MOL Group - slovnaft.sk fileSLOVNAFT a.s. R&M Division This document is property of MOL Group. The...

SLOVNAFT a.s.

R&M Division

This document is property of MOL Group. The use is only allowed with the written permission of MOL Group.

MOL Group

TECHNICAL SPECIFICATION

INSTRUMENTATION

22. Definition of requirements for the control and safety shutdown of centrifugal, reciprocating and screw

compressors

MGS-S-REF-I-22

Rev 1.00.00

SLOVNAFT a.s. MGS-S-REF-I-22 R&M Division

TECHNICAL SPECIFICATION - INSTRUMENTATION Rev.: 1.00.00

22 Definition of requirements for the control and safety shutdown of centrifugal, reciprocating and screw compressors

Date: 30.11.2011

Page/Pages: 2/4

This document is property of MOL Group. The use is only allowed with the written permission of MOL Group

Release list

Rev. Date Description Edited Verified Approved

1.00.00 30.11.2011 Structural modification Kocsmárszki L. Pallagi


Rev 1.00.00 3/4

Contents Release list ................................................................................................................................................................... 2 Book breakdown ........................................................................................................................................................... 4


4/4 Rev 1.00.00

Book breakdown

Description Identifier Rev.

Definition of requirements for the control and safety shutdown of centrifugal, reciprocating and screw compressors

MGS-S-REF-I-22 1.00.00

Definition of requirements for the control and safety shutdown of centrifugal compressors

MGS-S-REF-I-22.1 1.00.00

Definition of requirements for the control and safety shutdown of reciprocating compressors

MGS-S-REF-I-22.2 1.00.00

Definition of requirements for the control and safety shutdown of multi-stage screw compressors

MGS-S-REF-I-22.3 1.00.00

SLOVNAFT a.s.

R&M Division


MOL Group


INSTRUMENTATION


compressors

1. Definition of requirements for the control and safety shutdown of centrifugal compressors

MGS-S-REF-I-22.1

Rev 1.00.00

SLOVNAFT a.s. MGS-S-REF-I-22.1 R&M Division



Date: 30.11.2011

1 Definition of requirements for the control and safety shutdown of centrifugal compressors

Page/Pages: 2/23


Release list


0.00.00 26.04.2002 Issue of documentation L.Viszkai T.Szabó

0.00.01 20.01.2006

Revision based on the experiences of compressor installations

L.Viszkai R.Batha

0.00.02 31.03.2006 Revision on the basis of MOL comments L.Viszkai R.Batha

1.00.00 30.11.2011 General issue L.Viszkai R.Batha


Rev:. 1.00.00 3/23

Contents Definition of requirements for the control and safety shutdown of centrifugal compressors ........................................ 4 1 General requirements ............................................................................................................................................ 4

1.1 Standards and Specifications ......................................................................................................................... 4 1.2 General Specifications for Instrumentation .................................................................................................... 5 1.3 Documentation requirements ....................................................................................................................... 13

2 Specifications of local control board .................................................................................................................... 15 2.1 General requirements: .................................................................................................................................. 16 2.2 Cabinet construction and finish .................................................................................................................... 16 2.3 Control Functions ......................................................................................................................................... 16 2.4 Items to be installed on the front panel of the local control board ................................................................ 16 2.5 Items to be installed inside the cabinet of the local control board ................................................................ 16 2.6 Certification ................................................................................................................................................... 16 2.7 Documentation ............................................................................................................................................. 16 2.8 Testing and inspections ................................................................................................................................ 17

3 Specifications of main board and cabinets .......................................................................................................... 17 3.1 Requirements on scope of supply ................................................................................................................ 17 3.2 Construction and finish of main (remote control) board ............................................................................... 17 3.3 Control Functions ......................................................................................................................................... 17 3.4 Man machine interface ................................................................................................................................. 18 3.5 Other devices................................................................................................................................................ 18 3.6 Anti Surge Controller .................................................................................................................................... 18 3.7 Speed or capacity Control ............................................................................................................................ 19 3.8 Vibration and Temperature monitoring ......................................................................................................... 19 3.9 Intrinsically safe protection ........................................................................................................................... 20 3.10 Maintenance bypass switches ................................................................................................................. 20 3.11 Testing and inspections ........................................................................................................................... 20 3.12 Shipment .................................................................................................................................................. 20 3.13 Documentation ......................................................................................................................................... 21 3.14 Certification .............................................................................................................................................. 21

4 Specification of anti-surge control system ........................................................................................................... 21 4.1 Scope ............................................................................................................................................................ 21 4.2 Requirements to be satisfied by the anti-surge controller ............................................................................ 21 4.3 Engineering requirements ............................................................................................................................ 21 4.4 System inspection & test .............................................................................................................................. 22 4.5 Test equipment ............................................................................................................................................. 22

5 Appendix: ............................................................................................................................................................. 22 5.1 Standards: .................................................................................................................................................... 22 5.2 Instrument air supply: ................................................................................................................................... 22 5.3 Utilities .......................................................................................................................................................... 22


4/23 Rev.: 1.00.00

DEFINITION OF REQUIREMENTS FOR THE CONTROL AND SAFETY SHUTDOWN OF CENTRIFUGAL COMPRESSORS

1 General requirements

This specification covers the minimum requirements for the, engineering design, manufacturing, assembly and testing of the instrumentation/control system of electric motor driven centrifugal compressor.

The intent of this specification is not to supersede API Standards 617 and 614, but only to supplement, amend or limit them as required.

Exceptions or variations shown in the Basic engineering documentation or Project Specifications and the General Specifications for the Design of Instrumentation & Control Systems take precedence over the requirements shown herein.

No deviations from the Basic engineering documentation or Project Specification and the General Specifications for the design of Instrumentation & Control Systems as well as this specification are permitted unless approved in writing.

Compliance with this specification shall not relieve the responsibility to supply equipment of proper design and construction, ensuring the monitoring, diagnostic, control, alarm, regulation and shutdown functions required for the safe and reliable operation of the system.

It is to be emphasized that depending on the technological application, capacity, construction...etc. of the individual centrifugal compressors, the number of probes for machine protection and the shut/down and alarm conditions may vary from the items specified in this book. In all cases the machine supplier and the customer must consult each other. Also to be emphasized, that the machine protection system be connected to the Refinery’s “on line” diagnostic system as per MGS-M-REF-I-6.6 & MGS-S-REF-I-6.6. Regarding the number of probes and their location is contained in the specification book of machine No.: MGS-M-REF-M-2.1.8 & MGS-S-REF-M-2.1.8.

1.1 Standards and Specifications

1.1.1 EN STANDARDS

EN 60529 Enclosure classes provided by the housings of electrical products

EN 60079-10/14 Electrical apparatus for explosive gas atmospheres – Parts 10 & 14

61508-2/3 Functional reliability of programmable electric & electronic safety systems – Parts 2 & 3

EN 61511 Functional reliability, Safety systems used in the industrial process control sector – Parts 1, 2 & 3

EN 954 Safety of machinery. Safety-related parts of control systems.

EN 60584 Thermocouples

EN 60751 Industrial platinum resistance thermometers and platinum temperature sensors

EN ISO 5167-2 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full. Part 2: Orifice plates

EN 62305 Protection against lightning.

1.1.2 American Petroleum Institute (API) Standards

API 617 Axial and centrifugal compressors and expander-compressors for petroleum, chemical and gas industry services

API 671 Special-purpose couplings for petroleum, chemical and gas industry services

API 677 General-purpose gear units for petroleum, chemical and gas industry services

API 614 Lubrication, shaft-sealing, and control-oil systems for special-purpose applications

API 670 Machinery protection systems

API RP 550 Manual on installation of refinery instruments and control systems

API RP 551 Process measurement instrumentation

API RP 554 Process instrumentation and control


Rev:. 1.00.00 5/23

API RP 686 Machinery installation and installation design

1.1.3 Other International Standards

ISA-S18.1 Annunciator Sequences and Specifications

ISA-5.2 Binary logic diagrams for process operations

ISA-20 Specification forms for process measurement and control instruments, primary elements, and control valves

ISO 3511 Process measurement control functions and instrumentation, symbolic representation

1.1.4 Technical specifications for instrumentation per MOL Group Refineries

MGS-M-REF-I-1, MGS-S-REF-I-1, MGS-M-REF-I-9, MGS-S-REF-I-9,







MGS-M-REF-I-8, MGS-S-REF-I-8,

1.2 General Specifications for Instrumentation

This specification comprise all equipment and devices necessary for compressor measurements, controls (including anti-surge control), alarm annunciation and shutdown functions to be mounted on compressor base-frame, Local Board and Main Board complete with PLC and I/O & termination, galvanic isolation & barriers (Marshalling) cabinets as well as all junction boxes required for the connection of the input & output signals required for the operation of the compressor.

The system drawing of the centrifugal compressor control and safety shut-down system see on attachment No. 1

Unless required otherwise by the project specification, process control for compressor will be performed by Distributed Control System (DCS or ICS) which is to be regarded as existing.

All measured variables of the process, machinery, auxiliary units of machinery (regardless of whether performing indication, control, alarm, shutdown, etc. functions) shall be connected to the DCS for event detection, monitoring, reporting and controlling.

Design Criteria

1.2.1. The centrifugal compressor and its instrumentation/control system shall comply with the applicable safety and instrumentation/control requirements of the standards listed in Section 1.1.

1.2.2. Unless required otherwise by the basic documentation or project specification, the trip & emergency shutdown (ESD) system as well as the automatic control and related shutdown instrumentation shall satisfy the safety integrity level (SIL) of the safety requirement specification (SRS) in the relevant safety book.

1.2.3. The prove test intervals (PTI) shall comply with the specification of the safety requirement specification (SRS) in the safety book.

1.2.4. The maintenance routine within and during the operating cycle shall take into consideration only the inputs and 8 hours of MTTR (main time to repair of failure).

1.2.5. If maintenance override switches (MOS) or process override switches (POS) are used, the relevant requirements of MGS-M-REF-I-6.2 & MGS-S-REF-I-6.2 shall be satisfied.

1.2.6. Shutdown inputs shall be configured to meet the SIL category and spurious trip rate of the safety requirement specification (SRS) in the relevant safety book (e. g. shall be configured in 2003 voting system if max. 10 years spurious trip rate is specified), unless required otherwise by the project specification. The use of maintenance override (MOS) switches is not permissible for 2003 voting shutdown inputs.


6/23 Rev.: 1.00.00

1.2.7. Shutdown signals of main motor shall be displayed with first-out identification in compliance of Specification “F3A” of ISA Standard S18.1 and pre-alarms with ISA S18.1 Type “A” solution if realized on annunciator panel. First-out alarm indication by steady signals can also be realized on DCS operator panel.

1.2.8. Each instrumentation item shall be provided with an English datasheet indicating the tag number, the service description of the measurement and/or control function and the process & construction data (refer to MGS-M-REF-I-5 & MGS-S-REF-I-5 for the specification sheets to be used).

1.2.9. The instrumentation system shall comply with the specifications of EN Standards 60079 respectively, as applicable on the basis of ex-proof protection requirements defined in the basic design engineering or the project specification, and secondary lightning/surge/transient protection shall satisfy the requirements of EN 62305 standard and the valid rules and statues.

1.2.10. All explosion-proof instrumentation items, local control boards and equipment shall be intrinsically safe and certified accordingly, or – where this is not possible – flame-proof (Eexd) enclosures or enhanced (Eexe) protection shall be used and certified in accordance with the hazardous area classification given in the basic design engineering or the project specification. All explosion-proof instruments and equipment shall be certified in compliance with ATEX 94/9 EC (EU 100A) requirements.

1.2.11. Field indicator instruments operating at 70 barg (1000 psig) or higher pressure and all glass tube type level gauges regardless of pressure shall be fitted with check valves closing at high flow rates in order to prevent the escape of process fluids in the case of instrument failure/breakage.

1.2.12. Unless specified otherwise by the project specification, the weather-proof enclosure of field instruments shall satisfy minimum IP65 requirements as specified by EN Standard 60529.

1.2.13. All hook-up lines containing fluids liable to solidify or freeze shall be heat traced as required for the ambient temperature range of –25°C to +60°C.

1.2.14. Transmitters and limit switches or switching instruments used for alarm functions shall provide logic “0” signals (open contacts) when limit values are exceeded. The transmitters or switching instruments providing alarms (pre-alarms) shall be independent from the instruments used for starting and emergency stop. The transmitters or switching instruments used for emergency pre-alarm shall give an output alarm signals and sound the alarm horn before the actuating and emergency shutdown devices are activated.

1.2.15. Transmitters or switches used for starting shall provide logic “0” signals (open contacts) when limit values are reached in order to start e.g. the standby or primary pumps of the lubricating oil and cooling water systems, and – on the contrary – provide logic “1” signals (close contacts) at normal operating values for starting the main driver.

1.2.16. All control/shutdown analogue inputs and outputs shall be galvanically isolated by intrinsically safe barriers and use 4-20 mA signal range, unless required otherwise by the project or basic engineering specifications.

1.2.17. Analogue loops shall include HART communication.

1.2.18. All resistance temperature detectors shall be Platinum 100 (Pt 100) type according to EN Standard 60751.

1.2.19. The use of field-mounted temperature switches (bimetal temperature switches, contact temperature sensors, etc.) shall be avoided as far as possible.

1.2.20. The Boolean logic used for shutdown functions shall be “Negative”, the permission and trip gates shall be logic “AND” gates. The logic blocks of user functions shall be combination type, the use of “Flip-Flop” elements shall be avoided.

1.2.21. All discrete shutdown inputs shall be logic “1” (closed contact) in fault-free (normal operating) status and logic “0” (open contact) in trip (fail) status. Exceptions to this rule may be the limit switches (used e.g. for valve limit positions), which shall give output logic “1” signals in limit position status with the use of proximity sensors.

1.2.22. The break or shorting of electric circuits shall not result in the automatic disabling of shutdown functions.

1.2.23. Starting the main drive motor of the compressor shall be possible only by pressing the START pushbutton on the local control board even in the case of automatic sequential start-up procedure.

1.2.24. Manual emergency shutdown (emergency stop pushbuttons) shall be provided for the compressor both in the control room and on the local control board. A field emergency stop pushbutton located at a safe distance from the compressor may also be used additionally, if required by the tender project specification or specified in the basic design engineering documentation.


Rev:. 1.00.00 7/23

1.2.25. The expired or remaining time of timer settings longer than 3 seconds shall be displayed numerically on the DCS monitors if the control/ESD (emergency shutdown) system is implemented with the use of a fail-safe programmable logic controller (FS PLC).

1.2.26. The running signals shall not be connected to shutdown loops but only can be used in 2oo2 combination with the motor current and may be used for the control of main or auxiliary pumps only in combination with the discharge pressure min./max. limit signals.

1.2.27. The individual limit switch blocks of analogue inputs in the fail-safe PLC shall include alarm outputs for instrument failure but these shall not be connected to the shutdown outputs of the limit switch blocks (unless required otherwise by the basic engineering documentation or project specification). Discrepancy monitoring and display functions shall be provided for analogue and the binary shutdown inputs used in voting system.

1.2.28. Independent pre-alarms shall be provided for all shutdown signals at least on the DCS.

1.2.29. The DCS shall generate sequence of events (SOE) reports (by means of SOE cards in the fail-safe PLC or the DCS system) for all pre-alarm and shutdown signals.

1.2.30. The instrumentation, functional, hardware and software configuration requirements to be satisfied by the local and remote control boards, extended with the associated control room (PLC and Marshalling) cabinets, shall be stipulated in the specifications of the local and remote control boards in this book.

1.2.31. The design of the local & remote control boards as well as of the PLC and Marshalling cabinets shall comply with the requirements of Specifications MGS-M-REF-I-7, MGS-M-REF-I-13, MGS-S-REF-I-7 & MGS-S-REF-I-13.

1.2.32. The hardware and software configuration of the fail-safe PLC shall comply with the requirements of Specifications MGS-M-REF-I-6.2 & MGS-S-REF-I-6.2.

1.2.33. Status signals and shut down alarms shall be displayed on the local and/or remote control boards as well as on the DCS or ICS screens as determined by the list of point 1.2.37. Alarm horn shall be provided both on the local and remote control boards. DCS (or ICS) alarms shall be communicated by redundant serial signal transmission.

1.2.34. The safety instrumented technical solution (including the logic solution) of the control/shutdown system for the centrifugal compressor shall be included in the basic or detailed design engineering documentation of instrumentation.

1.2.35. All instruments ensuring the performance of the functions specified in the applicable API standards, including the following locally installed instruments (where used) shall be taken into consideration as a minimum:

pressure gauge for the main lube oil pump discharge,

pressure gauge for the stand-by lube pump discharge,

pressure gauge for the main lube oil pump suction,

pressure gauge for the stand-by lube pump suction,

pressure gauge for lube oil supply header pressure,

differential pressure gauge for the lube oil filters,

temperature indicator of lube oil at oil cooler inlet,

temperature indicator of lube oil at oil cooler outlet,

pressure gauge for lube oil at oil cooler inlet,

pressure gauge for lube oil at oil cooler outlet,

pressure gauge for the motor lube oil inlet,

pressure gauge for the compressor bearing lube oil inlet,

level indicator of lube oil rundown tank,

flow indicator of lube oil return from compressor,

temperature indicator of lube oil return from compressor,

flow indicator of lube oil return from motor,

temperature indicator of lube oil return from motor,

flow indicator of lube oil return from gear unit (if any),


8/23 Rev.: 1.00.00

temperature indicator of lube oil return from gear unit (if any),

pressure gauge for lube oil supply to gear unit (if any),

temperature indicator of lube oil reservoir,

pressure gauge for the (dry) gas seal gas supply,

differential pressure gauge for the seal gas,

flow indicator of sealing gas on suction side,

flow indicator of sealing gas on discharge side,

pressure gauge for sealing gas filter inlet,

differential pressure gauge for sealing gas filter,

pressure gauge for seal leakage on suction side,

pressure gauge for seal leakage on discharge side,

flow indicator of cooling water,

temperature indicator of cooling water,

indicator for compressor speed,

Note: The compressor Designer determines whether additional measurement and detection point are required or some of them may be omitted.

1.2.36. Utilities:

Electric power supply for instrumentation: see App.

1.2.37. The following alarm, control and shutdown devices shall take into consideration:

Item & Function

Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

1. Motor U, V, W winding temperature high

LB(motor common)-DCS

LM-CM LM-CM (Compr. stop)

2. Compressor thrust bearing (external) temperature high

LB(compressor common)-DCS

LM-CM LM-CM (Note 1)

3. Compressor journal bearing (external) temperature high

LB(compressor common)–DCS


4. Motor shaft journal bearing temperature high

LB(motor common)–DCS


5. Gear thrust bearing temperature high

LB(gear common)-DCS


6. Gear shaft journal bearing temperature high

LB(gear common)-DCS


7. Compressor shaft axial displacement high


LM-CM LM-CM

8. Gear shaft axial displacement high LB(gear common)-DCS


9. Compressor shaft journal bearing vibration high


LM-CM LM-CM

10. Gear shaft journal bearing vibration high

LB(gear common)-DCS


11. Compressor shaft Key- phasor (low/high speed)

MB LM-CM

12. Seal gas filter dP high LB(compressor common)-DCS

LM-CM

13. Seal gas dP low LB(compressor LM-CM LM-CM


Rev:. 1.00.00 9/23

Item & Function

Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

common)-DCS (Compr. stop)

14. Suction side seal gas flow low LB(compressor common)-DCS

LM-CM

15. Discharge side seal gas flow low LB(compressor common)-DCS

LM-CM

16. Separation gas supply pressure low

DCS LM-CM LM-CM (Compr. start prohibit & oil pump stop)

17. Separation gas supply pressure high

DCS LM-CM LM-CM (Compressor stop)

18. Buffer gas supply pressure low LB-DCS LM-CM LM-CM (Start prohibit)

19. Buffer gas suction side flow low/high


LM-CM

20. Buffer gas discharge size flow low/high


LM-CM

21. Buffer gas supply pressure low LB-DCS LM-CM LM-CM (Compressor start inhibit)

22. Buffer gas supply pressure low-low



23. Suction side seal leakage dP high LB(compressor common)-DCS

LM-CM

24. Suction side seal leakage dP high-high



25. Suction side seal leakage rupture disc broken



26. Discharge side seal leakage dP high


LM-CM

27. Discharge side seal leakage dP high-high



28. Discharge side seal leakage rupture disc broken

LB(compressor common)-MB-DCS


29. Lube oil supply header pressure low

DCS LM-CM

30. Lube oil supply header pressure low-low

LB-DCS LM-CM LM-CM (Compr. stop)

31. Lube oil rundown tank nitrogen supply pressure low

LB-DCS LM-CM LM-CM (Start prohibit)

32. Lube oil rundown tank heater temperature low-low / high-high

DCS LM-CM LM-CM (Oil heater ON / OFF)

33. Lube oil rundown tank level high

LB-DCS LM-CM LM-CM (Start permit)

34. Lube oil rundown tank level low LB-DCS LM-CM LM-CM (N2 shut-off & oil heater OFF)

35. Lube oil reservoir level low DCS LM-CM LM-CM (Oil heater OFF & oil pump stop)


10/23 Rev.: 1.00.00

Item & Function

Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

36. Lube oil reservoir heater temp high-high

DCS LM-CM LM-CM (Oil heater OFF)

37. Lube oil reservoir temp. low/high DCS LM-CM LM-CM (Oil Heater ON/OFF)

38. Lube oil pumps discharge pressure high

DCS LM-CM

39. Lube oil temp downstream cooler low

LB-DCS LM-CM LM-CM (Start prohibit)

40. Lube oil filter pressure drop high DCS LM-CM

41. Lube oil pressure downstream filter low

LB-DCS LM-CM LM-CM (Standby pump start)

42. Main/standby lube oil pump start command

LM-CM (Push button)

LM-CM (Pump start)

43. Main/ standby lube oil pump local/remote selector

LM-CM (Switch)

DCS LM-CM LM-CM (Oil pump selection)

44. Main/ standby lube oil pump stop command

LM-CM (Push button)

LM-CM (Oil pump stop)

45. Main/ standby lube oil pump motor running

LB-DCS RM-CS (MCC)

46. Motor purge ON (if EExp protected)

LB-LM-CM (Push button)

LM-CM (Purge valve open & purge timer start)

47. Motor purge OFF (if EExp protected)


LM-CM (Purge valve close & purge timer stop)

48. Motor purge in progress (if EExp protected)

LB-DCS RM-CM

49. Motor purging air flow low DCS LM-CM LM-CM (Purge stop)

50. Motor pressurized (if EExp protected)

DCS RM-CM LM-CM (Compressor start condition)

51. Motor pressurisation failure (pressure low) if EExp protected

LB-DCS LM-CM LM-CM (Compressor start condition & stop)

52. Compressor process gas diff. pressure low

DCS

LM-CM

53. Compressor suction pressure low-low

DCS LM-CM LM-CM (Compr. stop)

54. Compressor suction pressure high DCS LM-CM LM-CM (Start permit)

55. Compressor discharge temperature high-high


56. Compressor discharge pressure low


57. Compressor discharge pressure high



Rev:. 1.00.00 11/23

Item & Function

Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

58. Knock-out drum level high DCS LM-CS LM-CS (Compr. stop)

59. Cooling water pressure low-low LB-DCS LM-CS LM-CS (Compr. stop)

60. Instrument air pressure low-low LB-DCS LM-CS LM-CS (Compr. stop)

61. Compressor suction strainer dP high

DCS LM-CS

62. Compressor flow rate indication DCS(-LB) LM-CS

63. Compressor suction pressure indication

DCS(-LB) LM-CS

64. Compressor discharge pressure indication

DCS(-LB) LM-CS

65. Anti-surge valve open DCS LM-CM LM-CM (Start condition)

66. Surge shutdown signal from anti-surge controller

DCS RM-CM RM-CM (A/S valve open)

67. Failure signal from anti-surge controller

DCS RM-CM RM-CM (A/S valve open)

68. Close permissive command for anti-surge valve

MB-CM (Push button)

DCS RM-CM RM-CM (A/S valve close)

69. Compressor package unit permission to start command

MB-CM (Key-lockable Push button)

LB-MB-DCS RM-CM RM-CM (Compr. package unit start enable)

70. Compressor motor start command LB-CM (Push button)

LM-CM (Compressor motor start)

71. Compressor motor running signal LB-DCS RM-CS (MCC)

72. Compressor motor stop command LB-CM (Push button)

LM-CM (Compr. motor stop)

73. Compressor package unit emergency shut-down command

LB-Field-MB-CM

DCS RM-LM-CM LM-RM-CM (Compr. package unit ESD stop)

74. Compressor package unit stop state alarm

LB-DCS RM-CM

75. Main driver ammeter LB--DCS RM-CS (MCC)

76. Compressor dedicated MOS enable command

MB-RM-FM (Key lockable switch)

RM-FM (MOS condition in the related MOS group)

77. Compressor MOS command RM-FM (DCS or Key lockable switch in control room)

RM-FM (Service override of the related sensor)


12/23 Rev.: 1.00.00

Item & Function

Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

78. Compressor MOS status indication

DCS RM-FM

79. Compressor MOS status remaining time indication

DCS RM-FM

80. Compressor MOS status periodic alarm (in every 8 hours)

DCS RM-FM

81. Compressor dedicated POS command


RM-FM (Override of the related sensor by operator)

82. Compressor POS status indication

MB-DCS RM-FM

83. Compressor POS status remaining time indication

DCS RM-FM

84. Compressor POS status periodic alarm (in every 8 hours)

DCS RM-FM

85. First-out reset command (Main board) if exist

MB-CM (Push button)

86. Annunciator acknowledge command (Main board) if exist

MB-CM (Push button)

87. Lamp test command (Local board) LB-CM (Push button)

88. Lamp test command (Main board)

MB-CM (Push button)

Notes: 1. The shutdown functions for high bearing temperature, axial shaft displacement and shaft

(bearing) vibration signal of the compressor, driver and gear unit will be given in the project or Vendor specifications, respectively. The use of process override (POS) switches for trips shall be taken into consideration.

2. The project specification or compressor designer shall determine if additional points are required for the control system of the compressor and drive train as well as auxiliary units furnished or if certain above points may be omitted.

3. The “common” remark refers to common indication or alarm for separate machine units so; the driver, gear and compressor unit if lamps are installed.

Legend:

CM = Compressor package scope of supply

LM = Locally Mounted (field installed) item

LB = Local Control Board

MB = Main Board (remote control board in control room)

RM = Remote Mounted (installed in control room)

CS = Client’s scope of supply

MCC = Motor Control Centre (cabinet)

DCS = Distributed Control System

DE = Drive-end

NDE = Non drive-end

1.2.38. The thermo wells, the sensors and transmitters for the high-high discharge temperature alarm and emergency shutdown of the compressor shall be the scope of supply unless required otherwise by the


Rev:. 1.00.00 13/23

project or tender specification. One thermo well and one RTD for emergency alarm function shall be installed in the balance line of the compressor (if any) at the elbow adjacent to the discharge nozzle or shall be the scope of supply as loose items. The thermo wells and resistance temperature detectors into the discharge line of each stage in case of multistage compressor shall be also the scope of supply.

1.2.39. Vibration and Axial Displacement Monitoring

1.2.39.1. Proximity probes (X and Y) shall be provided for measuring shaft vibrations occurring adjacent to the radial bearings at the coupling ends of each shaft and adjacent to the transmission components between the fixed gears and the planetary gears in drive gears. Duplex probes shall be provided at the thrust bearings for measuring axial shaft displacements. Velocity or acceleration sensors shall be installed for measuring the vibrations of ball (antifriction) bearings. The vibration monitoring and processing unit shall be suitable for connection to the on-line vibration diagnostics system existing at the facility and shall have a port on its own back side to be able to connect the sensor signals directly. Analogue signals containing vibration spectra shall be provided for said expert system.

1.2.39.2. A separate probe shall be provided on the drive gear for monitoring the “key-phasor” (at the drive end of the compressor) and on the motor. A suitable groove shall be provided in the surface monitored by this probe.

1.2.39.3. Each probe shall be provided with an oscillator-type detector, connection wiring and readout equipment for continuous monitoring unless required otherwise by the project or tender specification. The vibration, axial position, thrust bearing temperature and journal bearing temperature signal processing and display units (monitors) shall be supplied and installed in the Main Board. Temperature signals will be processed by PLC. Duplex PT 100 type resistance temperature detectors shall be used for temperature detection and spare detectors wired up also to the junction boxes.

1.2.39.4. Probes, oscillator-detectors, power supply units and signal processing & display devices shall be supplied from the same manufacturer in order to assure perfect interfacing.

1.2.39.5. The vibration monitoring system shall be considered as an integral part of the compressor package unit.

1.2.39.6. All wiring shall be connected to an explosion-proof junction box at the edge of the base-plate, and shall be designed and certified as intrinsically safe unless required otherwise by the project specification.

1.2.39.7. The Vibration Monitoring System shall be tested and calibrated during the performance tests of the rotating equipment.

1.2.40. The bearings of the compressor, motor and drive gear unit shall be protected against overheating. A Platinum 100 resistance temperature detector shall be installed into each bearing for this purpose. Four-wire system shall be used and the cables shall be connected to a junction box mounted on the base-frame of the compressor unless required otherwise by the project or tender specification.

1.2.41. All local gauges on the compressor and on the accessories of the compressor shall be provided as specified by the API 617 standard or tender specification. The installation of wiring complete with cables and the junction boxes mounted on the base-plate (skid) of the compressor shall also be the scope of supply. The installation shall meet the requirements of API Standard 550 and be of intrinsically safe design unless required otherwise by the project or tender specification.

Signals shall be segregated as follows:

emergency shut-down signals,

alarm signals,

vibration, axial displacement signals,

resistance temperature detector (RTD) signals,

analogue signals.

1.3 Documentation requirements

1.3.1. System drawing and the latest revisions of all documents applicable to consultation and installation.

1.3.2. Piping & Instrumentation Diagram (P&ID) indicating the battery limits (the related design and supply limits) of the compressor and its auxiliary systems, all process data (flow, pressure, temperature values) as well as all instruments with process connections, instrumentation & control functions and signal connections in compliance with the requirements of Specification MGS-M-REF-I-10 & MGS-S-REF-I-10 and ISO Standard 3511. The P&ID shall also contain the isolation, vent, drain and test valves of all local instruments as required by API Standard 617.

1.3.3. The operating description of the system, containing the instructions for the safe starting, stopping and handling of all assemblies and equipment as well as describing the solutions employed for tagname


14/23 Rev.: 1.00.00

generation and systems design (in accordance with Specification MGS-M-REF-I-30.2 & MGS-S-REF-I-30.2).

1.3.4. Cause & Effect Matrix containing all the inputs (from transmitters, limit switches, pushbuttons, selector switches, etc.) as “Cause” by rows and all the final control and actuator elements as “Effect” by columns.

1.3.5. Narrative of ESD functions (in accordance with Specification MGS-M-REF-I-30.8 & MGS-S-REF-I-30.8).

1.3.6. Set-value list in tabulated form for the limit switches and timers of alarm control & shutdown functions (in compliance with Specification MGS-M-REF-I-30.7 & MGS-S-REF-I-30.7).

1.3.7. Complete Boolean logic diagram of the compressor and its auxiliary systems (including anti-surge protection), containing all control, shutdown and emergency or status alarm functions in compliance with Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6. The requirements of ISA Standard S5.2 and Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6 shall be taken into consideration for the symbols of logic elements.

1.3.8. Instrument schedule including in tabular form the following items for each instrument as a minimum:

Tag name

Function/service

Instrumentation items with their main characteristics and parameter such as tag name measurement range, signal range, explosion-proof protection, set-points, etc. (in compliance with Specification MGS-M-REF-I-30.4 & MGS-S-REF-I-30.4).

1.3.9. Instrument datasheets according to ISA Standard S20, completed for purchase order in compliance with the requirements of the applicable MOL Group specifications (Specifications MGS-M-REF-I-5, MGS-M-REF-I-30.9, MGS-S-REF-I-5 & MGS-S-REF-I-30.9) on format and contents

1.3.10. Sizing calculation sheets (in compliance with ISO Standard 5167-2 for orifice plates with manufacturer’s instructions for control valves, etc.).

1.3.11. Loop drawings (in compliance with Specification MGS-M-REF-I-30.14 & MGS-S-REF-I-30.14).

1.3.12. To scale layout drawings of instrumentation items (instrument boxes, other equipment, PLC & marshalling cabinets, local and remote control boards, junction boxes, etc.) complete with material take-off lists (in compliance with Specification MGS-M-REF-I-30.11 & MGS-S-REF-I-30.11).

1.3.13. Data supply for the design of interconnections between junction boxes, control boards and cabinets.

1.3.14. Single-line cabling diagram of the interconnection between the instruments, junction boxes, installed on the compressor skid, control boards and cabinets (in compliance with Specification MGS-M-REF-I-30.15 & MGS-S-REF-I-30.15).

1.3.15. Terminal assignment and wiring diagrams of instrument boxes, other cabinets and junction boxes.

1.3.16. Cable wiring diagrams (in compliance with Specification MGS-M-REF-I-30.17 & MGS-S-REF-I-30.17).

1.3.17. Cable schedule (in compliance with Specification MGS-M-REF-I-30.16 & MGS-S-REF-I-30.16).

1.3.18. Routing and cabling diagrams of interconnections between the centrifugal compressor site (junction boxes, local control board), the control room (equipment, remote control board) and electrical system (high voltage), etc. (in compliance with Specifications MGS-M-REF-I-30.18, MGS-M-REF-I-30.19, MGS-S-REF-I-30.18 & MGS-S-REF-I-30.19).

1.3.19. PLC software documentation with the minimum contents specified below:

PLC program package (PLC-FLD,

Source program of the system

1.3.20. Compressor PLC & DCS I/O list (in compliance with Specification MGS-M-REF-I-30.25 & MGS-S-REF-I-30.25).

1.3.21. Grounding system diagram and data supply for the design of the related local ground network (in compliance with Specification MGS-M-REF-I-30.10 & MGS-S-REF-I-30.10).

1.3.22. Hook-up drawings complete with heat tracing (in compliance with Specification MGS-M-REF-I-30.21 & MGS-S-REF-I-30.21).

1.3.23. Connection drawings of electric power supply for instrumentation & control systems (in compliance with Specification MGS-M-REF-I-30.20 & MGS-S-REF-I-30.20).

1.3.24. Connection scheme of instrument air supply for instrumentation (in compliance with Specification MGS-M-REF-I-30.22 & MGS-S-REF-I-30.22).

1.3.25. Schedule of process connections to instrumentation (in compliance with Specification MGS-M-REF-I-30.24 & MGS-S-REF-I-30.24).


Rev:. 1.00.00 15/23

1.3.26. Schedule of electrical/instrumentation interfaces (in compliance with Specification MGS-M-REF-I-30.23 & MGS-S-REF-I-30.23).

1.3.27. Specifications of other erection materials (junction boxes, cables, transmitter boxes, etc.) (in compliance with Specification MGS-M-REF-I-30.12 & MGS-S-REF-I-30.12).

1.3.28. Certificates explosion-proof protected of instruments and equipment in compliance with Directive ATEX 94/9 (EU 100A).

1.3.29. Bench test reports and OMH (National Office of Measures) approval report of instruments (if required).

1.3.30. List of erection materials (in compliance with Specification MGS-M-REF-I-30.13 & MGS-S-REF-I-30.13).

1.3.31. Spare part lists of instrumentation items.

1.3.32. Certificates explosion-proof protected of instruments and equipment in compliance with Directive ATEX 94/9 (EU 100A)

1.3.33. Manuals of instrumentation items with the minimum contents specified below:

User Guide

Operating Instructions

Functional block schemes

Circuit & wiring diagrams required for maintenance

Mechanical properties and certificates verifying chemical analysis of components wetted by process fluids

Test reports of the vibration and axial displacement monitoring equipment

Maintenance Instructions

1.3.34. Documentation of Anti-Surge System containing as a minimum:

Control scheme

Anti-Surge valve selection and sizing

Valve datasheet

Anti-surge algorithm

Working point display software

1.3.35. Final (as-built) documentation satisfying the minimum requirements specified below:

The final (as-built) documentation shall include separate mark-ups indicating any modifications made during manufacturing or installation.

Source language list about the final programming of the programmed units (PLC, etc.) and the documentation of configured units on electric media.

Manufacturer certificates of the instruments and erection materials used.

Test reports confirming the suitability of the equipment (pressure tests, cable test, shock-protection test, functional test, etc.).

1.3.36. Operating, assembly and maintenance documentation (instructions) with the minimum contents specified below:

Assembly & maintenance instructions

List of special tools including diagnostic instruments

Time schedule of maintenance

Test and set-up methods of control systems with reference to the instrument datasheets and schedules.

Note: The language of documents shall be English and the copies as specified in the project or the tender specification or during the kick-off meeting at the latest.

The Detailed engineering documentation for the construction of the instrumentation system and the as-built documentation shall satisfy the detailed requirements on contents stipulated in Specification MGS-M-REF-I-8 & MGS-S-REF-I-8 and on format in Specification MGS-M-REF-I-9 & MGS-S-REF-I-9 as well as Section 5 of API Standard 617.

2 Specifications of local control board

The function of the local control board is to start, stop and monitor the running conditions of the package unit comprising the compressor, the drive gear unit and the driver (electric motor) as well as the auxiliary units located in hazardous area.


16/23 Rev.: 1.00.00

2.1 General requirements:

All materials and instrumentation items required for the fabrication of the local control board shall be provided,

Fabrication, assembly, wiring, and labelling in the end user language of the local control board at high quality.

Facilities and personnel for witnessed testing and inspection of the local control board.

Quality assurance, inspection and testing complete with the supporting certificates, inspection & test plan, test and calibration certificates.

2.2 Cabinet construction and finish

The structural design of the local control board shall comply with the requirements of Specifications MGS-M-REF-I-7, MGS-M-REF-I-13, MGS-S-REF-I-7 & MGS-S-REF-I-13.

The local control board shall be of EExe type explosion-proof certified design with IP55 enclosure as a minimum, unless required otherwise by the project specification.

2.3 Control Functions

Manual (local) start up of the compressor train including the compressor, driver and auxiliary systems,

Local indication and alarms functions,

Manual local stopping function of the compressor train.

2.4 Items to be installed on the front panel of the local control board

2.4.1. The local control panel shall include the input functions and elements (push buttons, switches), alarm indication devices (e.g. lamps) marked “LB” under Item 1.2.37.

The alarm and start/stop signals will be generated by the PLC located in the control room. The alarm sequences specified by the applicable ISA standard or basic documentation or project or tender specification, will be configured in the PLC. All signals shall have EExi protection, unless required otherwise by the project specification.

If the use of alarm siren or horn is required, it shall be mounted on the top of the control board and its tone shall be different from that of the alarm horn warning of process emergencies. This horn shall be pneumatically operated and actuated by an Eexd protected solenoid valve. The instrument air supply for the pneumatic horn will be specified in project or tender specification.

Each motor driven pump shall be equipped with its own local control panel containing start/stop pushbuttons and local manual selector switches (for local & remote control). If these panels are not specified the pushbuttons and switches need not be located on the local control board.

Each lamp shall be an indicator light fitted with double bulbs and engraved nameplate in the end user language.

2.4.2. Inputs/Outputs

All the digital signals shall be EExi protected, unless required otherwise by the project specification. All digital signals will be powered by the main (remote) control board or its auxiliary cabinet located in safe area.

2.5 Items to be installed inside the cabinet of the local control board

The installed items shall comply with the requirements of Specifications MGS-M-REF-I-7 & MGS-S-REF-I-7.

Internal Eexd protected lighting with EExd protected limit switches shall be installed on the doors.

2.6 Certification

The local control board shall be certified explosion-proof for the hazardous zone level specified in the basic design engineering documentation or project specification.

The local control board shall be delivered with instrumentation items marked CE. All explosion-proof devices shall be furnished with certificates required by Directive ATEX 94/9 (EU 100A).

2.7 Documentation

The documentation of the local control board (local panel) shall comply with the requirements on format and contents stipulated by Specification MGS-M-REF-I-7 & MGS-S-REF-I-7.


Rev:. 1.00.00 17/23

2.8 Testing and inspections

The acceptance and functional tests of the local control board (local panel) shall comply with the requirements on format and contents stipulated by Specifications MGS-M-REF-I-13 & MGS-S-REF-I-13.

3 Specifications of main board and cabinets

The main (remote) control board shall contain all of the equipment and accessory PLC & Marshalling cabinets (hereinafter cabinets) required for the centrifugal compressor train and located in non-hazardous area. The functions of the main (remote) control board and the cabinets are to control, monitoring the operation and to stop the compressor package unit, comprising the compressor, the drive gear unit and the driver (electric motor), located in hazardous area.

3.1 Requirements on scope of supply

All necessary materials and equipment for the main (remote control) board and cabinets,

Assembly & wiring at high quality of the main (remote control) board and cabinets and labelling in the end user language.

Provision of facilities and personnel for witnessed testing and inspection of the main (remote control) board and cabinets.

Quality assurance, inspection & testing together with the supporting certificates, inspection & testing plan, test and calibration certificates.

3.2 Construction and finish of main (remote control) board

The structural design of the main (remote control) board shall comply with the requirements of Specification MGS-M-REF-I-7 & MGS-S-REF-I-7.

Single equipment is to be supplied as the main (remote control) board:

The main control board shall contain the vibration monitoring rack(s), the anti-surge controller, the annunciator panel of the alarm system (if exist), the necessary switches, pushbuttons and other devices marked “MB” under Item 1.2.37. The enclosure of the main control board and the associated auxiliary cabinets shall provide IP20 protection.

Two cabinets shall be supplied as the auxiliary equipment of the main control board, and can be located in central control room (CCR) or satellite control room (SCR) unless specified otherwise by the project or tender specification:

o One cabinet shall contain the fail-safe PLC complete with terminals and accessories,

o The other cabinet shall serve as the Marshalling cabinet and contain all the galvanic isolation barriers, power supply and distributor units, terminal strips, etc.

The cabinets shall be completely assembled, wired and tested.


General requirements to be satisfied by the fail-safe PLC:

The fail-safe PLC shall comply with the requirements of Specification MGS-M-REF-I-6.2 & MGS-S-REF-I-6.2.

The fail safe PLC shall be integrated from DCS manufacturer.

The safety integrity requirements of the fail-safe PLC shall satisfy the highest safety integrity level (SIL) of the safety instrumented functions (SIF), determined by the process hazard analyzes and the risk assessment of the compressor, unless determined otherwise by the project specification.

The fail-safe PLC shall be a 2002D voting type, fault-tolerant, increased availability, self-diagnosing system, unless specified otherwise by the project specification.

The diagnostic coverage shall include also the I/O interfaces.

Hardware requirements to be satisfied by the fail-safe PLC:

Redundant I/O’s shall be provided for all ESD and control/trip functions.

The HOST communication link to the DCS shall also be redundant.

The PLC shall perform the following alarm, control & shutdown functions:

Sequential control of compressor train start-up and stopping,

Internal and external process-related shutdown functions of the operating compressor train,


18/23 Rev.: 1.00.00

Sequential control of auxiliary systems, start-up and stopping (lube oil, seal gas, cooling water…etc. systems)

Provision of process shutdown override function (POS),

Maintenance shut-down override functions (MOS) to permit the testing and maintenance of shutdown devices during operation,

Timestamps for alarms and first-out alarm sequence according to specification “F3A” of ISA Standard S18.1 for annunciator panel or steady signals for DCS operator panel indication.

Sequence of events (SOE) logic display and print-out.

3.3.1 PLC configuration

3.3.1.1. The cycle time of the control/shutdown program shall be less than 100 msec. unless specified otherwise by the project or tender specification.

3.3.1.2. The laptop computer and software for programming of the fail-safe PLC shall be provided.

3.3.1.3. The PC-PLC interconnection (multi-drop) cable shall be 50 m long, unless specified otherwise by the project or tender specification.

3.3.1.4. The spare space and built-in spare shall be provided as specified by the project or tender specification.

3.3.2 Additional requirements

RS 232/485 port for printing by PC

On line configuration facility without shut-down

The communication between the Marshalling cabinet – main (remote control) board – PLC cabinet – local control board shall be hard-wired.

SIL (Safety Integrity Level) certification shall be provided if required because of classification.

The fail-safe PLC cabinet shall be completely assembled, wired, configured and tested.

3.4 Man machine interface

The alarm annunciation system shall manage all the main motor shutdown inputs of the compressor unit plus the shutdown signals received from the process system.

3.5 Other devices

Electric Horn (The tone shall be different from that of the process alarm horn).

Power supply

Cable protection components

3.6 Anti Surge Controller

Anti-surge control shall be managed by a separate controller. This controller shall control the discharge flow of the compressor in relation to the discharge pressure of the compressor by means of the recirculation valve in order to prevent the development of surge conditions in the compressor and minimise the recirculation flow as well in order to optimise the efficiency of the compressor. The controller shall handle the following analogue input and outputs as a minimum:

Compressor suction pressure

Compressor suction temperature

Compressor discharge pressure

Compressor discharge temperature

Compressor suction/discharge flows

Anti-surge control valve with I/P converter

A non-redundant serial line with MODBUS protocol shall be provided for communication between the controller and the DCS system.

The software package required for displaying the compressor curve and working point shall be provided complete with the following items as a minimum:

Display software license

Display software set-up

Display software configuration.


Rev:. 1.00.00 19/23

3.7 Speed or capacity Control

Speed control shall be provided either by a frequency converter unit or a variable hydraulic coupling unit, or eventually by some equipment unless specified otherwise by the project or tender specification. This specific controller shall be installed in the main (remote control) board. A frequency converter unit of non-special system may be acceptable below 400 kVA power consumption.

Vendor shall specify the method of speed or capacity control and the requirements of the associated alarm-regulation-shutdown functions, unless required otherwise by the project specification.

3.8 Vibration and Temperature monitoring

3.8.1 Vibration monitoring:

The vibrations of the compressor train shall be monitored by a separate vibration monitoring unit.

Unless specified otherwise by the project or tender specification, the monitoring unit shall receive and process the following signals as a minimum:

Motor:

Drive end journal bearing: X-Y Input

Non drive end journal bearing: X-Y Input

Gear Unit:

HSS Key-phasor: KE Input

HSS Drive end journal bearing: X-Y Input

HSS Non drive end journal bearing: X-Y Input

LSS Thrust bearing displacement: Z-Z Input

LSS Drive end journal bearing: X-Y Input

LSS Non drive end journal bearing: X-Y Input

LSS Key-phasor: KE Input

(HSS = high speed shaft; LSS = low speed shaft)

Compressor:



Thrust bearing axial displacement: Z-Z Input

The rack-mounted vibration monitoring unit shall comprise the following items as a minimum:

19” rack chassis

Power supply module (redundant)

System monitoring module

Monitor modules for proximity sensors

Monitor modules for velomitor sensors

Monitor modules for temperature detectors

Key-phasor module

Relay module for ESD

Interface module for serial communication with DCS

Each module shall provide hardwired digital outputs to the PLC for alarm and shutdown functions.

3.8.2 Temperature monitoring

The temperatures of the machines shall be monitored by the PLC.

Unless specified otherwise by the project or tender specification the following temperatures shall be monitored as a minimum:

Driver (motor):

Drive-end journal bearing

Non drive end journal bearing

U, V, W, windings

Gear:


20/23 Rev.: 1.00.00

HSS Drive-end journal bearing

HSS Non drive-end journal bearing

LSS Thrust bearing internal

LSS Non drive bearing external

LSS Drive-end journal bearing

LSS Non drive-end journal bearing


Compressor:

Compressor drive-end journal bearing

Compressor non drive-end journal bearing

Compressor thrust bearing internal

Compressor non drive end bearing external

Note: The project specification or compressor designer shall determine if additional sensors are required for the control system of the compressor and drive train furnished or if certain above points may be omitted.

3.9 Intrinsically safe protection

Unless specified otherwise by the project or tender specification, Zener barriers shall be provided for all the vibration, axial displacement and key-phasor signals of the compressor train. All the analogue and digital signals between the skid-mounted instruments, the local control board and the main (remote control) board and cabinets located in the control room shall be connected through intrinsically safe galvanic isolators.

3.10 Maintenance bypass switches

The dedicated (hard wired) maintenance bypass (MOS) switches shall be installed in the lockable PLC or Marshalling cabinet and used for shutdown override only for maintenance purposes in accordance with the operating instructions. If certified, software switch on the maintenance display also can be used by maintenance personnel, protected by maintenance pass word.

The SIL (Safety Integrity Level) requirements and DCS as well as the requirements of MGS-M-REF-I-6.2 & MGS-S-REF-I-6.2 shall be taken into consideration for the use of MOS switches.


The control system shall be tested and inspected according to the testing and inspection procedures of the MGS-M-REF-I-13 & MGS-S-REF-I-13 requirements. The test and inspection procedures shall comply with the requirements of the ISO 9001 specifications also.

Hardware and software shall also be tested.

NOTE:

The anti-surge controller needs to be tested only during the Site Acceptance Test (SAT).

3.11.1 Acceptance Tests

The following inspections and tests shall be carried out:

Visual inspection of all equipment and their parts and spare parts,

Test bench checking and disassembly,

Performance test,

Checking of documentation

Control test of main (remote control) board and cabinets (for control & shutdown functions, alarm annunciation, pushbuttons functionality, etc.)

3.11.2 Functional Test

After the successful commissioning of all equipment and the completion of the necessary adjustments and tuning, it shall be verified that the main (remote) control board, the cabinets and their parts and auxiliary equipment operate without problems and comply as a whole and in all parts with the requirements specified in the technical documents.

3.12 Shipment

The main (remote control) board and the cabinets shall be cleaned, properly wrapped in polyethylene foil and packed in wooden boxes on pallets.


Rev:. 1.00.00 21/23

3.13 Documentation

The standard drawings and document listed below shall be delivered after the receipt of order or according to the documentation delivery schedule as a minimum:

Front view and general arrangement drawing of main (remote control) board and cabinets

Wiring Diagram

Boolean logic Diagram

Terminal assignment

List of materials

Spare parts list

Operating and Maintenance Manual

PLC programs & codes

3.14 Certification

The main (remote control) boards and cabinets shall be supplied with CE marked devices. All the galvanic isolators and Zener barriers shall be furnished with ATEX 94/9 EC (EU 100A) certificates.

4 Specification of anti-surge control system

4.1 Scope

4.1.1. The hardware, cables, software, engineering documentation and tests required for satisfying all the functions specified below shall be provided. The anti-surge controller and associated hardware items shall be installed in the main control cabinet with all wiring, terminal and power distribution equipment installed, tested and certified in compliance with the hazardous area classification applicable to the installation site.

4.1.2. The system configuration, system integration, control algorithms and logic shall be complied with the requirements of the system drawing and operability. All software applications and engineering work shall be complete, with no additional programming required.

4.1.3. It shall be demonstrated by a functional test that the anti-surge control system provides all the functions defined in this specification and satisfies the requirements of safe and reliable monitoring, control and shutdown actions.

4.2 Requirements to be satisfied by the anti-surge controller

4.2.1. The anti-surge controller shall control and manipulate the recirculation flow control valve so as to maintain an adequate but not excessive margin of safety between the working point and surge limit of the compressor. The inputs to the anti-surge controller shall be as a minimum: suction pressure & temperature and discharge flow, pressure and temperature.

4.2.2. The anti-surge controller shall incorporate a surge detector and a surge cycle counter. Surge detection shall be based on comparing the rate of change in the flow and/or suction pressure to user-configurable limits. Provisions must also be made for recording and displaying the maximum observed rate-of-change for each of variable, using these threshold values as the basis for determining the results of the surge test conducted on the given machine.

4.2.3. Provision must be made for resetting the surge counter located on the front panel of the controller.

4.2.4. The anti-surge controller shall fully open the recirculation valve upon compressor shutdown and fully close it during purging operations. These statuses shall be selectable by discrete inputs and/or on the basis of the speed, flow rate and suction pressure of the compressor.

4.2.5. The anti-surge controller shall utilise serial digital communications for exchanging information with higher-level computers or control systems using the Modbus RTU protocol.

4.3 Engineering requirements

The following engineering services shall be provided in order to define the anti-surge control scheme:

4.3.1 Definition of Control

The optimum control system design which will protect the compressor from surge conditions shall be developed.


22/23 Rev.: 1.00.00

4.3.2 Design Review

The piping system, the locations of vessels, flow meters, check valves, recirculation valves and line lengths shall be reviewed in order to ensure optimum anti-surge protection and energy efficiency.

4.3.3 Engineering Specifications

4.3.3.1. Specific recommendations shall submit for the selection of transmitters and flow sensors in order to ensure proper interfacing with the anti-surge control system. The recirculation control valve complete with limit switches, the valve positioner and pneumatic power booster shall be the compressor scope of supply.

4.3.3.2. The data of the above mentioned instrumentation items on specification sheets stipulated by ISA Standard S20 shall be specified.

4.4 System inspection & test

This activity shall be completed on the compressor, the piping system, the primary control elements, the check valves and the instrumentation. The primary control elements shall be calibrated and checked for accuracy, repeatability and response time. The transmitters and transducers shall be calibrated.

4.4.1 Inspection & testing of the compressor anti-surge control system

The wiring of the anti-surge controller and associated hardware (including power supply, grounding, shielding, insulation) shall be checked. The anti-surge controller shall be powered up and the acceptability of installation shall be evaluated. The calibration and the functionality of the required algorithm of the anti-surge controller shall be checked by Vendor in order to verify the parameters.

4.5 Test equipment

PC-based configuration and trouble-shooting software for the anti-surge control system shall be provided by Vendor. The diagnostic channels of the controller shall be pre-wired and interchangeable. All necessary hardware shall include a standard DIN type connector for connection to the RS232 PC port.

5 Appendix:

5.1 Standards:

STN 33 2000-4-442 Electrical installations of buildings. Part 4: Protection for safety. Chapter 44: Protection against over voltages. Section 442: Protection of low-voltage installations against faults between high-voltage systems and earth.

STN 33 2000-4-41 Low-voltage electrical installations Part 4-41:Protection for safety Protection against electric shock

5.2 Instrument air supply:

Pressure range: 0,45-0,6 MPa

Temperature range: 30-45 °C

Dew point: -25°C

Note: The typical characteristics of instrument air supply are specified in the book No.: MGS-M-REF-I-4 & MGS-S-REF-I-4 however the characteristics are refinery and individual compressor specific, so the exact characteristics are specified in the project specification.

5.3 Utilities

ad. 1.2.36.

Electric power supply for instrumentation:

230 VAC ±5%, 50 Hz±3% UPS

24 VDC ±5% (convertor 230 VAC/24 VDC powered by UPS)

Field switches: 24 VDC

Solenoids: 24 VDC or 230 VAC UPS

Heat tracing: 230 VAC non-UPS

Lighting: 230 VAC non-UPS


Rev:. 1.00.00 23/23

SLOVNAFT a.s.

R&M Division


MOL Group


INSTRUMENTATION


compressors

2. Definition of requirements for the control and safety shutdown of reciprocating compressors

MGS-S-REF-I-22.2

Rev 1.00.00




Date: 30.11.2011

2 Definition of requirements for the control and safety shutdown of reciprocating compressors

Page/Pages: 2/21


Release list






Rev:. 1.00.00 3/21

Contents 1 General requirements ............................................................................................................................................ 4

1.1 Standards and Specifications ......................................................................................................................... 4 1.2 General specifications for instrumentation ..................................................................................................... 5 1.3 Documentation requirements ....................................................................................................................... 13

2 Specifications of local control board .................................................................................................................... 15 2.1 General requirements: .................................................................................................................................. 15 2.2 Cabinet construction and finish .................................................................................................................... 15 2.3 Control Functions ......................................................................................................................................... 16 2.4 Items to be installed on the front panel of the local control board ................................................................ 16 2.5 Items to be installed inside the cabinet of the local control board ................................................................ 16 2.6 Certification ................................................................................................................................................... 16 2.7 Documentation ............................................................................................................................................. 16 2.8 Testing and inspections ................................................................................................................................ 16

3 Specifications of main (remote control) board and cabinets ............................................................................... 16 3.1 Requirements on scope of supply ................................................................................................................ 17 3.2 Construction and finish of main (remote control) board ............................................................................... 17 3.3 Control Functions ......................................................................................................................................... 17 3.4 Man machine interface ................................................................................................................................. 18 3.5 Other devices:............................................................................................................................................... 18 3.6 Speed or Capacity Control ........................................................................................................................... 18 3.7 Vibration and Temperature monitoring ......................................................................................................... 18 3.8 Intrinsically safe protection ........................................................................................................................... 19 3.9 Maintenance bypass switches ...................................................................................................................... 19 3.10 Testing and inspections ........................................................................................................................... 19 3.11 Shipment .................................................................................................................................................. 20 3.12 Documentation ......................................................................................................................................... 20 3.13 Certification .............................................................................................................................................. 20

4 Appendix: ............................................................................................................................................................. 20 4.1 Standards: .................................................................................................................................................... 20 4.2 Instrument air supply: ................................................................................................................................... 20 4.3 Utilities .......................................................................................................................................................... 20


4/21 Rev.: 1.00.00

DEFINITION OF REQUIREMENTS FOR THE CONTROL AND SAFETY SHUTDOWN OF RECIPROCATING COMPRESSORS


This specification covers the minimum requirements for the engineering design, manufacturing, assembly and testing of the instrumentation/control system of electric motor driven reciprocating compressor.


Exceptions or variations shown in the Basic engineering documentation or Project Specifications and the General Specifications for the Design of Instrumentation & Control Systems take precedence over the requirements shown herein.

No deviations from the Project Specification and the General Specifications for the Design of Instrumentation & Control Systems as well as this specification are permitted unless approved in writing. Compliance with this specification shall not relieve the responsibility to supply equipment of proper design and construction, ensuring the monitoring, diagnostic, control, alarm, regulation and shutdown functions required for the safe and reliable operation of the system.

It is to be emphasized that depending on the technological application, capacity, construction...etc. of the individual reciprocating compressors, the number of probes for machine protection and the shut/down and alarm conditions may vary from the items specified in this book. In all cases the machine supplier and the customer must consult each other. Also to be emphasized, that the machine protection system be connected to the Refinery’s “on line” diagnostic system as per MGS-M-REF-I-6.6 & MGS-S-REF-I-6.6. Regarding the number of probes and their location is contained in the specification book of machine No.: MGS-M-REF-M-2.1.8 & MGS-S-REF-M-2.1.8.


1.1.1 EN STANDARDS


60079-10/14 Electrical equipment in explosive atmospheres – Parts 10 & 14

EN 61508-2/3 Functional reliability of programmable electric & electronic safety systems – Parts 2 & 3

EN 61511 Functional reliability, Safety systems used in the industrial process control sector – Parts 1, 2 & 3,

EN 954 Safety of machinery, safety-related parts of control systems

EN 60584 Thermocouples – Parts 1 & 2


EN 62305 Protection against lightning.


API 618 Reciprocating compressors for petroleum, chemical and gas industry services



API 614 Lubrication, shaft-sealing, and control-oil systems and auxiliaries for petroleum, chemical and gas industry services


API RP 550 Installation of refinery instruments and control systems





Rev:. 1.00.00 5/21















1.2 General specifications for instrumentation

This specification comprise all equipment and devices necessary for compressor measurements, controls (including load control), alarm annunciation and shutdown functions to be mounted on compressor base-frame, Local Board and Main Board complete with PLC and I/O & termination, galvanic isolation & barriers (Marshalling) cabinets as well as all junction boxes required for the connection of the input & output signals required for the operation of the compressor.

The system drawing of the reciprocating compressor control and safety shut-down system see on attachment No. 1

Unless required otherwise by the project specification process control for the compressor will be performed by an existing Distributed Control System (DCS or ICS) which is to be regarded as existing.

All measured variables of the process, machinery, auxiliary units of machinery (regardless of whether performing indication, control, alarm, shutdown, etc. functions) shall be connected to the DCS for event detection, monitoring, reporting or controlling.

Design Criteria

1.2.1. The reciprocating compressor and its instrumentation/control system shall comply with the applicable safety and instrumentation/control requirements of the standards listed in Section 1.1.

1.2.2. Unless required otherwise by the basic documentation or project specification, the trip & emergency shutdown (ESD) system as well as the automatic control and related shutdown instrumentation shall satisfy shall satisfy the safety integrity level (SIL) of the safety requirement specification (SRS) in the relevant safety book.







6/21 Rev.: 1.00.00

1.2.8. Each instrumentation item shall be provided with an English datasheet indicating the tag number, the service description of the measurement and/or control function and the process & construction data (refer to MGS-M-REF-I-5 & MGS-S-REF-I-5 for the specification sheets to be used).

1.2.9. The instrumentation system shall comply with the specifications of EN Standards 60079 respectively, as applicable on the basis of ex-proof protection requirements defined in the basic design engineering or the project specification, and secondary lightning/surge/transient protection shall satisfy the requirements of EN Standard 62305 standard and the valid rules and statues.

1.2.10. All explosion-proof instrumentation items, local control boards and equipment shall be intrinsically safe and certified accordingly, or – where this is not possible – flame-proof (Eexd) enclosures or enhanced (Eexe) protection shall be used and certified in accordance with the hazardous area classification given in the basic design engineering or the project specification. All explosion-proof instruments and equipment shall be certified in compliance with ATEX 94/9 EC (EU 100A) requirements.

1.2.11. Field indicator instruments operating at 70 barg (1000 psig) or higher pressure and all glass tube types level gauges regardless of pressure shall be fitted with check valves closing at high flow rates in order to prevent the escape of process fluids in the case of instrument failure/breakage.

1.2.12. Unless specified otherwise by the project specification the weather-proof enclosure of field instruments shall satisfy minimum IP65 requirements as specified by EN Standard 60529.






1.2.18. All resistance temperature detectors shall be Platinum 100 (Pt 100) type according to EN Standard 60751.






1.2.24. Manual emergency shutdown means (emergency stop pushbuttons) shall be provided for the compressor both in the control room and on the local control board. A field emergency stop pushbutton located at a safe distance from the compressor may also be used additionally, if required by the project specification or specified in the basic design engineering documentation.




Rev:. 1.00.00 7/21

1.2.27. The individual limit switch blocks of analogue inputs in the fail-safe PLC shall include alarm outputs for instrument failure but these shall not be connected to the shutdown outputs of the limit switch blocks (unless required otherwise by the basic engineering documentation or project specification). Discrepancy monitoring and display functions shall be provided for analogue and the binary shutdown inputs used in voting system.




1.2.31. The design of the local & remote control boards as well as of the PLC and Marshalling cabinets shall comply with the requirements of Specifications MGS-M-REF-I-7, MGS-M-REF-I-13, MGS-S-REF-I-7 & MGS-S-REF-I-13.



pressure gauge for the main lube oil pump discharge,

pressure gauge for the stand-by lube oil pump discharge,

pressure gauge for the lube oil pump common header discharge,

temperature indicator of the lube oil pump common header discharge,

temperature indicator of the lube oil after cooler

differential pressure gauge for the lube oil filter

pressure gauge for the lube oil main header

temperature indicator of lube oil main header

pressure gauge for inert gas inlet/outlet

level indicator of lube oil reservoir

pressure gauge for compressor discharge

temperature indicator of cylinder discharge dampener

level indicator of suction drain pot

temperature indicator of cooling water pumps outlet header

temperature indicator of cooling water main header

pressure gauge for cooling water pumps outlet header

temperature indicator of cooling water tank,

pressure gauge for cooling water tank,

pressure gauge for the compressor bearing lube oil inlet,

temperature indicator of cylinder jackets cooling water outlet

temperature indicator of cylinder packings cooling water outlet

flow indicator of cylinder jackets cooling water outlet

flow indicator of cylinder packings cooling water outlet

flow indicator of lubricator

Note The compressor Designer determines whether additional measurement and detection point are required or some of them may be omitted,

1.2.34. Utilities:




8/21 Rev.: 1.00.00

Item & Function Command Source

Alarm Annunciation

Location

Alarm Source

Shutdown Source

1. Motor U, V, W winding temp. high

LB(Motor common)-DCS

LM-CM LM-CM (Compr. Stop)

2. Motor NDE bearing temp. high

DCS LM-CM

3. Compressor DE bearing temp. high

DCS LM-CM

4. Compressor NDE bearing temp. high

DCS LM-CM

5. Compressor crankshaft bearing temp. high

DCS LM-CM

6. Crankcase DE vibration high DCS LM-CM

7. Crankcase DE vibration high-high

LB (compressor common)-DCS

LM-CM LM-CM (Note: 1)

8. Crankcase NDE vibration high

DCS LM-CM

9. Crankcase NDE vibration high-high



10. Rod drop high DCS LM-CM

11. Compressor shaft key-phasor low/high speed

MB LM-CM

12. Seal gas inlet pressure low

DCS LM-CM LM-CM (Start inhibit)

13. Seal gas inlet flow low


14. Seal gas outlet temp. high

DCS LM-CM

15. Cylinder distance piece purge gas inlet flow low


16. Lube oil reservoir level low

DCS LM-CM LM-CM (Compr. & heating inhibit lube oil pump stop) 17. Lube oil reservoir

temp. low/high DCS LM-CM LM-CM

(Heating control)

18. Lube oil reservoir heater temp. high-high

LB-DCS LM-CM LM-CM (Heating stop & compressor start inhibit)

19. Main/stand-by lube oil pump start/stop command

LM-CM (P.B.)

LM-CM (Pump Start/stop)

20. Main/stand-by lube oil pump local/remote switch

LM-CM (switch)

DCS LM-CM

21. Main/stand-by lube oil pump running signal

LB-DCS RM-CS (MCC)

22. Lube oil filter dP. high DCS LM-CM

23. Lube oil cooler inlet temp low

DCS LM-CM


Rev:. 1.00.00 9/21


Alarm Annunciation

Location

Alarm Source

Shutdown Source

24. Lube oil header temp. low

DCS LM-CM LM-CM (Compr. Start inhibit)

25. Lube oil header pressure low

LB (Lube oil common)-DCS

LM-CM LM-CM (Stand-by pump start)

26. Lube oil header pressure low-low (2003)

LB (Lube oil common)-DCS


27. Lubricator pump start/stop command

LM-CM (P.B.)


28. Lubricator pump local/remote switch

LM-CM (Switch)

DCS LM-CM

29. Lubricator pump running signal

LB-DCS RM-CS (MCC)

30. Cylinder lubricator tank level low


31. Cylinder lubricator heater temp. high-high

LB-DCS LM-CM LM-CM (Heating stop & compr. Start inhibit)

32. Cylinder lubricator pressure low

DCS LM-CM

33. Cylinder lubricator pressure low-low (2oo3)

DCS LM-CM LM-CM (Compr. Stop)

34. Cylinder lubricator oil flow low-low (2oo3)

DCS LM-CM LM-CM (Kompr. Stop)

35. Cooling water header inlet temperature low


36. Cooling water header inlet pressure low


37. Cooling water flow low (Compr. inlet)


38. Cylinder coolant jacket water outlet temperature high

DCS LM-CM

39. Cylinder packing cooling water outlet temperature high

DCS LM-CM

40. Cooling water header outlet temp. high

DCS LM-CM

41. Cooling water tank temperature low/high

DCS LM-CM LM-CM (Heating control)

42. Cooling water tank heater temperature high-high

LB-DCS LM-CM LM-CM (Heating stop & compr. start inhibit)

43. Cooling water tank level low

DCS LM-CM LM-CM (Cooling water pump & heating stop, compr. start inhibit)

44. Cooling water tank level low-low (2oo3)


45. Main/stand-by cooling water pump start/stop command

LM-CM (P.B.)


46. Main/stand-by cooling water pump local/remote switch

LM-CM (Switch)

DCS LM-CM


10/21 Rev.: 1.00.00


Alarm Annunciation

Location

Alarm Source

Shutdown Source

47. Main/stand-by cooling water pump running signal

LB-DCS RM-CS (MCC)

48. Cooling water pump discharge header pressure low

LB-DCS LM-CM LM-CM (Stand-by pump start & compr. start inhibit)

49. Cylinder outer end inlet valve temp. high

DCS

LM-CM

50. Cylinder frame end inlet valve temp. high

DCS LM-CM

51. Cylinder outer end discharge valve temperature high

DCS LM-CM

52. Cylinder frame end discharge valve temperature high

DCS LM-CM

53. Compressor by-pass valve open

DCS LM-CM LM-CM (Compr. start permission)

54. Barring device withdrawn limit position

LB-DCS LM-CM LM-CM (Compr. start & operation condition)

55. Barring device pushed limit position

LB-DCS LM-CM LM-CM (Barring device start condition.)

56. Motor purge on (if EExp protected)

LB-LM-CM (P.B.)


57. Motor purge off (if EExp protected)

LB-LM-CM (P.B.)

DCS LM-CM LM-CM (Purge valve close & purge timer reset)


LB-DCS LM-CM

59. Motor purge medium flow low (1001) (if EExp protected)

DCS LM-CM LM-CM (Purge stop)

60. Motor purge completed (if EExp protected)

DCS RM-CM RM-CM (Compr. start condition.)

61. Motor pressurization failure (2003) (if EExp protected)

LB-DCS LM-CM LM-CM (Compr. start inhibit & stop)

62. Compressor unit ready to start

LB-DCS RM-CM

63. Compressor unit ready to load

LB-DCS RM-CM

64. Load selector switch; (At manual step-by-step load control)

LB-MB CM LM-RM-CM (load selection)

65. SOR, EOR selector switch (At manual step-by-step load control)

MB-CM DCS RM-CM RM-CM (SOR, EOR selection)


Rev:. 1.00.00 11/21


Alarm Annunciation

Location

Alarm Source

Shutdown Source

66. Local/Remote load selection (At manual step-by-step load control)

MB DCS RM-CM RM-CM (Load control site selection))

67. Load indication LB-DCS RM-CM

68. Suction dampener pressure low

DCS LM-CM

69. Suction dampener pressure low-low (2oo3)



70. Suction dampener drain level high

DCS LM-CM

71. Suction dampener drain level high-high (2oo3)



72. Cylinder discharge damp. Temperature high

DCS LM-CM

73. Cylinder discharge dampener temp. high-high (2oo3)



74. Compressor discharge pressure high

DCS LM-CM

75. Compressor discharge pressure high-high (2oo3)



76. Suction K.O. drum level high-high (2oo3)


LM-CS LM-CS (Compr. stop)

77. Cooling water inlet pressure low-low (2oo3)

LB-DCS LM-CS LM-CS (Compr. stop)

78. Instrument air inlet pressure low-low (2oo3)

LB-DCS LM-CS LM-CS (Compr. stop)

79. Compressor unit start permission

MB-CM (Key lockable

P.B.)

LB-MB-DCS RM-CM RM-CM (Compr. unit start permission)

80. Compressor main motor start/stop command

LB-CM (P.B.)

LM-CM (Compr. motor Start/Stop)

81. Compressor main motor lock switch

LB-CM (switch)

LB-DCS LM-CM

82. Compressor main motor running signal

LB-DCS RM-CS (MCC)

83. Compressor main motor ESD stop command

LB-Field-MB-CM

DCS RM-LM-CM

LM-RM-CM (Compr. unit ESD Stop)

84. Compressor unit stop status

LB-DCS RM-CM

85. Compressor main motor ammeter

LB RM-CS (MCC)


MB-RM-FM (Key lockable

switch)



12/21 Rev.: 1.00.00


Alarm Annunciation

Location

Alarm Source

Shutdown Source

87. Compressor MOS command RM-FM (DCS or Key

lockable switch in

control room)



DCS RM-FM


DCS RM-FM


DCS RM-FM


MB-RM-FM (Key lockable

switch)



MB-DCS RM-FM


DCS RM-FM

94. Heater POS status periodic alarm (in every 8 hours)

DCS RM-FM


MB-CM (Push button)


MB-CM (Push button)

97. Lamp test command LB (CM)

98. Lamp test command MB (CM)

Notes: 1. The shutdown functions for high bearing temperature and vibration signal of the compressor, driver and gear unit will be given in the project or Vendor specifications, respectively. The use of process override (POS) switches for trips shall be taken into consideration.


3. The “common” remark refers to common indication or alarm for separate machine unit so; the driver, compressor or lube oil unit if lamps are installed.

Legend:









DE = Drive-end

NDE = Non drive-end


Rev:. 1.00.00 13/21

1.2.36. The thermo wells, the sensors and transmitters for the high-high discharge temperature alarm and emergency shutdown of the compressor shall be the scope of supply unless required otherwise by the project or tender specification. One thermo well and one RTD for emergency alarm function shall be installed in the balance line of the compressor (if any) at the elbow adjacent to the discharge nozzle or shall be the scope of supply as loose items. The thermo wells and resistance temperature detectors into the discharge line of each stage in case of multistage compressor also shall be the scope of supply.

1.2.37. Vibration monitoring

1.2.37.1. Dual velocity probes shall be provided for measuring shaft vibrations occurring adjacent to the radial bearings at the coupling ends of each shaft and adjacent to the transmission components between the fixed gears and the planetary gears in drive unit. The vibration monitoring and processing unit shall be suitable for connection to the on-line vibration diagnostics system existing at the facility and shall have a port on its own back side to be able to connect the sensor signals directly. Analogue signals containing vibration spectra shall be provided for said expert system.

1.2.37.2. A separate probe shall be provided on the drive gear for monitoring the “key-phasor”. A suitable groove shall be provided in the surface monitored by this probe.

1.2.37.3. Each probe shall be provided with an oscillator-type detector, connection wiring and readout equipment for continuous monitoring unless required otherwise by the project or tender specification. The vibration and journal bearing temperature signal processing and display units (monitors) shall be supplied and installed in the Main Board. Temperature signals will be processed by PLC. Duplex PT 100 type resistance temperature detectors shall be used for temperature detection and spare detectors wired up also to the junction boxes.

1.2.37.4. Probes, oscillator-detectors, power supply units and signal processing & display devices shall be purchased from the same manufacturer in order to assure perfect interfacing.



1.2.37.7. The Vibration Monitoring System shall be tested and calibrated during the performance tests of the rotating equipment.

1.2.38. The bearings of the compressor, motor and drive gear unit shall be protected against overheating. A Platinum 100 resistance temperature detector shall be installed into each bearing for this purpose. Four-wire system shall be used and the cables shall be connected to a junction box mounted on the base-frame of the compressor unless required otherwise by the project or tender specification.

1.2.39. All local gauges on the compressor and on the accessories of the compressor shall be provided as specified by the API 618 standard or tender specification. The installation of wiring complete with cables and the junction boxes mounted on the base-plate (skid) of the compressor shall also be the scope of supply. The installation shall meet the requirements of API Standard 550 and be of intrinsically safe design unless required otherwise by the project or tender specification.



alarm signals,

vibration signals,


analogue signals.



1.3.2. Piping & Instrumentation Diagram (P&ID) indicating the battery limits (the related design and supply limits) of the compressor and its auxiliary systems, all process data (flow, pressure, temperature values) as well as all instruments with process connections, instrumentation & control functions and signal connections in compliance with the requirements of Specification MGS-M-REF-I-10 & MGS-S-REF-I-10 and ISO Standard 3511. The P&ID shall also contain the isolation, vent, drain and test valves of all local instruments as required by API Standard 618.

1.3.3. The operating description of the system, containing the instructions for the safe starting, stopping and handling of all assemblies and equipment as well as describing the solutions employed for tag name generation and systems design (in accordance with Specification MGS-M-REF-I-30.2 & MGS-S-REF-I-30.2).


14/21 Rev.: 1.00.00



1.3.6. Set-value list in tabulated form for the limit switches and timers of alarm, control & shutdown functions (in compliance with Specification MGS-M-REF-I-30.7 & MGS-S-REF-I-30.7).

1.3.7. Complete Boolean logic diagram of the compressor and its auxiliary systems, containing all control, shutdown and emergency or status alarm functions in compliance with Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6. The requirements of ISA Standard S5.2 and Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6 shall be taken into consideration for the symbols of logic elements.


Tag name

Function/service


1.3.9. Instrument datasheets according to ISA Standard S20, completed for purchase order in compliance with the requirements of the applicable MOL Group standards (Specifications MGS-M-REF-I-5, MGS-M-REF-I-30.9, MGS-S-REF-I-5 & MGS-S-REF-I-30.9) on format and contents

1.3.10. Sizing calculation sheets (in compliance with ISO Standard 5167-2 for orifice plates with manufacturer’s instructions for control valves, etc.).


1.3.12. To scale layout drawings of instrumentation items (instrument boxes, other equipment, PLC & Marshalling cabinets, local and remote control boards, junction boxes, etc.) complete with material take-off lists (in compliance with Specification MGS-M-REF-I-30.11 & MGS-S-REF-I-30.11).


1.3.14. Single-line cabling diagram of the interconnection between the instruments, junction boxes, installed on compressor skid, control boards and cabinets (in compliance with Specification MGS-M-REF-I-30.15 & MGS-S-REF-I-30.15).




1.3.18. Routing and cabling diagrams of interconnections between the reciprocating compressor site (junction boxes, local control board), the control room (equipment, remote control board) and electrical system (high voltage), etc. (in compliance with Specifications MGS-M-REF-I-30.18, MGS-M-REF-I-30.19, MGS-S-REF-I-30.18 & MGS-S-REF-I-30.19).


PLC program package (PLC-FLD, diagnostics, application, verification)











Rev:. 1.00.00 15/21






User Guide





Test reports of the vibration monitoring equipment



The final (as-built) documentation shall include separate mark-ups indicating any modifications made during manufacturing or installation.









Note: The language of documents shall be English and the copies as specified in the project or the tender specification or during the kick-off meeting at the latest.

Detailed engineering documentation for the construction of the instrumentation system and the as-built documentation shall satisfy the detailed requirements on contents stipulated in Specification MGS-M-REF-I-8 & MGS-S-REF-I-8 and on format in Specification MGS-M-REF-I-9 & MGS-S-REF-I-9 as well as API Standard 618.


The function of the local control board is to start, stop and monitor the running conditions of the package unit comprising the compressor, the drive gear unit and the driver (electric motor) as well as the auxiliary units located in hazardous area.

2.1 General requirements:


Fabrication, assembly, wiring, and labeling in end user language of the local control board at high quality.

Facilities and personnel for VENDOR/CLIENT witnessed testing and inspection of the local control board.





16/21 Rev.: 1.00.00


Supplier shall provide opportunities for Client and/or its representative to witness the fabrication and testing procedures at manufacturer’s works.







The alarm and start/stop signals will be generated by the PLC located in the control room. The alarm sequences specified by the applicable ISA standard or another ones specified by the Client/Vendor will be configured in the PLC. All signals shall have EExi protection, unless required otherwise by the project specification.









2.6 Certification



2.7 Documentation




3 Specifications of main (remote control) board and cabinets

The main (remote) control board shall contain all of the equipment and accessory PLC & Marshalling cabinets (hereinafter cabinets) required for the reciprocating compressor train and located in non-hazardous area. The functions of the main (remote) control board and the cabinets are to control, monitoring the operation and to stop the compressor package unit, comprising the compressor, the drive gear unit and the driver (electric motor), located in hazardous area.


Rev:. 1.00.00 17/21

3.1 Requirements on scope of supply

Supply of all necessary materials and equipment for the main (remote control) board and cabinets,


Provision of facilities and personnel for VENDOR/CLIENT witnessed testing and inspection of the main (remote control) board and cabinets.




Single equipment is to be supplied as the main (remote control) board:

The main (remote control) board shall contain the vibration monitoring rack(s), the speed controller (if any), the annunciator panel of the alarm system, the necessary switches, pushbuttons and other devices marked “MB” under Item 1.2.35. The enclosure of the main (remote control) board and the associated auxiliary cabinets shall provide IP20 protection.

Two cabinets shall be supplied as the auxiliary equipment of the main (remote control) board:



The cabinets shall be completely assembled, wired and tested.






The fail-safe PLC shall be a 2002D voting type, fault-tolerant, increased availability, self-diagnosing system, unless specified otherwise by the project specification.




The HOST communication link to the Client’s DCS shall also be redundant.




Sequential control of auxiliary systems start-up and stopping (lube oil, seal gas cooling water… etc. systems)



Timestamps for alarms and first-out alarm sequence according to specification “F3A” of ISA Standard S18.1 for annunciator panel or steady signals for DCS operator panel indication,



3.3.1.1. The cycle time of the control/shutdown program shall be less than 100 msec unless specified otherwise by the project or tender specification.

3.3.1.2. The laptop computer and software for programming of the fail-safe PLC shall be provided.


18/21 Rev.: 1.00.00

3.3.1.3. The PC-PLC interconnection (multi-drop) cable shall be 50 m long unless specified otherwise by the project or tender specification.

3.3.1.4. The spare space and built-in spare shall be provided as specified by the project or tender specification.

3.3.2 Additional requirements:



The communications between the PLC and the DCS shall be redundant


As the CPU is redundant, no fast-acting shutdown system needs to be supplied in order to shut down the unit in case of the failure of one CPU. The train shall shut down only if both CPU units fail.


The fail-safe PLC cabinet shall be delivered in completely assembled, wired, configured and tested condition.


The alarm annunciation system shall manage all the main motor shutdown inputs of the package unit plus the shutdown signals received from the process system.

3.5 Other devices:


Power supply


3.6 Speed or Capacity Control

Speed control shall be provided either by a frequency converter unit or a variable hydraulic coupling unit, or eventually by some equipment specified, unless specified otherwise by the project or tender specification. This specific controller shall be installed in the main (remote control) board. A frequency converter unit of non-special system may be acceptable below 400 kVA power consumption.

Vendor shall specify the method of speed or capacity control (e.g. by discrete capacity selection manually, or step less analogue capacity control by holding the suction valve open for the required period during the compression stroke) and the requirements of the associated alarm-regulation-shutdown functions, unless required otherwise by the project specification.


3.7.1. Vibration monitoring:


Unless specified otherwise by the project or tender specification the monitoring unit shall receive and process the following signals as a minimum:

Motor:



Compressor:

Casing dual velocity

Compressor vibration


19” rack chassis







Rev:. 1.00.00 19/21

Key-phasor module



Each module shall provide hardwired digital outputs to the PLC for alarm and shutdown functions. Serial communication between the vibration monitor and the PLC shall be used only subject to Client’s specific written permission.

3.7.2. Temperature monitoring



Driver (motor):


Drive end journal bearing

U, V, W, windings

Compressor:



Compressor rod bearings

Suction valve cylinders

Discharge valve cylinders

Note: The project specification or compressor designer shall determine if additional sensors are required for the control system of the compressor and drive train furnished or if certain above points may be omitted

3.7.3. Rod drop monitoring

Rod drop monitoring using proximity sensors shall be provided for all rod of horizontal cylinder compressors.


Unless specified otherwise by the project or tender specification, Zener barriers shall be provided for all the vibration and key-phasor signals of the compressor train. All the analogue and digital signals between the skid-mounted instruments, the local control board and the main (remote control) board and cabinets located in the control room shall be connected through intrinsically safe galvanic isolators.





The control system shall be tested and inspected according to the testing and inspection procedures of the MGS-M-REF-I-13 & MGS-S-REF-I-13 requirements. The test and inspection procedures shall comply with the requirements of the ISO 9001 specifications also.


3.10.1. Acceptance Tests The following inspections and tests shall be carried out:



Performance test,




20/21 Rev.: 1.00.00

3.10.2. Functional Test


3.11 Shipment


3.12 Documentation

The standard drawings and document listed below shall be delivered after the receipt of order or according to the documentation delivery schedule as a minimum:


Wiring Diagram


Terminal assignment

List of materials

Spare parts list



3.13 Certification


4 Appendix:

4.1 Standards:



4.2 Instrument air supply:



Dew point: -25°C

Note: The typical characteristics of instrument air supply are specified in the book No.: MGS-M-REF-I-4 & MGS-S-REF-I-4., however the characteristics are refinery and individual compressor specific, so the exact characteristics are specified in the project specification.

4.3 Utilities

ad.1.2.34 Electric power supply for instrumentation:

230 VAC ±5%, 50 Hz±3% UPS






MOL SLOVAK OIL AND GAS PLC. MGS-S-REF-I-22.2 R&M Division

Rev:. 1.00.00 21/21

SLOVNAFT a.s.

R&M Division


MOL Group


INSTRUMENTATION


compressors

3. Definition of requirements for the control and safety shutdown of multi-stage screw compressors

MGS-S-REF-I-22.3

Rev 1.00.00




Date: 30.11.2011

3 Definition of requirements for the control and safety shutdown of multi-stage screw compressors

Page/Pages: 2/22


Release list



0.00.01 30.05.2004 Revision based on MOL comments L.Viszkai R.Batha

0.00.02 05.11.2004 Revision based on MOL comments L.Viszkai R.Batha




Rev:. 1.00.00 3/22

Contents 1 General requirements ............................................................................................................................................ 4

1.1 Standards and Specifications ......................................................................................................................... 4 1.2 General specifications for instrumentation ..................................................................................................... 5 1.3 Documentation requirements ....................................................................................................................... 13

2 Specifications of local control board .................................................................................................................... 15 2.1 General requirements ................................................................................................................................... 15 2.2 Cabinet construction and finish .................................................................................................................... 15 2.3 Control Functions ......................................................................................................................................... 16 2.4 Items to be installed on the front panel of the local control board ................................................................ 16 2.5 Items to be installed inside the cabinet of the local control board ................................................................ 16 2.6 Certification ................................................................................................................................................... 16 2.7 Documentation ............................................................................................................................................. 16 2.8 Testing and inspections ................................................................................................................................ 16

3 Specifications of main (remote control) board and cabinets ............................................................................... 16 3.1 Requirements on scope of supply: ............................................................................................................... 16 3.2 Construction and finish of main (remote control) board ............................................................................... 17 3.3 Control Functions ......................................................................................................................................... 17 3.4 Man machine interface ................................................................................................................................. 18 3.5 Other devices:............................................................................................................................................... 18 3.6 Speed or Capacity Control ........................................................................................................................... 18 3.7 Vibration and Temperature monitoring ......................................................................................................... 18 3.8 Intrinsically safe protection ........................................................................................................................... 19 3.9 Maintenance bypass switches ...................................................................................................................... 20 3.10 Testing and inspections ........................................................................................................................... 20 3.11 Shipment .................................................................................................................................................. 20 3.12 Documentation ......................................................................................................................................... 20 3.13 Certification .............................................................................................................................................. 20

4 System of Technical Requirements for Refrigerating Machines ......................................................................... 20 5 Appendix .............................................................................................................................................................. 21

5.1 Standards ..................................................................................................................................................... 21 5.2 Instrument air supply .................................................................................................................................... 21 5.3 Utilities .......................................................................................................................................................... 21


4/22 Rev.: 1.00.00

DEFINITION OF REQUIREMENTS FOR THE CONTROL AND SAFETY SHUTDOWN OF MULTI-STAGE SCREW COMPRESSORS


This specification covers the minimum requirements for the; engineering design, manufacturing, assembly and testing of the instrumentation/control system of electric motor driven screw compressor.


Exceptions or variations shown in the Basic engineering documentation or Project Specifications and the General Specifications for the Design of Instrumentation & Control Systems take precedence over the requirements shown herein. No deviations from the Project Specification and the General Specifications for the Design of Instrumentation & Control Systems as well as this specification are permitted unless approved in writing. Compliance with this specification shall not relieve the responsibility to supply equipment of proper design and construction, ensuring the monitoring, diagnostic, control, alarm, regulation and shutdown functions required for the safe and reliable operation of the system. It is to be emphasized that depending on the technological application, capacity, construction...etc. of the individual screw compressors, the number of probes for machine protection and the shut/down and alarm conditions may vary from the items specified in this book. In all cases the machine supplier and the customer must consult each other. Also to be emphasized, that the machine protection system be connected to the Refinery’s “on line” diagnostic system as per MGS-M-REF-I-6.6 & MGS-S-REF-I-6.6. Regarding the number of probes and their location is contained in the specification book of machine No.: MGS-M-REF-I-2.1.8 & MGS-S-REF-I-2.1.8.


1.1.1 EN STANDARDS


EN 60079-10/14 Electrical equipment in explosive atmospheres – Parts 10 & 14

EN 61508-2/3 Functional reliability of programmable electric & electronic safety systems – Parts 2 & 3

EN 61511Functional reliability. Safety systems used in the industrial process control sector – Parts 1, 2 & 3

EN 954 Safety of machinery, safety-related parts of control systems

EN 60584 Thermocouples


EN ISO 5167-2 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full. Part 2: Orifice plates

EN 62305 Protection against lightning


API 619 Rotary type positive displacement compressors for petroleum, petrochemical and natural gas industries



API 614 Lubrication, shaft-sealing, and control-oil systems and auxiliaries for petroleum, chemical and gas industry services


API RP 550 Installation of refinery instruments and control systems





Rev:. 1.00.00 5/22















1.2 General specifications for instrumentation

This specification comprise all equipment and devices necessary for compressor measurements, controls (including load control), alarm annunciation and shutdown functions to be mounted on compressor base-frame, Local Board and Main Board complete with PLC and I/O & termination, galvanic isolation & barriers (Marshalling) cabinets. as well as all junction boxes required for the connection of the input & output signals required for the operation of the compressor.

The system drawing of the centrifugal compressor control and safety shut-down system see on attachment No. 1.

Unless required otherwise by the project specification, process control for the plant will be performed by a Distributed Control System (DCS or ICS), which is to be regarded as existing.

All measured variables of the process, machinery, auxiliary units of machinery (regardless of whether performing indication, control, alarm, shutdown, etc. functions) shall be connected to the DCS for event detection, monitoring, reporting or controlling.

Design Criteria

1.2.1. The multi-stage screw compressor and its instrumentation/control system shall comply with the applicable safety and instrumentation/control requirements of the standards listed in Section 1.1.

1.2.2. Unless required otherwise by the basic documentation or project specification, the trip & emergency shutdown (ESD) system as well as the automatic control and related shutdown instrumentation shall satisfy the safety integrity level (SIL) of the safety requirement specification (SRS) in the relevant safety book.






1.2.8. Each instrumentation item shall be provided with an English datasheet according to ISA S20 indicating the tag number, the service description of the measurement and/or control function and the process & construction data (refer to MGS-M-REF-I-5 & MGS-S-REF-I-5 for the specification sheets to be used).


6/22 Rev.: 1.00.00

1.2.9. The instrumentation system shall comply with the specifications of EN Standards 60079 respectively, as applicable on the basis of ex-proof protection requirements defined in the basic design engineering or the project specification, and secondary lightning/surge/transient protection shall satisfy the requirements of EN 62305 standard and the valid rules and statues.

1.2.10. All explosion-proof instrumentation items, local control boards and equipment shall be intrinsically safe and certified accordingly, or – where this is not possible – flame-proof (Eexd) enclosures or enhanced (Eexe) protection shall be used and certified in accordance with the hazardous area classification given in the basic design engineering or project specification. All explosion-proof instruments and equipment shall be certified in compliance with ATEX 94/9 EC (EU 100A) requirements.

1.2.11. Field indicator instruments operating at 70 barg (1000 psig) or higher pressure and all glass tube types level gauges regardless of pressure shall be fitted with check valves closing at high flow rates in order to prevent the escape of process fluids in the case of instrument failure/breakage.

1.2.12. Unless specified otherwise by the project specification, the weather-proof enclosure of field instruments shall satisfy minimum IP65 requirements as specified by EN Standard 60529.






1.2.18. All resistance temperature detectors shall be Platinum 100 (Pt 100) type according to MSZ EN Standard 60751.






1.2.24. Manual emergency shutdown means (emergency stop pushbuttons) shall be provided for the compressor both in the control room and on the local control board. A field emergency stop pushbutton located at a safe distance from the compressor may also be used additionally, if required by the tender or project specification or specified in the basic design engineering documentation.




Rev:. 1.00.00 7/22

1.2.27. The individual limit switch blocks of analogue inputs in the fail-safe PLC shall include alarm outputs for instrument failure, but these shall not be connected to the shutdown outputs of the limit switch blocks (unless required otherwise by the basic engineering documentation or project specification). Discrepancy monitoring and display functions shall be provided for analogue and the binary shutdown inputs used in voting system.




1.2.31. The design of the local & remote control boards as well as of the PLC and Marshalling cabinets shall comply with the requirements of Specifications MGS-M-REF-I-7, MGS-M-REF-I-13, MGS-S-REF-I-7 and MGS-S-REF-I-13.


1.2.33. Status signals and shut down alarms shall be displayed on the local and/or remote control boards as well as on the DCS or ICS screens as determined by the list of point 1.2.37. Alarm horn shall be provided both on the local and remote control boards. DCS (or ICS) alarms shall be communicated by redundant serial signal transmission.

1.2.34. The safety instrumented technical solution (including the logic solution) of the control/shutdown system for the screw compressor shall be included in the basic or detailed design engineering documentation of instrumentation.


pressure gauge for suction pressure of compressor,

temperature gauge for suction temperature of compressor,

temperature gauge for discharge temperature of compressor,

pressure gauge for discharge pressure of compressor,

pressure gauge for lube oil inlet pressure,

temperature gauge for lube oil inlet temperature,

temperature gauge for lube oil return temperature of compressor.

Note The compressor Designer determines whether additional measurement and detection point are required or some of them may be omitted.

1.2.36. Utilities:



8/22 Rev.: 1.00.00



Alarm Annunciation Location

Alarm Source

Shutdown Source

1. Motor U, V, W winding temperature high-high



2. Compressor drive shaft DE bearing temperature high-high



3. Compressor drive shaft NDE bearing temperature high-high



4. Compressor driven shaft DE bearing temperature high-high



5. Compressor driven shaft NDE bearing temperature high-high



6. Motor DE bearing temperature high-high



7. Motor NDE bearing temperature high-high



8. Compressor drive shaft DE bearing vibration high

DCS LM-CM

9. Compressor drive shaft DE bearing vibration high-high



10. Compressor drive shaft NDE bearing vibration high

DCS LM-CM

11. Compressor drive shaft NDE bearing vibration high-high



12. Compressor driven shaft DE bearing vibration high

DCS LM-CM

13. Compressor driven shaft DE bearing vibration high-high



14. Compressor driven shaft NDE bearing vibration high

DCS LM-CM

15. Compressor driven shaft NDE bearing vibration high-high



16. Motor casing DE vibration high

DCS LM-CM

17. Motor casing DE vibration high-high



18. Motor casing NDE vibration high

DCS LM-CM

19. Motor casing NDE vibration high-high




Rev:. 1.00.00 9/22



Alarm Source

Shutdown Source

20. Compressor drive shaft displacement (+/-) high

DCS LM-CM

21. Compressor drive shaft displacement (+/-) high-high



22. Compressor driven shaft displacement (+/-) high

DCS LM-CM

23. Compressor driven shaft displacement (+/-) high-high



24. Compressor shaft (low/high speed) key-phasor detection

MB LM-CM

25. Lube oil reservoir (separator) level low

LB-DCS LM-CM LM-CM (Heating inhibit)

26. Lube oil reservoir (separator) temperature low/high

LB-DCS LM-CM LM-CM (Heating control)

27. Lube oil reservoir (separator) heater temperature high-high

LB-DCS LM-CM LM-CM (Heating stop)

28. Lube oil reservoir (separator) heater failure

DCS RM-CS (MCC)

29. Lube oil filter dP high

DCS LM-CM

30. Lube oil filter dP high-high


31. Lube oil cooler oil inlet temperature low

LB-DCS LM-CM LM-CM (Compressor start inhibit)

32. Main/stand-by lube oil pumps start/stop command

LM-CM (Push button)

LM-CM (Pump Start/top)

33. Main/stand-by lube oil pumps local-remote switch

LM-CM (Switch)

DCS LM-CM

34. Main/stand-by lube oil pumps running signal

LB-DCS RM-CS (MCC)

35. Main/stand-by lube oil pump MCC failure

DCS RM-CS (MCC)

36. Lube oil header temperature high

DCS LM-CM

37. Lube oil header temp. high-high


38. Lube oil header temperature low

LB-DCS LM-CM LM-CM (Compressor start inhibit)

39. Lube oil header pressure low

LB-DCS LM-CM LM-CM (Stand-by pump start)

40. Lube oil header pressure low-low



10/22 Rev.: 1.00.00



Alarm Source

Shutdown Source

41. Cooling water supply header temp. low

LB-DCS LM-CS LM-CS (Compr. start inhibit)

42. Cooling water return header temperature high

DCS LM-CS

43. Cooling water supply pressure low-low

DCS LM-CS LM-CS (Compr. Stop)

44. Cooling water tank heater temperature low/high

LB-DCS LM-CM LM-CM (Heating control)

45. Cooling water tank heater temperature high-high


46. Cooling water tank level low

LB-DCS LM-CM

47. Cooling water tank level low-low


48. Main/stand-by cooling water pumps start/stop command

LM-CM (Push button)

LM-CM (Pump Start/Stop)

49. Main/stand-by cooling water pumps local/remote switch

LM-CM (Switch)

DCS LM-CM

50. Main/stand-by cooling water pumps running signal

LB-DCS RM-CS (MCC)

51. Main/stand-by cooling water pumps MCC failure

DCS RM-CS (MCC)

52. Cooling water supply header pressure low

LB-DCS LM-CM LM-CM (Stand-by pump start)

53. Compressor by-pass valve open

DCS LM-CM LM-CM (Compr. start condition)

54. Motor purge on (if EExp protected)



55. Motor purge off (if EExp protected)


DCS LM-CM LM-CM (Purge valve close & purge timer stop)


LB-DCS LM-CM

57. Motor purge medium flow low (if EExp protected)

DCS LM-CM LM-CM (Purge stop)

58. Motor purge completed (if EExp protected)

DCS RM-CM RM-CM (Compressor start condition)

59. Motor pressurization failure (if EExp protected)

LB-DCS LM-CM LM-CM (Compr. start inhibit & Stop)

60. Compr. unit ready to load LB-DCS RM-CM

61. Load up & down command LB-MB CM LM-RM-CM (Load selection)

62. Local/remote switch for load selection (at manual step-by-step load control)

MB DCS RM-CM RM-CM (Load control site selection)

63. Load indication LB-DCS RM-CM


Rev:. 1.00.00 11/22



Alarm Source

Shutdown Source

64. Compressor discharge pressure high-high (2oo3)



65. Compressor discharge pressure low-low



66. Compressor discharge temperature high

DCS LM-CM

67. Compressor discharge temp. high-high (2oo3)



68. Compressor suction pressure low

DCS LM-CM

69. Compressor suction pressure low-low



70. Compressor suction K.O. drum level high-high


LM-CS LM-CS (Compr. stop)

71. Instrument air supply pressure low-low

DCS LM-CS LM-CS (Compr. stop)

72. Power supply ON LB- DCS RM-CS (MCC)

RM-CS (Start condition)

73. Motor Ammeter LB- DCS RM-CS (MCC)

74. Motor cooling fan run LB-DCS RM-CS (MCC)

75. Motor cooling fan MCC failure

DCS RM-CS (MCC)

76. Motor space heater ON LB-DCS RM-CS (MCC)

77. Motor space heater MCC failure

LB-DCS RM-CS (MCC)

RM-CS (Start inhibit)

78. Compressor unit start permission

MB-CM (Key-lockable Push button)

LB-MB-DCS RM-CM RM-CM (Compr. unit start permission)

79. Compressor main motor start/stop command

LB-CM (Push button)

LM-CM (Compr. motor Start/Stop)

80. Compressor main motor lock switch

LB-CM (Switch)

LB-DCS LM-CM

81. Compressor main motor running signal

LB-DCS RM-CS (MCC)

82. Compressor unit ESD stop command

LB-Field-MB-CM

DCS RM-LM-CM

LM-RM-CM (Compr. unit ESD Stop)

83. Compressor unit stop status

LB-DCS RM-CM





12/22 Rev.: 1.00.00



Alarm Source

Shutdown Source

85. Compressor MOS command RM-FM (DCS or Key lockable switch in control room)



DCS RM-FM


DCS RM-FM


DCS RM-FM





MB-DCS RM-FM


DCS RM-FM

92. Compressor POS status periodic alarm (in every 8 hours)

DCS RM-FM


MB-CM (Push button)


MB-CM (Push button)

95. Lamp test command (Local board)

LB-CM (Push button)

96. Lamp test command (Main board)

MB-CM (Push button)

Notes: 1. Shutdown functions for high bearing temperature, axial shaft displacement and shaft

(bearing) vibration signal of the compressor, driver and gear unit will be given in the project or Vendor specifications, respectively. The use of process override (POS) switches for trips shall be taken into consideration.


3. The “common” remark refers to separate machine unit so; the driver, gear and compressor unit.

Legend:









DE = Drive-end

NDE = Non drive-end

1.2.37. The thermo wells, the sensors and transmitters for the high-high discharge temperature alarm and emergency shutdown of the compressor shall be the scope of supply unless required otherwise by the project or tender specification. One thermo well and one RTD for emergency alarm function shall be installed in the balance line of the compressor (if any) at the elbow adjacent to the discharge nozzle or shall


Rev:. 1.00.00 13/22

be the scope of supply as loose items. The thermo wells and resistance temperature detectors into the discharge line of each stage in case of multistage compressor shall be also the scope of supply.

1.2.38. Vibration and Axial Displacement monitoring

1.2.39.1. Proximity probes (X and Y) probes shall be provided for measuring shaft vibrations occurring adjacent to the radial bearings at the coupling ends of each shaft and adjacent to the transmission components between the fixed gears and the planetary gears in drive unit. The vibration monitoring and processing unit shall be suitable for connection to the on-line vibration diagnostics system existing at the facility and shall have a port on its own back side to be able to connect the sensor signals directly Analogue signals containing vibration spectra shall be provided for said expert system.

1.2.39.2. A separate probe shall be provided on the drive gear for monitoring the “key-phasor” (at the drive end of the compressor) and on the motor. A suitable groove shall be provided in the surface monitored by this probe.

1.2.39.3. Each probe shall be provided with an oscillator-type detector, connection wiring and readout equipment for continuous monitoring unless required otherwise by the project or tender specification. The vibration, axial position, thrust bearing temperature and journal bearing temperature signal processing and display units (monitors) shall be supplied and installed in the Main Board. Temperature signals will be processed by PLC. Duplex PT 100 type resistance temperature detectors shall be used for temperature detection and spare detectors wired up also to the junction boxes.

1.2.39.4. Probes, oscillator-detectors, power supply units and signal processing & display devices shall be purchased from the same manufacturer in order to assure perfect interfacing.



1.2.39.7. The Vibration Monitoring System shall be tested and calibrated during the performance tests of the rotating equipment

1.2.39. The bearings of the compressor, motor and drive gear unit shall be protected against overheating. A Platinum 100 resistance temperature detector shall be installed into each bearing for this purpose. Vendor shall supply and install these resistance temperature detectors. Four-wire system shall be used and the cables shall be connected to a junction box mounted on the base-frame of the compressor unless required otherwise by the project or tender specification.

1.2.40. All local gauges on the compressor and on the accessories of the compressor shall be provided as specified by the API 617 standard or tender specification. The installation of wiring complete with cables and the junction boxes mounted on the base-plate (skid) of the compressor shall also be the scope of supply. The installation shall meet the requirements of API Standard 550 and be of intrinsically safe design unless required otherwise by the project or tender specification..



alarm signals,

vibration signals,


analogue signals.



1.3.2. Piping & Instrumentation Diagram (P&ID) indicating the battery limits (the related design and supply limits) of the compressor and its auxiliary systems, all process data (flow, pressure, temperature values) as well as all instruments with process connections,, instrumentation & control functions and signal connections in compliance with the requirements of Specification MGS-M-REF-I-10 & MGS-S-REF-I-10 and ISO Standard 3511. The P&ID shall also contain the isolation, vent, drain and test valves of all local instruments as required by API Standard 619.

1.3.3. The operating description of the system, containing the instructions for the safe starting, stopping and handling of all assemblies and equipment as well as describing the solutions employed for tag name generation and systems design (in accordance with Specification MGS-M-REF-I-30.2 & MGS-S-REF-I-30.2).


14/22 Rev.: 1.00.00



1.3.6. Set-value list in tabulated form for the limit switches and timers of alarm, control & shutdown functions (in compliance with Specification MGS-M-REF-I-30.7 & MGS-S-REF-I-30.7).

1.3.7. Complete Boolean logic diagram of the compressor and its auxiliary systems, containing all control, shutdown and emergency or status alarm functions in compliance with Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6. The requirements of ISA Standard S5.2 and Specification MGS-M-REF-I-30.6 & MGS-S-REF-I-30.6 shall be taken into consideration for the symbols of logic elements.


Tagname

Function/service


1.3.9. Instrument datasheets according to ISA Standard S20, completed for purchase order in compliance with the requirements of the applicable MOL Group standards (Specifications MGS-M-REF-I-5, MGS-M-REF-I-30.9, MGS-S-REF-I-5 & MGS-S-REF-I-30.9) on format and contents.

1.3.10. Sizing calculation sheets (in compliance with ISO Standard 5167-2 for orifice plates, with manufacturer’s instructions for control valves, etc.).


1.3.12. To scale layout drawings of instrumentation items (instrument boxes, other equipment, PLC & Marshalling cabinets, local and remote control boards, junction boxes, etc.) complete with material take-off lists (in compliance with Specification MGS-M-REF-I-30.11 & MGS-S-REF-I-30.11).


1.3.14. Single-line cabling diagram of the interconnection between the instruments, junction boxes, installed on the compressor skid, control boards and cabinets (in compliance with Specification MGS-M-REF-I-30.15 & MGS-S-REF-I-30.15).




1.3.18. Routing and cabling diagrams of interconnections between the multi-stage screw compressor site (junction boxes, local control board), the control room (equipment, remote control board) and electrical system (high voltage), etc. (in compliance with Specifications MGS-M-REF-I-18, MGS-M-REF-I-30.19, MGS-S-REF-I-30.18 & MGS-S-REF-I-30.19).


PLC program package (PLC-FLD,











Rev:. 1.00.00 15/22






User Guide





Test reports of the vibration monitoring equipment



The final (as built) documentation shall include separate mark-ups indicating any modifications made during manufacturing or installation.









Note: The language of documents shall be English and the copies as specified in the project or the tender specification or during the kick-off meeting at the latest

The detailed engineering documentation for the construction of the instrumentation system and the as-built documentation shall satisfy the detailed requirements on contents stipulated in Specification MGS-M-REF-I-8 & MGS-S-REF-I-8 and on format in Specification MGS-M-REF-I-9 & MGS-S-REF-I-9 as well as API Standard 619.


The function of the local control board is to start, stop and monitor the running conditions of the package unit comprising the compressor, the drive gear and the driver (electric motor) as well as the auxiliary units located in hazardous area.

2.1 General requirements


Fabrication, assembly, wiring, and labeling in the end user language of the local control board at high quality.

Facilities and personnel for witnessed testing and inspection of the local control board.





16/22 Rev.: 1.00.00








The alarm and start/stop signals will be generated by the PLC located in the control room. The alarm sequences specified by the applicable ISA standard or basic documentation or project/tender specification will be configured in the PLC. All signals shall have EExi protection, unless required otherwise by the project specification.









2.6 Certification



2.7 Documentation




3 Specifications of main (remote control) board and cabinets

The main (remote) control board shall contain all of the equipment and accessory PLC & Marshalling cabinets (hereinafter cabinets) required for the screw compressor train and located in non-hazardous area. The functions of the main (remote) control board and the cabinets are to control, monitoring the operation and to stop the compressor package unit, comprising the compressor, the drive gear unit and the driver (electric motor), located in hazardous area.

3.1 Requirements on scope of supply:

All necessary materials and equipment for the main (remote control) board and cabinets,


Rev:. 1.00.00 17/22


Provision of facilities and personnel for VENDOR/CLIENT witnessed testing and inspection of the main (remote control) board and cabinets.




One single equipment is to be supplied as the main (remote control) board:

The main (remote control) board shall contain the vibration monitoring rack(s), the speed controller (if any), the annunciator panel of the alarm system (if exist), the necessary switches, pushbuttons and other devices marked “MB” under Item 1.2.37. The enclosure of the main (remote control) board and the associated auxiliary cabinets shall provide IP20 protection.

Two cabinets shall be supplied as the auxiliary equipment of the main (remote control) board:








The fail-safe PLC shall be a 2002D voting type, fault-tolerant, increased availability, self-diagnosing system unless specified otherwise by the project specification.




The HOST communication link to the Client’s DCS shall also be redundant.




Sequential control of auxiliary systems start-up and stopping (lube oil, seal gas, cooling water…etc. systems)



Timestamps for alarms and first-out alarm sequence according to specification “F3A” of ISA Standard S18.1 for annunciator panel or steady signals for DCS operator panel indication,



3.3.1.1. The cycle time of the control/shutdown program shall be less than 100 msec. unless specified otherwise by the project or tender specification.

3.3.1.2. The laptop computer and programming software for the programming of the fail-safe PLC shall be provided.

3.3.1.3. The PC-PLC interconnection (multi-drop) cable shall be 50 m long unless specified otherwise by the project or tender specification.


18/22 Rev.: 1.00.00

3.3.1.4. The spare space and built-in spare shall be provided as specified by the project or tender specification

3.3.2 Additional requirements:




As the CPU is redundant, no fast-acting shutdown system needs to be supplied in order to shut down the unit in case of the failure of one CPU. The train shall shut down only if both CPU units fail.


The fail-safe PLC cabinet shall be delivered in completely assembled, wired, configured and tested condition.


The alarm annunciation system shall manage all the main motor shutdown inputs of the package unit plus the shutdown signals received from the process system.

3.5 Other devices:


Power supply


3.6 Speed or Capacity Control

Speed control shall be provided either by a frequency converter unit or a variable hydraulic coupling unit, or eventually by some equipment unless specified otherwise by the project or tender specification. This specific controller shall be installed in the main (remote control) board. A frequency converter unit of non-special system may be acceptable below 400 kVA power consumption.

Vendor shall specify the method of speed or capacity control and the requirements of the associated alarm-regulation-shutdown functions, unless required otherwise by the project specification.


3.7.1 Vibration monitoring:


Unless specified otherwise by the project or tender specification, the monitoring unit shall receive and process the following signals as a minimum:

Motor:



Gear Unit:

HSS Key-phasor: KE Input

HSS Drive end journal bearing: X-Y Input

HSS Non drive end journal bearing: X-Y Input

LSS Thrust bearing displacement: Z-Z Input

LSS Drive end journal bearing: X-Y Input

LSS Non drive end journal bearing: X-Y Input

LSS Key-phasor: KE Input


Compressor:



Thrust bearing axial displacement: Z-Z Input

Motor:

Motor casing DE


Rev:. 1.00.00 19/22

Motor casing NDE


19” rack chassis






Key-phasor module



Each module shall provide hardwired digital outputs to the PLC for alarm and shutdown functions. Serial communication between the vibration monitor and the PLC shall be used only subject to Client’s specific written permission.

3.7.2 Temperature monitoring



Driver (motor):

Drive-end journal bearing


U, V, W, windings

Gear:

HSS Drive-end journal bearing

HSS Non drive-end journal bearing

LSS Thrust bearing internal

LSS Non drive bearing external

LSS Drive-end journal bearing

LSS Non drive-end journal bearing


Compressor:



Compressor thrust bearing internal

Compressor non drive end bearing external

3.7.3 Compressor drive and driven shaft displacement monitoring

Compressor drive shaft displacement

Compressor driven shaft displacement

Note: The project specification or compressor designer shall determine if additional sensors are required for the control system of the compressor and drive train furnished or if certain above points may be omitted.


Unless specified otherwise by the project or tender specification Zener barriers shall be provided for all the vibration and key-phasor signals of the compressor train. All the analogue and digital signals between the skid-mounted instruments, the local control board and the main (remote control) board and cabinets located in the control room shall be connected through intrinsically safe galvanic isolators.


20/22 Rev.: 1.00.00





The control system shall be tested and inspected according to the testing and inspection procedures of the MGS-M-REF-I-13 & MGS-S-REF-I-13 requirements.

The testing and inspection procedures shall comply with the requirements of the ISO 9001 specifications also.


3.10.1. Acceptance Tests

The following inspections and tests shall be carried out:



Performance test,



3.10.2. Functional Test


3.11 Shipment


3.12 Documentation

The standard drawings and document listed below shall be delivered after order receipt or according to the documentation delivery schedule as a minimum:


Wiring Diagram


Terminal assignment

List of materials

Spare parts list



3.13 Certification


4 System of Technical Requirements for Refrigerating Machines

The system of technical requirements for refrigerating machines is identical with the requirements detailed in this specification and in the Technical Specifications for the Instrumentation of Reciprocating Compressors (MGS-M-REF-I-22.2 & MGS-S-REF-I-22.2) but completed with the following functions as a minimum:

Indication/display and low-high alarm of the inlet and outlet temperatures of the compressor discharge gas cooler on DCS, MB and LB;


Rev:. 1.00.00 21/22

Indication/display and low-high alarm of the coolant (e.g. cooling water) inlet and outlet temperatures of the compressor discharge gas cooler on DCS, MB and LB;

Indication/display and low-high alarm of the gas temperature downstream the expansion valve on DCS, MB and LB;

Indication/display and low-high alarm of the coolant inlet and outlet temperatures of the evaporator on DCS, MB and LB.

5 Appendix

5.1 Standards



5.2 Instrument air supply



Dew point: -25°C

Note: The typical characteristics of instrument air supply are specified in the book No.: MGS-M-REF-I-4 & MGS-S-REF-I-4. however the characteristics are refinery and individual compressor specific, so the exact characteristics are specified in the project specification.

5.3 Utilities

ad. 1.2.36. Electric power supply for instrumentation:

230 VAC ±5%, 50 Hz±3% UPS







22/22 Rev.: 1.00.00

Date post:	18-May-2018
Category:	Documents
Upload:	tranduong
View:	218 times
Download:	1 times

MOL Group - slovnaft.sk fileSLOVNAFT a.s. R&M Division This document is property of MOL Group. The...

Documents