Materials System Specification

32-SAMSS-016 30 September, 2003 Inlet Air Filtration Systems for Centrifugal Air Compressors Compressors, Gears & Steam Turbines Standards Committee Members
Al-Alshaikh, T.H., Chairman Al-Khateeb, E.M., Vice Chairman Al-Abbad, H.A. Al-Hussain, K.M. Al-Issa, M.A. Al-Jamea, K.H. Al-Janabi, S.H. Al-Khowaiter, A.O. Al-Mugahwi, S.S. Al-Odan, N.M. Asiri, S.M. Brown, E.W. Bukhamsin, S.A. Khogair, H.A. Nguyen, L.V. Sabri, H.A.

Saudi Aramco DeskTop Standards

Table of Contents

1 2 3 4 5 6 7 8 9 10 11

General.......................................................... 2 Basic Design.................................................. 4 Construction................................................... 5 Design Requirements.................................... 6 Electrical and Instrumentation....................... 8 Protective Coatings........................................ 9 Design Drawings............................................ 9 Inspection..................................................... 10 Test Requirements....................................... 10 Guarantee.................................................... 14 Export Packing, Marking and Shipping........ 14

Previous Issue: 30 June, 2003 Next Planned Update: 1 October, 2008 Revised paragraphs are indicated in the right margin Primary contact: Tariq H. Alshaikh on 873-2671

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CopyrightSaudi Aramco 2009. All rights reserved.

Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

General 1.1 Scope 1.1.1 This Specification together with the Purchase Order covers the minimum mandatory requirements for the design, performance and testing of inlet air filtration systems for centrifugal air compressors. The Specification is intended for use in both inland and marine environments subject to high ambient dust and salt concentrations. 1.1.2 1.1.3 1.1.4 The system specified herein is intended for continuous duty, high efficiency air filtration at a constant system pressure drop. Air filtration systems covered by this Specification are limited to the single stage automatic pulse-jet self cleaning type. Air filtration systems shall be supplied by Vendors qualified by experience in manufacturing the units proposed. To qualify, the Vendor must have manufactured at the proposed manufacturing location, at least two systems of similar design, type and performance. These systems must have been in service for at least one year and must be performing satisfactorily. Air filtration systems shall also meet the test requirements outlined in paragraph 9 of this Specification. Test results shall be subject to review and approval by the Coordinator, Rotating Equipment Division, Consulting Services Department. Compliance with the provisions of this Specification does not relieve the Vendor from the responsibilities for furnishing equipment properly designed to meet the specified operating service conditions.

1.1.5

1.2

Alternative Designs All deviations from this Specification shall be separately listed by the Vendor in his quotation and shall refer to the relevant paragraph numbers.

1.3

Conflicting Requirements Any conflicts between this Specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs) or industry standards, codes and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department, Saudi Aramco, Dhahran. Direct all requests to deviate from this Specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302

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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

and forward such requests to the Manager, Consulting Services Department, Saudi Aramco, Dhahran. 1.4 Referenced Publications Material or equipment supplied to this Specification shall comply with the latest edition of the references listed below, unless otherwise noted. 1.4.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Materials System Specification 34-SAMSS-831 Package Unit Instrumentation

Saudi Aramco Engineering Standards SAES-A-112 SAES-H-101 Meteorological and Seismic Design Data Approved Protective Coating Systems

Saudi Aramco Standard Drawing AE-036005 Air Filter Test Dust Particle Size Distribution

Saudi Aramco Inspection Requirements Form 175-325500 1.4.2 Air Filtration System: Inlet, for Gas Turbines or Centrifugal Compressors

Industry Codes and Standards American Society for Testing and Materials ASTM A36 ASTM A36M ASTM A283 ASTM A283M Standard Specification for Carbon Structural Steel Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates

American Society of Mechanical Engineers ASME B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)
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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

ASME B1.13M SAE International SAE J 726

Metric Screw Threads - M Profile

Air Cleaner Test Code, Recommended Practice

Basic Design 2.1 The inlet air filtration system shall be suitable for operation with the air compressor as specified in the Purchase Order description, and environmental conditions specified below: Unless otherwise specified, equipment will be installed outdoors in a desert area, with relative humidity from zero to 100% (condensing). Site specific meteorological and seismic data as specified in SAES-A-112 shall be used for equipment design.
Commentary Note: Metal temperatures can reach 70C when exposed to direct solar radiation.

The following ground sample analysis can be considered typical for an inland site:
Constituent Silica Calcium Magnesium Alumina Potassium Sodium Quantity % of Sample 50 32 9 5 3 1

The hot desert regions of the Arabian Peninsula are subject to extreme fluctuations in wind force both daily and seasonally. The particle size distribution of airborne particulate varies greatly with wind velocity. Analysis of airborne particulate gives the following distribution:
Size range (micrometer) 0 - 1.5 1.5 - 6.0 6.0 - 12.0 12.0 - 20.0 20 plus Percent 50 25 15 5 5

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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

During severe dust storm conditions the airborne dust concentrations may be up to 0.57 g/m and the sodium quantity may increase by a factor of ten. 2.2 2.3 The aerodynamic design shall be such that air intake velocities shall be uniform across the entire filter area. Inland environment installations shall be considered as located further than 25 km inland from the nearest point on the shoreline. Marine environment installations are defined as any location on land within 25 km of the shoreline and all locations over open water. The intent of the inlet air filtration system is to limit the ingestion of airborne contaminants such as sand, dust and alkali metal salts so as to prevent compressor corrosion, erosion and fouling. In addition, the intent is to maintain a low inlet system resistance in order to minimize compressor performance penalties.

2.4

Construction 3.1 The filter house shall be of a bolted and welded design fabricated from hot rolled sheet steel. The clean air plenum sheet steel shall be at least 4.5 mm ( 316 inch) thick (ASTM A36/ASTM A36M or ASTM A283/ASTM A283M or equivalent) and shall be reinforced with steel members. The unit shall be designed to withstand a minimum pressure differential of 3 kPa (12 inches water gauge). All seams and joints shall be airtight. The dirty air plenum sheet steel shall be at least 3 mm ( 18 inch) thick. No more than 8 filter elements shall be attached to the clean air plenum without a plenum wall reinforcement to reduce the movement of filter cartridges during pulsing. The structure shall be rigid enough to be lifted/located at any specified elevation. Where assembly requires bolting, all holes shall be pre-drilled. All bolting shall comply with ASME B1.1/ASME B1.13M or equivalent standards. For marine environment locations, heat treated high strength bolts shall be used for structural joints. The minimum tensile strength of the bolts shall exceed 1,034 MPa (150,000 psi). Cadmium plated lockwashers shall be provided on all bolting. All nuts and bolts used inside the clean air plenum during assembly shall be welded after assembly to prevent air leaks and loose hardware from entering the compressor. The filter house assembly shall be manufactured in pre-fabricated subassemblies of suitable size to facilitate transportation and the minimum possible site erection. Sub-assemblies shall be provided with lifting points. When specified in the Purchase Order, the filter house shall be capable of being lifted as a complete assembly and placed on a prepared foundation. When so
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3.2

3.3

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

specified, the complete assembly shall be provided with suitable lifting points for this purpose. 3.4 Filter elements shall be designed for easy installation and quick changeout, avoiding blind assembly, loose retaining nuts, ungasketed washers and other undesirable assembly features. Where blind assembly cannot be avoided, leadin devices shall be provided on the element or filter house to facilitate assembly. The design shall be such that inlet air is drawn from a point not less than 1.5 m (5 ft) above grade level to avoid excessive ingestion of heavy ground level dust and sand during windy conditions. The exact elevation shall be as specified in the Purchase Order. The inlet to the filtration system shall be aligned 180 opposite to the direction of the prevailing wind for the site. Where not already provided by the compressor manufacturer, a stainless steel trash screen with 13 mm ( inch) square mesh of minimum 5 mm diameter (6 gauge) wire or rod shall be provided in the transition section between the clean air plenum and compressor intake duct. Automatic or gravity weighted by-pass doors are not permitted. Components having inspection or service intervals of less than 10,000 hours shall not be installed inside the clean air plenum. Platforms or other suitable access shall be provided to service these components.

3.5

3.6

5.7 5.8

Design Requirements 4.1 4.2 The filter system design shall be based on 105% of the compressor system rated airflow. The filter system shall provide a minimum NaCl capture efficiency of 99.95% at the rated air flow and stabilized operating pressure drop when tested in accordance with the procedures outlined in paragraph 9 of this Specification. The stabilized pressure drop shall not exceed 0.625 kPa (2.5 inches water gauge) across the complete system. The air to media velocity shall not exceed 1.5 cm/s (3.0 feet per minute) through the pulse-clean filter element in the case of vertical hanging cylindrical cartridges. The updraft velocity into the filter bank shall not exceed 1.52 m/s (300 feet per minute) and the vertical velocity between filter elements shall not exceed 2.54 m/s (500 feet per minute). The horizontally hanging filter system generates a downward flow of air over the filter elements during operation, so that when an element is pulsed, the dust is released into the airflow which carries it away from the elements and
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4.3

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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

downward into the dust collection hopper. Hence, it has a negative updraft velocity as defined in this paragraph (downdraft). The vertical velocity between the elements is downward. This type of filter operates at 1.7 cm/s (3.3 feet per minute). 4.4 The initial pressure drop across the filter system shall not exceed 0.4 kPa (1.5 inches water gauge) and the pulse-clean cycle shall be initiated at not more than 0.625 kPa (2.5 inches water gauge) pressure differential across the self-cleaning filter element. The system shall be capable of operating continuously at a constant pressure drop during simulated dust storm conditions with an inlet dust concentration of 0.57 g/m, when tested in accordance with the requirements of Section 9 of this Specification. The system shall be capable of self cleaning back to the stabilized operating pressure drop from a pressure drop of not less than 2.5 kPa (10 inches water gauge) across the pulse clean stage. Individual filter elements shall be capable of withstanding 3.7 kPa (15 inches water gauge) pressure differential without degradation of filter performance and shall be able to withstand 6.2 kPa (25.0 inches water gauge) pressure differential without rupture of the media. Testing shall be in accordance with Section 9 of this Specification. Sealing gaskets shall be attached to the filter elements such that new gaskets are provided at each filter change. A metal stop or similar device shall be incorporated to ensure correct gasket compression. Filter media shall be glued to the face guard or the wrapping cord at sufficient locations to maintain adequate pleat spacing. The month and year of manufacture shall be permanently marked on each new or replacement element's exposed end cap. The markings shall be sufficiently large to be readable from a distance of 3 m (10 ft). The filter element and the end caps shall be sufficiently strong to allow a 30 cm (1 foot) drop to the metal walk floor without disabling damage to the filter element. The pulse mechanism shall be activated by a high set point pressure switch and may be deactivated by a low set point pressure switch or by allowing the mechanism to complete a minimum of six full cleaning cycles. Each separately controlled filter unit or module shall have a pressure switch and an active back-up pressure switch with separate pressure sensing lines, either of which acting alone shall be capable of activating the pulse-clean mechanism. Failure of either pressure switch shall automatically activate the pulse clean mechanism.
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4.5

4.6

4.7

4.8

4.9

4.10

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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

4.11 4.12

A manual switch shall be supplied to initiate pulse-cleaning independently of the pressure switch settings. High set points, low set points, pulse frequency, pulse duration and, where applicable, number of full cleaning cycles shall be field adjustable. All adjustable parameters shall be factory set by the Vendor. The Vendor shall supply details of the field adjustment available on these parameters. The overall design shall be such as to minimize flow and pressure perturbations due to pulse cleaning. In no case shall more than 20% of the filter elements in any given module be pulse cleaned simultaneously. Solenoid valves and air diaphragm valves shall be from an approved vendor. The system shall be designed to operate with a pulse air pressure of 550 kPa gauge (80 psig). Plant quality air shall be used for pulsing. A relative humidity switch shall be provided.

4.13

4.14 4.15 4.16 4.17 5

Electrical and Instrumentation 5.1 5.2 Instrumentation shall be in accordance with 34-SAMSS-831. Electrical accessories and pressure switches shall be housed in weatherproof boxes per NEMA 4, with the exception of those in marine/corrosive environments which shall be in watertight boxes, per NEMA 4X. For hazardous areas, where specified in the Purchase Order, boxes shall also be explosion proof (NEMA 7). Wiring shall be in rigid conduit, conduit fittings and terminal boxes. Solid state electronic timer/sequencer devices shall be housed in weatherproof boxes (NEMA 4) at a convenient location to avoid radiant and convected heat. Where specified in the Purchase Order, boxes shall also be explosion proof. Control pressure switches/indicators shall be from an approved vendor. A high differential pressure warning system shall be provided across the pulseclean stage. The pressure warning system shall be controlled by a two position pressure indicating switch. The pressure indicating switch shall be located where it can be conveniently reached from grade level. The high differential pressure indicating switch shall be wired to give annunciation in the central control room. The lower set point shall provide an alarm annunciation and the high set point shall be wired to shut down the compressor. The alarm and shut down set points shall not exceed the following:
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5.3

5.4 5.5

5.6

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Document Responsibility: Compressors, Gears & Steam Turbines Issue Date: 30 September, 2003 Next Planned Update: 1 October, 2008

32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

Alarm Shut down

1.00 kPa (4.0" W.G.) 1.75 kPa (7.0" W.G.)

These figures should be agreed with the compressor Vendor. 6 Protective Coatings The filtration unit shall be painted in accordance with the following: 6.1 Inland Environment Installations APCS-6 Alkyd Enamel Coating System, in accordance with SAES-H-101. 6.2 Marine Environment Installations APCS-2A Epoxy Coating System for General Immersion, in accordance with SAES-H-101.
Commentary Notes for 6.1 and 6.2: 1) 2) 3) 4) The selected coating shall not contain vanadium, lead, mercury or any other heavy metals. Non-ferrous metal and stainless steel surfaces generally do not require painting. Welds, corners and edges shall be brush painted prior to application of the first spray coat to ensure adequate coverage in these areas. Color shall be as specified in the Purchase Order.

Design Drawings The Vendor shall submit to the Company or Buyer Representative for review, as required in the Purchase Order and prior to fabrication, detailed drawings for the structure he proposes to furnish in accordance with this Specification.

Inspection The filter system components are subject to inspection in accordance with the referenced Form 175-325500.

Test Requirements Results of the following tests, certified by a Principal Officer of the Vendor Company, must be submitted with the bid proposal for evaluation purposes. Results of these tests

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

shall serve to qualify the proposed filtration system as meeting the requirements and intent of this Specification. 9.1 Scope This test procedure defines the test equipment, materials, conditions and procedure required to determine the initial pressure drop, collection efficiency, cleanability and integrity of a pulse-jet self-cleaning air filtration system. 9.2 Test Equipment 9.2.1 The test equipment shall consist of a complete air filtration system including pulse-clean mechanism (as proposed by the Vendor to meet this Specification), airflow system, air sampling system and dust feeding system. The test filter system shall consist of a full size module, identical in component size, materials and fabrication to the proposed design. The air valve flow coefficient [C(v)] divided by the sum of the areas of the orifices in the blow pipe shall not be greater than in the proposed design. Pulse air pressure shall be maintained at a pressure of 550 kPa gauge (80 psig). The airflow system shall consist of an exhauster with suitable controls and airflow measuring equipment to insure constant airflow throughout the tests. Airflow sampling shall be conducted using isokinetic probes and Gelman Closed Face Holders fitted with 0.45 micrometer type membrane filters or equal. Isokinetic probes shall be minimum length and the quantity of air sampled shall be measured by approved methods and corrected to standard conditions. The dust feeding system shall consist of a dust feeder and one or more compressed air operated dust injectors. The dust feeder shall feed the dust at a uniform continuous rate and the dust injectors shall disperse the dust uniformly across the air inlet face of the test filtration system. The dust injectors shall be configured per Figure 3F of SAE J 726.

9.2.2

9.2.3

9.2.4

9.2.5

9.3

Test Materials 9.3.1 The test dust shall be silica and shall have a particle size distribution within the limits shown on Standard Drawing AE-036005.

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

9.3.2

For efficiency tests, dry sodium chloride (NaCl) particulate of 0 to 5 micrometer size (2 micrometer mean diameter) shall be added to the test dust to make a 90% dust and 10% NaCl mixture.

9.4

Test Conditions 9.4.1 The test airflow shall be maintained constant throughout the efficiency and dust capacity tests and shall not be less than 105% of the compressor system rated airflow. The pulse-jet cleaning mechanism shall be activated and operated continuously, except where otherwise specified, throughout the efficiency and dust capacity tests. Individual filter elements shall be pulse cleaned at the same frequency, pulse duration and pulse air pressure as in the proposed design. The test dust feed rate during the dust capacity test and the dust/NaCl mixture during the efficiency test shall be maintained constant at an inlet concentration of 0.57 g/m. The minimum relative humidity during the dust capacity test shall be 40% and at least one of the efficiency tests shall be conducted with an air inlet relative humidity in excess of 90%. The NaCl capture efficiency shall be based on the theoretical upstream and measured downstream NaCl concentrations. The quantity of test dust and the quantity of air sampled shall be selected to give a measured downstream sodium quantity of at least 5 times the minimum sensitivity of the sodium measuring instrument.

9.4.2

9.4.3

9.4.4

9.4.5

9.5

Test Procedure 9.5.1 Initial Pressure Drop 9.5.1.1 9.5.1.2 9.5.2 The initial pressure drop shall be determined, using clean filters, at 80%, 90%, 100% and 110% of the proposed airflow. The system resistance shall be graphed as a function of media velocity.

Dust Capacity and Efficiency 9.5.2.1 A three phase dust capacity and efficiency test shall be conducted to determine the following:

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

Phase 1 - time taken to reach the stabilized pressure drop and achieve the minimum NaCl capture efficiency of 99.95%. Phase 2 - a real time test of 50 hours minimum duration to demonstrate a constant system resistance under simulated dust storm conditions. Phase 3 - a real time test to demonstrate the system ability to clean back from an abnormally high pressure drop (as might occur due to a temporary loss of pulse cleaning). 9.5.2.2 The phase 1 test shall be conducted at the test flow rate, with test dust as defined in paragraph 12.3.1 of this Specification at an inlet concentration of 0.57 g/m until the stabilized pressure drop is attained. The time to reach this pressure drop shall be recorded. The efficiency test shall be conducted at sufficient points during the period to determine the time and pressure drop at which the minimum NaCl capture efficiency of 99.95% is attained. The phase 2 test shall continue on from the phase 1 test utilizing the same equipment and filter elements. Test dust, as defined in paragraph 12.3.1 shall be fed continuously at an inlet concentration of 0.57 g/m for a minimum period of 50 hours. System pressure drop, relative humidity, and dust feed shall be recorded hourly. NaCl capture efficiency shall be determined at the end of each 10 hour period. During this phase, the measured NaCl capture efficiency shall be not less that 99.95% and the system resistance shall not show a rising pressure characteristic. The phase 3 test shall be conducted at the end of the 50 hour period. The pulse clean mechanism shall be deactivated and test dust shall be fed continuously at 0.57 g/m until the pressure drop across the self cleaning stage reaches 2.5 kPa (10 inches water gauge). At this point, NaCl capture efficiency, system pressure drop, relative humidity and dust feed shall be recorded. The dust feed shall be terminated and the pulse clean mechanism reactivated. The system shall be allowed to self clean back to the previously determined stabilized operating pressure drop, at which point the NaCl capture efficiency shall be measured. The time taken to reach 2.5 kPa (10 inches water gauge) pressure differential, the number of pulse clean cycles and the
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9.5.2.3

9.5.2.4

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

time taken to clean back to the stabilized system operating pressure shall be recorded. 9.5.2.5 The results of phase 1, 2 and 3 tests shall be plotted on a composite graph showing system resistance in inches water gauge, NaCl capture efficiency and relative humidity as a function of time.

9.5.3

Integrity of Filter Elements 9.5.3.1 The Vendor shall demonstrate, by independent laboratory testing, that filter elements meet the requirements of paragraph 4.7 of this Specification. The Vendor shall furnish certified evidence that filter elements are able to withstand rough handling. This may be demonstrated by a minimum of 15 (fifteen) hours continuous shaker testing to U.S. Army Corps Manual 136-300-178 without sustaining structural damage or loss of dust collection efficiency. Shaker testing shall be performed on the filter element alone without transport packaging.

9.5.3.2

9.6

Test Report The test report shall include, but shall not be limited to, the following material: 1. Sketches showing the overall test set-up and details of each of the systems outlined in paragraph 9.2, including make and model of all measuring instruments and equipment. A graph of initial system resistance as a function of media velocity. Composite graphs of system resistance, NaCl capture efficiency and relative humidity as a function of time. Certified results of laboratory tests and rough handling tests on individual elements. Supportive test or operating experience, if available, demonstrating a minimum of 2 years operating life of filter media.

2. 3. 4. 5.

10

Guarantee 10.1 The Vendor shall supply certified copies of all test results demonstrating that the proposed filtration system meets the detailed requirements of this Specification.

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32-SAMSS-016 Inlet Air Filtration Systems for Centrifugal Air Compressors

10.2

The Vendor shall guarantee a minimum pulse-clean element life of two years operating in the environment as specified. The total filter life, including storage and operation time, shall not be less than three years from date of manufacture. The Vendor shall not, without receiving the Buyer's written permission, alter the design, method of manufacture or change materials in any way from the original design as submitted and qualified by the testing specified, during the course of manufacture of a specific order. Changes to filter paper media and major changes in the method of construction or controls shall be re-qualified on the basis of all specified tests.

10.3

11

Export Packing, Marking and Shipping The inlet filter assembly shall be marked for identification and packed for export shipment in accordance with the requirements of the Purchase Order.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with minor revision.

30 September, 2003

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