unbalanced forces, couples and location of the center of gravity.
The direction of rotation.
The size, type, location and identification of all SABIC’s connections, including vents, drains, lubricating
oil, and instruments. The vendor’s plugged connections shall be identified.
When applicable, the make size and type of couplings and the location of guards and their coverage.
Complete bill of materials covering the vendor’s entire scope of supply.
A list of reference drawings.
Special weather protection and climitization features, if any.
The vendor shall supply schematic diagrams of each system in the vendor’s scope of supply, plus outline
drawings and specifications for the components thereof.
The vendor shall supply cross sectional or assembly type drawings for all equipment furnished showing all
parts, running fits, clearances and balancing data required for erection or maintenance. Typical drawings
are unacceptable.
Data
The vendor shall provide full information to enable completion of the data sheets, first for ’as purchased’
and then ’as built’. This should be done by correcting and filling out the data sheet and submitting copies.
The vendor shall make available to SABIC the following information;
The vendor’s physical and chemical data from mill reports or certifications of materials.
Completed as built data sheets.
A parts list shall be furnished for all equipment supplied and shall include pattern, stock or production
drawing numbers and materials of construction. The list shall completely identify each part so that SABIC
may determine the interchangeability of parts with other equipment furnished by the same manufacturer.
The original manufacturer’s part numbers shall identify standard purchased items.
No later than 5 days after the scheduled shipping date, the vendor shall furnish the required number of
instruction manuals for the equipment and any auxiliaries and instruments provided. The manual shall
include legible drawings for the specific equipment, parts list and completed data sheets. It shall include
instructions covering installation, final tests and checks, start-up, shutdown, operating limits and operating
and maintenance procedures. The recommended clearances and maximum and minimum design
clearance shall be clearly stated.
The vendor shall submit a supplementary proposal for spare parts other than those included in the original
quotation. This supplementary proposal shall include recommended spare parts, cross sectional or
assembly type drawings, parts numbers, materials, prices and delivery. Parts numbers shall identify each part for interchangeability purposes. The original manufacturer’s numbers shall identify standard
purchased items. This supplementary proposal shall be forwarded to SABIC promptly after receipt of
approved drawings and in time to permit order and delivery of parts prior to field start-up.
Certified copies of the shop running test log, performance data and other test data agreed upon shall be
submitted to SABIC prior to shipment.
Vendor Information
The vendor shall complete the vendor information data sheet detailing the time schedule for transmission
of drawings, curves and data as agreed to at time of order and the exact number of copies required by
SABIC.
When specified, progress reports shall be submitted to SABIC at the specified frequency. The reports shall
include engineering and manufacturing on all major components.