API Spec Review

Gas Turbine Technology Center
Southwest Research Institute
Gas Machinery Conference API Specification Review
Dr. Klaus Brun - Southwest Research Institute Dr. Rainer Kurz Solar Turbines, Inc.
11/15/2001 - #1 Gas Turbine Technology Center

O&G Applications
Why Differentiate O&G Gas Turbines from other Applications?

Oil & Gas Requirements: - Availability / Reliability - Ruggedness - High Power/Weight Ratio - Efficiency not very critical Industrial Power Generation Requirements: - Cost of Electricity - Efficiency - Cost of O&M
Different Gas Turbine Products for O&G Market


Outline
Oil & Gas Definitions Gas Turbine and Package Components Instrumentation Compression Station Layout Offshore Gas Turbine Issues Fuel Considerations Why Standards Relevant Standards API Philosophy 101 API Data Sheets Review of API 616 Highlights of API 614 and 670
Introduction to Gas Turbine Oil and Gas Applications

a) b) c) d) e) f)
Codes and Standards

a) b) c) d) e) f)
Factory Tests NFPA 70 Hazardous Area Classifications API 616 Data Sheets Review API 617 Review

O&G Definitions
Upstream The Oil & Gas Production and Gathering Process
Crude Oil
Unprocessed oil from well. Natural gas that is recovered from the well with crude oil (also, gasto-oil ratio).
Associated Gas

O&G Definitions Contd

Power generation to meet needs of oil field or platform. Advanced technologies to improve oil recovery. Injecting gas into the production well to help lift the oil.
Self-Generation
Enhanced Oil Recovery (EOR) Gas Lift
Red Processes that involve gas turbines.



Injection of water into the reservoir to increase reservoir pressure and improve production. Re-injection of natural gas into the reservoir to increase the reservoir pressure.
Waterflood
Gas Re-injection



Initial boosting of natural gas pressure from field into pipeline (a.k.a. header compression). Collecting natural gas from multiple wells.
Export Compression
Gas Gathering



Processing of gas to pipeline quality; i.e., removal of sulfur, water, and CO2 components. Injecting of gas into underground structure for later use: summer storage, winter withdrawal.
Gas Plant and Gas Boost
Gas Storage/Withdrawal



Compression stations on pipeline to pump natural gas; typically 800-1200 psi compression. Pumping of crude or refined oil.
Midstream The Oil & Gas Transportation Process
Pipeline Compression
Oil Pipeline Pumping

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Liquid natural gas plant. NG is cooled and compressed for transportation in liquid form. Loading and unloading of liquid natural gas onto LNG tanker (vessel).
Midstream The Oil & Gas Transportation Process
LNG Plant
LNG Terminal

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Processing of crude oil into its various sellable components. Advanced process to convert heavy oils and pet-coke into synthesis gas and hydrogen.
Downstream the Refining and Distribution of Oil & Gas
Refinery
Integrated Gasification Combined Cycle



Plant that produces methy alcohol from methane (natural gas). Artificial gasoline produced from coal and/or other lower cost hydrocarbons.
Methanol Plant
Fischer-Tropsch Liquid



Distillation tower to separate crude oil into its gasoline, diesel, heating oil, naphtha, etc. Breaking large hydrocarbon chains to smaller chains (chocker, visbreaking, thermal, catalytic).
Fractional Distillation Column
Cracking


Mixing of hydrocarbons to obtain sellable refinery products. Liquid petroleum gas (propane, butane, pentane).
Blending
LPG


Natural gas liquids: liquids that drop out during gas processing. Delivery of oil and gas products to end-users.
NGL
Distribution


Components & Layout
Inside the Package:

Fuel System and Spark Igniter
Natural Gas (control valves) Liquid (pumps, valves)
Bearing Lube Oil System

Tank Filter Pumps (main, pre/post, backup)
Accessory gear Fire/Gas Detection System Starter/Helper Drive (pneumatic, hydraulic, variable speed AC motor) Controls and Instrumentation (on-skid, off-skid) Seal Gas/Oil System (compressors)

Components & Layout

Outside the Package: Enclosure and Fire Protection System Inlet System
Air-filter (self-cleaning, barrier, inertial) Silencer
Exhaust System
Silencer Stack
Lube Oil Cooler (water, air) Fuel Filter/Control Valve Skid Motor Control Center Switchgear, Neutral Ground Resistor Inlet Fogger/Cooler

Components & Layout
Steam & Power Gas Turbine Cogeneration

- Steam to Steam Turbine Combined Cycle Plant - Steam to Other Plant Requirements Co-Generation Plant
Heat Recovery Steam Generator

Use Gas Turbine Exhaust Heat to Generate Steam
(aka HRSG, Waste Heat Recovery Unit, WHRU, Boiler) By-Pass Stack
Stack
Gas Turbine Generator
Exhaust Heat Supplemental Duct Firing
Economizer
Boiler

Gas Turbine Package Systems

Control Systems
Human Machine Interface Machinery Monitoring and Protection

Equipment Startup, Shutdown and Protective Sequencing Alarm, Shutdown Logic Backup (Relay) Shutdown
Driven Load Regulation

Fuel / Speed Control Process Control
Communication (SCADA) Interface


Gas Turbine Instrumentation
Temperature Sensors (RTDs and Thermocouples)

Lube Oil Drains Fuel Gas Bearing Metal Gas Path (T1, T2, T4, T5) Driven Compressor (Ts, Td) Driven Generator Stator Coils
Pressure Sensors
Gas Path (P1, P2) Fuel Gas Air Inlet Filter Delta P Lube Oil Pump Delta P Lube Oil Filter Delta P Driven Compressor (Ps, Pd)

Position Sensors (Proximity Probes)

Measures Relative Movement Between Housing and Shaft GT Bearings X, Y, Z Gearbox Bearings X, Y, Z Driven Equipment X, Y , Z
Velocity Pick-ups or Accelerometers

Measures Absolute Motion Gas Turbine Case Main Gearbox Case Auxiliary Gearbox Case Driven Equipment Case


Lube Oil Level, Temperature, and Pressure Lube/Seal Oil Filter Delta P High Casing Vibration Proximity Probe Clearance (Large Orbit) Fuel Gas Temperature and Pressure Gas and Fire Detectors Inlet Filter Delta P Key Phasor (Shaft Speed) Exhaust Temperature Spread Flame-Out (Flame Detector) Bearing Metal Temperatures Seal Gas or Oil Pressure and Temperature (Driven Compressor) Synchronization / Grid Frequency (Driven Generator) Manual Emergency Shutdown Button
Critical Alarm and Shutdown Switches

Compressor Station Layout

Turbo-Compressor In Buildings
Major Equipment:
- Turbo-Compressors and Ancillaries/Auxiliaries - Surge Recycle Loop with Surge Control Valves - Gas Coolers (Intermediate, Discharge) - Suction Scrubbers, Discharge Scrubbers - Station Isolation and By-Pass Valves - Suction and Discharge Valves - Compressor Loading and Bypass Valves - Unit and Station Control Room - Fuel Gas Heaters - Fuel Gas Filter and Control Skid - SCADA System - Fire Fighting Water System - Fire Fighting CO2 System - Emergency Power Supply (Diesel Generators, Tanks) - Instrument and Seal Gas Air Compressor - Slug catcher, Scrubbers, Filters - Flare and/or Blow-Down - Station and Unit Flow Meters - Pig Launcher - Gas Treatment Plant (De-Hydration, CO2 Removal, Sour Gas Treatment)
Discharge Coolers

Compressor Station Layout

TURBINE COMPRESSOR
Gas Turbine
Compressor
FLOW ORIFICE SURGE CONTROLLER GAS COOLER DP LOADING SWITCH
DISCHARGE VALVE LOADING VALVE SUCTION VALVE SURGECONTROL VALVE
Isolation Valves
CHECK VALVE
Pipeline
Station By-Pass Valve

Offshore Platform (Marine)

Jack-Up Semi-Sub FPSO Tension Leg
Land Based
Fixed Leg
Technical Requirements
Low weight and dimensions Low Vibrations Resistance to Saltwater List, trim, pitch, roll operation Marine codes Foundation twisting
Features
Compact design, reduced lube oil tank, single lift modules Vibration isolators, special grouting Stainless steel (enclosure and inlet/exhaust system) Baffles/Scavenging pump in LO tank, inclinometers Lloyds, DNV, ABS, Coast Guard Certification Sub base, three point mount, gimbles, vibration mounts
Operational Requirements
Highest availability as platform often depends on GT, but No direct access to technicians and repair facilities Limited spare parts storage capabilities
?

Offshore Features
Compressor
Gas Turbine
Inclinometer
Mount Sub Base Lube Oil Tank Baffles Scavenging Pump for Pressurized Bearings
Inclinometer Sub Base Baffles Scavenging Pump Mounts Single Lift Module
- Alarm and Shutdown at High List, Trim, Pitch, Roll Angles - Added Stiffness for Gas Turbine and Compressor Skids - Continued Supply of Lube Oil at Inclined Operation - Forced Supply of Lube Oil at Inclined Operation - Isolation from Twisting and Vibration - Simplified Installation and Transportation to Platform
Single Lift Module
Gas Fuels - Dew Point

Heavy Hydrocarbons Increase Dew Point - Liquid Dropout Must Be Prevented May Require Fuel Heating/Fuel Treatment May Require Heat Tracing of Fuel System Accurate Fuel Analysis Necessary - ASTM D1945 only Reports C6+ - C14 Down to ppmv Level Desirable - Measured Dew Point
Liquid phase
Liquid and gas phase
Gas phase
Dew Point and Fuel System Pressure Drop

Liquid Drop Out K
PRESSURE Saturated Vapor Saturated Liquid
Fuel Supply Pressure (Skid Edge)
Lowest Combustor Pressure
ENTHALPY

Codes & Standards
Review of Codes and Standards

Codes & Standards
Why Codes:
Codes provide design guidelines and definitions:

Example: Vibrations, Materials, Service Connections, Package Design
Intent to Facilitate, Manufacture, and Procurement No Code Designs a Gas Turbine Codes are by nature rather general. Any particular application may require modifications.

Relevant Codes
Description Gas Turbines for the Petroleum, Chemical, and Gas Industry Services Special Purpose Gear Units For Petroleum, Chemical, And GasIndustry Services Lubrication, Shaft-Sealing, and Control - Oil Systems for Special - Purpose Applications Combustion Gas Turbine for General Refinery Service Air-Cooled Heat Exchangers for General Refinery Service Vibration, Axial Position and Bearing Temperature Monitoring System General Purpose Gear Units Special Purpose Couplings for Refinery Services Accelerometer-Based Vibration Monitoring System Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 and Division 2
Manual on Installation of Refinery Instruments and Control System
Specification number API 616 4th edition API 613 4th edition API 614 3rd edition API 614 4th edition API 661 5th edition API 670 4th edition API 677 2nd edition API 671 3rd edition API 678 API 500 2nd edition API RP 550 ASME VIII Div 1 ASME B 31.3 ASME B 16.5 AWS D1.1 IEEE 112A PTC 22-1977 PTC 1 ANSI C50.14-1997 ANCI B133.4 NEMA NEMA MG1 NFPA 12 1989 edition NFPA 69 1997 edition NFPA 70 2002 edition NFPA 70E NFPA 72 2002 edition NFPA 85 2001 edition (extract) OSHA ISO 2314 1989 API RP 11PGT UL 1604
Boiler and Pressure Vessel Code Chemical Plant and Petroleum Refinery Piping Steel Pipe Flanges and Flanged Fittings Structural Welding Code for Steel Polyphase Induction Motors and Generators Performance Test Code on Gas turbine General Instructions Requirements for combustion gas turbine driven cylindrical rotor synchronous generators Gas turbine Control and Protection System National Electrical Manufacturers Association Motors and Generators Carbone Dioxide Extinguishing Systems Standard on Explosion Prevention Systems National Electric Code National Fire Code Errata National Fire Alarm Code Boiler and Combustion Systems Hazards Code Noise Procedure Specification Gas turbines - Acceptance tests Recommended Prcatice for Packaged Combustion Gas Turbines Electrical Apparatus for Explosive Gas Atmosphere

Codes & Standards
Most Common Codes for US Oil & Gas Applications: API 616 - Gas Turbines API 617 Compressors API 614 Lube Oil System API 670 Machinery Protection Mostly Affects API 613 Load and Accessory Gear Packaging API 677 Accessory Drive Gear API 671 Flexible Couplings NFPA 70 Electric Code ASME PTC-22 Gas Turbine Testing ASME PTC-10 Compressor Testing ASME B133 - Gas Turbines

Other International Codes
ISO Codes (ISO 3977 - Gas Turbines) IEC/CENELEC (Electrical and Fire Systems) Local Government Codes EU Environmental and Health Compliance User Specific Specifications:
Upstream: Mostly API/firm Midstream: Some API/flexible Downstream: Mostly API/very firm

What is API?
American Petroleum Institute (API):

US Petroleum Industry Primary Trade Association 400 Member Companies Covers all Aspects of Oil & Gas Industry Accredited by ANSI (American National Standards Organization) Started Developing Standards in 1924 Maintains about 500 Standards API Codes are Widely Referenced by EPA, OSHA, OPS, MMS, BLM, and Many Local Codes

What is API? Contd
Philosophy:
Improve Safety Improve Environmental Performance Reduce Engineering Costs Improve Equipment Interchangeability Improve Product Quality Lower Equipment Cost Allows for Exceptions for Reason API Specifications Typically Lag Technology Developments!

What is API? Contd
API Standards as Purchasing Specifications:

Provide the means for a customer to normalize the quotations by forcing all vendors to quote similar scopes. Provides a common language and set of rules between vendor and customer to limit misunderstandings; e.g., definitions of efficiencies, test procedures, vendor data, data sheets. Clearly states in the Foreword that Exceptions are allowed if they lead to improved or safer technical offer.

What is API? Contd
For gas turbine applications in the oil & gas sector, API 616 is the foundation for almost all purchase specifications. API 617 is used for critical centrifugal compressor applications (high pressure, high energy) NFPA 70 electric code for hazardous locations is a fundamental requirement within API. Gas turbine electrical wiring must at least meet Class 1, Division 2 (Zone 2), Group D. Some Applications require Division 1 (Zone 1).

API Standard Topics
Definitions: ISO Rating, Normal Operating Point, Maximum Continuous Speed, Trip Speed, etc. Mechanical Integrity: Blade Natural Frequencies, Vibration Levels, Balancing Requirements, Alarms and Shutdowns

API Standard Topics
Design Requirements and Features: Materials, Welding, Accessories, Controls, Instrumentation, Inlet/Exhaust Systems, Fuel Systems Inspection, Testing, and Preparation for Shipment Minimum Testing, Inspection and Certification Documentation Requirements Does not cover government codes & regulations

API
API Data Sheets

API Data Sheets
API Data Sheets:

Forms technical basis of proposal Define Customer Site, Operating, and Equipment Minimum Requirements Most important technical contractual document Must always be filled out:
API 616 Appendix A & B (Gas Turbine) API 614 Appendix D (Lube Oil System) API 670 Appendix A (Machinery Protection)

API Data Sheets
When filling out the API Data Sheets
Cross-out requirements you do not comply with. Read all the notes: Some critical requirements are often hidden here. Fill out as much info as is available: Even partially filled out sheet is better than no sheet.

API Data Sheets
By Purchaser
By Manufacturer
By Manufacturer if not by Purchaser


API 616 Gas Turbine

Note: API 616 does not apply to Aero-Derivative Gas Turbines Only Industrial!

API 616 Intro & Definitions
1.0 1.1
Alternative Designs Alternative designs allowed. Emphasized in API Foreword.
2.0 References 2.1 All reference standards are automatically included. All manufacturers take exception to this. 3.0 Definitions 3.17 ISO defined as T=15C, P=1.0133 bar, RH=60% 3.19 Maximum allowable speed. Speed at which unit can safely operate continuously per manufacturer. 3.22 Maximum continuous speed: 105% highest design speed.

API 616 - Definitions
3.26 Normal Operating Point: Usually the performance guarantee (heat rate, power) point for gas turbine. Defined by speed, fuel, and site conditions. 3.38 Rated speed: Power turbine speed at which site rated power is achieved. 3.42 Site rated conditions: Worst site condition at which still site rated power can be achieved. Provided by User. 3.45 Site rated power: The maximum power achievable at site rated conditions. Provided by Manufacturer. Note: Unless specifically stated by purchaser this is not a guarantee point.

API 616 - Engine
3.50 Turbine trip speed: Speed where controls shut unit down. 3.51 Unit responsibility: Prime package contractor to user. Either GT or compressor manufacturer. 4.0 Basic Design 4.1.1 Equipment designed for 20 years and 3 years of uninterrupted service. Hot section inspection every 8000 hours. 4.1.2 Gas turbine vendor has unit responsibility unless otherwise specified. 4.1.5 Speed ranges: Two-shaft 50-105% rated speed, Single-shaft 80-105% rated speed.

API 616 - Engine
4.1.14 On-skid electric shall meet NFPA 70. 4.1.16 Most gas turbine internals shall be exchangeable at site. Disqualifies most aeroderivate gas turbines. 4.1.17 Unit shall meet performance acceptance criteria both in the factory and at site. Most manufacturers take exception to site performance guarantee unless field test is performed. 4.1.18 Vendor shall review customers installation drawings. 4.1.21 Gas turbine must meet site rated power with no negative tolerances.

API 616 Engine
4.2.1 Casing hoop stresses must meet ASME Section VIII. 4.2.7 Openings for borescope inspection must be provided for entire rotor without disassembly. 4.2.9 Field balancing (if required) without removal of casing is OK. 4.3.1 Combustors must have two igniters or igniter and cross-tubes. 4.3.2 Requires temperature sensors in each combustor. Not feasible in most gas turbine designs. T5 (2-shaft) or T6 (1-shaft) normal. 4.3.7 Fuel Wobbe index range must be indicated in proposal.

API 616 - Engine
4.4
Casing Connections: Section outlines good design practices. Most manufacturers are OK.
4.5.1.2 Shafts shall be single piece heat treated steel. Stacked rotors with a tie-bolt are not allowed. Difficult to meet for most manufacturers and not critical if rotor has been operationally proven. 4.5.2.1 Rotor shall be designed for overspeed up to 110% of trip speed. 4.5.2.2 All rotor components must withstand instantaneous loss of 100% shaft load (e.g. coupling failure). 4.6 Seals: Renewable seals at all close clearance points.

API 616 - Engine
4.7
Rotordynamics: Follow good design practices for progressive balancing with residual unbalance check. High speed balancing is discouraged.
4.8.1.1 Hydrodynamic radial and thrust bearings are preferred. ThrustTilt pad, Radial Tilt pad or sleeve. 4.8.2.5 If rolling element bearings are used they must meet 50,000 hours of continuous operation. 4.8.5.2 Bearings: Labyrinth type seal required. Lip seal not acceptable. 4.8.5.3 Two radial proximity probes in radial bearings and two axial proximity probes in thrust bearings.

API 616 - Engine
4.9.2 4.9.5 4.9.7
Synthetic lube oil is OK. Integrated or separate lube GT / Compressor oil system OK. Lube oil system must meet API 614. Note: Lube oil tank typically integrated into skid. Materials: Follow good design rules. Purchaser may require 100% radiography magnetic particle inspection, or liquid penetrant inspection on all welds.
4.10
4.11.3 A SS nameplate to include rated performance and conditions, critical speeds, maximum continuous speed, overspeed trip, and fuel type.

API 616 - Accessories
5.0 Accessories 5.1.1.1 Electric, pneumatic, electro-hydraulic, gas engine, steam turbine all acceptable starter/helper motors. Starter drivers are uncoupled after startup, helper drivers remain coupled. 5.1.1.7 Starter motors must be supplied with all necessary gears, couplings, and clutches. 5.1.2.1 Starters shall be rated 110% of starting torque required. Vendor to supply torque curves. 5.1.3 Turning gear: Device to periodically rotate to avoid shaft deformation. Generally not required on smaller turbines.

API 616- Accessories
5.2.1 Vendor to supply accessory gear for starting, auxiliary equipment (LO pump). Vendor to also supply separate load gear if required. All gears shall meet API 613. Accessory gears shall be rated for 110% of required load. 5.2.2 Vendor to supply all couplings and guards for load and accessory shafts. Couplings to be sized for maximum continuous torque and meet API 671. 5.3 Gas turbine to be supplied on single mounting plate (baseplate). Typically interpreted to allow for skid mounting. Skid to be designed to limit worst case shaft alignment change to 50 micrometers.
5.3.2 Single piece baseplate preferred. Baseplate shall extend under driven equipment.

API 616 Accessories/Controls
5.3.2.4 Skid to permit field leveling. 5.4.1.2 Controls and instrumentation shall be suitable for outdoor installation. Usually not necessary or practical. 5.4.1.3 GT instruments and controls shall meet API 670. 5.4.1.4 GT control system must provide for safe startup, operation, and shutdown of gas turbine. 5.4.1.6 Unit shall continue to operate for specified time after AC failure. To overcome delay of emergency power startup. 5.4.2.1 Automatic start to require only single operator action.

API 616 - Controls
5.4.2.2 5.4.3.4
Control system to completely purge unit prior to startup. Load control to limit driven equipment speed to 105% rated speed. Alarm/shutdown system to be provided to protect unit and operator. Both Normal and Emergency (Fast) shutdown (i.e., cut of of fuel supply) must be available. Fuel control must include separate shutoff and vent valves, separate from fuel control valve, with local and remote trip.
5.4.4.1
5.4.4.3
5.4.4.8.1 Alarm and shutdown switches shall be separate. Often not practical (e.g., flame detector, axial thrust position).

API 616 - Alarms
Minimal Requirements

API 616 - Sensors
5.4.4.8.3 Alarm and trip settings not adjustable from outside housing. Not relevant with modern control systems. 5.4.4.9 All instruments (other than shutdown switches) shall be replaceable without shutting unit down. Not practical on many switches.
5.4.5.1.1 Off-skid or on-skid control system to be supplied with unit. 5.4.5.1.1 Any on-skid control system must meet hazardous area requirements (NFPA70). 5.4.6.2 On-skid electric systems must meet NFPA 70.

API 616 Inlet/Exhaust
5.4.7
Instrumentation: The API 616 Data Sheets Must be Filled Out by Purchaser to Indicate the Required Instrumentation. Manufacturer will often cross out line to indicate noncompliance. Vendor must include in proposal full list of instrumentation. API 670 governs basic requirements for temperature and vibration sensors.
5.5.3.1 Air inlet and exhaust system including inlet filter, inlet/exhaust silencers, ducting, and joints to be provided by vendor. 5.5.3.3 Inlet system shall be designed for maximum 4 in H2O pressure drop at site rated power. 5.5.3.4 Inlet/exhaust system design life is 20 years.

API 616 - Anciliaries
5.4.2.2 Bolts, rivets or fasteners are not permitted in inlet system. 5.5.3.9 A gas turbine compressor cleaning system must be provided. 5.5.4.4 Inlet Filter System requires walkways and handrails. Not necessary for very small units. 5.5.5 Inlet/Exhaust Silencer: Internals to be Stainless Steel. External Carbon Steel. Unit must be supplied with gas detection system, fire detection system, and fire suppression system to meet NFPA. Fire suppression shall be automatic based on thermal detection. Typical: Thermal, thermal gradient, LEL, and flash detector. CO2 for suppression.
5.7.3

API 616 Enclosure/Fuels
5.7.5
When enclosure is supplied it must be weatherproof and include fire detection/suppression, ventilation/purging, lights, and doors, and windows.
5.8.1.2 Gas fuel system: Must include strainer, instrumentation, manifolds, nozzles, control valve, shutoff valve, pressure regulator, and vent valve. 5.8.1.3 Fuel gas piping must be stainless steel. 5.8.1.4 Liquid fuel system: Must include pump, atomizing air, two shutoff valves, instrumentation, control valves, flow dividers, nozzles, and manifolds. Newer systems employ variable speed pumps instead of control valves.

API 616 - Fuels

If dual fuel system is provided it must allow bumpless bidirectional transfer.
5.81.5.2
5.8.2.2.2 Vendor must review customers fuel supply system. 5.8.2.4 5.8.4.2 Heating value of fuel cannot vary by more than 10%. Purchaser must specify required site emissions levels for NOx, CO, UHC, et al. Inspection, Testing, and Preparation for Shipment Inspections: Standard machinery type includes, materials, mechanical, Radiographic, ultrasonic, magnetic particle, dye penetrant, etc.
6.0

API 616 - Testing
6.3.2.3 Hydrostatic tests: Vessels and piping per ASME Section VIII (1.5 times rated pressure). 6.3.3 Mechanical Running Test: 4 hour no load full speed (maximum continuous speed) test to verify that the complete gas turbine package (including all auxiliaries except for inlet/exhaust system) operates within vibration and operational control limits. Contract coupling should be used. Rotordynamic signature and vibrations must be recorded. Compliance with these requirements is critical. Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)
6.3.4

API 616 - Testing
6.3.4.1 Optional Performance Test: Unit full load tested to PTC 22. 6.3.4.2 Optional Complete Unit Test: Similar to Mechanical run test but to include driven equipment. 6.3.4.3 Gear must be tested with unit during mechanical run test. Other optional test: Sound level, Auxiliary Equipment, Fire Protection, Control response, Spare Parts. 6.3.4.6 If unit fail mechanical run test, complete disassembly is required.

API 616 Vendor Data
6.4 Preparation for Shipment: Short term plastic wrapping. Long Term crating, surface anti-corrosion treatment, nitrogen fill of all vessels. 7.0 Vendors Data: Strictly follows Data Sheet requirements. Manufacturers must cross out line if they do not meet API. Minimum must contain performance maps, performance calculations, mechanical, hydraulic, layout, and electrical drawings, P&IDs, test and inspection results, as-built, parts lists, operation and maintenance manuals, installation manual, and technical data.

API 616 Vendor Data
Purchaser and Vendor To Fill in Delivery Dates Or Cross Out if Not Applicable.

API 614 Highlights
Lubricating Systems:
20 years service life Single full capacity pump with backup Duplex oil filters with smooth transfer All wetted surfaces to be stainless steel Lube oil tank minimum time 8 minutes All pumps, valves, switches, and sensors to have block and bleed valves Lube oil piping downstream of filter is stainless steel Sight indicators and levels sensors for tank Skid integrated lube oil tank OK Tank has vent with flame trap

API 670 Highlights
Machinery Protection:
Provides minimum design, installation, and accuracy standards for package alarms/shutdown switches and sensors. Must meet NFPA 70 hazardous area classifications. Signal and power wiring must be segregated. Alarms and shutdown switches must be separate. Lube oil piping downstream of filter is stainless steel. Bearings must have metal temperature sensors. Axial thrust bearings must have two proximity probes. Covers all instruments specified in API 616 data sheets.

API GT Instruments
Purchaser must Specify on API 616 Data Sheets

API GT Alarms/Shutdowns
Purchaser must Specify on API 616 Data Sheets. Note: Should be Separate from Instruments but not Always Feasible.

Factory Performance Tests
ASME PTC-22 Gas Turbine Performance ASME PTC-10 Compressor Performance

Factory Tests
PTC-10 Compressor
Closed loop test to determine performance of compressor Type I: Actual Gas, Type II: Simulated Gas Typically used for high pressure / high energy applications Reduces risk of startup delays due to vibrations or lack of performance.
PTC-22 Gas Turbine Full Speed, Full Load Test. Typically against a water break or generator/load cells. Determines maximum output power and efficiency.

Detailed Performance Tests

E Flare E Process Gas/Liquid Station Outflow Process P Exhaust P T Process Compressor Turbine P T P T P T P T T Heater Fuel Gas Seal Gas/Oil Lube Oil P P T F E
Electric System
Ambient (P,T) Relative Humidity
Air Inlet Compressor
Burner
P T F
P T
P T P T P T P T P T P T F
Lube Oil
Process
Process Gas/Liquid Station Inflow
05/16/05
PTC-22 (Gas Turbine)
PTC-10 (Compressor)

National Electric Code (NEC) NFPA 70

National Fire Protection Association NFPA 70
Hazardous Location Summary Electrical Requirements: Class 1: Flammable Gases, Vapors, or Liquids Class 2: Dust and combustible dust that can form explosive mixtures. Class 3: Fibers or flyings suspended in air that are easily ignitable. Divisions Within Class 1: Class 1, Division 1 (Zone 0 & Zone 1): Ignitable concentration of flammable mixtures exist most of the time. Class 1, Division 2 (Zone 2): Ignitable concentrations of flammable mixtures are not likely to exist under normal conditions.
MOST OIL & GAS APPLICATIONS ARE CLASS 1, DIVISION 2. SOME OFFSHORE AND REFINERY APPLICATIONS REQUIRE CLASS 1, DIVISION 1.

NFPA 70
What Does NFPA 70 Apply To:

-
On-Skid Electrical
Wiring and Cables Electric Motors (Pumps, Fans, Starter) Instruments and Alarms Junction Boxes Lights and Heaters (if applicable)
On-Skid Fire Systems

UV/IR Flash Sensors Flammable Mixture Detectors Temperature, Temperature Rise Detectors Smoke Detectors (if used) CO2 (or other) Fighting System
Air Inlet and Lube Oil Electrical Elements
Does Not Apply To Non-Electrical Components


NFPA 70
Exception To NFPA 70 Can Often Be Taken For:

-
Off-Skid Control System Battery Charger and Batteries Starter Motor Variable Frequency Drive Synchronization Panel Located in Control Room

NFPA 70
Basic Requirements for Class 1, Divisions 1 & 2 (Details in NFPA 70 Sections 500 and 501):

Grounded Explosion Proof Conduit for all Wiring Conduit and Conduit Connections are Copper Free Gas Sealed Conduit Connections Instruments, Connectors, Terminals in Explosion Proof Boxes Motors Rated Explosion Proof Fire Detection System (UV/IR, Thermal Gradient Detectors Gas (Flammable Mixture) Detectors Fire Fighting System (Inert Gas or Water Mist)

NFPA 70
On-Skid Explosion Proof Boxes

NFPA 70
On-Skid Explosion Proof Boxes Conduit Sealing
Copper Free Conduit

NFPA 70
Explosion Proof Flexible Conduit
Explosion Proof Instruments

NFPA 70
Explosion Proof Conduit
NonExplosion Proof Conduit


API Review
API 616 Data Sheet Review













API 617
Axial and Centrifugal Compressors and Expandercompressors for Petroleum, Chemical and Gas Industry Services
Seventh Edition, July 2002
Codes and Standards

Codes provide design guidelines and definitions
Example: Vibrations, materials, service connections, package design
Intent to Facilitate Manufacture and Procurement

Information Exchange between User and Manufacturer
No code designs a gas compressor Codes are by nature rather general. Any particular application may require modifications Codes React Slow to Technical Changes
Observation
API 617 very prevalent in Off-Shore, and Refineries Usually less prevalent in Pipeline Applications Often referenced within user-company specific Specifications All manufacturers have various amounts of comments and exceptions.
Convergence
Experience vs. API
In particular an issue for standardized designs
Seems to Converge
I.e API adopts modifications if they prove to be successful Slow Process
What Does Adherence to Codes Buy?

A better design? More security?
Downtime Commissioning Time Decommissioning Time Performance Safety Requirements
Cost ?
Codes Critical Technical Requirements

Definitions
ISO rating, normal operating point, maximum continuous speed etc.
Mechanical Integrity
Blade Natural Frequencies, Vibration Levels, Balancing Requirements, Alarms and Shutdowns
Design Requirements and Features

Materials, Welding, Accessories, Controls, Instrumentation, Inlet/Exhaust systems, Fuel Systems
Inspection, Testing and Preparation for Shipment Documentation Requirements Does not cover government codes & regulations
Whats in it?
General Requirements Centrifugal and Axial Compressors Integrally Geared Compressors Expander Compressors
PRIMARY FOCUS
SCOPE
API 617 covers the minimum requirements for axial compressors, single-shaft and integrally geared process centrifugal compressors and expander-compressor for use in the petroleum, chemical, and gas industries services that handle air or gas. This standard does not apply to fans (covered by API Std 673) or blowers that develop less than 34 kPa (5 psi) pressure rise above atmospheric pressure. This standard also does not apply to packaged, integrally-geared centrifugal plant and instrument air compressors, which are covered by API Std 672. Hot gas expanders over 300C (570F) are not covered in this standard.
SECTION 1GENERAL
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Alternative Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 Conflicting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.5 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.6 Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.7 Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.8 Unit Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Benchmark
The vendor may offer alternative designs. All designs should comply with this standard. Any exceptions to the standard including, alternate design differences from this standard, shall be clearly stated in the proposal.
Definitions
1.5.3 Compressor Rated Point The intersection on the 100% speed curve corresponding to the highest capacity of any specified operating point. Note: This is generally a derived point rather than an actual operating point (see Figure 2.1-1a for a graphical representation). Problem: Imposes requirements that are potentially not useful for the actual operation 105% speed definition is not very practical
Annex 2C-Cross Section/Nomenclature
Section 2 Basic Design

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.2 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2.3 Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 2.4 Guide Vanes, Stators, and Stationary Internals . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 2.5 Rotating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 2.6 Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 2.7 Bearings and Bearing Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 2.8 Shaft End Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 2.9 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 2.10 Lubrication and Sealing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 2.11 Nameplates and Rotation Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 2.12 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
2.3.1 Pressure-Containing Casings

2.3.1.1 The purchaser will specify the relief valve setting. The maximum allowable working pressure of the casing shall be at least equal to the specified relief valve setting. 2.3.1.1.1 When a relief valve setting is not specified, the maximum allowable working pressure shall be at least 1.25 times the maximum specified discharge pressure (gauge). System protection shall be furnished by the purchaser.
2.5.3 Shafts
2.5.3.1 Shafts for non through-bolt rotors shall be made of one-piece, heat treated steel that is suitably machined. Shafts that have a finished diameter larger than 200 mm (8 in.) shall be forged steel. Shafts that have a finished diameter of 200 mm (8 in.) or less shall be forged steel or hot rolled barstock, providing such barstock meets all quality and heat treatment criteria established for shaft forgings. 2.5.3.2 When modular (through bolt) rotors are provided, the stubshafts shall meet all quality and heat treatment criteria for shaft forgings. Refer to Annex 2C for rotor arrangements and nomenclature.
Dynamics
2.6.1.1 In the design of rotor-bearing systems, consideration shall be given to all potential sources of periodic forcing phenomena (excitation) which shall include, but are not limited to, the following sources:
a b. c. d. e. f. g. h. i. j. k. l. m. Unbalance in the rotor system. Oil-film instabilities (whirl). Internal rubs. Blade, vane, nozzle, and diffuser passing frequencies. Gear-tooth meshing and side bands. Coupling misalignment. Loose rotor-system components. Hysteretic and friction whirl. Boundary-layer flow separation. Acoustic and aerodynamic cross-coupling forces. Asynchronous whirl. Ball and race frequencies of rolling element bearings. Electrical line frequency.
2.6.1.2 For the purposes of this standard, a resonant condition of concern, such as lateral and torsional critical speeds, are those with an amplification factor (AF) equal to or greater than 2.5.
Rotor Response and Critical Speed

2.6.2 Lateral Analysis 2.6.2.1 Critical speeds and their associated AFs shall be determined by means of a damped unbalanced rotor response analysis. 2.6.2.2 The location of all critical speeds below the trip speed shall be confirmed on the test stand during the mechanical running test (see 2.6.3.1). The accuracy of the analytical model shall be demonstrated (see 2.6.3).
Stability Analysis
2.6.5 Level I Stability Analysis 2.6.5.1 A stability analysis shall be performed on all centrifugal or axial compressors and/or radial flow rotors except those rotors whose maximum continuous speed is below the first critical speed in accordance with 2.6.2.3, as calculated on rigid supports. For this analysis, the machine inlet and discharge conditions shall be at either the rated condition or another operating point unless the vendor and purchaser agree upon another operating point. Note: Level I analysis was developed to fulfill two purposes: first, it provides an initial screening to identify rotors that do not require a more detailed study. The approach as developed is conservative and not intended as an indication of an unstable rotor. Second, the Level I analysis specifies a standardized procedure applied to all manufacturers similar to that found in 2.6.2. (Refer to API Publ 684, 1.6 for a detailed explanation.)
Decision Criteria
Radial Bearings
2.7.2.4 The bearing design shall suppress hydrodynamic instabilities and provide sufficient damping over the entire range of allowable bearing clearances to limit rotor vibration to the maximum specified amplitudes while the equipment is operating loaded or unloaded, operation at any critical frequency within the specified operating speed range.
Bearing Temperature
2.7.1.3 As a design criteria, bearing metal temperatures shall not exceed 100C (212F) at specified operating conditions with a maximum inlet oil temperature of 50C (120F). Vendors shall provide bearing temperature alarm and shutdown limits on the datasheets. 2.7.1.3.1 In the event that the above design criteria cannot be met, purchaser and vendor shall mutually agree on acceptable bearing metal temperatures. Many applications use air-to-oil coolers, that produce oil temperatures in excess of 120F, and bearing metal temperatures above 212F. This should be acceptable, as long as the compressor is designed for these conditions.
Vibrations
2.6.8.8 During the mechanical running test of the machine,assembled with the balanced rotor, operating at its maximum continuous speed or at any other speed within the specified operating speed range, the peak-to-peak amplitude of unfiltered vibration in any plane, measured on the shaft adjacent and relative to each radial bearing, shall not exceed the following value or 25 m (1 mil), whichever is less: In SI units:
In U.S. Customary units:
where A = amplitude of unfiltered vibration, in m (mil) true peak-to-peak, N = maximum continuous speed, in rpm. At any speed greater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration level shall not increase more than 12.7 m (0.5 mil) above the maximum value recorded at the maximum continuous speed.
Section 3 Accessories
3.1 Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 3.2 Couplings and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 3.3 Mounting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 3.4 Controls and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 3.5 Piping and Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 3.6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Section 4 Inspection, Testing, and Preparation for Shipment

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Preparation for Shipment. . . . . . . . . . . . . . . . .
Some of the testing and inspection requirements are very much geared towards one-off designs. They usually add to the manufacturing time (especially if hold points are defined)
Section 5 Vendors Data

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 5.2 Proposals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 5.3 Contract Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Testing
4.3.6.2.1 All hydrodynamic bearings shall be removed, inspected, and reassembled after the mechanical running test is completed.
One of the purposes of this test is to protect against assembly errors. It is good engineering practice to not disassemble the compressor after a successful test. Some test procedures would require a re-test after re-assembly.
4.3.3.1 Performance Test
4.3.3.1.1 The compressor shall be performance tested in accordance with ASME PTC 10-1997, ISO 5389 or other approved national standard. A minimum of five points, including surge and overload, shall be taken at normal speed. For variable-speed machines, additional points may be specified. Note: Refer to the applicable test code for general instructions. ASME PTC 10-1997 may not apply to some low pressure ratio compressors. Refer to the scope, 1.2.2, of PTC 10-1997 for the selection of the appropriate test code to be used.
4.3.3.1 Performance Test

4.3.3.1.2 For variable speed machines, head and capacity shall have zero negative tolerance at the normal operating point (or other point as specified), and the power at this point shall not exceed 104% of the vendor predicted shaft power value. This tolerance shall be inclusive of all test tolerances. Surge shall comply with provisions of 2.1.1.1. Note: Both of the performance test codes referred to have provision for calculating inaccuracy based on instrumentation and procedures. These test inaccuracies are already included in the above tolerance and, therefore, are not to be further additive. 4.3.3.1.3 For variable-speed compressors, a speed other than the normal speed may be used, if necessary, to achieve the specified performance and performance tolerances, provided that this adjusted speed meets the criteria specified in Chapter 1, 2.6.
Performance Test
4.3.3.1.4 For constant-speed compressors, the capacity shall be as specified in 4.3.3.1.2. The head shall be within the range of 100% 105% of the normal head. The horsepower, based on measured head at normal capacity, shall not exceed 107% of the value at the specified normal operating point. If the power required at this point exceeds 107%, excess head may be removed by trimming impellers at the purchasers option.
Datasheets
ANNEX 1A REFERENCE LIST OF U.S., ISO, AND INTERNATIONAL STANDARDS (NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 ANNEX 1B PROCEDURE FOR THE DETERMINATION OF RESIDUAL UNBALANCE (NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 ANNEX 1C TYPICAL SHAFT END SEAL CROSS-SECTIONAL DRAWINGS (INFORMATIVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59 ANNEX 1D TESTING OF GAS SEALS IN SEAL VENDORS SHOP (NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67 ANNEX 1E TYPICAL MATERIAL SPECIFICATIONS (INFORMATIVE) . . . . . . . . . . . . . . . . .

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