Pump Centre - Water and Industry Mechanical Electrical Specification 8.07 - MB

WATER INDUSTRY MECHANICAL AND ELECTRICAL SPECIFICATION 8.07 COMPRESSED AIR SYSTEMS WIMES 8.07 ISSUE 1 OCTOBER 2012

Copyright � 2012,  2012, ESR Technology. All rights reserved. No part part of of this Specification, Specifi cation, except the DATA SHEETS may be reproduced in any form electronic or mechanical, including photocopying, recording or any other information storage and retrieval system without permission in writing from the Pump Centre.

The Pump Centre is a Centre of Excellence within ESR Technology, one of the UK’s leading engineering, safety and risk consultancies. ESR Technology provides independent technical expertise to help its customers ensure asset integrity, improve machine reliability, manage safety and risk and transfer best practice.

WATER INDUSTRY MECHANICAL AND ELECTRICAL SPECIFICATION 8.07

COMPRESSED AIR SYSTEMS

Prepared by:

M Craven R Marlow

Pump Centre Pump Centre

With technical support and co-operation from the WIMES Steering Group consisting of: G Cameron F Davis T White S Hudson R Dorr P Davison M Overy B Spence K Gaunt M Ison M Keen S Whatley M Rush J Wright M Ward

Affinity Water Anglian Water Bristol Water Cambridge Water Dwr Cymru NI Water Service Northumbrian Water Scottish Water Severn Trent Water South West Water Southern Water Thames Water United Utilities Wessex Water Yorkshire Water

Please Note This Specification will be reviewed periodically to take account of feedback from Water Companies/Suppliers. Companies/Suppliers. If changes to the Specification Specification are necessary, necessary, it will be re-issued.

WIMES 8.07

Page 1 CONTENTS

NOTES

3

1.0 SCOPE

4

2.0 GENERAL GENERAL 2.1 General 2.2 Compliance with Directives, Regulations, Standards and Quality Assurance 2.3 Definitions

4 4 4 5

3.0 OPERATING ENVIRONMENT AND SITE DETAILS

5

4.0 AIR COMPOSITION AND PHYSICAL PROPERTIES

5

5.0 PERFORMANCE PERFORMANCE SPECIFICATION 5.1 General 5.2 Volume Flow Rate (Capacity), Pressure and Power Input 5.3 Air Temperature and Purity 5.4 Noise and Vibration 5.5 Life Cycle Costs 5.5.1 Energy Consumption 5.5.2 Service Lives and Costs of Components 5.5.3 Maintenance Requirements/Costs

5 5 5 6 6 7 7  7  7 

6.0 DESIGN SPECIFICATION 6.1 General (All System Components) 6.1.1 General 6.1.2 Weights and Lifting Arrangements 6.1.3 Materials Selection 6.1.4 Corrosion Protection 6.1.5 Guarding 6.1.6 Maintainability 6.1.7 Marking and Identification 6.1.8 O & M Manuals 6.2 Compressor Package 6.2.1 Compressor(s) 6.2.2 Compressor Drive System(s) 6.2.3 Compressor Ancillaries 6.2.4 Acoustic Enclosure (If Provided) 6.3 Local Control Panel (LCP) (If Required/Provided) 6.4 Air Receiver 6.5 Air Treatment Equipment 6.5.1 General 6.5.2 Aftercooler (If Required/Provided) Required/Provided) 6.5.3 Dryer (If Required/Provided) Required/Provided) 6.5.4 Filters 6.6 Air Delivery Pipework

7 7 7  8  8  8  9  9  9  9  9 9  10  11 12  13 13 14 14  15  15  16  16

7.0 CONTROL PHILOSOPHY 7.1 General 7.1.1 General 7.1.2 Normal Operation 7.1.3 Shut-Down Modes 7.1.4 Emergency Stop 7.1.5 Miscellaneous

17 17 17  17  18  18  18 

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 2

8.0 TEST SPECIFICATION 8.1 Factory Acceptance Tests (FATs) 8.2 Site Acceptance Tests (SATs) (If Required)

18 18 18

APPENDIX A – REGULATIONS, REGULATIONS, STANDARDS & SPECIFICATIONS SPECIFICATIONS REFERENCED 20 APPENDIX B1 – TEXT GUIDANCE

22

APPENDIX B2 - DATA SHEET GUIDANCE GUIDANCE

29

APPENDIX C – DATA SHEET

30

APPENDIX D – SUPPLIER’S SUPPLEMENTARY DATA SHEET INFORMATION

35

APPENDIX E - INFORMATION TO BE SUPPLIED WITH TENDER

36

APPENDIX F – DETAILS OF NON-COMPLIANT INNOVATIONS

37

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 3 NOTES

1. Accommodation of Innovation This Specification has been written to reflect the current state of the art with regard to commercial products and will have a finite life (nominally four years). The purpose of this Specification is to ensure that products supplied meet relevant safety standards, offer reasonable standards of engineering in design, materials and construction and represent value for money in both initial purchase and subsequent running costs. It is recognised that Suppliers will continue to develop products as part of the commercial process and it is not the intention of this Specification to stifle such innovation. Suppliers of products incorporating innovative design features which enhance process performance and/or reduce whole life costs, but which do not comply with this Specification, should detail these items in Appendix F, for consideration/approval by the Purchaser as part of the Tender. Suppliers are further encouraged to bring the benefits of these innovations to the attention of the Pump Centre for consideration at the next Specification review.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 4

1.0 SCOPE This Specification defines the requirements for the performance, design, construction and testing of compressed air systems (hereafter termed the ‘system’) for use in the Water Industry in the form of text and a DATA SHEET. The system shall typically comprise the following items: a) A compressor package (typically comprising a number of compressors, their associated ancillary equipment and an acoustic enclosure) (refer to Section 6.2) ; b) A local control panel (LCP), if required (refer to Section 6.3) ; c) An air receiver (refer to Section 6.4) ; d) Air treatment equipment (i.e. an aftercooler, dryer, filters, etc.) (refer to Section 6.5);  and e) Air distribution pipework (refer to Section 6.6) . 2.0 GENERAL 2.1 General 1. The system application shall be as specified on the DATA SHEET (refer to Guidance Notes). 2.2 Compliance with Directives, Regulations, Standards and Quality Assurance 1. The design, construction and testing of the system shall comply with all relevant EC directives and UK statutory regulations and the latest editions (current at the time of tender) of all relevant international, harmonised European and British standards (refer to Appendix A for a list of the regulations, standards and specifications referenced in this Specification). 2. The system shall also comply with: a) This Specification including all DATA SHEETS; and b) Any documentation issued by, or on behalf of the Purchaser in respect of the system. 3. Where the documentation referenced in clause 2.2.2 imposes additional requirements to an international, harmonised European or British standard, the requirements of the documentation referenced in clause 2.2.2 shall prevail. 4. The Supplier shall operate an approved, auditable quality assurance procedure covering the design, construction and testing of the system.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 5

2.3 Definitions 1. The following definitions are used in this specification: a) The term ‘Purchaser’ shall mean the end user of the system or the end user’s nominated representative; b) The term ‘approved’ shall mean approved by the Purchaser or his nominated representative (approval shall be obtained in writing); c) Unless otherwise specified elsewhere (e.g. in a Particular Specification), the term ‘Supplier’ shall mean the party responsible for the design, construction, and testing of the system. 2. Unless indicated otherwise, all clause and section references refer to clauses/sections within this Specification. 3.0 OPERATING ENVIRONMENT AND SITE DETAILS 1. The operating environment of the system shall be as specified on the DATA SHEET (i.e. the site location, system location, ambient temperature and humidity ranges, EMC environment, etc.). 2. Any special hazards associated with the operating environment shall be as specified on the DATA SHEET. 3. Any references for any further information relating to the operating environment or site not transferable via the DATA SHEET (e.g. drawings of site/building layouts, pipework installations etc.) shall be as specified on the DATA SHEET. 4.0 AIR COMPOSITION AND PHYSICAL PROPERTIES 1. The composition and physical properties of the air to be pressurised by the system shall be as specified on the DATA SHEET. 5.0 PERFORMANCE SPECIFICATION 5.1 General 1. The system asset life and utilisation shall be as specified on the DATA SHEET. 5.2 Volume Flow Rate (Capacity), Pressure and Power Input 1. The maximum required volume flow rate (capacity) of the compressor package shall be as specified on the DATA SHEET. The rated volume flow rate (capacity) of the compressor package (at the full load operating pressure) shall be as stated on the DATA SHEET. This rated volume flow rate shall be measured at the outlet terminal point of the compressor package in accordance with BS ISO 1217, Annex C (refer to Guidance Notes).

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 6

2. The required maximum delivery pressure of the compressor package shall be as specified on the DATA SHEET. The rated full load operating pressure of the compressor package shall be as stated on the DATA SHEET. 3. The maximum full flow operating pressure shall be as stated on the DATA SHEET (refer to Guidance Notes). 4. The compressor package power input shall be as stated on the DATA SHEET, under the following conditions: a) At the rated volume flow rate (capacity) and full load operating pressure; b) At the full flow operating pressure; and c) At zero flow/load (unloaded power input) (refer to Guidance Notes). Tolerances on the above shall comply with BS ISO 1217 Annex C. Refer to Guidance Notes. 5. The specific compressor package power input (at the rated volume flow rate (capacity) and full load operating pressure) shall be as stated on the DATA SHEET (refer to Guidance Notes). 5.3 Air Temperature and Purity 1. The required air temperature at the point of use shall be as specified on the DATA SHEET 2. The required air purity at the point of use shall be as specified on the DATA SHEET (refer to Guidance Notes) . 5.4 Noise and Vibration 1. Unless otherwise specified on the DATA SHEET, noise levels from the compressor package shall not exceed 80 dB(A) at a distance of 1 m from the compressor centre line or acoustic enclosure, as appropriate (under free-field conditions). The expected noise levels shall be as stated on the DATA SHEET, based on the results of type tests performed under free-field conditions, in accordance with BS EN ISO 2151. 2. Any additional site specific noise requirements shall be as specified on the DATA SHEET (e.g. site boundary limits). 3. Unless otherwise specified on the DATA SHEET, vibration levels from the compressor shall not exceed the acceptance levels specified in the relevant part of BS ISO 10816. The actual maximum vibration level from the compressor(s) shall be as stated on the DATA SHEET.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 7

5.5 Life Cycle Costs 5.5.1 Energy Consumption 1. The power input of the system at the specified duty points (including all air treatment equipment) shall be as stated on the DATA SHEET (refer to Guidance Notes). 5.5.2 Service Lives and Costs of Components 1. The expected service lives of the system components specified on the DATA SHEET shall be as stated on the DATA SHEET ( refer to Guidance Notes). 2. The replacement costs and approximate times required to replace each of the components specified in clause 5.5.2.1 shall be as stated on the DATA SHEET. 5.5.3 Maintenance Requirements/Costs 1. Details of the maintenance tasks required to achieve the specified system asset life and if appropriate, the expected service lives of the components detailed in clause 5.5.2.1, shall be provided with the tender. This information shall be presented as separate lists of tasks that must be performed on a daily, weekly, monthly, yearly and less frequently than yearly basis and shall include the approximate times and number and discipline of personnel required to perform each task. 6.0 DESIGN SPECIFICATION 6.1 General (All System Components) 6.1.1 General 1. The following information shall be provided with the tender: a) A typical general arrangement drawing of the system indicating the designation, overall dimensions/footprint and typical layout of key components; b) A component schedule or asset list including, for each major component, the component manufacturer and all relevant technical specifications (including details of materials); c) A lubrication schedule detailing all components requiring lubrication, the method and frequency of lubrication and the type and manufacturer of the lubricants; d) A schedule of spares required for 2 years of normal operation (plus associated costs and lead times); e) A typical control philosophy, if specified on the DATA SHEET; and f) A typical commissioning plan (including timescales for completion) if specified on the DATA SHEET. With respect to a), the drawing shall indicate, where appropriate, the minimum clearance distance required for the removal of components (including acoustic enclosures, if provided) for refurbishment or replacement and details of interfaces with other equipment.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 8

2. The Supplier shall provide the first fill of lubricants to all components requiring lubrication. All grease lubricated bearings and associated lubrication pipework shall be fully charged with grease. Automatic grease lubricators, if provided, shall provide a clear indication of grease contents. The minimum capacity/life of the lubricators shall be as specified/stated on the DATA SHEET. 3. The design, construction and testing of the system components shall, where necessary, comply with the Pressure Equipment Directive (97/23/EC). The installation of the system shall comply with the Pressure Systems Safety Regulations (PSSR) 2000 and the associated HSE Approved Code of Practice. 4. The system safety requirements shall comply with BS EN 1012-1. 6.1.2 Weights and Lifting Arrangements  1. The weights of the components specified on the DATA SHEET and the heaviest individual erection and maintenance lifts shall be as stated on the DATA SHEET. 2. Any components weighing over 25 kg, that are likely to be removed for maintenance, shall either: a) Incorporate clearly identified, permanent lifting points located to give a safe, balanced, lift; or b) Be designed in such a way that standard lifting accessories (e.g. slings) can easily be attached. With respect to item a) above, if lifting points are not designed for lifting the complete component, they shall be clearly marked accordingly. 6.1.3 Materials Selection 1. Materials shall be selected with proper reference to the specified operating environment (refer to Section 3.0) , the composition and physical properties of the air to be pressurised (refer to Section 4.0)  and the expected service lives of the specified system components (refer to Section 5.5.3) . 6.1.4 Corrosion Protection 1. Protection against corrosion shall be achieved by the use of suitable materials or by the application of protective coatings, taking into account the operating environment and the required system asset life (refer to Section 3.0 and clause 5.1.1). 2. All metal fabrications (i.e. baseplates, support frames, etc.) shall be designed to prevent the collection of liquids and debris and if appropriate, facilitate the application of paint systems and protective coatings. 3. All wetted, mild steel fabrications shall be continuously welded to prevent moisture traps. The ends of all wetted, mild steel sections shall be sealed to prevent the ingress of liquids after all corrosion resistant coatings have been applied.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 9

4. All metal fabrications (including pipework, valves and fittings etc.) shall be designed and assembled to avoid galvanic corrosion. If necessary, insulating washers and sleeves shall be used to prevent direct contact between dissimilar metals. 5. If paints/polymeric coatings are required for corrosion protection, they shall comply with WIMES 4.01. 6. Galvanising shall comply with BS EN ISO 1461. 6.1.5 Guarding 1. Guarding shall comply with BS EN ISO 12100 and BS EN 953. 2. Interlocking of guards shall comply with BS EN 1088. 3. Guarding of machinery (e.g. belt drives) shall be independent of the acoustic enclosure, if provided. 4. Components and associated pipework that  present a burns hazard shall be insulated/guarded (refer to Guidance Notes). 6.1.6 Maintainability 1. Components that require regular inspection, cleaning or maintenance shall be readily and safely accessible and where appropriate, easily replaceable. 2. Components shall be designed to avoid the need for the use of special tools for maintenance. If special tools are required, they shall be provided. 6.1.7 Marking and Identification 1. The marking and identification of components shall comply with all relevant EU directives and harmonised standards. 2. Any further items (identification labels, asset/tag numbers etc.) to be fixed to components shall be as specified on the DATA SHEET. 6.1.8 O & M Manuals 1. O & M manuals shall be provided in accordance with the Purchaser’s Particular Specification. The reference for this Specification shall be as specified on the DATA SHEET. 6.2 Compressor Package 6.2.1 Compressor(s) 1. The number of compressors required/provided and their configuration/mode of operation (e.g. duty, duty/assist, duty/standby, etc.) shall be as specified/stated on the DATA SHEET.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 10

2. The type of compressor(s) required/provided shall be as specified on the DATA SHEET (i.e. reciprocating, sliding vane, rotary screw, rotary claw, etc.). 3. The following compressor design information shall be as specified/stated on the DATA SHEET: a) b) c) d)

The method of compressor cooling (i.e. air or water cooling); The number of compressor stages; Whether the compressor is single or double acting (reciprocating compressors); Whether an oil-injected or oil-free compressor design is required/provided (refer to Guidance Notes) 

With respect to item a) above, water cooled compressors shall be provided with a pressurised, closed-circuit cooling system that is capable of continuous effective operation at the rated compressor output. The cooling system shall be filled with a non-alcohol based, anti-freeze mixture containing corrosion inhibitors and shall be rated for the specified minimum ambient air temperature (refer to Section 3.0) . With respect to item d), where oil-injected compressors are required/provided, the type of oil required/provided shall be as specified/stated on the DATA SHEET. 4. Compressors shall be designed and rated for continuous operation with a minimum motor service factor of 1.1. 5. All rolling element bearings shall be rated for a minimum L10h  life of 50,000 hours (under maximum load conditions). 6. Oil lubrication systems shall incorporate readily accessible oil filling and drain points to allow oil removal/replacement ‘in situ’ without excessive spillage and without disturbing the compressor stage mountings and/or ancillary equipment. Oil level windows/sight glasses shall be provided. 7. If necessary, to prevent transmission of excessive levels of noise/vibration to the surrounding building/plinth, compressors (and their drive systems) shall be effectively isolated from their support structures and acoustic enclosures (where provided) with anti-vibration or noise attenuating mountings. 6.2.2 Compressor Drive System(s) 1. Compressors shall be electric motor driven. 2. The type of motor starting required/provided shall be as specified/stated on the DATA SHEET (i.e. DOL, star delta, etc). 3. Electric motors shall comply with WIMES 3.03. 4. The type of drive transmission required/provided shall be as specified/stated on the DATA SHEET.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 11

5. Couplings (where required/provided) shall be replaceable without disturbing the compressor and/or its drive (i.e. spacer-type couplings shall be fitted). Couplings shall be designed with a service factor of 1.6 (based on the maximum power input at the compressor shaft stage). 6. Pulley and V-belt transmissions (where required/provided) shall incorporate an automatic belt-tensioning device. V-belt drives shall be designed with a service factor of 1.6 (based on the maximum power input at the compressor shaft stage). 7. All drive systems shall be effectively guarded. Guards fitted to pulley and V-belt transmissions shall incorporate facilities for inspecting V-belt condition (e.g. mesh sections or inspection covers). 6.2.3 Compressor Ancillaries 1. Each compressor or the compressor package, as appropriate, shall be provided with the following items, as a minimum: a) b) c) d) e)

An inlet filter (with silencer, if necessary); An automatic unloading valve (with silencer, if necessary); A non-return valve (to prevent reverse air flow from the receiver); An isolating valve; and Flexible connections to the inlet and outlet pipework, as appropriate (to prevent transfer of vibration).

With respect to item a), the filter(s) shall be of the replaceable, paper element type, housed in a metal retaining cage. With respect to item b), the valve shall discharge to a safe position. With respect to item e), the inlet and outlet connection details (pipework sizes and flange details) required/provided shall be as specified/stated on the DATA SHEET. Any additional items required/provided shall be as specified/stated on the DATA SHEET. 2. Each compressor or the compressor package, as appropriate, shall be provided with the following instrumentation, as a minimum: a) An outlet pressure gauge with isolating valve. The gauge full scale deflection shall be between 1.5 and 2.0 times the maximum outlet pressure; and b) A coolant temperature gauge (for water cooled compressors). Any additional instrumentation required/provided shall be as specified/stated on the DATA SHEET.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 12

3. Each compressor or the compressor package, as appropriate, shall be provided with the following condition monitoring and protection facilities, as a minimum: a) b) c) f) g) h) i)  j)

A high outlet air pressure switch; A low outlet air pressure switch; A high outlet air temperature switch; A high inlet filter restriction/pressure drop switch; A high motor temperature switch; High coolant temperature and low coolant level switches (water cooled compressors); High oil temperature and low oil pressures switches (compressors incorporating pressurised oil lubrication systems); and A high compressor vibration switch (reciprocating compressors).

Any additional facilities required/provided shall be as specified/stated on the DATA SHEET. 6.2.4 Acoustic Enclosure (If Provided) 1. If stated on the DATA SHEET, the compressor(s) shall be provided with an acoustic enclosure to comply with the maximum noise levels specified (refer to Section 5.4). 2. The method of corrosion protection of the acoustic enclosure shall be appropriate to the operating environment (refer to Section 3.0)   and shall be as stated on the DATA SHEET. 3. The dimensions and external colour of the enclosure shall be as specified/stated on the DATA SHEET. 4. The enclosure shall incorporate hinged doors or lift-off panels to provide safe access to all components requiring inspection, cleaning or maintenance. The structural integrity of the enclosure shall be maintained when one or more panels are removed. Doors/panels shall comply with the following requirements, as a minimum: o

a) Doors shall open to a minimum angle of 90  and be restrained against wind loads when open; b) Panels shall be easily removed and manipulated by one person (e.g. fitted with suitable handles) and have a maximum weight of 25 kg; c) Doors/panels shall be securely held in place when closed/in position; d) If necessary, seals shall be provided around doors/panels to maintain the acoustic performance of the enclosure; e) Door/panel locking arrangements shall be as specified/stated on the DATA SHEET. All locks shall be fitted before delivery of the enclosure to site. 5. The enclosure shall be provided with a suitable method of ventilation for compressor cooling. The design of the ventilation system shall ensure that the maximum air temperature inside the enclosure does not exceed 40 °C under the most arduous compressor operating conditions (i.e. maximum load and ambient temperature) ( refer to Guidance Notes).

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 13

6. All monitoring instruments (oil temperature/pressure gauges, filter pressure drop indicators etc.) shall be visible without the need to remove panels or enter the enclosure. 6.3 Local Control Panel (LCP) (If Required/Provided) 1. If specified/stated on the DATA SHEET, the system shall be provided with a local control panel (LCP). If an LCP is not provided (i.e. the system is controlled by the site motor control centre), all power, control and instrumentation cabling shall be suitably terminated in one or more readily accessible terminal boxes. 2. The LCP shall incorporate all necessary components (e.g. selector switches, pushbuttons, lamps and indicators etc.) and control systems to provide the following functions, as a minimum: a) b) c) d) e)

Automatic and/or manual control of the system; Local and remote indication of the operational and/or fault status of the system; Interlocking of adjacent drives, as required; Controlled restart of the system after mains failure; and Latching and/or reset of all system protection and emergency stop systems.

3. The LCP and its associated electrical installation shall comply with WIMES 3.04. 4. The position of the LCP shall be as specified/stated on the DATA SHEET (e.g. integral with or outside the acoustic enclosure). 6.4 Air Receiver 1. The system shall be provided with an air receiver, designed in accordance with the specified system flow rate and pressure requirements (refer to Section 5.2). 2. The receiver capacity shall be as specified/stated on the DATA SHEET. 3. Receivers with a stored energy (PV) of less than or equal to 10,000 bar.litres shall comply with the Simple Pressure Vessels Directive (2009/105/EC) ( refer to Guidance Notes). 4. Receivers which are outside the scope of the Simple Pressure Vessels Directive shall comply with the Pressure Equipment Directive (97/23/EC).

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 14

5. The receiver shall incorporate the following features/facilities, as a minimum: a) A pressure relief valve (PRV), set at 110 % of the maximum compressor operating pressure and rated to pass the maximum compressor flow rate; b) An outlet isolation valve; c) An automatic drain valve with strainer/filter; d) A pressure gauge; e) Any sensors/switches necessary for interfacing with the compressor package control system; and f) Lifting facilities, as determined by the receiver weight. Any additional features/facilities required/provided shall be as specified on the DATA SHEET. 6.5 Air Treatment Equipment Refer to Guidance Notes. 6.5.1 General 6.5.1.1 General 1. If specified/stated on the DATA SHEET, the system shall incorporate one or more of the following items of air treatment equipment to comply with the specified air temperature/purity requirements (refer to Section 5.3) : a) b) c) d)

An aftercooler; Various air/oil and/or air/water separators; A dryer; and/or A number of filters.

Full details of each of the above items shall be provided with the tender. 2. All air treatment equipment shall be rated for the maximum system air flow rate and pressure. 3. All air treatment equipment shall be designed to deliver the required air treatment performance with minimal energy consumption and pressure drop. 4. Requirements for lubricators (e.g. for compressed air driven tools) shall be agreed with the Purchaser. Where lubricators are required, these shall generally be incorporated within a combined filter-regulator-lubricator (FRL) unit, installed close to the point of use of the compressed air. 6.5.1.2 Automatic Drain Valves (ADVs) Refer to Guidance Notes. 1. Aftercoolers, separators, dryers, and filters shall be provided with ADVs for the automatic removal of condensate from the system.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 15

2. The type of ADV required/provided shall be as specified/stated on the DATA SHEET (i.e. float operated type, electronic sensor type or electronic timer type). 3. ADVs shall be designed so that there is no loss of air during condensate discharge. 4. ADVs shall be provided with a strainer to prevent debris blocking the valve drain orifice. 6.5.1.3 Oil/Water Separators (If Required/Provided) Refer to Guidance Notes. 1. If specified on the DATA SHEET, the condensate from the ADV shall be piped to an oil/water separator, to remove the oil from the condensate prior to condensate discharge from the system. 2. The type of separator required/provided shall be as specified/stated on the DATA SHEET. 6.5.2 Aftercooler (If Required/Provided) Refer to Guidance Notes. 1. The aftercooler shall be sized for the highest ambient temperature that is likely to occur in the system vicinity (refer to Section 3.0)   and an ambient relative humidity of 100 %. 2. The aftercooler shall incorporate a pressure relief valve. 6.5.3 Dryer (If Required/Provided) 6.5.3.1 General 1. The type of dryer required/provided shall be as specified/stated on the DATA SHEET (i.e. desiccant, refrigerant type, etc.) (refer to Guidance Notes). 2. The dryer shall comply with BS ISO 7183. 3. The dryer shall be provided with the following features/facilities, as a minimum: a) A valved bypass for maintenance purposes; b) A pressure dew point monitor, to measure the moisture content of the air exiting the dryer. The monitor shall incorporate a high moisture content switch for remote monitoring purposes. 6.5.3.2 Desiccant Dryers (If Required/Provided) 1. The type of desiccant regeneration process required/provided (i.e. heated or heatless) shall be as specified/stated on the DATA SHEET (refer to Guidance Notes).

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 16

2. If specified/stated on the DATA SHEET, the dryer shall incorporate a device to optimise the duration of the regeneration cycle (Dew point Demand Switching (DDS) device) (refer to Guidance Notes). 6.5.4 Filters Refer to Guidance Notes. 1. Unless otherwise agreed with the Purchaser, the system shall, as a minimum, incorporate a number of coalescing filters to remove oil and water aerosols and solid particulates to the required levels (refer to Section 5.3) . 2. Coalescing filters shall be of the disposable element, cartridge type and shall generally be installed in pairs, comprising a general purpose filter installed upstream of a high efficiency filter. 3. In addition to any coalescing filters installed, activated carbon filters shall be installed as the final stage of filtration for the following applications, as a minimum: a) Applications where the compressed air may come into contact with water intended for public consumption; and b) Ozone treatment equipment applications. 4. The number and type of filters required/provided shall be as specified/stated on the DATA SHEET. 5. Filters shall be located as close as possible to the point of use of the compressed air. 6.6 Air Delivery Pipework 1. The piping size (NB) and material shall be as specified/stated on the DATA SHEET. 2. The type of pipework connections required/provided shall be as specified/stated on the DATA SHEET (refer to Guidance Notes). Solvent-welding of metal pipework shall not be permitted. 3. Branch connections shall be designed to prevent the transfer of condensate. The following requirements shall apply, as a minimum: a) Drop legs shall be taken from the top of horizontal trunk (main) piping; and b) Final air outlet connections shall be taken from the side of vertical drop legs. 4. As a minimum, each final air outlet connection shall incorporate a check valve, isolating valve and pressure regulator close to the point of use. 5. Final terminations may be made using push-fit or threaded pneumatic hose, where suitable for the flow-rates. Hose connections using hose-tails shall not be permitted.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 17

6. To ensure effective condensate drainage, the pipework system shall incorporate the following design features, as a minimum: a) Horizontal pipework shall be installed with a minimum fall of 1 in 100 in the direction of the air flow; b) Pipework shall incorporate drain points at all low points in the system (e.g. where pipework dips to go around an obstruction), where changes in pipework direction occur and at distances of not less than 30 m on long pipework runs; c) Drain points shall be formed using equal tees with downwards-pointing drain legs and be fitted with automatic drain valves (ADVs) (refer to Section 6.5.1.2) . 7. Where practicable, drain points shall be constructed so that it is possible to confirm that condensate is draining effectively from the system. 7.0 CONTROL PHILOSOPHY 7.1 General 7.1.1 General 1. The system shall be designed to be fail-safe, such that failure of any essential components shall generate an alarm and if necessary, shut-down the system. 7.1.2 Normal Operation 7.1.2.1 Hand Mode 1. Starting and stopping of the system shall be performed manually with ‘start’ and ‘stop’ push-buttons on the LCP or site motor control centre (MCC), as appropriate. 7.1.2.2 Automatic Mode 1. The system shall start and stop automatically as required by its control system. 2. During starting, the compressor(s) shall not dwell at or near any critical speed, but shall rapidly accelerate through it. 3. Where two compressors are operated on a duty/standby basis, the duty compressor shall operate whenever the low pressure switch/transducer closes and shall cease operation when the high pressure switch/transducer opens. Should the pressure fall to the standby low pressure, the standby compressor shall operate in conjunction with the duty compressor and shall similarly cease operation when the high pressure switch/transducer opens. The circuits for the duty and standby compressor motor starters shall be completely separate. Either unit shall be capable of duty or standby operation and periodically their modes shall be reversed. 7.1.2.3 Off Mode 1. The system shall immediately stop. This position shall also be used to clear a fault and allow restarting of the system after it has shut down for any fault condition.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 18

7.1.3 Shut-Down Modes 1. The system shall automatically shut-down (or starting shall be inhibited) under the following fault/alarm conditions. Re-starting of the system shall not be possible unless the fault/alarm is manually reset at the LCP or site MCC, as appropriate: a) b) c) d)

Motor starter fault (overload, earth fault etc.) (all drives); High drive motor insulation temperature (thermistor trip) (all drives); High coolant temperature (water cooled compressors); Low lubricating oil level in the compressor sump or tank (oil lubricated compressors); e) Low lubricating oil pressure (oil lubricated compressors); f) High compressor vibration (reciprocating compressors); g) Dryer fault or high air moisture content at the dryer outlet (if the system incorporates a dryer). 2. All alarms shall be indicated on the LCP or site MCC, as appropriate. Resetting of the alarm shall only be possible at the LCP. 7.1.4 Emergency Stop 1. Operation of an emergency stop pushbutton (on the LCP, site MCC or elsewhere) shall cause the system to stop immediately in both Manual and Automatic modes. 7.1.5 Miscellaneous 1. No alarm or shutdown shall isolate the LCP display, if an LCP is provided. 8.0 TEST SPECIFICATION Refer to Guidance Notes. 8.1 Factory Acceptance Tests (FATs) 1. The compressor package shall be performance tested in accordance with the test standard specified/stated on the DATA SHEET (i.e. BS ISO 1217, BS 1571-2, DIN 1945-1, etc) (refer to Guidance Notes). 2. The compressor package shall be noise tested in accordance with BS EN ISO 2151. 3. Type testing is acceptable for compressor packages rated below 50 kW. 4. Test certificates, confirming all FATs results, shall be provided. 5. If specified on the DATA SHEET, the FATs shall be witnessed. requirements shall be as specified on the DATA SHEET.

The notice

8.2 Site Acceptance Tests (SATs) (If Required) 1. If specified on the DATA SHEET, the system shall be subjected to SATs.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 19

2. The SATs details shall be as specified on the DATA SHEET. 3. If specified on the DATA SHEET, the SATs shall be witnessed. requirements shall be as specified on the DATA SHEET.

ISSUE 1

The notice

OCTOBER 2012

WIMES 8.07

Page 20

APPENDIX A – REGULATIONS, STANDARDS & SPECIFICATIONS REFERENCED Directives and Regulations The Pressure Equipment Directive (97/23/EC). The Simple Pressure Vessel Directive (SPVD) (2009/105/EC). The Pressure Systems Safety Regulations (PSSR) 2000. Standards BS Series BS 1571-2: 1975  - Specification for testing of positive displacement compressors and exhausters. Methods for simplified acceptance testing for air compressors and exhausters BS EN Series BS EN 953: 1997 + A1: 2009 – Safety of machinery. Guards. General requirements for the design and construction of fixed and movable guards. BS EN 1012-1: 2010 - Compressors and vacuum pumps. Safety requirements. Air compressors. BS EN 1088: 1995 + A2: 2008 - Safety of machinery. Interlocking devices associated with guards. Principles for design and selection. BS ISO Series BS ISO 1217: 2009 – Displacement compressors. Acceptance tests. BS ISO 7183: 2007 - Compressed-air dryers. Specifications and testing. BS ISO 8573-1: 2010 - Compressed air. Contaminants and purity classes. BS ISO 10816 (relevant parts) - Mechanical vibration. Evaluation of machine vibration by measurements on non-rotating parts. BS EN ISO Series BS EN ISO 1461: 2009 - Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods. BS EN ISO 2151: 2008 - Acoustics. Noise test code for compressors and vacuum pumps. Engineering method (Grade 2). BS EN ISO 12100: 2010  - Safety of machinery. General principles for design. Risk assessment and risk reduction. ISO Series ISO 3864 (relevant parts): 2002-2006 – Safety colours and safety signs. Miscellaneous DIN 1945-1: 1980  - Displacement compressor; thermodynamic acceptance and performance test.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 21

Specifications WIMES WIMES 3.03 – Low-voltage ac electric motors for use in the Water Industry. WIMES 3.04 - Low-voltage electrical specification for package plant for use in the Water Industry. WIMES 4.01 – Paints/polymeric coatings for corrosion protection in the Water Industry.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 22 APPENDIX B1 – TEXT GUIDANCE

Clause 2.1.1 Typical applications will include: a) b) c) d) e) f)

Service air (e.g. for pneumatic tools) Mixing; Air lift/air scour duties; Valve actuation; Instrument actuation; Filter backwashing.

Clause 5.2.1 The capacity of the compressor package should be measured at its outlet terminal point in accordance with BS ISO 1217 Annex C. Performance should be expressed in terms of a free air delivery (m3 /min) at a stated working pressure (barg) under the following ‘standard’ inlet conditions: a) Inlet air pressure - 1 bar abs; b) Inlet air temperature – 20 ºC; and c) Inlet air relative humidity – 0 % RH. Clause 5.2.3 The maximum full flow operating pressure is the maximum pressure at which full flow can be maintained with a given compressor package. This is usually the unload pressure setting for load/no load control or the maximum pressure attainable before capacity control begins and may require additional power. Clause 5.2.4c) The power input at zero flow/load is the power consumed by the compressor package with the inlet valve closed and the sump pressure relieved to its lowest required pressure. Clause 5.2.4 When comparing power inputs between suppliers, it is important to ensure that the power input of any remote cooling packages is included. Some suppliers may not count remote cooling packages in this figure (e.g. remote-mounted, air coolers and closed-loop water cooling systems). Clause 5.2.5 This is a measure of how efficiently a compressor package produces compressed air. Comparing specific power ratings allows the Purchaser to determine which compressor delivers air at the lowest cost per unit of flow.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 23

Clause 5.3.2 The compressed air purity requirements at the point of use will vary according to the application and should be specified in accordance with BS ISO 8573-1. BS ISO 8573-1  identifies the three major contaminants of compressed air as solid particles, water and oil. The required levels of these contaminants in the compressed air should be specified by three digits, in accordance with the following table. The first digit relates to the particle size and density, the second to the moisture content and the third to the oil content. Class

0 1 2 3 4 5 6

Particle Size and Density (per m ) 0.1-0.5 µm 0.5-1.0 µm 1.0–5 µm

Water Pressure dew point2 (°C)

Oil Oil content3 (mg/m3)

As specified by the equipment user or supplier and more stringent than class 1 100 100,000 -

1 1000 10,000 -

0 10 50 1000 2000 -

-70 -40 -20 +3 +7 +10

0.01 0.1 1 5 -

Notes: 1 - particle size and density  - this is the size and concentration of any solid particles entrained in the compressed air, such as dirt or rust. 2 - pressure dew point  – this is the temperature to which the compressed air can be cooled without condensation of any entrained moisture. The pressure dew point changes with the air pressure. 3 - oil content – this is the residual quantity of hydrocarbons (aerosols and vapour) in the compressed air.

For example, specifying an air purity class of 2.4.1 would impose the following restrictions: Class 2 (particles) - no more than 100,000 particles in the 0.1 - 0.5 µm size range, 1,000 particles in the 0.5 - 1 µm size and 10 particles in the 1 - 5 µm size range are allowed in each m3 of compressed air; Class 4 (water)  - a pressure dewpoint of +3°C or lower is required; no liquid water is allowed; and Class 1 (oil) - no more than 0.01 mg of oil is allowed in each m3 of compressed air. This is a combined level for both oil aerosols and vapours. Applications requiring XX1 or XX0 air purity levels may require the specification of oil-free compressors and activated charcoal filters as the final stage of filtration. It is important to realise that the ‘over-specification’ of air purity will result in the procurement of systems which are unnecessarily complex and expensive to maintain. When designing a system, it is also important to ensure that the air is treated/purified as close as possible to the point of use, as this will avoid ‘over-treating’ large volumes of air and also reduce the likelihood of air purity decreasing after treatment, e.g. due to leaks in pipework etc.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 24

Clause 5.5.1.1 The Purchaser will typically specify a number of duty points (i.e. pressures and flows) that best describe the anticipated duty of the system. The Supplier should state the system power input at each duty point, enabling the Purchaser to calculate an average power input, based on the system utilisation at the various duty points. The power input figures provided by the Supplier should refer to the power input at the motor terminals or inverter drive and should be summed for all drives. Clause 5.5.2.1 If required, the Purchaser should specify selected system components on the DATA SHEET. The Supplier should then state the expected service lives of these components, based on the information provided by the Purchaser pertaining to the system duty. Any maintenance tasks necessary to achieve the expected service lives of the relevant components should be detailed with the tender. If any of the specified components fail before their expected service lives, the Purchaser/Supplier should investigate the reason for the ‘shortfall’ with a view to resolving the issue to the satisfaction of both parties. Clause 6.1.5.4 The acoustic enclosure can perform the guarding function (against burns hazards), provided there is a suitable warning symbol on the enclosure (see ISO 3864, symbol 6043). Clause 6.2.1.3d) Oil free reciprocating compressors typically use extended connecting rods, non-lubricated packings and self-lubricating, PTFE piston rings. The ‘bottom end’ of the machine (crankshaft, crosshead, etc) will still, however, be oi-lubricated. Clause 6.2.4.5 The maximum ambient air temperature inside the enclosure should be limited to 40 °C. Motors will need to be de-rated if the ambient air temperature is above this value! Clause 6.4.3 Simple pressure vessels are vessels which are intended to contain air at a pressure greater than 0.5 barg but less than or equal to 30 barg and are not intended to be exposed to heat. They must be manufactured in series production and be of welded steel or aluminium construction, with a total stored energy of less than or equal to 10,000 bar.litres.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 25

Section 6.5 For most applications, the air generated by a compressor package must be treated to remove contaminants (e.g. dirt, water and oil) from it. Contaminants originate from many sources, such as the ambient air itself, compressor lubricants, pipework corrosion products and microbial sources. A common misconception is that, by installing an ‘oil free’ compressor, there is no need for downstream filtration to achieve low oil levels in the compressed air. However, the term ‘oil-free’ simply means that oil is not used in the compression chamber and therefore does not come into contact with the air being compressed. Even with an oil-free compressor, filtration may still be required to remove oil vapour (present in the ambient air) drawn into the compressor inlet. Section 6.5.1.2 Automatic drain valves are installed on moisture separators, coalescing filters, air receivers, air dryers and drip legs to automatically remove condensate from the system. Section 6.5.1.3 The condensate from an ADVs should be piped to an oil/water separator to remove the oil from the condensate prior to discharge to a drain. Oil/water separators based on four different principles of operation are available, as follows: a) b) c) d)

Chemical adsorption; Gravitational separation; Mechanical separation; and Vaporization separation.

Section 6.5.2 The compressed air discharged from a compressor is hot and loaded with water vapour. An after-cooler reduces the temperature of the compressed air, causing a substantial amount of the entrained moisture to condense. This moisture is then removed from the compressed air system with a air/water separator and drain assembly. In a typical compressed air system, an after-cooler and separator are installed before the compressed air dryer. A properly sized after-cooler significantly reduces the water load that would otherwise be placed on the dryer. After coolers are usually sized with a Cold Temperature Difference (CTD) of 2.7 °C, 5.5 °C, 8.3 °C, or 11 °C. This means that the compressed air temperature at the outlet of the aftercooler will be equal to the cooling medium temperature (approach temperature) plus the CTD when sized at the specified inlet air temperature and air flow.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 26

Clause 6.5.3.1.1 When selecting a dryer, several factors need to be considered, as follows: a) b) c) d) e) f)

The dew point requirement; The inlet air temperature; The ambient air temperature; The system operating pressure; The system airflow; and The available utilities.

Desiccant Dryers The term ‘desiccant dryer’ refers to a broad class of dryers. Other terms commonly used are regenerative dryer and twin tower dryer, and to a lesser extent, adsorption dryer. Desiccant dryers typically provide water vapour removal with a pressure dew point of -40°C; this means that when the air leaves the dryer there is as much water in the air as if the air had been ‘cooled’ to −40 C. The required dew point is dependent on the application and −70°C is required in some applications (a dew point of less than -26°C will inhibit the growth of micro-organisms within the compressed air system). Desiccant dryers use desiccant beads to adsorb water vapour from the compressed air. Three different types of desiccant bead are commonly used – silica gel, activated alumina and molecular sieve. Desiccant dryers usually incorporate two pressure vessels filled with desiccant beads, although single tower versions are also available. The basic operating mode of a desiccant dryer involves one drying cycle, followed by one regeneration cycle, the two together being commonly referred to as a NEMA cycle. For example, a 10 minute NEMA cycle consists of a 5 minute drying cycle and 5 minute regeneration cycle. This NEMA cycle is continuously repeated. During the drying cycle, compressed air, at full pressure, flows through one vessel. As the air flows through the desiccant bed, microscopic pores on the surface of the desiccant beads ‘strip’ the water vapour and hydrocarbon molecules from the air, thereby reducing the relative humidity of the air. The relative humidity of the dried air is equivalent to a pressure dew point of -40ºC or lower. Since this ‘stripping’ is a result of a chemical reaction, it produces a small amount of heat, called ‘heat of adsorption’. The heat produced is minimal and increases the outlet temperature only slightly. During the regeneration cycle, switching valves isolate the moisture saturated vessel, which is then depressurized in readiness for the regeneration cycle.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 27

Refrigerated Dryers Most refrigerated dryers cool the compressed air to a temperature of approximately 1.6°C to 10°C, which results in a pressure dew point range of 0.5°C to 3.8ºC. This range permits the pressure dew point to fall within limits that are achievable with common refrigeration system controls. This pressure dew point range is also the lowest achievable with a refrigerated design since the condensate will begin to freeze at 0ºC. Specifying Class 2 for water content will generally mean that a desiccant dryer is required! Clause 6.5.3.2.1 Regeneration of the desiccant vessel can be achieved by three different methods, as follows: a) Heatless ‘pressure-swing’ regeneration - this uses some of the dry compressed air from the drying vessel to dry/purge the desiccant in the regenerating vessel at a lower pressure; b) Heated regeneration - this uses a hot air blower to dry the desiccant in the regenerating vessel, so there is no loss of compressed air; or c) Heat of compression regeneration - this can only be used with oil free compressors. Clause 6.5.3.2.2 Desiccant dryers operate using two separate towers containing desiccant – one tower is always in operation, while the other tower is being regenerated or purged using a portion of the dried exiting air. Some towers switch based on a timer, regardless of whether the desiccant has been fully saturated. By integrating a dew point sensor with the dryer control system, the towers will not switch until the sensor detects a degrading dew point temperature, thus ensuring full utilization of each desiccant tower and minimizing wasted purge air. Section 6.5.4 Aerosols (droplets) of oil and water are effectively removed using coalescing type filters, which also remove solid particulates to very low levels (as small as 0.01 µm in size). Oil vapour will, however, pass through coalescing filters, and therefore requires removal by activated carbon filters. Clause 6.6.2 Where aluminium pipework is provided, the connection type will be dependent on the system used by the pipework manufacturer, e.g. push fit or clamp type. Section 8.0 Most positive displacement compressors will only require type testing at the Suppliers Works. Witness testing or testing at site will incur considerable extra costs and should not generally be specified.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 28

Clause 8.1.1 For the vast majority of compressors, BS ISO 1217 Annex C is the relevant performance testing standard. DIN 1945-1 has been largely replaced by most German compressor manufacturers with ISO 1217. Some manufacturers still quote their compressor performance to the predecessor of ISO 1217 Annex C, Pneurop PN2PTC2.3; this performance statement is identical to ISO 1217 Annex C.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 29 APPENDIX B2 - DATA SHEET GUIDANCE

1. Items to be completed by the Purchaser are marked (P) and by the Supplier (S). Items which the Purchaser may wish to specify, or alternatively may wish to leave for the Supplier to complete are marked (P/S). 2. The Purchaser may customise the DATA SHEET included in Appendix C to provide for: a) The Purchaser’s name, issue reference, format for inclusion of Contract/Project title and references etc.; and b) The Purchaser’s standard technical and procedural requirements which apply to every Contract/Project carried out for the Purchaser provided that such inclusions comply with the requirements indicated in clause 5 below. 3. Reference numbers incorporated on the DATA SHEET in Appendix C relate to Sections or Clauses, as appropriate, within WIMES 8.07. 4. The technical content and any incorporated reference to WIMES 8.07 shall not be altered from the form shown on the DATA SHEETS in Appendix C. 5. The person(s) responsible for completing the DATA SHEET shall only employ the form of DATA SHEET approved for use by the Purchaser. 6. The DATA SHEET should be completed by ticking the feature(s) required or by entering requirements or information, as appropriate, in the column/row adjacent to the feature description. 7. Where there is a need for the Purchaser to enter more information on the DATA SHEET than space permits, a reference should be entered as to where the requirement is specified. This approach may be used where: a) Further clarification or definition is required on a feature description, or b) The feature description needs to be read in conjunction with another Standard or Specification applicable to the Contract/Project, or c) A particular feature or arrangement is not listed on the DATA SHEET, in which case the option ‘Other (specify)’ should be used. The referencing system employed shall be defined in the Contract/Project documentation. 8. Where there is a need for the Supplier to enter more information on the DATA SHEET than space permits, this information should be given in Appendix D and crossreferenced to the relevant clause. This approach may be used where: a) Further clarification or definition is required on a feature description; or b) A particular feature or arrangement is not listed on the DATA SHEET. In both of the above cases, the words ‘refer to Appendix D’ should be entered in the column/row adjacent to the feature description.

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 30 APPENDIX C – DATA SHEET COMPRESSED AIR SYSTEMS

PROJECT TITLE (P) PROJECT NUMBER (P) PROJECT LOCATION (P) SYSTEM SUPPLIER (P/S)

DOCUMENT REFERENCE (P) REVISION (P) DATE (P) REFERENCE DRAWINGS INCLUDED (Y/N) (P)

TAG NO/ASSET CODE (P) * - indicates Purchaser’s default requirements

4.0 AIR COMPOSITION PROPERTIES

AND

PHYSICAL

2.0 GENERAL 2.1 General 1

1

1 1 1

2

Air Composition (Detail Levels of Any Contaminants) (P)

1 1

Physical Properties (P) Temperature Range (°C) Minimum/maximum Relative Humidity Range (%) Minimum/maximum Inlet Pressure Range (bar) Minimum/maximum

System Application () (P)

3.0 OPERATING ENVIRONMENT AND SITE DETAILS 1

1

Operating Environment (P) Site Location () Inland Coastal Other (specify) System Location () Inside Outdoors Other (specify) Ambient temperature Range (°C) Minimum/maximum Ambient Relative Humidity Range (%) Minimum/maximum EMC Environment () Class B - light industrial Class A - Industrial Special Environmental Hazards (P)

1 1

5.0 PERFORMANCE SPECIFICATION 5.1 General 1 1

5.2 Volume Flow Rate (Capacity), Pressure and Power Input 1

2

3 3

Asset Life (years) (P) Utilisation (%) (P)

3

Volume Flow Rate (Capacity) (m  /min) (P/S) Maximum required Rated Operating Pressure (barg) (P/S) Maximum required Rated full load Maximum Full Flow Operating Pressure (barg) (S)

References For Further Information (P)

ISSUE 1

OCTOBER 2012

WIMES 8.07 4

5

Page 31 2

Power Input (kW) (S) At the rated volume flow rate and full load operating pressure At the full flow operating pressure At zero flow/load Specific Power Input 3 1 ((kW/m  /min)  (S)

Required Air Purity (°C) (P) Solid particle content Moisture content Organic vapour content

5.4 Noise and Vibration 1

1 – At the rated volume flow rate and full load operating pressure.

2

Noise Levels (dB(A) at 1 m) (P/S) Maximum (80*) (P) Expected (S) Additional Site Specific Requirements (P)

Noise

5.3 Air Temperature and Purity (At Point of Use) 1

3

Required Air Temperature (°C) (P)

Vibration Levels (mm/s) (rms) (P/S) Maximum (as per BS ISO 10816*) (P) Actual (S)

5.5 Life Cycle Costs 5.5.1 Energy Consumption Duty Point 1

Duty Point 2

Duty Point 3

Duty Point 4

3

Volume Flow Rate (m  /min) (P) Operating Pressure (barg) (P) Utilisation Factor (%) (P) Power Input (kW) (S) Composite Power Input (kW) (P) 5.5.2 Service Lives and Costs of Components 1

Expected Service Lives of System 3 Components (x 10  hrs) (P/S) Component (Specify) Life (S)

2

Costs of Components (£)/Time Required to Replace Components (hrs) (S) Component (Specify) Cost Time

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 32

6.0 DESIGN SPECIFICATION

2

6.1 General (All System Components) 6.1.1 General 1 e f 2

Information to be Provided with the Tender () (P) Typical control philosophy Typical commissioning plan Minimum Capacity/Life of Auto-Lubricators (cc/months) (P/S)

6.1.2 Weights and Lifting Arrangements 1

Component (Specify) (P)

3 3a)

3b) 3c)

Weight (kg) (S)

3d)

3d) 1 1

Heaviest erection lift (S) Heaviest maintenance lift (S)

Type of Compressor(s) Required/Provided () (P/S) Reciprocating Sliding vane Rotary screw Other (specify) Compressor Design Information (P/S) Method of Cooling () (P/S) Air cooled – natural convection Air cooled – forced convection Water cooled Number of Stages (S) Single or Double Acting Design () (S) Single acting Double acting Oil Injected or Oil Free Design () (P/S) Oil injected Oil free Type of Oil Required/Provided (Oil Injected Designs) (P/S)

6.2.2 Compressor Drive Systems 6.1.7 Marking and Identification 2 2

Further Items (Asset/Tag Numbers etc.) to be Fixed to Components (P)

4 6.1.8 O & M Manuals 1

Reference for Purchaser’s O & M Manual Specification (P)

Type of Motor Starting Required/Provided () (P/S) DOL Star delta Other (specify) Type of Drive Transmission Required/Provided () (P/S) Direct Close-coupled (via coupling) Pulley and V-Belt

6.2.3 Compressor Ancillaries 6.2 Compressor Package

1e

Inlet Connection Details (P/S)

1e

Outlet Connection Details (P/S)

1

Additional Items Required/Provided (P/S)

6.2.1 Compressor(s) 1 1

Number of Compressors Required/Provided (P/S) Configuration/Mode of Operation (P/S) Duty Duty/assist Duty/standby

ISSUE 1

()

OCTOBER 2012

WIMES 8.07 2

Page 33

Additional Instrumentation Provided (P/S)

Required/

6.5.1.2 Automatic Drain Valves (ADVs) 2

3

Additional Facilities Required/ Provided (P/S)

Type of ADV Required/Provided () (P/S) Float operated type Electronic sensor type Electronic timer type

6.5.1.3 Oil/Water Required/Provided)

Separators

(If

6.2.4 Acoustic Enclosure (If Provided) 1 1 2

Acoustic Enclosure Provided (Y/N) (S) Method of Corrosion Protection (S)

3

Dimensions (L x W x H) (m) (S)

3

External Colour (P/S)

4

6.5.3 Dryer (If Required/Provided) 6.5.3.1 General 1

4e)

Door/Panel Locking Arrangements (P/S)

6.3 Local Control Required/Provided) 1 4

Panel

(LCP)

(If

5

Type of Dryer Required/Provided () (P/S) Desiccant type Refrigerant type Other (specify)

6.5.3.2 Desiccant Dryers (If Required/Provided)

LCP Required/Provided (Y/N) (P/S) LCP Position (P/S)

1

2

6.4 Air Receiver 2

Separator Required/ Provided (Y/N) (P/S) Type of Separator Reqd./ Provided (P/S)

Air Receiver Capacity (litres) (P/S) Additional Features/Facilities Required/ Provided (P/S)

Type of Desiccant Regeneration Process Required/Provided () (P/S) Heated Heatless Other (specify) DDS Required/Provided (Y/N) (P/S)

6.5.4 Filters 4

Number and Type of Filters Required/ Provided (P/S)

6.5 Air Treatment Equipment 6.5.1 General

6.6 Air Delivery Pipework

6.5.1.1 General 1 1a) 1b) 1c) 1d)

Air Treatment Required/Provided () (P/S) An aftercooler Various air/oil and/or air/water separators A dryer A number of filters

ISSUE 1

1

Piping Size (NB) (mm) (P/S)

1

Piping Material (P/S)

Equipment

OCTOBER 2012

WIMES 8.07 2

Page 34

Type of Pipework Required/Provided (P/S)

Connections

8.0 TEST SPECIFICATION 8.1 Factory Acceptance Tests (FATs) 1

5 5

Performance Testing Standard () (P/S) BS ISO 1217 BS 1571-2 DIN 1945-1 Pneurop PN2PTC2.3 Witness FATs Required (Y/N) (P) Witness FATs Notice Requirements (Days) (P)

8.2 Site Acceptance Tests (SATs) (If Required) 1 2

3 3

SATs Required (P) SATs Details (P)

(Y/N)

Witness SATs Required (Y/N) (P) Witness SATs Notice (Days) (P)

ISSUE 1

Requirements

OCTOBER 2012

WIMES 8.07

Page 35

APPENDIX D – SUPPLIER’S SUPPLEMENTARY DATA SHEET INFORMATION Clause

ISSUE 1

Supplementary Information

OCTOBER 2012

WIMES 8.07

Page 36

APPENDIX E - INFORMATION TO BE SUPPLIED WITH TENDER 1. Details of the maintenance tasks required to achieve the specified system asset life (refer to Section 5.1.1)   and if appropriate, the expected service lives of the components detailed in clause 5.5.2.1 (refer to clause 5.5.3.1). 2. All of the items listed in clause 6.1.1.1. 3. All of the items listed in clause 6.5.1.1.1. 4. A set of completed DATA SHEETS with all fields marked ‘S’ and if appropriate, ‘P/S’ completed (refer to Appendix C). 5. Appendix F, if appropriate (refer to Notes).

ISSUE 1

OCTOBER 2012

WIMES 8.07

Page 37

APPENDIX F – DETAILS OF NON-COMPLIANT INNOVATIONS Clause

ISSUE 1

Details

OCTOBER 2012