Sched w4
Sched w4
Sched w4
Custodian: SEE/1
SEE/1
Date: 20/03/01
This document contains proprietary information and is intended for use by AFPC staff
only. The contents of this controlled document shall not be altered without formal
approval of the document Custodian.
SCHEDULE W-4
March 2001
Rev. 2
TABLE OF CONTENTS
1.1 This standard specification covers the minimum requirements of Al Furat Petroleum Company for
the design and construction of centrifugal pumps and related auxiliaries for use in onshore oil and gas (related)
operations.
INSPECTOR : The individual(s) designated by COMPANY to act on COMPANY's behalf for all
matters relating to Quality Control, Testing, and Acceptance of the work.
2.1 The pump package to be designed and constructed according to this Schedule will be
operated semi- attended in a remote desert area. It will be operated and maintained by production
personnel with only periodic maintenance by trained mechanics.
2.2 Of primary concern to COMPANY are safety, operability, reliability and maintainability of its
facilities. As CONTRACTOR shall be ultimately responsible for the safe 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 feels necessary.
- Review equipment location and layout to permit easy access for maintenance and operation.
- Propose any alternatives which will, in his opinion, result in improved safety, operability, reliability
or maintainability
2.3 Pump ratings shall not exceed the limits of the manufacturer’s proven design and shall be well within
his actual experience. Only equipment which has proven its reliability in similar service will be
acceptable. Similar service and actual experience are defined as follows:
The manufacturer shall have at least three pumps of the same model in proven operation under
comparable service conditions including liquid type, suction/discharge pressures and temperatures, and
capacity, at the time of bid. These units shall have similar design features to the units proposed,
including: operating speed/speed range, staging arrangement, shaft sealing, bearing design, casing/casing
joint design, material selections and load coupling design.
CONTRACTOR shall include appropriate reference data with his bid to demonstrate that the
above requirements are met by his proposed design.
2.4 All items of equipment and materials shall comply with the latest edition of the listed Schedules, Codes
and Standards and with those referenced therein, and with the requirements of this Schedule, the data
sheets and the RFQ Document. CONTRACTOR shall advise COMPANY, with his bid, of any
exceptions to or deviations from the Schedules, Codes and Standards and submit specific details, and
obtain COMPANY's approval prior to award.
2.5 In the absence of a COMPANY specification or a relevant international code the design shall be
in accordance with CONTRACTOR's specification or standard, which shall adhere to accepted design
methods and good engineering practice, and shall be supplied to COMPANY for review prior to
its adoption.
2.6 In the event of a conflict arising between the requirements of the RFQ, this Schedule, the Data Sheets
or any of the applicable Schedules, Codes and Specifications, such discrepancy shall be brought to the
attention of COMPANY in writing.
In addition to the requirements contained herein, the requirements of the following Standard
Specifications for COMPANY shall apply as appropriate.
Centrifugal pumps shall comply with API Standard 610, latest edition, except as amended or
supplemented in the following. Clause numbers in this section refer to the relevant paragraphs of
the 8th Edition. Additional requirements have been given new Clause numbers sequential to the
existing API Clause numbers.
1.1.2 Pumps designed and manufactured in accordance with ANSI B73.1, "Horizontal End-Suction
Centrifugal Pumps for Chemical Process" and ANSI B73.2, "Vertical In-Line Pumps for
Chemical Process" may be selected, for non hydrocarbon service and all criteria stipulated in
Appendix "A" of API 610 are met.
2.1.8 The Available NPSH shall exceed the NPSHR by no less than 1 m throughout the
entire operating range of the pump. For pumps with rated suction pressures below
atmospheric or pumping liquids below 0 °C this margin shall at least be 2m.
2.1.14 Sound pressure limits (in dB ref. 20 mPa), under any operating condition, at a
distance of 1 m. from the equipment surface, shall not exceed 87 dB(A) for the
pump/gear/driver combination, including auxiliaries such as lube oil motors, fin-fan
coolers, control valves etc. Any acoustic treatment required to achieve the above
sound levels shall require prior approval by COMPANY. CONTRACTOR shall
submit guaranteed sound pressure levels with his bid.
2.1.17 CONTRACTOR is to state if cooling of seal buffer liquid, stuffing box, or bearing
housing is required.
Cooling coils shall be stainless steel, with design and test pressures to be equal to
those for the pump case.
Closed system type radiator cooling (with either shaft or electric motor driven fans)
shall be selected if the process liquid properties are not suitable for cooling.
Cooling by means of utility/cooling water is not normally available and shall only be
applied if specifically stated on the data sheet or in the RFQ.
2.1.22 Electrical motors, associated remote control units, electrical components, earthing
and installation etc. shall comply with COMPANY's Schedules "F", "F-CP" and
COMPANY’s Specification" Electric Motors: Cage-induction and Synchronous Type ".
2.1.29 The pump will be installed under conditions as specified in the RFQ/data sheet. As
a minimum, it shall be suitable for operation in a desert environment, with frequent
sand/dust storms, ambient temperatures ranging from -10 to +51 °C and black bulb
temperatures of up to 82 °C. Electrical equipment located outdoors shall be IP55
rated and shaded against direct sunlight.
2.2.2 The maximum discharge pressure shall further be based on the maximum impeller
diameter and maximum suction pressure.
2.2.4 All pump pressure casings (as defined in 1.4.19) shall be rated for the maximum
allowable working pressure.
2.2.6.c Radially split casings shall be required for toxic or flammable liquids at a rated
discharge pressure above 40 bar(g).
2.2.6.d Radially split casings shall be required for all liquids at a rated discharge pressure
above 70 bar(g).
2.2.9 All pumps other than self-priming pumps shall be centerline mounted.
2.3.2.4 Flat-faced flanges on casings other than cast iron or bronze require COMPANY’s
specific approval.
2.3.3.4 All auxiliary connections to the casing shall be fitted with flanged stubs, full-
penetration welded to the casing. Socket welded connections are not acceptable.
2.3.3.11 Pressure gauges (1/2" NPT connection) shall be installed on pump suction and
discharge piping (not on the nozzles), or on the local gauge panel if such is
provided under the Contract.
Both the drive-end and the non-drive-end seal, including the seal system, shall be designed to
operate/seal properly at the maximum stuffing box pressure at static conditions, as well as,
dynamic.
All packed pumps shall be provided with a replaceable shaft wear sleeve at the
packing area. Shaft wear sleeves shall be steel (or stainless steel for corrosive
services) and be hard faced with a stellite or colmonoy overlay to a hardness of not less
than 500/550 Brinell.
2.7.3.17 CONTRACTOR shall advise whether stuffing box cooling is required for the design
conditions specified. Also refer to Clause 2.1.17 above.
CONTRACTOR shall advise whether buffer liquid reservoir cooling is required for
the design conditions specified. Also refer to Clause 2.1.17 above. Finned piping
sections in the buffer liquid piping are acceptable if this will provide adequate
cooling at the maximum ambient temperature specified by COMPANY.
CONTRACTOR shall specify the most suitable buffer liquid for the application as well
as normal consumption rates.
2.7.3.20 Single seals shall be furnished with either a replaceable throttle bushing in the
gland plate or an auxiliary outer seal. Each seal shall be fitted with an orifice/
pressure transmitter arrangement to sense pressure between the primary seal and
throttle bushing or auxiliary seal and initiate a seal failure alarm.
2.7.3.21 Pumps in high pressure hydrocarbon service (35 bar(g) or above) shall be provided
with tandem balanced mechanical seals. The CONTRACTOR shall provide the complete seal
buffer liquid system including buffer liquid reservoirs, with high pressure gauge glass
and gauge valves, fill, drain and vent connections, vent/outlet orifice and interconnecting piping.
Pressure transmitters shall be provided upstream of the orifice to sense loss of buffer
liquid/primary seal failure, and a low level switch in the seal oil tank to sense an outer seal
failure. The outer seal in these systems shall include a pumping ring for buffer liquid circulation.
Design of the seal buffer system shall be reviewed by the seal manufacturer and COMPANY
prior to fabrication.
Pumps in produced water systems shall be equipped with double mechanical seals, back to
back arrangement, plan 53M. Also, where the concentration of abrasive solids is too high to
be effectively removed by a Plan 13 cyclone separator or where specified in the RFQ and or
data sheet.
The selected double mechanical seal should not suffer from any problem, such as leakage,
scale hung-up (i.e narrow gaps between the seal sleeve and the seal faces must be
prevented) especially where low flow & high temperature conditions can be present.
Pumps in brine service shall have provisions for manually flushing the atmospheric
side with clean water to remove any accumulated salt deposits. Relevant procedures shall
be included in the Operating Manual.
All cooling and seal piping shall be installed and shall be in operation during
factory performance tests.
2.8.1 A lateral critical speed analysis shall be performed for all multistage pumps, and for
single stage pumps operating above their first critical speed.
The lateral analysis shall cover all items of the train, including driver, load gear and
couplings. It shall be CONTRACTOR's responsibility to collect all data required
from his subcontractors.
2.9.2.9 CONTRACTOR shall advise whether oil heaters are required for his recommended
lube oil grade at the minimum ambient temperature specified by COMPANY. If required,
heaters shall be electrical in accordance with this Clause.
2.11.1.1 Material classes shall generally conform to those specified in Appendix H of API
610. CONTRACTOR may, in his bid, propose alternative materials where, based on is
experience, he considers such superior for the intended service.
3.1.4 Add to the first sentence: “or equal to the maximum power required throughout the
entire head capacity curve (with the impeller furnished), whichever is higher".
Deviation from use of a motor with non- overloading characteristics must have
specific approval by COMPANY.
Electric motor drivers and motors for auxiliary equipment shall comply with
COMPANY's Specification " Electric Motors: Cage-induction and Synchronous
Type " and be suitable for the applicable area classification.
CONTRACTOR shall demonstrate, with his bid, the basis for his proposed motor
output rating. This shall include the ultimate power required by the pump,
derating factors for ambient temperature, Class F insulation/Class B temperature rise, gear
box losses, API design allowances etc.
3.1.9 Gas turbine drivers shall comply with API Std. 616.
3.1.10 Speed increasers/reducers shall comply with API Std. 677 or with API Std. 613 as
amended by COMPANY's Schedule "U-2".
3.1.13 “New”
When operating in electrical classification areas of Division 1 or Division 2,
internal combustion engines shall comply with EEMUA-107.
3.2.2 Couplings for horizontal pumps shall be dry flexible metallic disc type, make
Thomas, Metastream, Kopflex or COMPANY approved equivalent, with retained
spacer if discs should fail.
Hydraulically mounted coupling hubs shall be provided for shafts 50 mm and larger
in diameter. Driver shafts shall have a matching taper.
All couplings shall have rigidly supported, removable non-sparking coupling guards
for personnel protection and prevent any physical contact with moving parts.
3.2.8 Couplings shall comply with API Standard 671 for applications above 3000 rpm
and/or 1000 kW. However, all couplings shall comply with the design requirements
stipulated in API Standard 671 (Second Edition) Clauses 2.1.1, 2.1.2 and 2.1.3.
3.3.2 Driver, load gear (if required), driven equipment and lube oil system shall be
mounted on a single baseplate, unless otherwise agreed. The layout of the skid shall
allow easy access for maintenance (e.g. to seals, bearings, couplings etc.) without the
need for dismantling auxiliaries, piping etc., and for filling, draining and cleaning of lube oil and
seal buffer liquid reservoirs.
3.3.5 In addition to the stiffness criteria stipulated in this Clause, deflection of the
baseplate, both when installed on the foundation as well as during lifting/
installation, shall not exceed 1/1200 of the free span.
3.3.7 The cross-members located underneath the supports of major items of equipment
shall be full-depth.
3.3.13 CONTRACTOR shall advise in his bid whether pedestal cooling is required for the
process conditions specified.
3.3.15 Vertical levelling screws shall be provided in accordance with this Clause.
3.3.19 CONTRACTOR shall provide all lifting gear (spreader bars, slings etc.) required for
transportation, installation and removal of major components. All gear shall be certified by
appropriate Authorities.
3.3.20 “New”
Anchor bolts shall be provided by CONTRACTOR.
3.4 General
The provision of a complete control system, integrated with those of the driver,
auxiliary systems and process equipment as specified in the RFQ/Purchase Order shall
be in CONTRACTOR's scope of supply.
CONTRACTOR, in consultation with the pump manufacturer, shall confirm that all
necessary process controls (start-up/shutdown, capacity control features, spill-
back/recycle, minimum flow protection etc.) and protection systems are compatible with
the intended pump and overall system application and meet the pump manufacturer’s
approval.
A unit control panel (UCP) shall contain all monitoring and supervisory control logic systems.
Machine and process related status/alarm/trip signals shall include first- out annunciation and
shall be made available for transmission to COMPANY's remote DCS system. These signals
shall include all relevant process parameters (suction and discharge pressures and
temperatures, flows etc.) and unit operating parameters (vibration levels, bearing
temperatures, speed(s), motor driver kW, turbine temperatures, PCD's etc.).
Starting of the pump unit shall be by a single push-button action at the Unit Control
Panel and/or other locations as specified in the RFQ. The automatic start-up logic shall
ensure that all permissives for safe start-up are met. Station/pump block valves,
bypass valves, recycle valves etc. shall be incorporated in the automatic start sequence.
For variable speed drives, facilities shall be provided to set the speed of the driver
either by manual action from the Unit Control Panel, or automatically by (an)
external process signal(s). Mode of control shall be selected by means of a
manual/auto select transmitter at the Unit Control Panel.
The shutdown logic shall also actuate block, blowdown and recycle valves as
required.
All local instrumentation shall be mounted on a local panel/gauge board to the maximum
extent feasible. The gauge board shall be self-supporting and Isolated from equipment
vibration.
All instrumentation shall have features for in-service testing, calibration and
maintenance. Gauge board instrumentation shall include, but not necessarily be limited to,
the following:
- Suction pressure
- Suction temperature
- Discharge pressure
- Discharge temperature
- Lube oil system instrumentation.
3.4.3.1 For pump sets with antifriction bearings, CONTRACTOR shall install a
velocity or accelerometer type vibration detector at the rotating element centerline on
both inboard and outboard bearing housings of pump, gear and driver. The detector shall
be installed in the horizontal plane.
- 2 each proximity probes, mounted at 90° from each other, adjacent to each radial
bearing.
- 2 each axial position monitoring proximity probes, one facing the active, the other
the inactive side of the thrust collar.
- 1 each oscillator/demodulator per probe.
- 1 each monitor per bearing, mounted in the unit control panel, complete with
signal output jacks on the front of the monitor (one jack per probe) for external recording/
analysis.
- 1 each key phasor for each shaft system running at different speeds.
- 1 each key phasor output card per keyphasor, mounted in the unit control panel,
complete with signal output jack on the front of the card for external recording/ analysis. .
3.4.3.2 This Clause shall apply for all pumps with hydrodynamic bearings. Two RTD's per bearing
shall be provided, of which one shall be hooked-up to the monitoring system, the other shall
be an installed spare. Both RTD's shall be wired to the same junction box.
Temperature monitoring may be integrated with the available display in the Unit
Control Panel where such is included in the scope of supply.
3.5.1.9 Add: Threaded connections are permitted only at mechanical seal glands and shall
not be seal welded. Threaded flanges shall not be used.
3.5.5 All lube oil piping shall be grade 316L stainless steel.
4.1 CONTRACTOR shall witness all tests as specified in the RFQ or on the data
sheet. COMPANY’s Inspector participation in tests and inspections will be defined at
the time of order placement. The extent of Inspector's participation, including identification of
Witnessed (Hold) points, shall be identified in CONTRACTOR's overall Test and Inspection
Plan, which shall be included in CONTRACTOR's QA/QC plan.
4.3.2.1 All pump pressure containing parts shall be tested to the same pressure.
4.3.3 A performance tests in accordance with this section shall be required on centrifugal
pumps rated 100 kW and larger. Certification is required. When feasible, Contract
driver, gear, lube oil system, monitoring devices and control panel shall be used during the
performance test.
Following the performance test, the pump shall be run at rated point, under stable conditions,
for two more hours. Throughout the entire test, horizontal pumps shall run at an NPSHA
within 10% of that specified; vertical line shaft pumps shall be run at minimum submergence.
Where pressure lubricating systems are used, the oil temperature shall be held for 30 minutes
at minimum, and 30 minutes at maximum allowable oil viscosity. Bearing vibration and
temperatures shall be recorded at the end of each 30 minute period. Bearing vibration
frequencies shall be analysed under both conditions for instabilities.
The pump curve derived from a performance test on water shall be corrected for the
actual process medium. The rated and design conditions shall be clearly marked on the
curve.
4.3.3.2.1 Test data taken at each point (except shut-off) shall further include filtered and
unfiltered vibration levels and bearing temperatures.
4.3.3.4.3 Bearing/seal removal and inspection shall not be required in the case of a fully
successful running/performance test.
4.3.4.1 An NPSHR test shall be performed if the requirements of Clause 2.1.9 as amended
by this Schedule cannot be met.
4.3.4.2 A complete unit test shall be performed for all pumps with driver ratings of 100 kW
and higher. A complete unit test is not required if all major contract equipment was used
during the performance test. (See Clause 4.3.3 above).
4.3.4.3 A sound level test shall be performed if specified in the RFQ or on the data sheet.
4.3.4.4 Auxiliary equipment testing is not required for equipment used during the performance test.
(See Clause 4.3.3 above).
5.2.6.1 Where driver size exceeds 500 Kw, pump, drivers and gears to be equipped with a
common pressurised lube oil system in accordance with API 610 . The lube oil system shall be
equipped with a temperature-controlled by-pass around the cooler to maintain acceptable
temperatures during cold ambient conditions.
Pressure lubrication systems shall comply with API Std. 614 as modified by COMPANY’s
Schedule U-3 for all pumps driven by gas turbines.
The lubrication system shall be made of from AISI 316 L stainless steel, except for lubricating
oil pump casing, valve bodies and filter housings.
CONTRACTOR shall be responsible for the selection of a lube oil type compatible with all
elements of the pump/driver train, taking into account the application and the environment
conditions.
5.2.6.2a The lube oil pump shall be either electric motor or shaft driven. Positive displacement type
pumps shall be either screw or gear type and be provided with an external pressure relief
valve. This valve shall be not be used for pressure regulation.
5.2.6.2b The lube oil cooler shall be a fin-fan air cooler with a shaft or electric motor driven fan, unless
water cooling water utility water is specified in the RFQ or on the data sheet. The cooler shall
be sized to maintain a temperature not more than 10 deg C above maximum ambient
temperature.
5.2.6.2e Filters shall have a continuance flow transfer valve including a pressure equalisation line.
Filter elements shall be replaceable during operation.
Contractor shall supply all required data, including drawings and documents, as per
API 610 8th edition- paragraphs 6. 2 & 6. 3
CONTRACTOR shall be responsible for timely submission of all relevant data, drawings,
documentation etc. for equipment and systems supplied by his subcontractor(s), and for
verification of correctness and completeness of this information.