43869973 api-spec-review

11/15/2001 - #1

API Specification ReviewDr. Klaus Brun - Southwest Research Institute®

Dr. Rainer Kurz – Solar Turbines, Inc.

Gas Machinery Conference

Gas Turbine Technology Center

Gas TurbineGas TurbineTechnology CenterTechnology Center

Southwest Research InstituteSouthwest Research Institute

11/15/2001 - #2

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




11/15/2001 - #3

Outline




• Introduction to Gas Turbine Oil and Gas Applicationsa) Oil & Gas Definitionsb) Gas Turbine and Package Componentsc) Instrumentationd) Compression Station Layoute) Offshore Gas Turbine Issuesf) Fuel Considerations

• Codes and Standardsa) Why Standardsb) Relevant Standardsc) API Philosophy 101d) API Data Sheetse) Review of API 616f) Highlights of API 614 and 670

• Factory Tests• NFPA 70 Hazardous Area Classifications• API 616 Data Sheets Review• API 617 Review

11/15/2001 - #4

O&G Definitions

Crude Oil

Associated Gas

– Unprocessed oil from well.

– Natural gas that is recovered from the well with crude oil (also, gas-to-oil ratio).



Upstream – The Oil & Gas Production and Gathering Process


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O&G Definitions – Cont’d

Self-Generation

Enhanced Oil Recovery (EOR)

Gas Lift

– 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.



Red – Processes that involve gas turbines.



11/15/2001 - #6

Waterflood

Gas Re-injection

– 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.







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Export Compression

Gas Gathering

– Initial boosting of natural gas pressure from field into pipeline (a.k.a. header compression).

– Collecting natural gas from multiple wells.







11/15/2001 - #8

Gas Plant and Gas Boost

Gas Storage/Withdrawal

– 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.







11/15/2001 - #9Gas Turbine Technology Center


Southwest Research InstituteSouthwest Research Institute O&G Definitions – Cont’d

Midstream – The Oil & Gas Transportation Process

Pipeline Compression

Oil Pipeline Pumping

– Compression stations on pipeline to “pump natural gas; typically 800-1200 psi compression.

– Pumping of crude or refined oil.

Red – Processes that involve gas turbines. Gas Turbine Technology Center




Midstream – The Oil & Gas Transportation Process

LNG Plant

LNG Terminal

– 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).

Red – Processes that involve gas turbines. Gas Turbine Technology Center




Downstream – the Refining and Distribution of Oil & Gas

Refinery

Integrated Gasification Combined Cycle

– Processing of crude oil into its various sellable components.

– Advanced process to convert heavy oils and pet-coke into synthesis gas and hydrogen.






Methanol Plant

Fischer-Tropsch Liquid

– Plant that produces methy alcohol from methane (natural gas).

– Artificial gasoline produced from coal and/or other lower cost hydrocarbons.






Fractional Distillation Column

Cracking

– 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).





Blending

LPG

– Mixing of hydrocarbons to obtain sellable refinery products.

– Liquid petroleum gas (propane, butane, pentane).





NGL

Distribution

– Natural gas liquids: liquids that drop out during gas processing.

– Delivery of oil and gas products to end-users.


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Components & LayoutInside the Package:

- Fuel System and Spark IgniterNatural Gas (control valves)Liquid (pumps, valves)

- Bearing Lube Oil System TankFilterPumps (main, pre/post, backup)

- Accessory gear

- Fire/Gas Detection System

- Starter/Helper Drive (pneumatic, hydraulic, variable speedAC motor)

- Controls and Instrumentation (on-skid, off-skid)

- Seal Gas/Oil System (compressors) Gas Turbine Technology Center



11/15/2001 - #17

Components & LayoutOutside 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 Gas Turbine Technology Center



11/15/2001 - #18

Components & LayoutSteam & Power – Gas Turbine Cogeneration- Steam to Steam Turbine – Combined Cycle Plant- Steam to Other Plant Requirements – Co-Generation Plant

Heat Recovery Steam GeneratorHeat Recovery Steam GeneratorUse Gas Turbine Exhaust Heat to Generate Steam

(aka HRSG, Waste Heat Recovery Unit, WHRU, Boiler)

Gas TurbineGenerator Exhaust

Heat

Boiler

Economizer

SupplementalDuct Firing

By-Pass Stack Stack




11/15/2001 - #19

Gas Turbine Package SystemsControl 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




11/15/2001 - #20

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)




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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 AccelerometersMeasures Absolute Motion

– Gas Turbine Case

– Main Gearbox Case

– Auxiliary Gearbox Case

– Driven Equipment Case




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Critical Alarm and Shutdown Switches– 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




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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)

Compressor Station Layout

Discharge Coolers

Turbo-Compressor In Buildings




11/15/2001 - #24

Compressor Station Layout




TURBINECOMPRESSOR

GAS COOLER

DISCHARGE VALVE

CHECK VALVE

SURGECONTROL VALVE

SURGE CONTROLLER

DP LOADING SWITCH LOADING

VALVE

FLOW ORIFICE

S D

SUCTION VALVE

Gas Turbine

Pipeline

Compressor

Station By-Pass Valve

Isolation Valves

11/15/2001 - #25

Offshore Platform (Marine)

Technical RequirementsLow weight and dimensionsLow VibrationsResistance to SaltwaterList, trim, pitch, roll operationMarine codesFoundation twisting

FeaturesCompact design, reduced lube oil tank, single lift modulesVibration isolators, special groutingStainless steel (enclosure and inlet/exhaust system)Baffles/Scavenging pump in LO tank, inclinometersLloyds, DNV, ABS, Coast Guard CertificationSub base, three point mount, gimbles, vibration mounts

Land Based Fixed Leg Jack-Up Semi-Sub FPSO Tension Leg

Operational RequirementsHighest availability as platform often depends on GT, but

• No direct access to technicians and repair facilities• Limited spare parts storage capabilities

?Gas Turbine Technology Center



11/15/2001 - #26

Offshore Features

Compressor

Gas Turbine

Sub BaseMount

Lube Oil Tank Baffles Scavenging Pump forPressurized Bearings

Inclinometer

Inclinometer - Alarm and Shutdown at High List, Trim, Pitch, Roll Angles Sub Base - Added Stiffness for Gas Turbine and Compressor SkidsBaffles - Continued Supply of Lube Oil at Inclined OperationScavenging Pump - Forced Supply of Lube Oil at Inclined OperationMounts - Isolation from Twisting and VibrationSingle Lift Module - Simplified Installation and Transportation to Platform

Single LiftModule




11/15/2001 - #27

Gas Fuels - Dew Point

Heavy Hydrocarbons Increase Dew Point- Liquid Dropout Must Be

Prevented May Require Fuel Heating/Fuel TreatmentMay Require Heat Tracing of Fuel SystemAccurate 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


11/15/2001 - #28

Dew Point and Fuel System Pressure Drop

PRES

SUR

E

ENTHALPY

Saturated Liquid

Saturated Vapor

K

Lowest Combustor

Pressure

Liquid Drop OutFuel Supply

Pressure (Skid Edge)


11/15/2001 - #29

Codes & Standards

Review of Codes and Standards




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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.







Specification number Description

API 616 4th edition Gas Turbines for the Petroleum, Chemical, and Gas Industry ServicesAPI 613 4th edition Special Purpose Gear Units For Petroleum, Chemical, And GasIndustry ServicesAPI 614 3rd edition Lubrication, Shaft-Sealing, and Control - Oil Systems for Special - Purpose ApplicationsAPI 614 4th edition Combustion Gas Turbine for General Refinery ServiceAPI 661 5th edition Air-Cooled Heat Exchangers for General Refinery ServiceAPI 670 4th edition Vibration, Axial Position and Bearing Temperature Monitoring SystemAPI 677 2nd edition General Purpose Gear UnitsAPI 671 3rd edition Special Purpose Couplings for Refinery ServicesAPI 678 Accelerometer-Based Vibration Monitoring SystemAPI 500 2nd edition Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities

Classified as Class I, Division 1 and Division 2API RP 550 Manual on Installation of Refinery Instruments and Control SystemASME VIII Div 1 Boiler and Pressure Vessel CodeASME B 31.3 Chemical Plant and Petroleum Refinery PipingASME B 16.5 Steel Pipe Flanges and Flanged FittingsAWS D1.1 Structural Welding Code for SteelIEEE 112A Polyphase Induction Motors and GeneratorsPTC 22-1977 Performance Test Code on Gas turbinePTC 1 General InstructionsANSI C50.14-1997 Requirements for combustion gas turbine driven cylindrical rotor synchronous generatorsANCI B133.4 Gas turbine Control and Protection SystemNEMA National Electrical Manufacturers AssociationNEMA MG1 Motors and GeneratorsNFPA 12 1989 edition Carbone Dioxide Extinguishing SystemsNFPA 69 1997 edition Standard on Explosion Prevention SystemsNFPA 70 2002 edition National Electric CodeNFPA 70E National Fire Code ErrataNFPA 72 2002 edition National Fire Alarm CodeNFPA 85 2001 edition (extract) Boiler and Combustion Systems Hazards CodeOSHA Noise Procedure SpecificationISO 2314 1989 Gas turbines - Acceptance testsAPI RP 11PGT Recommended Prcatice for Packaged Combustion Gas TurbinesUL 1604 Electrical Apparatus for Explosive Gas Atmosphere

Relevant Codes

11/15/2001 - #32

Codes & Standards

Most Common Codes for US Oil & Gas Applications:API 616 - Gas TurbinesAPI 617 – CompressorsAPI 614 – Lube Oil SystemAPI 670 – Machinery ProtectionAPI 613 – Load and Accessory GearAPI 677 – Accessory Drive GearAPI 671 – Flexible CouplingsNFPA 70 Electric Code ASME PTC-22 Gas Turbine TestingASME PTC-10 Compressor TestingASME B133 - Gas Turbines


Mostly AffectsPackaging



11/15/2001 - #33

Other International Codes

ISO Codes (ISO 3977 - Gas Turbines)IEC/CENELEC (Electrical and Fire Systems)Local Government CodesEU Environmental and Health ComplianceUser Specific Specifications: – Upstream: Mostly API/firm– Midstream: Some API/flexible– Downstream: Mostly API/very firm




11/15/2001 - #34

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

11/15/2001 - #35

What is API? – Cont’d




• 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!

11/15/2001 - #36





API Standards as Purchasing Specifications:

• Provide the means for a customer to normalize thequotations 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.

11/15/2001 - #37





• 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).

11/15/2001 - #38

APIStandard 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




11/15/2001 - #39

APIStandard 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 RequirementsDoes not cover government codes & regulations




11/15/2001 - #40

API Data SheetsAPI Data Sheets



Southwest Research InstituteSouthwest Research Institute API

11/15/2001 - #41

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)

11/15/2001 - #42

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.

11/15/2001 - #43

API Data Sheets




By Purchaser

By Manufacturer

By Manufacturerif not by Purchaser

11/15/2001 - #44

API 616Gas Turbine

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




11/15/2001 - #45

API 616 Intro & Definitions




1.0 Alternative Designs1.1 Alternative designs allowed. Emphasized in API Foreword.

2.0 References2.1 All reference standards are automatically included. All

manufacturers take exception to this.

3.0 Definitions3.17 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.

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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 siterated 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.

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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 Design4.1.1 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.

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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.

11/15/2001 - #49

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.

11/15/2001 - #50

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 rotorswith 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.

11/15/2001 - #51

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. Thrust-Tilt 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.

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API 616 - Engine




4.9.2 Synthetic lube oil is OK.

4.9.5 Integrated or separate lube GT / Compressor oil system OK.

4.9.7 Lube oil system must meet API 614. Note: Lube oil tank typically integrated into skid.

4.10 Materials: Follow good design rules. Purchaser may require 100% radiography magnetic particle inspection, or liquid penetrant inspection on all welds.

4.11.3 A SS nameplate to include rated performance and conditions, critical speeds, maximum continuous speed, overspeed trip, and fuel type.

11/15/2001 - #53

API 616 - Accessories




5.0 Accessories5.1.1.1 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.

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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 for110% of required load.

5.2.2 Vendor to supply all couplings and guards for load and accessoryshafts. Couplings to be sized for maximum continuous torque andmeet 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.

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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.

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API 616 - Controls




5.4.2.2 Control system to completely purge unit prior to startup.

5.4.3.4 Load control to limit driven equipment speed to 105% rated speed.

5.4.4.1 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.

5.4.4.3 Fuel control must include separate shutoff and vent valves, separate from fuel control valve, with local and remote trip.

5.4.4.8.1 Alarm and shutdown switches shall be separate. Often not practical (e.g., flame detector, axial thrust position).

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API 616 - Alarms




Minimal Requirements

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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.

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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 non-compliance. 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.

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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.

5.7.3 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.

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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.

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API 616 - Fuels




5.81.5.2 If dual fuel system is provided it must allow bumpless bidirectional transfer.

5.8.2.2.2 Vendor must review customer’s fuel supply system.

5.8.2.4 Heating value of fuel cannot vary by more than ±10%.

5.8.4.2 Purchaser must specify required site emissions levels for NOx, CO, UHC, et al.

6.0 Inspection, Testing, and Preparation for Shipment Inspections: Standard machinery type includes, materials, mechanical, Radiographic, ultrasonic, magnetic particle, dye penetrant, etc.

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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.

6.3.4 Optional Tests (These tests are not optional if purchaser marks them in the API 616 data sheets)

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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.

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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 Vendor’s 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.

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Southwest Research InstituteSouthwest Research Institute API 616 – Vendor Data

Purchaser and VendorTo Fill in Delivery DatesOr Cross Out if NotApplicable.

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Southwest Research InstituteSouthwest Research Institute API 614 – HighlightsLubricating 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

11/15/2001 - #68





Southwest Research InstituteSouthwest Research Institute 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.

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Southwest Research InstituteSouthwest Research Institute API GT – Instruments


Purchaser mustSpecify on API 616Data Sheets

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Southwest Research InstituteSouthwest Research Institute API GT – Alarms/Shutdowns


Purchaser mustSpecify on API 616Data Sheets.

Note: Should beSeparate fromInstruments but notAlways Feasible.

11/15/2001 - #71

ASME PTC-22Gas Turbine Performance

ASME PTC-10Compressor Performance





Southwest Research InstituteSouthwest Research Institute Factory Performance Tests

11/15/2001 - #72





Southwest Research InstituteSouthwest Research Institute Factory TestsPTC-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.

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05/16/05

Process

Process

Process Gas/LiquidStation Inflow

FlareE

Process Gas/LiquidStation Outflow

P T

Process Compressor

P P P P

T T T T

P P P P

T T T T

Electric System HeaterE

Ambient (P,T)Relative Humidity

F

T

P

E

Air Inlet Compressor TurbineBurner

Exhaust

Lube Oil

Fuel Gas

P P

T

F T

P

T

P

T

P

E

T

P

F

Seal Gas/OilLube Oil

E

Detailed Performance Tests

PTC-22 (Gas Turbine) PTC-10 (Compressor)




National Electric Code (NEC) NFPA 70

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National Fire Protection AssociationNFPA 70




Hazardous Location Summary Electrical Requirements:Class 1: Flammable Gases, Vapors, or LiquidsClass 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.

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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

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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

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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)

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NFPA 70




On-Skid Explosion

Proof Boxes

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NFPA 70




On-Skid Explosion

Proof Boxes

Copper Free

Conduit

ConduitSealing

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NFPA 70




ExplosionProof

Instruments

Explosion Proof

Flexible Conduit

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NFPA 70




Non-Explosion

Proof Conduit

Explosion Proof

Conduit

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API Review

API 616 Data SheetReview



Gas Turbine Technology CenterGas Turbine Technology Center

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API 617Axial and Centrifugal

Compressors and Expander-compressors for Petroleum, Chemical and Gas Industry

Services Seventh Edition, July 2002


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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 compressorCodes are by nature rather general. Any particular application may require modificationsCodes React Slow to Technical Changes


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Observation

API 617 very prevalent in Off-Shore, and RefineriesUsually less prevalent in Pipeline ApplicationsOften referenced within user-company specific SpecificationsAll manufacturers have various amounts of comments and exceptions.


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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


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What Does Adherence to Codes Buy?

A better design?More security?– Downtime– Commissioning Time– Decommissioning Time– Performance– Safety Requirements

Cost ?


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Codes CriticalTechnical 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 ShipmentDocumentation RequirementsDoes not cover government codes & regulations


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What’s in it?

General RequirementsCentrifugal and Axial CompressorsIntegrally Geared CompressorsExpander Compressors

PRIMARY FOCUS


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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 300°C (570°F) are not covered in this standard.


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SECTION 1—GENERAL

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Alternative Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3 Conflicting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.5 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.6 Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.7 Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41.8 Unit Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4


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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.


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Definitions

1.5.3 Compressor Rated PointThe 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


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Annex 2C-Cross Section/Nomenclature


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Section 2 – Basic Design

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42.2 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52.3 Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72.4 Guide Vanes, Stators, and Stationary Internals . . . . . . . . . . . . . . . . . . . . . . . . . 1-112.5 Rotating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112.6 Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122.7 Bearings and Bearing Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-252.8 Shaft End Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-262.9 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-272.10 Lubrication and Sealing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-272.11 Nameplates and Rotation Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-272.12 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28


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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.


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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 afinished 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 stub-shafts shall meet all quality and heat treatment criteria for shaft forgings. Refer to Annex 2C for rotor arrangements and nomenclature.


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Dynamics2.6.1.1 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 Unbalance in the rotor system.b. Oil-film instabilities (whirl).c. Internal rubs.d. Blade, vane, nozzle, and diffuser passing frequencies.e. Gear-tooth meshing and side bands.f. Coupling misalignment.g. Loose rotor-system components.h. Hysteretic and friction whirl.i. Boundary-layer flow separation.j. Acoustic and aerodynamic cross-coupling forces.k. Asynchronous whirl.l. Ball and race frequencies of rolling element bearings.m. 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 anamplification factor (AF) equal to or greater than 2.5.


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Rotor Response andCritical Speed

2.6.2 Lateral Analysis2.6.2.1 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).


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Stability Analysis

2.6.5 Level I Stability Analysis2.6.5.1 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 anindication 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.)


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Decision Criteria


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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.


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Bearing Temperature

2.7.1.3 As a design criteria, bearing metal temperatures shall not exceed 100°C (212°F) at specified operating conditions with a maximum inlet oil temperature of 50°C (120°F). 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 120°F, and bearing metal temperatures above 212°F. This should be acceptable, as long as the compressor is designed for these conditions.


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Vibrations2.6.8.8 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 μm (1 mil), whichever is less:In SI units:

In U.S. Customary units:

where

A = amplitude of unfiltered vibration, in μm (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 μm (0.5 mil) above the maximum value recorded at the maximum continuous speed.


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Section 3 – Accessories

3.1 Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-283.2 Couplings and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-283.3 Mounting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-293.4 Controls and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-353.5 Piping and Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-353.6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36


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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)


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Section 5 – Vendor’s Data

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-405.2 Proposals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-405.3 Contract Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42


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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.


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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.


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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 specifiedperformance and performance tolerances, provided that this adjusted speed meets the criteria specified in Chapter 1, 2.6.


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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 purchaser’s option.


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Datasheets


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ANNEX 1A REFERENCE LIST OF U.S., ISO, AND INTERNATIONALSTANDARDS (NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45ANNEX 1B PROCEDURE FOR THE DETERMINATION OF RESIDUALUNBALANCE (NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49ANNEX 1C TYPICAL SHAFT END SEAL CROSS-SECTIONALDRAWINGS (INFORMATIVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59ANNEX 1D TESTING OF GAS SEALS IN SEAL VENDOR’S SHOP(NORMATIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67ANNEX 1E TYPICAL MATERIAL SPECIFICATIONS(INFORMATIVE) . . . . . . . . . . . . . . . . .


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API Review

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