Controlled Document Ref.

: Schedule D-2 Custodian: TES/1

Originated by:
TES/11/1D Engineering Standard
Verified by:
TES/3/4, TED, TES, TES/D
Approved by:
TEN, TEN/1
Revision & Date:
Rev 01, 11/97

Reason for Revision: Inclusion of dry type screw compressors and of current
AFPC design philosophies

SYRIA

Packaged Instrument Air

Compressors
Schedule D-2
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PACKAGED INSTRUMENT AIR COMPRESSORS
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SYRIA

TABLE OF CONTENTS

1. Scope and Definitions

2. Reference Specifications

3. Functional Requirements

4. Skid and Piping Design

5. Compressor and Driver Design

6. Auxiliary Equipment Design

7. Quality Control

8. Drawings and Manuals

Attachment 1: Packaged Instrument Air System Configuration

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l. SCOPE

1.1 This Schedule covers the minimum requirements for the design and construction of
instrument air compressor packages used in oil and gas operations.

1.2 Within this specification the following definitions shall apply:

COMPANY: Al Furat Petroleum Company.

CONTRACTOR: The party selected by COMPANY to perform the work or provide
equipment and services as described in this specification.
RFQ: COMPANY’s Request for Quotation

2. REFERENCE SPECIFICATIONS

In addition to the requirements contained herein, the instrument air package shall comply with the
requirements of the COMPANY Schedules related to the following items:

Electrical equipment, electric motors and electrical systems.

Instruments and control systems
Piping design. fabrication & assembly
Unfired pressure vessels
Structural steel

All items of equipment and materials shall comply with, in order of prevalence, the RFQ, the data
sheets, the latest edition of the above Schedules and with the Codes and Standards referenced
therein. CONTRACTOR shall advise COMPANY in writing of any exceptions to or deviations from
the Schedules, Standards and Codes and submit specific details with his bid.

In the event of conflict between the requirements of this Schedule, the Data Sheets or any of the
applicable codes, such discrepancy shall be brought to the attention of COMPANY in writing.

3. FUNCTIONAL REQUIREMENTS

3.1 The instrument air package will be installed in a non-hazardous area. It will be operated
unattended and maintained by production personnel with only periodic maintenance by
trained mechanics. All equipment shall be suitable for operation in desert conditions with
ambient temperatures ranging from -10 to 51 C, black bulb temperatures of up to 82 C,
heavy rain and sand storms and relative humidities of up to 80%.

3.2 Compressor ratings shall not exceed the limits of CONTRACTOR's design and shall be well
within his actual experience. Only equipment which has proven its reliability in similar
service will be acceptable.

3.3 The air delivered shall be dry and free of oil. Solids content shall be no more than 0.1 g/m 3
and particle size shall not exceed 3 m. The dew point shall be -20 C or lower at the
maximum delivery pressure. A high dew point alarm shall be initiated at -15 C.

3.4 The compressors, compressor drivers, air dryers, all associated coolers and pre-and after
filters shall have a design duty of 110% of the calculated air requirement of the facility,
taking into account the quantity of air dryer regeneration air.

3.5 All equipment shall be manifolded such, that maintenance on any standby equipment can
be performed while the duty unit is in service. CONTRACTOR shall ensure this is achieved
by means of adequate and safe isolation facilities and maintenance access to the
equipment. Piping disassembly shall not be required for any routine maintenance.

3.6 Sparing of all package equipment shall be as stated in this Standard, unless specifically
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stated otherwise in the RFQ. See Attachment 1 for details.

3.7 Of primary concern to COMPANY are safety, operability, reliability and maintainability of its
facilities. As CONTRACTOR shall be ultimately responsible for the safe functional
operation of the equipment supplied by him, he shall include the following activities in his
Scope of Supply:

- Review all safety features and systems which COMPANY has specified and suggest, in
writing, all revisions and additions which he deems necessary.

- Review operation and integrity of entire control and shutdown system.

- Review equipment location to permit easy access for maintenance and operation.

- Propose any alternatives which will, in his opinion, result in improved safety, operability,
reliability or maintainability.

4. SKID AND PIPING DESIGN

4.1 All equipment shall be arranged on a heavy-duty oil field skid. All mechanical equipment
shall be installed over drain pans, designed to contain all spillage and/or leakage from any
equipment or piping installed on the skid. Drain pans shall be sufficiently strong to resist
mechanical damage and be equipped with sufficient drains and welded drain manifolds to
facilitate removal of polluting substances. All equipment shall be contained within the skid
boundaries. Skid stiffeners and cross-members shall not interfere with the drainage into
or out of the overall skid drip-pan system.

4.2 The skid shall be fitted with tested and certified lifting arrangements to ensure the package
can be removed, lifted, transported by truck and relocated easily and without risk to the
on-skid equipment.

4.3 Unless installation in a building is specified in the RFQ, a separable roof shall be installed
over the equipment to provide adequate protection against rain and direct sun radiation.
Roof structures shall include hoisting facilities suitable for lifting the heaviest
single component requiring removal for maintenance to a lay-down area outside the
building boundary via a cantilevered beam.

4.4 Walk areas at skid operating level and area around equipment shall be constructed of
galvanized serrated grating. No components requiring access for operation or
maintenance shall be located underneath the grating.

4.5 All piping, instrumentation and equipment shall be adequately designed and supported to
prevent excessive stress and vibration levels.

4.6 All automatic and manual drains shall be connected to a common drain header, which
shall terminate in a flanged connection at the skid perimeter. Drain connections and
header shall be electrically heat traced to prevent ice formation in winter.

4.7 Piping shall comply with COMPANY’s relevant Engineering Standard.

4.8 Design, fabrication, testing and inspection of pressure vessels (air receiver, dryers, filters
etc.) shall be in conformance with the ASME Pressure Vessel and Boiler Code Section
VIII, or British Standard BS 5500, as amended by the relevant COMPANY Standard. The
design pressure and temperature shall be 11 barg (minimum) and 100 C respectively.
The vessels shall have a 3 mm corrosion allowance and be provided with an internal
protective coating. Vessel nozzles shall be minimum 2” flanged.

5. COMPRESSOR DESIGN

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5.1 General

5.l.1 Two electric motor driven compressors (one duty, one standby) shall be provided, unless
specified otherwise in the RFQ. The compressors shall be either reciprocating or screw
type and be mounted on vibration attenuating supports.

5.1.2 The compressor shall be two stage, air or water cooled, oil free (non-lubricated) design.
CONTRACTOR shall ensure that the cooling method elected will be adequate for
maximum ambient and black bulb temperatures of 51 C and 82 C respectively.

5.1.3 Inter-, after- and jacket water cooling (where provided) shall be by one electrical or shaft
driven fin-fan air cooler unit per compressor. Fan tip speed shall not exceed 60 m/s.
Cooling surface shall be sufficient to assure that after cooled air supply to the dryers will
not exceed 60 oC with 51 oC ambient cooling air. Downstream of the inter- and
aftercooler, stainless steel water separators with solenoid, timer operated drain valves and
manually operated drain valves shall be installed.

Each water-cooled compressor shall have an air-cooled, closed circuit cooling water
system, including an electric motor driven jacket water circulating pump.

5.1.4 Each compressor discharge shall be provided with a full flow safety relief valve, a check
valve, a manual block valve and a local pressure gauge, adjacent to the unit.

5.1.5 Each compressor unit shall be equipped with a two-stage dry type inlet air filter-silencer,
suitable for the environmental conditions specified. The first stage shall be inertia type,
the second impingement high-efficiency type. The inlet filters shall be provided with
differential pressure indication.

5.1.6 Dynamic unbalance shall be minimized by means of dynamic balancing and/or

counterweight balancing. The use of light alloy pistons (i.e., aluminum) to reduce balance
forces in reciprocating compressors is permitted.

5.2 Reciprocating Compressors

5.2.1 The compressor piston rings, rider rings and rod packing shall be either Teflon or Teflon
based material.

5.2.2 Piston rods shall have oil wiper rings. Furthermore, distance piece length and rod design
shall ensure that no section of the rod in contact with the crankcase oil enters the air
compression chamber.

5.2.3 Piston speeds shall not exceed 4 m/s.

5.2.4 Compressors shall be equipped with automatic unloaders on suction valves.

5.2.5 Motors shall drive reciprocating compressors through an anti-static matched V-belt
system. The belt guard shall be of a non-sparking material.

5.3 Screw Compressors

5.3.1 Screw compressors shall have sliding vane or similar device unloaders.

5.3.2 The following materials shall be used for screw compressors:

Casing : Carbon steel

Rotors : ASTM A 182-F6 stainless steel

5.3.3 If a gear transmission is required, it shall comply with the latest edition of API Std. 677.

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5.3.4 Shaft seals shall be labyrinth type.

6. AUXILIARY EQUIPMENT DESIGN

6.1 Air Receiver

6.1.1 A vertical air receiver shall be provided in the system complete with a standard spring-
loaded type thermal pressure relief valve (rupture discs/shear devices are not acceptable),
level, pressure and temperature gauges, an automatic liquid drain and a manual drain.

6.1.2 Sizing shall be based on the minimum requirement that 200% of the total calculated air
consumption can be sustained for 5 minutes before the pressure reduces from 8.6 barg to
4.5 barg, or a capacity of 1.4 m3, whichever is larger.

6.1.3 The air receiver shall be located downstream of the dryers/after filters.

6.2 Air Dryers, Pre- and Afterfilters

6.2.1 CONTRACTOR shall provide 2 each dryer systems (one duty, one standby), of the
automatic heatless regenerative absorption type (activated alumina bead desiccant).
CONTRACTOR may propose alternative dryer types for COMPANY’s consideration.

Desiccant capacity shall be sufficient for 10 hours of operation at maximum ambient

humidity level, across the entire pressure range of 5.2 to 8.6 barg, before the specified
dew point will be exceeded and the regeneration cycle is initiated.

6.2.2 Each dryer unit shall be equipped with a signal light indication of cycle status and standard
spring-loaded thermal relief valves (rupture discs/shear devices are not acceptable).

6.2.3 Upstream of the dryers, 2 each 3 m dust and 2 each activated carbon pre-filters shall be
provided, with full flow continuous transfer valves and differential pressure indicator, liquid
trap, automatic and manual draining facilities.

 Downstream of the dryers, 2 each 1 m afterfilters shall be provided, identical in

configuration to the pre-filters.

6.3 Controls and Instrumentation

6.3.1 The minimum unit alarms and shut downs shall be as follows:

Alarm Shutdown Comment

Low Lube Oil Pressure (if pressure lubricated) X X

High Compressor Discharge Pressure X X
Low Compressor Discharge Pressure X
High Cooling Water Temperature X X
Unit Vibration X
High Compressor Discharge Temperature X
Low Air Receiver Pressure X X Plant trip
High Dew Point at Skid outlet X
Standby Compressor Fail-to-Start X
Lead Compressor Not Running X Start lag compressor

CONTRACTOR shall furnish additional shutdowns which he feels are necessary. Panel
shall indicate first failure shutdown. All running/stopped, alarm and shutdown signals shall
be indicated on the front of the panel, and be transmitted to COMPANY’s control room or
DCS system.

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Pressure alarm and trip signals shall be from independent transmitters, e.g. one
transmitter for low/high pressure alarm and one for low-low/high-high pressure trip.

6.3.2 CONTRACTOR shall furnish a combined alarm and control panel to shut down the unit in
emergency situations and allow both automatic and manual control of the unit. (lead/lag
control, dryer sequencing etc.) The panel shall be operating on 24 VDC (power supply by
COMPANY) and be either relay or solid state logic based. The panel shall be mounted on
the skid, at skid edge and be provided with adequate vibration isolation.

6.3.3 The normal mode of the operation of the compressors shall be in “LEAD” or “LAG” mode.
The panel shall enable selection of either compressor in the “LEAD” or “LAG’ mode (also
see 6.4 below).

6.3.4 The pressure transmitters on the air receiver shall automatically control the on-off
operation of the compressor to maintain the supply pressure between 6.9 and 8.6 barg.
Compressor sequencing shall be as follows:

1. At 7.6 barg in the air receiver tank, falling, the LEAD compressor shall be loaded and
operate until the pressure reaches 8.6 barg. At this point the compressor shall be
automatically unloaded; this cycle will be repeated when pressure again falls to 7.6 barg.

2. If the pressure continues to drop to 6.9 barg, the LAG compressor shall be started and
loaded. Both units shall then operate until 8.6 barg is reached, at which point the LAG
compressor shall be stopped and the LEAD compressor unloaded. In order to avoid
continuous starting/stopping and loading/unloading because the LEAD compressor fails to
deliver the required air quantity, the LAG compressor shall take over the LEAD duty and
the LEAD compressor shall be assigned LAG duty. This changeover shall be annunciated
on the control panel and in COMPANY's control room or DCS system where such is
specified.

3. The control system shall allow continuous compressor operation with automatic
unloading by pressure controller.

6.3.5 Low pressure alarm shall be initiated when the skid outlet pressure drops to 6 barg.

6.3.6 Low low pressure of 4.5 barg shall automatically initiate a total plant shutdown, an alarm
on the local control panel and a remote alarm on the plant annunciation system. The trip
shall be provided with a maintenance override to permit on-line testing.

6.3.7 All pneumatic instrumentation and controls shall be installed with type 3l6 stainless steel
tubing and fittings and shall be permanently tagged for easy identification. Tubing fittings
shall be in accordance with COMPANY's Approved Manufacturers List.

6.3.8 Mounting and support of all instruments shall prevent damage or malfunctioning due to
vibration.

6.3.9 Pressure relief valves shall relieve vertically upwards at a location at least 2 m above the
skid.

6.3.10 Instrumentation which may be exposed to sun radiation resulting in temperatures outside
its design limits shall be separately covered or shaded to protect it throughout the year.

6.3.11 Where utility/tool air is taken from the instrument air system, the utility air take-off line
shall be provided with a pressure control valve which shall close if the supply air pressure
falls below 6 barg.

6.4 Electrical

6.4.1 The power supply to the skid motor starter panel shall be 3 phase and neutral, 50Hz.

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Supply voltage shall be 380V or 415V as specified on the purchase order.

On-skid, all requisite power, control and earth cabling, glands, lugs, etc. shall be included
to interconnect the motor starters, motors, remote control units, anti-condensation heater
switches, etc. such that only the two main feeder cables and two main earth cables to the
skid earth bosses are required to be provided by COMPANY. On-skid cabling shall be run
neatly on galvanized, earthed cable tray and be secured at regular frequent intervals.

Motor starters shall be in accordance with the relevant COMPANY Schedules, shall
include four pole isolating switches/circuit breakers and shall have ‘running’, (red),
‘stopped’ (green) and ‘tripped’ (amber), long life indicating lights. Each starter contactor
shall be provided with 1 n/o and 1 n/c voltage free contacts for remote motor
running/stopped indication.

6.4.2 Motors shall be in accordance with the relevant COMPANY Schedules. Motors shall be
TEFC type, suitable for prevailing ambient conditions, have a minimum degree of
protection of IP55 to IEC 529 and shall be protected from direct sunlight by the skid
canopy. Motors shall be direct-on-line starting.

Motors 22.5kW and above shall be equipped with thermostatically controlled anti-
condensation heaters unless other means of protection against high humidity have been
provided. Motors 30kW and above shall have earth-fault protection of 1A sensitivity
supplied from core-balance current transformer in each motor starter.

6.4.4 Each motor shall be controlled via a readily accessible ‘remote control unit’ (RCU) located
in close proximity to the associated motor. The RCU shall be minimum IP55 and mounted
on the edge of the skid at a convenient height and location for operation.

Each RCU shall be connected directly into the motor starter low voltage control circuit to
provide a positive break in the RCU 'OFF' position and shorting of the de-energized
contactor coil. In 'ON' position, the motor is able to be started manually. ‘ON’ and ‘OFF’
positions shall only be maintained momentarily, the switch having a spring return to central
‘AUTO’ position. Each switch shall be padlockable in the ‘OFF’ position. Two padlocks and
four sets of keys shall be provided for each RCU.

In the 'OFF' position, the contactor operating coil is shorted through RCU switch contact 1-
2, thereby preventing the motor from being started accidentally either locally or remotely.

The 'AUTO' position allows automatic operation in lead/lag configuration as described in

section 6.3.5. The individual start and stop contacts shall be a momentary (typically
200ms pulse) contact. The stop contact shall be normally closed, failing safe to the open
position.

In the 'ON' position, contact 3-4 closes energizing the contactor operating coil which is
held via a contactor auxiliary seal-in contact. When the RCU is switched to the 'ON'
position, a wiping action on contact 5-6 prevents a starter control relay used for indicating
RCU/plant status (to control room via the DCS) from dropping out. The contact is opened
at the ‘ON’ position.

6.4.4 The instrument air skid shall be provided with two earthing bosses (M10 studs) at opposite
ends of the skid. All on-skid equipment shall be effectively earthed, including motors and
remote control units. Minimum size of on-skid earthing conductor shall be 25 mm 2.

6.4.5 The power supply to anti-condensation heaters, where fitted, shall be isolated on the skid
by suitably rated 220V-240V 2-pole isolation switches mounted at a convenient height on
the edge of the skid. The switches shall be padlockable in the Off position and two
padlocks and four sets of keys shall be provided for each switch.

6.4.6 220V and 110V ac circuits, as applicable, shall be kept separated from 24V dc circuits.
Where high and low voltage terminals in the same compartment/terminal strip cannot be

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avoided, adequate secure, removable barriers inscribed with warning of high voltages
shall be provided. Terminal strips shall segregate the different voltage levels.

6.5 Painting

Painting and protective coatings, including surface preparation and coating or paint application
shall be applied to all equipment, structural steel, base plate etc. All grit blasting required for
surface preparation shall be accomplished prior to instruments and controls being mounted on the
skid. Paint systems may be CONTRACTOR’s standard, provided this is suitable for the
environmental conditions specified.

7. QUALITY CONTROL

7.1 During fabrication, CONTRACTOR shall maintain inspection and quality control to insure
adherence to COMPANY's specifications and standards. CONTRACTOR shall submit his
Test and Inspection Plan within six (6) weeks of contract award for COMPANY review
and comments and submit updates on a monthly basis. A copy of test/inspection reports
and records shall be submitted with the updated Plan for the month in which the test/
inspection activity has taken place.

7.2 CONTRACTOR shall perform a complete functional run test of all equipment, including
control and safety devices, on package and panel prior to shipment from CONTRACTOR's
facility. CONTRACTOR shall give COMPANY a minimum one week notice of this run test
to enable COMPANY to witness the test if COMPANY so elects. CONTRACTOR shall
submit his proposed test procedure for COMPANY’s review two months prior to the
scheduled test date. The minimum requirements to be accomplished prior to and during
the run test shall be as follows:

7.2.1 All instrumentation, protection and control devices shall be fully loop checked and
functionally tested prior to the unit run test.

7.2.2 All panel components shall be operating and the unit shall be started through the
panel board. No lockout or shutdown signals shall be bypassed during start-up
and the run test.

7.2.3 The unit shall be run at full load for a minimum of one (1) hour, during which the
various LEAD/LAG/MANUAL modes shall be verified.

8. DRAWINGS AND MANUALS

8.1 Review Drawings

CONTRACTOR shall, as a minimum, submit three (3) copies of the drawings and
schedules listed below for “Review and Comments” at the time specified in the RFQ.

Piping and Instrument Diagrams (P&ID’s)

Equipment and General Arrangement Drawings
Electrical Schematics and Wiring Diagrams
Connection Diagrams
Electrical Earthing Plans
Electrical Panel Detail Drawings
Instrument Index/Schedule
Logic Diagrams
Cause & Effect Matrix
Instrument Alarm and Shutdown Settings
Equipment Specification Data Sheets
Electric Motor Data Sheet

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Instrument Data Sheets

Test and Inspection Plan

8.2 Final Documentation

CONTRACTOR shall submit seven (7) hardcopies copies and one ACAD/MS
Word/Access/Excel (as appropriate) copy on CD-ROM of the final, as-built drawings and
schedules as listed above and of the procedures, manuals and documentation stated
below, at the time specified in the RFQ.

Erection, Installation and Commissioning Procedures

Operating and Maintenance Manuals and Manual of Parts Lists
QA/QC Documentation

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