PIP RESR001 Packaged, Skid-Mounted Industrial Process Refrigeration Systems Specification

Transcription

1 EDITORIAL REVISION October 2010 Process Industry Practices Machinery PIP RESR001 Packaged, Skid-Mounted Industrial Process Refrigeration Systems Specification

2 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas PIP Member Companies and Subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User s client. PIP s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PRINTING HISTORY August 2000 Issued February 2008 Complete Revision January 2002 Editorial & Technical Revision October 2010 Editorial Revision Not printed with State funds

3 EDITORIAL REVISION October 2010 Process Industry Practices Machinery PIP RESR001 Packaged, Skid-Mounted Industrial Process Refrigeration Systems Specification Table of Contents 1. Introduction Purpose Scope References Process Industry Practices Industry Codes and Standards Government Regulations Requirements General Package System Compressors Drivers Heat Exchangers Vessels Lubrication Oil System Purge System System Controls and Instrumentation Electrical Pipe, Valves, and Fittings Pressure-Relieving Devices Insulation Structural Steel Base Noise Compressor Vibration and Critical Speeds Painting Inspection Testing Preparation for Shipment Documentation Appendix A Monitoring System Instrumentation Table Appendix B Purchaser s Quality Surveillance Checklist Data Forms RESR001-R Documentation Requirements Sheet RESR001-D Skid-Mounted Industrial Process Refrigeration Systems Data Sheet Process Industry Practices Page 1 of 20

4 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October Introduction 1.1 Purpose This Practice provides requirements for packaged, skid-mounted industrial process refrigeration systems. 1.2 Scope 2. References This Practice describes the minimum requirements for the performance, design, fabrication, testing, inspection, and preparation for shipment of packaged, skidmounted process refrigeration systems. This Practice is not intended to cover commercial or absorption chiller systems. Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles will be used herein where appropriate. 2.1 Process Industry Practices (PIP) PIP ELSMT01 - AC Squirrel Cage Induction Motors (600 Volts and Below) PIP ELSPS01 - Electrical Requirements for Packaged Equipment PIP ELSPS01D - Data Sheet for Electrical Requirements for Packaged Equipment PIP ELSPS01V - Electrical Requirements for Packaged Equipment Preferred Vendor and Component List PIP PCDPS001 - Packaged Equipment Instrumentation Documentation Requirements Data Sheet and Instructions PIP PCERE001 - Rotating Equipment Monitoring Guidelines PIP PCSPS001 - Packaged Equipment Instrumentation Specification PIP PCSPS010 - Small, General Purpose Packaged Equipment Instrumentation Specification PIP REEE003 - Guidelines for General Purpose Nonlubricated Flexible Couplings PIP STF Fixed Ladders and Cages Details PIP VECV Vessel Design Criteria, ASME Code Section VIII, Divisions 1 and 2 PIP VEDST003 - Shell and Tube Heat Exchanger Specification Sheet PIP VEFV Vessel/S&T Heat Exchanger Standard Details (US Customary Units) PIP VESSM001 - Specification for Small Pressure Vessels and Heat Exchangers with Limited Design Conditions Page 2 of 20 Process Industry Practices

5 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems PIP VESV Vessel Fabrication Specification, ASME Code Section VIII, Divisions 1 and Industry Codes and Standards American Petroleum Institute (API) API Form-Wound Squirrel-Cage Induction Motors Horsepower and Larger API General Purpose Steam Turbines for Petroleum, Chemical, and Gas Industry Services API Special Purpose Steam Turbines for Petroleum, Chemical, and Gas Industry Services API Axial and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical and Gas Industry Services API Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services API Rotary-Type Positive-Displacement Compressors for Petroleum, Petrochemical, and Natural Gas Industries API Machinery Protection Systems Air Conditioning and Refrigeration Institute (ARI) ARI Positive Displacement Condensing Units American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) ASHRAE 15 - Safety Code for Mechanical Refrigeration American Society of Mechanical Engineers (ASME) ASME Boiler and Pressure Vessel Code Section VIII, Div.1 - Pressure Vessels, (ASME Code) ASME B Chemical Plant and Petroleum Refinery Piping ASME B Refrigeration Piping American Welding Society (AWS) AWS D1.1 - Structural Welding Code National Fire Protection Association (NFPA) NFPA 70 - National Electrical Code (NEC) Rubber Manufacturer s Association (RMA) RMA IP-20 - Classical V-Belts and Sheaves RMA IP-24 - Drives Using Synchronous Belts Process Industry Practices Page 3 of 20

6 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October Government Regulations 3. Requirements U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) 3.1 General OSHA 29 CFR Occupational Safety and Health Standards The supplier shall assume full responsibility for the complete, as shipped, unit Subsuppliers and subcontractors used by the supplier shall be subject to written approval by the purchaser before placement of suborders Any proposed exceptions to this Practice or any referenced PIP Practices, purchaser s data sheets, and referenced codes and standards shall be provided with the proposal Unless otherwise specified in writing by the purchaser, no substitution for material, equipment, or components shall be permitted A qualified project engineer shall be named and assigned. The project engineer shall coordinate the project and serve as sole contact with the purchaser from issuance of purchase order through completion of startup and commissioning. 3.2 Package System The refrigeration package shall provide liquid refrigerant to its chiller(s) (evaporator[s]) in the quantity and at the temperature necessary to produce the specified process temperature and refrigeration duty The purchaser shall specify the period of continuous operation required on the data sheet, RESR001-D Performance, capacity, and operating conditions shall be in accordance with the purchaser s data sheet, PIP RESR001-D The refrigeration system shall consist of a complete package with all components (compressor, evaporator, condenser, driver, instrumentation, etc.) factory mounted, piped, and wired Unless written approval is received from purchaser, multiple baseplates designed to facilitate shipping shall not be permitted The system shall be capable of stable operation at specified minimum load Rating condition used to establish the capacity of the refrigeration package system shall be provided with the proposal Storage capacity for refrigerant receiver shall be sufficient to retain the entire system refrigerant inventory if 90% full, including the volume of purchaserfurnished heat exchangers and piping if applicable. Purchaser shall provide piping and exchanger refrigerant volumes if they impact receiver sizing. Page 4 of 20 Process Industry Practices

7 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems Fluorocarbon systems shall have a replaceable-element desiccant filter dryer with visual moisture indication. The element shall be replaceable while system is in operation Unless otherwise specified, the system refrigerant shall be supplied by purchaser The refrigeration system high-pressure side maximum allowable working pressure (MAWP) shall be greater than the condensing pressure by a minimum of 170 kpa (25 PSI) or 10%, whichever is greater The refrigeration system low-pressure and high-pressure MAWPs shall be a minimum of 340 kpa (50 PSI) greater than the refrigerant vapor pressure at the maximum specified ambient temperature Unless otherwise specified on the purchaser s data sheet, PIP RESR001-D, the system and all auxiliaries shall be designed for unprotected outdoor installation The refrigeration system shall be designed for the area electrical classification specified on the purchaser s data sheet, PIP RESR001-D Any special tools required for operation and/or maintenance shall be provided with the package The complete package shall meet the noise limits in accordance with the purchaser s data sheet, PIP RESR001-D. 3.3 Compressors General The compressor shall be designed and manufactured for the refrigerant being compressed The system shall be provided with proper equipment to ensure that liquid cannot enter the compressor suction. Equipment provided for this purpose shall be detailed in the proposal Unless purchaser has specified a desired compressor type on the data sheet, vendor shall provide the type of compressor that is most suited for this specific application The compressor shall be provided with seals to prevent the loss of refrigerant or the contamination of refrigerant over the range of operating conditions and during periods of idleness. 1. Seal operation shall be suitable for variations in suction conditions that may prevail during startup and shutdown. 2. A description of the seal system and the guaranteed maximum refrigerant leakage rate shall be provided with the proposal Unless otherwise approved by purchaser, complete compressor casing, including all welded connections, shall be hydrostatically tested to 1.5 times the maximum case design pressure or pneumatically tested at 1.1 times the maximum case design pressure. 1. The test shall be maintained for 30 minutes or more to permit complete examination of parts under pressure. Process Industry Practices Page 5 of 20

8 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October The certified test results shall be submitted to purchaser within five business days of the test being performed Cast iron and ductile iron pressure-containing parts shall not be permitted for compressors that handle flammable or hazardous refrigerants Compressor inlet pressure shall be greater than atmospheric pressure if flammable refrigerants are used Compressors shall be in accordance with ASHRAE If multiple compressors are provided, isolation valves and controls shall be provided that permit the operation of the system with the remaining compressors if one or more is out of service Reciprocating Compressors The compressor may be open, semi-hermetic, or hermetic in accordance with the purchaser s data sheet, PIP RESR001-D Compressors shall have a method to prevent liquid refrigerant accumulation in the crankcase if compressor is unloaded or idle with the system under pressure. The method and equipment provided for this purpose shall be detailed in the proposal If a flooded evaporator is used in the refrigeration cycle, the compressor shall have the following features: a. Automatic control from temperature- or pressure-sensing elements b. Crankcase heater energized during off cycles c. An automatic solenoid to close liquid line when the compressor is stopped d. A solenoid valve to shut off cooling water to water-cooled compressors when the compressor is stopped Layout shall provide sufficient room around and above the compressor to permit removal of cylinders and valves from the compressor frame and to permit removal of the flywheel and crankshaft Compressors less than 20 kw (25 hp) shall be provided with feet with vibration isolation pads A detailed description of the compressor-unloading system shall be provided in the proposal Open compressors shall be directly connected through a coupling. The drive coupling shall be in accordance with PIP REEE Hermetic and semi-hermetic compressors shall be in accordance with ARI 520 and have the following features: a. Cooled by suction gas b. Accessible for maintenance c. Drivers shall not require motor heaters Page 6 of 20 Process Industry Practices

9 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems Rotary Compressors The compressor shall be helical rotor, screw compressor type If the compressor is an oil flooded design, the oil shall be compatible with the refrigerant. Comment: Oil flooded designs may be preferred because they require fewer seals The seal system shall be designed to contain the refrigerant during all modes of operation such as startup, shutdown, and periods of idleness If specified, the seal system shall be designed for zero leakage Capacity control from full load down to specified minimum load shall be provided by internal slide valves and, if required, by hot gas bypass that provides automatic unloading Oil separation in compressor discharge shall be the supplier s recommended design for refrigeration systems Drive coupling shall be in accordance with PIP REEE Centrifugal Compressors 3.4 Drivers Unless otherwise specified, the compressor may be open or hermetic Compressor capacity control may be variable speed drive, inlet guide vanes, suction dampers, or a combination subject to purchaser approval. The control system proposed shall be explained and detailed in the proposal The purchaser shall provide applicable gear specification for gear boxes, if required Drive coupling shall be in accordance with PIP REEE Electric Motors (Open Drive Systems) Electric motors shall be in accordance with PIP ELSMT01 or API 541, as applicable Steam Turbines Steam turbines shall be in accordance with API 611 or API 612, as specified by purchaser Belt Drives V-belts shall be in accordance with RMA IP Synchronous belts shall be in accordance with RMA IP-24. Comment: Synchronous belts provide a more positive drive mechanism. Process Industry Practices Page 7 of 20

10 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October Heat Exchangers General System heat exchangers shall be in accordance with PIP VECV1001 and PIP VESV1002 or PIP VESSM001, as applicable Exchangers shall be arranged such that maintenance space for tube pulling or cleaning shall be to the outside of the skid. Space required shall be shown on proposal drawings The condenser and evaporator shall be independent vessels Unless otherwise specified, the condenser and evaporator shall have a DN 20 (NPS ¾) drain and vent connection(s) on both the shell and tube sides, complete with valve and plug. Drains shall be at the low point to allow for complete drainage Shell and Tube Unless otherwise specified on purchaser s exchanger specification sheet, PIP VEDST003, exchangers shall be, as a minimum, TEMA C The purchaser shall furnish exchanger design requirements on specification sheet PIP VEDST A completed exchanger specification sheet, PIP VEDST003, shall be provided with the proposal For systems using water as the condensing media, the following design requirements shall apply: a. The condensing system shall be sized for full capacity and maximum inlet water supply temperature. b. The water side of the condensing system shall be designed to not require throttling. Comment: Throttling the cooling water accelerates fouling of the exchanger If a flooded type evaporator is provided, it shall be provided with a full-length, level gauge Direct Expansion If approved by the purchaser, a direct expansion type evaporator up to 350 kw. (100 tons) of refrigeration may be provided Direct expansion evaporators shall include thermal expansion valve(s), equalizing line, and a back-pressure regulator Subcooler If approved by the purchaser, a subcooler may be provided Design details of the subcooler shall be provided with the proposal. Page 8 of 20 Process Industry Practices

11 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems 3.6 Vessels General System vessels shall be in accordance with PIP VECV1001 and PIP VESV1002 or PIP VESSM001, as applicable Receiver The receiver shall have a dip tube with vortex breaker and/or adequate submergence to prevent vortexing in the liquid outlet line The receiver shall be provided with a full-length sight level gauge Unless otherwise specified, the receiver shall have a DN 20 (NPS ¾) minimum vent and drain complete with valve and plug. Drains shall be at the low point to allow for complete drainage The receiver shall have a DN 25 (NPS 1) minimum refrigerant charging/evacuation connection complete with valve and plug Oil Separator (Rotary Compressor Systems) Unless otherwise approved by purchaser, mounting the motor/compressor drive train on a horizontal oil separator shall be limited to 600 kw (800 hp) driver. If the driver is greater than 600 kw (800 hp), the system shall be provided with an independently supported drive train The separator design shall incorporate a method for removing oil from the dry side of the separator Adequate access for changing and maintaining the coalescing elements shall be provided. The coalescing elements shall be replaceable The oil carryover rate shall be provided in the proposal The oil separator shall have a heater(s) that is capable of raising the oil temperature from minimum ambient temperature to minimum allowable starting temperature within 12 hours maximum. Any requirements for insulating the separator to meet this requirement shall be detailed on review drawings provided with the proposal The oil separator shall have a replaceable heater(s) If multiple compressors are used, each compressor shall have an individual discharge line into the separator The separator shall have a low-oil-level switch interlocked to turn the heater(s) off if oil level is low The oil separator shall have level gauges Oil Recovery Pots (Reciprocating or Rotary Compressor) Oil recovery systems shall be provided with the following features as a minimum: a. A direct level indicator Process Industry Practices Page 9 of 20

12 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October 2010 b. An oil still/receiver with a thermostatically controlled electric heater for flashing liquid refrigerant. Minimum liquid level shall be maintained above heating elements while energized c. A solenoid-operated feed valve to automatically charge oil to the recovery system if the heater is energized d. Oil recovery piping from recovery pot to the oil reservoir Recovery pots shall be in accordance with PIP VECV1001 and PIP VESV1002 or PIP VESSM001, as applicable Suction Knockout Drum A suction knockout drum shall be provided On direct expansion units, the system shall be provided with a suction trap to prevent liquid from entering the compressor. The trap shall be arranged for automatic draining On flooded or thermosyphon evaporator units, the evaporator shall be provided with an integral surge drum to provide for complete separation of liquid and gas Design details of the suction knockout drum shall be provided prior to fabrication. If applicable details shall include mesh pad sizing and boil-out coil Sizing criteria shall be provided with the proposal A high-liquid-level shutdown switch shall be provided, as a minimum A liquid-level indicator shall be provided Suction knockout drums shall be in accordance with PIP VECV1001 and PIP VESV1002 or PIP VESSM001, as applicable Economizer (If Provided) A description of the system, system efficiencies, and any additional costs associated with the economizer shall be provided with the proposal Design details shall be provided with the proposal If used for a screw compressor application, a pressure-regulating device shall be provided to prevent exceeding the vessel minimum design temperature during low-load operation A high-liquid-level shutdown switch shall be provided on the economizer A level indicator shall be provided on the economizer Economizers shall be in accordance with PIP VECV1001 and PIP VESV1002 or PIP VESSM001, as applicable. Page 10 of 20 Process Industry Practices

13 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems 3.7 Lubrication Oil System General A pressurized lubrication system(s) shall be provided that will supply oil to meet the requirements of the bearings, seals, and controls Unless otherwise specified on purchaser s data sheet, PIP RESR001-D, the system shall be in accordance with supplier s standard If a water-cooled oil cooler(s) is required, it shall be in accordance with PIP VESSM001 and TEMA C, and the materials of construction shall be as specified for the refrigerant. The oil cooler(s) shall be piped and in place within the packaged unit Provisions for monitoring the oil system shall be, as a minimum, in accordance with the Monitoring System Instrumentation Table in Appendix A When specified by the purchaser, the system refrigerant may be used as the cooling medium for the oil cooler Pumps Main and auxiliary oil pumps shall be positive displacement and shall be rated to sustain continuous operation of the compressor Main (if required and not shaft driven) and auxiliary lube oil pumps shall be provided with maintenance block valves and discharge check valves The proposal shall state whether a main oil pump shall be provided Auxiliary oil pump shall be electric motor driven. Requirements for the motor shall be specified on the purchaser s data sheet, PIP RESR001-D Pump casings shall be steel or ductile iron System low-oil-pressure switch shall start auxiliary oil pump and alarm on the local control panel Reservoir Oil reservoirs that are not pressurized shall be stainless steel If a pressurized carbon steel oil reservoir is specified, the reservoir shall be provided with the supplier s standard internal coating. Note: The oil reservoir may be part of the oil separator The reservoir shall have an oil heater and temperature control capable of increasing the oil temperature from minimum ambient temperature to minimum starting temperature within 12 hours maximum Lube oil heaters shall be thermostatically controlled, stainless steel, sheathed, and shall have a maximum watt density of 2.0 watts/cm 2 (13 watt/inch 2 ). Process Industry Practices Page 11 of 20

14 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October A reservoir shall have the following features: a. Oil-level indication device b. Low-point drain valve c. Temperature indicator d. A nonpressurized reservoir shall have an air eductor or motorized oil mist demister (Any requirements for the motor shall be specified on the data sheets.) e. Removable cover plate for inspection and cleanout Stand alone (non-oil separator) reservoir retention time shall be 10 minutes minimum Piping/Valves Piping vibration levels shall be limited to 12 mm/sec (0.5 inches/sec) Stainless steel tubing may be provided for lines up to 25 mm (1 inch) Lubrication oil system piping shall be welded and shall be in accordance with ASME B Slip-on flanges are permitted Piping and tubing downstream of the oil filter shall be stainless steel Carbon steel piping upstream of the filter is permitted Piping and tubing shall have a leak-free design that uses flanges and/or tubing fittings. 1. Use of threaded connections shall be minimized. 2. Piping, tubing, and flanges shall be proven leak-free in accordance with Section 3.20 of this Practice As a minimum, pressure relief valves shall be made of cast steel Oil pump discharge lines shall have check valves Each oil pump discharge line shall have a separate pressure relief valve Oil drain lines shall operate no more than half full Filters and Cooler The lubrication oil system shall have the following features: a. Dual oil filters (1) The filter arrangement shall include valves that allow element changeout while the refrigeration system is in operation. (2) Filter-housings shall include vents and drains. Page 12 of 20 Process Industry Practices

15 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems 3.8 Purge System b. Unless otherwise specified on data sheet RESR001-D, dual oil coolers shall be provided. c. A self-contained, thermostatically controlled oil temperature control valve that bypasses oil for temperature control Unless otherwise specified, materials of construction for filters and valve bodies shall be carbon steel Filters shall have a removal efficiency of 90% at 10-micron nominal and 15 micron absolute capability Lube oil cooler shall have the following features: a. A fixed tubesheet bundle with water in the tube side b. An average wall thickness of 1.2 mm (18 BWG) minimum c. Materials of construction as specified for the condenser. d. Fouling factor as specified for the condenser Filter housings and coolers shall be in accordance with PIP VESSM Systems shall have a high-efficiency automatic purge system The purge system shall continuously remove non-condensable gas from the refrigerant Refrigerant shall be returned to the system Non-condensables shall be provided with a connection for venting to purchaser s vent system The purge system shall be detailed, including a description of all associated instrumentation, controls, and valves in the proposal. 3.9 System Controls and Instrumentation General Controls and Instrumentation 3.10 Electrical PIP PCDPS001 Packaged Equipment Instrumentation Documentation Requirements Data Sheet and Instructions PIP PCSPS001 Packaged Equipment Instrumentation Specification PIP PCSPS010 Small, General Purpose Packaged Equipment Instrumentation Specification PIP PCERE001 Rotating Equipment Monitoring Guidelines General PIP ELSPS01 Electrical Requirements for Packaged Equipment Process Industry Practices Page 13 of 20

16 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October PIP ELSPS01D Data Sheet for Electrical Requirements for Packaged Equipment PIP ELSPS01V Electrical Requirements for Packaged Equipment - Preferred Vendor and Component List 3.11 Pipe, Valves, and Fittings Fluorocarbon-based refrigerant system piping and valves shall be in accordance with ASME B31.5 and ASHRAE Hydrocarbon and ammonia-based refrigerant systems shall be in accordance with ASME B Unless otherwise approved in writing by the purchaser, the use of copper pipe and tubing shall not be permitted Threaded connections in refrigerant service shall not be greater than DN 20 (NPS ¾) Vent and drain connections or valves shall be socket-weld by threaded and have plugs or blinds of the same material as the connection or valve Individual system components shall have isolation and vent valves to permit maintenance with minimum depressuring of the system and/or piping All valves shall have a stainless steel identification tag. The purchaser shall provide tag numbers All refrigerant isolation valves shall be back seat design with seal caps and socket-weld or flanged connections All fasteners in pressure/process containment applications shall be in accordance with DIN or ASTM/ANSI standards for chemical and physical properties. In accordance with ASTM/ANSI, the fasteners shall bear the manufacturer s symbol (stamp) and the applicable specification grade. Fasteners without these features shall not be permitted The allowable forces and moments for battery limit connections shall be provided by the supplier If flexible expansion joints are required to avoid excessive loads on the compressor, they must be approved by the purchaser Unless otherwise specified, interconnecting piping between skids shall be provided by purchaser If supplier is providing interconnecting piping, the piping shall be matchmarked and numbered for easy installation If piping and/or equipment shall be assembled and disassembled in supplier s shop, purchaser retains the right to inspect and approve shop fit-up Pressure-Relieving Devices Pressure-relieving devices shall be provided in accordance with ASME Code, ASHRAE 15, and as specified by purchaser. Page 14 of 20 Process Industry Practices

17 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems The sizing basis and inlet pressure-drop calculations shall be provided for purchaser s approval The inlet pressure drop to the relief valve shall be calculated and shall be in accordance with paragraph M-7 of ASME Code, (i.e., shall be less than 3%) For compressible fluid systems, the irreversible pressure losses in the relief valve inlet piping shall not exceed 3% of set pressure based on a flow rate equal to the relief valve ASME-rated capacity (nameplate capacity) Relief valve mounting locations and inlet and outlet piping requirements for refrigerants that are toxic or hazardous may require special design considerations to avoid liquid accumulation or undesirable discharges to the atmosphere. In such applications, the purchaser shall advise relief valve mounting locations, piping layout, pressure drop, and maximum back pressure for relief valves piped to a closed system Insulation Unless otherwise specified, insulation shall be provided by purchaser Space shall be provided for purchaser-supplied and -installed insulation system. Adequate spacing for valve actuation, equipment maintenance, and other component functionality shall be maintained Insulation and insulation thickness shall be indicated on the P&ID Structural Steel Base General A structural steel base shall be provided upon which all system equipment shall be mounted Equipment, piping, and conduit shall not extend below the top of the structural steel base beams. Piping and conduit shall not protrude beyond the outer perimeter of the base beams Equipment shall be arranged on the base for accessibility and ease of maintenance The common structural steel base shall be sufficiently rigid to prevent flexing or distortion of skid equipment during lifting, transportation and installation Skid shall conform to local environmental requirements Fabrication Structural steel shall be seal welded in accordance with AWS D Maintainability must be considered when attaching equipment supports to the skid. Note: Welding supports may cause difficulty when performing maintenance on the skid. Cutting the members may lead to corrosion issues Ends of tubular steel members shall be capped and seal welded. Process Industry Practices Page 15 of 20

18 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October Noise Installation Lifting Note: The purpose of seal welding is to minimize or prevent hidden corrosion which shortens the life of the base Skids shall be designed for mounting on a concrete foundation Anchor points and foundation requirements shall be specified Vertical jack bolts located next to anchor bolt holes shall be provided for positioning the structural baseplate(s) prior to grouting. Stainless steel shims shall be used for supporting the skid. The shims shall straddle the anchor bolts Machined mounting blocks for compressor and driver shall be provided Stainless steel shim packs shall be provided for aligning the compressors and main drives mounted on the structural steel skid. Shims shall be a minimum of 3 mm. (1/8 inch) and shall straddle bolt holes Axial and transverse alignment bolts shall be provided for driver System shall be provided with lifting lugs for a minimum four-point lift If required, spreader bars shall be provided Individual system components shall have eyebolts or lifting lugs to facilitate lifting Weights of individual components shall be provided A drawing that indicates system lifting points, center of gravity of each skid, and the weight at each point shall be provided by the supplier Ladders and Platforms Refer to PIP STF05501, Fixed Ladders and Cages The noise level at a distance of 1 meter (3 feet) from each skid shall be provided If the sound pressure level exceeds the level specified on the purchaser s data sheet, PIP RESR001-D, information indicating additional sound treatment required to obtain the conditions specified shall be included Compressor Vibration and Critical Speeds The supplier shall be responsible for performing necessary torsional studies and eliminating any lateral or torsional vibrations that can affect the operation of the system Operating speed(s) shall have at least a 20% separation margin from the torsional and lateral critical speeds or system resonances. Page 16 of 20 Process Industry Practices

19 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems Peak unfiltered velocity (with compressor installed on the supplier s baseplate and within the specified operating range) in any plane measured on the bearing housing relative to a radial bearing shall not exceed the following: 3.17 Painting a. For reciprocating compressors, 10 mm./sec. (0.4 inch per second) b. For screw compressors, 6 mm./sec. (0.25 inch per second) c. For centrifugal compressors and drive motors, 2.5 mm./sec. (0.1 inch per second) Unless otherwise specified, the painting shall be the supplier s standard. The proposed paint system shall be detailed in the proposal Paints and coatings shall be stored, mixed, catalyzed, thinned, and applied according to paint manufacturer s instructions Paint systems shall be shop-applied Components that are inaccessible after fabrication shall be primed and coated before installation with paint acceptable for service conditions for the component Surfaces that cannot be accessed for painting after assembly shall be prepared and primed before final assembly Top or final coat shall not be applied until all fabrication and assembly is complete and all surfaces are primed in areas to be coated Primer(s) shall be applied the same day as surface preparation and before oxidation Exposed alloy equipment shall not be painted. However, alloy equipment shall be painted before being insulated Inspection General Supplier and subsuppliers shall perform the inspections that are necessary to ensure conformance to the purchase order specification and referenced documents Additional inspections of the equipment by the purchaser s representative shall not relieve supplier or subsuppliers of responsibility for meeting purchase order requirements If specified on the purchaser s data sheet, PIP RESR001-D, a prefabrication meeting of the responsible purchaser and supplier personnel shall be arranged to review all purchase order requirements. Comment: Site and design personnel are encouraged to attend. Process Industry Practices Page 17 of 20

20 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October Quality Surveillance by Purchaser Quality surveillance shall be performed by purchaser s representative of items provided on this purchase order The intent of purchaser s quality surveillance shall be to monitor and audit supplier s quality control (QC) effort to assure compliance with purchase order specification and drawings so that quality requirements are attained and verifiable The purchaser s representative shall participate in and witness surveillance activities as deemed necessary. The following surveillance activities shall be conducted by purchaser as a minimum: a. Preliminary - Inspect shop before start of fabrication b. Intermediate - Witness hydrostatic/pneumatic tests of all pressure vessels c. Intermediate - Inspect motor at motor manufacturer s facility d. Intermediate - After blast cleaning but before painting, perform electrical check-out and witness functional test of all controls e. Final - Witness mechanical run (if specified) and leak test Comment: See Appendix B Purchaser s Quality Surveillance Checklist for activities that may be performed by the purchaser s representative The purchaser s representative shall contact supplier to schedule surveillance visits A complete set of approved drawings for use at the time of the surveillance activities shall be made available to the purchaser s representative The following documents/records shall be made available for review by the purchaser s representative: a. Vessel manufacturer s pressure vessel data reports b. Certified mill test reports c. Certification of hydrostatic/pneumatic testing, including pressures, time held, type and location of any leaks and methods of repair; microprocessor shop logs; and certification of compressor run test d. Compressor assembly records A safe work area and testing equipment shall be provided for purchaser s representative If major components or services are obtained from subsuppliers, purchaser surveillance and notification requirements shall be included in suborders. Page 18 of 20 Process Industry Practices

21 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems 3.19 Testing 1. Purchaser s representative shall be notified and given the option of inspecting items provided by subsuppliers at the point of manufacture. 2. The supplier shall arrange for approved drawings to be used by the purchaser s representative at the subsupplier s location Purchaser shall be notified a minimum of 10 working days before any testing, including testing of parts or assemblies in subsupplier s facilities, so that purchaser s representative may witness the system tests Purchaser reserves the right to conduct a field performance test with the participation of the supplier s representative. If this test is to be conducted, purchaser and supplier shall agree beforehand on the acceptance criteria Before assembly on system skid, pressure vessels and/or heat exchangers shall be pneumatic-tested or hydro-tested at fabrication facilities Water for hydro-testing shall have a maximum Chloride content of 50 PPM. Hydro-tested components shall be thoroughly drained Compressors shall be given manufacturer s standard pressure and running tests. Test procedure shall be provided to purchaser for review a minimum of 2 weeks before test Controls shall be functionally tested Lubrication System Tests Functional Test 1. The supplier s standard oil system functional test shall be described in the proposal. 2. The supplier s test shall be reviewed, modified and approved by the purchaser. 3. The functional test shall include the control panel and all electrical circuits Cleanliness Test 1. As a minimum, after the lubrication oil system is clean, it shall be given a cleanliness test consisting of circulating the lubrication oil for a minimum of 1 hour through test screens or filters. 2. Compressor and bearings shall be bypassed during oil system run test. 3. There shall be no surface evidence (either visible or tactile) of scale, rust, metal shavings, or sand in the lubrication oil filters. 4. The supplier s standard oil system cleanliness test shall be described in the proposal A continuity test shall be performed on all electrical circuits before final inspection. Process Industry Practices Page 19 of 20

22 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October All shutdown and safety devices, except relief valves and rupture disks, shall be functionally tested by simulating the conditions required for actuation Vacuum Test Assembled refrigeration system shall be evacuated to 20-mm Hg absolute for a minimum of 2 hours System shall then be sealed with the vacuum pump off, and vacuum shall hold for a minimum of 6 hours with less than 2-mm Hg rise If refrigeration system fails to hold vacuum, leaks shall be identified and repaired and the vacuum test shall be repeated Upon successful completion of the vacuum test, vacuum shall be broken with dry nitrogen, and system shall be pressurized to 1 bar (15 psi) for shipment If system consists of more than one skid, each skid shall hold vacuum on the refrigerant side in accordance with Section Preparation for Shipment Refrigeration packages shall be completely assembled at the factory before shipment Items to be disassembled for shipment shall be detailed in the proposal System shall be pressurized to 1 barg (15 psig) with dry Nitrogen for shipment Pressure gauges shall be provided to monitor pressure during shipment and placement of unit All instrument panel openings shall be plugged for shipment to prevent water or dirt from entering during shipment and storage before installation The purchaser s representative shall have the right to perform a final inspection before shipment Final release by the purchaser s representative shall be obtained before shipment of material or equipment Documentation Documentation shall be provided in accordance with purchaser s documentation requirements sheet, PIP RESR001-R, and this Practice. Page 20 of 20 Process Industry Practices

23 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems Appendix A Monitoring System Instrumentation Table Evaporator Unit System Instrumentation Alarm Shutdown Process Inlet Temperature Local Panel Process Outlet Temperature 1 High/Low Process Inlet Pressure 2 Process Outlet Pressure 2 Level Indication Condenser Cooling Water Outlet Temperature 2 High High Cooling Water Outlet Pressure 2 Cooling Water Inlet Temperature 2 Cooling Water Inlet Pressure 2 Low Low Refrigerant Outlet Pressure Refrigerant System Receiver Liquid Level Dryer Moisture Content Compressor Suction Pressure Low Low Discharge Pressure Low Suction Temperature Low Low Discharge Temperature High High Vibration High Bearing Temperature High High Oil System Reservoir Level Low Reservoir Temperature Pump Discharge Temperature Low Low Return Oil Temperature High High Cooling Water Return High Filter Differential Pressure High Low-Pressure Switch Low Low Oil Separator Level Indication Receiver Level Indication Motor (if appl.) Bearing Temperature High Vibration Probes High Gear Box (if appl.) Winding Temperature NOTES: 1) Low-process-outlet-temperature alarm and shutdown may be required to prevent freeze damage. 2) By Purchaser. Process Industry Practices Page A-1

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25 EDITORIAL REVISION October 2010 PIP RESR001 Packaged, Skid-Mounted Process Industrial Refrigeration Systems Appendix B Purchaser s Quality Surveillance Checklist B.1 In-Process B.1.1 B.1.2 B.1.3 B.1.4 B.1.5 B.1.6 B.1.7 B.1.8 B.1.9 Witness hydrostatic/pneumatic test of all pressure vessels. Verify material and thickness of tubesheets. Witness/verify tube expansion procedures on all heat exchangers. Review the following documents: a. Mill test reports b. Certificates of compliance c. ASME Code data reports d. Microprocessor shop logs e. Pressure test results for vessels f. Compressor assembly records g. Certification of compressor run test Visually inspect all welding before painting, including baseplate, piping, vessels, and peripherals. Spot-check piping internal diameter, where possible, for burn through, excessive protrusion, or unremoved slag. Review dimensional records for the package. If determined to be necessary, perform a check of critical dimensions, including location and elevation of field connections, runout, and alignment with compressor and drive motor. Check for satisfactory results of blast cleaning in accordance with supplier s standard procedure. B.1.10 Ensure proper application of all pipe dope and/or joint compound on all threaded connections and conduit before paint application. B.1.11 Verify that all thermocouples, probes, and other instrument appurtenances are adequately taped and protected from spray painting. B.1.12 Verify that small gages and panel devices are removed before painting if they cannot be adequately protected from paint. B.1.13 Check all bolting for proper identification and markings in accordance with Section Request and verify replacement of any fasteners not in accordance with Section B.1.14 Witness compressor mechanical run test and leak testing of the complete system before painting. Process Industry Practices Page B-1

26 PIP RESR001 EDITORIAL REVISION Packaged, Skid-Mounted Process Industrial Refrigeration Systems October 2010 B.2 Electrical Check-out B.2.1 Verify the following local panel requirements: a. Meet electrical area classification b. Material c. Type d. Configuration e. Dimensions f. Welds g. Cutting h. Bolting i. Shaping j. Type of cable entry k. Exit door pad-locking and hinge l. Access openings for field use m. Lifting means n. Workmanship o. Painting B.2.2 Verify type and arrangement of the following components: a. Pushbuttons b. Selector switches c. Pilot lights d. Terminal blocks e. Raceways f. Color-coding. B.2.3 Verify the following instrument requirements: a. Model number b. Chart or dial range c. Calibration d. Specified identification tag B.2.4 Verify the following alarm system requirements: a. Alarm operation sequence b. Alarm acknowledge c. Test d. Reset Page B-2 Process Industry Practices