Santos Engineering Standard

Draft Specification 1515-30-S002-0, Rev 4A

Page 1 of 27

Title: Specification for Reciprocating Compressors

1.0 FOREWORD..............................................................................................................................................4
1.1 ABBREVIATIONS.......................................................................................................................................4
2.0 SCOPE OF SUPPLY.................................................................................................................................5
2.1 PACKAGER HARDWARE SCOPE................................................................................................................5
2.2 REQUISITION DATASHEET........................................................................................................................6
3.0 STANDARDS, CODES OF PRACTICE, AND REFERENCES..........................................................6
3.1 SANTOS TECHNICAL REQUIREMENTS......................................................................................................6
3.2 SANTOS STANDARDS................................................................................................................................7
3.3 ISO 13631 BULLET POINTS......................................................................................................................7
3.4 APPLICATION OF PACKAGER AND MANUFACTURER STANDARDS...........................................................8
4.0 COMPRESSOR SPECIFICATIONS......................................................................................................9
4.1 GENERAL..................................................................................................................................................9
4.2 SERVICE LIFE...........................................................................................................................................9
4.3 COMPRESSOR OPERATION........................................................................................................................9
4.4 COMPRESSOR SIZING................................................................................................................................9
4.5 PERFORMANCE STUDIES..........................................................................................................................9
4.6 COMPRESSOR FRAME.............................................................................................................................10
4.6.1 Compressor frame lubrication..........................................................................................................10
4.6.2 Oil cooling and heating....................................................................................................................11
4.7 COMPRESSOR DRIVE COUPLING..............................................................................................................11
4.8 COMPRESSOR CYLINDERS......................................................................................................................11
4.8.1 General.............................................................................................................................................11
4.8.2 Design pressure................................................................................................................................11
4.8.3 Compressor cylinder lubrication......................................................................................................11
4.8.4 Discharge temperatures....................................................................................................................12
4.8.5 Piston rods........................................................................................................................................12
4.8.6 Rod Loads.........................................................................................................................................12
4.8.7 Pistons...............................................................................................................................................13
4.8.8 Piston and crankshaft speeds............................................................................................................13
4.8.9 Packing cases....................................................................................................................................13
4.8.10 Cylinder valves.............................................................................................................................13
4.9 STRUCTURAL RAW MATERIALS.............................................................................................................14
4.9.1 NDT - cylinders.................................................................................................................................15
4.9.2 Hydro-test – cylinders.......................................................................................................................15
4.10 PULSATION BOTTLES..............................................................................................................................15
4.10.1 Pulsation Control and Analysis....................................................................................................15
4.11 TORSIONAL ANALYSIS AND CONTROL...................................................................................................16
5.0 COMPRESSOR CONTROL..................................................................................................................18
5.1.1 Valve removal or unloading.............................................................................................................18
5.1.2 Unloaders.........................................................................................................................................18
6.0 COMPRESSOR SAFEGUARDING AND MONITORING................................................................18
6.1.1 Compressor safety shutdown............................................................................................................18
6.2 COMPRESSOR PERFORMANCE MONITORING..........................................................................................18
6.3 COMPRESSOR MACHINE MONITORING..................................................................................................18
7.0 ELECTRICAL EQUIPMENT AND CERTIFICATION....................................................................20
7.1 MOTORS AND VSD..............................................................................................................................20

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Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 2 of 27

8.0 PERFORMANCE TEST.........................................................................................................................20

9.0 REVISION NOTES.................................................................................................................................21

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Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 3 of 27

1.0 FOREWORD
This Specification covers general mechanical rotating equipment specifications for
reciprocating compressors.
Santos shall ensure that the application of this Facilities Project Specification meets the
requirements of the Santos Environment Health and Safety Management System – in
particular, but not limited to:
 EHSMS 02 – Legal and Other Obligations
 EHSMS 06 – Training and Competency
 EHSMS 09 – Hazard Identification, Risk Assessment and Control
 EHSMS 10 – Contractor and Supplier Management
 EHSMS 11 – Operations Integrity
 EHSMS 12 – Management of Change
 EHSMS Glossary
 HSHS 06 – Electrical Safety

Santos Engineering Standards apply to all Santos onshore facilities and are based on
Australian Regulations and Standards. When applied outside of Australia, Local
Regulations, Codes of Practice and Environmental Regulations shall take precedence.
Compliance with Regulations and Engineering Standards is compulsory in
accordance with EHSMS 02 and EHSMS 11.2. The current Santos Engineering
Standards shall apply unless specifically stated within individual standards or when
directed by the Custodian of the relevant Standard. Regulations may superimpose
retroactive provisions.
Use of this Santos Engineering Standard is MANDATORY. If any part of this Standard
appears inadequate, unsuitable or not cost effective, consult with the Custodian to
agree a suitable solution. This may result in a revision to the Standard.

1.1 Abbreviations
ANSI American National Standards Institute
API American Petroleum Institute
AS Australian Standard
AS/NZS Australian/New Zealand Standard
ASME American Society Mechanical Engineers
ASTM American Society for Testing and Materials
CA Conformity Assessment
ESD Emergency Shutdown
OEM Original Equipment Manufacturer
VSD Variable speed drive

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Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 4 of 27

2.0 SCOPE OF SUPPLY

This specification is for the supply of a reciprocating compressor nominally greater than
100 kW power rating. Refer to separate specifications for the supply of the compressor
driver and the remaining compressor package.
This specification excludes integral engine/compressors of the type supplied by
Compressco.
Within this document, Manufacturer refers to the gas engine original equipment
manufacturer, and Packager refers to the packager of the driver, compressor and
compressor skid and ancillaries. The Packager is referred to as the Contractor in
tender documents.
Technical specifications contained within this document are based on the technical and
build standards of the selected supplier (Manufacturer) whilst meeting recognised
international, Australian and Santos standards.

2.1 Packager Hardware Scope

Compressor unit Reciprocating compressor.

Driver Either gas engine or electric motor. Depending on power the electric
motor could be LV or HV.
Coupling between
the driver and
compressor
Lube oil pumps Prelube Pump, Cylinder lube and crank case pump
Coolers Compressor oil and main gas process coolers, inter coolers and after
coolers as required.
Variable clearance Refer to Requisition Datasheet for requirement
pockets
Weather shelter Self-support steel structure extended over the engine, compressor, on-
skid vessels, and out rigger platforms. Shelter shall have enough over
hang to prevent rain ingress when working on the compressor.
Pulsation bottles With provisions for restriction orifices for fine tuning pulsation and
acoustics.
Tanks Engine coolant header and salvage tanks, and engine lubricant and
waste oil collection tanks are required.
A separate compressor lubricant header tank is required.
Waste oil collection tank shall include a vertical vent to end at a point
3.5m above the highest point on the package, and at least 3.5m away
from the engine exhaust.
Cranage The compressor shelter structure shall include monorails or bridge or
davit type manual cranes for lifting of the maximum maintainable
removable part for either the engine or the driver.
Control panel Control panel is mounted on-skid, preferably at scrubber end.

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Draft Specification 1515-30-S002-0, Rev 4A
Page 5 of 27

Valves Suction and discharge shut down valves, suction control valve.
Valves that require frequent operation during compressor use, shall be
located above skid level.
Relief valves
Blowdown valves to allow the compressor to be fully blow down to a
condition with no pressurised gas.
Recycle valves
On skid piping Process and utility piping shall run below deck or above head height to
provide clear walk-through access in the area between compressor
and scrubbers and clear access to sides of the engine.
Piping run below deck level shall include drains to remove any liquids
collection due to pocketing.
Where piping is run underneath the skid floor grating, the grating shall
be removable. Where piping is run along the outside of the skid, it shall
be mounted to the top of the pipe is at least 75mm below floor grating
level.
Interconnecting pipe between all the main and utility process valves.
Suction scrubbers Located upstream of every compressor process stage,

2.2 Requisition Datasheet

Santos shall provide a compressor Requisition Datasheet clearly indicating a full range
of anticipated operating condition throughout the compressor life. Typical design
conditions shall include but not be limited to the following:
 Nominal flow (at low, medium and high discharge pressures)
 Nominal flow (at low, medium and high suction pressures)
 High flow
 Low flow (end of life gas from the field)
 Certified point (max case for sizing the compressor)
 Max compressor capacity at full speed
 Any interaction when any upstream equipment is offline,

3.0 STANDARDS, CODES OF PRACTICE, AND REFERENCES

The compressor shall, as far as practical, conform to the Manufacturer’s technical
standards except where specifically noted as a Santos variation as listed in this project
specification.

3.1 Santos Technical Requirements

All standards referred to in the table are to be interpreted as the most recent versions
of those standards.

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Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 6 of 27

Item Nominated Santos Build Alternative Build Standard

Standard subject to Santos approval
Compressor API Spec 618 Manufacturers build standard based on
ISO 13631 general conformance to API Spec 618 -
Reciprocating Compressors for
Downstream General Refinery or Gas
Plant Service,
OR
Manufacturer’s build standard based on
general conformance to ISO 13631 for
Upstream field compression units
Pressure vessels AS 1210 Unfired Pressure vessel code

AS 3920.1 Pressure equipment manufacture_ Quality

Assurance

AS 4343 Pressure Equipment_ Hazard Levels

Piping ASME B 31.3 Chemical Plant and Petroleum Refinery

Piping

3.2 Santos Standards

1515-10-S001 Packaged Reciprocating Compressors – Process Design

1515-20-S001 Unfired Pressure Vessels
1515-30-G008 Design Practice for Compression Packages. (Draft)
1515-30-S002 Specification for Compression Packages (Draft)
1515-67-G001 Electrical Design in a Hazardous Area
1515-70-G005 SIS Modification
1515-70-S006 Control Systems for Packaged Compressor Systems
1515-90-S001 Skids and Skid Mounted Assemblies
1515-120-S012 Above Ground Protective Coating

Alternative Standards or Codes of Practice other than those listed above may be allowed by
approved exception.
Exceptions to all specifications and standards shall be stated in tender documents, proposed
alternates shall be clearly identified.
Revisions to all documents and drawings shall be clearly identified by revision number, and
date, and by revision bar in text or by clouding on drawings.

3.3 ISO 13631 bullet points

ISO 13631 gives requirements and recommendations for the design, materials,
fabrication, inspection, testing and preparation for shipment of packaged skid-mounted,
reciprocating, separable or integral compressors with lubricated cylinders and their
prime movers, for use in the petroleum and natural gas industries for the compression
of hydrocarbon gas.
ISO 13631 is also applicable to all necessary auxiliary equipment, such as water and

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Draft Specification 1515-30-S002-0, Rev 4A
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gas coolers, silencers, emission control equipment, filters, separators, control panel,
piping, etc., required to install an operable unit in compliance with the purchase
specifications and with the intent of minimizing field construction and field-purchased
equipment.

Careful consideration shall be given when completing the compressor data sheet to
ensure that all the bullet points which are indicated in ISO 13631 at the beginning of
subclauses or paragraphs that indicate a decision are provided by Santos.

3.4 Application of Packager and Manufacturer Standards

The Packager shall ascertain that the codes or standards used for the materials and
equipment supplied conform to relevant Australian, International and Santos standards
(latest revision unless otherwise noted) and identify any deviations.

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Draft Specification 1515-30-S002-0, Rev 4A
Page 8 of 27

4.0 COMPRESSOR SPECIFICATIONS

4.1 General
The reciprocating compressor shall be the Manufacturer's standard model for the
specified duty, provided the standard model meets the specifications detailed in the
following sections. The Packager may, base on their experience and technological
advances, propose alternative specifications for the approval of the Principal Engineer.
The compressor Manufacturer must have manufactured, on a production basis at
proposed point of manufacture, compressors of comparable design, power rating,
speed and discharge pressure, for a gas of comparable characteristics. The selected
compressor must also have a proven reliability service record.

4.2 Service Life

The compressor shall be designed and constructed for a minimum service life of 20
years, with operating periods of at least 6 years between major maintenance
overhauls.

4.3 Compressor Operation

The pressure and flow conditions for which the compressor is designed and/or
operated at can vary across a wide range.  The three primary reasons for changing the
capacity of a compressor are process flow requirements, suction or discharge pressure
management, or load management due changing pressure conditions and driver power
limitations. Several methods can be used to reduce the effective capacity of a
compressor. The addition of clearance will reduce capacity and required power through
a decrease in the volumetric efficiency of the cylinder. A variable volume clearance
pocket is used to change the clearance volume of the head end of a cylinder. The
amount of clearance will vary depending upon the position of the clearance pocket
piston. Clearance is added to the cylinder by turning the piston / stem assembly
counter clockwise (CCW). Clearance pockets shall be of manually adjustable and
balanced design to permit adjustment online. Cylinder unloading and valve spacers
may also be used to utilise available driver power.

4.4 Compressor Sizing

Selection of engine driver determines the nominal compressor horsepower available.
Compressor frame and cylinders sizing shall be matched to standard engine sizing.
Refer to the nominated design cases specified in the Compressor Package Requisition
Datasheet.
Performance curves for flow rate and horsepower versus suction pressure shall note
limitations due to power, rod load, valve configuration and clearance settings. For two
stage units, curves of inter-stage pressure verses suction pressure are required.
Variable volume clearance pockets, cylinder unloading and valve spacers shall be used
to utilise available driver power. Clearance pocket adjustment will be used to
compensate off-rated conditions of composition and suction temperature. Clearance
pockets shall be of manually adjustable, balanced design to permit adjustment on-line

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Draft Specification 1515-30-S002-0, Rev 4A
Page 9 of 27

4.5 Performance Studies

Documentation requirements shall allow for possibility of the compressor being used in
a different service during its lifetime. Each compressor package shall be represented
by a unique P&ID which includes a unique tag number for each item of equipment (i.e.
header tanks, oil filters, control valves, pressure safety valves, pressure and
temperature switches). Where applicable, each item shall be designated a set point
specific to the mode of operation. A separate P&ID is required for each mode of
operation detailing respective set points for PSV, pressure and temperature switches
etc.
Compressor and engine performance curves covering both specified operating range
and equipment limits are required.

4.6 Compressor Frame

The compressor frame shall be fixed mounted on the package skid frame in
accordance with the OEM’s mounting and grouting instructions.. The driver shall have
provision for alignment adjustment with the compressor.. For Gas engine drivers,
Vibracon machine supports are preferred for alignment and vibration attenuation
purposes.
The frame enclosure shall be moisture and dust proof. Explosion relief doors shall be
provided.
Cylinders shall be mounted using single piece distance pieces, such as extra long type
2 distance pieces (per ISO 13631:2002), or Type B distance pieces per API 618. Two
piece distance pieces shall only be required for toxic gases, or where contamination of
the lube oil is unacceptable.
. Connecting rods shall be constructed from forged steel with removable cap. . Big-
end bolts larger than M30 shall be furnished with hydraulically tightened nuts.
Replaceable precision-bored shell (sleeve) crankpin bearings and main bearings shall
be used. Anti-friction bearings are not acceptable. For compressors with drivers over
1,500 kW, each main bearing shall incorporate a single element three-wire 100-ohm
platinum RTD.
Frame material shall be ductile iron ASTM A395 Gr 60-40-18 or equivalent, or cast
steel.
Crankshafts shall be forged steel and shall be heat-treated and machined on all
working surfaces and fits. Crankshaft oil seals shall be replaceable without the
coupling or flywheel having to be removed.

4.6.1 Compressor frame lubrication

The compressor frame lube oil pump shall be a rotary internal screw or gear-type pump
with a pressure relief valve not integral with the pump.
The compressor frame oil make-up shall be supplied via an automatic level regulator
from an on-skid tank.
The compressor frame lubrication pre-lube and post lube pump shall be full-flow, full-
pressure with automatic starting facilities.

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Draft Specification 1515-30-S002-0, Rev 4A
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4.6.2 Oil cooling and heating

The lubricating oil cooling system shall be designed to maintain the lubricating oil at an
acceptable temperature to ensure proper lubrication and prevent lubricant degradation,
under all specified ambient temperatures.
Air cooled heat exchangers shall be sized to provide 10% excess heat transfer area
over and above the heat transfer area required at the specified maximum ambient
temperature.
The compressor shall be able to start from cold under all specified ambient
temperatures. If a start will not be possible with the lubricating oil at the minimum
specified ambient temperature, a suitable oil heating system shall be installed that will
heat the oil to an acceptable temperature prior to the compressor start.

4.7 Compressor drive coupling

The drive coupling shall be selected from types & manufacturers of proven reliability in
similar service.
For electric motor driven compressors, the drive coupling shall use torsional damping
and resilient couplings designed as per API 671. For other drive unit types, API 671 is
preferred, but not essential.
A coupling guard shall be fitted and be removable with minimum of dismantling of
equipment. The guard shall be made of non-sparking marine grade aluminium and
designed in accordance with AS 4024-series.

4.8 Compressor Cylinders

4.8.1 General
The compressor cylinders shall be horizontal with top suction and bottom discharge
and double-acting. Multi-cylinder units shall be of balanced opposed design.
Compressor cylinders without replaceable cylinder liners are acceptable.

4.8.2 Design pressure

As per the requirements of ISO 13631 Section 6.5.1.1 the design pressure of the
cylinders shall be 1.22 times maximum operating pressure and also includes for the
10% accumulation over the PSV set pressure. This is for the compressor cylinders
only.

4.8.3 Compressor cylinder lubrication

Cylinder and packer lubrication shall be a separate distribution block system lubrication
of compressor cylinder ring travel bore and piston rod packing. A stainless steel
integral double-ball check valve (fully rated) shall be provided as close as possible to
each lubricating point.
This system shall be fitted with a digital no flow shutdown device in the event of loss of
supply to the distribution block. The distribution block shall be fitted with indicator pins
for troubleshooting individual oil supply line problems.

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Draft Specification 1515-30-S002-0, Rev 4A
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The cylinder and packer lubrication system shall be fitted with a filtration system
immediately prior to the distribution block. The oil supply shall be separate to
crankcase oil.

4.8.4 Discharge temperatures

For lubricated cylinders, compressor cylinder design discharge temperature shall not
exceed 150 °C or 90% (whichever is lower) of the manufacturers maximum allowable
discharge temperature at all specified operating conditions (including lowest suction
pressure and highest suction temperature conditions) based on manufacturers
predicted discharge temperatures. This temperature limitation does not apply to
temporary excursions to relief valve set point. The performance software should
provide alarms and shut down functions based on the compressor manufacturers
proven maximum temperature limits. Packagers shall supply supporting evidence of
satisfactory performance of rings, riderbands, packings and valves at the expected
maximum operating temperatures.
The compressor manufacturer should give guidance on the type of cooling required for
the packing at elevated temperatures based on proven operating experience.

4.8.5 Piston rods

Rods may be tungsten carbide coated, induction hardened or nitrided to achieve the
required minimum surface hardness of HRC 50. In sour gas applications where
ISO 15156 or NACE MR0103 applies, the core hardness shall not exceed HRC 22 (in
these applications nitriding shall not be used).
Rod surface finish shall be suited to the type of packing material selected.
Required tolerances for finished rods are 0.013 mm (0.0005 in) for roundness and
0.025 mm (0.001 in) for diametrical variation over the packing length of the rod.

4.8.6 Rod Loads

Gas rod load ratings are based upon calculated internal gas rod loads. The maximum
allowable gas rod load of a given frame shall not be exceeded at any operating point.
Internal Gas Rod Load is the force imposed on the rod, caused by pressure inside the
cylinder against the head end and crank end piston areas. The manufacturer’s gas rod
load equations apply internal cylinder pressure, accounting for pressure losses through
valves and cylinder passages. Internal gas rod loads are used for a compressor frame
rating. Combined gas and inertia loads are not part of the frame rating, but are used for
determining the crosshead pin load reversal.

The maximum operating gas pressure rod loads and combined rod loads (inertial plus
pressure loads) shall not exceed 90% of the Manufacturer’s total allowable rod load.
For all specified operating conditions the rod loading shall fully reverse during a
complete turn of the crankshaft with sufficient rod load reversal to ensure proper
crosshead lubrication.
Piston rods shall be designed to accommodate a guide sleeve or bullet for proper
installation through packing assemblies.

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Draft Specification 1515-30-S002-0, Rev 4A
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4.8.7 Pistons
Pistons shall be segmented if so required on account of the material of the selected
wear band. Only one band per groove may be used.
Piston rings and rider bands shall be made from PTFE, filled with fiberglass-
molybdenum disulfide or fiberglass-graphite. Wear bands shall be non-metallic.

4.8.8 Piston and crankshaft speeds

Piston speeds should be limited to maintain acceptable wear rates. Crankshaft
revolution speeds shall also be limited maintain acceptable wear rates and valve life.
The following design guidelines are provided.
Shaft power (kW) Maximum shaft Maximum average
rotational speed (rpm) sliding velocity
< 200 1500 5 m/sec
200 to 750 1200 5 m/sec
750 to 1500 1200 5 m/sec
> 1500 1000 5 m/sec

For non-lubricated cylinders with high pressure and power rating greater than 1.5 MW
applications, the crankshaft speed limitation shall be reduced further to keep within the
limits of the Manufacturer’s proven experience for near identical operating conditions
and gas composition.
If for economical and/or technical reasons a speed or power above the recommended
limit is selected, this shall be supported by sufficient references and the impact on
maintenance shall be included in the economic evaluation, and the final selection shall
be approved by the Principal.

4.8.9 Packing cases

Packing cases shall be designed to accommodate piston rod radial movements without
metal-to-metal contact between rod and case in the event of loss of the total rider ring
height.

4.8.10 Cylinder valves

The cylinder valves shall be selected from types & manufacturers of proven reliability in
existing Santos service.
In wet gas, dirty gas and sour gas service where ISO 15156 or NACE MR0103 applies,
valve plates and rings shall be non-metallic (e.g. PEEK). Peek grade shall be
crystalline.
Metal valve discs or plates and damper plates shall be fully milled or laser cut; they
shall not be punched.
Valve seat to cylinder gaskets shall be of soft iron or steel and of solid rectangular
design. Metal-jacketed gaskets shall not be used.

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4.9 Structural Raw Materials

Raw materials for compressor structural components shall conform to the following
specifications and their manufacture shall be fully traceable. The Packager may
propose alternative material specifications for the approval of the Principal Engineer.
Material ASTM
Nodular iron, cast A 395 or A 536 Grade 60-40-18
Gray iron, cast A 48 grade 30
A 278 grade 30
Ni-resist, cast A 439 grades D4 andD3A
A 436 grade 2B
Steel, cast A 216 grades WCA or WCC

Material certificates (ISO 10474 type 2.1 or equivalent manufactures certificate) shall
be provided for the following components:
 pressure containing parts in non-hazardous service
 pressure containing parts in non-hydrocarbon service
 non-ferrous materials
 crankcases
 distance pieces
 valves and internals
Material certificates (ISO 10474 type 3.1 or equivalent) shall be provided for the
following components:
 pressure-containing parts in hazardous service- Cylinders
 pressure-containing parts in hydrocarbon service-Cylinders
 crankshafts
 connecting rods
 crossheads
 piston rods
 cylinder liners
 main bolts and nuts.

Grey cast iron shall not be used for compressor cylinders or any other pressure
components, nor for valve seats, valve guards and packing cases.
Nodular cast iron (ductile iron) should not be used above 7000 kPag cylinder relief
valve pressure. If ductile iron is proposed to be used above 7000 kpag then the
compressor manufacture shall provide proven operating history to support the material
selection and such application requires the approval of the Principal engineer..
Cylinder liners, if provided, shall be ASTM A 48 grade 40 with a Brinell hardness
exceeding 200 HBW (for both non-lubricated and lubricated service).

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4.9.1 NDT - cylinders

Radiographic non-destructive testing of critical sections of cylinder castings shall be
carried out in accordance with ASME VIII, Division 1, Appendix 7.
After final machining, all surfaces shall be examined by the wet magnetic particle
method in accordance with ASME VIII, Division 1, Appendix 6. If magnetic particle
examination is not possible, then liquid penetrant examination shall be performed in
accordance with ASME VIII, Division 1, and Appendix 8.

4.9.2 Hydro-test – cylinders

All cylinders shall successfully hydro tested to 1.5 x the cylinder design pressure.

4.10 Pulsation bottles

Suction/discharge pulsation bottles shall be completely self-draining. No separate,
dedicated drain connections are required. Discharge bottles shall have the outlet
nozzle exiting in the axial direction flush with the internal bottom of the pulsation bottle.
Any baffles in the bottle that may hold up liquids shall have weep holes 13 mm
diameter minimum to allow drainage. Suction pulsation bottles shall have no baffles.
No portion of the exit nozzles shall protrude inside the bottles. Before welding, the
nozzles shall be shaped to match the bottle. The weld shall be dressed so that it is
flush with the inside surface of the bottle.
Suction and discharge nozzles on pulsation bottles shall not have internal risers.
The suction and discharge piping connections of cylindrical volume bottles shall be
located at the longitudinal centre or at the end of the volume bottle in such a way that
optimal symmetry is obtained to eliminate free gas forces.
The size of the inlet connection of the suction bottles and of the outlet connection of the
discharge bottles shall be at least equal to the size of the compressor suction and
discharge nozzles respectively. Weld neck flanges shall be used for all connections to
pulsation suppression devices.
All flanged branch connections shall be reinforced in accordance with the specified
pressure design code. Additional reinforcement and/or local stress analysis may be
required to take into account stress concentration and fatigue loads resulting from
pulsations and vibrations. Flanges shall be in accordance with ASME B16.5 except that
slip on flanges shall not be used.

4.10.1 Pulsation Control and Analysis

Pulsation suppression devices shall be provided on the suction and discharge of each
cylinder to reduce pressure pulsations and to ensure package mechanical natural
frequencies and acoustic frequencies are not coincident with pulsation frequencies
generated by the compressor.
Cylinders operating in parallel may be connected to a common suction and a common
discharge pulsation suppression device.
Suction pulsation bottles shall not be used for liquids removal.

An acoustic and pulsation study of each reciprocating compressor package shall be

performed based on the Packager’s standard pulsation devices and piping support

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 15 of 27

design. . It shall include all piping, pulsation suppression devices, process cooler tubes
and equipment between the first major vessel located upstream and downstream of the
compressor. Process vessels may be used as terminal points for studies.
The study shall conform to the requirements of API 618, Design Approach 3.
Verification of these studies by an Independent third party is required.
Full-bore spacer orifice plates are required on suction and discharge of each cylinder
as provision for on-site acoustic tuning. Pipe back nozzle designs shall not be used in
multicylinder applications.
Piping design shall eliminate acoustical frequencies that coincide with piping or
compressor mechanical frequencies. It shall minimise forces due to pressure
pulsations that will permit piping to be restrained by conventional pipe guides, anchors
or supports and remain within allowable stress levels. Pipe anchors shall be designed
to prevent vibration but still allow freedom to accommodate thermal movement.
Results of pulsation, vibration and noise studies shall be submitted with Packager
documentation.

4.11 Torsional Analysis and Control

The Packager, having unit responsibility shall carry out torsional studies for the
complete train as part of the rotor dynamic analysis report submission to
demonstrate the elimination of any lateral or torsional vibrations that may hinder the
operation of the complete unit within the specified operating speed range in any
specified loading step.
The packager shall provide a cross check of any assumptions and calculations with
actual tested compressors.
The Packager shall provide copies of the studies and shall inform Santos of all
critical speeds from zero to trip speed that occur during acceleration or deceleration.
The torsional natural frequencies of the driver-compressor system including couplings
shall have a separation of at least 10 percent of any operating shaft speed and within 5
percent of any other multiple of operating shaft speed in the rotating system. All speed
ranges that do not meet these criteria shall be identified and the control system shall
eliminate these speed ranges from the operating envelope.
If these separation margins cannot be met, the Packager shall perform an additional
response analysis in order to prove that the stress levels at resonance conditions are
within well-proven limits of the Manufacturer.
The Packager shall perform a response analysis of the rotating system during
all possible resonance conditions which may occur during run-up and within the
complete operating speed range for gas engine driven compressors. All possible
excitation frequencies and consequent torques shall be considered.
The packager shall provide for following Campbell diagrams clearly highlighting any
resonance interactions:
 The interactions between natural torsional and forced torsional frequencies,
 The interactions between natural lateral frequencies and forced lateral
frequencies.

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 16 of 27

The selection of couplings by the Packager shall be based on the torsional analysis of
the complete unit (i.e. compressor, gears, coupling and driver), within the normal speed
range and for all load conditions from 0 % to 100 %. This analysis shall indicate
the relationship of the natural frequencies to the exciting frequencies of the system.

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 17 of 27

5.0 COMPRESSOR CONTROL

5.1.1 Valve removal or unloading

Removal of all the suction valves from the head-end side of a double-acting
compressor cylinder is permitted to completely unload that end of the cylinder.
Discharge valves shall not be removed at either end. Suction valves shall not be
removed from the crank-end side.

5.1.2 Unloaders
Where valve unloaders are specified, plug type unloaders are preferred. Unloaders
shall be pneumatically operated unless otherwise specified. Finger type unloaders are
not preferred and require Santos approval.

If "air-to-unload" actuators are specified, unloaders on valve depressors shall be

capable of maintaining the suction valve fully depressed without any plate fluttering,
while operating on the minimum specified instrument air pressure.
Stepless capacity control by means of "flow regulation" on suction valve depressors is
subject to the approval of the Principal Engineer.

6.0 COMPRESSOR SAFEGUARDING AND MONITORING

Systems for monitoring and protecting the compressor from damage shall be in
accordance with API 670

6.1.1 Compressor safety shutdown

A compressor safety shutdown system shall be provided. Shutdowns shall include the
following.
 Cylinder discharge nozzle temperature
 Lube oil pressure, low
 Cylinder lube oil temperature, high
 Lube oil level controller and low level switch. Kenco make is preferred.
 Crankcase vibration acceleration, high

6.2 Compressor Performance Monitoring

Compressor cylinders shall each be provided with plugged threaded port/ports integral
to both the crank side and cylinder side of the piston volume for Beta Trap Analysis
testing purposes.

6.3 Compressor Machine Monitoring

For large compressors in critical service the following machine monitoring may be
specified by Santos – refer to Requisition Datasheet.
 Frame main bearing temperature
 Frame X and Y vibration acceleration
 Crankcase vibration acceleration
 Distance piece vibration acceleration

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 18 of 27

 Single event or multi-event keyphasor

 Rod drop indicators
 API 670 Condition monitoring system
 Integration with Enalysis compressor optimisation system which is managed by
Detechtion technologies
For compressor process control see the Specification and design practice for
Compression Packages .

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Santos Engineering Standard
Draft Specification 1515-30-S002-0, Rev 4A
Page 19 of 27

7.0 ELECTRICAL EQUIPMENT AND CERTIFICATION

7.1 MOTORS and VSD

Motor start-up analysis shall be conducted to confirm that the motor has enough
torque to reach full speed fast (before the high inrush current) overheats the motor.
Careful consideration should be given when driving a motor passed its synchronous
speed as the motor torque starts to fall off and there may not be sufficient torque to
reach the anticipated speed beyond synchronous.
In accordance with ISO 13631 Current pulsation analysis shall be conducted to limit
motor current to a value not exceeding 66% of the full load current (See IEC 60034)

8.0 PERFORMANCE TEST

Minimum performance test requirements are:
Ÿ Manufacturer’s standard engine load test Compressor, four hours no load in
Packager’s works
Ÿ Provision for full field performance tests with materials for test supplied by Santos,
including:
o 24 uninterrupted hour reliability test
o Capacity test at nominated duty point condition
o Vibration and pulsation survey
o Compressor valve (Beta trap) test
o Cylinder PV measurement.
Data from field tests shall form basis of package acceptance

9.0

Rev Date: TBATBA Issued by Project Management Office Engineering Team  Santos Ltd: TBA
Printed document may not be current issue. Check ‘TIMS’ ABN 80 007 550 923
Specification 1515-30-S002-0, Rev 4, Page 20 of 20

10.0REVISION NOTES
Revision 4A
Ÿ Document updated with technical changes that provide additional requirements for the
machinery component design and to reflect the latest project design and procurement
strategies.

Prepared Vince Loye: Senior Project Engineer Mar 2014

Jaron Whalley: Senior Facilities Engineer
Reviewed Lawrence Sequeira: Principal Engineer Rotating Mar 2014
Equipment
Approved Michael McCarthy, Chief Facilities Engineer TBA

Revision 3
Document updated (January 2009) as part of continuous improvement. All changes are for
improved useability and no technical changes have been made since the last revision.

Revision 2
Revised to include coal seam methane compression requirements.

Prepared R J Schulz, Principal Mechanical Engineer Nov 2006

Reviewed Sadik Hurem, Team Leader Machinery Reliability Dec 2006
Mark Buckland/Tim Palmer, Tech Services Team Leader
Approved S Correll, Manager – Projects and Services Jan 2007

Revision 1
Reaffirmed, minor revisions.

Prepared R J Schulz, Principal Mechanical Engineer Oct 2005

Reviewed Sadik Hurem, Team Leader Machinery Reliability Oct 2005
Approved D A Craig, Manager – Facilities Engineering Governance Nov 2005

Revision 0
Ÿ Formerly SABU Specification 1500-30-S002 Rev 0, 1500-30-G002 Rev 1
Ÿ Minor layout revisions.

Prepared R J Schulz, Principal Mechanical Engineer Aug 2001

Reviewed L Nicholls-Goffey, Staff Mechanical Engineer Sept 2001
Approved D P Young, Manager CBU Engineering & Reliability May 2002
P J Strimaitis, Manager Major Projects
B F Atkinson, Team Leader NBU Tech Services
Issued D R Poole, Corporate Engineering May 2002

Rev Date: 15 Oct 1919 Mar 14 Printed document may not be current issue  Santos Ltd 2019 ABN 80 007 550 923