Spec Reference

DESIGN, MANUFACTURING / FABRICATION,
ASSEMBLING & SUPPLYING OF PACKAGED

RECIPROCATING COMPRESSORS WITH
INSTALLATION SUPERVISION, PRE-COMMISSIONING,
COMMISSIONING & START-UP SERVICES
ISSUED FOR BIDDING
0 04-July-2016 Issued For Bidding MA HHQ SFA MHQ TH

Re-Issued For Review
B 28-June-2016 MA HHQ SFA MHQ TH
(PPL comments incorporated)
A 14-June-2016 Issued For Review MA HHQ SFA MHQ TH
LOCAL PROJ.
REV DATE DESCRIPTION ORIG CHKD LE QA PM
REPR. MAN
CLIENT
REVISIONS APPROVAL
APPROVAL
TITLE:
SCOPE & SPECIFICATION FOR RECIPROCATING COMPRESSOR
ENAR Petrotech Services (Pvt.) PACKAGE
Limited , 7-B , Sector 7-A ,
Korangi Industrial Area , Karachi
Pakistan
PROJECT CODE: DOCUMENT NO:
RG-1501 RG-1501 - MA - 3502 - 0
CLIENT REF NO. DOCUMENT

PROJECT CODE SEQUENCE REV
32-0157 CODE
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PAKISTAN PETROLEUM LIMITED DOC NO: RG-1501-MA-3502
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DESIGN, MANUFACTURING / FABRICATION, REV: 0
DATE: 04 – July – 2016
INSTALLATION SUPERVISION, PRE-
COMMISSIONING, COMMISSIONING & START-UP
SERVICES
SCOPE & SPECIFICATION FOR RECIPROCATING
COMPRESSOR PACKAGE
TABLE OF CONTENTS
1. GENERAL ........................................................................................................................................... 3
2. SCOPE OF SUPPLY & SERVICES .............................................................................................. 8
3. PACKAGE OVERVIEW ................................................................................................................. 13
4. PACKAGE REQUIREMENTS ....................................................................................................... 15
5. INSPECTION AND TESTING ....................................................................................................... 30
6. QA/QC AND CERTIFICATION .................................................................................................... 34
7. SHIPPING ......................................................................................................................................... 36
8. GUARANTEE ................................................................................................................................... 36
9. DOCUMENTATION REQUIREMENT ........................................................................................ 37
10. REFERENCE DOCUMENTATION .............................................................................................. 39
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1. GENERAL
1.1. Introduction
PPL is producing hydrocarbons from number of fields including Adhi field from two
independent retrograde condensate “Tobra” & “Khewra” (T/K) reservoirs and crude oil
from Sakaesar reservoir. The well fluids produced from T/K reservoirs are processed
by two independent process plants “Plant-I & Plant-II” installed at Adhi field. Each
plant is capable of processing ~25 MMSCFD of raw gas to produce sales gas, LPG and
NGL. Another LPG/NGL Recovery Plant & Oil Stabilization facility recently installed
containing capacity of 30 MMSCFD raw gas & 5000 BPD oil. The new Plant-III is
located adjacent to the existing Plants as an independent Plant.
Currently there are 17 nos. of producing wells which are scattered around the
production facilities in North-South direction of the processing plant. Most of the wells
are dual producers (Tobra & Khewra formations). However, some wells also
producing wax & Asphaltenes, as their temperatures are very near or below to wax
appearance temperature (WAT). In addition to above, these wells are also having high
pour points. Therefore, special design consideration shall be given for compressor
packages by the Supplier to handle such waxy and Asphaltenes based feed gas.
On the basis of well head flowing pressures some wells are named as high pressure
(HP) wells (operating range 63- 93 barg), some are medium pressure (MP) wells
(operating range 28-62 barg) and few are low pressure (LP) wells (operating range 7 –
28 barg).
Wells with 29-45 API fluids are fed to Crude Oil Stabilization facility while wells with
45-58 API are fed to LPG /NGL Plant. Accordingly, some wells have a single feeder
line producing both formations commingle and some wells have two feeder lines for
producing each formation separately due to significant difference in their API
gravities.
Keeping in view declining pressure profiles ADHI wellheads modifications have been
suggested to overcome the problem of high back pressure on ADHI wells to maintain
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the productivity through their existing gas gathering networks. In this regard, Pakistan
Petroleum Limited (PPL) is implementing compression (Nodal) for some of wells of
ADHI gas field to maintain the production plateau from depleting pressures wells.
Following nodal compressions are envisaged to install.
1. Nodal Compressor at Adhi-17 (for Adhi-17 & Adhi-21)

4. Nodal Compressor at Adhi-14 (for Adhi-14, Adhi-24 & Adhi-26)
5. Nodal Compressor at Plant (for Adhi 16, Adhi 22, Adhi 5 & Adhi 13)
1.2. Definitions
Terms used in this scope and specification have the following meanings:
“Company” shall mean PPL (Pakistan Petroleum Limited) installing

the Packaged Reciprocating Compressor.
“Vendor / Supplier” shall mean the entity with which PPL shall place order for the
Packaged Reciprocating Compressors covered in this scope and
specification on outright purchase.
1.3. Codes, Standards & Company’s Specifications Requirements

Supplier shall ensure compliance with Company supplied specification(s) and relevant
industry accepted codes and standards listed below with the requirements for the items.
API 11P Packaged Reciprocating Compressors for Oil and Gas Production
Services.
API 615 Sound Control of Mechanical Equipment for Refinery Services

ASME VIII Pressure Vessels
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ANSI B16.5 Pipe Flanges and Flanged Fittings
ANSI B31.3 Process Piping

API 618 Reciprocating Compressors for Petroleum, chemical and Gas
industry services
RP 500B Recommended Practice for Classification of Locations for

Electrical Installations at Drilling Rigs and Production Facilities
on Land and Marine Fixed and Mobile Platforms.
RP 520 Recommended Practices for the Design and Installation of

Pressure Relieving Systems in Refineries, Part I–Design and
Part II–Installation.
RP 521 Pressure Relieving & De-Pressuring Systems
RP 551 Process Measurement Instrumentation
RP 552 Transmission Systems
RP 554 Process Instrumentation & Control
ASME Sec-II Boiler and Pressure Vessel Code, Material Specifications.
ASME Sec-VIII Boiler and Pressure Vessel Code. Rules for Construction of
Pressure Vessels
Section IX Boiler and Pressure Vessel Code, Welding and Brazing

Qualifications
NFPA70 National Electrical Code
MG-1 Motors and Generators
NEMA 250 Enclosures for Electrical Equipment
All applicable codes and standards of ASTM, GPSA, IEC, ISA, NACE, NFPA,
OSHA, SSPC, TEMA.
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1.4. Errors or Omissions

The review and comments by Company on Supplier’s or its manufacturer’s drawings
procedures or documents shall only indicate acceptance of general requirements and
shall not relieve Supplier of its obligations to comply with the requirements of this
scope and specification and other related parts of the Contract Documents.
Any errors or omissions noted by Supplier in this scope and specification shall be
immediately brought to the attention of the Company. All deviations to this scope and
specification, other related specifications or annexure and relevant codes & standards
shall be brought to the knowledge of the Company in the bid. All deviations made
during the procurement, design, manufacturing, testing and inspection shall be with
written approval of the Company prior to execution of work. Such deviations shall be
shown in the documentation prepared by Supplier.
1.5. Conflicting Requirements

In the event of any conflict, inconsistency or ambiguity between the contract scope of
work, this scope and specification, codes & standards referenced in this specification
or any other contract documents. Supplier shall refer to the Company whose decision
shall prevail.
1.6. Company’s Intention

Company intends to directly purchase the compressor package based on specifications
/ Data sheet / Gas composition referred in this document. The supplier shall be
responsible for design, manufacturing / fabrication, assembling, installation
supervision, pre-commissioning commissioning, start-up & testing of the compressor
package. Company after the successful handover, shall be responsible for the operation
and maintenance of the compressor package.
The Supplier shall be responsible to size the Packaged Reciprocating Compressors, in

view of the requirements as detailed in relevant specifications, procure material,
perform mechanical design (Supplier shall submit the package general arrangement
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drawings for Company’s approval prior to finalization of design), fabricate, paint, test
and prepare for shipment.
Supplier is advised to select from its standard range, compressors that will operate at
given operating conditions. It should be noted that any equipment, instrument, etc.
required making package operational throughout the operating life as indicated shall be
considered in Supplier’s scope.
Supplier shall also be responsible for all Sub-suppliers coordination, data and other
documents, provision of guarantees, provision of equipment and personnel for the trial
assembly, mechanical run and functional testing of complete packages at Supplier’s
works and packaging and delivery as specified in the tender document.
Supplier shall arrange each package according to good industry and well recognized
practices, which facilitates operation and maintenance.
Supplier shall ensure that all components of the Reciprocating Compressor Packages
are new.
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2. SCOPE OF SUPPLY & SERVICES
Supplier shall be responsible for the design, engineering, supply of all materials,
manufacturing / fabrication, assembling, testing, painting, preservation, shipment
transportation, installation supervision, pre-commissioning and commissioning
required for the Compressor package in accordance with this scope and specification.
Supplier shall submit all design details, general arrangement, and detailed drawings
(03 sets of each) for company approval prior to finalization of design.
Supplier's scope shall include the following as a minimum:
- Supply of Compressor package complete with gas engine including lube oil, fuel
gas, PLC system, field instrumentation, F&G detectors & control devices,
machine monitoring sensors, power supply etc. as outlined in this document.
- Designing, engineering, manufacturing, fabrication, assembling, painting,

configuration, programming, preservation, supplying, installation supervision,
inspection, testing, start up and commissioning and inclusion of all the hardware
and software for provision of Main Supervisory and Data Control & Telemetry
System (SCADA).
- Supply of Open path Gas Detectors and UV/IR flame detectors along with all
mounting accessories and calibration testing equipment.
- Provision of all necessary documentation including equipment dossiers, etc. (03

sets).
- Indication of all technical deviations/exceptions to this scope and specification

and notifying Company about such deviations/exceptions.
- Preparation of shipping arrangement for delivery
- Provision of required material certification.
- Protective coating/painting including preparation for shipment.
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- Supply of two (02) years spare parts list with price (containing OEM / vendor part
no. for traceability and ordering purposes to ensure 02 years smooth operation
after commissioning.
- Supply of commissioning spares. Separate price list of commissioning spares is

also required with OEM / vendor part no.
- Provision of set of special tools & lifting arrangements.
- Development and provision of manufacturing schedule
- Access for inspection, witnessed by Company / Company’s Representative of

skids during and after assembly.
- Arrange guarantee & warrantee certificates from the original manufacturer of the
equipment.
- Supply of operating consumables, and first fill of lubricants, chemicals, etc.
- Arrange undertakings from the original equipment manufacturers to the supply of

spare parts and other after sales services obligations.
- Supervision of installation of hook-up.
- Startup, pre-commissioning & commissioning services.
- Performance Testing (Factory and at Site) and Training to operating staff at site.
- Complete civil foundation design of the package. In this respect, Supplier shall
provide detailed civil foundation drawings along with all calculations and design
consideration details. Supplier shall also be responsible to supply foot-print
anchor bolts templates of major equipment skids for an early error free
construction of foundations at site.
- 3-D model of the whole package along with all interconnecting piping for
Company’s review / approval
2.1 Commissioning Spares
A complete set of spare parts required for commissioning and start-up shall also be
supplied and shipped with the package. These parts shall be tagged to show the part
number for cross-referencing against a materials list.
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Supplier shall also specify and supply the first fill of lubricants and consumables for
commissioning and start-up. This shall include the necessary quantity required for
flushing the various systems.
Supplier shall provide following commissioning spares in addition to the parts

recommended for each compressor package and by Original Equipment Manufacturer
(OEM) of pumps, motors, instrumentation, etc.
- Lube oil for first charge of oil + 20% extra

- Other chemicals, consumables, etc. initial fill + 20% extra
- Oil filters elements (2 times of the installed quantities).
- Suction strainer elements (3 times of the installed quantities).
2.2 Operation Spare Parts

Supplier shall recommend and provide list of spare parts needed for two (02) years of
operation with C&F Karachi price. The spares should be in accordance with
recommendation by OEM of all supplied components. Recommended spares should
take into account related factors of item’s reliability, effect to equipment downtime
upon production or safety, costs of parts, and availability of equipment service
facilities. The Company shall separately order these spares once supply of the package
is finalized.
All spare parts furnished by Supplier shall be wrapped and packaged so that they can
be preserved in original as-new conditions of storage and shall be properly tagged and
coded so that later identification for intended equipment usage would be facilitated.
They shall be packaged separately, clearly marked as "Spare Parts", and shipped along
with the packages. Packing lists shall be furnished so that the parts can be handled
without uncrating if desired.
Supplier shall also provide complete parts list with OEM / vendor part numbers for
traceability of ordering purposes.
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2.3 Capital Spares

Parts or complete sub-assemblies with long delivery, generally of high cost and whose
unavailability leads to prolonged shutdown of the equipment and curtailing production.
They comprise such items as spare rotating parts, heat exchanger parts, and
instruments, complete spare pumps, equipment without a standby etc. Supplier shall
develop fully detailed list of these spares along with prices and submit with the bid.
2.4 Special Tools

The Supplier shall list in the quotation and supply all special tools, gauges, appliances
and fixtures necessary for installation, maintenance and repair of all equipment in his
supply including any special lifting/spreader beams, handling appliances, rotating
element supports, calibration kits including sample gas cylinders etc. Each item shall
be indelibly marked with its size and purpose. These special tools shall include any
non-metallic standard tools, torque wrenches and the hydraulic tools for coupling,
fitting and removal.
2.5 Third Party Pre-Shipment Inspection

Final inspection and testing of equipment prior to dispatch shall be carried out by Third
Party Inspector. Preliminary inspections, e.g. to examine package instruments and
junction boxes during or on completion of fabrication, will be performed as necessary
and recorded separately.
A report and a completed test dossier shall be produced by the inspector on
completion of all inspection and testing, or at intervals as testing proceeds. A
release certificate will be issued by the inspector when all testing has been completed
to his satisfaction and equipment may then be dispatched to site.
2.6 Installation Supervision, Pre- Commissioning / Commissioning & Startup

Services
2.6.1 Installation Supervision

Supplier shall provide Installation Supervision of the complete package. Supervision
services shall be continued till the mechanical completion of the package.
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Before commencing installation, Supplier shall participate in overall package

inspection at site for verification of completeness of the package.
For installation supervision services, supplier shall submit a detailed schedule of
construction / installation with HOLD points where check / inspection by supplier
representative / supervision are mandatory. Supplier will indicate the category of field
personnel to be deputed and their estimated man–days involved
2.6.2 Pre- Commissioning / Commissioning & Startup Services

Supplier shall provide Pre- Commissioning / Commissioning & Startup services after
the completion of installation works and when the package is accepted as mechanically
complete. Supplier will indicate the category of field personnel to be deputed and their
estimated man–days involved.
2.7 Performance Test

After successful startup, the package will be subjected to performance testing as per
section 5.5 of this document. It shall be the responsibility of the supplier to conduct
performance test to demonstrate the package’s suitability for the intended operating
parameters as referred in section 4.1.1 of this document.
 Training of Operating Personnel
Supplier shall be responsible for conducting training sessions for personnel at OEM
premises and at site. In this respect, supplier shall submit detailed training program in
his proposal.
2.8 Meetings / Design Reviews

Company shall review all the basic and detailed engineering documents.
Standardization of equipment, instruments and materials is also desirable as far as
practicable. To achieve these objectives, follow up meeting and reviews are anticipated
to take place at supplier’s design office during the project implementation period. In
this meeting, representatives of Company will participate. Upon award of contract, a
kick-off meeting for detailed discussions on the design basis, supplier's design
standards and criteria, operation philosophy of equipment will be held. This meeting
may be conducted on tele-conferencing.
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During detail engineering, one (01) design review meeting would be performed with
supplier at his design office to discuss/finalize the design information such as control
concept, plot plan, equipment specifications, and HAZOP study of the package; which
would be provided / performed by the Supplier for civil, structural, piping, mechanical,
electrical, instrumentation and other detailed engineering works for the Project and its
tie-ins/interconnections with other units.
2.9 HAZOP & Safety Screening of Complete Package

HAZOP study during the design of package shall be carried out by a team of
professional with expertise in different areas such as process, systems &
instrument etc. The team will proceed with a well-structured brainstorming, which
guides the examination of each probable deviations from normal conditions at
specified process nodes and referring to a set of guidewords.
The outcome of HAZOP will be shared with the Company in form of close-out
report. The outcomes of the report shall be implemented at design and
manufacturing / assembling stages of the Compressor package. Any addition /
installation of item or design change if identified during HAZOP then supplier is
responsible for the implementation of the same on his own cost.
3. PACKAGE OVERVIEW
Gas engine driven reciprocating compressors are required for compression service for
continuous operation.
The package shall be complete with lubrication, sealing, cooling, ignition, exhaust,
instrument gas, fuel gas and start gas system for compressor & driver as required.
Process vessels i.e. suction scrubber(s), blow-case vessels, pre-separation separator,

suction and discharge pulsation bottles, oil storage tanks etc. shall be the part of the
package, all necessary interconnection piping shall also be included, including vent
and drain header, as required.
The design life of the package shall be minimum twenty (20) years.
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The minimum general piping and instrumentation requirements are shown on P&ID
no. RG-1501-PID-1011 however, Supplier is responsible for provision of any other
instrumentation, piping equipment etc. which are required to fulfill the safe and
reliable operation of the package.
All platforms, ladders and other access facilities required for the proper operation and
maintenance of the compressors and associated auxiliaries shall also be included.
Special lifting equipment required for maintenance, loading, unloading and delivery at
site including any required lifting beams or frames shall be included.
Microprocessor based instrumentation, controls and local PLC control panel are
required to provide necessary protection for the equipment and desired control of the
package operation.
The package shall be suitable for use in Class-I Division-2 and Group C&D area.
Supplier shall be responsible for carrying out Pulsation and Torsional studies of each
type of compressor package.
Adequate system to generate electricity for the package is also required as no

electricity is available for package at the installation site. The required electricity
generation should be arranged through a P.T.O (Power Take-Off) from the
compressor’s engine instead through a separate source.
The package shall have its own instrument gas / fuel gas conditioning and supply
system for on- skid instrumentation and control system only.
The package shall be supplied with its own fuel gas conditioning system. Fuel gas take
off shall be from compressor suction piping within the package limit. Startup gas shall
also be considered supplied from the same conditioning system.
Inspection and testing of the complete package shall be performed in accordance with
the industry standards and codes, to ensure the quality and functioning of the packages.
Painting or/and coating of the packages shall be adequate to prevent them from rust,
corrosion and any other sediment during shipment and after installation on site.
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All the above components shall be mounted on a structural steel skid. Proper
packaging of the complete package before shipment is required to avoid damage to any
of the component /equipment during the shipment.
Supplier shall be responsible for the provision of necessary foundation design data
including but not limited to verification of size and location of all anchor bolts, static
and dynamic loading conditions for foundation design.
After installation, Supplier shall be responsible for all checks prior to commissioning.
These checks include alignment of the packages, operability of lube oil system, and all
instrumentation field tests. Supplier will depute its Engineer/Technician or a technical
team at the time of commissioning).
4. PACKAGE REQUIREMENTS
Details on the requirements of the package are provided in the following sections.
4.1 Compressor & Engine Sizing Requirement

The compressors and their drivers shall be sized in view of the following conditions:
4.1.1 Operating Conditions (Battery Limit of the Package)
Start and End of Operation the operating conditions shall be as the scenarios
mentioned in the Data Sheets RG-1501-DS-1821 to RG-1501-DS-1825.
4.1.2 Environmental Conditions

The environmental conditions are outlined in Design Basis document RG-1501-A-
1051.
4.2 Compressor
Compressors shall be reciprocating type, separable, meeting the requirements of API
11P and this Scope & Specification for Packaged Reciprocating Compressor
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Supplier shall clearly indicate any deviation(s) or exception(s) to the standard(s) and/or
specification in its bid. The compressors shall contain the following
components/systems as a minimum:
4.2.1 Basic Components

i) Compressor frame
ii) Distance piece
iii) Crankshaft
iv) Bearings
v) Connecting rod
vi) Cylinder
vii) Valves
viii) Piston, crosshead, piston rod, piston rings, wear bands,
ix) Rod packing
x) Manually operated variable clearance pockets to change the capacity of the
compressor.
The package shall be equipped with automatic capacity control through engine rpm
control together with the auto – recycling valve.
4.2.2 Lubrication System

Compressor shall include Integrated Lubricating Oil Systems for Compressor, Driver, and
Gearbox etc. inclusive of Lube Oil Coolers etc. Flexible non-lube, multi element, spacer type
couplings along with non- sparking coupling guards shall also be included.
Compressor lubrication system is required with following as minimum;
 Frame Lubrication System

i) Duplex Suction strainer
ii) Oil pump
iii) Oil cooler
iv) Duplex Oil filter
v) Crankcase oil breather
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vi) Oil level sight glass
 Force Feed Lubrication System

i) Lube oil supply tank with sight glass, breather and isolation valves
ii) Force feed lubricator pump
iii) Distribution pump
iv) Lubricator oil no flow sensor
4.3 Driver
Gas engine is required as driver of the compressors. Supplier must indicate the type of
engine whether two or four stroke and indicate the engine rated rpm. The engine can be
turbo charged or natural aspirated, however Supplier shall give full justification of the
type selected for the packages. The gas engine shall be of RPM suitable for continuous
operation. The organ shall contain the following components/systems as a minimum.
 Basic Components/Systems
i) Crankcase breather
ii) Carburetor
iii) Governor
iv) Ignition system including igniter
v) Exhaust system including expansion joint, residential spark arresting grade
exhaust muffler, silencer, detonation sensors, etc.
vi) Cooling system including jacket and auxiliary coolant pump, intercooler (for
turbocharged engine), air cooler for engine jacket water etc.
vii) Lubrication system including oil strainer, pump, filter, oil cooler etc.
viii) Oil bath air filter
ix) Control system.
x) Separate lube oil day tank with stand.
xi) Shielded ignition system, alternator power with battery pack.
xii) Crankcase oil level control.
xiii) Able to operate at variable speed to enable Compressor operation at various
capacities/varying demand in terms of flow and suction / discharge pressures.
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4.4 Fuel Gas System

Process gas at suction will be used as fuel gas for the engines. The fuel gas must be
considered at saturated condition at the inlet of the fuel gas system. Please refer to gas
composition mentioned in Design Basis Document no. RG-1501-A-1051 and
Datasheet no RG-1501-DS-1821 to 1825.
Supplier to provide the following as a minimum in the fuel gas system.
i) Fuel gas connection from process suction (at suction scrubber);

ii) Manual block valve for fuel gas supply.
iii) Duplex Fuel gas strainer
iv) Fuel gas supply high-pressure regulator(s) as required.
v) Pressure relief valve
vi) Fuel gas pressure transmitter.
vii) Duplex Fuel gas filter/separator complete with level gauge high level switch
and drain valve.
viii) Low pressure regulator.
ix) Flexible connecting lines
x) Differential pressure transmitter for fuel gas filter.
4.5 Start Gas System

Process gas shall be used as starting medium of the package. The gas starter should of
appropriate type and compatible for use on respective gas composition with moisture
contents. The size should be based on minimum gas pressure available during life of
the field at suction sides of the packages.
Supplier to provide the following as a minimum in the start gas system:
i) Start gas connection from process suction or fuel gas scrubber.

ii) Manual block valve for start gas supply.
iii) Duplex Start gas strainer.
iv) Start gas high pressure regulator and relief valve.
v) Duplex Start gas in-line coalescing filter with manual drain valve.
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vi) Gas powered engine starter.

vii) Start gas relay valve complete with solenoid.
viii) Flexible connectors as required.
ix) Start gas pressure indicator
x) Start gas vent line (directed to the skid edge above the package at suitable
height).
4.6 Instrument Gas System

Supplier to provide the following as a minimum in the instrument gas system:
i) Instrument gas connection from process suction (at suction scrubber)

ii) Manual block valve for instrument gas supply.
iii) Duplex Instrument gas strainer.
iv) Instrument gas high-pressure regulator and relief valve.
v) Instrument gas in-line coalescing filter with manual drain valve.
vi) Flexible connectors as required.
vii) Instrument gas pressure transmitter
viii) Differential pressure transmitter for the instrument gas filter.
ix) Instrument gas vent line (to the skid edge) if required.
4.7 Cooling System for Compressor / Driver and Process Gas

Process gas air cooled heat exchanger shall be sized in view of the maximum ambient
temperature 49°C and maximum gas temperature at air cooler discharge 60°C. Cooling
system shall be complete with following as a minimum:
i) Air cooled heat exchanger (after / interstage cooling of process gas, engine
jacket water, etc.)
ii) Manually operated louvers
iii) Cooling fan
iv) Coolant pump
v) Bug screen
vi) Tank for coolant
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4.8 Scrubbers and Pulsation Bottles

Following process vessels including all local instruments are required as a minimum:
i) First stage suction scrubber with Demister Pads (API 11P class C)
ii) Interstage scrubber with Demister Pads (API 11P class B).
iii) Suction and discharge pulsation bottles.
iv) Blow-case Vessels
4.9 Pressure Vessels

All pressure vessels shall be designed, fabricated and tested in accordance with ASME
Boiler and Pressure Vessel Code, Section VIII, Division I. All vessels shall be U–
stamped. All vessels shall have a minimum corrosion allowance of 3mm.
4.10 Safety and Relief Valves

Supplier shall be responsible for adequate arrangement of protection to the package
against over pressure by means of suitable pressure safety valves. Full flow safety
valve must be supplied at package inlet as per applicable code API-520 and 521.
4.11 Piping & Valves

All interconnecting piping between package components shall be included in the scope
of supply.
All the pipe work shall be designed, tested and fabricated according to ANSI B31.3.
The design should facilitate ease of operation and maintenance. Suitable break flanges
and/or couplings should be provided for easy removal/re-installation of pipe work for
maintenance purposes. Supplier shall ensure that all the pipe work (on-skid and
interconnecting) is free from any stress by carrying out Piping Flexibility Analysis.
Considering the fact that Wax and Asphaltenes are present in feed gas therefore,
Supplier must provide minimum 3” line sizes in liquid section of the package. Further,
no pocket consideration must be given in inter-connecting piping as much as possible.
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Piping shall be well supported on skid and on foundations for interconnecting piping.
Pipe supports shall be designed considering dead loads, live loads, dynamic loads due
to flow induced vibration, pulsation, wind, shipping, etc. Pipe supports shall be so
designed to accommodate pipe movement due to thermal and pressure stresses and
shall be sufficiently supported to prevent differential settlement and undue forces and
stresses in the piping or connected equipment.
Also, Relief valve vent header, starting bypass line and recycle line shall be provided.
Compressor recycle line shall be with recycle valve. Compressor bypass line shall be
equipped with a double Block & Bleed Valve with Non-Return Valves (NRV).
Pneumatic automatic isolating valves for emergency shutdown (ESDs) required at
suction and discharge linked with compressor tripping. Valves loading / unloading
devices and capacity control arrangement such as automatic kickback, speed control
with variable pockets and a bypass loop for operation during compressor outage.
Common header for all Blow down, Relief Vent and Packing Vent.
Supplier shall provide vent and drain tank for compressor packing and distance piece
with sight glass. Supplier shall determine size of the tank. The tank can be shipped
loose for installation at site by Supplier.
Valves only from a renowned top quality manufacturer shall be acceptable. Automatic
actuated Shutdown valves together with manual isolation valves shall be required at the
process gas inlet and outlet of the package.
Check valve is also required at the process gas outlet of the package. Available line
sizes at battery limit of the package are as per following Supplier is required to provide
skid connections at battery limit with RF flanges (upto 600#) and for 900#, RTJ
flanges are required.
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Liquid Reinjection System
As the wellhead stream contains gas, condensate and free water, the liquids must be
removed upstream of the compression stages. Therefore, the compression package re-
injects the liquids into the compressor discharge stream. A system of blow-case vessels
shall be provided in the compression package, in which gas from the compressor
discharge drives the liquid into the downstream pipeline. All major, interconnecting
piping and valves shall be supplied by vendor. Refer Piping & Instrumentation
Diagram RG-1501-PID-1011 to P&ID RG-1501-PID-1011.
4.12 Instrumentation and Controls

Supplier shall be responsible for complete supply of associated instrumentation,
machine monitoring sensors and control system as a part of compressor package. The
packages will be complete with built-in controls and all instrumentation requiring no
additional equipment. Complete instrumentation, controls, alarms and shutdowns for
the compressor & driver shall be provided. Control panel to be skid mounted with its
power source to be engine mounted alternator / battery charging systems. Control
system shall be able to import / export data with other control systems. Minimum
desired Instruments and controls requirement to be followed are mentioned on project
P&IDs and compressor data sheet. Separate instruments shall be used for control and
shutdown service. Project specification RG-1501-ISP-6006 (General Specification for
Instrumentation) shall be referred for selection of desired Instrumentation. Supplier
shall provide terminal strips to wire required signals to respective wellhead control
panel. Dry contacts shall be provided for compressor running, fault, shutdown etc.
signals. Similarly provision shall be provided to read wellhead control panel dry
contacts signal as detailed in Sec 3.3 of RG-1501-ISP- 6003 Analog signals (if
required and mutually agreed) shall also be provided to a separate terminal strip for
wiring to control panel monitoring. All instruments should be provided in all
weatherproof and explosion proof enclosures. Sunshades shall also be provided for all
local instrumentations. All Instruments shall have local indication. All instruments
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shall have respective root valves / manifolds in addition to piping isolation valves. All
transmitter and gauges shall be logically arranged and mounted on instrument racks.
Each compressor skid shall supplied with following Fire and Gas Detectors (loose
supplied).Installation of detectors shall be done by others;
Fire Detector: 03 numbers SIL-2 UV/IR along with all accessories
Gas Detector: 02 sets SIL-2 Open Path (line of Sight)
The package shall have its own microprocessor based PLC control unit. A local
display shall be provided for monitoring and control of the unit. Project RG-1501-ISP-
6003 (Control System Design Basis) shall be referred for selection of desired PLC for
compressor skid control system. Annunciation of Alarms and Shutdown conditions
shall be skid mounted.
There should be no unnecessary sharp bends / pockets / slopes in connections of

Tubing and Instruments to minimize risk of Instrument failure due to chocking from
Wax / Asphaltenes present in gas stream. Bridles will be installed on all vessels.
All electrical equipment and instruments shall be suitable for use in Class-I, Division-
2, Group C&D classified area. The method of protection shall be Ex‘d’ certification.
OEM/Vendor supplied Hazardous Area Certification for all electronic
instrument/equipment shall be provided.
Supplier shall supply all electrical supplies required for complete functioning of the
packages. The electrical generators and battery should be of appropriate capacity and
should be driven through P.T.O (Power Take-Off) from compressor’s engine.
There will be ex-proof lighting arrangement (i.e. Light assemblies, glands, junction
boxes etc.) on skid.
Suitable no. of earthing bosses shall be provided.
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Following are equipment wise instruments and controls required as a minimum and
shall be read in conjunction with requirement mentioned on P&ID and compressor
data sheet:
 Compressor
i) Crankcase oil level controller , transmitter with low level alarm and trip.
ii) Lubricator no flow sensor
iii) Oil pressure transmitter
iv) Oil pressure indicating transmitter (in and out of oil filter)
v) Oil temperature indicating transmitter (in and out of oil cooler)
vi) Vibration Transmitters
 Gas Engine
i) Crankcase oil level controller , transmitter with low level alarm
ii) Oil pressure transmitter
iii) Oil pressure gauges
iv) Jacket water temperature transmitter with high temperature alarm and trip Jacket
water cooler temperature indicating transmitter (in and out of cooler)
v) Auxiliary water cooler temperature indicating transmitter (in and out of cooler)
vi) Jacket water coolant level transmitter with alarm and trip
vii) Auxiliary water coolant level transmitter with alarm and trip.
viii) Oil cooler temperature indicating transmitter (in and out of cooler)
ix) Governor actuator for automatic speed control
x) Mechanical vibration transmitter
 Scrubbers
i) Electronic level controller , transmitter with High / Low alarms
ii) Electronic level transmitter with High-High / Low-Low alarms and trips
Pressure regulator
iii) Suction scrubber thermal PSV
iv) 1st stage discharge PSV
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 Air Cooler
i) Mechanical vibration switch
ii) Temperature indicating transmitter (in and out of air cooler/service)
 Local Process
i) Process temperature indicating transmitter for suction and discharge.
ii) Process pressure transmitters for sensing;
 Each stage suction pressure
 Each stage discharge pressure
iii) Final stage flow through orifice meter
 Requirements for Compressor skid Control System

Project RG-1501-ISP- 6003 (Control System Design Basis) shall be referred for
selection of desired PLC for compressor skid control system.
The basic requirements mentioned below for supply of a Microprocessor based system
to control the wellhead compressor packages should be read in conjunction with
requirement mentioned in RG-1501-ISP- 6003 and considered as a minimum.
– Standard microprocessor based PLC control system shall be provided mounted

on skid for complete control and monitoring of the compressor, driver and other
skid equipment.
– Skid PLC shall be powered from 24VDC Solar supply, provision and all
arrangements shall be provided to power PLC from compressor engine alternator,
battery set.
– The redundant PLC based control system shall be equipped with at least one
serial port and redundant Modbus TCP/IP ports for communication of data. The
communication ports shall employ Modbus TCP/IP protocol and should be able
to communicate data to control room through SCADA UHF Radios, Signals and
monitoring data shall be provided, as minimum.
– All type of software involved in PLC programming, configuration, simulation,
HMI development shall have un-limited time license in favour of Company and
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shall be able to install and function on atleast 06 workstation/laptops. All 06 sets

of software/dongle/passwords along with licenses shall be handover to Company.
The control system shall be provided with Ethernet Modbus TCP/IP communication
ports for communication with Wellhead compressors’ SCADA RTUs. Project
Specification RG-1501-ISP- 6003 (Control System Design Basis) and RG-1501-ISP-
6002 (SCADA System Specification) shall be referred for selection of desired SCADA
system for Wellhead compressors remote monitoring and control in Central control
room.
– The system shall be suitable to operate in the environmental conditions specified

for the compressor package.
– The enclosure of the Microprocessor Based system shall be Explosion proof type
suitable for Class-1, Div-2, and Group C&D area. ExP type is not acceptable.
– 02 Nos. Laptop computer shall be provided for program loading, modification,

set-point changes etc..with project required 05 numbers compressors.
– There shall be no compressor shutdown in case of communication failure with

SCADA system. Alarms shall be configured to indicate communication failure
– Vendor shall provide separate instrument for control and shutdown requirements
– Panel of Compressor skid PLC system and HMI shall be provided with adequate
sunshades to protect panels from direct sunlight.
– PLC along with all of its components such as I/O modules, power supply,
communication modules, programming suite, HMI software shall be of latest
type / model being offered at time of bid by selected Vendor/OEM. Any
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equipment which is going to obsolete in nearby future and is under notice period
by OEM in term of spare or services support shall not be provided.
HMI of the Skid

– The HMI (minimum 15” screen size) shall also be installed integrated with
microprocessor on the same skid in the hazardous area and shall therefore be
suitable for use in Class-1, Division-2, Group C&D area.
– The enclosure of the HMI shall be Explosion proof type suitable for Class-1, Div-
2, and Group C&D area.
– The HMI software shall be user friendly and shall require minimum skill to
operate, configure, download program or modify settings etc.
 Requirements for Wellhead Compressor SCADA System

Wellhead Compressor SCADA System along with all installation, supervision,
configuration, engineering and supply services shall be provided as detailed in project
specification RG-1501-ISP-6003 (Control System Design Basis) and RG-1501-ISP-
6002 (SCADA System Specification).
The SCADA System and Telemetry supply shall include Remote Telemetry Panels
housing (transceivers/UHF radios, Power supplies, Switches), Antennas, radio to
antenna cables, Antennas Structure, PLC Hardware, Base Station (Power Supplies,
Communication equipments, communication cabinets, redundant transceivers/UHF
radios and Antenna), redundant SCADA servers, workstation and other associated
required equipment for complete and reliable operation.
The control system PLC of each Compressor Package shall interface with the Plant
Control Room/System through New SCADA system. This Compressor PLC shall have
redundant module for Modbus TCP/IP communication which will be interfaced with
UHF radios placed in Remote Telemetry Panels (RTPs).
These RTP will have Transceivers/Radios that shall be powered by new independent
Solar Panel to be provided by Supplier, Antennas and other required accessories for
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license free UHF (900 MHz) two way radio communications. This SCADA
communication is used for complete monitoring of the Compressor Packages
including process parameters.
Facility for remote monitoring and on-line configuration changes of compressor skid
PLC from SCADA station and CCR shall be provided.
Power Supply
Compressor skid PLC and Compressor SCADA Remote Terminal Panel shall be
powered by Supplier supplied Solar Panel. Solar panel along with all accessories such
as cells, charge controller, batteries etc shall be sized, supplied and installed as
detailed in project specification for Solar Power System RG-1501-ELA-6500.
SCADA servers and HMIs at Central Control room shall be powered by Supplier
supplied UPS system along with all accessories. UPS system along with all accessories
such as charge controller, batteries etc shall be sized, supplied and installed as detailed
in project specification for UPS Power System RG-1501-ELA-6501.
4.13 Skid
Supplier shall be responsible for supply and design of the skid structure suitable for oil
field applications. All calculations to prove compliance with the specific requirements
and standards shall be held by Supplier and available for audit by Company. The
subject structure shall be designed to include all dead loads, live loads, equipment
vibration, bundle-pull, pipe load, pipe expansion thermal and friction, wind load,
seismic load, impact and erection loads and forces and any other loads.
The skid frame shall be suitable for oil field applications and handling with mobile
crane using a single point lift at the construction site. Where it is necessary to use
special lifting beams, slings, shackles, etc. these shall be provided by Supplier.
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4.14 Vibrations and Emission Requirement
Vibration
 As per API 11P

 Maximum noise level shall be less than 85 dBa
Emission Requirement
The emission shall be within limits as per NEQS attached otherwise Catalytic converter shall
be provided.
4.15 Painting & Corrosion Protection

Supplier must ensure that equipments, piping, structures, etc. shall be adequately
protected from the prevailing atmosphere by means of correct material selection.
SSPC (Steel Structures Painting Council) manuals shall be followed for preparation of
surfaces before painting and application of appropriate paint and number of coats.
Color coding for equipment & piping etc. shall be finalized after approval by
Company.
4.16 Equipment Tagging, Labeling & Nameplates

All items need to be identified for operation and maintenance purposes shall be
allocated with tag numbers to be mutually agreed afterwards. Supplier must indicate
these numbers on all design documents. Supplier shall provide list of all equipment,
instrumentation, etc to the Company.
All tagged items shall have corrosion resistant nameplates or labels permanently at-
tached, which shall include Supplier’s standard identification together with the
Company’s tag number. All other controls and indication devices that operators will
need to access/maintain shall have corrosion resistant identification/duty labels per-
manently attached.
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4.17 Packing, Preservation and Transportation of Material & Equipment

Packing and Preservation shall be suitable for transportation of material and equipment
during their handling, inland transportation, shipment through sea and storage at site
for up to 06 months in an uncovered and unheated location. Packing shall account for
fragility and physico-chemical/mechanical damages of items. Company shall consider
seaworthy packing of all the equipment and packages. Loose piping material, valves,
instruments, etc. shall be properly tagged to allow easy identification/site assembling.
Nozzle openings shall be protected with steel cover with rubber gaskets. Nitrogen
blanketing will not be required.
Chemicals/consumables shall be delivered in non-returnable steel drums or pallets.
4.18 Package Cleaning

Prior to shipment and after hydro testing, the packages shall be subject to thorough
cleaning by Supplier. Supplier shall give recommendation for the packages cleaning.
The packages-cleaning program shall be agreed with the Company. As a general rule
Supplier shall clean the packages internals in the workshop prior to preparation for
shipping. Supplier shall ensure that the packages are free from any foreign material,
dirt, etc.
5. INSPECTION AND TESTING
5.1. Fabrication & Welding

Supplier shall submit WPS, PQR and WQT for approval by Company. The approval
shall be sought in a manner not disturbing the overall delivery schedule of the
packages. Supplier shall notify Company at least fifteen working days prior to the start
of fabrication.
5.2. Hydrostatic Tests

All equipment including pressure vessels and piping shall be hydro tested in
accordance with the appropriate code requirements. Water for hydro testing shall be of
suitable quality not to harm any component of the packages in any manner.
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Process piping or tubing shall be tested with water after shop fabrication into sub-
assemblies.
5.3. NDE Inspection

The NDE and Inspection procedures shall be submitted by Supplier and agreed upon
by Company prior to its finalization.
5.4. Shop Witness Testing

The complete package, together with the associated equipment shall be witness tested
in the presence of Company/ Company Representative at the Manufacturer’s assembly
workshop as an integrated system to verify that the supply conforms to the
specifications in the order from the stand point of mechanics, safety devices,
accessories controls at guaranteed performance parameters, etc. In this respect, shop
testing will be required only for each type of compressor package.
The Supplier shall perform the Factory Test as per API-618 “Mechanical Running
Test” requirements. The unit including integral auxiliary system packages shall receive
a 4-hours mechanical running test before shipment. Further, Auxiliary equipment not
integral with the unit such as oil pumps, oil coolers, filters, inter-coolers and after-
coolers shall receive both an operational test and a 4-hours mechanical running test
before shipment.
The Supplier shall perform the full load test of each Compressor Unit at
Manufacturer’s Facility.
The Supplier shall ensure that all workshop tests and inspections of main components
shall be conducted (during and/or on completion of manufacture) in accordance with
the recommended standards & practice.
Manufacturer shall inform Company/ Company Representative about the date of test
60 days in advance. No testing shall commence without written approval of Company/
Company representative. Company reserves the right to witness any aspects of the
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assembling process. The Supplier shall submit an inspection and testing procedure for
review and approval by Company/ Company Representative prior to start assembling.
The manufacturer shall submit for Company’s review and approval a complete plan for
the factory and site acceptance testing. This plan must be complete and provide
sufficient detail to indicate the exact nature of each test, time required, expected results
and systematic procedure. The plan shall be submitted at least 60 days in advance to
the FAT.
The objective of the FAT is to verify that the purchased systems, as configured for
delivery to site, meets or exceeds the specified designed functional requirements. The
FAT shall be a 100% complete system functional test and shall be witnessed by
Company/ Company Representative.
The Supplier shall submit an inspection and testing procedure for review and approval
by Company prior to start assembling for testing at shop.
All examination methods shall be as per API 11P 2nd edition, ASME VIII and other
applicable codes to the relevant equipment, piping, etc.
All inspection methods to be employed shall be subject to the approval by the

Company.
FAT / SAT for SCADA Systems

The Supplier shall be responsible of complete SAT and FAT of SCADA system as
detailed in Section-19 of project document RG-1501-ISP- 6002 (SCADA System
Specification). The Supplier shall submit an inspection and testing procedure for
review and approval by Company prior to carrying out any test.
5.5. Performance Test at Site

The Performance test shall be carried out in accordance with the approved procedures
for a minimum period of seventy-two (72) continuous hours. The Supplier shall submit
such procedure for approval at least twenty (20) days before commencing the test. Test
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shall be carried out only if prior to the test the continuous operation of the compressors
has been attributable to the supplier, the continuous test shall be started from the
beginning (day 1) again.
If the Performance Test is interrupted for reasons attributable to the Supplier. The
Supplier shall, at promptly re-engineer and /or carryout such modifications as are
required to rectify the causes of the interruption. Company will thereafter give notice
in writing to the Supplier specifying the date on which Performance Test may be
recommended.
If the Compressor fails to meet the Performance Guarantee herein specified for reasons
attributable to the Supplier; Tests of the Compressors or the said portion shall be
repeated within a reasonable time upon the same terms and conditions.
Conditions of Compressor Site Performance Test:

– Details of Site Performance Test to be mutually agreed upon prior to site test.
– Elaboration of test procedure is included in Supplier scope of supply.
– Evaluation of site performance test and preparation of test report is included in
Supplier scope of supply.
– Any special equipment / instrumentation required during Site Performance Test
shall be arranged by Supplier.
– Site Performance Test will be conducted by Supplier commissioning engineer
after commissioning. The price for Supplier on site preparation and conduction
of the site performance test will be included in the commissioning services
being offered on lump sum basis.
– During the performance test all equipment should perform without any
indication of being overloaded under normal operating conditions as mentioned
in Attachment-III of Conditions of Contract.
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6. QA/QC AND CERTIFICATION
6.1 Quality Assurance & Control
6.1.1. Quality Management System

Supplier shall operate an independently verified Quality Management System that
satisfies the applicable provisions of BS-EN-ISO 9000 (series), or agreed equivalent
standard, commensurate with the goods and services to be provided. Current details of
registration, approval of other demonstration of the status and efficient operation of the
Quality System shall be provided with the bid submission. Further information may be
requested at the PO stage.
Company reserves the right to require Supplier to implement additional controls, where
a satisfactory level of competence cannot be demonstrated in this regard, and/or
exercise additional controls not detailed in this scope and specification.
Company reserves the right to visit the premises of Supplier for the purpose of
undertaking Quality Audits relating to the unit and services covered by this scope and
specification, the extent of which will be discussed with Supplier before, PO award.
Prior notice of five working days will be given to Supplier of any such audits. A copy
of the audit report will be forwarded to Supplier on completion. Any findings resulting
from such audits shall necessitate the implementation of appropriate corrective actions
based on a time scale to be agreed with Company.
6.1.2. Quality Control

It is the intention of Company to determine its involvement in the inspection of
materials and activities at Supplier’s work dependent on the unit complexity/criticality
and the effectiveness of Supplier’s QA/QC procedures. Supplier shall provide its
standard format Quality Control Plan, relating to the scope of work for review at the
time of bid submission. This should include those activities, which have been sub-
contracted, and provision made for Company design review/inspection.
Regular visits by Company for the purpose of surveillance and documentation review
will not be carried out as a matter of course. However, should it become apparent that
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Supplier’s agreed Manufacturing Quality Control Plan is either inadequate or not being
implemented, Company reserves the right to increase the level or frequency of its
Quality Control activities or request Supplier to revise its working practices, as
necessary.
To assist Supplier in evaluating the expected level of Company involvement applicable

to this scope and specification, the following activities in Quality Control Level by
Company have been identified:
- QC Plan review/markup
- Surveillance of major Sub-suppliers
- Certification and manufacturing data review
6.1.3. Material Traceability & Certification

Supplier shall advice its proposed material traceability system by which material is
assured to be fit-for-purpose and identified throughout the manufacturing process, as
part of the bid submission. Supplier should note that material certification is to be
provided for all pressure containing and load bearing components.
6.1.4. Inspection & Testing

The unit and structural items shall be tested and inspected as per API Standard 11P,
2nd Edition.Certification & Manufacturing Records
6.1.5. Inspection and Certification Records

Supplier shall ensure that all inspection, test and certification records for unit and
materials procured by Supplier, and test and inspection records for Supplier’s
assemblies and fabrications required by legislation, codes, standards and specifications
or otherwise required are provided, safely stored and available on request.
6.1.6. Certification and Manufacturing Data Requirements
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Certification and manufacturing data requirements consist of a collection of original

and type test certification, inspection and test records and final release documentation
generated during the approval, manufacture and testing of the unit or material.
All Certification and Manufacturing Data (08 sets) is to be issued to Company.
7. SHIPPING
Complete package shall be properly conditioned for shipping against all possible
damages. The Supplier shall be responsible for shipment of package equipment to the
Company’s site in Pakistan and for the adequacy of the preparations for shipment
ensuring that materials and equipment arrive at their destination in undamaged
condition. The Supplier shall provide the Company shipment details, date of
equipment departure and arrival at site and a list of weights and sizes of shipment
packages prior to dispatch, to ensure that there are adequate facilities available at the
site for safely unloading and placing the equipment in its designated location.
8. GUARANTEE / WARRANTY
If the supplied equipment fails to meet the guarantee/warranty conditions, Company

shall promptly notify the Supplier in writing about the defects and claims under the
warranty. Upon receipt of such notice the Supplier shall within the time mutually
agreed between Company and Supplier repair / replace the defective material and of
portion of works within the mutually agreed timeframe, with no cost or expense to
Company. Travelling, including all expenses, of the personnel required for the repair /
replacement in good running condition of the equipment shall be borne by Supplier.
The repaired or replaced material or works shall be warranted by Supplier for twelve
(12) months from the date of repair / replacement.
The supplier should submit statement of Guarantee / Warranty for the equipment and
packages.
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9. AFTER SALES SERVICE
The manufacturer/seller should have good established facilities in Pakistan or in the

region with no restriction to travel to Pakistan for field services personnel’s after sales
service, maintenance cells and spare parts supply, the bidder should provide the proof
of these facilities and Company will have the right to visit these facilities prior to
finalization of order. The manufacturer shall also provide client list in Pakistan or in
the region.
10. DOCUMENTATION REQUIREMENT
10.1 Transmittals
All documents submitted to the Company shall be accompanied by a transmittal com-
pleted by Supplier. All transmittals will be sequentially numbered.
10.2 Use of English Language

All documents shall be written in English Language.
10.3 Documents to be Submitted

- Completely filled API standard 11P, 2nd edition data sheet.
- Material test certificates
- Compressor operating manual including characteristic curves.
- Mechanical design calculations
- Detail fabrication drawings
- Sectional details/drawings
- List of spare parts along with OEM / vendor part number with C&F Karachi
prices.
- List of sub vendors with complete address and references.
- Welding procedure specifications
- Welding qualification record
- Hydro testing certificates
- Performance test certificates/Performance curves.
- NDT/Painting inspection certificates
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- Manufacturing Data Records (MDR)

- Motors performance curve including torque vs. speed curve.
- Electrical equipment certification with reference to hazardous area classification.
- SIL Certification (where applicable)
- Instrumentation Calibration / Verification reports.
- Repair and overhauling manuals.
- Any other documents not specified above, but essential to make the unit
operational and maintainable.
- Undertaking from the original equipment manufacturer to entertain warrantees
and other after sales service obligations.
- SCADA related documents as per relevant specifications.
- Pulsation and Torsional Study reports
- HAZOP Close-out Report
All above documents eight (08) sets shall be submitted in clearly labeled 4 ring white
hard cover binders. All documents smaller than A4 shall be inserted into A4 pre-
punched, top-opening plastic wallets (if original certification, etc.) or attached to A4
sheets. Documents larger than A4 shall be folded to A4 size and inserted into A4 pre-
punched, top-opening plastic wallets with the project document number/title block
clearly visible to the front.
10.4 Drawing Sizes

Sizes A1, A2, A3, and A4 shall be used.
NB. A0 size drawings are NOT acceptable.
10.5 Scale Ratios

Except where stated, all drawings will be supplied in metric units using one of the
following scales 1:1, 1:2, 1:5, 1:10, 1:20, 1:25, 1:50, 1:100, 1:250, 1:500, 1:1000.
10.6 Electronic Data
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Supplier shall also submit electronic/soft copies of all design data, documents,
drawings, etc. This also includes design details by Supplier’s Sub-suppliers.
All drawings shall be provided in AutoCAD 2000 format. All documentation shall be
prepared in MS Office 2000.
11. REFERENCE DOCUMENTATION

11.1 Order of Precedence for Documents
In case of conflict among this Specification, the referenced specifications and the International
Codes and Standards, the Supplier shall bring the matter to the Company’s attention for
resolution and approval in writing.
The order of precedence shall be as follows:
1. Equipment Data Sheets (RG-1501-DS-1821 to RG-1501-DS-1825)
2. This specification and the referenced Project Specification
3. Piping & Instrumentation (RG-1501-PID-1011-A)
4. Referenced International Codes and Standards
In the event of any conflict of data or requirements in any of above documents, it is the
Supplier’s responsibility to resolve these conflicts and obtain Company’s approval before
proceeding with design, manufacture or purchase. In any case the most stringent requirement
shall prevail. However, Company’s interpretation shall be final.
11.2 Referenced Project Documents
RG-1501-A-1051 Process Design Basis

RG-1501-PU-8601 Specifications for Skid Mounted Equipment Packages
RG-1501-ISP-6002 SCADA System Specification
RG-1501-ISP-6003 Control System Design Basis
RG-1501-ELA-6500 Specification for Solar Power System
RG-1501-ISP-6501 Specification for UPS Power System
RG-1501-VA- 3001 Specification for Unfired Pressure Vessels
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RG-1501-AEA- 5901 Specification for Air Cooled Heat Exchangers
11.3 API
- Specification for Packaged Reciprocating Compressors for Oil and Gas

Production, Services, API Standard 11P – Second Edition, November 1, 1989.
- Specification for oil field V – belting, API Standard 1B.
- Recommended Practice for Design and Installation of Electrical Systems and
Offshore Production Platforms, API RP 14F.
- Recommended Practice for Classification of Locations for Electrical Installations
at Drilling Rigs and Production Facilities on Land and Marine Fixed Mobile
Platforms, API RP 500B.
- Recommended Practice for the Design and Installation of Pressure Relieving
Systems in Refineries, Part I – Design and Part – II Installation, API RP 520
(Latest Edition).
11.4 ANSI / ASME
- Unified Screw Threads, ANSI B1.1

- Pipe Threads, General Purpose (inch), ANSI B1.20.1
- Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800, ANSI
B16.1
- Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys,
ANSI B16.5
- Ductile Iron Pipe Flanges and Flanged Fittings Class 150 and 300, ANSI B16.42
- Chemical Plant and Petroleum Refinery Piping, ASME B31.3
- Boiler and Pressure Vessel Code, Material Specifications, ASME section II.
- Boiler and Pressure Vessel Code, Rules for Construction of Pressure Vessels,
ASME section VIII.
- Boiler and Pressure Vessel Code, Welding and Brazing Qualifications, ASME
IX.
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DESIGN, MANUFACTURING / FABRICATION,

ASSEMBLING & SUPPLYING OF PACKAGED

ISSUED FOR BIDDING

0 04-July-2016 Issued For Bidding MA HHQ SFA MHQ TH

PROJECT CODE: DOCUMENT NO:

RG-1501 RG-1501 - MA - 3502 - 0

CLIENT REF NO. DOCUMENT

2. SCOPE OF SUPPLY & SERVICES .............................................................................................. 8

3. PACKAGE OVERVIEW ................................................................................................................. 13

4. PACKAGE REQUIREMENTS ....................................................................................................... 15

5. INSPECTION AND TESTING ....................................................................................................... 30

6. QA/QC AND CERTIFICATION .................................................................................................... 34

9. DOCUMENTATION REQUIREMENT ........................................................................................ 37

10. REFERENCE DOCUMENTATION .............................................................................................. 39

1. Nodal Compressor at Adhi-17 (for Adhi-17 & Adhi-21)

“Company” shall mean PPL (Pakistan Petroleum Limited) installing

1.3. Codes, Standards & Company’s Specifications Requirements

API 615 Sound Control of Mechanical Equipment for Refinery Services

ANSI B16.5 Pipe Flanges and Flanged Fittings

ANSI B31.3 Process Piping

RP 500B Recommended Practice for Classification of Locations for

RP 520 Recommended Practices for the Design and Installation of

RP 521 Pressure Relieving & De-Pressuring Systems

RP 551 Process Measurement Instrumentation

RP 552 Transmission Systems

RP 554 Process Instrumentation & Control

ASME Sec-II Boiler and Pressure Vessel Code, Material Specifications.

Section IX Boiler and Pressure Vessel Code, Welding and Brazing

NFPA70 National Electrical Code

MG-1 Motors and Generators

NEMA 250 Enclosures for Electrical Equipment

1.4. Errors or Omissions

1.5. Conflicting Requirements

1.6. Company’s Intention

The Supplier shall be responsible to size the Packaged Reciprocating Compressors, in

2. SCOPE OF SUPPLY & SERVICES

Supplier's scope shall include the following as a minimum:

- Designing, engineering, manufacturing, fabrication, assembling, painting,

- Provision of all necessary documentation including equipment dossiers, etc. (03

- Indication of all technical deviations/exceptions to this scope and specification

- Preparation of shipping arrangement for delivery

- Provision of required material certification.

- Protective coating/painting including preparation for shipment.

- Supply of commissioning spares. Separate price list of commissioning spares is

- Provision of set of special tools & lifting arrangements.

- Development and provision of manufacturing schedule

- Access for inspection, witnessed by Company / Company’s Representative of

- Supply of operating consumables, and first fill of lubricants, chemicals, etc.

- Arrange undertakings from the original equipment manufacturers to the supply of

- Supervision of installation of hook-up.

- Startup, pre-commissioning & commissioning services.

Supplier shall provide following commissioning spares in addition to the parts

- Lube oil for first charge of oil + 20% extra

2.2 Operation Spare Parts

2.3 Capital Spares

2.4 Special Tools

2.5 Third Party Pre-Shipment Inspection

2.6 Installation Supervision, Pre- Commissioning / Commissioning & Startup

2.6.1 Installation Supervision

Before commencing installation, Supplier shall participate in overall package

2.6.2 Pre- Commissioning / Commissioning & Startup Services

2.7 Performance Test