ENGINEER’S STAMP: CONTRACTOR’S STAMP:

C Issued for Tender Wilken 06.11.2020

Gasic Nyoundou
B Issued for Tender Shahab Nyoundou Wilken 22.07.2020

0 Issued for Tender Nyoundou Wilken 20.04.2020

Shahab
REV DESCRIPTION PREPARED CHECKED APPROVED DATE

KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﯿــﺔ اﻟﺴــﻌـﻮدﯾـــﺔ‬

‫اﻟﻤـﺆﺳــﺴــــﺔ اﻟﻌــﺎﻣــﺔ ﻟﺘﺤــﻠـﯿﺔ اﻟـﻤــﯿــﺎه اﻟـﻤــﺎﻟــﺤــﺔ‬
SALINE WATER CONVERSION CORPORATION
CONSTRUCTION OF SALES GAS SUPPLY PIPELINE TO YANBU
PLANT PHASE-3 PROJECT

FICHTNER GMBH & CO. KG

TENDER DOCUMENTS

LOCATION: TITLE:
Western Coast VOLUME IX PART PG-B215
PACKAGE: TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM
SCALE: REV:
None Q A 1 0 - H - 0 4 1 5 C
SUBCONTRACTOR:
Sheet 1 of 12
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Subject: VOLUME IX PART PG-B215 Page 2 of 12

TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

Disclaimer
The content of this document is intended for the exclusive use of Fichtner’s client and
other contractually agreed recipients. It may only be made available in whole or in part to
third parties with the client’s consent and on a non-reliance basis. Fichtner is not liable to
third parties for the completeness and accuracy of the information provided therein.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

Table of Contents

1. General 4

2. Scope of Works 5
2.1 Definition 5
2.2 Scope of Equipment / Items 5

3. Layout 7

4. Particular Design / Construction Requirements 8

4.1 General 8
4.2 Instrument Air Receiver 9
4.3 Pipework and Valves 9
4.4 Pressure Dampers 11
4.5 Service Air 11
4.6 Corrosion Protection 12
4.7 Instrumentation and Control Material and Configuration 12
4.8 Control System 12

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Subject: VOLUME IX PART PG-B215 Page 4 of 12

TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

1. General
This specification covers the complete separated service air and instrument
air systems for satisfactory operation.
The system and its components supplied to meet this Technical
Specification shall also conform to the applicable requirements of these and
other general articles or specifications of the Tender Documents.
However, if any equipment/device is not covered by the specification but
deemed to be necessary at the discretion of the Employer/Engineer for safe
and reliable operation of the system, it shall also be provided.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

2. Scope of Works

2.1 Definition
The service and instrument air system shall deliver all compressed air
required for all associated equipment of the plant for the following two
systems:
· Service air for operation of mechanical air tools, wrenches, fire-fighting
system pressure tank (if required) etc., during all modes of unit operation
and for maintenance purposes.
· Instrument air of high purity, oil-free and moisture-free compressed air to
all pneumatically operated plant instrumentation and control devices.

The service and instrument air system shall be connected to the similar
systems of the main Yanbu plant.

The scope of works comprises all pipes with supports, valves,

instrumentation and controls necessary to ensure proper, safe and easy
operation and maintenance of the compressed air system under normal and
abnormal conditions.
The distribution pipework shall ensure safe supply of compressed air to the
whole plant. Necessary arrangements shall be made such that a plant trip
due to a pipe failure in either of the compressed air lines is positively
prevented.
Separate distribution systems for instrument air and service air shall be
supplied by the Contractor.

2.2 Scope of Equipment / Items

The service and instrument air system shall be connected to the similar
systems of the main Yanbu plant and shall include the following equipment
but not limited to:
For instrument air system:
All equipment necessary for plant system such as:
· Instrument air receiver (1 x 100%) shall have useful storage capacity of
60 minutes based on the GRS instrument air peak consumption. The
receiver shall be also able to have adequate buffer volume to ensure safe
shutdown of the system in case of emergency and scheduled shutdown.
The receivers shall be complete with all ancillary equipment.
· Local pressure accumulators for single large users to prevent a pipeline
pressure drop of more than 1 bar during peak demands

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

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· Skids requiring instrument air which shall have piping/ tubing fully
routed and connected to each user on the skid with a single connection on
the edge of the skid labelled: “Instrument Air Supply”
· Each instrument requiring air supply shall have a dedicated individual air
supply block valve on the air supply header.
· Contractor shall verify that the maximum and minimum air pressure
required for the users is adequate for valve actuation performance.
Maximum operating pressure supplied shall be within actuator maximum
operating pressure limit.
· All electrical connections up to the low voltage terminal boards of
panels, cubicles, motors, valves and pneumatically operated valves, etc.
· All interconnection piping for air distribution to all users of the GRS.
· All minor pipes necessary for installation and operation
· Lifting and hoisting devices for easy compressor maintenance
· All necessary base frames, base plates, anchor bolts, supports, etc.
· All steel parts embedded in foundation.
· All standard equipment and accessories that are normally included in the
delivery.
· Required platforms, stairs and ladders for operation and maintenance, as
specified in Volume IX- Part PG-B211 & Volume VII- Part P-B0.11.
· Contractor shall provide an overall instrument air consumption table for
all packages associated with the GRS equipment and project.
· Metallurgy for instrument air header shall meet the project piping class
specification as defined by the Contractor or Company/ Engineer.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

3. Layout
The air compressors and the air dryers are located at the main Yanbu plant
in a building with adequate air ventilation system.

Major pipes and ducting are to be grouped logically and shall be laid on
sleepers or pipe racks.

The consumption of air is mainly intermittent. Therefore, the air receivers

together with the distribution pipe work shall serve as a pressure
accumulating system against pulsation and allows for short time peak
consumption without the need of a compressor start.

The operating pressure of the system is about 8.0 bar gauge on the user
terminal during normal operation. The pressure variations must not exceed
1.0 bar. This requires a minimum discharge pressure for the compressor of
9.0 bar gauge plus all pressure losses in the system. There shall be a
pressure difference between the instrument and service air system of at least
0.5 bar.

The terminal valves must restrict the maximum possible air flow to the
actually required one in order to avoid excessive pressure losses in case of
failure.

For a later interconnection to other plants a connection point has been

foreseen in the main plant.

The leak rate of the complete system must be less than the value specified in
Part P-A5 “Inspection and testing”.

Pressure damper vessels shall be provided to prevent local pressure collapse

as a result of peak consumption by any of the users.

The instrument air and service air systems shall have different pipe color,
which shall be as per Employer’s standard.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

4. Particular Design / Construction Requirements

4.1 General
The pipes and material shall conform to high standards of engineering,
design, workmanship and construction and shall be capable of operating
efficiently and satisfactorily without excessive wear or maintenance under
the service conditions.

All components shall be selected from designs, proven in service with at

least 5 years satisfactory operating experience. The items shall be heavy
duty type and be designed for a minimum anticipated plant life of 30 years.

Particular attention shall be paid to keep noise and vibration levels at a

minimum and to reduce it to the inevitable values. This is particularly valid
for the compressors itself, and distribution piping as well as all valves or
fittings.

The values must not exceed those of internationally acknowledged standards

or the specified values in Volume IV- Part P-A3 “General Project
Requirements “of the Tender Documents.

In any case the noise shall be less than 85 dBA at 1 m distance from the
noise source.

If a single large user (more than 5 % of one compressor’s capacity) is a peak

demand only, a local pressure accumulator drum shall be provided. It shall
prevent a local pressure drop of more than 1.0 bar.

The continuous large users shall be equipped with a trip valve. It shall stop
the airflow if the air pressure drops below a certain value. Should this not be
acceptable, other measures such as separate piping shall be provided.

Certain reliable measures against pressure drops are required for single large
users.

However, upon failures, e.g. hose rupture, pressure drops shall be avoided.
This shall be achieved by flow restriction devices on each user terminal.

All temporary and hose connections shall be limited to the pipes with a
quick shut-off coupling.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

4.2 Instrument Air Receiver

The air receiver shall store an ample amount of air storage capacity based on
the GRS air peak consumption.

The construction shall be a vertical welded cylindrical vessel. The design

pressure shall be 13 bar.

A 600 mm manhole shall be provided.

The vessels shall be of galvanized carbon steel and located outside the
building under a sunshade.

Between vessel bottom head and drain valve a sight glass shall be provided
to detect condensate. Draining must be possible when the vessel is
pressurized.

Automatic drains shall be provided in the service air receivers.

4.3 Pipework and Valves

All piping to all users in the plant shall be provided. This includes pipe
supports, pipe racks and steelwork for piping in trenches and protection
sheets for street crossings, etc.

For continuous service air user, fixed connections are required. The air
system shall be piped to the equipment nozzle. Isolating and non-return
valves shall be provided close to the equipment, either directly on the
provided equipment nozzle or 1 m apart from the equipment.

The pipe sizing shall ensure low noise, moderate velocities, small pressure
drop, virtually no pressure pulsation and a large storage volume.

The total pressure drop to any consumer shall not exceed 0.3 bar measured
between air receiver and the consumer during its peak consumption and also
during normal consumption of all other users.

In the distribution piping the velocities shall not exceed 6.0 m/s for normal
operating conditions and 10.0 m/s for peak consumption.

Minimum pipe size for headers shall be DN 50.

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INSTRUMENT AND SERVICE AIR SYSTEM

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The design of the piping system with all accessories like vents, drains,
fittings and instrument connections shall be as specified in Part P-B0.1
“Mechanical Equipment and Piping”.

On each terminal point whether from branch line, header or equipment an

isolating valve shall be provided. Each branch line shall be connected to the
header with a ball valve.

The branch pipes shall be distributed in such a way that all individual lines
terminate near the users and shall be provided with isolating valves at the
beginning and at the end.

A ball valve shall be installed at each instrument take-off connection and

shall be located as close to the main line as possible. These connections
shall be taken off the top of the mains.

Except for throttling services, all valves shall be ball valves. Their free cross
section shall be identical with the connected pipes. Valve casing materials
shall be made from spherical graphite cast iron or welded carbon steel
construction. Internals shall be resistant against the media handled. The
offered materials and valve design shall be subjected to the approval of the
Engineer.

Pipe materials shall be hot dip galvanized carbon steel. Only the short (less
than 2 m) connecting piping between the sub-headers for instrument air and
the instruments shall be made of seamless copper pipes 6 x 1 mm, according
to DIN 1754 or equivalent. Fittings shall be made of copper or brass
compression type according to DIN 2353 or equivalent.

Seamless pipes shall be used for the entire system.

The pipe connections shall be carried out as screwed ones up to DN 50. For
pipe sizes DN 80 and upwards on control and isolating valves, equipment,
etc. and where technically advisable, flange connections shall be used. Site
welding of hot dip galvanized pipes shall not be permitted.

All bolts must be galvanized.

The number of connections from ring main and headers shall be at least 15
% larger than necessary at design stage. They shall serve for future air
consumers. Each of these connections shall be equipped with a ball valve.

Immediately upstream of every consumer connection, i.e. next to the valve,

a tapping for pressure measurement shall be provided.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

A sampling connection is necessary behind every equipment in the

compressed air system.

The air distribution system shall be designed as a ring main system.

4.4 Pressure Dampers

For consumers with a short time peak consumption of more than 1 % of one
compressor's capacity, a local pressure collapse (i.e. a pressure drop of more
than 1.0 bar) must be prevented by pressure dampers.

The dampers are small, welded air storage vessels installed next to the
consumer, sized for the needs of that consumer.

The inner surface shall be painted or galvanized. If reasonable and possible,

dampers shall be avoided by generous pipe sizing.

Appropriate calculations and measuring tapping shall be provided for the

specified cases, remote users and where particularly requested by the
Engineer.

Measurements during commissioning will finally decide if, where and

which pressure dampers shall be provided.

4.5 Service Air

In order to supply compressed air to all locations in the buildings, local air
stations shall be provided.

Identical air hoses 15 m long of DN 20 shall be provided at no more than 20

meter intervals around the plant. The connection to the distribution piping
shall be by quick shut off couplings. Sufficient number of flexible Hose
reels shall be provided and stored inside cabinets at various sections of the
plant.

The number and distribution of the air stations shall allow to reach any point
inside the buildings as well as all equipment in other plant areas, with a 15
m long hose connected to a local air station.

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TECHNICAL SPECIFICATION
INSTRUMENT AND SERVICE AIR SYSTEM

Doc No.: Q A 1 0 - H - 0 4 1 5 Rev. C

4.6 Corrosion Protection

The outside surfaces of all pipes and valves shall be painted except if
produced of corrosion free material like copper or stainless steel.

The piping system shall be made of galvanized pipes. The valves shall be of
corrosion resistant material.

The inner equipment surfaces possibly in contact with humid air, shall be
galvanized or made from corrosion resistant or corrosion free material.

For the galvanized materials a corrosion allowance of 1.0 mm and for

painted materials, 2.0 mm shall be provided.

4.7 Instrumentation and Control Material and Configuration

All instrumentation and control tubing, manifolds, valves and fittings shall
be of stainless steel 316 TiSS. The design and configuration shall fully
comply with the Specification in Volume VII-Part P-B0.1 and Volume IX-
Part PG-B210.

4.8 Control System

The system will be controlled and supervised by the DCS system via the
CCR operator workstations.

Final control design is subject to the Employer/Engineer’s approval.

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