HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY DIESEL HYDROTREATER PROJECT ENGINEERING DESIGN BASIS ROTATING EQUIPMENT

Transcription

1 HINDUSTAN PETROLEUM CORPORATION LIMITED MUMBAI REFINERY DIESEL HYDROTREATER PROJECT ENGINEERING DESIGN BASIS ROTATING EQUIPMENT DOCUMENT NO : 44LK M A4 Rev No. Issue Date Pages Rev Description Prepared By Checked By Approved By P Issued for HPCL s PDB SNG SNG Comments HPCL comments ASK PDB SNG incorporated and approved Approved by HPCL and issued for implementation ASK PDB SNG

2 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 2 of 33 44LK-5100 Rev. 1 TABLE OF CONTENTS 1.0 APPLICABLE CODES AND SPECIFICATIONS DESIGN PHILOSOPHY / CRITERIA GENERAL DESIGN CRITERIA / REQUIREMENTS SPECIFIC APPLICATIONS CENTRIFUGAL COMPRESSORS (PROCESS GAS SERVICES) RECIPROCATING COMPRESSORS (PROCESS GAS SERVICES) PACKAGED INTEGRALLY GEARED CENTRIFUGAL AIR COMPRESSOR RECIPROCATING COMPRESSOR (UTILITY AND INSTRUMENT AIR) GENERAL PURPOSE STEAM TURBINES CENTRIFUGAL PUMPS FANS (CENTRIFUGAL / F.D. / I.D. FANS - GENERAL REQUIREMENTS) RECIPROCATING PUMP POSITIVE DISPLACEMENT PUMP CONTROLLED VOLUME API 614 OIL SYSTEMS SPECIAL PURPOSE GEAR UNITS SPECIAL PURPOSE STEAM TURBINES 30 ANNEXURE I API FLUSHING PLAN 32 ANNEXURE II SEAL FLUSHING PLAN 52/53

3 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 3 of 33 Rotating Equipment DHDT Project Rev. 1 44LK APPLICABLE CODES AND SPECIFICATIONS The latest edition of following codes and standards shall be followed: Item International Standard a) Pumps All Centrifugal pumps including water pumps Positive displacement pumps Reciprocating Positive displacement pumps Controlled volume Positive displacement pumps Rotary Shaft sealing systems for centrifugal and rotary pumps. b) Turbines General purpose steam turbines Special purpose steam turbines Gas turbines c) Compressors Centrifugal compressors (Gas services) Packaged integrally geared centrifugal air compressors. Reciprocating compressor Utility and Instrument air service. Reciprocating process gas compressors Rotary type positive displacement compressors Rotary Lobe blowers / compressors API-610, 10 th Edition API-674 API-675 API-676 API-682 API-611 API-612 API-616 API-617 API-672 IS 6206 / Equivalent. API-618 API-619 API 619, 2 nd Edition d) Reciprocating Internal Combustion Engines ISO-3046/BS-5514 e) Others Centrifugal Fans Special purpose gear units for Petroleum, Chemical and Gas industry service IS 4894/API 560 (App.E) API-613 General purpose gear units for Petroleum, API-677 Chemical and Gas industry service Lubrication, shaft-sealing and control oil system API-614 for special purpose applications Vibration, axial piston and bearing temperature API-670 monitoring systems. Machinery installation and installation design API-RP 686 Inspection of fans, blowers, gear boxes & OISD 122 agitators Inspection and maintenance of mechanical seals OISD 125 Vibration limits for rotating machines ISO 1940

4 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 4 of 33 44LK-5100 Rev. 1 Item General purpose gear units API 677 Special purpose couplings for Refinery service Heat exchangers for oil coolers Fire water pumps and drivers Noise control International Standard API-671 TEMA C, H.E.I. Std. NFPA 20, TAC Regulations, OISD. OSHA Standards 2.0 DESIGN PHILOSOPHY / CRITERIA GENERAL 2.1 Selection of rotating equipment shall be based upon the following considerations: Suitability for the specified range of duty conditions. Standard models under supplier s regular manufacturing range. Proven track record in similar service as specified under acceptance criterion. Optimum operating and maintenance costs. Maximum inter-changeability of parts. Inter-changeability charts to be furnished by contractors/ vendors. Ease of operation and maintenance. Foreign vendor shall preferably have a liaison office in India 2.2 For design aspects not specifically covered by data sheets, specifications, codes and standards or regulations, the design shall be based on good engineering practices. 2.3 Contractor shall make all possible efforts to comply strictly with the requirements of this design basis. In case deviations are considered essential by the contractor (after exhausting all possible efforts), these shall be clearly brought out and consolidated under technical exception chapter at bidding stage. However, vendor specific deviation (if any) to applicable codes / specifications arise during detailed engineering then the same will be subject to PMC / Owner s approval. 2.4 The enquiry documents for procurement of rotating equipment shall be prepared by the contractor and shall as a minimum, contain the following documents: Job specifications which will describe special requirements / features of the subject equipment such as brief description of the system, process requirements, applicable codes and standards, basis of design, operating philosophy, start up and shutdown condition, site conditions, and utilities available during normal operation, start up, normal and emergency shutdown, special control and safety requirements, special lubrication and sealing systems, etc. Scope of supply / work of equipment vendor, Contractor s scope of work, list of terminal points/battery limits, guarantee parameters with specified tolerances. For major packages/equipment contractor shall include in the specifications a scope break up table between equipment supplier and Contractor for design, engineering, supply, inspection, erection and commissioning activities and handing over. Inspection and testing requirements, shop / site testing requirements with procedure, QA/QC guidelines.

5 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 5 of 33 Rotating Equipment DHDT Project Rev. 1 44LK-5100 Mechanical data sheets of driver, driven equipment, accessories and all auxiliaries etc., indicating operating parameters, performance requirements, construction features, material of construction, instrumentation and controls, inspection and testing etc., using respective API data sheet formats. Specifications shall clearly spell out the order of precedence of various documents viz. Job specifications, data sheets, P&IDs / drawings, codes/standards, standard specifications. Vendor data requirements, which shall be inline with the data, specified in the owner s specification and applicable API Standards. Experience record formats required to be filled by the equipment vendor as original equipment manufacturer (OEM). Mandatory spares list, O&M Spares, Commissioning spares. Drawings e.g. P&IDs of the equipment process and auxiliary systems, equipment layout drawing etc. Requirement of vendor s services during equipment installation, hook-up, precommissioning and commissioning schedule of activities. Requirements for special tools and tackles. 2.5 The equipment supplier shall fill in Experience record formats completely indicating information on operating conditions and construction features of the vendors past supply in sufficient detail to evaluate provenness of the equipment proposed. 2.6 The supplier of equipment shall be selected from the approved list of vendors specified elsewhere in bid document. Equipment of proven design and performance shall only be considered. Equipment qualification criteria as specified in bid document for equipment and auxiliaries shall be followed. 2.7 The number of spare equipment to be installed shall be as per the equipment sparing philosophy in the Licensor s process package, datasheets and specified in the bid. 2.8 Air compressors, Centrifugal fans, Internal combustion engines and gas turbines handling ambient air shall be sized on the basis of maximum site coincident ambient temperature and relative humidity. 2.9 Electrical items, instrumentation and controls, piping, pressure vessels, mechanical equipment, heat exchangers etc., associated with rotating equipment shall comply with the design requirements as given in the respective engineering documents enclosed in the bid package The ratings of drivers (electric motor / steam turbine / diesel engine) shall comply with the requirements specified individually for each driven equipment. All rotating equipments shall be driven by electric motor, turbine as a drive is not acceptable Equipment layout shall incorporate adequate maintenance platforms, support structures, hand rails, material handling facilities for operational access, inspection, erection and maintenance of equipment.

6 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 6 of 33 44LK-5100 Rev Equipment design and engineering shall incorporate adequate safety features (as per applicable specifications of respective equipment as well as Health, Safety and Environment codes and standards applicable for the subject project) to provide protection to operating personnel, equipment and environment All electrical components and installations, instruments shall be suitable for the electrical area classification and grouping in which the equipment is installed Material exposed to sour environment as defined by NACE MR-0175 & 0103 shall be in accordance with requirements of the NACE standard. Ferrous materials not covered by NACE MR-0175 & 0103 shall be limited to yield strength not exceeding 90,000 psi and hardness not exceeding Rockwell C Noise level of continuous operating equipment (for Driver + Driven equipment + Auxiliary) shall not exceed 85 dba when measured at 1M distance from the equipment skid in any direction. For turbine driven equipment and equipment with rating above 500 kw this shall be reviewed based on case to case basis. Note: This requirement is not applicable for intermittent operation equipment such as firewater pump, engine driven emergency generator, high speed high speed integrally gear driven type of pumps etc. For safety relief valve vents the noise level shall be limited to 105 dba at 5m distance Acoustic enclosures are not preferred. However, it may be provided for equipment such as gas turbines, rotary screw compressors, high speed integrally gear driven type of pumps, compressors and root blowers to meet the specified noise levels. Requirement of silencers at fan/blower/compressor suction, relief valve outlets shall be accordingly decided All compressor sheds shall be provided with adequately sized EOT crane, depending upon the maximum weight of one component to be handled for maintenance of the compressor and its driver. Electric motor driver shall be considered a single component for maintenance except for the single bearing motors where the motor rotor and stator shall be considered as individual components Maximum allowable working pressure and temperature of the equipment shall not be less than the design pressure and temperature specified in the data sheet or not less than those specified in specifications, codes and standards Spare rotors where supplied shall be boxed in a metal containers for vertical storage with adequate corrosion protection. Nitrogen purging shall be considered Unless otherwise specified, equipment shall be driven directly Compressors and drivers (including gear units and couplings if any) shall be designed to perform satisfactorily under specified start up conditions, part load operation, maximum differential pressure operation and relief valve set pressure and upto full speed including any design margin specified considering future requirements. This shall also include operating conditions envisaged during regeneration cycle of plant and as specified in respective equipment data sheets.

7 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 7 of 33 Rotating Equipment DHDT Project Rev. 1 44LK Couplings shall be of non-lubricated diaphragm / metallic flexible membrane type with spacer for all equipment. However, coupling shall conform to API 671 for all the equipment with speed greater than 3600 rpm and / or driver rating greater than 160 kw. All coupling guards shall be of non-sparking type. Couplings shall be dynamically balanced separately with match marked coupling bolts/coupling halves. All coupling models shall be selected for a minimum service factor of As a minimum Centrifugal compressors, centrifugal integrally geared compressors, special purpose steam turbines, special purpose gear units and multi stage centrifugal pumps with hydro dynamic bearings shall be provided with probes / detector and monitors in accordance with API standard 670 for measuring shaft radial vibration, axial position, and bearing temperatures. The drive motors of these equipment shall also be provided with probes for measuring winding temperature, bearing temperature and bearing vibrations (X and Y). Fan and pumps above 160 KW shall be provided with vibration monitoring system. Alarm (alert) and shutdown (danger) annunciation shall be provided for each of the monitored variables. This system shall comply with requirements specified in specification for instrumentation covered elsewhere in the Bid document. Separate keyphasors shall be provided for input and out shaft of gear box In case of oil coolers the oil side operating pressure shall be higher than waterside operating pressure Unless otherwise specified, oil coolers and cooling water console coolers shall be water cooled shell and tube with removable bundle. The design of such coolers as per TEMA C is acceptable. Cooling water shall be on tube side. MOC shall be as follows: Channel : Super Duplex SS Cover plate : Super Duplex SS Tube sheet : Super Duplex SS Floating head : Super Duplex SS Baffles, support plates : Super Duplex SS Tubes : Super Duplex SS 2.26 Unless otherwise specified, coolers (inter cooler and after cooler) shall be watercooled shell and tube with water on tube side type with removable tube bundle. Design pressure of the low pressure side shall be two third of the design pressure of high pressure side as a minimum Unless otherwise specified the inter and after coolers shall be designed with following considerations: The fouling resistance of hr m 2 - O C / kcal shall be considered for water side. Tubes shall be preferably more than 20 mm (3/4 ) or 25 mm (1 ) outside diameter (OD). The minimum allowable tube wall thickness is 2.5 mm in case of carbon steel tube. Coolant velocity in tubes shall be at least 1.0 m/sec All exchangers shall be provided with test rings Unless otherwise specified, for centrifugal compressors and steam turbines the following shall be provided. Portable lube oil drain pump.

8 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 8 of 33 44LK-5100 Rev. 1 Portable lube oil purifier for online purification with fine filter (1 micron) in return line / oil purification system. Fuel storage / transfer pump (as applicable) 2.30 Electrical motor drivers as per (IEC / IS) shall be rated for continuous duty (duty type SI) whereas motor as per American standards shall be designed to operate at a service factor of The rated BKW considered as the basis for sizing of the drivers shall include the positive tolerance as permitted in the applicable code or as specified i.e. the margin of 10%, 15%, 25% etc. as applicable for driver sizing shall be kept over and above the (rated BKW + tolerance) In case of bladder type pulsation suppression devices for reciprocating pumps / accumulators for oil systems, gas charging assembly kit shall be supplied one for each service All rotating equipment base plates shall have jacking provision for levelling and screws for alignment. Only stainless steel shims shall be used for equipment alignment. Number of shims shall be minimum having thickness less than 1mm, rest SS packer plates shall be used to minimise number of shims In case of compressors, non-skid decking covering all walk and work areas shall be provided on top of the baseplates Thermal relief valves shall be provided for components that they may be blocked in by isolation valves (including any cooling water return circuit piping of a cooler or jacket) In case of centrifugal compressors and steam turbines (special purpose), the lube oil system shall comply with API Bearing housings for pumps and fans with oil lubricated bearings shall be provided with bearing guard type shaft seals to prevent oil leakage or contamination After completion of shop performance test, mechanical seals of pumps shall be removed and shall be reassembled at pump vendor s works with recommended secondary packing The installed mechanical components like gland plates, sleeve, etc. shall be of seal vendor s make only. In case pump manufacturer provides the same, the drawing shall be vetted by seal vendor Small Air-cooled heat exchangers shall be preferred than water-cooled heat exchangers All special tools and tackles including hydraulic equipment required for maintenance purpose for the rotary equipment should be provided along with main equipment All rotating equipment shall be packed for an storage period of 12 months. Preservation of rotating equipment shall be as per OISD standards Initial fill:

9 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 9 of 33 Rotating Equipment DHDT Project Rev. 1 44LK Interface: The initial fill of lubricants, sealing fluid and other consumables shall be supplied by contractor. Equipment nozzles at Purchaser s interface shall be as per piping specifications and sizes. In case non-standard sizes are unavoidable, companion flanges along with gaskets and fasteners shall be procured from the equipment vendor Erection of Equipment: Erection of all rotating equipment except D.G. set shall be carried out by mechanical contractor under supervision of equipment vendor Suction and discharge piping of rotating equipment shall be free from any stress. The execution cotractor shall measure the alignment of piping before and after tightening the flanges Installation criteria: Pumps Compressors All pumps shall be suitable for outdoor installation. No equipment shelter is envisaged. All compressors shall be located under roof with side walls partially open and shall be suitable for outdoor installation Centrifugal compressors driven by steam turbine/electric motor All centrifugal compressors driven by steam turbine/ electric motor shall be installed on tabletop foundation and with antiskid mezzanine floor with adequate working platform all around and drop out facility for maintenance. Other associated auxiliaries such as lube oil system, surface condenser, condensate water pumps etc. shall be located on ground floor (i.e. on finished floor level) Integrally geared packaged centrifugal compressors All integrally geared packaged centrifugal compressors shall be installed on ground floor (i.e. on finished floor level) Reciprocating multi-stage / multi-cylinder compressors Reciprocating compressors shall be so located that no trenches are required for volume/pulsation bottles. Large reciprocating multi-stage piping/auxiliary equipment can be installed on Mezzanine floor with its interstage piping/auxiliary equipment located on the ground floor. Skid mounted reciprocating compressors shall be located on finished floor level Spares and special tools

10 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 10 of 33 44LK-5100 Rev Commissioning spare parts Commissioning spare parts shall be procured along with the main equipment as per equipment manufacturer s recommendations. The list of such recommended spares shall be obtained along with the offer Special tools/tackles Special tools/tackles shall be procured along with the main equipment as per equipment manufacturer s recommendations. The list of such recommended special tools/tackles shall be obtained along with the offer Mandatory spares Only mandatory spares shall be procured along with the main equipment. Such spares shall be specified in the enquiry document and shall include only those spares, which are critical for equipment and require longer delivery periods, such as, spare rotors for compressors, multistage pumps and spare gas generator for gas turbines etc Spare parts for two years normal operation Recommended spare parts for two years normal operation along with unit prices shall be obtained from equipment manufacturer for client to order the same separately. 3.0 DESIGN CRITERIA / REQUIREMENTS SPECIFIC APPLICATIONS 3.1 CENTRIFUGAL COMPRESSORS (PROCESS GAS SERVICES) Equipment Qualification Criteria The vendor for the complete unit shall be an established manufacturer of Centrifugal Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same The vendor shall have engineered, packaged, tested and supplied at least two identical or validly similar packages in terms of type of compressor, driver, sealing system, inlet volumetric capacity (Am 3 /hr) and driver rating (kw) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major O&M problem as on the date of issue of invitation to bid The vendor besides satisfying the requirements of Cl. no and above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package including control system The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical in frame size and identical or validly similar in terms of power rating, inlet and discharge pressures, inlet temperatures, actual inlet flow,

11 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 11 of 33 Rotating Equipment DHDT Project Rev. 1 44LK-5100 process gas, induction/ extraction side streams, speed, number and materials, bearing span, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have been operating satisfactorily in the field for at least 8000 hours without any major problems as on the date of issue of invitation to bid The compressor shall be designed to deliver the rated head and rated capacity without negative tolerance and the BKW at the above condition shall be guaranteed with zero positive tolerance All compressors shall be located under shed. All centrifugal compressors (other than gas turbine driven and API 672 packaged air compressors) shall be located on mezzanine floor with adequate working platform all around and drop out facility for maintenance Riveted impellers are not acceptable Dry gas seal for process gas centrifugal compressors shall be of dual unpressurised tandem type with an intermediate labyrinth as per API 617. Dry gas seal shall be Bidirectional Mechanical contact type seals shall incorporate a suitable design feature to prevent process gas leakage when the compressor is pressurized and not running and the seal oil system is shut down Centrifugal compressors shall be provided with tilting pad type radial and thrust bearings. Thrust bearing shall be of multi segmented, self-equalising double acting type of proven make The compressor vendor shall perform a composite torsional vibration analysis of the compressor-driver unit and shall be responsible for the satisfactory mechanical performance of the complete train. All necessary co-ordination required for the purpose shall be the responsibility of compressor supplier so that no resonances should occur during range of operation Unless otherwise specified in code, Gear units for the compressors having rated BKW upto 750 kw shall comply with API Standard 677 and for rated BKW above 750 kw, gear units shall comply with API Standard Minimum instrumentation and process controls shall be as specified in the data sheets / job specification/ P & IDs/ engineering design basis and other documents referenced in the FEED Document and shall be supplied by the vendor. The vendor shall specify and provide any additional instrumentation and controls as deemed necessary for the smooth and safe operation of the unit under all specified operating conditions. The vendor shall review owner s overall compressor control system for compatibility with the vendor furnished controls/ instrumentation with local and DCS operation as required The design, engineering, supply, installation, testing, commissioning of complete antisurge control system shall be in vendor s scope. The anti-surge control system furnished shall include all instruments viz. (flow, diff. pressure, suction pressure, discharge pressure, speed) transmitters, indicators, control valves, anti-surge

12 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 12 of 33 44LK-5100 Rev. 1 controller and with all accessories as required for completion of anti surge loop. Transmitters shall be smart type Vendor shall provide strainer with spool pieces for each stage inlet. Each strainer shall be installed in the suction side of the compressor between block valve and compressor suction flange Straight piping of minimum 5D shall be provided at compressor inlet unless longer length is advised by compressor manufacturer or dictated by the measuring instruments or as required to meet requirements of performance test procedure The compressors along with their drivers shall be mounted on a common skid. In case splitting of base plate becomes essential due to transportation problems, the splitting of the base plate shall be so designed as to make a common base plate in the field by doweling and bolting Inspection And Testing Material certificate for chemical and physical properties for the following components shall be provided. Casing, impeller, shaft, shaft sleeve, lube oil skid, anti-surge control valve % Radiography shall be done in case of connections welded to pressure castings. In addition cast compressor casings shall be radiographed in critical areas. (Critical areas are section having abrupt changes in thickness, neck areas) Ultrasonic testing of shaft liquid penetrant and magnaflux test of Impellers shall be performed Dynamic balancing of each rotor (job and spare) The following test shall be witnessed by the third party inspection agency: Hydrostatic test. Helium Pressure test (for casing of compressors handling gas containing 30% mole or higher of H 2 ). Dynamic balancing of assembled job/ spare rotor with coupling hub assembled. Impeller over speed test. Mechanical run test (for main and spare rotor) During the test apart from other API requirements, the following data shall be recorded Vibration data at rated speed, start and shut down data in form of orbit, polar, cascade plots. Gas leak test (After post test inspection). Post test inspection after mechanical run test. Performance test as per PTC-10. Sound level test (during mechanical run test) String test (including all auxiliaries) Dry gas seal test. Rated load, pressure and rated speed test

13 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 13 of 33 Rotating Equipment DHDT Project Rev. 1 44LK RECIPROCATING COMPRESSORS (PROCESS GAS SERVICES) Equipment Qualification Criteria The vendor for the complete unit shall be an established manufacturer of Reciprocating Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing, testing facilities for the same The vendor shall have engineered, packaged, tested and supplied at least two identical or validly similar packages in terms of type of equipment and driver, inlet volumetric capacity (am 3 /hr) and driver rating (kw) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major problem as on the date of issue of invitation to bid The vendor besides satisfying the requirements of Cl and above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements. Compressors shall be identical in frame size and identical or validly similar in terms of frame rating, rod loadings, rotational speed / piston linear speed, inlet temperatures, actual inlet flow, process gas, cylinder sizes and pressure ratings, number of throws/ cylinders, number of stages, mechanical design, materials, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and atleast one of these units shall have successfully operated in the filed for atleast 8000 hours without any major problems as on the date of issue of invitation to bid Skid mounted compressor units, may be located under shed on grade level. Other compressors shall be located under shed at an elevation of 3.5 m with working structural platform all around within the compressor shed. Lube oil and cooling water consoles (as applicable) shall be located underneath the platform. Enough headroom shall be made available for access and maintenance of all the equipment under the platform Reciprocating compressors shall be horizontally balanced opposed type (with equal no. of throws on each side) Rotational speeds of reciprocating compressors in Hydrogen Service shall be limited to a maximum of 350 rpm Unless otherwise specified, the average linear piston speed for lubricated cylinders and non-lubricated cylinders shall not exceed 4 m/ sec and 3.5 m/sec respectively. For `Bone Dry Nitrogen Service, the piston speed shall be limited to 2.5 m/sec Compressor shall be designed for any excess capacity as specified in data sheets to meet future requirements. In such a case, compressor shall be so selected that it is suitable for continuous, uninterrupted and safe operation at normal loads, which would be part load due to over design.

14 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 14 of 33 44LK-5100 Rev Air cooled / uncooled cylinders are not acceptable Compressor suction / discharge valves shall be of plate or port-plug type. Feather type (flexible plate) valves shall not be used. The design of valves shall be suitable for all operating conditions including start up, shut down and regeneration services. The same valve shall be designed for all operating gases and their corresponding molecular weights The maximum predicted discharge temperature shall be limited to 135 o C for hydrogen rich services (molecular weight less than 12) and 150 o C for other services The actual rod loading due to inertial forces of reciprocating masses alone shall not exceed the maximum allowable continuous rod load, in addition to requirements of API The compressor driver shall be capable to start the compressor under unloaded condition with maximum suction pressure as specified in the data sheet Unless otherwise specified, reciprocating compressor shall be driven by motor with diaphragm type coupling. It shall be compressor supplier s responsibility to co-ordinate with drive manufacturer to ensure reliable design, alignment and operation of train. The necessary co-ordination shall be done as required for torsional analysis of train, selection of motor, matching of coupling, rod run out monitoring system with required pulsation dampeners Pulsation dampeners shall not have separate flanges mounted with studs. The flanges shall be integral part of volume bottle Reciprocating compressors shall be skid mounted packages upto a motor rating of 160 kw. Gearbox driven equipment arrangement may be considered for reciprocating compressor including diaphragm compressors up to 160 kw. Belt drive arrangement is not acceptable When pulsation study as per Approach 3 of API 618 is specified, Compressor vendor shall get the Pulsation study carried out by an agency, which has sufficient experience in carrying out similar studies. The vendor shall furnish sufficient data / reference in his bid to prove the capability of the proposed agency. The compressor vendor shall be responsible for all co-ordination with the agency carrying out the study. In case of any malfunctioning in the compressor installation, which is caused by any errors in the acoustical and mechanical evaluation, the compressor vendor shall carry out a field survey to identify the cause of the problem and rectify the same. The complete recommendations of the acoustic and mechanical system response study for the compressor and the associated equipment and piping shall be implemented by the contractor prior to the mechanical completion. The drawings shall be suitably revised to incorporated the study recommendations on piping routing and supports Suction strainers along with piping spool pieces will be installed in compressor suction lines of each stage and shall be supplied by the vendor. These strainers will be positioned as close as possible to the cylinder inlets but in no event shall they be located downstream of the inlet pulsation suppression equipment. The design of piping system pulsation suppression equipment, suction strainer shall afford easy removal / reinsertion of these strainers without necessity of pipe springing.

15 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 15 of 33 Rotating Equipment DHDT Project Rev. 1 44LK Intercoolers and after-coolers shall be designed as per TEMA R standard with integral or separate condensate separation and collection facilities, and shall include the following A drain system on the knock out vessel shall be with an automatic level control, isolating valves and a manual bypass around the control valve and emergency shut off valve acting when level in knockout vessel is low low An armoured gauge glass (with isolating valves and blow down valve) on the collection pot Condensate pot shall be sized to provide minimum holding capacity for two hours and a 5 minute time span between high level alarm and trip based on expected maximum liquid condensation rate Separate connections and level transmitteres for high level alarm and trip on the collection pot All internal parts of instruments, valves, strainer, etc. coming in contact with condensate shall be of stainless steel Pulsation suppresser connections shall be flanged Crankcase explosion relief device shall be furnished for all compressors, in process gas service Where automatic start feature of auxiliary oil pump is provided in case of failure of main oil pump an audio visual alarm shall be actuated simultaneously The compressor emergency shutdown instrumentation shall be provided electronic and with first out feature that will allow determination of the first alarm to trip in event that multiple alarms are activated. This feature shall include all trip initiators, including process trip inputs. Trip inputs shall be communicated to process control instrumentation for data logging Emergency transmitteres shall have a cover to prevent accidental trips Drivers shall have rating as a minimum 110% of then maximum brake power (including transmission losses and + 3% tolerance) required under any of the specified compressor operating conditions or 5% higher than the power required at the relief valve set pressure condition (including transmission losses) whichever is higher Inspection And Testing Material certificate for Chemical and Physical properties of the following components shall be provided Cylinder and liner, Piston, Piston rod, Crank shaft, Connecting rod, Cross head, Crankcase, Valves, Heat exchangers, Pressure vessels, Bolts (Connecting rod and Main Bearing) Ultrasonic testing of the following Crank shaft, Piston rod, Pressure vessels.

16 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 16 of 33 44LK-5100 Rev Magnaflux testing/ D. P. Testing of the following Cross head, Connecting rod, Piston rod, Pressure vessels % X-ray examination for all the welded joints for Pipes, Vessels and Heat exchangers handling process gas Surface roughness and hardness check for the following: Cylinder bore / Linear bore, Piston rod in packing area. Crank shaft journal and Crank pin The following tests shall be witnessed by the third party inspection agency : Hydrostatic test (for all pressure containing parts and auxiliaries). Leak proof test of crankcase and distance piece (24 hrs. with kerosene). Checking of cylinder clearance and rod run out. Mechanical run test (for 4 hours) with job auxiliaries. Performance test as per PTC 9. Stripping check and internal inspection : Main bearing drive end side, connecting rod bid end bearing (atleast 1 no.) piston assembly (1 no.) cylinder bore effective surface (all cylinder). Static balancing of fly wheel. Vibration level check (for record during mechanical run test). Lube oil console, cylinder cooling circuit console run test at subvendor works (as applicable). Functional test of control panel (by simulation at subvendor works). 3.3 PACKAGED INTEGRALLY GEARED CENTRIFUGAL AIR COMPRESSOR Equipment Qualification Criteria The vendor for the complete unit shall be an established manufacturer of Centrifugal Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same The vendor shall have engineered, manufactured, packaged, tested and supplied at least two identical or validly similar packages in terms of equipment and driver, inlet volumetric capacity (Am 3 /hr) and driver rating (kw) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid.

17 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 17 of 33 Rotating Equipment DHDT Project Rev. 1 44LK The vendor besides satisfying the requirements of Cl and above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements Compressors shall be identical in frame size and identical or validly similar in terms of power rating, inlet and discharge pressure, inlet temperatures, actual inlet flow, rotor speeds, number of stages, rotor dynamics, mechanical design, materials etc., as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant at least one of these units shall have successfully operated in the field for atleast 8000 hours without any major problems as on the date of issue of invitation to bid All metal parts of filters such as housing, filter elements, inlet silencer, supporting and fixing system of filter elements inside the housing including supports, stays, nuts, bolts etc., shall be type of 304 or 316 stainless steel. Complete piping from filter element to compressor inlet including any expansion joint shall be of type 304 or 316 stainless steel The orientation and location of intake shall be such as to minimise dust, heat ingress and free air flow shall be possible without any obstructions. The filter shall be located outside the compressor house at an elevation of approximately 6 m from grade minimum and shall take care of personnel protection. The filter construction shall have suitable provision for preventing water ingress into the filter due to rains and a bird screen. The filter shall have primary filter and secondary filter elements All interstage air piping upto suction of final stage casing inlet shall be of ASTM A312 type of 304 or 316 stainless steel Inspection and Testing Material certificate for chemical and physical properties for the following components shall be provided: Casing, impeller, shaft, shaft sleeve, lube oil skid, anti-surge control valve The following tests shall be witnessed by the third party inspection agency: Hydrostatic test (pressure containing parts and auxiliaries) Combined mechanical and performance test (for main and spare rotor as applicable). Impeller overspeed test. Check bearings and seals after test. Functional tests of job lube oil system and job control panel at sub-vendor works. Noise level test. Typical test certificate of torsional vibration analysis of compressor, gear box and drive motor as total system to safeguard any resonances during range of operation. Guide vane calibration check. Gear contact pattern check before and after mechanical run test by blue matching.

18 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 18 of 33 44LK-5100 Rev RECIPROCATING COMPRESSOR (UTILITY AND INSTRUMENT AIR) Equipment Qualification Criteria The vendor for the complete unit shall be an established manufacturer of Reciprocating Compressors and he shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing and testing facilities for the same The vendor shall have engineered, manufactured, packaged, tested and supplied at least two identical or validly similar packages in terms of equipment and driver, inlet volumetric capacity (am 3 /hr) and driver rating (kw) from the proposed plant and at least one of these shall have successfully operated in the field for at least 8000 hours without any major overhaul as on the date of issue of invitation to bid The vendor besides satisfying the requirements of Cl and above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package The compressor model offered shall be from regular manufacturing range of the manufacturer and shall meet the following minimum service and manufacturing experience requirements All compressors shall be designed for unsheltered outdoor location Compressors shall be identical in frame size and identical or validly similar in terms of frame rating, rod loadings, rotational speed/ piston linear speed, inlet and discharge pressures, inlet temperatures, actual inlet flow, cylinder sizes and pressure ratings, number of throws/ cylinders, cylinder arrangement, number of stages, mechanical design, materials, etc. as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully operated in the field for at least 8000 hours without any major problems as on the date of issue of invitation to bid Compressors, drivers, auxiliary equipment, piping and other appurtenances shall be designed and constructed for continuous full load duty at the specified operating conditions for atleast 2 years and shall be accessible for rapid and easy maintenance, particularly with regard to cylinder packing and valves. The unit shall also be suitable for start up/part load conditions, maximum differential pressure conditions, operation at relief valve set pressure. Compressors shall be horizontal balance opposed type. Reciprocating compressors shall be used provided upto 60 kw motor rating max. above 60 kw motor rating, compressors shall be screw type or centrifugal type Unless otherwise specified, the average linear piston speed for lubricated cylinders and non-lubricated cylinders shall not exceed 4 m/ sec and 3.5 m/sec respectively The compression ratios shall be so adjusted that the adiabatic discharge temperature shall not exceed C and the actual discharge temperatures for any specified operating condition, including part load conditions, shall not exceed C Drivers shall have rating as a minimum 110% of then maximum brake power (including transmission losses and + 3% tolerance) required under any of the specified

19 44LK M A4 Engineering Design Basis HPCL Mumbai Sheet 19 of 33 Rotating Equipment DHDT Project Rev. 1 44LK-5100 compressor operating conditions or 5% higher than the power required at the relief valve set pressure condition (including transmission losses) whichever is higher Gear units, when used, shall be designed in accordance with AGMA 420 or an equivalent standard and shall have an AGMA service factor of not less than 2, based on the driver nameplate rating when the driver is electric motor. For other drives it shall be as recommended by the gear box manufacturer Provision shall be made for unloading the compressor at the time of start. The driver starting system shall be interlocked with the control circuit to protect against loaded start. On power supply cut-off or failure, the compressor shall be unloaded automatically Volume bottles shall be provided at the inlet and the outlet of each cylinder to limit the residual peak and peak pulsations to 2% at the line side nozzle of the volume bottle. In case pulsation study is conducted, the requirement of API 618 shall be applicable. These volume bottles shall be designed and fabricated in accordance with ASME Sec. VIII Div. I. Volume bottles shall not be used as cylinder supports Compressor crankshaft bearing system shall be suitable to take into account additional loads imposed due to motor rotor. It shall be compressor supplier s responsibility to co-ordinate with drive manufacturer to ensure proper design, alignment and operation of train. The necessary co-ordination shall be done as required for torsional analysis of train, selection of motor, matching of coupling, etc Inspection And Testing As per Reciprocating Compressors (Except Helium pressure test which is not applicable). 3.5 GENERAL PURPOSE STEAM TURBINES Equipment Qualification Criteria The Steam Turbines offered shall be from a regular and established manufacturer of general purpose Steam turbines having requisite design, engineering, manufacturing and testing facilities The Steam turbine model offered shall be from regular manufacturing range of the manufacturer Steam turbines shall be identical in frame size (Model number) and validly similar in power rating, rated speed, steam flow, steam inlet conditions, steam exhaust conditions, rotor dynamics, bearing span, mechanical design and materials as compared to at least two units designed, manufactured, tested and supplied from the proposed manufacturing plant and at least one of these units shall have successfully operated in the field for minimum 8000 hours without any major problem as on the date of issue of invitation to bid Turbine shall be preferably of multi-stage design. Single stage overhung design shall not be provided In case pressurized lube oil system is required the same shall be vendor s proven system. Vendor shall provide proof for the same.

20 HPCL Mumbai Engineering Design Basis 44LK M A4 DHDT Project Rotating Equipment Sheet 20 of 33 44LK-5100 Rev A sentinel valve shall be supplied on the turbine casing A relief valve shall be provided on the turbine exhaust side For turbine end shaft sealing, mechanical seal shall be provided Inspection and Testing NDTs shall be carried out as per vendor s standard quality plan Following test shall be witnessed by third party inspection agency : Hydrostatic Test (All pressure parts and auxiliaries). Mechanical run test. 3.6 CENTRIFUGAL PUMPS Equipment Qualification Criteria The pump vendor shall be an established centrifugal pump manufacturer having adequate engineering, manufacturing and testing facilities for pumps conforming to the relevant API standard. The pump model offered shall be from the existing regular manufacturing range of the pump manufacturer. Pumps shall be identical or validly similar in terms of power rating. Hydraulic performance (including NPSHR for centrifugal pumps), inlet flow, differential head, operating pressure and temperature, pumping liquid, speed, number and type of impellers / heads. Mechanical design, materials bearing span (applicable for between bearing centrifugal pumps), column length (applicable for vertically suspended pumps) etc., as compared to at least 2 units of the proposed model designed, manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least one of these units shall have successfully operated in the field for atleast 8000 hours individually without any major overhaul as on the date of issue of invitation to bid Two stage pumps shall be of in between bearing types All pumps shall be designed for unsheltered outdoor location Pumps with suction specific speed >11000 (U.S. Units) shall not be used. Inducers shall not be used except for high speed integrally gear driven type of pumps Pumps shall have continuously rising curves with shut off head of 110% of rated head. Pump supplier shall explore the possibilities to improve the margin by offering a suitable model or by providing other arrangements. Also shut off head shall not exceed 120% of rated head. Impeller diameter shall be selected such that minimum 5% increase and decrease in head at rated capacity is possible with the same casing by changing impeller. Impellers with minimum and maximum diameters for the particular casing model shall not be used No cast iron pressure containing parts shall be used for hydrocarbon service Pumps for high head, low flow duties (falling outside the range of two stage pumps without continuous bypass) shall be High-speed integral gear-driven pumps.