空气压缩机规范.doc

台灣中油股份有限公司空氣壓縮機規範AIR COMPRESSOR GENERAL REQUIREMENTLPG加氣站設備、器材規範-2日期98年02月26日頁次第8頁共14頁1.0 GENERAL1.1. IntroductionThis specification covers minimum requirements for the mechanical design, materials, fabrication, inspection, shipment and testing of reciprocating type air compressor unit.1.2. Conflicting RequirementsWhenever the data included on the purchase documents conflicts with the provision of this specification, the former shall govern. However, any conflicts must be brought to the attention of the purchaser for complete clarification prior to manufacturing of the affected parts.1.3. Compliance by Vendor with the provisions of this specification and data sheets does not relieve him of the responsibility of furnishing equipment and accessories of proper design, material and fabrication to meet guarantees at the specified operating conditions.1.4. Measurement SystemThe system of measurement for all engineering design, calculation, documentation, drawings, instrument calibration and equipment nameplates shall be in English and in the Metric system except that the nominal pipe size can be in inch units.2.0 SCOPE OF SUPPLY BY VENDORScope to supply shall include, but not limited to the following:2.1. Air compressor unit shall include two sets of Air Compressor, Air Dryer, and Air Filter etc. for alternate use, and two sets of Air Regulators to become a complete unit for supplying high pressure instrument air, or maintaining the positive pressure inside the required closed cabinet.2.2. Reciprocating type air compressors with motor drivers.2.3. Air receivers and necessary accessories.2.4. Refrigerated air dryer units and necessary accessories.2.5. Filters.2.6. Furnishing and installing the interconnecting piping, valves and fittings.2.7. Furnishing and installing the interconnecting wiring and conduit.2.8. Inspection and testing at the manufacturers shop.2.9. Special tools (if required).2.10. Packing and transportation to the jobsite.2.11. After service and parts supply capability.3.0 DESIGN BASISVendor shall supply the design data for approval.4.0 MECHANICAL REQUIREMENTS4.1. Codes and Standards4.1.1. All electrical components shall be suitable for installation in a non-hazardous area.4.1.2. Piping shall conform to ANSI B31.3- Pressure Piping Code, or JIS equivalent standard. But pipe size of 1-1/4, 2-1/2, 3-1/2, 5, 7, 9 inches and primary service pressure rating 400 lb shall be avoided.4.1.3. Receiver shall be designed and construction per CNS Pressure Vessel Codes from B5084 to B5099 (Except B5096).4.1.4. ASME Section IX, Welding Qualifications4.1.5. ASTM PTC 9 - 1970, Performance Test Code for Compressor4.1.6. Reference to any standard or code shall mean the latest edition of that standard or code including addenda or supplements.4.2. Air Compressor4.2.1. Compressor, dryer, driver and all components shall be suitable for continuous full load duty under the specified operating conditions. All parts of compressor, dryer and driven equipment shall be safe for operation at the maximum load and torque capability of the driver. Equipment which must operate at its design limit in order to meet the specification is not acceptable.4.2.2. Intake Air Filter: Dry Type.4.2.3. CrankcaseThe crankcase of each compressor shall be designed for rugged application. The oil reservoir with oil level indicator shall be sealed completely.4.2.4. Cylinder headA. The cylinder head shall be fine-grained and honed for smooth running.B. The integral cooling water shall be throughout the cylinder and cylinder head to ensure the maximum cooling effect.4.2.5. Connecting rodThe connecting rod shall be adequate in size and strength to withstand safely and continuously all the stresses from starting and operating conditions.4.2.6. Crank shaftA. The crank shaft integral with counterweight shall be carefully calculated counterweights neutralize, the inertia of the reciprocating parts to hold smoothly long-term running.B. The shafts shall be rifle-drilled to provide force feed lubrication to the crank pins and perfect seating with bearings.4.2.7. PistonThe piston shall be selected for perfect dynamic balance and fitted with the adequate compression rings and oil ring to provide efficient operation and better oil control.4.2.8. ValveA. The suction and discharge valves shall be designed with large valve blow area, low lift make low valve temperature and high valve efficiency.B. Valve discs and springs shall be fully interchangeable.4.2.9. Control PanelA. Control shall be provided to allow air compressor load and unload (without shutdown) automatically as the air pressure in the air receiver below the low set point or above the high set point. Set point pressure shall be field-adjustable.B. A main circuit breaker and a full voltage motor starter with control transformer shall be provided for motor operation and system control.C. When one air compressor is out of order, the stand-by unit shall be able to start automatically.4.2.10. MotorMotor shall be TEFC enclosure, insulation class B and shall be furnished in accordance with Specification for Induction Motor.4.3. Air Receiver4.3.1. The air receiver shall be stamped by Taiwan Provincial Industry and Mining Inspection Office.4.3.2. Pressure gauge, safety relief valve, drains valve, temperature gauge, auto-drain-trap and necessary accessories shall be furnished on receiver by Vendor.4.4. Air Dryer4.4.1. Type: Refrigerated type with air cooled condenser.4.4.2. Inlet air temperature gauge, auto-drain-trap, thermostatic expansion valve, hot gas bypass valve, refrigerant filter-dryer, suction pressure gauge, discharge air pressure gauge, on/off switch with lights, high outlet air temperature gauge (or with light) and other necessary accessories shall be furnished. 4.4.3. Total dryer pressure drop shall not exceed 0.35 kg/sq. cm.4.4.4. A mounted and pre-wired full voltage starter shall be provided to protect the compressor motor from over current or a system failure.4.5. NoiseThe noise generated by the rotary machine shall not exceed 85 dBA at 1 meter away from the machine. Vendor shall verify the noise level of the proposed rotary machine with published documents, and the noise data shall be acquired and recorded during machine mechanical and performance test. If the anticipated noise level of the proposed machine exceeds 85 dBA at 1 meter, vendor shall furnish within his scope of the supply like the noise reduction equipment such as acoustic hood or blanket etc. to reduce the noise level below 85 dBA at 1 meter.4.6. Asbestos material and lead material shall not be used on the air compressor unit.4.7. Type: Air Cooling Type.4.8. Capacity: At 10 kg/cm2 outlet pressure, each air compressor shall have the rated capacity of 450 lpm at least or twice the calculated required capacity whichever is higher.4.9. Pressure at every point: Can reach 5 kg/cm2 at least (The bidder shall submit the calculation to ensure the capacity can meet the requirement after deducting the transportation pressure loss from the outlet pressure10 kg/cm2). The bidder shall adjust the regulators until the working pressure can meet the site requirement.4.10. Capacity of Air Receiver (Air storage tank): 150 liters at least.4.11. Power Supply: 220VAC, 3 Phase, 60HZ.4.12. After the treatment of air compressor, air dryer and air filter for effect shall meet Maximum 0.01 Micron Particle Size, Below 5 at 7 kg/cm2 Dew Point:, as well as maximum 0.01 ppm volume Oil Content.4.13. Motor Enclosure: Totally Enclosed Fan Cooled (TEFC).4.14. General Requirement: Shall meet the attached general requirements of the air compressor and electric motor.5.0 INSPECTION AND TESTING5.1. All equipment shall be subject to the following inspections and tests.5.1.1. Dimensional Inspection.5.1.2. Hydrostatic Pressure Test (at least double the discharge pressure for thirty minutes).5.1.3. Mechanical Running and Performance.5.1.4. Noise Measurement.6.0 NAMEPLATEThe following data shall be stamped in a stainless steel nameplate permanently attached to the compressor with fasteners.6.1. Manufacturers name.6.2. Manufacturers model number and serial number.6.3. Size and type.6.4. Rated capacity6.5. Maximum allowable working pressure.6.6. Maximum allowable discharge temperature.6.7. Owners name and tag/item no.6.8. Date of manufacture.7.0 PREPARATION FOR SHIPMENT7.1. Upon completion of all inspection and testing and before the shipment, all parts shall be coated in accordance with manufacturers standard, but without containing any ingredient. Surfaces shall be cleaned thoroughly and painted as a normal for one layer of primer and two layers of finish-paint.7.2. The equipment shall be thoroughly cleaned, free from grease, scale, rust and rubble.7.3. All exterior parts of the compressor except finished machine parts shall be painted per manufacturers standard.7.4. Machined surfaces shall be suitably protected from rust and damage during shipment, handling and storage. Threaded connections shall have thread protectors, beveled ends of pipes shall be capped, and flanges shall be full face covered with steel or plywood, bolted in place.7.5. Vendor shall be solely responsible for preventing damage during shipment.8.0 OTHER8.1. The bidder shall submit the following documents for approval.8.1.1. Original detail catalogues and performance curve of the equipment selected.8.1.2. Filled data sheets of the air compressor and the motor.8.1.3. Spare Parts Description.8.2. The successful bidder shall submit the calculation of the capacity that can meet the demand and the pressure of 5 kg/cm2 as a minimum at every point when at outlet pressure10 kg/cm2 for approval.8.3. The successful bidder shall submit the manufacturer test report, inspection certificate of the pressure vessel (air receiver), together with the operation, maintenance and installation manuals in both Chinese and English.DATA SHEETJOB NO. : SHEET NO. : of REV. : DATE: BY: CHK: RECIPROCATING COMPRESSOR UNITClient: Project: Plant Locatio : Service: Site and Utility DataAmb. Temp.() :Max. 40 Min. 5 Avg. 30 ,Altitude (M) : Below 1000 m above sea level Relative humidity (%) : Max. 90 Min. Avg. Electrical classification : Non-hazardous Hazardous NEC Class , Group , Div. Cooling water supply for: CylindersIntercoolerOil Cooler Type water: Temperature, : Pressure, kg/ cm2G Quantity required. Lit/Min. Installation : Indoors Under roof Outdoors Without roofOther : Unusual conditions : Dust FumesOther : APPLICABLE CODES, STANDARDS, & SPECS.Compressor (Test) : CNS STD. 3038 B7044 ANSI/ASME PTC-9 Other : Pressure Vessels : CNS ASME SEC. VIII, DIV. 1Piping : ANSI B31.3 JISElectrical : Pressure Vessels : CNSASME SEC. VIII, DIV. 1Safety : OSHA Local Labor Safety and Hygiene Regulation Others : CNS 12406, Z2067 1. COMPRESSOR(S)(1) Item No. : ,No. Reqd : Sets (2) Mfr.: ,Model No.: (3) Gas compressed : ,w/mol. Wgt. inlet : (4) Type : Lubricated Oil - freeOil - less Water - cooledAir - cooled(5) Stage : Single Two Multi(6) Capacity reqd N Cu. M/Hr (per each set) : (7) Inlet pressure, kg/cm2G :Max. ,Nor. ,Min. (8) Inlet temperature, :Max. Nor. ,Min. (9) Discharge pressure, kg/cm2G:Max. ,Nor. ,Min. (10) Discharge temp.(Compr. Outlet):Max. ,Nor. ,Min. (11) Discharge temp.( Aftercooler Outlet):Max. ,Nor. ,Min. (12) Compressor materials :Cylinders: Valve seats: Pistons: Valve stops: Piston rings : Valve plates: Rider rings: Valve springs: Piston rods: Rod packing: Others : DATA SHEETJOB NO. : SHEET NO. : of REV. : DATE: BY: CHK: RECIPROCATING COMPRESSOR UNITCOMPRESSOR(S) (CONTD)(13) Frame lubrication : Splash system Pressure system Other : (14) Compr. Lube oil press. Setting. kg/cm2G : (15) Comp. Operating speed, rpm :Max. Rated Min. (16) Hydrostatic test press., kg/cm2G :Cylinder Cylinder cooling jacket 2. MOTOR DRIVER(1) Item No. : ,No. Reqd : Sets (2) Mfr.: ,Model No.: (3) Power supply : Volts, Phase, cycle(4) Nameplate :Hp. : KW,Speed: rpm,Frame no.: (5) Insulation : ,Enclosure : ,(6) Start method : ,Service factor : ,(7) Nameplate hp (excluding service factor) 110% of max. compr. Bhp.(8) Motor mounted by : Purchaser Compr. vendor3. POWER TRANSMISSION V- Belt drive Direct coupled Geared & coupled 4. CAPACITY CONTROLBy : Purch. by-pass Mfr. Capacity controlFor : Part load condition Start-up only BothNo. of steps : Two (0% - 100%), load/unload Three (0% - 50% -100%) Five (0% - 25% - 50% - 75% - 100%) Motor auto start/stop Other : ,Step control : Piloted by receiver press. kg/cm2G : , Piloted by purch. instr. w/_ kg/cm2G air single Piloted by purch. instr. w/_ kg/cm2G air single Manual Auto Other: Using : Clearance pockets cy Suct. Valve unloaders cyl.5. ACCESSORIES(1) Drive guard, Type : Spark proof Mfr. Standard Other : (2) V - belt(3) Baseplate: Common Separate Other : (4) Drive : Static cond. & oil resistant V-belts Total enclosed V-belt guard(5) Intake filter : w/Silencer w/