TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

List of illustrations 2

1.0 General 3

2.0 Reciprocating Compressors 3

3.0 Centrifugal Compressors 4

4.0 Auxiliary Equipment 4 - 5

5.0 Piping Arrangement 5

6.0 Reference Code 5 - 6

Applicable Revision:Prepared:

Date:

Checked:

Date:

Approved:

Date:First Edition: R0Prepared: AKB

Date:

Checked: TNG

Date:

Approved: RUD

Date:File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209

TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 2

LIST OF ILLUSTRATIONS

SR.NO. DWG.NO. DESCRIPTION

1 CHP1 RECIPROCATING COMPRESSOR - PIPING STUDY (PLAN)

2 CHP2 RECIPROCATING COMPRESSOR - PIPING STUDY(ELEVATION)

3 CHP3 LUBE OIL CONSOLE PIPING AND INSTRUMENTATIONDIAGRAM

4 CHP4 SEAL OIL CONSOLE PIPING AND INSTRUMENTATIONDIAGRAM

5 CHP5 COMPRESSOR SUCTION DRUM / KNOCKOUT POT

6 CHP6 PULSATION DAMPENERS / VOLUME BOTTLES

TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 3

1.0 GENERALCompressors are normally located inside a permanent shelter or building (Compressor House) forweather protection. The compressor house can be fully covered by side cladding to grade level ifhandling non-hazardous materials e.g. air.

1.1 For compressor, handling flammable materials, ventilation and weather protection is assured bysignificant openings upto 2.5m ht. at grade level together with roof ventilators.

1.2 Except for lighter than air gases, trenches, pits and similar gas traps should be avoided within gasCompressor House. This will eliminate chances of suffocation or explosion risk due toaccumulation of heavy gases in pits.

1.3 For open compressor house, the side cladding on all sides should be provided upto 1m belowcrane level.

1.4 The general arrangement of compressor house shall consider the vendor drawings and vendorrecommendation, if any, for space and location of auxiliary units.

1.5 For compressor house where a number of installations from multiple vendors are to beaccomodated, a thorough discussion should be held among the engineers of Piping, Process andCivil discipline to finalise the detail plot plan of the unit.

1.6 The clear space between compressors shall be minimum 1.5m or half width of the compressors.The clearance between rows of compressor and at the end of each compressor shall be also1.5m.

1.7 Built-in maintenance equipment viz. travelling gantry with overhead crane / monorail with hoist andchain-pulley blocks as well as the drop-out areas shall be provided in the compressor house.

1.8 The clearance above the compressor should be at least 3m more than the longest internal part tobe removed.

1.9 The substantial space required for lube oil and seal oil consoles shall be taken into considerationto prepare unit plot plan.

2.0 RECIPROCATING COMPRESSORS2.1 Reciprocating compressor generates considerable vibrations due to unbalanced forces, pulsation

etc. For this reason, the reciprocating compressors should be located as close as possible to thegrade level.

2.2 The building foundation and the compressor foundation should be separate to avoid transmissionof vibrations from compressor to the building structure.

2.3 The pulsation dampeners are used to eliminate pulsation in suction and discharge piping and toseparate the source of vibration from the piping system.

2.4 The piping arrangement around the reciprocating compressor should be planned at grade level forease of supporting with minimum changes in direction (Refer Fig.CHP1, CHP2)

2.5 The grade supports should be spaced unevenly to reduce harmonic motion in the piping.

2.6 The piping routed simply with short run is less prone to vibration, but at the same time the lineshould be checked for the flexibility and the compressor nozzle loadings within the allowable limitsfurnished by the vendor.

2.7 The piping shall remain clear of the cylinders and the withdrawal space at cylinder heads.

TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 4

3.0 CENTRIFUGAL COMPRESSORS3.1 The general considerations for centrifugal compressor layout is same as the reciprocating

compressor, exception being that for centrifugal compressor, the pipeline size is larger,temperatures can often be higher and nozzle loadings on compressor casing is lower.

3.2 The knockout pots, interstage exchangers can be located at grade outside the compressor housewith auxiliary equipment consisting of lubricating, seal and control oil systems be placed adjacentto the machine.

3.3 The centrifugal compressor inside a building normally have foundations separate from the buildingfoundation.

3.4 The centrifugal compressor with drive are generally mounted on the concrete table supported onRCC column.

3.5 The maintenance facilities like overhead crane or monorail at the centre of the compressor bayand the drop-out area at one of the building or shed is the usual practice.

3.6 If the building is having installation of several compressors, the height of the travelling crane is tobe carefully estimated so the machine components and rotors can be lifted over the adjacentequipment.

3.7 The compressor suction lines must be free of any foreign particles that could damage the internalsof the machine. Strainers are installed in the inlet line between the isolation valve and thecompressor inlet nozzle.

3.8 ASME PTC code recommends a minimum 3 times diameter of straight run piping between elbowand the inlet nozzle.

3.9 The designer shall ensure that all connections shown on the vendor piping and instrumentationdiagrams are properly taken care in the piping layout. All valves shall be arranged in such a waythat they are accessible from the operating floor around the machine.

4.0 AUXILIARY EQUIPMENT4.1 Centrifugal and reciprocating compressors and their drives require a variety of auxiliary equipment

to support their operation. The equipment for these compressors are discussed below.

4.2 Lube Oil Consoles :

Compressor bearings receive lubricating oil from the lube oil console (Refer Fig.CHP3). Theseconsoles may be either stand alone or be mounted directly onto the compressor frame. Theconsole consists of lube oil reservoir, oil filters, oil coolers and lube oil pumps.

4.3 Seal Oil Consoles :

The hydraulic seals located at the outer ends of the compressor shaft receive oil from the seal oilconsole (Refer Fig.CHP4). The seal oil console consists of seal oil reservior, oil filters and mainseal oil pumps.

4.4 Inlet Filters :

The inlet filters for air compressors are installed outside the building /shed at a level suitable forclean air suction without any obstruction in the air flow. The vendor drawing of the filter shall bereviewed for correct inlet/outlet ducting and the supporting arrangement.

4.5 Suction drum / knockout pot :

As compressors require dry gas free of foreign particles, it is necessary to pass inlet gas throughthe suction drum or knockout pot. This vessel removes moisture and particles from the gas bypassing it through a demister screen located just below the outlet nozzle. A typical knockout pot isillustrated in Fig.CHP5.

TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 5

4.6 Pulsation dampener / volume bottles :

The negative effects of vibration on the life of reciprocating compressors and associated pipingcan be minimized by the use of pulsation dampeners (Refer Fig.CHP6). The pulsation dampenersare sized by the compressor vendor and are mounted directly on the cylinder nozzles.

Volume bottles are used to reduce vibration. They are located downstream of the dischargepulsation dampener and are similar to snubbers without internal baffles or choke tubes.

5.0 PIPING ARRANGEMENT5.1 The compressor house piping consist of suction / discharge piping, auxiliary equipment piping and

utility system piping. The main suction line with its components shall be as short and direct aspossible. The discharge line with its main components shall be routed clearing the compressorand its driver and supported independent of compressor foundation or building column foundation.This will minimise the transmission of damaging vibrations to the building structure / frame.

5.2 The vendor furnishes that P&ID for the compressor with its auxiliary equipment. These drawingsshould be reviewed fully for the provisions of vents and drains requirement of the installation.

5.3 For reciprocating compressors, API 618 provides the acceptance criteria for nozzle loads.

For centrifugal compressors, API 617 provides the acceptance criteria for nozzle loads.

5.4 Reciprocating compressor piping arrangement should be finalised after analog study whichidentifies potentially damaging accoustic or pulsation problems during design phase itself.

6.0 REFERENCE CODEAPI 617 Centrifugal Compressors for Petroleum, Chemical and Gas Industry Service.

API 618 Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services.

PTC9 ASME Performance Test COde

6.1 Key words :

- Fluid for compression - Air, Ammonia, Process gas etc.

- Type of compressor

- Type of suction

- Type of discharge

- Short suction line

- Lube oil console

- Seal oil console

- Suction filter

- Type of drive

- Discharge bottle / snubber

- Anti vibration measures

- Shelter requirement

- Maintenance space

- Operation space

- Handling Facilities

- Acoustic hood

TRAINING MANUAL- PIPING

PIPING STUDYCOMPRESSOR HOUSE PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1008

Rev. : R0

Page : 6

- Utilities requirement

- Control panel

- Vendor's specific requirements

- Thermal load on nozzles / flexibility analysis

- Independent supports

- Straight length requirement at suction

- Relief valves on discharge

- Orientation of compressor w.r.t. overall and unit Plot Plan and other facilities viz.piperack,underground facilities, drainage, road access etc.

- Layout concept from the vendor offer stage.

DOC NO.

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PageUhde India Limited

TRAINING MANUAL - PIPING

PIPING STUDY

DWG. NO.

COMPRESSOR HOUSE PIPING

: 29040-PI-UPS-1008

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: 1 OF 1

: CHP1

SU

CT

ION

HE

AD

ER

SU

CT

ION

HE

AD

ER

C K.O.DRUML

INTER COOLERS &AFTER COOLERS

(1S

T S

TA

GE

)

(1S

T S

TA

GE

)

FOR SUPPLY & RETURNCONCRETE SLEEPERS

AND SUCTION HEADERS

VALVE ACCESS

DRIVER

C COMPRESSORL

1ST STAGEDRIVER

2ND STAGE

C COMPRESSORL

CYLINDERSUPPORT

PULSATIONDAMPENERS

(2N

D S

TA

GE

)

(2N

D S

TA

GE

)

RECIPROCATING COMPRESSORS - PIPING STUDY (PLAN)

2ND STAGE

1ST STAGE

1/2 WIDTH OFCOMPRESSOR ORMIN. 1500MM

DROPOUT AREA

ACCESS

DOC NO.

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TRAINING MANUAL - PIPING

PIPING STUDY

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COMPRESSOR HOUSE PIPING

: 29040-PI-UPS-1008

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: CHP2

RECIPROCATING COMPRESSORS - PIPING STUDY (ELEVATION)

GRADE

2400

MIN

.

C SUCTIONDAMPENERL

C DRIVERL

ADEQUATECLEARANCE

HOIST

RUNWAY BEAMGUIDE

VENT TO ATMOSPHEREAT SAFE LOCATION

K.O.DRUM

(ALTERNATE)

SUPPORTINDEPENDENT

PREFERED

UTILITIES

COMPRESSORFOUNDATION

DISCHARGEPULSATIONDAMPENER

LAYOUTALTERNATIVE PREFERED

LAYOUTSLEEPERS

MIN. 1.5M

MIN. 3M

TI

(TYP.)TI

LUBE OIL CONSOLE PIPING AND INSTRUMENTATION DIAGRAM

DOC NO.

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: CHP3

COMPRESSOR TURBINE

COMPRESSOR/TURBINE

PI

FILTER

LUBE OILCOOLER

AUXILIARYPUMP

PUMPMAIN

LUBE OILRESERVOIR

LUBE OIL CONSOLE

COOLINGWATER

(FREE DRAINING)SLOPING

STAINLESSSTEEL LINE

(TYP.)BEARING

TI

TO COILHEATING MEDIUM

(IF REQUIRED)

SEAL OIL CONSOLE PIPING AND INSTRUMENTATION DIAGRAM

DOC NO.

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TRAINING MANUAL - PIPING

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COMPRESSOR

CONTINUOUS

OILRESERVOIR

SEAL OIL CONSOLE

DRAINERS

PUMPS

VENDOR

FILTER

CONTRACTOR

CONTRACTORVENDOR

COOLER

SEAL OILTANK

COMPRESSOR SUCTION DRUM / KNOCKOUT POT

LIQUID OUTLET

WET GAS INLET

DOC NO.

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TRAINING MANUAL - PIPING

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DEMISTER SCREEN

GAS OUTLET

GRADE

BAFFLE

MANTENACE ACCESS

PULSATION DAMPENERS / VOLUME BOTTLES

DOC NO.

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TRAINING MANUAL - PIPING

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PULSATION DAMPNER

ADJUSTABLE SUPPORT

TYPICAL DAMPNER SUPPORT

INLET PULSATION DAMPNER

TEMPORARY START-UPSTRAINER

C COMPRESSORL

VOLUME BOTTLE

OUTLET PULSATION DAMPNER

C SNUBBERL

ALTERNATENOZZLE LOCATIONS