ENGINE-DRIVEN COMPRESSOR PROJECT

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DETAIL DESIGN DOC.NO.: KERUI-KCP70-GEN-0017 REV. 1 PAGE 1 OF 25

Installation Procedure

1 FINAL ISSUE 13-11-2015

0 ISSUED FOR APPROVAL 16-10-2015

B ISSUED FOR APPROVAL 07-09-2015

A ISSUED FOR APPROVAL 24-08-2015

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

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DETAIL DESIGN DOC.NO.: KERUI-KCP70-GEN-0017 REV. 1 PAGE 2 OF 25

TABLE OF CONTENTS
1. Background ................................................................................................................3

2.  Purpose & Scope of Document ................................................................................3 

3.  Referenced Documentation ......................................................................................4 

4.  Installation Specification ..........................................................................................5 

4.1  Unit In Place ...............................................................................................................5 

4.1.1.  Prepare The Foundation For ReceivingThe Skid 5 
4.1.2.  Lift Skids Onto Foundation And Position Them Over Foundation Bolts 7 

4.2  Pipeline Assembly ...................................................................................................11 

4.3  Instruments and control components installation ...............................................18 

4.4  Compressor Leveling ..............................................................................................13 

4.5  Anchor Bolts Grouting ............................................................................................15 

4.6  Secondary Grouting ................................................................................................17 

4.7  Coupling Alignment .................................................................................................18 

4.8  Unit Final Assembling .............................................................................................25 

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DETAIL DESIGN DOC.NO.: KERUI-KCP70-GEN-0017 REV. 1 PAGE 3 OF 25

1. Background

TGI has engaged Kerui Shandong Petroleum to supply one modular skid-mounted gas engine driven
reciprocating compressor unit, for installation at the Miraflores station. The compressor will be be
installed adjacent to other existing compressors.

Detailed design of the unit has been completed on behalf of Kerui.This document consists of
requirements and guidelines for the installation.The unit will also be installed under the instruction of
kerui after-sale engineers .

This document is valid for KCP70 M station compressor package.

2. Purpose & Scope of Document

The objective of this procedure is to instruct the staff to install the package on the foundation
correctly and efficiently to ensure that the unit will operate smoothly.

The installation should be performed according to this document,only if the kerui after-sale engineers
at site agree on other methods excluded in this document.

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3. Referenced Documentation

This section contains documentation that is referenced to the Installation Procedure. Detailed
documentations are listed below.

Document Number Description

KERUI-KCP70-PRO-DWG-0001
KERUI-KCP70-PRO-DWG-0002
KERUI-KCP70-PRO-DWG-0003
KERUI-KCP70-PRO-DWG-0004
KERUI-KCP70-PRO-DWG-0005
KERUI-KCP70-PRO-DWG-0006
KERUI-KCP70-PRO-DWG-0007
KERUI-KCP70-PLO-DWG-0001
KERUI-KCP70-PLO-DWG-0002
KERUI-KCP70-PLO-DWG-0003
KERUI-KCP70-GEN-0003
KERUI-KCP70-EQP-DWG-0001
KERUI-KCP70-ELE-DWG-0001
KERUI-KCP70-GEN-0021
KCP70.01 Process Gas P&ID
KCP70.02 Major Equipment P&ID
KCP70.03 Compressor Oil and Drain P&ID
KCP70.04 Engine Coolant System P&ID
KCP70.05 Engine Start Gas P&ID
KCP70.06 Engine Fuel Gas P&ID
KCP70.07 Engine Oil and Drain P&ID
General Arrangement Drawing
Skid Structural Detailed Drawing
Location Drawing of Anchor Bolts
Pipe Connection List
Air Cooler Drawing
Local Control Panel Drawing
Operarion and Maintenance Manual

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4. Installation Specification

4.1 Unit In Place

Before the package is installed, the end user should have completed the foundations of skid and air-
cooler according to the Location Drawing of Anchor Bolts. Specific requirements are as follows:

4.1.1. Prepare The Foundation For ReceivingThe Skid

 Roughen or scar the top of the foundation to permit a good bonding surface for the grouting
materials.
 Clean all loose pieces of concrete and dirt from top surface of thefoundation (generally 15-20 mm
deep).
 Remove portion of liner around foundation bolts extending above the top surface of foundation.
 Clean threads of anchor bolts of all concrete, burrs, etc.
 Wash all dirt, etc from top of foundation to insure a good clean surface for the bonding of the
grouting materials.
 Purging the moisture in the base of the foundation and the anchor bolts' holes by dry compressed
air.
 Mapping the horizontal centerline of the main skid on base of the foundation refering to the
Location Drawing of Anchor Bolts.
 Measuring the anchor bolt holes on the base of center lines to make sure they are in right
positions with the dimensions required in the Location Drawing of Anchor Bolts and check the
depth of all the anchor bolts whether they can satisfy the length of anchor bolts.
 Determine the basic level,and inspect the basic level of the main and deputy skids by the
gradienter.Then place the sizing block of which the hight is 50mm.And then place other sizing
blocks.
 Refer to the following figures.

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Figure-1 Prepared foundation

Figure-2 Roughen the top of the foundation

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Figure-3 Clear the top of the foundation

4.1.2. Lift Skids Onto Foundation And Position Them Over Foundation Bolts

 Prepare the cranes,lifting slings,measuring tools and other tools for lifting work(The biggest lifting
component of the compressor is the main skid,the model of the crane should be determined
according to the site conditions).
 Lifte the main skid to the foundation ,mark the center of the vertical and horizontal at the bottom
of the skid.Then penetrate the anchor bolts to make the skid lands up on the sizing blocks
prepared before.
 Put grease on the jacking screws to ensure a convenient operation and prevent the grouting
materials from being attached to the bolts. Jacking screws should be installed on the main skid,
and make them through the bottom of the main skid by 25.4－50mm. Pads should be placed on
proper positions under the jacking screws.

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 Lift the air-cooler in place by the same way. Get the air cooler jacking screws across the bottom
plate.
 Install the pipelines,blind windows,air wings and other components of the air cooler according to
the drawing.
Note: The lifting activities shall be prepared prior to the the execution of the works and will be
discussed with all staff involved in the work / activities.
 Refer to the following figures

Figure 4 Lift the unit

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Figure 5 Lift the container

Figure 6 Lift the Air-cooler

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Figure 7 Air cooler-1

Figure 8 Air cooler-2

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4.2 Pipeline Assembly

 Place pipeline supports on the corresponding foundation or on a proper position if there are
anchor bolts on the supports.
 Installing the cylinder and VVCP of the compressor.And all the bolts should be torqued according
to the torque value of the manual.
 Install the compressor pressure vessels including scrubbers and pulsation bottles.
 Connect and fasten all the process gas pipelines and its accessories, to ensure all the flanges
can connected to the pipelines freely.
 Install other accessories of the process system such as the ball valves and safety valves.
 Install the pipelines of the water coolant system.
 Install the pipelines of the fuel gas and start gas system.
 Install the pipelines and tubings of the compressor and engine lube oil system, including the
pipelines of the forced oil system.
 Install the inlet and exhaust pipelines, including the support of the air filter ,the seat of the
exhaust silencer,exhaust silencer etc.

 Refer to the following figures

Figure 9 Pipeline Assembly-1

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Figure 10 Pipeline Assembly-2

Figure 11 Pipeline Assembly-3

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4.3 Compressor Leveling

 Remove crankcase and crosshead guide inspection doors.

 Clean all leveling pad surfaces and insure that they are free of paint, rust, dirt, etc. Be careful that
they are not burred or dented.
 By means of the leveling screws bring skid up to the desired height and level with a cross level
vial on the leveling pads and the bottom of crosshead guides. Before leveling the unit, care
should be taken that all of the leveling screws are adjusted to carry the same weight.
 Unlevel should not exceed 0.001 per foot.
 Refer to the following figures

Figure 12 Compressor Leveling-1

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Figure 13 Compressor Leveling-2

Figure 14 Compressor Leveling-3

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4.4 Anchor Bolts Grouting

 Protect all the thread part on the anchor blots to avoid damages during grouting.
 Align the anchor bolts and fix them.
 Place concrete to the anchor bolt hole and implement maintenance according to the
requirements.
 Tamp the grouting materials when grouting,and do not make the anchor bolts incline
 Refer to the following figures

Figure 15 Grouting in the anchor bolts hole

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Figure 16 Grouting-1

Figure 17 Grouting-2

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4.5 Secondary Grouting

 Level the skid in accordance with the requirements, and implement back grouting right away. The
unit skid is not allowed to be supported on the leveling bolts for a long time due to some reasons
such as the flexibility of the skid will change as the site temperature changes, or there may be a
slightly distortion on the skid.
 A proper framework, which is slightly higher than the top of the foundation, should be made
around the skid. All the seams should be sealed by caulking materials or through other sealing
methods to avoid grouting materials leakage. Here epoxy resin is advised for back grouting and
the materials should be mixed according to the manufacturer’s instruction. The grouting materials
can only be injected from one side of the base. By pouring the grout to the level of the top of the
form boards, a head will be provided causing the grout to flow under the skid base.
 Remove the excess grout material from outsides of skid as soon as it has hardened sufficiently to
prevent any flow when the form boards are removed.
 Release the leveling bolts and fasten the anchor bolts 5 days later or after the grouting materials
are completely solidified.
 Refer to the following figures
Figure 18 Secondary grouting-1

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4.6 Instruments and control components installation

 Install the instruments,gauges,electrical appliances,wires,pipelines of the instrument

air,automatic blowdown system etc according to the control and flow chart.
 Make sure all the connections of the wires are reliable,insulation,non-destructive and non-
unclad,all the wire protection tubes,wire protection joints and their connection are conform to the
requests of the anti-explosion.
 Refer to the following figures

Figure 19 Instruments and control components installation-1

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Figure 20 Instruments and control components installation-2

Figure 21 Instruments and control components installation-3

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4.7 Coupling Alignment

 Coupling centring should be inspected and rectified. Make sure the error of centration is within
0.127mm through adjusting shims on the minor engine base.
 Refer to the following figures
Figure 22 Coupling alignment-1

Figure 23 Coupling alignment-2

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Figure 24 Coupling alignment-3

4.8 Auxiliary Components Assembly

 Install the remained compressor lube oil tank ,oil pipes and the accessories.
 Install the remained engine lube oil tank ,oil pipes and the accessories.
 Install the remained exhaust pipelines ,the support and the accessories.
 Install the remained air-intake pipelines ,the support,air-cleaners and the accessories.
 Install the remained starting pipelines ,the support and the accessories.
 Install the remained fuel gas pipelines ,the support and the accessories.
 Install the ladders, platforms and the accessories.
 Refer to the following figures

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Figure 25 The compressor lube oil tank

Figure 26 The air-intake system

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Figure 27 The starting system

Figure 28 The exhaust system

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Figure 29 The platforms, ladders and the engine lube oil tank

Figure 30 The fuel gas system

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Figure 31 The ladder and the platform

4.9 Unit Final Assembling

 Assemble all the components of the unit in accordance with the requirements and fasten them.
 Check all the connections and make sure all the components are correctly installed.

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