Compressor Hamworthy HP (Gold Star)

Keppel FELS
H9520
Gold Star
MANUAL
USER
USER MANUAL
Compressors & Standby APV’s

Compressors & Standby APV’s
T9534
Vol. 1 of 1
T9534
Customer References
Customer
Rig Keppel FELS Hull 9520 “Gold Star”
Main Tag No.
National Oilwell Varco References

Project
Serial Number
Document No. T9534-Z-MA-001
Volume Vol. 1 of 1
User Manual
APV Bottles for Tensioner
(Compressors & Standby APVs)
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Gold Star T9534 APV Bottles Incl. Heat Exchangers
ADDITIONAL CODE SDRL CODE TOTAL PGS
8 2 This document contains proprietary and confidential National Oilwell Norway AS
information which belongs to National Oilwell Varco; it is Servicebox 401
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Norway
to others is not permitted without the express written
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Phone +47 38 19 20 00
DSS38-IC1090 any event upon completion of the use for which it was Fax +47 38 19 23 11
loaned.
© Copyright National Oilwell Varco - 2009
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
T9534-Z-MA-001 1
www.natoil.com
Document number T9534-Z-MA-001
Revision 1
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REVISION HISTORY
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0 09.12.2008 Issued for Implementation PAVW IONO IONO
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
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1 Document T9534-Z-MA-018 updated to rev 1
0
REFERENCE MANUALS
The following user manuals are referred to in this manual or describing machines interfacing
with subject equipment:
Manual Doc No. Manual Title
T9521-Z-MA-001 CMC & AHC

T9533-Z-MA-001 Wireline Riser Tension System
NOTE
The overall user manual is composed of this front document plus the User Manual Table of Contents
(doc. no. T9534-Z-MA-002) plus the documents and drawings listed in the table of contents.
www.natoil.com
User Manual Table of Contents
Compressors & Standby APVs

Part of user manual of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
loaned.
T9534-Z-MA-002 0
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USER MANUAL TABLE OF CONTENTS
VOLUME 1 OF 1:
SECTION DOCUMENT TITLE SUPPLIER DOC. NO.
User Manual T9534-Z-MA-001

User Manual Table of Contents T9534-Z-MA-002
1 Introduction
User Manual Introduction T9534-Z-MA-016
2 Main Data
Main Data T9534-Z-MA-017
3 Technical Description
See section 11.
4 Preparation
See note below.
5 Operating Instructions
See section 11.
6 Maintenance
See section 11.
7 Safety and Service Bulletins

See note below.
8 Spare Parts List

Spare Parts List T9534-Z-MC-001
9 Data Sheets
See section 11.
10 Drawings and Parts Lists

Drawings and Parts Lists T9534-Z-MA-018
11 Standard Documentation
Standard Documentation T9534-Z-MA-010
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NOTES:
Section 4: Preparation
“Preparation” is in the NS 5820 documentation standard defined as all system activities

between completed installation and routine operation. These activities shall be covered
by the user manual.
In supplier’s understanding the installation is incomplete until commissioning has been

carried out, and the commissioning procedure is therefore not normally included in the
user manual. Exceptions are made if the covered equipment is of a portable type, and
the required handling, installation and commissioning procedures will then be attached
in this section. Subject equipment is however not of that type.
The preparations covered by this manual are therefore limited to the routine
preparations the operator must carry out before using the equipment. This type of
preparation is described in the Normal Operation section of the Operating Instructions.
Section 7: Safety and Service Bulletins
If supplier, after the equipment is taken into use, becomes aware of urgent equipment
information needed by user for safe operation, this information will be submitted in the
form of safety or service bulletins.
Safety bulletins are used when immediate corrective action is needed to secure the
safety of operators and maintenance personnel. Service bulletins are used when
immediate corrective action is needed to prevent damage or malfunction of the
equipment.
Upon receipt of a safety or service bulletin, user is required to confirm that the content is
read and understood, and will be implemented soonest. After the implementation a copy
of the bulletin should be placed in this section of the user manual.
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User Manual Introduction

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TABLE OF CONTENTS
1 USER MANUAL INTRODUCTION.................................................................................... 4

1.1 General Information about the User Manual ........................................................... 4
1.2 Storage and Retrieval of Manufacturing Records ................................................... 4
1.3 Restrictions in Guarantee ....................................................................................... 4
1.4 Quality Assurance System ...................................................................................... 4
2 SUPPLIER DETAILS ........................................................................................................ 5
3 SERVICE SUPPORT ........................................................................................................ 5
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1 USER MANUAL INTRODUCTION
1.1 General Information about the User Manual
Thank you for purchasing a National Oilwell Varco product.
This user manual is primarily based on sub-vendor literature, and contains the required
information for safe operation and maintenance. Efforts have been made to keep the
manual brief and well arranged, keeping the user’s needs in mind at all times.
The manual is composed of a number of independent but interconnected documents,

and thereby prepared for easy updating. The different documents making up the manual
are listed in the User Manual Table of Contents document.
1.2 Storage and Retrieval of Manufacturing Records
The manufacturing records are stored for a minimum of ten years, and available from
supplier upon request. Always refer to supplier’s reference number for this equipment
(T-number or V-number, see the first part of the manual’s document number) when
support is needed.
1.3 Restrictions in Guarantee
Subject equipment must only be used for the prescribed purpose and within the
specified limitations. The operators must be qualified for the task.
Repairs and modifications must not be carried out without prior written approval from
supplier, except for the minor corrections that are described in the maintenance
instructions. If such work is carried out by others, supplier’s procedures for this kind of
work must be followed. Lead sealings must not be broken without written approval from
supplier. Only approved materials and original spare parts must be used.
Supplier refuses all responsibility caused by breach of these restrictions. The guarantee
for good performance is strictly linked to the correct and careful application of the
instructions in this user manual. If, during the warranty period, these restrictions are
breached, the warranty/guarantee shall no longer be valid.
1.4 Quality Assurance System
Supplier’s quality system is based on the ISO 9001 standard.
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2 SUPPLIER DETAILS
Subject equipment is supplied by National Oilwell Norway AS (previously Hydralift ASA).

The company is located at Korsvik Industriområde in Kristiansand, Norway. For postal
address etc, see the next section.
3 SERVICE SUPPORT
The below contact information applies for support from supplier. Always refer to
supplier’s project number (T-number or V-number, see the first part of the document
number) when contacting supplier for assistance or spare parts.
National Oilwell Norway AS

Servicebox 401
N-4604 Kristiansand S
NORWAY
Switchboard, main office: +47 381 92000

After market fax: +47 381 92604
24 hours duty phone: +47 381 92482
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Main Data

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TABLE OF CONTENTS
1 MAIN DATA ...................................................................................................................... 4

1.1 Safety Summary ..................................................................................................... 4
1.2 Main Data................................................................................................................ 4
1.2.1 Abbreviations............................................................................................... 5
1.3 External Connections .............................................................................................. 5
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1 MAIN DATA
1.1 Safety Summary
The hazards and protective measures (cautions and warnings) applicable to this
equipment are given at the beginning of the compressor manual (in section 11).
1.2 Main Data
Equipment: National Oilwell Varco TM Compressors &

Standby APVs
Rig/vessel: Gold Star Keppel HULL 9520
Supplier’s project no.: T9534

Year of delivery: 2008
Main tag numbers: See the tag sign drawings.
General arrangements: T9534-D1157-G0119 Standby APV’s 1600L/300 Bar.

T9534-D1157-G0302 APV’s Compressor Skid
T9534-D1157-G0203 Fresh/Seawater Heat
exchanger Skid
Weight and dimensions: See the general arrangements.
Compressors & APVs serving: Crown Mounted Compensator
Wireline Riser Tension System
Further data: Compressors: See the standard documentation.

Standby APVs: See the APV general arrangement.
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1.2.1 Abbreviations
AHC Active heave compensator (supplement to CMC)

APV Air pressure vessel
AW Auxiliary well
CMC Crown mounted compensator
CPU Central processing unit (part of PLC)
DCDA Drilling control and data acquisition (= Cyberbase displays & keypads)
DCR Drilling control room (= driller’s cabin)
FAT Factory acceptance test
FW Fresh water
HP High pressure
HPU Hydraulic power unit
LER Local equipment room (= LIR)
LIR Local instrument room (= LER)
LP Low pressure
MCC Motor control centre
MW Main well
NOV National Oilwell Norway AS (previously Hydralift ASA), now a part of
National Oilwell Varco, Inc.
NS Norwegian Standard
PLC Programmable logic controller
PPM Parts per million
RPM Revolutions per minute
SD Shutdown
SP Setpoint
SW Sea water
UPS Uninterruptible power supply
WC Wellcentre
1.3 External Connections
The equipment is externally hooked up as follows:
Electrical connections: See the electrical block diagram.

Air connections: See the flow diagrams.
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Technical Description
HP Compressor for Tensioner - QGP
Gold Star

FB 11 This document contains proprietary and confidential National Oilwell Norway AS
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
loaned.
T9534-Z-SA-001 0
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Document number T9534-Z-SA-001
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1 INTRODUCTION ............................................................................................................... 4
2 COMPRESSOR................................................................................................................. 5
2.1 Drive ....................................................................................................................... 5
2.2 Suction .................................................................................................................... 5
2.3 Instrumentation ....................................................................................................... 5
2.4 Protection and safety devices ................................................................................. 5
2.5 Coolers, Separators and Drainage.......................................................................... 5
3 PRIME MOVER: ELECTRIC MOTOR............................................................................... 6
4 DESICCANT DRYER SPECIFICATION ........................................................................... 7
5 COOLING SYSTEM .......................................................................................................... 8
6 CONDENSATE BLOW DOWN RECEIVER/SILENCER ................................................... 9
7 STARTER / CONTROL PANEL...................................................................................... 10
8 CONTROL SYSTEM ....................................................................................................... 11
9 SPECIFIC NATIONAL OILWELL REQUIREMENTS...................................................... 11
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1 INTRODUCTION
The NOV compressor package is a purpose designed and manufactured unit producing
dry, filtered, high pressure air for Riser Tensioning applications in offshore conditions
world-wide. Its principal components are listed as follows:
1. A belt driven four stage high-pressure compressor

2. An IEC class marine motor
3. A fully automatic desiccant dryer.
4. FW cooled via a solenoid operated water shut off valve
5. A condensate blow down receiver/silencer with drain connection.
6. PLC based starter/controller mounted and wired on a frame adjacent to the compressor.
The base is an open frame modular design, with a major base supporting the compressor and
motor, and a sub-baseplate supporting the dryer & control panel. Both bases are provided with
lifting points, bolted together and all services are fully integrated. This split design could assist
in the installation of the compressor.
The unit is provided fully piped and wired with all connections being brought to the base edge
and identified for ease of installation.
Also supplied loose there are:
7. Tico resilient mounts 7 off
Service: Continuous operation - Riser Tensioning duty.

Compressor
75 cfm (127.5m3/hr) FAD
capacity:
Pressure: 4350 psi (300 bar) G
Ambient Temp: 50°C
Survey: ABS/DNV
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2 COMPRESSOR
The compressor will be a 4 stage, twin crank, 3 bearing, single acting, vee cylinder configuration
reciprocating compressor complete with balanced crankshaft and concentric “quick change” suction
and delivery valves. Each cylinder is fitted with an “O” ring sealed replacement wet liner,
conveniently sited for easy service access.
The three-bearing, two-throw, totally balanced crankshaft is produced from high specification sg.
Iron to ISO1083 standards. Main bearings are steel backed white metal, with the centre main and
big end bearings being steel backed aluminium. The first stage small end is a plain bearing with
remaining small ends being fully complement needle roller bearings. The crankcase is fitted with a
sump heater and the breathing arrangement is completely enclosed, venting to the first stage inlet.
The cylinders “V” configuration ensures excellent balance to minimise vibration and stress, whilst
providing maximum cylinder surface area to achieve maximum cooling.
2.1 Drive
The compressor will be belt driven by a Power Band drive via the electric motor. The drive
will be guarded in accordance with British standards Slide rails are provided for ease of
belt tensioning.
2.2 Suction
Combined suction filter/silencer.
2.3 Instrumentation
Compressor mounted instrument panel incorporating:- - Air pressure gauge for each stage.
- Oil pressure gauge.
Control panel mounted:- - Air temperature gauge for final discharge.

- Fresh water inlet temperature gauge.
2.4 Protection and safety devices

- Air pressure safety valve on each stage.
- Cooling water jacket safety valves.
- Low lubricating oil pressure switch
- High air temperature switch
- High fresh water temperature switch.
- Low cooling fresh water flow switch.
- Control pressure switch.
2.5 Coolers, Separators and Drainage

The compressed air is cooled by inter-stage and discharge coolers, compressor is subsequently
fitted with:-
- Integral multipass interstage coolers.
- Integral multipass aftercoolers.
- Interstage oil/moisture separators.
- Automatic unloader and moisture drain system, operated by solenoid valves.
Note: All compressor block pipework to remain as standard (Walterscheid Compression Type)
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3 PRIME MOVER: ELECTRIC MOTOR
Construction TEFV, Light Alloy
Power 50kW
Speed 1760 rpm (approx)
Mounting Horizontal Foot (B3)
Starting DOL
Insulation Class F
Maximum Ambient Temperature 50o C
Supply 440V – 690V 3-phase 60Hz
Frame size: M3AA 225 SMC
Spec. IEC IP 55
Fittings Anti Condensation Heaters (220 VAC)
Drive Arrangement Power Band Belt Drive
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4 DESICCANT DRYER SPECIFICATION
Conditions: Compressed air; 4350 psi (300 bar); 75scfm (127.5 m3/hr).
Medium Compressed Air free of oil & dirt

3
Capacity 127.5 m /hr
Max. Inlet Temperature 47°C
Dewpoint -40°F/°C Dewpoint @ atmospheric pressure
Minimum Operating Pressure 250 bar
Design Pressure 300 bar
Electrical Supply & Enclosure Type 220 VAC IP55 Steel Enclosure
• Automatic start/stop w/memory - Dryer only purges when compressor is running - picks up where dryer left off
after compressor shuts down running - picks up where dryer left off after compressor shuts down.
• Coalescer and Prefilter drained via compressor automatic unloader via a suitable orifice and NRV.
• Dust particle retention to 1 micron.
• Oil removal to 0.01 ppm
• Low purge use: less than 4.5%
• Instrumentation includes:-
o Power On/Off lights

o Adsorber Pressure Gauges, full safety pattern,
o LED status for each pneumatic valve (V1-V4).
• All seamless stainless tubing with Walform + ends and DIN type couplings.
• Fitted with pressure maintaining valve set at 10% below working pressure
• Works Test & Hydrotest Certificates, Material Certs to 3.1.B. Drawings and Operating Instructions.
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5 COOLING SYSTEM
Maximum fresh water inlet temperature from vessel central cooling system is 370 C.
Maximum inlet pressure 3.5 barg (50psi)
Flow rate required is 17.9 us gal/min (68 l/min)
Heat dissapated to cooling water is 36 kW.
Inlet and outlet connections are 1” BSPP FEMALE.
A solenoid operated water shut off valve and water flow balancing valve are fitted.
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6 CONDENSATE BLOW DOWN RECEIVER/SILENCER
The compressor utilises a blow down receiver/silencer for condensate air separation. The air is
discharged through a silencer element and the condensate is discharged at ambient pressures
through an automatic drain.
Outlet connections are ¾ “ BSPP FEMALE x 2.
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7 STARTER / CONTROL PANEL

• Single stand alone panel
The system is controlled by a PLC and an operator interface mounted in an IP55 enclosure, designed
specifically to be user friendly, whilst protecting the entire system from damage due to abnormal
conditions.
The panel incorporates the following:

• Interlocked fused isolator
• Magnetic starter with overload (main motor)
• Power transformer for: dryer, crankcase heater and control circuits
• Computerised controller with touch pad operator interface
• Control logic and timers to give unloaded automatic start-up and controlled automatic stop
• Power-loss restart control
• Emergency stop button
• Hours run meter via HMI
• Audible alarm
Message display for:

• Maintenance Timer ● Overtime Timer ● Run
• Auto Drain ● Delayed stop ● High Air Temperature
• Low Oil Pressure ● Low Water Flow ● Start up
• Standby ● Power Loss ● Comp Purge
• Motor Overload ● High Water Temperature
The panel will also utilise Indicator lights for the following conditions:
• Power “on”
• Alarm/message
• Motor ACH “on”
Panel is to be IP55. All entries to the box to be properly glanded to ensure IP rating is not infringed. All
terminals are to be located at the bottom of the panel. Customer is to supply 3 phase power supply
only. All terminals and cables to have appropriate cable markers that conform to issued production
drawings.
Durable tags or labels are to be fitted for each panel-mounted device or instrument e.g. “Low Oil
Pressure”
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8 CONTROL SYSTEM
Compressor will be arranged for fully automatic control via a combined starter/control panel.
On start-up a solenoid operated centralised moisture dump valve will open drains on inter-stage
moisture traps and filter system, providing “off-load” starting conditions. When the compressor
has reached full operating speed, the drains will automatically close and compression will
commence. An adjustable pressure switch will sense when the pre-selected pressure has been
reached and will initiate a purge cycle followed by an automatic shut-down of the compressor with
all moisture drains in a dump mode.
During the charging cycle, moisture will be automatically drained via the solenoid operated dump
valve at timed intervals (adjustable), requiring no further operator attention.
9 SPECIFIC NATIONAL OILWELL REQUIREMENTS
• The Walform + pipe system is to be used for all interconnecting skid and dryer pipework.
• Complete package is to be finish painted to National Oilwell Yellow, RAL1006. All fabricated
parts to be painted in accordance with Norsok M-501 system 1. Dryer and motor to be finished
to supplier’s standard offshore paint specification.
• Material certificates for pressure parts to BS EN 10204 3.1.b.
• Hydraulic test certificates for all pressure retaining parts
• Package to be wired with NEK606 armoured cable mounted on stainless steel cable tray and
terminated with Hawke brass glands, were possible. Approval to be requested from NOV if
alternative required.
• All termination points and instruments to be identified with durable Trafalite or SS tags/labels.
• If supplied, the sequence selector panel is to be mounted and wired on the skid.
• Electrical interface to be in accordance with standard used on NOV drawing D1157-E0200.
• General arrangement drawing number for the 300 bar version is D1157-00302.
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Drawings and Parts Lists

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TABLE OF CONTENTS
1 DRAWINGS AND PARTS LISTS...................................................................................... 4

1.1 Drawings and Parts Lists ........................................................................................ 4
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1 DRAWINGS AND PARTS LISTS
1.1 Drawings and Parts Lists
The drawings and parts list sheets (PL) listed below are attached after this page. Each
drawing has generally one or more parts list sheets, which in the hardcopies are placed
before the drawing.
Supplier's Dwg. No. Rev Drawing Title PL
T9534-D1157-G0119 0 Standby APV 1600L/300 barg, Gen. Arrang. 1

T9534-D1157-G0302 1 APV Compressor Skid 120ncum/300bar 1
General arrangement
T9534-D1157-G0303 1 Fresh/Seawater Heat Exchanger Skid 1
General Arrangement
T9534-D1157-0001 0 Standby APVs, Tag Signs 0
T9534-D1157-0002 0 Compressor, Tag Signs

T9534-D1157-H1001 0 Standby for Riser tensioner, Flow Diagram 1
T9534-D1157-H1002 0 Compressors, Flow Diagram 1
T9534-D1157-E0001 1 Air Compressor Package & Stand By APV’s, 1

Block Diagram Instrument
T9534-D1157-E0100 0 Air compressor Package & Stand By APV’s, 0
Termination Drawing
T9534-D1157-E0101 0 Air Compressor Package & Stand By APV’s, 0
Termination Drawing
Note: The electrical drawings referred to in the layout reference drawing are found in the
user manual for the Wireline Riser Tension System.
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Standard Documentation

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TABLE OF CONTENTS
1 STANDARD DOCUMENTATION...................................................................................... 4
1.1 Sub-vendor Literature ............................................................................................. 4
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1 STANDARD DOCUMENTATION
1.1 Sub-vendor Literature
This document contains the Hamworthy sub-vendor literature that makes up the main
part of the user manual. The following literature is included:
Equipment: Hamworthy Air Compressor

Description: Installation, Operation and Maintenance Manual for
(standard) Hamworthy 4SW80Mk3 Riser Tensioning
Compressor
Total pages: Multiple (self-contained manual)
NOV item: T9534-D1157-G0300
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Compressor Hamworthy HP (Gold Star)

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National Oilwell Varco References

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

1 27.08.2009 Reissued for Implementation VIAX IONO IONO

Revision Change description

Manual Doc No. Manual Title

T9521-Z-MA-001 CMC & AHC

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

0 09.12.2008 Issued for Implementation PAVW IONO IONO

Revision Change description

USER MANUAL TABLE OF CONTENTS

SECTION DOCUMENT TITLE SUPPLIER DOC. NO.

User Manual T9534-Z-MA-001

7 Safety and Service Bulletins

8 Spare Parts List

10 Drawings and Parts Lists

“Preparation” is in the NS 5820 documentation standard defined as all system activities

In supplier’s understanding the installation is incomplete until commissioning has been

Section 7: Safety and Service Bulletins

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

0 09.12.2008 Issued for Implementation PAVW IONO IONO

Revision Change description

1 USER MANUAL INTRODUCTION.................................................................................... 4

1 USER MANUAL INTRODUCTION

1.1 General Information about the User Manual

Thank you for purchasing a National Oilwell Varco product.

The manual is composed of a number of independent but interconnected documents,

1.2 Storage and Retrieval of Manufacturing Records

1.3 Restrictions in Guarantee

1.4 Quality Assurance System

Supplier’s quality system is based on the ISO 9001 standard.

Subject equipment is supplied by National Oilwell Norway AS (previously Hydralift ASA).

National Oilwell Norway AS

Switchboard, main office: +47 381 92000

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

0 09.12.2008 Issued for Implementation PAVW IONO IONO

Revision Change description

1 MAIN DATA ...................................................................................................................... 4

1.1 Safety Summary

1.2 Main Data

Equipment: National Oilwell Varco TM Compressors &

Rig/vessel: Gold Star Keppel HULL 9520

Supplier’s project no.: T9534

Main tag numbers: See the tag sign drawings.

General arrangements: T9534-D1157-G0119 Standby APV’s 1600L/300 Bar.

Weight and dimensions: See the general arrangements.

Compressors & APVs serving: Crown Mounted Compensator

Wireline Riser Tension System

Further data: Compressors: See the standard documentation.

AHC Active heave compensator (supplement to CMC)

1.3 External Connections

The equipment is externally hooked up as follows:

Electrical connections: See the electrical block diagram.

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

0 07.08.2008 Issued for Approval IONO AOT IONO

Revision Change description

1. A belt driven four stage high-pressure compressor