Section 1 – General ……………………………………………………………………………………1.1 Scope ……………………………………………………………………………………1.2 Alternative Designs ……………………………………………………….1.3 Conflicting Requirements ……………………………………………………….1.5 Referenced Publications ……………………………………………………….Section 2 – Basic Design …………………………………………………………………………………..2.1 General ……………………………………………………………………………………2.2 Allowable Speeds ……………………………………………………….2.3 Allowable Discharge Temperature ……………………………………………………….2.4 Rod and Gas Loading ……………………………………………………….2.5 Critical Speeds ……………………………………………………………………………………2.6 Compressor Cylinders ……………………………………………………….2.7 Valves and Unloaders ……………………………………………………….2.8 Pistons, Piston Rods, and Piston Rings …………………………..2.9 Crankshafts, Connecting Rods, Bearings, and Crossheads2.10 Distance Pieces ……………………………………………………………………………………2.11 Packing Cases and Pressure Packing …………………………..2.12 Compressor Frame Lubrication ……………………………………………………….2.13 Cylinder and Packing Lubrication ……………………………………………………….2.14 Materials ……………………………………………………………………………………Section 3 – Accessories ………………………………………………………………………………….3.1 Drivers ……………………………………………………………………………………3.2 Couplings and Guards ……………………………………………………….3.3 Reduction Gears ………………………………………………………………………………….3.4 Belt Drives ……………………………………………………………………………………3.5 Mounting Plates …………………………………………………………………………………..3.6 Controls and Instrumentation ……………………………………………………….3.7 Piping and Appurtenances ……………………………………………………….3.9 Pulsation and Vibration Control Requirements …………………………..3.11 Special Tools ……………………………………………………………………………………Section 4 – Inspection, Testing, and Preparation for Shipping …………………………..4.1 General ……………………………………………………………………………………4.4 Preparation for Shipment ……………………………………………………….Section 5 – Vendor’s Data ……………………………………………………….5.1 General ……………………………………………………………………………………5.2 Proposals ……………………………………………………………………………………5.3 Contract Data ……………………………………………………………………………………Revision History………………………………………..………………………
1 Purpose
American Petroleum Institute (API) standard 618, Reciprocating Compressors for Petroleum,
Chemical, and Gas Industry Services, Fourth Edition, dated June 1995 is adopted as a
SABIC Engineering Standard (SES) with the following addendum.
2 General
Reciprocating compressors manufactured and packaged to this standard shall comply with
API 618, Fourth Edition, except as modified herein or as set forth in the data sheets, project
specifications, or the purchase order.
3 Addenda
The following section, subsection, paragraph numbers refer to API
618, Fourth Edition.
Section 1 – General
1.1 Scope
1.2.1 Add the following new paragraphs:
1.1.3.1 Compressors shall be supplied by vendors qualified by experience to
manufacture and package the units being proposed. The vendor
shall be considered qualified if, at the location proposed for
manufacture and packaging, they have previously manufactured and
packaged at least two units of the same model as that being
proposed which meet the following requirements:
a. Compressor units being proposed shall be of identical
design
b. The materials for the compressor running gear being
proposed shall be identical to that on which the identical
compressor experience is based
c. Rated power, inlet temperatures and discharge temperatures
shall be equal to or greater than those of the compressor
being proposed
d. The speed range of the compressor being proposed, from
minimum governor to maximum continuous speed, shall not
exceed those on which the identical machine experience is
based
1.1.3.2 The two machines shall have been in continuous operation for a
minimum of 8,000 hours each and shall have performed satisfactorily
throughout their operation. Major damage to the compressor/driver
components shall constitute cause for disqualification.
1.1.3.3 Proof of compliance with the above requirements shall be submitted
to SABIC with the equipment proposal.
1.1.3.4 Where the vendor qualification requirements of 2.2 and 2.3 prevents
the application of the latest technology, vendor shall submit a second
alternative proposal incorporating the latest technology features for
evaluation by SABIC. This alternative proposal shall specifically
identify the features undemonstrated by experience, and state their
advantages.
1.1.3.5 When the compressor vendor is assigned unit responsibility for a
complete train, their unit responsibility shall include the following:
a. An integrated control system, including a system to monitor
and protect the unit
b. Gear boxes, when required
c. Couplings
d. Equipment layout and baseplate design
e. All required auxiliary equipment, including the lubrication
systems
f. Performance and reliability of the complete train
g. Lateral and torsional dynamic analysis
h. Noise attenuation to the required 85 dBA level at one meter
1.2 Alternative Designs
1.2.1 Add the following paragraph:
The compressor package shall be the manufacturer’s standard design to the
maximum extent possible. The vendor shall fully describe their exceptions to
this Engineering Standard in the proposal. The vendor may submit an
alternative proposal incorporating the latest technology features for
evaluation by SABIC, but SABIC is not bound to evaluate this proposal.
1.3 Conflicting Requirements
Add the following sentence:
Any conflict(s) between this specification, SES and industry standards, engineering
drawings, and contract documents shall be resolved at the discretion of SABIC.
1.5 Referenced Publications
1.5.2 Add the following paragraph:
The following standards are part of this addendum. The latest issues,
amendments and supplements to these documents shall apply unless
otherwise indicated.
SABIC Engineering Standards (SES)
E02-E02 Hazardous Area Classification
E06-S01 Induction Motors 150 kW and Below
E06-S02 Induction Motor 185 kW and Above
E06-S03 Synchronous Motors
E19-S01 Packaged Equipment Electrical Requirements
G06-S01 General Purpose Steam Turbines
G06-S02 Special Purpose Steam Turbines
G07-S01 General Purpose Gear Units
G07-S02 Special Purpose Gear Units
G12-S01 Special Purpose Couplings
G13-T01 Shop Inspection and Testing of Reciprocating Compressors
G19-S01 Machinery Protection Systems
S20-G01 Plant Equipment Noise Limits
X01-S02 Local Control Panels
X01-S03 Instrumentation for Packaged Units
X05-S01 General Specification for PLC Systems
Steel Structures Painting Council (SSPC)
SSP10 White Metal Blasting
Section 2 – Basic Design
2.1 General
2.1.2 Add the following sentence:
Maximum allowable SPL shall be 85 dBA at one meter. See SES S20-G01.
2.1.4 Add the following sentence:
If the unit is equipped with a PLC, the PLC shall be programmed to avoid the
undesirable speeds specified by the vendor.
2.1.5 Substitute the paragraph as follows:
Equipment shall be designed to run simultaneously to the trip-speed and
relief valve setting without damage.
2.1.7 Substitute the paragraph as follows:
Motors, electrical components, and electrical installations shall be suitable for
the area classification (class, group, division, or zone) specified by SABIC on
data sheets and shall meet the requirements of NFPA 70, Article 500, 501,
502 and 504 and SES E02-E02 and E19-S01.
2.1.9 The decision is as follows:
Major components shall be shouldered and cylindrically doweled, to ensure
alignment on reassembly.
2.1.14 The decision is as follows:
Unless otherwise specified on the data sheets, the installation shall be
designed for unprotected outdoor desert environment. Site specific data shall
be used for the equipment design. Connections shall be provided on, for
example, the crankcase, distance piece and other necessary parts, for N2
purge, to prevent dirt intrusion into critical areas.
2.1.16 The decision is as follows:
Periodic loading shall be used to purge and cool cylinders. SABIC and the
vendor shall jointly determine the loading/unloading sequencing required to
accomplish the desired results.
2.1.20 Add the following new paragraph:
Vendor shall give special consideration to the selection of material for rider
and piston rings for non-lubricated cylinders handling dry gases. Vendor to
submit details for approval.
2.2 Allowable Speeds
Add the following sentence:
Unless otherwise specified, the maximum allowable average piston speed shall not
exceed 4.3 m/s (850 ft/min) for a lubricated machine, and 3.05 m/s (600 ft/min) for a
non-lube machine.
2.3 Allowable Discharge Temperature
2.3.1 Add the following sentence:
In the proposal stage, the vendor shall provide expected maximum discharge
temperatures for all stages at all loading conditions.
2.3.2 The decision is as follows:
SABIC will specify on the data sheets whether or not 100 percent automatic
unloading to control discharge temperature is allowed.
Note: Whether or not 100 percent unloading is allowable as a means to
control discharge temperature is normally a function of the effect this
condition will have on the process. A preliminary HAZID should be conducted
to determine if this is acceptable.
2.4 Rod and Gas Loading
2.4.1.6 Add the following new paragraph:
The vendor shall, at SABIC’s request, furnish all rod load
calculations as required to show compliance with paragraphs 2.4.1 to
2.4.5 at SABIC’s designated operating conditions for all loading
sequences.
2.5 Critical Speeds
2.5.1 Add the following sentence:
The compressor vendor shall perform lateral and torsional studies to
demonstrate that the unit will operate satisfactorily within the specified
operating speed range at any load step.
2.6 Compressor Cylinders
2.6.1 General
2.6.1.3 Add the following sentence:
A preliminary general arrangement drawing showing cylinder spacing
shall be furnished with the proposal.
2.6.1.4 The decision is as follows:
Tandem cylinder arrangements shall not be furnished.
2.6.2 Cylinder Appurtenances
2.6.2.3 The decision is as follows:
Each cylinder shall have a replaceable liner be held in place by a
shoulder.
2.6.2.11.2 Add the following paragraph:
Studs shall be furnished for all bolted connections unless
specific exceptions are approved by SABIC. All
proposed use of cap screws shall be called out in the
proposal.
2.6.2.11.4 Add the following sentence:
Hex-head bolting shall be used, unless specifically
approved otherwise by SABIC.
2.6.2.11.5 Add the following sentence:
The preferred locking method shall be with a dog-point
set screw.
2.6.4 Cylinder Connections
2.6.4.4 Add the following sentence:
The finish of gasket contact surfaces of cast iron, ductile iron, steel
connections (other than ring-type joints) shall be a serrated
concentric finish.
2.6.4.6 The decision is as follows:
All cylinders shall be fitted with indicator taps and plugged in
accordance with API 618, Figure G-2. The taps shall be rated for the
maximum working pressure and temperature of the cylinder and for
the gas service. For labyrinth-type compressors, pressure taps on
inter-stage piping suffice.
2.7 Valves and Unloaders
2.7.4 Add the following paragraph:
O-ring style valve cover to cylinder gasket sealing shall be preferred over
other methods. Care shall be taken in the selection of the O-ring material, to
ensure compatibility with the gas being compressed. If no O-ring material is
compatible with the gas, then a soft metal gasket shall be used.
2.7.9 The decision is as follows:
Unless otherwise specified, vendor shall submit a written valve dynamics
report to SABIC.
2.7.10 The decision is as follows:
Unless otherwise specified, PEEK valve plates shall be furnished in all
applications. If PEEK material is deemed unacceptable by the manufacturer,
then the reasons and a suitable alternative shall be specified in the proposal.
2.8 Pistons, Piston Rods, and Piston Rings
2.8.3 Add the following paragraphs:
Wear bands shall be specified on all applications that allow for their
installation. Single piece, ‘fixed’, shrink fit, non-metallic wear bands shall be
used in all these applications.
Note: The use of fixed wear bands in conjunction with rod drop indicators will
allow for the maximum run time between overhauls. By alarming rod drop
before cylinder to piston contact is made, rotation of the rod will allow for
longer runs before piston removal is required.
2.8.4 Add the following sentences:
All piston rods shall be coated with a tungsten carbide, high-velocity, highimpact,
thermal
coating.
The
procedure
for
coating
the
rods
shall
be mutually
agreed upon by the vendor and SABIC.
2.8.6 Add the following sentence:
Tail rods shall not be used unless otherwise specified.
2.9 Crankshafts, Connecting Rods, Bearings, and Crossheads
2.9.7 The decision is as follows:
Relief devices shall be provided.
2.10 Distance Pieces
2.10.2 The decision is as follows:
All distance piece access openings shall be equipped with metal covers.
2.11 Packing Cases and Pressure Packing
2.11.1 The decision is as follows:
Shield shall not be specified unless recommended by the vendor, based on
past experience with flooding.
2.11.9 Add the following sentences:
Entering sleeves shall be designed in a way that the outside diameter of the
sleeve is equal to or smaller than the diameter of the rod in the packing area.
Tapered step-ups shall be utilized if necessary, to transition the packing from
a smaller size rod area to the final rod diameter in the area where the
packing will seal.
2.12 Compressor Frame Lubrication
2.12.3 Add the following paragraph:
Compressors larger than 150 kW (200 hp) shall be fitted with a dual, full flow
oil filter assembly, piped and valved to allow changing of oil filters without
requiring shutdown of the compressor. Valving shall be designed in a way
that it shall be impossible to shut off oil flow to the compressor when
switching filters. (See 2.12.6).
2.12.3.1 Add the following sentence:
Heavy walled stainless steel tubing shall be acceptable for use in
lube oil distribution systems.
2.12.3.2 The decision is as follows:
Unless otherwise specified, auxiliary lube oil pumps shall be electric
motor driven.
2.12.3.3 The decision is as follows:
Crankcase driven oil pumps shall have an external relief valve.
2.13 Cylinder and Packing Lubrication
2.13.1 General
2.13.1.1 The decision is as follows:
Single-plunger-per-point oil systems shall be provided for
compressor cylinder and packing lubrication. 20 percent spare
points shall be available on the lubricator.
2.13.1.2 The decision is as follows:
Lubricators shall be driven independently by an electric motor.
2.13.1.6 The decision is as follows:
As a minimum, a lubricator malfunction alarm shall be provided that
will indicate when there is no lube oil flow.
2.14 Materials
2.14.1.8 The decision is as follows:
Austenitic stainless steels shall not be used in services that will be
exposed to conditions that will promote intergranular corrosion.
Alternative materials shall be agreed upon by SABIC and the
vendor.
2.14.5 Fabricated Cylinders
Add the following new paragraph:
Fabricated cylinders shall not be used without SABIC written approval.
Section 3 – Accessories
3.1 Drivers
3.1.1 General
3.1.1.6 The decision is as follows:
V-belt driven applications shall not be allowed above 150 kW
(200 hp).
3.1.2 Motor Drivers
3.1.2.7 Add the following note:
Note: The motor should be furnished by the compressor vendor, to
maintain unit responsibility with the compressor vendor.
3.1.3 Turbine Drivers
3.1.3.1 Substitute API 611and 612 with SES G06-S01and G06-S02
respectively.
3.1.3.2 Substitute ‘API 614’ with ‘SES G03-S01’.
3.2 Couplings and Guards
3.2.1 Couplings
3.2.1.1 The decision is as follows:
When a flexible coupling is supplied, it shall be supplied by the
compressor vendor, to maintain unit responsibility.
3.2.1.2 Substitute ‘API 671’ with ‘SES-G12-S01’.
3.3 Reduction Gears
3.3.1 Substitute ‘API 613 and 677’ with ‘SES G07-S02 and G07-S01’.
3.4 Belt Drives
Add the following paragraph:
Belt drives shall only be used with SABIC approval. The side force required to
properly tension a drive belt has a detrimental impact on both the driver and driven
unit bearings. If a belt drive is the only viable alternative, then paragraphs 3.4.1 to
3.4.4.4 shall be strictly adhered to.
3.5 Mounting Plates
3.5.1 General
3.5.1.1 Add the following sentence:
In all cases where the compressor is to be grouted in place,
soleplates or rails shall be furnished.
3.5.1.2.6 Substitute the paragraph as follows:
Anchor bolts are not used to fasten drivers to the driver
mounting plates. The driver mounting plates are to be
designed in a way that the mounting plate jack screws
and mounting plate anchor bolts are to be used to level
and align the driver. The driver shall be bolted to the
mounting plate by its hold-down bolts during this
process.
3.5.1.2.7 Add the following sentence:
Mounting plates shall be radiused on the bottom four
edges, as shown in the section View A, Figure L 1.
3.5.1.2.8 Add the following sentence:
Mounting plates shall extend at least 50 mm beyond the
outer three sides of both driven and driver equipment
feet.
3.5.1.2.13 Add the following sentences:
Only the driven equipment in a compressor drive train
shall be doweled. Drivers shall not be doweled, except
the stator units in engine-type electric motors.
Note: Units with frame type drivers utilizing flexible
coupling members should not be doweled, as the shaft
center will drift based on the extent of
maintenance/overhaul work performed.
3.5.1.2.15 The decision is as follows:
Unless otherwise specified, epoxy grout shall be used on
all equipment covered by this standard. The mounting
plates shall be coated at the factory with a rust resistant
primer. When set in the field, the underside of the
mounting plates shall be blasted to white metal in
accordance with SSPC SSP10 and set in epoxy grout.
Note: The grout manufacturer should be consulted to
ensure proper field preparation of the mounting plates.
3.5.1.2.16 The decision is as follows:
Leveling plates shall be utilized in accordance with
Appendix L. The plates shall be set in epoxy grout
before the machine leveling process is started.
3.5.2 Baseplates and Skids
3.5.2.3 The decision is as follows:
Except for extremely small units, when a baseplate is specified, only
the compressor, driver and cylinder/packing lubricator shall be
mounted on the baseplate. All other auxiliary equipment shall be
packaged separately. Multiple section baseplates shall be fitted and
assembled in the shop before shipment to the field. In the case of
multiple units, the corresponding baseplate sections shall be match
marked in the shop prior to disassembly for shipping.
3.5.2.12 The decision is as follows:
Non-skid decking shall be provided covering the entire baseplate.
3.6 Controls and Instrumentation
3.6.3 Instrument and Control Panels
3.6.3.1 Add the following sentence:
Unless otherwise specified, a freestanding control panel shall be
supplied. The panel shall be suitable for outdoor operation in the
environment specified.
3.6.3.2 Add the following sentence:
Control panels shall be constructed of stainless steel materials.
3.6.3.4 Add the following sentence:
All interconnecting shop-fabricated piping, tubing, and wiring that is
disassembled for shipment, shall be tagged for re-assembly in the
field.
3.6.4 Instrumentation
3.6.4.2 Temperature Measurement
3.6.4.2.1 Add the following sentence:
The location and number of temperature transmitters
shall be mutually agreed upon by SABIC and vendor.
3.6.4.2.8 Add the following paragraph:
When main, connecting rod, or crosshead pin bearing
temperature detectors are specified, they shall be
installed in a way that the detector tip is in contact with
or embedded in the bearing backing material located to
not be influenced by the oil supply.
3.6.4.3 Pressure Measurement
3.6.4.3.1 Compressor suction and discharge pressure indicators
shall be furnished for SABIC installation in the piping
system immediately upstream and downstream of each
compressor cylinder in the interconnecting piping. The
readout from these shall, as a minimum, be located on
the monitor panel. See the data sheets for additional
requirements.
3.6.4.3.2 Add the following sentence:
All pressure gages furnished shall be liquid filled, to
promote long life and accurate readings.
3.6.4.5 Relief Valves
3.6.4.5.2 The decision is as follows:
All relief valves shall be furnished with steel bodies.
3.6.5 Alarms and Shutdowns
3.6.5.8 The decision is as follows:
An annunciator system shall be provided as specified in this section.
3.6.7.1 Substitute ‘API 670’ with ‘SES G19-S01’.
3.6.7.2 Substitute ‘API 670’ with ‘SES G19-S01’.
3.6.7.3 The decision is as follows:
Phase reference indication shall be provided. Transducer shall be
provided when specified. Substitute ‘API 670’ with ‘SES G19-S01’.
3.7 Piping and Appurtenances
3.7.1 General
3.7.1.12.9 The decision is as follows:
Threaded connections in flammable or toxic services
shall not be permitted. As a minimum, socket-welded
connections shall be used.
3.7.1.12.16 The decision is as follows:
Internal retaining rings shall be provided on all spiral
wound gaskets.
3.7.1.1.14 The decision is as follows:
All utility connections shall be manifolded to a common
connection.
3.9 Pulsation and Vibration Control Requirements
3.9.2.1 Add the following sentences:
Unless otherwise specified, Design Approach 3 shall be utilized in
3.11 Special Tools
the analysis of pulsation and mechanical properties of the system. If
the vendor has proven experience in utilizing other design
approaches in similar applications, it shall be so stated in the
proposal.
3.11.5 The decision is as follows:
A shaft locking device for maintenance shall be supplied with each
compressor.
Section 4 – Inspection, Testing, and Preparation for Shipping
Add the following sentence:
See SES G13-T01.
4.1 General
4.1.4 SABIC will specify the extent of their participation in inspection and testing on
the data sheets.
4.1.6 SABIC and vendor shall indicate compliance in accordance with the
inspector’s checklist in API 618, Appendix K, by initialing and dating the
checklist, and the vendor submitting the completed checklist to SABIC before
shipment.
4.1.6.1 Add the following new paragraph:
In addition to the above, SABIC and vendor shall indicate the degree
of compliance with SES G13-T01.
4.4 Preparation for Shipment
4.4.1 The decision is as follows:
The compressors and all auxiliary units shall be prepared for export boxing
and storage for a minimum of 6 months.
4.4.3.10 The decision is as follows:
All equipment shall be crated for export shipment. All special lifting
and rigging devices shall be supplied with the unit. Boxes containing
lifting and rigging devices and load-out instructions shall be
permanently and prominently marked on the outside of the
container.
Section 5 – Vendor’s Data
5.1 General
5.1.1 VDDR Form
5.1.1.2 Add the following new paragraph:
A completed VDDR form shall be submitted with the proposal.
5.1.3 Coordination Meeting
Add the following paragraph:
The coordination meeting should preferably be held at the vendor’s plant.
The agenda for the meeting shall be published two weeks prior to the
meeting along with the initial General Arrangement (GA) Drawing. The
manufacturing shall not proceed nor shall the coordination meeting be held
before the issuance of the GA drawing(s).
5.2 Proposals
5.2.1 General
Add the following sentence:
The vendor shall submit the original and three (3) copies of the proposal to
SABIC.
5.2.2 Vendor shall provide a priced parts list as part of the proposal as follows:
a. Recommended spare parts and consumables for the first two years
of operation
b. Recommended insurance spare parts and consumables for a major
turnaround, with a complete spare set of, for example, suction and
discharge valves, piston rods, pistons, and liners
c. Recommended long lead spare parts to be stored by SABIC
5.2.3 .t The decision is as follows:
The vendor shall provide a list of similar machines installed and operating
under conditions similar to those proposed.
5.3 Contract Data
5.3.3 Performance Data
5.3.3.1 The decision is as follows:
The vendor shall submit performance data in accordance with the
requirements of this paragraph.
5.3.3.3 The decision is as follows:
The vendor shall furnish rod load calculations based on the effect of
valve failure.
5.3.4 Progress Reports
Add the following sentences:
The vendor shall submit monthly progress reports. The format of these
reports shall be mutually agreed upon between SABIC and the vendor.
5.3.6 Recommended Spares
Add the following sentence:
The ‘complete list of spare parts’ referenced shall be a total bill of materials
for the package(s) furnished.
5.3.7 Manuals
5.3.7.2.1 Add the following new paragraph:
A complete set of drawings and an installation manual
shall be placed in the shipping crate for retrieval at the
site. The shipping crate containing the installation
manual shall be clearly marked ‘Drawings and
Installation Manual Enclosed’.