STANDARD SPECIFICATION STANDARD SPECIFICATION No. FOR 6-36-0004 Rev. 4 INSTRUMENT AIR DRYER UNIT Page 168 eles CRA aegic UR grt & faq are fates STANDARD SPECIFICATION FOR INSTRUMENT AIR DRYER UNIT 4 ost010 REVISED AND REISSUED PR ANDY Ni ND 3260207 REVISED AND REISSUED AKRCYKS: SMA ve 2 26/1208 REVISED AND REISSUED bee RN NN AS + oat REVISED AND REISSUCD co sac KD aS © 1911288 __ISSUED AS STANDARD SPECIFICATION —~Sindards Standards Committee Bureau Cowener Chairman ‘Approved by Rev. baty Purpoce Prepared Checked No by by Format No, 8-00-0001-F1 Rev. 0 (Copyright EL = All rights reservedSTANDARD SPECIFICATION STANDARD SPECIFICATION No. SEHfSAER By ENGINEERS Bate ONAN For 6-36-0004 Rev. 4 Aucernse wansnmimies INSTRUMENT AIR DRYER UNIT Page 209 Abbreviations: ANSI American National Standard Institute APL : ‘American Petroleum Institute ASME : American Society of Mechanical Engineers ASTM, “Amcrican Society for Testing and Materials FAT Factory Acceptance Test Is Indian Standard TEMA Tubular Exchanger Manufacturer's Association Packaged Equipment Standards Committee Convenor: Mr. Manoj kumar Members: Mr. A.P.S Ahluwalia Mr. P. Bhattacharjee Mr. P. P. Pandey Mr. J. Ghosh Mr. R. K. Bhandari (Project) Format No. -00-0001-F1 Rev. 0 “Copyright BL ~ AI igh resorvedSTANDARD SPECIFICATION STANDARD SPECIFICATION No. SGifetze By ENGNEERS, ane ORT UMITED FOR 6-36-0004 Rev. 4 Seeawe awvwumey INSTRUMENT AIR DRYER UNIT Page Sot CONTENTS 1.0 GENERAL. 2.0 CODES, STANDARDS AND REGULATIONS 3.0 TECHNICAL REQUIREMENT 4.0 INSPECTION AND TESTING 5.0 PROTECTION AND PAINTING.. 6.0 PACKAGING AND IDENTIFICATION .. 7.0 SPARE PARTS. Format No. &-00000%-F1 Rev. 0 Copright EL ~ Al ighis reservedSSG ZTE ale ENGINEERS. STANDARD SPECIFICATION —_ STANDARD SPECIFICATION No. sarkeleics NOV ie FOR 6-36-0004 Rev. 4 seaavavees INSTRUMENT AIR DRYER UNIT Page 4 of 9 10 dd 2.0 2a GENERAL This specification outlines the minimum requirements under which the manufacturer shall design, ummufacture, test and supply the Instrument Air Dryer unit, complete with all accessories. This specification also lays down the requirements for control and instruments, electrical and associated pipe work. CODES, STANDARDS AND REGULATIONS This standard is based on the following Indian Standard, and the standards referred therein, which shall he deemed to be part of this standard: ASME Sec. VII Div.1 & : Boiler and Pressure Vessel Code- Pressure Vessels & Div2 Alternative rules ASME Sec. IX : Boller and Pressure Vessel Code- Welding and tsrazing Qualifications EIL Standard Spec. 6-12 : Stancard Specification of Pressure Vessels for Packaged Items 0030 FIL. Standard 7-12-0001 + Vessel Tolerances EIL Standard 7-12-0006 : Angle Leg Support EIL Standard 7-12-0007 Pipe Leg Support BIL Standard 7-12-0010 + Mantole with Davit EIL Standard 7-12-0013 2 Nozz’e Reinforcement and Projection EIL Standard 7-12-0015 Standard Bolt Hole Orientation EIL Standard 7-12-0025 2 Fire Proofing and Insulation TEMA“ Tubular Exchanger Manufaclurer’s Association APL 661 Air Cooled Heat Exchanger for General Refinery Services (For Offshore Applications) EIL Standard Spec. 6-24- : Standard Specification for Cartridge Filter 0004 ANSIB 313 2 Process Piping APIRP 14 E, : Recommended Practice for Offshore Production Platform Piping System ANSIB 16.5 Pipe Flanges and Flanged Fittings ANSIB 16.11 Forged Steel Fitting, Socket Welding ard Threaded ANSIB 36.10 Carben, Alloy and Stainless Steel ASME Sec. II + Boiler and Pressure Vessel Code- Materials ASTM + American Society for Testing and Materials, API RP-520 Part UI : Recommended Practise for Pressure Relieving System EIL Standard Spec. 6-44- : Specification for Hot insulation of Vessels, Piping and 0002 Equipments EIL Standard Spec. 6-44- : Specification for Insulation for Offshore Application 0507 EIL Standard Spec. 6-51- : Specification for Electrics of Package Equipments (For 0093 ‘Onshore Applications) Format No. €-00-0001-F1 Rev. 0 Copvight EL —Allighis reservedSTANDARD SPECIFICATION STANDARD SPECIFICATION No, ENGINEERS sear SEES OPO crewmen at onren uur SogiRE Reva EIL Standard Spec. 6-51- : Offshore Electrical Works 0058 TEC + International Electro-technical Commission NEMA + National Electrical Manufacturer's Association FIL Standard Spec. 6-52- : Instrument Standard Specification for Package Units (For ous2 Onshore Applications) FIT. Standard Spec. 6-52- + Design of Instruments and Controls for Offshore 0085 EIL Standard 7-52-0001 + Instrument Connection on Vessels Standpipes and Tanks EIL Standard 7-52-0002 Instrument Connection on Piping EIL Standard 7-52-0035 2 Thermowell EIL Standard 7-52-0036 + Thermocouple/RTD Assembly with Thermowell OSHA + Ovcupational Safety & Health Act 22 23 30 3a 32 3.21 3.22 3.23 3.24 3.2.5 Latest revisions of the above-mentioned standards as on the date of enquiry shall be applicable. Other international standards may also be acceptable subject to their being equivalent or superior to those listed above, with prior approval of purchaser. For provisions not covered by the above codes & standards, applicable good engineering pavtives aud nosis shall yover. TECHNICAL REQUIREMENT ‘Type of Unit ‘The drying process shall be one of the following types, as mentioned in the data shect: i) Heatless Purge type ii) Split flow no purge loss type iit) Heat of Compression type General Requirement Unless otherwise specified the package shall be designed for 20 years operation and continuous duty. A corrosion allowance of min. 3.0 mm shall be considered for all carbon steel vessels unless otherwise specified The unit shall be fully automatic in operation, with a provision for manual operation in case of timer failure. Regeneration flow splitter shall be control valve type. Following interlocke/alarme indication chell be provided on the skid x @ minimum, av applicable for the system: i) Interlock system to ensure that regeneration system is initiated only when the Change over valves are switched in correct position. ii) Audio-visual indication to indicate failure of Change over valves. Format No. 8-00-0001-F1 Rev. 0 Copyright BL — Alvighis reservedSTANDARD SPECIFICATION STANDARD SPECIFICATION No, SERRATE By ENGINEERS. anes ONIN UMITED FOR 6-36-0004 Rev. “nese towvnwvere INSTRUMENT AIR DRYER UNIT Page 6of9 iii) Very low flow in the regeneration circuit to trip the heater iv) Audio-visual indication to indicate low flow in regeneration circuit, ¥) Audio-visual indication to indicate excessive regeneration air temperature. vi) Indicating lamps for power ON of control panel, adsorber under adsorption, regeneration or cooling, heater ON, timer ON etc. vii) Audio visual alarm to indicate high air temperature after regeneration cooler. 3.2.6 Control Panel Shall be PLC based type. Change over valves in the skid and the PLC control systems sitll be shop tested at the vendor's shop. PLC shall be subject to FAT at shop. separately. Shop testing of change over valves shall include stroking of actuators, check of valve opening-closing etc. besides hydro test of the assembled skid. Also functional test of the change over valves, with the PLC to be supplied for this job, involving sequential operation of the valves as programmed in the PLC shall be carried out at the shop. 33 Adsurber Vessel 3.3.1 The Unit shall consist of two identical adsorber vessels arranged for automatic change over such that one vessel is always under drying and other under regeneration mode. Direction of air flow during heating and cooling cycles for regeneration of desiccant shall be in counter flow. 3.3.2 ach adsorber shall be equipped with a suitable corrosion resistant austenitic stainless steel sereen for desiccant support. Screen shall be in suitable sections so as to facilitate replacement through manhole. Provision shall be made for replacing and removing desiccant without dismantling the connected pipe work. 3.3.3 Desiccant bed shall be of Activated alumina or molecular sieve as mentioned in the data sheet. 3.3.4 Each adsorber shall be fitted with safety valve. Pressure and temperature gauges at the air inlet and outlet of each adsorber shall be provided. 3.3.5 Adsober vessel for heatless type dryers shall be designed for cyclic loading as per ASME See. VIII Div. 2. 3.3.6 Access platform with ladder for desiccart filling in adsorber vessels shall be provided. 34 Heater 3.4.1 Heating of regeneration air, wherever applicable, shall be by means of Electric Heater. Heater shall have atleast 20% excess capacity over and above calculated heater capacity (including unconnected spare). The unconnected spare elements shall be distributed equally in all banks. 3.4.2 Heater shall be external type. The electric heating elements shall be U-Type and made from Ni-chrome steel or incolloy material. 3.4.3 When heat of compression type air dryer package is specified, the reactivation heater shall be designed for full heating load ie. from wet air inlet temperature to regeneration temperature, without taking credit of the inlet temperature of hot air being used for regeneration. However the number of heater(s) to be operated for heet of compression system shall be automatically selected to be suitable for the variable load based on the inlet temperature of supplied air (wet/hot air) Zor the regeneration mode. 3.44 The heater shall have 3 numbers of banks. One of the banks shall be thyristor controlled for fine control of regeneration ait temperature. Suitable arrangement shall be provided to control regeneration air temperature, Format No. 8-00-0001-F1 Rev. 0 ‘Copyright BIL — All ighis reservedSTANDARD SPECIFICATION STANDARD SPECIFICATION No. Git Qi ENONEERS ane SNiniD FOR 6-36-0004 Rev. 4 Sewast tucwemieen INSTRUMENT AIR DRYER UNIT Page 79 34.5 Safety valve shall be provided for heater vessel 3.4.6 Electric Heater shall comprise of required numbers of elements of same KW rating. 35 Regeneration Cooler 3.5.1 Regenerative cooler for onshore application shall be water cooled shell & tube type exchanger. 3.5.2 The heat exchanger shall be horizontal type with carbon steel saddle supports. 3.5.3 Regeneration cooler shall have 20% margin on surface area, 3.54 The heat exchanger shall have SA 179 (Carbon steel) cold drawn tubes. The standard tube size shall be 20mm O.D. and tube pitch shall be 25mm. Minimum tube thickness shall be 14 BWG, The tube shall be seamless. Expanded tube to tube sheet joints stall be provided. U tubes shall not be used. 3.5.5 Heat exchangers shall be designed and located such that they can be removed or serviced ‘without disturbing pipe work 3.5.6 Minimum 20 NB vent shall be provided at the highest point and drain shall be provided at the lowest point on the shell. Safety valve discharge shall be located at the highest point. 3.5.7 Bolting for channel and girth flanges shall consist of continuously threaded studs conforming wo SA 193-B7 with nuts in accordance with SA 194-211 3.5.8 The tube side velocity for cooling watzr shall be in the range of 1.25 to 2.Smv, 359 Feuling factor for air side shall he (0007 hr m? °C/keal and cooling water side shall be (0.0004 hr m’ °C/keal unless otherwise specified 3.5.10 Fer offshore applications, air cooled heat exchangers shall be considered. Regeneration cooler shall be forced air-cooled fined pipe heat exchanger. The design of cooler shall comply with API 661 3.6 Pre-Filter and After-Filters 3.6.1 A cartridge type Pre-filter with isolation and by-pass arrangement shall be provided at the ‘niet, Pre-fiter shall be feed with an euromatic drain tap with by-pass arrangement 3.6.2 Incase of Heat of compression type dryer, one separate pre-filtcr shall be provided in hot air stream. 3.6.3 The Pre-filter shall have filtration efficiency of 99 % down to 5 micron. 3.64 Two numbers of after filters, one in operation and one as stand-by, shall be provided at the dry air outlet for arresting the desiccant dust particles. The after filters shall be valved to permit each item to be serviced durirg normal operation. The after filtes shall have 99% efficiency for 5 microns particle size. 3.7 Moisture Separator 3.7.1 Moisture separator with automatic drain trap and by pass arrangement shall be provided after the regeneration cooler. A demister shall be provided in the moisture separator outlet Format No. 6-00-0001-F1 Rev. 0 Copyiight EL — Alghts resovedSTANDARD SPECIFICATION STANDARD SPECIFICATION No. FOR 6-36-0004 Rev. 4 INSTRUMENT AIR DRYER UNIT Page 809 40 an 42 ald 423 424 43 44 44d 442 443 aaa 58.0 SA ‘Thermal Insulation Thermal insulation of vessels, piping and equipments shall be as per Standard specification for Hot insulation of Vessels, Piping and Equipments (Doc. No. 6-4-0002). for onshore application, For offshore application, insulation shall be as per Standard specification for Insulation for Offshore Application (Doc. No. 6-44-0507). INSPECTION AND TESTING Equipment shall he subjected to stagewise expediting, inspection and testing at vendor’s/sub- vendor's works by purchaser/its authorised inspection agency. Vendor shall submit Quality Assurance (QA) plan before commencement of fabrication. Approved QA plan shall form the basis for equipment inspection. Testing at Works Vendor shall perform tests and inspection necessary to ensure that the material and ‘workmanship conform to the requirement of this specification Fistings, valves. instruments. other accessories like filters ete. shall be duly tested and ‘manufacturer's test certificates shall be furnished. All the pressure vessels shall be hydrostatcally tested and inspected as per applicable codes and standards. The total skid shall te hydro tested or pneumatically tested at applicable pressure. Any other tests as per data sheets, standards, and codes shall also be performed. Fumetional test of me change over valves and FLU as per clause no, $.2.6 of this specification. Any or all the tests, at purchaser's option, shall be witnessed by purchasev/its authorised inspection agency. However, such inspection shall be regarded a3 check up and shall in no way absolve the vendor of his responsbbility. Performance Testing and Guarantees ‘A eld performance test shall be conducted by the vendor to demonstrate the performance of, the plant after commissioning. ‘The following shall be guaranteed and demonstrated during the performance testing: i) Dry air Capacity of the nnit at ckid entlat ii) Dew point of air at the outlet throughout the cycle including the cycle changeover period. iii) Pressure drop across the unit. Necessary instruments for the performance testing shall be arranged by the vendor, and shall be tested and calibrated before undertaking the performance test ‘The procedure of performance testing shall be submitted for Purchaser's review and shall be ‘mutually agreed between the purchaser and the vendor. PROTECTION AND PAINTING Surface preparation and painting shall be done as per standard Specification for Shop and Field painting (specification no.6-44-0004). For Offshore application respective Project, Specitication for Protective coating for offshore platform shall be referred. Format No. €-000001-F1 Rev. 0 ‘Conyight 1L— Al igh reservedSTANDARD SPECFICATION Na SE yevcners__ STANDARD SPECIFICATION SNe FOR 6-36-0004 Rev. 4 Event ames INSTRUMENT AIR DRYER UNIT Page 9of8 S2 53 60 61 62 64 65 70 7 12 13 Stainless steel surfaces, both inside and outside, shall be pickled and passivated. Machined and bearing surfaces shall be protected with vamish or thick coat of grease. PACKAGING AND IDENTIFICATION All packaging shall be done in such a manner as to reduce the volume. The equipment shall be dismantled into major components, suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection. Atachments, spare parts of the equioment and small items shall be packed separately in ‘wooden-cases. Each item shall be appropriately tagged with identification of main ‘equipment, item denomination and reference number of the respective assembly drawing. Detailed packing list in water-proof envelope shall be inserted in the package together with equipment Each equipment shall have au identification plate giving salient equipment data, make, year of manufacture, equipment number, name of manufacturer etc. Vendor shall furnish procedure for prolonged storage of supplied equipment/ material at site. ‘SPARE PARTS. ‘Vendor shall submit list of spare parts with recommended quantities and itemised prices for fist wo yeaty of operation Of ue eyuipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment is facilitated. Recommended spares and their quantitics should take into account related factors of eqjnipment reliability, effect of equiprrent downtime upon produetion or safety, cost of parts and availability of vendor's service facilities around the proposed location of equipment, ‘Vendor shall also submit a list of commissioning spares with quantities. The commissioning spares shall be sufficient for trouble free commissioning of the system at site. Any commissioning spares required during commissioning, over and above, the commissioning spares supplied, shall be made available by the vendor without any cost sax! ‘ime implication to purchaser. If for any reason, during commissioning, vendor needs to utlise spares from 2 years’ operation spares, the same shall be replenished by vendor within a reasonable time without any cost implication to purchaser. Any unused commissioning spares shall be handed aver to oxime. Format No, &-00-000%-F1 Rev. 0 Copyaght EL — Al ights reserved