APPD.BY DATE DATE VOLUME 11 E PDVSA, 1983 LTP2.2 SPECIFYING PACKAGE UNITS FOR APPROVAL Jos Gilarranz Eduardo Santamaria FEB.86 FEB.86 ENGINEERING SPECIFICATION FEB.86 NOV.89 L.T. J.S. 1 0 Modified Section 3 Para. P and S.2 and Para. 4 No- te 1 11 15 J.G. J.G. E.S. E.S. ENGINEERING DESIGN MANUAL ESPECIALISTAS APPD.BY PDVSA REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 1 PDVSA .Men Principal Indice manual Indice volumen Indice norma Index 1 GENERAL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Introduction 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Scope 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 EXECUTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MECHANICAL CHECK LIST FOR PACKAGE UNITS 2 . . . . . . . . . . . 4 DRAWING REQUIREMENTS SPECIFICATION FOR PACKAGE UNITS MANDATORY 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 2 PDVSA .Men Principal Indice manual Indice volumen Indice norma 1 GENERAL 1.1 Introduction When package units are to be ordered, it is necessary that the vendor supplies a unit which: a. Meets the process requirements b. Meets the mechanical requirements c. Is fully defined, so no items are forgotten or duplicated d. Forms part of the standardization policy 1.2 Scope The procedure indicated below outlines the steps the package unit specification originator should follow in the preparation of a requisition. Since the complexity of a package unit may vary, the specification originator must decide which of the Project Engineering Specifications are mandatory and which are optional. For instance a relatively simple package unit such as a chemical feed system should at least follow the Instrumentation Project Specifications for standardization goals, but would waive the Structural Project Specifications for the design and fabrication of the skid baseplate. The package unit specification originator should strive to have simple units designed and fabricated to vendors industry standard practices provided the components adhere to the project standardization policy, as a minimum. For relatively complex units, such as a demineralization plant, the specification originator should follow essentially all of the criteria listed below. This procedure is a guide and should be used by the package unit specification originator with judgement, keeping in mind the goals outlined in paragraph 1.1 above. 2 EXECUTION The requisitor representative shall be responsible for the coordination of approvals before submitting a requisition and during the execution period. 3 MECHANICAL CHECK LIST FOR PACKAGE UNITS The following check list, represents some of the optional or mandatory requirements which should be provided and/or considered in package units. As applicable, the requirements should be an integral part of the inquiry/purchase order requirements. A. Overall Planning Mandatory REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 3 PDVSA .Men Principal Indice manual Indice volumen Indice norma 1. Unit (will) (will not) be expanded in the future. provision should be made accordingly in equipment layout. 2. Unit will be located (outdoors) (indoors). 3. Materials of construction shall either be specified by requisitor or provided by the vendor, in which case review and approval by requisitor will be required. B. Special Vendor Responsibilities Mandatory 1. The package unit is to be designed for use at (city, country). The originator of the requisition shall ensure the package unit vendor adheres to all applicable Venezuelan codes and regulations for the use of the package unit. 2. The vendors compliance with these specifications shall not relieve him of the responsibility for use of proper design, workmanship and materials in meeting the package unit requirements. C. Standardization Requirements Mandatory It is required that the number of varieties of pumps, seals, couplings, instruments and certain other equipment or components be restricted to a minimum for reasons of standardization. The approved vendors for these items shall be as follows: a. To be advised later ( ). b. See attached tabulation ( ). D. Certificates Mandatory The vendor shall be responsible for obtaining all certificates for piping, pressure vessel, heaters, boilers, heat exchangers, electrical equipment, etc. which are required by the safety authorities in the location in which the package is to be installed. E. Utilities Available Mandatory Utilities available for use in the package units are specified in Engineering Specification PDVSA SD252 Utility Data. F. Meteorological and Plant Design Data Mandatory Refer to Engineering Specification PDVSA SD251 Site Data for design parameters which must be specified in requisitions of package units, where applicable. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 4 PDVSA .Men Principal Indice manual Indice volumen Indice norma G. Piping Requirements Mandatory 1. Buyer will make (all utility connections to equipment) (only one connection for each utility service) on the package unit. 2. All (No) process and utility piping shall be installed between the package component parts. If not possible, piping will be provided between components, prefabricated with assembly drawings. 3. Piping wall thickness shall be in accordance with the applicable piping class of engineering Specification PDVSA H221, Piping Materials. 4. Valve and fittings shall be in accordance with the applicable piping class of Engineering Specification PDVSA H221 Piping Materials. 5. Review engineering Specification PDVSA H251 Process and Utility Piping Design Requirements for compliance by Package Unit vendor. 6. Pipe sized 11/4, 21/2 and 31/2 inch and all larger odd number sizes such as 5 inch and 7 inch shall not be used except where required for connections to mechanical equipment of standard design or where specific velocities must be maintained. 7. Minimum vent and drain size is 3/4 inch. 8. Tracing for all equipment, piping and instruments shall be provided as required. Tracing shall be per vendors standards or attached standard drawing. 9. Minimum pipe size shall be (.....). 10. Steam traps with (block and bypasses) (blocks and bleeds) shall be provided where required for either: a. Ensuring that supply steam is dry, or b. For withdrawal of condensate. 11. If plastic piping is required, vendor shall supply it together with complete specifications for same. 12. Depending on the size and complexity of the package unit, all of the Project General Piping Specifications may either be attached as mandatory or parts extracted and spelled out in the packet unit specification, in which case the package unit specification shall assure compatibility and compliance with the Project General Piping Specifications. H. Structural Requirements Optional 1. If the package unit is supplied completely piped, the unit shall be furnished on a structural steel baseplate or skid. 2. If the package unit consists of two or more separate, completely piped small packages, each shall be provided on a baseplate. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 5 PDVSA .Men Principal Indice manual Indice volumen Indice norma 3. Structural steel baseplate shall be designed for anchoring to foundations. 4. Sufficient structural steel, guides, anchors, springs, etc. Shall be provided so all equipment, piping and other components supplied are adequately braced and supported. 5. For package with large components not supplied as assembled units, structural steel (shall) (shall not) be provided with all platforms, stairs, ladders, railings, etc. required for safe operation. Structural steel for above mentioned platforms, etc. (shall) (shall not) be designed, even if excluded from scope of supply. 6. Other structural steel design shall be in accordance with Engineering Specification PDVSA JB251 Steel Structures Design. 7. All structural steel shall be painted. Steel shall be painted in accordance with the requirements of Engineering Specification PDVSA O201, Painting Material and Application Requirements. I. Pressure Vessel and heat Exchanger Requirements Mandatory 1. Pressure Vessels a. Vendor shall provide vessels in accordance with Engineering Specification PDVSA D211 Pressure Vessel Design and Fabrication Specification. b. Pressure vessel design specifications shall meet the intent of engineering Specification PDVSA D211 Pressure Vessel Design and Fabrication Specification. c. Saddles for horizontal vessels shall be in accordance with the (attached standard) (vendors standard practice). If on concrete saddles, corrosion plate shall be welded to the vessel. d. Dimensional tolerances shall be in accordance with (manufacturers standard practice to be reviewed and approved by Requisitor) (attached Requisitor Vessel Engineering Design Standard). e. For vertical outdoor insulated vessels, insulation rings and a flashing ring shall be supplied in accordance with (attached standard) (vendors standard practice). f. Davits shall be provided as required for proper maintenance of the unit. g. Where double welded butt joints are not practical, the welding procedure shall be approved by requisitor. h. Nameplate shall be (vendor standard but submitted to Buyer for review) (Requisitor Vessel Engineering Design Standard for nameplates). REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 6 PDVSA .Men Principal Indice manual Indice volumen Indice norma i. The fabrication and testing of all vessels purchased under this specification is subject to inspection by requisitor, and also by national, local, or insurance company representative when so required by Code. This inspection, however, does not relieve the fabricator of his responsibility to ensure the pressure vessels meet all requirements of this specification. j. Vendor shall supply matching flanges for nonstandard, size, shape or materials where package interfaces with the Buyers systems. 2. Heat Exchangers a. Vendor shall furnish equipment in accordance with engineering Specification PDVSA EA201PR Shell and Tube Heat Exchange Equipment or PDVSA EA202PR Double Pipe Heat Exchange Equipment, whichever is applicable. b. Fouling factors shall be in accordance with the (TEMA Recommendations) (attached tabulation) for the fluids involved. Vendor shall be responsible for completing heat exchanger data sheets when supplied as part of a package. c. Tube diameters, lengths, gauge, layout, exchanger type, and materials shall be in accordance with (vendors standard practice) (attached specification). d. Corrosion allowance shall be (shell....., tube......) (when not specified, TEMA R will govern). e. Screwed connections in each exchanger nozzle, if required shall be provided, for example for temperature or pressure gaging. f. One 1 screwed connections for exchanger shall and tubeside vent and drain shall be provided. g. Design pressure and temperature shall be established in accordance what the heat exchanger requirements. J. Insulation Requirements Mandatory 1. If insulation is to be supplied for (heat conservation) or (personnel protection) for piping, equipment or instruments, it should meet the requirements of Engineering Specification PDVSA L212 Insulation material and Application Hot Service. K. Machinery Requirements Mandatory 1. Machinery such as pumps compressors etc. and their drivers shall comply with the applicable specifications. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 7 PDVSA .Men Principal Indice manual Indice volumen Indice norma 2. If vendors are unable to comply with these specifications, they shall submit complete detailed lists of exceptions with their proposals. 3. Approved vendors will be specified. L. Instrument Requirements Mandatory The instruments shall be supplied in accordance with the following 1. Standardization The instrumentation furnished by package unit vendors, approved manufacturer, type and model will be specified by customer. The purpose of this requirement is to ease maintenance, spare parts and training requirements. 2. Engineering Specification Package unit instrumentation shall be in accordance with the following PDVSA Engineering Specifications: K335 Packeged Unit Instrumentation K330* Control Panels and Consoles HF201* Instrument Piping Design and Instrument Installation * Not mandatory for relatively simple package units. Note: The above specifications, particularly PDVSA KA335, may not be normally used directly for instrument purchasing. Attachment of an engineering specification to a package unit requisition without additional information may be insufficient. 3. Specific Requirements for a Package Unit a. The package unit requisition originator shall request the lead instrument engineer to write the instrument portion of the specification. b. The instrument portion may vary from several paragraphs based on the engineering specifications for simple packages to a custom writeup with engineering specifications attached. 4. Instrument Tagging All instruments shall be tagged with requisitor instrument tag numbers. tag numbers shall be utilized on all vendor documentation and on the instruments. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 8 PDVSA .Men Principal Indice manual Indice volumen Indice norma M. Electrical Requirements Mandatory 1. All electrical equipment, wiring and devices shall be in accordance with the applicable specifications. when the packaged equipment has been defined and located, the electrical engineer should be consulted to determine the applicable specifications, type of vendor drawings required and other specific requirements. 2. The package shall be suitable for the environmental conditions as well as the Area Classifications. 3. All materials provided should be compatible with those specified throughout the project. N. Painting Requirements Mandatory Vendor shall furnish package units with protective coatings on equipment in accordance with Engineering Specification PDVSA O201 Painting Material and Application requirements. O. Noise Requirements Mandatory Equipment supplied by vendor shall meet the noise requirements stipulated in Engineering Specification PDVSA SN252, Equipment Noise Control. P. Spare Parts Requirements Mandatory Equipment and components supplied by vendor shall be reviewed to ensure compatibility with the criteria established for procurements of spare parts. Q. Testing Requirements Mandatory Equipment supplied by vendor shall be shop tested in order to confirm compliance with applicable codes, to ensure mechanical integrity, and to perform running test as required. R. Instruction Requirements Mandatory 1. Operating manuals supplied by equipment vendors shall be supplied in English and Spanish. 2. Vendor supplied drawings will be required to follow the MKS system for unit identification. Attachment No. 2 Gaceta Oficial de la Repblica de Venezuela No. 2823 lists the applicable units. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 9 PDVSA .Men Principal Indice manual Indice volumen Indice norma 4 DRAWING REQUIREMENTS SPECIFICATION FOR PACKAGE UNITS MANDATORY The following drawings and information shall be furnished by the vendor. The schedule to which After Order drawings and information are to be issued to the buyer shall be confirmed by the vendor prior to placement of order. With Quotation After Order 1. List of drawings and documents vendor intends to issue with dates for issues * * 2. Piping and instrumentation diagram (see Note 1) * * 3. Equipment outline or package general assembly drawings (see Note 2) Preliminary drawings & brochures * 4. All information required to enable purchaser to design foundations Weights of equipment * 5. List of pumps, blowers, etc. including manufacturer, type, HP, all materials, and Performance curve. Also driver manufacturer and type * * 6. Instrument list including vendor and type * * 7. Completed applicable equipment data sheet (i.e. pump, compressor, heat exchangers, etc.) * 8. List of electrical items other than motors including vendor and type * * 9. Instrument panel drawing and instrument wiring diagrams. * 10. Electrical panel drawings * 11. Wiring diagrams * 12. Building layout for indoor preliminary equipment (complex packages only) * 13. Equipment layout for outdoor preliminary outdoor equipment (complex packages only) * 14. Operating and maintenance instructions * 15. Recommended spare parts list with prices * * 16. Complete parts list with prices * 17. Process and utility guarantee * * 18. Utility Consumptions * * REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 10 PDVSA .Men Principal Indice manual Indice volumen Indice norma After Order With Quotation 19. Vessel ASME Code data sheet (U1) * 20. Vessel fabrication detail drawings * 21. Plan and elevation views of detailed piping drawings (Note 4) * 22. Prefabricated piping assembly drawing * 23. Bill of material for piping components * NOTE 1 The piping and instrument diagram shall show on a single drawing all of the equipment, piping, valves and instruments for the package unit. The diagram shall include piping which is not supplied by the vendor if this piping design is important for the entire package operability. The final diagram shall show the sizes of all the above mentioned items and the process and utility mediums at each tiein. (The vendors equipment shall be given item numbers in the Purchase Order Requisition, for ease location on the plot plan and identifying motors and other electrical devices). The final diagram shall indicate instrumentation in accordance with the Buyers symbols. These symbols and their description will be issued at time of order placement. The final diagram shall also show piping line numbers for all interconnecting piping between the vendors components. Also, these shall be indicated the type of material, valves, flanges, as well as size (OD x wall thickness) for all tiein connections. The diagram shall clearly indicate which items (equipment piping, valves, instruments ) are included in the scope of the vendors supply and which are to be supplied by the Buyer. NOTE 2 The following drawings(s) shall be provided either for a completely assembled package unit or for a complex package consisting of several components. a. Weight of package (or each component) if not already shown on a separate drawing and at least the erection weight of the heaviest single piece that can be dismantled. See Note 3. b. Size, pressure, rating, flange facing and location in plan and elevation of all process and utility connections to which Buyer must tiein. c. Location in plan and elevation of all electrical terminal boxes and cable gland connections, together with the size of all cable glands. The power requirements shall be stated for each electrical user. REVISION FECHA ENGINEERING SPECIFICATION SPECIFYING PACKAGE UNITS NOV.89 1 PDVSA LTP2.2 Pgina 11 PDVSA .Men Principal Indice manual Indice volumen Indice norma NOTE 3 The foundation information drawings shall include plan drawings of the baseplate or supports showing anchor bolt holes locations and sizes. In addition, an elevation outline shall be shown indicating the location of center of gravity. The information given on this drawing shall be sufficient to design foundations on the following basis: a. Test weight without wind. Test weight shall be understood to include, besides the equipment, all platforms and piping supported on the equipment and the weight of the test fluid. b. Empty load with wind. Empty load is test weight less the weight of the test liquid. c. Operating load with wind. Operating load is empty load plus weight of liquid at maximum operating level. d. Unbalanced forces with directions are to be indicated for reciprocating compressors. e. Maximum permissible forces and moments for compressor, pump, and turbine nozzles. NOTE 4 The service or intended use of all piping connections shall be shown on vendors drawings regardless of whether these are plugged, open or piped away.