NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES K.04

ROTARY TYPE POSITIVE DISPLACEMENT COMPRESSORS

(API 619)

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 2 of 23
COMPRESSORS (API 619) Rev 0 1999
INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 5

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Additions and Exceptions to API 619 6

4.0 MATERIALS 14

4.1 API 619 Requirements 14

5.0 INSPECTION 15

5.1 Procedures 15
5.2 Scope 16
5.3 Nameplates 16

6.0 TESTING 16

6.1 Required Tests 16

6.2 Test Procedures 17
6.3 Test Certificates 19
6.4 Start-up 19

7.0 DOCUMENTATION 19

7.1 Introduction 19
7.2 Schedules, Reports and Co-ordination Meeting 20
7.3 Data and Calculations 20
7.4 Drawings 20
7.5 Final Records Documents and Manuals 21
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 3 of 23
COMPRESSORS (API 619) Rev 0 1999
SEC TITLE PAGE

8.0 PRIOR TO SHIPMENT 22

8.1 Painting and Coatings 22

8.2 Spares 22
8.3 Packing and Storage 22
8.4 Shipping 23
8.5 Warranty 23

DATA SHEETS

Rotary - Type Positive Displacement Compressor Data Sheets (API 619) (9 sheets)
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 4 of 23
COMPRESSORS (API 619) Rev 0 1999
1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the general requirements for the design, fabrication, inspection, testing,
documentation and preparation for shipment for skid mounted self-contained, packaged rotary positive
displacement compressors. Included are the related driver, lubricating systems, controls, instrumentation
and other auxiliary equipment that form a complete compression package.

1.1.2 This specification is based on, and must be read with API Standard 619 "Rotary Positive Displacement
Compressors for General Refinery Services".

1.1.3 This specification applies to equipment for refineries, onshore oil and gas installations, and processing
facilities including items purchased either directly or as a part of a package.

1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.5 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
Codes and Standards, the Vendor/Contractor shall inform the Owner in writing, and receive written
clarification from the Owner before proceeding with the work.

1.1.6 This General Engineering specification will form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

Where indicated in this specification, the following additional NOC Specifications shall apply.

GES E.01 Shell and Tube Heat Exchangers

GES E.04 Finned Air Cooled Exchangers

GES K.10 General Purpose Steam Turbines (API 611)

GES K.11 Special Purpose Steam Turbines (API 612)

GES L.11 Induction Motors (Low Voltage)

GES L.12 Medium Voltage Induction and Synchronous Motors

GES M.03 General Purpose Gear Units (API 677)

GES M.04 Special Purpose Gear Units (API 613)

GES M.05 Lubrication, Shaft Sealing and Control Oil Systems for Rotating Equipment
(API 614)

GES M.06 Monitoring Systems for Rotating Equipment (API 670)

GES M.10 Special Purpose Couplings for Refineries (API 671)

GES N.01 Thermal Insulation for Hot Service

GES P.01 Piping Material Specification

GES P.02 Plant Piping Systems

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 5 of 23
COMPRESSORS (API 619) Rev 0 1999

GES S.06 Skid Assemblies

GES V.01 Coded Pressure Vessels (ASME VIII)

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

GES X.03 External Protective Coatings

The Vendor/Contractor shall ensure all Sub-Contractors comply with the relevant sections of the above
specifications.

1.3 Data Sheets

The technical data supplied by the Owner for the equipment is given on the API Standard 619 Data Sheets
which are attached at the end of this specification.

The Vendor/Contractor shall complete the Data Sheets with the remaining information and submit them
with his proposal. Prior to shipment, the Vendor/Contractor shall submit a complete set of "As-Built" Data
Sheets as part of the final documentation.

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined in paragraph 1.4 of API 619.

2.2 Contractual

The contractual terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main Contractor for a defined piece of work.

Sub-Contractor.

A company awarded a contract by a contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 6 of 23
COMPRESSORS (API 619) Rev 0 1999
Inspector

A qualified individual representing the Owner, Vendor/Contractor or assigned Inspection Authority, who
verifies that the equipment has been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

3.1.1 The design shall comply with this specification and the following Codes and Standards.

API 619 "Rotary Type Positive Displacement Compressors".

3.1.2 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the Purchase Order/Contract should be used.

3.2 Additions and Exceptions to API 619

The following paragraph numbers refer to API 619 Second edition, May 1985, which shall be considered
as forming a part of this General Engineering Specification.

In API 619 paragraphs are marked with a bullet (•) if the Owner has to make a decision or provide
information. Where possible, these decisions have been made or alternatively guidelines provided. Such
paragraphs are marked "*" in this specification.

All requirements specified in this specification are additions to those of API 619 unless otherwise stated.
Paragraph numbers in this specification which do not appear in API 619 are new paragraphs.

API 1.0 General

1.2 Alternative Designs

Add:

Metric flanges/connections are not acceptable. Flanges or studded connections shall be

to ANSI B16.1 and B16.5 except as qualified in section 2.3. Metric fasteners may be
used with the prior approval of the Owner, except on flanges.

API 2.0 Basic Design

2.1 General

2.1.1 Add:

Rotary positive displacement compressors shall be supplied only by Vendors/Contractors

qualified by experience in manufacturing the units required. To qualify, the
Vendor/Contractor shall have manufactured at the proposed point of manufacture, at least
two compressors of comparable power, speed and service conditions. These compressors
must have been in operation for at least one year and be performing satisfactorily.

2.1.3 Add:

Cooling water and air cooling systems when utilised shall be designed for the high
ambient conditions.

2.1.4 Add:
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 7 of 23
COMPRESSORS (API 619) Rev 0 1999

The arrangement of piping and accessories shall be executed by the Vendor/Contractor so

as to provide safe easy access to the equipment for operation and maintenance.

2.1.6 Add:

The Vendor/Contractor shall quote for spares in accordance with paragraph 8.2 of this
specification.

2.1.11* The Vendor's/Contractor's representative shall be present during piping and shaft
alignment checks and startup of the compressor.

2.1.12* The Owner will advise the electrical classification on the Data Sheets.

2.1.13 Add:

The sound pressure level measured at 3.3 feet (1.0 metre) from the surface of the
equipment including driver shall not exceed 90 dB(A) assuming there is no background
noise. It is not expected that special noise abatement treatment will be required. The
Vendor/Contractor shall submit anticipated and guaranteed overall maximum noise data
with and without acoustic treatment, with his proposal. The Vendor/Contractor shall
submit details of proposed acoustic treatment and ensure that it does not interfere with
access to the equipment for maintenance.

2.1.14* Add:

The Vendor/Contractor shall determine from the Owners inlet gas composition, the
amounts of condensation after cooling and shall provide efficient liquid separators
complete with automatic condensate traps with manual isolation and bypass valves.

2.1.15* Add:

Full environmental conditions at the installation site will be given in the Data Sheets.

2.1.16* Compressor shall be suitable for "run-in" on air. The Vendor/Contractor shall advise the
pressure conditions for run in on air, which shall not compromise the compressor
performance/efficiency for the design duty.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 8 of 23
COMPRESSORS (API 619) Rev 0 1999
2.2 Pressure Casing

2.2.7 Add:

Both axially and radially split casings shall to provided with jacking screws to ease
breaking of the joints for maintenance.

2.2.10* Add:

The Vendor/Contractor shall propose and give details of cladding necessary based on his
experience of the service. Full details of reduction in pressure due to over machining and
overlay shall be given.

API 2.3 Casing Connections

2.3.1* Inlet and outlet connections shall be flanged.

2.3.4* Flanged auxiliary connections are required as indicated below:-

(a) vent connections are not required on the compressor;

(b) pressure and temperature gauge connections are not required on the compressor;
they will be installed in the package piping;

(c) liquid injection connections shall be provided where required for the service;

(d) water cooling connections shall be provided if water cooling is required for the
service;

(e) lube oil connections are required; seal oil connections shall be provided, if seal
oil is required for the seals specified;

(f) flushing connection shall be provided if required by the service;

(g) buffer gas connections shall be provided if buffer gas sealing is specified;

(h) casing drain connections are required.

API 2.4 External Forces and Moments

2.4.1 Add:

External forces and moments shall meet 2.5 times NEMA SM23 as a minimum and
Vendors/Contractors shall state if these figures can be exceeded. Connections shall
preferably not be fitted with expansion bellows.

API 2.5 Rotating Elements

2.5.1.1 Add:

All structural welds on rotors shall be full penetration.

2.6 Seals

2.6.1.1 Add:
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 9 of 23
COMPRESSORS (API 619) Rev 0 1999

Shaft seals and seal oil systems shall be designed to seal against maximum case-working
pressure and temperature.

Seal systems shall be designed to maintain a positive internal gas pressure under all start-
up and operating conditions, including possible negative suction pressure required for air
"run-in". The Vendor/Contractor shall provide full information on the seal leakage rates
and ejector consumption with the compressor proposal.

2.6.1.4 Shaft-seals in air or inert gas service shall be the Vendor's/Contractor's standard straight
labyrinth design.

For flammable gas service, labyrinth type or restrictive ring type seals shall be provided
with eductor or injection systems; alternatively mechanical/liquid film seals may be
specified.

Shaft seals in toxic gas service shall be of the mechanical (contact) liquid film type, or
restrictive ring type operated with a sealing liquid.

2.6.3.2* For ejector systems the motive fluid shall be compressor discharge gas unless otherwise specified.

2.6.3.3* A separate source of inert buffer gas is not available unless specified. When buffer gas is
necessary, the Vendor/Contractor shall advise the normal and maximum consumption and
shall supply a locally mounted flow indicator in the supply line.

API 2.7 Dynamics

2.7.1.10 The Vendor/Contractor shall be responsible for the torsional vibration of the complete machinery
train and shall submit a train torsional analysis to the Owner.

2.8 Bearings and Bearing Housings

2.8.1.2* Radial bearings shall not be fitted with temperature sensors.

2.8.2.6* Thrust bearings of all dry machines shall be fitted with temperature sensors in accordance with
GES M.06. Thrust bearings of oil flooded machines should preferably be fitted as
aforementioned and Vendors/Contractors are requested to offer these as an option.

2.8.2.7 Thrust bearing sensors, when installed, shall be located in 50% of the thrust pads.

Anti-friction type bearings are not acceptable except on smaller compressors below
200hp (150kW) and below 4000 rpm.

API 2.10 Lube Oil and Seal Oil Systems

2.10.1 Add:

For unspared large compressors with sleeve bearings, the lube oil/seal oil system shall
comply with GES M.05.

For compressors with anti friction bearings, the Vendor/Contractor shall submit his
standard proven oil system details for the Owner's review and approval.

API 3.1 Drivers

3.1.1* The Owner will specify the type of driver required on the Data Sheets. An electric motor
driver is most common but steam turbines may also be specified.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 10 of 23
COMPRESSORS (API 619) Rev 0 1999

The Vendor/Contractor shall advise the power required to run the compressor at the
recommended relief valve pressure setting. In addition to paragraphs 3.1.4 and 3.1.5, the
driver shall be able to operate the compressor at the relief valve set point.

3.1.2* The Owner will specify any process variations and starting requirements which might
affect the sizing of the driver.

3.1.4* The requirements for steam turbine drivers, if requisitioned, will be specified by the
Owner on turbine Data Sheets. Steam turbine drivers shall conform to GES K.10 or
K.11, as applicable.

3.1.5* The operating conditions shall be advised by the Owner on the Data Sheets.

3.1.6* Requirements for motor drivers, if requisitioned, will be specified by the Owner on the
motor Data Sheets. Electrical motor drivers shall comply with NOC Specifications GES
L.11 and GES L.12 as applicable.

3.1.8* Gear units with transmitted power exceeding 1000 bhp (746kW) and pitch line velocities
over 12,000 ft/min on unspared critical duty shall comply with GES M.04 (API 613).
Otherwise, they shall comply with GES M.03 (API 677).

API 3.2 Couplings and Guards

3.2.2 Add:

The couplings shall comply with GES M.10.

API 3.3 Mounting Plates

3.3.1.1* A baseplate shall be provided by the Vendor/Contractor.

3.3.1.2.5* Epoxy grout will be used and all grouting under surfaces shall be precoated with epoxy
by the Vendor/Contractor.

3.3.2.1* Levelling pads or targets shall be extended to include all equipment.

3.3.2.2* The baseplate shall be extended to include all equipment.

3.3.2.3* The baseplate does not have to be suitable for column mounting.

3.3.2.5* Sub-soleplates are not required.

3.3.2.6* The oil reservoir may be incorporated into the machinery baseplate otherwise all other
requirements of API 614 shall be met. Particular attention shall be given to easy access
for maintenance which will dictate that the reservoir is not beneath any of the main
equipment items. The Vendor/Contractor shall submit with his bid a dimensional
arrangement drawing of the skid layout proposed which shall comply with GES S.06.

3.4 Controls and Instrumentation

3.4.1.1 Add:

The Vendor/Contractor shall include all necessary equipment/instrumentation to execute

the safe automatic start-up, operation, and shut-down of the compressor package.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 11 of 23
COMPRESSORS (API 619) Rev 0 1999
Operation shall include capacity variation over the range specified and instrumentation
shall include all controls, readout gauges, alarms, shutdown and monitoring etc. required
for effective operation and maintenance.

3.4.2.1 Add:

The Owner will advise the compressor parameter (suction/discharge pressure or flow
etc.) to be controlled and the control limits. The control system shall be fully automatic
with manual override.

A slide valve or similar control acting directly on the rotor compression cycle is the
preferred method of primary control unless the driver has variable speed: Secondary
control may be by "on-off blow off" or "bypass".

Constant speed compressors for plant air service, or dry compressors for instrument air
service may be offered with slide valve or suction throttling primary control and on-off
blow off secondary control. The Vendor/Contractor shall recommend the receiver
volume required for normal control operation.

Constant speed process compressors shall use primary control as above and by pass for
secondary control. All controls and valves (Blow-off or Bypass) shall be provided by the
Vendor/Contractor.

3.4.2.2 Add:

Variable speed primary control shall be provided when a variable speed driver is
specified.

3.4.2.3 Add:

The control valves shall be furnished by the Vendor/Contractor.

3.4.3.1* An instrument panel shall be provided, complying with the data and instrumentation listed in the
Data Sheets as a minimum. Critical instrument readings alarms etc. shall be grouped and
arranged for connection to the plant distributive control system.

3.4.4.1 Add:

Gauges and sensing devices/switches shall be furnished to perform the following

functions in addition to the functions on the Data Sheets:
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 12 of 23
COMPRESSORS (API 619) Rev 0 1999
(1) Gauges Local Mount Panel Mount

Seal Labyrinth Chamber/Pressure (Ejector or Injector Seal) X

X
Motive Fluid Pressure (Entering Ejector) X
--
Fluid Header Pressure (Leaving Ejector) X --
Temperature and Pressure before each stage compression X X
Temperature and Pressure after each stage compression X
X
Temperature inlet and outlet casing cooling water X
--

(2) Switches Alarm Shutdown

High seal labyrinth chamber pressure (Ejector or Injector Seal) X

--
Low seal labyrinth chamber pressure (Ejector or Injector seal) X --
Low buffer gas differential pressure X X
High temperature after each stage of compression X X
High temperature casing cooling water X X
High thrust bearing temperature X X
High separator liquid level X X

For plant and instrument 125 psig (860 kPag) air compressors, Vendors/Contractors shall
offer their standard package instrumentation with extras to meet this specification.

3.4.4.3 Add:

All switches and circuitry shall be arranged to de-energise to trip.

3.4.4.4 Add:

An annunciator system shall be provided and shall contain 20% minimum spare points.

3.4.5.1 Add:

Non-contacting vibration and axial position instrumentation shall be provided only when
specified on the Data Sheets. This equipment shall not be required on standard air
compressors and small gas compressors but when supplied for critical unspared duties
shall conform to GES M.06.

3.4.5.2 Add:

Seismic vibration instrumentation shall be provided where non-contacting proximity

equipment is difficult or impossible to install. Seismic instrumentation shall be installed
on compressors of 200 hp (150 kW) or above and when specified on the Data Sheet shall
conform to GES M.07.

API 3.5 Piping and Appurtenances

3.5.1 General

3.5.1.1 Add:

Piping shall also comply with GES P.01 and P.02.

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 13 of 23
COMPRESSORS (API 619) Rev 0 1999

3.5.1.4 Delete last sentence only and add:

The Vendor/Contractor shall also design and furnish all inter-connecting piping between
equipment groupings (typically the process and other piping to and from silencers,
coolers etc.) whether mounted "on" or "off" the main equipment base. Where practical
common services shall be manifolded and brought to a single flanged connection at the
edge of the skid i.e oil and condensate drains.

3.5.1.16 Add:

Internals of piping and appurtenances shall be accessible through openings or by

dismantling for visual inspection or cleaning.

3.5.1.17 Add:

Connections NPS 1½ and smaller shall be designed for minimum length and shall be
braced in two planes to provide rigidity against vibration.

3.5.3 Process Piping

3.5.3.1 Add:

The Vendor/Contractor shall provide all process piping to interconnect the compressor
with its intercoolers and aftercoolers as appropriate.

3.5.3.2 Replace paragraph with:

The Vendor/Contractor shall be responsible and shall guarantee the safe reliable
operation of the complete package including the pipework furnished by the
Vendor/Contractor.

3.5.5 Intercoolers and Aftercoolers

3.5.5.1* Air cooling is required between stages unless utility cooling water is available and details are
given on the Data Sheets. In this latter case, water shall be used as a cooling medium.

3.5.5.2* The Vendor/Contractor shall furnish an air cooled aftercooler unless utility cooling water is
available and details are given on the Data Sheet. In the latter case, water shall be used as
the cooling medium.

3.5.5.3* Shell and tube coolers shall comply with GES E.01. TEMA Class "R" design only will be
accepted.

3.5.5.6* Air cooled coolers shall comply with GES E.04.

3.5.5.9* Air cooled intercoolers and aftercoolers shall be machine baseplate mounted where small size
allows short pipe runs without hindrance to maintenance access. Water cooled coolers
shall be machine baseplate mounted.

3.5.5.11 Add:

Separation and condensate collection equipment shall be provided by the

Vendor/Contractor. The separators shall be individual vessels having impingement
baffles, an outlet low velocity mist mat and a liquid hold up time of 20 minutes minimum
where practical.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 14 of 23
COMPRESSORS (API 619) Rev 0 1999

3.5.6 Air Intake Filters

3.5.6.2 Add:

For air compressors, the Vendor/Contractor shall supply the inlet filter complete with
supports and inlet pipework to the compressor. The filter shall be suitable for desert
sandstorms and access provided for changing the filter elements. Filters shall be
provided with suitable silencing.

3.5.7 Silencers and General Insulation

3.5.7.4* It is preferred that the silencers be mounted directly on the compressor flanges. All pressure
vessels shall meet GES V.01.

3.5.7.7* The Vendor/Contractor shall advise the material and corrosion allowance for the approval of the
Owner when corrosive gases are present.

3.5.7.8* The Vendor/Contractor shall specify relief valve settings which shall not be less than 110% of the
rated discharge pressure.

3.5.7.11 Add:

Silencers shall also be provided with 6" flanged inspection openings to allow complete
viewing of all internals.

3.5.7.15* Insulation clips, insulation and cladding shall be provided for all hot surfaces, including
interconnecting piping etc, for personnel protection. Protection from hot surfaces shall
meet the requirements of GES N.01.

4.0 MATERIALS

4.1 API 619 Requirements

The Vendor/Contractor shall provide materials in accordance with paragraph 2.11 of API 619 as amended
below:

API 2.11 Materials

2.11.1.1 Add:

Casings for flammable hydrocarbon service shall be of steel. Cast iron and nodular iron
castings for casings are not acceptable for services other than air or inert gases.

2.11.1.5* The presence of hydrogen sulphide or chlorides will be specified on the Data Sheets.
Chemical and physical data including hardness is required for all materials in contact
with sour gas.

2.11.1.2 Delete:

"shall have corrosion resistance equal to that of specified parts in the same environment".
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 15 of 23
COMPRESSORS (API 619) Rev 0 1999
and replace by:

"shall be corrosion-resistant materials suitable for the process or site environment as

applicable".

2.11.2.5.1 & 2 Add:

Defects to all castings requiring repair shall be brought to attention of the Owner prior to
commencing the repair.

2.11.4.6.1* The extent of weld inspection required will depend on the service/duty. Stainless steel
piping and piping in H2S service will require 100% radiography inspection. For other
materials the Vendor/Contractor shall propose in his Quality Control Plan the type of
inspection and the percentage coverage for the approval of the Owner.

2.11.5.3* The Vendor/Contractor shall propose in his Quality Control Plan the type of inspections
for the approval of the Owner.

5.0 INSPECTION

5.1 Procedures

5.1.1 All items of plant and equipment referenced within this specification shall be subject to inspection by the
Owner or the Inspection Authority.

All inspection requirements shall be incorporated in the Quality Control Plan which shall be provided by
the Vendor/Contractor with his proposal for review by the Owner.

5.1.2 Inspection shall be in accordance with API 619 and this specification. All inspection activities to be
performed, including any special requirements, shall be agreed with the Owner and shall be incorporated
within the agreed Quality Control Plan provided by the Vendor/Contractor. The Quality Control Plan shall
be coordinated with and shall include the quality plan of major Sub-Contractors. The Vendor/Contractor
shall submit procedures for all applicable NDT techniques for approval by the Owner before production
commences.

5.1.3 All operators of NDT equipment shall have thorough knowledge of the operation of the equipment to be
used and shall hold an appropriate certificate of competence, which is to be agreed by the Owner. All NDT
procedures and qualifications shall be subject to approval by the Owner.

5.1.4 The Vendor/Contractor furnish the Inspector with all reasonable facilities to satisfy himself that the
equipment is fabricated and tested in accordance with the relevant codes and this specification.

5.1.5 Any approvals given by the Owner's Inspector and/or the Inspection Authority do not relieve the
Vendor/Contractor of any responsibility regarding guarantees, workmanship or compliance with the code
and this specification.

5.2 Scope

The inspection scope shall comply with API 619, Section 4.2 as amended below:

4.2.1 (e) Add:

The Vendor/Contractor shall keep maintenance/running clearances for the specified

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 16 of 23
COMPRESSORS (API 619) Rev 0 1999
period.

4.2.4 (f) Add new paragraph:

Physical and chemical material data is required for all pressure containing parts taken
from the melt or heat from which the part is made.

The oil system shall meet the cleanliness requirements of API 614 paragraph 4.3.3.7.

4.2.5 Add:

The cleanliness inspection will not be made by the Owner prior to welding. Cleanliness
will be inspected immediately prior to test.

4.2.6 Add:

Vendors/Contractors standard hardness check shall include all parts in contact with
process gas where H2S is present in the gas compressed.

4.2.7 Add:

The Vendor/Contractor shall propose in his quality plan, the parts to be examined and the
type of examination for the approval of the Owner.

4.2.8 Add new paragraph:

The Owner reserves the right to "observe" any inspections carried out by the
Vendor/Contractor.

4.2.9 Add new paragraph:

Acceptable surface discontinuities and finish shall be assessed using "Visual Method
MSS SP 55".

5.3 Nameplates

Nameplates shall be provided complying with paragraph 2.12 of API 619.

6.0 TESTING

6.1 Required Tests

The following tests shall be performed by the Vendor/Contractor:

(a) NDT on compressor components;

(b) hydrostatic tests (and Helium Tests for Gas MW less than 12);

(c) mechanical run test;

(d) complete unit mechanical run test (one casing, including tandem test if more than one casing,
including gear, driver and job lube system);

(e) performance test;

(f) sound level test;

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 17 of 23
COMPRESSORS (API 619) Rev 0 1999

(g) auxiliary equipment tests (see paragraph 4.3.4.7 below) optional;

(h) post test inspection disassembly (see paragraph 4.3.4.8 below);

(i) spare rotor test (optional);

(j) leak test for toxic/flammable service (optional);

(k) pressure vessels hydrostatic tests (silencers) the hydrostatic and pressure tests shall be carried out
in the presence of the Owner's Inspector: other tests will be witnessed by the Owner.

6.2 Test Procedures

The Vendor/Contractor shall submit the test procedures in writing to the Owner for approval at least 4
weeks prior to the start of the testing programme.

Testing shall be carried out in compliance with paragraph 4.3 of API 619 2nd edition amended as follows:

API 4.3 Testing

4.3.1.4* Add:

The Owner reserves the right to observe all inspection/testing activities in the Quality
Control Plan.

4.3.1.5 Test Gauges. Add new paragraph:

Test gauges shall be of the direct reading type and shall be periodically calibrated. The
certificate of calibration shall be presented to the Inspector prior to commencement of
testing.

4.3.1.6 Add new paragraph:

Test items (a) (b) (c) (d) (e) (f) and (k) of paragraph 6.1 above are mandatory - see
comments below.

4.3.2.6 Test/Painting. Add new paragraph:

No type of preservative or paint shall be allowed to cover any pressure containing

components any mechanical or welded joint, before the pressure test is completed.

The Owner reserves the right to observe all inspection/testing activities in the Quality
Control Plan.

4.3.3.1 Add:

The mechanical run test shall be of 4 hours minimum duration and shall be performed
using a lube oil viscosity and temperature close to that expected in the field.

4.3.4.1 (Performance test) Add:

When the Vendor/Contractor is unable to operate the compressor at rated conditions on

the performance test, he shall state this and shall give clear details of the proposed
alternative conditions in his proposal.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 18 of 23
COMPRESSORS (API 619) Rev 0 1999

4.3.4.2 (Complete Unit Test) Add:

This test shall include all the requirements of the "mechanical run test" paragraph 4.3.3
but shall additionally include the complete drive train and job lube oil system but need
not include the interstage equipment when furnished. It is simply a full train mechanical
run test.

4.3.4.3 (Tandem Test) Add:

Where the compression duty requires two or more casings and these are in a single
mechanical train then they shall be tested together mechanically as in 4.3.4.2 above.

4.3.4.4 (Gear and Driver) Add:

Gears and drivers shall be tested in accordance with the appropriate NOC Specification at
the equipment manufacturers works before despatch to the compressor
Vendor/Contractor for the complete unit test above.

4.3.4.7 (Auxiliary Equipment Test) Add:

Operational testing of controls and other auxiliary equipment, included in the package but
not included in the full train mechanical run above, shall in all cases be given a
comprehensive check prior to assembly on the skid. They shall also be fully functionally
tested with the compression train under 4.3.4.2 above.

4.3.4.8 Post Test Dismantling/Inspection (optional) Add:

Complete dismantling is not required unless compressor distress is noticed during the
mechanical run or general post test inspection.

4.3.4.9 (Full load, speed, pressure test) Add:

It is desirable to carry out the mechanical run test at as close to full load as is permitted
by the Vendor's/Contractor's test facilities. The Vendor/Contractor shall give details of
pressure and load attainable in his proposal.

4.3.4.10 Leak test for toxic/flammable service (optional) Add:

The Owner will indicate whether this option is required on the Data Sheets.

4.3.4.11 Spare Rotor Tests (optional) Add:

The Vendor/Contractor shall quote for spare rotors plus testing extra. The
Vendor/Contractor shall also state the delivery time for these rotors based on (a) normal
and (b) urgent delivery requirements. The Owner will decide on the requirement to stock
a site spare based on the foregoing and the criticality of the service.

6.3 Test Certificates

The following test certificates shall be provided:-

(a) The manufacturer's physical and chemical certification of steel pressure parts and forgings.
Certification of all parts in contact with process gas if hydrogen sulphide is present;

(b) Certification for magnetic particle, dye penetrant, radiographic and ultrasonic examination;
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 19 of 23
COMPRESSORS (API 619) Rev 0 1999
(c) Certified shop logs of running test and performance test;

(d) Hydrostatic Tests;

(e) Sound level, and helium tests when applicable;

(f) A record of shop test data (which the Vendor/Contractor shall maintain for at least 5 years after
the date of shipment). The Vendor/Contractor shall supply certified copies of test data to the
Owner before shipment; this data is to be placed in the Data Dossier.

6.4 Start-up

6.4.1 When required by the Owner, the Vendor/Contractor shall be responsible for the compressor startup until
unit is accepted as operational by the Owner. In this case, the Vendor/Contractor shall be responsible for
the supply of competent servicemen for the duration of the checking, startup and run-on period.

6.4.2 When required by the Owner, the Vendor/Contractor shall supply for startup, all lubricating fluids,
including oil, grease and coolants as required by the unit. The Vendor/Contractor shall recommend the
amount and type of lubrication and cooling fluids for subsequent operation.

6.4.3 When required by the Purchase Order/Contract, the Vendor/Contractor shall carry out a performance test
on the equipment at site.

7.0 DOCUMENTATION

7.1 Introduction

7.1.1 This section covers the documentation required for the design, selection, fabrication, inspection and testing
for all the equipment, components and services to be provided against this specification.

7.1.2 The detailed list of documents that are required is included with the Purchase Order/Contract.

7.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications, and to allow a full and continued appraisal to be made of the
Vendors/Contractors proposals and interpretations of the ordered equipment, should be submitted in
accordance with the schedule specified in the Purchase Order/Contract.

7.1.4 Any production or procurement undertaken by the Vendor/Contractor which is prior to the relevant
documentation being submitted and reviewed by the Owner is at the Vendor's/Contractor's risk.

7.1.5 On all documentation the Purchaser Order/Contract number, equipment title, tag number and project name
shall be quoted.

7.1.6 All documentation shall be checked and signed by the Vendor/Contractor's checker before submission.

7.2 Schedule, Reports and Co-ordination Meeting

7.2.1 The Vendor/Contractor shall supply with his proposal, a schedule showing the submission of all documents
for review and approval, proposed Sub-Contractors and material procurement and a production/fabrication
programme.

7.2.2 The Vendor/Contractor shall submit with his proposal a preliminary Quality Control Plan for the contract.

7.2.3 After the contract award monthly reports on design, material procurement and production progress shall be
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 20 of 23
COMPRESSORS (API 619) Rev 0 1999
submitted to the Owner.

7.2.4 A co-ordination meeting shall be held within six weeks of the placement of the Purchase Order/Contract.

7.3 Data and Calculations

7.3.1 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

7.3.2 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

7.3.3 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

7.3.4 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

7.3.5 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

7.3.6 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

7.4 Drawings

7.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

7.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised eg, plating drawings, shall as a minimum, show the position of all through thickness welds,
together with material thicknesses and specifications, clearly indicating the welding procedure specification
which is applicable to each weld.

7.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations and orientations of nozzles, lifting lugs, nameplates and supports.

7.4.4 Detail drawings which may be included on the general arrangement shall include thicknesses and
dimensions of all components, weld details, machining and surface finish requirements, gasket and
nameplate details.

7.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.

7.5 Final Records, Documents and Manuals

7.5.1 Two (2) copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
As a minimum it shall contain the following:

- general arrangement drawing and bill of material,

- the Quality Control Plan,
- material certificates,
- chemical analysis certificates,
- positive material identification certificates,
- weld procedures,
- welder qualifications,
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 21 of 23
COMPRESSORS (API 619) Rev 0 1999
- NDT procedures and records,
- heat treatment charts,
- hazardous area certificates,
- balance certificates,
- hydrostatic pressure tests procedures, and test certificate,
- performance test procedures, and test certificate,
- non-conformity records,
- approvals by the Independent Inspection Authority,
- certificate of conformity,
- Owner's release certificate.

7.5.2 Six (6) sets of the Installation, Operations and Maintenance Manual shall be specifically compiled for the
equipment supplied. A compendium of manufacturer's data for a range of like products is not acceptable.
The Manual shall contain the following:

- a description of the equipment, process and controls philosophy,

- the master document list and certified copies of key drawings,
- packing, shipping and site preservation instructions,
- step by step installation instructions,
- step by step pre-commissioning procedures,
- step by step commissioning procedures,
- normal start up, operating and shutdown procedures,
- step by step procedures for dismantling and re-assembly,
- normal operating and set point values for all instruments,
- routine preventive maintenance schedule and major repair procedures,
- lubrication, chemicals, consumables schedule,
- list of special tools,
- spare parts ordering information,
- for PLCs, a copy of the programme and re-programming procedures.

The Manuals shall be presented in A4 format, and be securely bound in heavy duty 4 ring binders.

7.5.3 The Vendor/Contractor shall produce as built documents revised to indicate field changes.

7.5.4 The Vendor/Contractor shall supply one set of mylar original drawings and documents in an agreed
electronic format.

7.5.5 The Vendor/Contractor shall submit as a minimum, the data and drawings as defined in API 619 Section 5
with the additions/amendments below:

5.1 Proposals

(1) Dimensional arrangement to include total equipment package with driver coolers
silencers and panel etc.

(22) Acceptance of nozzles loadings in paragraph 2.4.1 or a statement of max

resultant loads permissible.

(23) Priced spares list for commissioning and (2) years operation.

5.2 Contract Data

(22) Maximum nozzle loadings for all nozzles.

(31) Fabrication drawings of silencers and all pressure vessels

 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 22 of 23
COMPRESSORS (API 619) Rev 0 1999
8.0 PRIOR TO SHIPMENT

8.1 Painting and Coatings

Surface preparation painting and painting materials shall be in accordance with NOC Specification GES
X.01, GES X.02 and GES X.03. The coating of electrical equipment and instruments shall be in accordance
with GES X.06.

8.2 Spares

The Vendor/Contractor shall submit with his proposal, a priced list of recommended spare for "start-up"
and for "two years operation ", for review by the Owner.

8.3 Packing and Storage

8.3.1 This section describes the minimum requirement for the preservation and protection of rotary positive
displacement compressors during the sea and land transportation and storage, prior to installation.

8.3.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months
shall be assumed.

8.3.3 The following preparation for shipment shall be a minimum requirement:

(a) After mechanical completion at the works, the rotary compressors shall be left in a dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment. This shall be done at the Vendor's/Contractor's works, and may be
achieved by firmly fixing the equipment to wooden pallets or crates, as part of an approved
packing procedure.

Additions and Exceptions to API 619

The preparation for shipment shall comply with API 619 Section 4.4 as amended below:

4.4.1 Delete this paragraph and replace with the requirements of 8.3.2 above and:

The equipment shall be prepared for export shipment by sea. Shipment as non-
containerised deck cargo is not permissible.

4.4.3.1 Delete this paragraph and replace by the requirements of 8.1 above.

4.4.4 Add new paragraph:

The spare parts when ordered shall also be suitably boxed for export shipment.

8.4 Shipping

Detailed shipping arrangements will be given in the Purchase Order/Contract.

Compressors with seals installed, drivers and all furnished auxiliaries shall be shipped fully assembled on
the baseplate except that coupling spacers shall be removed, boxed and tagged and attached to the skid with
any other items which are better shipped separately e.g. silencers.

The equipment shall not leave the Vendor's/Contractor's works for shipment until the release certificate has
been approved by the Owner's Inspector.
 GENERAL ENGINEERING SPECIFICATION GES K.04
ROTARY TYPE POSITIVE DISPLACEMENT Page 23 of 23
COMPRESSORS (API 619) Rev 0 1999
8.5 Warranty

8.5.1 The Vendor/Contractor shall provide manufacturer's written guarantees of the compressor performance.
8.5.2 The Vendor/Contractor shall warrant all materials and services supplied against any defect for a minimum
of 12 months after commissioning or 24 months from the date of delivery to site, whichever is the shorter
period, or for the period stipulated in the Purchase Order/Contract.

8.5.3 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.

Data Sheets

Rotary - Type Positive Displacement Compressor Data Sheets (API 619) (9 sheets)