11/29/14

PETROLEUM CENTRAL CONTROL BUILDING

1.             Laying Damp Proof Course

Any course on which a damp-proof material is to be laid shall be flushed up with cement mortar No. 2 to form an even bed Damp-Proof material shall then be laid and protected from injury until the mortar is set, when building may proceed.
Damp-proof materials shall be lapped 150 mm at joints and angles.
A damp-proof course shall be laid between the structural concrete floor slab and the walls forming the superstructure of any building.

2.            Masonry Construction

Bricks and concrete blocks shall not be wetted before lying. If not otherwise indicated, masonry units shall be laid in stretcher bond breaking joints with the course below. Walls shall be started on the structural beam, or slab and laid out with one starting course to define spaces, doors, openings, etc., and to serve as a guide for other trades. Joints shall be  finished flush where exposed to view, and shall be raked to an even depth of 10 mm, Masonry units shall be laid on a full unfurrowed bed of mortar and with end joints solidly filled with mortar. Units shall be tamped into place, squeezing out all air pockets and insuring a full bed of mortar.
Wall ties shall be of the following types and spacing:
·         Between cavity wall skins (where applicable), twisted galvanized steel butterfly type at 800 mm horizontally and 450 mm vertically.
·         At structural columns, galvanized steel dovetail ties with tang for embedment in block work joint for fixing to insert strip in column at 450 mm vertically.
Masonry shall have bed joint reinforcement in every third course consisting of 2 No. 6 mm mild steel bars or other approved proprietary system. In cavity walling, both skins shall have bed joint reinforcement. Reinforcement shall also be provided above and below all window and door openings.
The faces of walls shall be laid plumb and true with cells in vertical alignment. Chases, pockets, and other breaks in masonry construction shall be formed where shown or directed. Frames and other built-in items shall be maintained in proper position and bracing for the same shall not be removed until they have been securely anchored in the masonry. During progress of the work, the exposed surfaces of masonry, and of other construction and finishes shall be kept clean at all times and protected against damage.
Lintels and cills shall be laid true to line and level, bedded on cement mortar No. 2. An open joint, not less than 15mm wide, shall be left between the ends of all concrete lintels and cills, whether precast or cast in-situ, and the walls adjacent to these ends. These open joints shall be left as long as possible during construction and not filled until plastering or other works render such filling necessary. All such joints shall be properly filled before completion of the work.
Concrete screen blocks shall not be wetted before laying, and blocks shall be laid in stacking bond, unless otherwise shown on the Contract Drawings. Blocks shall be laid in alignment from bottom to top of wall with joints not exceeding 15mm., uniform throughout and finished slightly concave and smooth.
Cleaning of exposed masonry shall be performed by removing all excess mortar, dust, efflorescence and stains, using a five (5) percent muriatic acid and water solution or soap powder applied with brushes. The masonry shall be thoroughly rinsed with water for final cleaning. All damaged and defective work shall be cut-out and replaced with new     materials and joints shall be repainted where necessary to leave them in a satisfactory and approved condition. The same type and color of mortar shall be used for pointing as for the original work.
All masonry shall be protected from damage until completion and acceptance of the Works. The replacing of damaged work shall be the   responsibility of the CONTRACTOR and such repair work shall be performed prior to acceptance by COMPANY and at the CONTRACTORS expense.

3.            Fix and Build into Masonry

The Contractor shall ascertain from the suppliers of prefabricated or manufactured goods any special fixing instructions and shall refer them to COMPANY for approval.
Care must be taken to protect faces and other working parts from mortar and other droppings.
Under no circumstances shall uncoated aluminum be built into masonry.
Where aluminum or ferrous members are built into masonry the contact surfaces shall be first painted with two coats of bituminous paint.
Where aluminum surfaces are in contact the jointing compound shall be loaded with zinc chromate.

4.            Doors, Windows and Louvers

All buildings shall be weather tight before installation of equipment. In some cases, removable sections may have to be designed into buildings to allow later installation of major equipment.
Openings left in walls for fixing doors or windows or louvers shall be of minimum practical size required or directed by COMPANY.
All internal doors shall be mounted on metal sub-frames. The sub-frames shall be sized to allow building finishes to be completed prior to unit installation.
The CONTRACTOR shall obtain the approval of COMPANY for the method of fixing the door or window or louvers.
All doors shall be flush type, 44 mm thick, constructed of 1.2 mm (18-gauge) thick prime quality cold rolled steel, exterior doors shall be 1.5 mm (16-gauge) for conforming to ASTM A526, galvanized.
Doors shall be factory-prepared with internal reinforcing & cutouts for the specified hardware.
Double doors shall have a one piece overlapping metal astragal on both the outside of the active leaf & the inside of the inactive leaf.
Doors shall be filled with mineral wool.
All metal door frames shall be accurately fabricated.
All metal frames shall be fabricated from 1.2 mm (18-gauge) thick steel exterior frames shall be 1.5 mm (16-gauge).

5.            Rendering

Cement rendering shall be applied in two or three coats as specified on the Approved Drawing.
Undercoats shall have an average thickness of 10 mm and finishing coats an average thickness of 6 mm.
Two-coat rendering shall be to a total thickness of 16 mm and three coats rendering to a total thickness of 25 mm.
The CONTRACTOR shall take all measures necessary to provide an adequate key for rendering on concrete. Wire brushing of timber formwork will be permitted and when metal formwork is used hacking of the concrete will be allowed. The use of a retardant on formwork will not be permitted in any circumstances.
The surface of brickwork or masonry to be rendered shall be thoroughly prepared before the first undercoat is applied by raking out the joints to form an efficient key for the rendering.
Surfaces shall be thoroughly brushed down to clean off all dust and loose material. Particular attention shall be paid to the removal of mould oil or other deleterious substances. Each undercoat shall be scored to form an adequate key for subsequent coats.
Each rendering coat shall be kept moist for at least 48 hours and then given adequate time to dry out thoroughly before the application of any subsequent coats. The surfaces shall be moistened immediately before the application of any further coat.
The finishing coat shall have a steel float finish to true planes and regular curves and to an even and polished surface. Arises shall be rounded and lineable and a hollow fillet shall be run at internal angles.
Trowelled beds with a plain surface to receive flexible and thin coverings shall be brought to a smooth plane surface completely free of all marks grooves and the like.
The finished rendering shall be protected and cured as specified for concrete.

6.            Plastering

Premixed plaster shall be protected as for cement. Sand shall be stored under clean conditions and no contamination by soil or other harmful substances shall be allowed.
All plastering shall be carried out in two coats except on expanded metal lathing, which shall be carried out in three coats.
All materials shall be obtained from approved manufacturers and shall be used in accordance with their instructions.
Plastering to walls shall consist of a backing coat of cement lime sand 1. 1:6 to a thickness of 10 mm and a finishing coat of anhydrous gypsum plaster 3 mm thick.
Alternatively, a 2 mm thick coat of retarded hemihydrates premixed gypsum plaster may be used with a backing coat of browning plaster, 11 mm thick.
Plastering to concrete soffits, beams and the like shall be by proprietary skim coat.
Galvanized expanded metal angle and casing beads shall be fixed with plaster dabs at not more than 600 mm centre’s to suit the finished thickness of the plaster and where possible in one length. Where jointing is found to be necessary a dowel of heavy galvanized wire shall be         inserted in the hollow head of each piece to ensure perfect alignment.
Plastering on expanded metal lathing shall be in three coats and the pricking up and floating coats shall be in metal lathing plaster to a total thickness of 8 mm from the face of the lath and a finishing coat 2 mm thick of finishing piaster.
Dubbing out shall be carried out in a similar mix to the subsequent coat and shall be a maximum of 10 mm thick in any one application.
Metal lathing shall be galvanized steel lathing having a weight of 1.63 kg/sqm.
All surfaces shall be cleaned down and the surfaces of brickwork concrete or similar materials shall be well wetted before plastering is commenced.
The CONTRACTOR shall take all measures necessary to provide an adequate key for plastering on concrete, which shall include scrubbing the whole area. Wire brushing of timber formwork will be permitted and when metal formwork is used hacking of the concrete will be allowed. The use of a retardants on formwork will not be permitted in any circumstances.
Where dissimilar wall backgrounds meet to form an internal angle the plaster shall be severed at the intersection by a trowel cut and made good with an approved cellulose filler immediately prior to decoration. The junction between wall and ceiling plaster shall be treated in the same manner.

7.            Floor and Wall Tiling

Floors specified as concrete painted shall be screeded to finished floor level with steel float finish.
Ceramic tiles shall be bedded to the cement/sand Semi Dry Mix Method, using one part cement to four parts of sand spread evenly over the floor firmly compacted and covered by a sand cement slurry 3 mm thick. The tiles shall then be placed and firmly beaten into the bedding to finished floor level.
PVC tiles of a pattern and color to COMPANY's approval are to be supplied and fixed with approved adhesive to screed with steel float finish to provide the required finished floor levels.
Tiled areas shall be returned into window reveals to the height of the wall tiling. Window cills shall also be tiled unless otherwise indicated. The CONTRACTOR shall allow for all cuttings round edge tiles, internal and external, angles, coves and other specials necessary to complete the work.

8.            Roof Waterproofing and Insulation

Waterproofing to flat roofs shall consist of bitumen-based felts, asphalt or similar material. The design for flat roof waterproofing and insulation shall demonstrate that requirements are clearly set out regarding water tightness, drainage, thermal insulation, fire precautions, and access for maintenance and repair.
Waterproofing shall be of the 'inverted' type whereby loose-laid rigid insulation boards are placed over the waterproof membrane. Boards shall be protected by geotextile and ballasted with gravel and/or paving flags. This will ensure that membranes are protected both from deterioration arising from exposure to ultraviolet light, and from roof traffic.
All roofs shall be insulated with minimum 50mm thickness of extruded flame-retardant polystyrene boards or similar to the approval of COMPANY. White expanded polystyrene bead board is not acceptable. meets ASTM C-578, D-1621, C272, D696, C-203; also, meets to Underwriters Laboratories (UL) Fire Hazard Classification No. 723.
Waterproofing shall be fully protected at up-stands from direct sunlight by means of aluminum fashings.
Rainfall in Indonesia is often infrequent but violent. Designs shall allow for 75mm per hour precipitation. Parapet walls shall always have sufficient openings to ensure that roofs do not flood as a result of blockage to piped outlets.
Design proposals shall always include details of roof entries for piped services, demonstrating that adequate waterproofing is allowed for. Any openings required in roof slabs for access, skylights etc. shall have upstands a minimum of 150mm above the top of all roof finishes.
Membrane roofing shall be used EDPM (Ethylene Propylene Diene Monomer) Rubber (Neoprene), minimum 1.15 mm (0.045 inches) thick. Single membrane roofing system, which meets the minimum physical properties of ASTM D 5637 (Standard Specification for Vulcanized Rubber Sheet Used in Single-Ply Roof Membrane).
Vapor Barrier shall be provided under-slab moisture vapor barrier of 0.15 mm thick polyethylene film.

9.            Joinery and Carpentry

Joinery and carpentry work shall be carried out by qualified master tradesmen to a good finished quality.

10.          Plumbing and Sanitary Work

Samples of all plumbing and sanitary fittings shall be submitted to COMPANY for his approval before installation is commenced.
The whole of the plumbing installation shall be executed in accordance with the national or local water regulations.
Pipework shall be wrapped in protective wrapping tape and paste where it passes through walls or floors. Fixing shall be by means of standard brackets and clips of approved design and materials, and spaced at not more than 1200 mm centres.
The completed cold and hot water services shall be flushed out after completion and tested for water tightness. A test pressure of 20 m head of water shall be applied and maintained for one hour without any sign of leakage or pressure drop. Except where otherwise stated by COMPANY all plumbing pipework shall be surface mounted.
A sump arrangement with submersible sewage handling pumps shall be provided for all buildings with kitchen or toilet facilities in basements. The sumps shall have completely sealed covers to prevent escape of odours, but consideration shall be given to space and access for cleaning and removal of equipment for maintenance.

11.          Glazing

All glazing to air-conditioned spaces shall be double glazed by hermetically sealed units. Glazing shall be carried out with the recommendations of the glazing manufacturers.
Samples of all glass shall be submitted to COMPANY for his approval before glazing is commenced.
All glass shall be kept dry during transit and storage and shall be cut with clean straight edges.
Glazing to metal shall include for plastic spacers at bottom and sides of panes where necessary.
Glazing with beads shall include for taking off and re-fixing beads where necessary. Glazing with beads and putty mastic or other glazing compound shall include for bedding the beads in compound.

11/26/14

INSTRUMENT CONTROL VALVES

1.1          Control Valves

Control valves shall be installed with the actuator in the vertical position on a horizontal line. Control valves shall be installed so that they are readily accessible from grade or platforms.  Wherever possible, they should be located at grade for ease of maintenance. Clearance shall be provided above and below a control valve so that the bottom flange and plug or the actuator and plug may be removed with the valve body in the pipeline.  Sufficient clearance shall also be provided for valve removal.

1.2          Shutdown/ Blowdown Valves

All actuated ball valves shall be of the 90ยบ rotation type and be complete with all necessary controls mounted on the valve. Actuator types shall be Pneumatic Spring Return. The valve stem orientation shall be as stated on the data sheet. Correct operation of the valve shall not be affected by the position of the valve or actuator.

1.3          Pressure Relief Valves

All pressure relieving devices shall be sized in strict accordance with applicable local, state, and national code requirements. Safety relief valves shall be sized by calculating ASME areas required for the most severe relieving case and shall follow the ASME requirements. Nomenclature and formulas used shall be according to API RP 520. Valve selection and installation shall be based on API RP 520, Part I and Part II.  Closed relief valve discharge systems shall be designed in accordance with API RP 521.

11/25/14

CENTRIFUGAL COMPRESSORS FOR HYDROCARBON SERVICE

As a rule of The Centrifugal Compressor package for hydrocarbon service shall be designed to API 617.
In case of conflict among this specification, data sheets, referred codes & standards and statutory requirements & regulations, the Contractor shall bring the conflict into the notice of Company in writing for resolution before proceeding with the work.
The compressor shall comply with compressor data sheet and this specification. All components shall be suitable for the operating conditions stated on the compressor data sheet.
Material shall be new, free from defects.
All equipment supplied shall be finished machined.  On site only pure assembly work is acceptable.  Piping not completely prefabricated is to be marked on the Piping arrangement drawing(s).  All spare components are to be machined at manufacturer’s shop with suitable tolerances in order to allow replacement without any re-machining.
The compressor and its auxiliaries shall be suitable for outdoor installation (without roof) unless otherwise stated in the data sheet. All equipment supplied must be suitable for start-up and for operation at minimum ambient site temperature as indicated in the specification’s data sheets.

Driver shall be Gas turbine, the specification please see Gas Turbine below.
At normal speed and normal suction condition, the volume capacity at the surge point shall not exceed 70% of the normal operating point. The rise in pressure ratio from the normal operating point to the surge point at normal speed shall not be less than 5%. The head developed at 115% of the normal operating flow at normal speed shall be not less than 85% of the head developed at normal operating point.
Noise emission data shall be provided as well as data of other emissions exhausted to the atmosphere (gas leakages, oil vapour, etc) with the proposal. Please see bellow for specification of noise.
Facility for optical alignment shall be provide and the manufacturer’s supervisor shall be present during initial alignment check at site.
Process gas compressors will be run-in on air in the field. Run-in on air means mechanical test run in the field where compressor is priming and discharging to atmosphere. Compressor manufacturer to propose procedure for run-in on air (flows, discharge pressures and temperature, speed, horsepower requirement, necessity of bleed connections, safety screens, etc) and to provide performance curves and temperature limitations, etc, for this operation. If specified in the specification’s data sheet, process gas compressors will be operated for several weeks on air for pre-start-up equipment drying.
All casing drains shall have isolation valves.  All casing drains down stream of isolation valve shall be connected to common drain header terminated with a flange connection at the edge of skid/base plate.
Compressor shall be designed to withstand the external loading defined bellow:
•    Vertical component. Combined forces and moments due to all piping connections or to any one piping connection resulting in a vertical reaction (either upward or downward) at any support point of at least one-half the dead weight reaction of the compressor at the support point.
•    Horizontal transverse component. Combined forces and moments due to all piping connections or to any one piping connection resulting in a horizontal transverse reaction at any support point of at least one-third the total dead weight reaction of the compressor at the support point.
•    Axial component. Combined axial forces of all piping connections or to any one piping connection resulting in an axial force on the compressor casing of at least one-sixth the compressor weight.
Shaft shall be made of one-piece, heat treated steel that is suitably machined. Shafts shall be made of forged steel.
Impellers shall be assembled on the shaft with fit and a key. Other methods shall not be acceptable without Company approval. Impellers shall be designed to limit the maximum stress at maximum continuous speed to a value not exceeding 70% of the material yield strength. Proven impellers shall be provide.
Balance line sizing shall consider also noise generation due to high gas velocities in the balance line. During mechanical run test in manufacturer’s shop balance line (s) must be installed.
If the compressor is driven by turbine particular attention concerning bearing design must be given to turbine turning gear speed, which may be very low.  Compressor manufacturer to coordinate with turbine manufacturer.
Nonpressurised bearing housings shall be provided with a 25 mm vent connection equipped with the standard breather cap or closed with a steel plug, if no venting is necessary.
Torsional Analysis, A composite torsional vibration analysis shall be performed for all compressor units.  For compressor units driven by electric motor or turbine through a gear box, both the compressor and driver manufacturer shall perform an independent torsional analysis. The input and results of this analysis shall be prepared for submission to Company.
Vibration and Balancing, the final balancing of the rotating element shall be carried out with the coupling half installed. Along with the compressor a fully integrated vibration monitoring system complete with the cabinet (series and protection as defined by Purchaser suitable for service) shall be provided. Vibration probes and system shall be in accordance with API 670.
Drivers shall be sized and rated to develop at least 110% of the horsepower or as specified in data sheet (whichever is higher) at the maximum compressor operating conditions, including either gear or hydraulic coupling losses, or both. Steam turbine drivers for compressors shall be in accordance with API 611 or API 612 as called for in the individual turbine specifications.  Auxiliary drive turbine shall be capable of continuously developing 110 % of the horsepower required at the relief valve pressure of the driven equipment, at the corresponding speed under minimum steam inlet and maximum back pressure.
The coupling (whether hydraulically or mechanically fitted) shall be designed for easy removal. Devices shall be provided by the manufacturer for the mounting and removal of this coupling.

11/23/14

CONNECTIONS PIPE TO EQUIPMENT

Piping shall be erected and supported in a manner that will not put undue strain on equipment such as compressors, engines, pumps, vessels and heat exchangers. Cold pull shall be to Company’s approval.

The following procedure shall be observed:
·            Initially, piping shall be attached to the equipment using finger tightened bolts
·            Flat face flanges and full face gaskets shall be used on piping connecting to equipment with flat face flanges only.
·            Flanges shall be checked to ensure that no strain is placed on the equipment. If the pipe is not in correct alignment it shall be removed and corrected. The correction in alignment shall not be made while the pipe is connected to the equipment.  Heating of piping to correct misalignment shall not be permitted.

·            Finally tighten bolts to correct torque.

·            All brazed aluminum heat exchanger misalignment tolerances, bolt torque values and flange tightening procedures shall be strictly observed. Hammer wrenches shall not be used. Company shall witness all brazed aluminum heat exchanger flange bolt-ups.

Cold pulls shall be approved by Company.

The following procedure shall be applied for the alignment of flanges to rotating equipment:
·            Align pipe work to equipment flanges to within the more stringent of either the manufacturer’s tolerances or ASME B31.3. Adjust pipe support where necessary.

·            Flange faces shall be parallel within 1/16” measured across any diameter.

·            Bolt up piping to equipment flanges and torque the bolts to the specified tension.

·            Check the coupling alignment during the bolting and tensioning of the pipe flanges to the equipment flanges. The bolting up and tensioning of the flanges shall not affect the coupling alignment between the driver and driven equipment.

·            Check setting of pipe support.

·             Finally tighten bolts to correct torque.
Flange Connections

Flange connections shall be made up as follows:

·            Clean protective grease from flange gasket faces and position for bolt up.  Flange faces shall be parallel and aligned axially in the horizontal and vertical plane to the tolerances. Position gasket and install bolts and nuts to hand tight.

·            All bolts for flanged connections require extreme attention in assembly to ensure uniform loading on the gasket surfaces.  Non uniform bolt loading, dirt at the mating surfaces or scratched flange surfaces shall be subject to release and flange joint re-assembly or flange face redressing.

·            Regardless of the scheme selected for flange joint assembly, i.e. gauge between flanges, torque wrench or bolt elongation, it is important to tighten uniformly and not prematurely set the gasket.  Hand tighten all nuts first, and then gradually tighten opposite nuts on the flange.  Do not bring a single nut to full tightness before the others have been carefully stepped up toward this final position.

·            Flange bolt and stud threads shall protrude a minimum of ¼ inch or two full thread pitches, whichever is the greater, past the nut. Extremely long bolt projection will not be accepted unless required for hydraulic tensioning.  Uniformity of bolt projection through the nuts of stud bolts shall be observed.

·            New gaskets shall be used whenever a set of flanges is broken apart and then re-connected.
FRP Flange Connections

All flanged joints shall be uniformly tightened and shall be torque no more than the pipe manufacturer’s recommended limit.

FRP flanged joints shall be fully tightened, with the pipe support to FRP pipe clamps loose.

The FRP pipe clamps shall be tightened only once final flange bolting shall have been completed.

Washers shall be used at all bolted connections where all FRP flat faced flanges mate together or with wafer type valves. Flat faced flanges shall not be used with raised faced flanges.

The specification break between carbon steel and FRP piping shall utilize flat faced carbon steel flanges.


MATERIAL AND EARTH WORK SPECIFICATION

Borrow Material Borrow material shall meet the requirement specified for satisfactory fill materials per ASTM D2487 or ASTM D...