Hydrobursting System Specfication
Hydrobursting System Specfication
Hydrobursting System Specfication
1. Scope
• Supply, pre-despatch inspection, safe delivery, installation and commissioning of two sets of
Reciprocating Air compressor system equipped with all accessories, two nos. of Air receiver
tanks, cooling tower, cooling tower pumps, interconnecting piping & valves (piping termination
within maximum 5 metres from Air Receiver Tanks at shore pump house) and interconnection
cabling complete as shown in the attached P&I drawing for smooth trouble free logic-based
operation. The department will provide power cable and energize local control panel of
compressor system.
• Each compressor set should have accessories like Solenoid Valve, Pressure Relief Valve,
Automatic Pressure Switch, Drain valve, Pressure Transmitter etc. as detailed in this technical
specification annexure and attached drawing.
2. Purpose
The Reciprocating Air Compressor system is required for periodic hydro-bursting in offshore velocity
cap intake filter located at the mouth of pipeline based sub-sea seawater intake system at OSCOM
Desalination plant.
3. Technical specification
The supply includes following items:
• Compressor system.
• Compressor cooling system comprising of cooling tower along with cooling tower
pumps.
• Air Receiver Tanks
• Local Control Panel (Electrical & Instrument Panel)
• Instruments
• Interconnecting Piping with valves
• Interconnection Cables (Power cable & control cable)
3.1. Compressor System
Compressor package consisting of all auxiliaries, including but not limited to the
following:
i. Suction filter.
ii. Electrical motor and compressor capacity control device.
iii. V-belt drive consisting of compressor pulley, motor pulley and set of V-belts and belt
guard.
iv. After cooler heat exchanger with moisture separator and automatic drain traps (as
applicable).
v. Pressure Relief Valve at outlet of compressor.
vi. Forced feed Lubrication system along with first fill of lubricant.
vii. Oil cooler and oil filter.
viii. Silencer(s), as applicable.
ix. Expansion joint and check valve at the discharge.
x. All piping and pipe supports within the battery limits.
xi. Instrumentation and controls equipment as specified.
xii. Local Control Panel.
xiii. Interconnection Cabling from main incomer power panel to local control cable to job
motor/equipment.
xiv. Tubing from control panel /gauge panel to individual instruments within battery limit
xv. Local push button stations for all drivers/motor.
xvi. Acoustic hood (as applicable).
xvii. Common base frame for the complete assembly unit.
xviii. Foundation bolts and nuts.
xix. Epoxy Painting.
xx. Inspection and testing as detailed in this specification.
xxi. Documentation as specified
3.2. Compressor cooling system: It includes Cooling tower with fan and motor,
cooling water circulation pumps
Description Specifications
Vertical Air receiver Capacity – 6.3 M3 (6000 Litres) suitable for Maximum working
pressure 12.5 bar.
Air receiver manufactured as per BS 5169 / IS 2825
Standard or ASME Sec VIII Div. 1
Receiver Tank fitted with Safety Valves, pressure gauge with
isolation valve, and pressure regulator valve & drain ball valve
Quantity Two unit
Code of Construction IS 2825
Minimum Shell thickness 10 mm, Minimum Dish thickness
12mm, Actual thickness to be arrived with design calculation.
Material of Construction – SA 516 Gr. 70
Shell & Dish end
Corrosion Allowance 3 mm
a. Application/Uses: This panel will be powered from main power panel (substation room
ground floor). All instruments will be powered from 24 V DC power supply via SMPS
installed in control panel. All the process parameters will be shown in control panel via
process indicator (installed in front door of panel). Control switches (pressure switch,
level switch, motor on/off trip indications) states will be indicated be indicating lamps.
All-important parameters mentioned elsewhere in the tender documents needs an alarm
indication (Audio and Visual via annunciator block).
All the control and process instruments signal needs to be fed to PLC Panel for remote
operation.
b. Main components: Main incomer MCCB, starter, indication lamps, electromagnetic type
relay (as required), SMPS (1 nos.), push button station for motor (3 nos.) Process
indicator (2nos.) Solenoid valve starter (4 nos.) Timer for control circuit, signal
multiplier (2nos.) control switches indication lamp and relay (5 nos.) auto manual
switches, auto/manual switches, Annunciator block, panel light, receptacle etc.
c. Type & size of panel Non compartmentalised.
3.5. Instrumentation
Instrument Quantity
Pressure Transmitter 2
Temperature Transmitter 1
Pressure Gauge 6
Pressure Switch 5
Solenoid Valve 4
Rotameter 2
Level Switch 1
Pressure Transmitter
Parameters Specification
Process temperature (max.) Vendor to specify
Temperature Transmitter
Parameters Specifications
Process pressure (max.) Vendor to specify
Process temperature (max.) Vendor to specify
Service medium Vendor to specify
Ambient temperature 45 °C
Area classification Saline atmosphere
Type of element Pt- 100
No of wire 3-wire
No of elements Simplex
Accuracy As per (IEC-751) Class A
Sheath material SS316
Sheath diameter 6 mm
Element length As per chosen stem length of Thermowell plus its union
Insulation MgO
Element connection 1/2" NPT(M)
Enclosure protection IP65
Enclosure Material Die Cast Aluminium
Cable entry ½” NPT(F)
Loading Spring loaded
Construction Bar stock
Shape Tapered
Material SS316
Insertion length Vendor to specify
Pressure Gauge
Parameters Specifications
Process pressure (max.) Vendor to specify
Process temperature (max.) Vendor to specify
Service medium (density) Vendor to specify
Ambient temperature 45 °C
Area classification Saline atmosphere
Instrument range and dial Vendor to specify
marking
Resolution 0.1 bar (a)
Over range 125% FSD
Dial size 150mm
Sensor Bourdon tube
Accuracy (+/-)0.6 % FSD as per EN 837-1
Bourdon SS316
Movement SS304
Socket SS316, bottom entry, 1/2" NPT(F)
Dial and Pointer Aluminium
Housing SS304
Protection IP65
Name Plate Tag Required
2 Valve Manifold To be provided (SS316)
Quantity 6
Pressure Switch
Parameters Specifications
Process pressure (max.) Vendor to specify
Ambient temperature 45 °C
Area classification Saline atmosphere
Enclosure rating IP 65
Solenoid Valve
Parameters Specifications
Type 2/2, Normally closed, energized to open, direct acting
plunger type.
Rotameter
Description parameters
Type Rotameter
Meter size Vendor to specify
Flow range Vendor to specify
Flow tube material SS316
Float material SS316
Float type Cone
Test pressure 5 kg/cm2
Accuracy/class ±2.5%of full flow
Quantity 2 Nos.
Level Switch
Description parameters
Type Level Switch (Float type)
MOC SS316
Quantity 1 Nos.
3.6. Interconnecting Piping & Valves
The compressed air piping shall be of SA 106 Gr. B seamless and thickness as per acceptable standards
and process requirements ( test pressure 15 kg/cm2) and shall contain following valves:
4. STANDARD SPECIFICATIONS
Compressor shall comply with all currently applicable statutes, regulations and safety codes.
Nothing in this specification shall be construed to relieve the vendor of his responsibility. Any changes,
if required, to meet the statutory norms shall be carried out by the vendor at no extra cost.
The equipment shall conform to the following codes and standards:
5. BASIC DESIGN
5.1.1. Unless otherwise specified, compressor shall be stationary, reciprocating, electric motor driven,
and heavy duty.
5.1.2. Any part weighing above 50 kg, required to be removed for maintenance purpose, shall be
provided with cast or provision of slinging may be provided with welded on lifting lugs.
5.1.3. Vendor shall ensure that the installation is free from harmful vibrations under any of the
possible operating conditions including starting, stopping, steady running, operating transients
or when tripped.
5.1.4. Major parts on the cylinder and compressor shall be designed with positioning dowels to ensure
accurate alignment after reassembly. Drainage points shall be provided at all low points in the
compressor, piping and other equipment. These shall be individually terminated with valves.
5.1.5. Piston rod shall be surface hardened where contact is made with gland packing. Liners shall be
provided in compressor cylinder.
5.1.6. Crankshaft shall be properly balanced and provided with antifriction bearings so that no thrust
shall be transferred to drive train. The L10 life of anti-friction bearings shall be of minimum of
50,000 hours with continuous operation at rated condition.
5.1.7. Crankcase shall be provided with oil seals/labyrinths to avoid any inside contamination by
foreign particles and dust etc. A bull-eye sight glass shall be provided on housing to monitor
the oil level.
5.1.8. Forced feed lubrication system shall include one shaft driven oil pump complete with strainers,
relief valves and oil cooler to maintain oil temperature below 70°C.
5.1.9. Accessories:
• A suction filter cum silencer for each compressor shall be provided to have cleaner air at
compressor inlet flange. It shall be suitable to be mounted outdoor with hood and bird screen
arrangement.
• Filtered air to 20-micron particle size will be made available. Compressor shall be provided
with a dry-type suction filter with filtration efficiency 97% down to 3 μm particle size. Filter
shall be provided with a differential pressure transmitter.
• After-cooler shall be provided for each compressor. These shall be shell and tube; air on
shell side and water through tubes. U-tubes shall not be used. Tubes shall be fusion welded
to tube sheet and it shall be possible to remove the tube bundle without dismantling the
piping connections. It shall have corrosion allowance of 3.0 mm. These shall be provided
with vent, drain valves and relief valves.
• A moisture separator with auto drain trap shall be provided at each exchanger.
• A non-return valve shall be provided at discharge of each compressor.
5.1.10. The delivery relief valves set pressure shall be minimum 110% of the maximum delivery
pressure but less than maximum operating pressure. Valves shall be full-bore type, sized for
full flow.
5.1.11. Motor shall be rated for power required at relief valve set pressure or 125% of absorbed power
at rated duty condition, whichever is higher.
5.1.12. Flanges at battery limit shall be as per ANSI B16.5.
5.1.13. All moving parts shall be guarded for personnel protection.
5.1.14. Service factor for V-belt drive shall be 2.0 on motor HP.
5.1.15. Compressor shall be manually unloaded for start-up
6. OTHER REQUIREMENTS
6..1. CONTROLS AND INSTRUMENTATION
All necessary instrumentation shall be provided to ensure efficient and safe functioning of the package.
However, following are the minimum requirements:
• Pressure transmitter, pressure gauge with isolation valve for discharge pressure (if applicable)
and lube oil pressure.
• Temperature indication for discharge air temperature and lube oil temperature.
• Pressure safety valve at discharge air.
Provision for the following safety interlock with audio/visual alarm shall be made:
• High Discharge Air Temperature (each stage) -Alarm / Trip
• High Discharge Air Pressure (each stage) -Alarm / Trip
• Motor overload -Trip
• Low lube oil pressure -Alarm / Trip
• Low cooling water pressure -Alarm / Trip
• High lube oil temperature -Alarm / Trip
• High liquid level in separator -Alarm / Trip
• High Pressure drop across air filter -Alarm
• High Pressure drop across air dryer -Alarm
• Low Pressure at compressor outlet -Alarm
First–out type annunciation windows shall be provided.
Alarm settings shall always precede the shutdown function. Each alarm and shutdown instrument shall
be provided in separate housing. A potential free contact shall be provided for common fault
annunciation in Purchaser’s main control panel.
Alarm /Trip conditions shall be displayed on the Local Control Panel.
Air Compressor vendor shall provide a detailed write-up on control logic scheme offered.
Indications for power supply ON/OFF, unit ON/OFF, compressor status load / unload shall be
provided. Local start/stop controls shall be provided.
The following control and monitoring systems shall be provided:
6..2. ELECTRICAL
The power supply feeder to the skid motor starter panel shall will be given at main power panel at intake
system substation building. System voltage for which the panel will be designed is of 415 V (10%
variation), TPN, 50 Hz. All the power cable, control cable and instrument cable for interconnecting the
equipment (job motors, instruments, anti-condensation heater, valves etc.) to local control panel with
termination kit and Earthing is in the scope of the contractor. The earthing connection to be taken from
nearest earth grid in pump house via 2 nos. of 50 x6 mm GI earth strip.
6..3. PIPING
The compressed air piping within the skid shall be of carbon steel and thickness as per acceptable
standards and process requirements.
6..4. WELDING
The welding procedure specification and procedure qualification records shall be made
available to the Purchaser for review and approval on request.
6..5. PAINTING
Painting and protective coatings, including surface preparation and coating or paint application
shall be applied to all equipment, structural steel, base plate etc. All grit blasting required for surface
preparation shall be accomplished prior to instruments and controls being mounted on the skid. Paint
systems may be CONTRACTOR’s standard, provided this is suitable for the environmental conditions
specified.
• Discharge pressure
• FAD (without negative tolerance)
• Specific power consumption (without any positive tolerance) for maximum capacity
• Discharge temperature at minimum capacity.
• Air quality test
In addition, the following tests shall also be performed and witnessed:
11. Packing
Compressor unit and all items shall be despatched in suitable packing to avoid ingress of dust and
handling, safe transit and storage.
12. Drawings
P&ID of compressor air system with control logic shown in attached drawing.
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The drawing, design and details given on this format are the property of BARC