RESR001

EDITORIAL REVISION/TECHNICAL REVISION
January 2002
Process Industry Practices

Machinery
PIP RESR001
Packaged, Skid-Mounted
Industrial Process Refrigeration
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.
This Practice is subject to revision at any time by the responsible Function Team and
will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.
Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.
PIP will not consider requests for interpretations (inquiries) for this Practice.
PRINTING HISTORY
August 2000
Issued
January 2002
Editorial Revision/Technical Revision
Not printed with State funds

January 2002

Machinery
PIP RESR001
Packaged, Skid-Mounted
Industrial Process Refrigeration Systems
Table of Contents
1. Introduction .................................. 3
1.1 Purpose ............................................. 3
1.2 Scope................................................. 3
2. References ................................... 3
2.1 Process Industry Practices ................ 3
2.2 Industry Codes and Standards .......... 4
2.3 Government Regulations ................... 4
3. General ......................................... 4
4. System .......................................... 5
5. Compressors................................ 5
5.1
5.2
5.3
5.4
General .............................................. 5
Reciprocating Compressors .............. 6
Rotary Compressors.......................... 7
Centrifugal Compressors................... 7
6. Drivers .......................................... 8
6.1 Electric Motors
(Open Drive Systems) ....................... 8
6.2 Steam Turbine ................................... 8
7. Heat Exchangers ......................... 8

7.1
7.2
7.3
7.4
General .............................................. 8
Shell and Tube................................... 8
Direct Expansion................................ 9
Subcooler........................................... 9
8. Vessels ......................................... 9
8.1 General .............................................. 9
8.2 Receiver............................................. 9
8.3 Oil Separator
(Rotary Compressor Systems) .......... 9
8.4 Oil Recovery Pots (Reciprocating or
Rotary Compressor) ........................ 10
8.5 Suction Knockout Drum ................... 10
8.6 Economizer (If Provided) ................. 11
9. Oil System .................................. 11

9.1
9.2
9.3
9.4
9.5
9.6
General ............................................ 11
Pumps.............................................. 11
Reservoir ......................................... 12
Piping/Valves ................................... 12
Filters and Cooler ............................ 12
Lubrication System Tests ................ 13
Page 1 of 26
PIP RESR001
Packaged, Skid-Mounted Industrial Process Refrigeration Systems
January 2002
10. Purge System ............................13

11. System Instrumentation and
Controls .....................................14
11.1 Controls ............................................14
11.2 Instruments ......................................14
11.3 Rotary Compressor Control and
Instrumentation ................................17
11.4 Centrifugal Compressor Control and
Instrumentation ................................17
RESR001D - Specification for SkidMounted Industrial Process

Refrigeration Systems
Data Sheet
12. Control Panel ............................18

13. Electrical....................................18
13.1 General.............................................18
13.2 Wiring and Terminations ..................18
14. Pipe, Valves, and Fittings.........19

15. Pressure-Relieving Devices.....19
16. Insulation...................................20
17. Structural Steel Skids...............20
18. Noise ..........................................21
19. Compressor Vibration and
Critical Speeds..........................21
20. Painting......................................21
21. Inspection..................................22
21.1
21.2
21.3
21.4
21.5
Vendor Quality Requirements ..........22

Special Considerations.....................22
Documentation .................................22
Prefabrication Meeting .....................23
Surveillance Schedule......................23
22. Testing and Preparation for

Shipment ...................................23
23. Documentation..........................25
Table Monitoring System
Instrumentation.........................26
Appendix - Surveillance
Instructions ............................. A-1
Page 2 of 26
PIP RESR001
Packaged, Skid-Mounted Process Industrial Refrigeration Systems
January 2002
1.
Introduction
1.1
Purpose
The purpose of this Practice is to specify requirements for packaged, skid-mounted
industrial process refrigeration systems.
1.2
2.
Scope
1.2.1
This Practice, along with the data sheet, appendix, and referenced
attachments, defines the minimum requirements for the performance, design,
fabrication, testing, inspection, and preparation for shipment of packaged,
skid-mounted process refrigeration systems. This Practice is not intended to
cover commercial or absorption chiller systems.
1.2.2
The refrigeration package shall provide liquid refrigerant to its chiller(s)

(evaporator[s]) in the quantity and at the temperature necessary to produce
the specified process temperature and refrigeration duty.
1.2.3
The refrigeration system shall consist of a complete package with all

components (compressor, evaporator, condenser, driver, etc.) factory
mounted, piped, and wired.
1.2.4
A single skidded system is preferred. Multiple baseplates designed to

facilitate shipping shall not be acceptable unless written approval is received
from purchaser.
References
Applicable requirements in the latest edition (or the edition indicated) of the following PIP
Practices, codes and standards, and regulations shall be considered an integral part of this
Practice. Short titles will be used herein when appropriate.
2.1
Process Industry Practices (PIP)

PIP ELSMT01 - AC Squirrel Cage Induction Motors (200 HP and below up to
600 Volts)
PIP ELSMT02 - General Purpose Application of API 541 Form-Wound
Squirrel Cage Induction Motors 250 HP and Larger
PIP RESE003 - Application of General Purpose Non-Lubricated Flexible
Couplings
PIP VECV1001 - Vessel/S&T Heat Exchanger Design Criteria, ASME Code
Section VIII, Divisions 1 and 2
PIP VEDST003 - Shell and Tube Heat Exchanger Specification Sheet
PIP VEFV1100 - Vessel/S&T Heat Exchanger Standard Details
PIP VESSM001 - Specification for Small Vessels and Heat Exchangers with
Limited Design Conditions
Page 3 of 26
PIP RESR001
January 2002
PIP VESV1002 - Vessel/S&T Heat Exchanger Fabrication Specification,

ASME Code Section VIII, Divisions 1 and 2
2.2
Industry Codes and Standards

American Petroleum Institute (API)
API Std 611 - General Purpose Steam Turbines for Petroleum, Chemical, and
Gas Industry Services
API Std 612 - Special Purpose Steam Turbines for Petroleum, Chemical, and
Gas Industry Services
Air Conditioning and Refrigeration Institute (ARI)
ARI 520 - Positive Displacement Condensing Units
American Society of Heating, Refrigerating and Air Conditioning Engineers
(ASHRAE)
ASHRAE 15 - Safety Code for Mechanical Refrigeration
American Society of Mechanical Engineers (ASME)
ASME Boiler and Pressure Vessel Code
Section VIII, Div.1 - Pressure Vessels
ASME B31.3 - Chemical Plant and Petroleum Refinery Piping
ASME B31.5 - Refrigeration Piping
American Welding Society (AWS)
AWS D1.1 - Structural Welding Code
National Fire Protection Association (NFPA)
NFPA 70 - National Electrical Code (NEC)
2.3
Government Regulations
U.S. Department of Labor, Occupational Safety and Health Administration
(OSHA)
OSHA 29 CFR 1910 - Occupational Safety and Health Standards
3.
General
3.1
Vendor submitting the bid shall assume full responsibility for the complete, as
shipped, unit.
3.2
Subvendors and subcontractors used by vendor shall be subject to written approval

by purchaser before placement of suborders.
3.3
A qualified project engineer shall be named and assigned by vendor. Such engineer
shall coordinate the project and serve as sole contact with purchaser from issuance of
purchase order through completion of startup and commissioning.
3.4
The system shall be suitable for 4 years continuous operation.
Page 4 of 26
PIP RESR001
January 2002
3.5
4.
5.
Performance, capacity, and operating conditions are as indicated on attached process

data sheet.
System
4.1
The refrigeration system shall be designed to operate continuously at the maximum

specified refrigeration duty with no negative tolerance. The system shall also be
capable of stable operation at reduced loads, including no load operation at startup
(if specified).
4.2
Rating condition used to establish the capacity of the refrigeration package system
shall be included in the proposal. System-rated capacity shall be determined by the
purchasers specified performance data on PIP RESR001 Data Sheet.
4.3
Refrigeration packages shall be completely assembled at the factory before shipment.

Items to be disassembled for shipment shall be detailed in the proposal.
4.4
Unless specifically approved in writing by purchaser, no substitution for material,

equipment, or components shall be made.
4.5
Storage capacity for refrigerant receiver shall be sufficient to retain the entire system
refrigerant inventory when 90% full, including the volume of purchaser-furnished
heat exchangers and piping when applicable. Purchaser shall provide piping and
exchanger refrigerant volumes when they impact receiver sizing.
4.6
Fluorocarbon systems shall have a replaceable-element desiccant filter dryer with

visual moisture indication. Element shall be replaceable while system is in operation.
4.7
System refrigerant shall be supplied by purchaser unless otherwise specified.
4.8
The refrigeration system high-pressure side maximum allowable working pressure

(MAWP) shall be greater than the condensing pressure by at least 25 psi or 110%,
whichever is greater. In addition, the system (low pressure and high pressure)
MAWPs shall be at least 50 psi greater than the refrigerant vapor pressure at the
maximum specified ambient temperature.
4.9
Unless otherwise specified on the data sheet, the system and all auxiliaries shall be
designed for unprotected outdoor installation.
4.10
The refrigeration system shall be designed for the area electrical classification as
specified on the data sheet.
4.11
Any special tools required for operation and/or maintenance shall be provided.
Compressors
5.1
General
5.1.1
The system shall have proper equipment to ensure that liquid does not enter
the compressor suction. Equipment supplied for this purpose shall be
detailed in the proposal.
Page 5 of 26
PIP RESR001
January 2002
5.2
5.1.2
Vendor shall provide the type of compressor most suited for this specific
application unless purchaser has specified a desired compressor type on the
data sheet.
5.1.3
Compressor(s) shall be provided with seals to prevent the loss of refrigerant

or the contamination of refrigerant over the range of operating conditions
and during periods of idleness. Seal operation shall be suitable for variations
in suction conditions that may prevail during startup and shutdown. Vendor
shall provide a description of the seal system and the guaranteed refrigerant
leakage rate with the proposal.
5.1.4
Complete compressor casing, including all welded connections (unless

otherwise approved by purchaser), shall be hydrostatically tested to 1.5 times
the maximum case design pressure or pneumatically tested at 1.1 times the
maximum case design pressure. The test shall be maintained for a sufficient
period of time to permit complete examination of parts under pressure.
Certified test results shall be submitted to purchaser.
5.1.5
Cast iron and ductile iron pressure-containing parts shall not be used for
rotary and centrifugal compressors that handle flammable refrigerants.
5.1.6
Compressor inlet pressure shall be greater than atmospheric pressure when

flammable refrigerants are used.
5.1.7
Compressors shall conform to ASHRAE 15.
5.1.8
If multiple compressors are to be used, isolation valves and controls shall be

provided that allow for the operation of the system with the remaining
compressors when one or more is out of service.
Reciprocating Compressors
5.2.1
The compressor(s) may be open, semi-hermetic, or hermetic as specified on

the PIP RESR001 Data Sheet.
5.2.2
Compressors shall have a method to prevent liquid refrigerant accumulation

in the crankcase when compressor is unloaded or idle with the system under
pressure. The method and equipment provided for this purpose shall be
detailed in the proposal.
5.2.3
If flooded evaporator is used in refrigeration cycle, the compressor(s) shall

have the following features:
1. Automatic control from temperature- or pressure-sensing elements
2. Crankcase heater energized during off cycles
3. An automatic solenoid to close liquid line when compressor is stopped
4. A solenoid valve to shut off cooling water to water-cooled compressors
when compressor is stopped
5.2.4
Page 6 of 26
The compressor shall have a discharge muffler if required to meet noise

limits specified on the PIP RESR001 Data Sheet.
PIP RESR001
January 2002
5.2.5
Layout shall provide sufficient room around and above-mentioned

compressor to allow removal of cylinders from compressor frame and to
allow removal of flywheel and crankshaft.
5.2.6
Compressors below 25 hp shall have feet supplied with vibration isolation

pads.
5.2.7
Vendor shall provide a detailed description of the compressor-unloading

system in the proposal.
5.2.8
Open compressors shall be directly connected through a coupling. Drive

coupling shall be per PIP RESE003.
5.2.9
Hermetic and semi-hermetic compressors shall have the following features:

5.2.9.1 Compressors may be cooled by suction gas.
5.2.9.2 Compressors shall be accessible for maintenance.
5.2.9.3 Compressors shall conform to ARI 520.
5.2.9.4 Compressor drivers shall not require motor heaters.
5.3
5.4
Rotary Compressors
5.3.1
The compressor shall be helical rotor, screw compressor type.
5.3.2
Pipe vibration levels shall be less than 0.5 inch/sec.
5.3.3
Unit shall be oil flooded for operation with refrigerant.
5.3.4
The seal system shall be designed to positively contain the refrigerant during
operation, startup, shutdown, and periods of idleness.
5.3.5
Capacity control from full load down to purchaser-specified minimum of full

load shall be provided by internal slide valves and, if required, by hot gas
bypass that provides automatic unloading.
5.3.6
Oil separation in compressor discharge shall be vendors recommended

design for refrigeration systems.
5.3.7
Drive coupling shall be per PIP RESE003.
Centrifugal Compressors
5.4.1
The compressor(s) proposed may be open or hermetic and single or

multistage unless otherwise specified.
5.4.2
Compressor capacity control may be variable speed drive, inlet guide vanes,
suction dampers, or a combination subject to purchaser approval. The
control system proposed shall be explained and detailed in the proposal.
5.4.3
Purchaser shall provide applicable gear specification for gear boxes, if

required.
5.4.4
The compressor shall be specifically designed and manufactured for

refrigeration service.
5.4.5
Drive coupling shall be per PIP RESE003.
Page 7 of 26
PIP RESR001
January 2002
6.
Drivers
6.1
Electric Motors (Open Drive Systems)

Vendor provided electric motors shall be per PIP ELSMT01 or PIP ELSMT02, as
applicable.
6.2
Steam Turbine
If a steam turbine is specified, it shall meet requirements of API 611 or API 612, as
specified by purchaser.
7.
Heat Exchangers
7.1
7.2
General
7.1.1
System heat exchangers shall be per PIP VECV1001 and PIP VESV1002 or
PIP VESSM001, as applicable.
7.1.2
Exchangers shall be arranged such that maintenance space for tube pulling or
cleaning shall be to the outside of the skid. Space required shall be shown on
proposal drawings.
7.1.3
The condenser and evaporator shall be independent vessels.
7.1.4
The condenser and evaporator shall have a NPT 3/4 drain and vent
connection(s) on both the shell and tube sides, complete with valve and plug.
Drains shall be at the low point to allow for complete drainage.
Shell and Tube

7.2.1
Inserts or integral fin tubes may be quoted as an option.
7.2.2
Exchangers shall, as a minimum, be TEMA C unless otherwise specified by

purchaser on the PIP VEDST003 Specification Sheet.
7.2.3
Purchaser shall indicate design requirements on the PIP VEDST003

Specification Sheet. Vendor shall submit a completed PIP VEDST003
Specification Sheet with the proposal.
7.2.4
Marine water boxes shall be provided when specified on the PIP VEDST003
Specification Sheet.
7.2.5
Any exceptions to this Practice or any referenced PIP Practices, TEMA, or,
PIP VEDST003 Specification Sheet shall be provided with the proposal.
7.2.6
For systems using water as the condensing media, a regulating valve shall be
provided by the vendor if required.
Note: The system shall be designed to allow for as low a condensing
pressure as possible to utilize the lower cooling water temperatures
without throttling. Minimum condensing pressure/water
temperature shall be provided in the proposal.
Page 8 of 26
PIP RESR001
January 2002
7.2.7
7.3
7.4
If a flooded type evaporator is utilized, it shall be supplied with a full-length,

reflex type level gauge.
Direct Expansion
7.3.1
A direct expansion type evaporator, up to 100 tons, may be proposed if

approved by purchaser.
7.3.2
Direct expansion evaporators shall include a thermal expansion valve(s),

equalizing line, and back-pressure regulator.
Subcooler
Vendor shall provide design details with the proposal.
8.
Vessels
8.1
General
System vessels shall be per PIP VECV1001 and PIP VESV1002 or PIP VESSM001,
as applicable.
8.2
8.3
Receiver
8.2.1
The receiver shall be provided and sized to hold system charge when 90%
full (see Section 4.5).
8.2.2
The receiver shall have a dip tube with vortex breaker and/or adequate
submergence to prevent vortexing in the liquid outlet line.
8.2.3
The receiver shall be supplied with a full-length, reflex type sight level
gauge.
8.2.4
The receiver shall have a minimum NPS 3/4 vent and drain.
8.2.5
The receiver shall have a NPS 1 minimum refrigerant charging/evacuation

connection.
Oil Separator (Rotary Compressor Systems)

8.3.1
Mounting of the motor/compressor drive train on a horizontal oil separator

shall be limited to 800 hp driver unless otherwise approved by purchaser. If
the driver is over 800 hp, then the system shall be supplied with an
independently supported drive train.
8.3.2
Vendors design shall incorporate a method for removing oil from the dry
side of the separator.
8.3.3
Adequate access for changing/maintaining the coalescing elements shall be

provided. The coalescing elements shall be removable and replaceable.
8.3.4
The oil carryover rate shall be stated in the proposal.
8.3.5
The oil separator shall have a heater(s) that is capable of raising the oil
temperature from minimum ambient temperature to minimum allowable
starting temperature within 12 hours maximum. Any requirements for
Page 9 of 26
PIP RESR001
January 2002
insulating the separator to meet this requirement shall be detailed on review

drawings.
8.4
8.3.6
The oil separator shall have a removable and replaceable heater(s).
8.3.7
If multiple compressors are used, then each shall have an individual

discharge line into the separator.
8.3.8
The separator shall have a low-oil-level switch interlocked to turn the

heater(s) off when oil level is low.
8.3.9
The oil separator shall have reflex type or bulls-eye type level gauges.
Oil Recovery Pots (Reciprocating or Rotary Compressor)

8.4.1
Oil recovery systems shall be provided with the following features as a

minimum:
1. Reflex level gauge or bulls-eye (sight glass)
2. An oil still/receiver with a thermostatically controlled electric heater
for flashing liquid refrigerant. (Minimum liquid level shall be
maintained above heating elements while energized.)
3. A solenoid-operated feed valve to automatically charge oil to the
recovery system when the heater is energized
4. Oil recovery piping from recovery pot to compressor suction
8.4.2
8.5
Page 10 of 26
Recovery pots shall be per PIP VECV1001 and PIP VESV1002 or

Suction Knockout Drum

8.5.1
A suction knockout drum shall be provided.
8.5.2
On direct expansion units, the system shall be supplied with a suction trap to
prevent liquid from entering the compressor. The trap shall be arranged for
automatic draining.
8.5.3
On flooded or thermosyphon evaporator units, the evaporator shall be

equipped with an integral surge drum to provide for complete separation of
liquid and gas.
8.5.4
Vendor shall provide design details of the suction knockout drum. Details
shall include mesh pad sizing (if applicable) and boil-out coil (if applicable).
8.5.5
Vendor shall state sizing criteria in the proposal.
8.5.6
Vendor shall provide a high-liquid-level shutdown switch as a minimum.
8.5.7
Vendor shall provide a liquid-level indicator.
8.5.8
Suction knockout drums shall be per PIP VECV1001 and PIP VESV1002 or
PIP RESR001
January 2002
8.6
9.
Economizer (If Provided)

8.6.1
Vendors may include an economizer. The proposal shall describe the system
and state efficiencies and any additional costs associated with the
economizer.
8.6.2
Vendor shall provide design details with the proposal.
8.6.3
If used for a screw compressor application, a pressure-regulating device shall

be provided to prevent exceeding the vessel minimum design temperature
during low-load operation.
8.6.4
A high-liquid-level shutdown switch shall be included on the economizer.
8.6.5
Vendor shall provide a level indicator on the economizer.
8.6.6
Economizers shall be per PIP VECV1001 and PIP VESV1002 or

Oil System
9.1
9.2
General
9.1.1
Vendor shall provide a pressurized lubrication system(s) that will supply oil
at pressure(s) and temperature(s) to bearings, seals, and controls as required.
9.1.2
The system shall be per vendors standard unless otherwise noted on

purchasers data sheet.
9.1.3
If a water-cooled oil cooler(s) is required, it shall be per PIP VESSM001 and

TEMA C, and the materials of construction shall be as stated for the
refrigerant condenser. The oil cooler(s) shall be piped and in place within the
packaged unit.
9.1.4
Monitoring of the oil system shall be based on the Monitoring System

Instrumentation table in this Practice.
9.1.5
The system refrigerant may be used as the cooling medium for the oil cooler
if specified and approved by purchaser.
Pumps
9.2.1
Main and auxiliary oil pumps shall be positive displacement and shall be
rated to sustain continuous operation of the compressor. Main (if required)
and auxiliary lube oil pumps shall be provided with maintenance block
valves and discharge check valves. (Vendor shall state whether main oil
pump is included in the proposal.)
9.2.2.
Auxiliary oil pump shall be electric motor driven. Requirements for the
motor shall be specified on the PIP RESR001 Data Sheet.
9.2.3
Pump casings shall be steel or ductile iron.
9.2.4
System low-oil-pressure switch shall start auxiliary oil pump and alarm on
the local control panel.
Page 11 of 26
PIP RESR001
January 2002
9.3
Reservoir
9.3.1
If a carbon steel oil reservoir is specified, it shall be provided with the

vendors standard internal coating.
9.3.2
Reservoir shall have an oil heater and temperature control capable of

increasing the oil temperature from minimum ambient temperature to
minimum starting temperature within 12 hours maximum.
9.3.3
Lube oil heaters shall be thermostatically controlled, stainless steel,

sheathed, and shall have a maximum watt density of 15 watt/inch.2
9.3.4
Reservoir shall have the following features:

1. An oil-level indication device
2. A mounted low-point drain valve
3. A temperature gauge
4. An air eductor or motorized oil mist demister (Any requirements for the
motor shall be specified on the data sheets.)
5. A removable cover plate for inspection and cleanout
9.3.5
9.4
9.5
Stand alone (non-oil separator) reservoir retention time shall be 3 minutes

minimum for centrifugal compressors.
Piping/Valves
9.4.1
Stainless steel tubing shall be used for lines NPS 1-1/2 or smaller.
9.4.2
Lubrication oil system piping shall be welded and shall conform to

ASME B31.3. Slip-on flanges are acceptable.
9.4.3
Piping and tubing downstream of the oil filter shall be stainless steel. Carbon
steel piping upstream of the filter is acceptable.
9.4.4
Piping/tubing shall have a leak-free design that uses flanges and/or leak-free
tubing fittings. Use of threaded connections shall be minimized. Piping,
tubing, and flanges shall be proven leak-free per Section 22 of this Practice.
9.4.5
Pressure relief valves shall be made of cast steel as a minimum.
9.4.6
Oil pump discharge lines shall have check valves.
9.4.7
Each oil pump discharge line shall have a separate pressure relief valve.
9.4.8
Oil drain lines shall run no more than half full.
Filters and Cooler

9.5.1
The lubrication oil system shall have the following features:

1. Dual, 10-micron oil filters. The filter arrangement shall include valves
that allow element changeout while system is in operation. Filterhousing vents and drains shall be included.
2. A single oil cooler, unless otherwise specified on the PIP RESR001
Data Sheet
Page 12 of 26
PIP RESR001
January 2002
3. A self-contained, thermostatically controlled oil temperature control

valve that bypasses oil for temperature control
9.5.2
Materials of construction for filters and valve bodies shall be carbon steel
unless otherwise specified.
9.5.3
Filters shall have a removal efficiency of 99.97% at 10-micron absolute

capability.
9.5.4
Lube oil cooler shall have the following features:

1. A fixed tubesheet bundle with water in the tube side
2. An average wall thickness of 18 BWG minimum
3. Materials of construction as stated for the condenser. Fouling factor
shall be the same as that used for the condenser.
9.5.5
9.6
Filters and coolers shall be in accordance with PIP VESSM001.
Lubrication System Tests

9.6.1
Lubrication system shall be given a functional test, including a test of the

control panel and all electrical circuits. Vendor shall describe the standard
system functional test in the proposal.
9.6.1.1 Vendor shall describe the standard oil system cleanliness test in the
proposal.
9.6.1.2 As a minimum, after the lubrication oil system is clean, it shall be
given a cleanliness test consisting of circulating the lubrication oil
for a minimum of 1 hour through test screens or filters. Compressor
and bearings shall be bypassed during oil system run test.
9.6.1.3 There shall be no surface evidence (either visible or tactile) of scale,
rust, metal shavings, or sand in the lubrication oil filters.
9.6.1.4 The lube oil functional and cleanliness tests shall be performed
when the skid is complete, but before painting the system. Purchaser
shall be notified 1 week before tests so that purchasers
representative may witness the tests.
9.6.1.5 Purchasers representative may perform a final inspection before
shipment.
10.
Purge System
10.1
Systems operating below atmospheric pressure shall have a high-efficiency

automatic purge system. The purge system shall continuously remove noncondensable gas from the refrigerant.
10.2
Refrigerant shall be returned to the system. Non-condensables shall be vented to

purchasers vent system.
10.3
Vendor shall detail the purge system including a description of all associated
instrumentation, controls, and valves in the proposal.
Page 13 of 26
PIP RESR001
January 2002
11.
System Instrumentation and Controls

11.1
Controls
11.1.1 System shall be furnished with operating and safety controls for automatic
operation of the system. A complete list of all instrumentation to be supplied
by vendor shall be provided with the proposal.
11.1.2 Minimum required indications, alarms, and shutdowns shall be provided as
listed below and as identified on purchasers Monitoring System
Instrumentation table. Vendor shall provide any additional instrumentation
required for safe operation. A complete description of all instrumentation,
including manufacturer and model, shall be provided in the maintenance
manuals.
11.1.3 Vendor shall provide a description of the method of system capacity control
in the proposal.
11.1.4 System monitoring and control shall be provided by a single skid, locally
mounted microprocessor control panel.
11.1.5 Microprocessor control shall have the following features:
1. Graphic display with English units unless otherwise specified
2. First-out annunciation freeze screen display with manual reset
3. Battery back-up to maintain set-points during periods of no power
4. Common alarm contacts for connection to purchasers remote alarm
5. Alarm and shutdown contacts energized to close and fail open
6. Capability of two-way communication with purchasers distributed
control system (DCS) or other microprocessors when specified
7. Save program memory for restart after power failure
11.1.6 The operating capacity control signal shall be taken from the
chiller/evaporator process outlet temperature, the compressor suction
pressure, or as specified.
11.1.7 For centrifugal and screw compressor systems, control signal shall vary
refrigeration capacity in stepless, continuously variable mode to
automatically match process load demand.
11.1.8 Critical system variables for purchaser trend monitoring shall be
recommended by vendor.
11.2
Instruments
11.2.1 General Instrument System Design
Page 14 of 26
11.2.1.1
Pressure gauges shall have isolation valve with vent valve for
maintenance.
11.2.1.2
Compressor-mounted pressure gauges shall be oil filled,

shatterproof, and blowout back.
PIP RESR001
January 2002
11.2.1.3
Temperature elements shall be mounted in stainless steel

thermowells.
11.2.1.4
Level gauges shall have armored, external reflex gauge glass with
gauge cocks and ball checks.
11.2.1.5
Switches and transmitters shall be hermetically sealed.
11.2.1.6
Instrument tubing shall be seamless, 316 stainless steel with

stainless steel fittings and valves.
11.2.1.7
Vendors standard instrument numbering system shall be used

unless otherwise specified by purchaser.
11.2.1.8
All instruments shall be supplied with a permanently attached

stainless steel tag engraved with tag number, model number,
serial number, electrical enclosure classification, and materials of
construction.
11.2.1.9
Instruments shall be located and installed such that accuracy and

reliability are not impaired by vibration, pulsation, temperature,
or contamination. Length of impulse lines connected to process
pipelines or equipment shall be minimized.
11.2.1.10 Process transmitters shall be used preferentially to process

switches (e.g., level, flow, pressure temperature, etc.). Use of
switches requires purchaser approval. Nominal working pressure
shall be between 30% and 70% of scale range, and maximum
work pressure shall not exceed the scale range.
11.2.1.11 Temperature-sensing devices shall be mounted in thermowells
except in applications such as machinery bearings (e.g.,
compressor bearings) and skin temperature measurement. Where
practical, thermowells shall be installed in a piping elbow pointed
toward the flow.
11.2.1.12 Pneumatic instruments shall normally operate with a nominal
20 psig air supply and with 3 to 15 psig input and output signals.
Each pneumatic instrument shall have an individual air supply
complete with shutoff valve and air set (air filter/regulator with
output gauge). Pneumatic instruments shall fail-safe on supply
failure.
11.2.2 General System Requirements Regarding Signal and Power
Wiring
11.2.2.1
All electrical and electronic equipment and circuits for

instrumentation shall be designed and certified for the electrical
classification in which they are to be installed. All instruments
and related electrical components shall be UL/FM and/or CSA
approved.
11.2.2.2
The entire instrumentation system shall be fully wired to junction

boxes or control panel. Wiring shall be appropriately labeled to
identify instrument to which it is associated. Junction boxes shall
Page 15 of 26
PIP RESR001
January 2002
be located at the skid limits for easy access unless specified

otherwise by the purchaser.
11.2.2.3
Electrical power wiring (AC) shall be clearly labeled and

physically separated (e.g., separate conduit) from low-voltage
(DC) wiring.
11.2.2.4
AC and DC power wiring shall be a minimum of 14 AWG copper

THHN/THWN 600-volt rated.
11.2.2.5
Single conductor panel wiring used for AC and DC signals shall

be 18 AWG minimum size, 7-strand copper construction and have
90C insulation suitable for DC circuits in accordance with NEC
Article 310-13.
11.2.2.6
Wiring from junction boxes to individual instruments shall be

shielded twisted pair or triad 16 AWG minimum in conduit.
11.2.2.7
Each instrument shall have a disconnecting means for removal of

power source. Wiring shall be designed and installed to allow the
removal of any single device without affecting another device.
Wiring and conduits shall dead-end at each device.
11.2.2.8
Terminal strips in junction boxes and local panels shall have

connections external to the panel on one side and internal panel
connections on the other side and shall be consistent throughout
the skid.
11.2.2.9
Vendor shall provide opening(s) and designated space for wire

and tubing that will be installed after package arrives at site. Field
installation shall not require cutting holes in panel or installing
hardware inside the panel to secure purchaser-installed wire and
tubing. All panel openings shall be plugged for shipment to
prevent water or dirt from entering during shipment and storage
before installation.
11.2.2.10 Rigid conduit and piping shall not be routed over the cases of
rotating machinery (or other equipment) and shall not be routed
over or in front of removable heads on vessels and exchangers or
where they impair the functionality of inspection openings or
panel doors. Drains shall be installed at low points, or a drip loop
with a low-point drain shall be used to prevent water from
draining down the conduit system into an instrument or enclosure.
11.2.2.11 Conduits shall be liquid-tight. Flexible conduits shall be used for
any rotating equipment and may be as long as 18 inches. Conduits
that are greater than 18 inches shall be rigid.
11.2.2.12 Power and instrument wiring shall be run in separate conduits and
shall be terminated in separate boxes.
11.2.2.13 Control, instrument, and electrical terminations shall be made
only on labeled terminal strips.
11.2.2.14 Conduit seals shall not be poured by skid supplier.
Page 16 of 26
PIP RESR001
January 2002
11.2.3 Documentation Requirements
11.3
11.2.3.1
Vendor shall provide a schedule of all purchasers

instrumentation connections. The schedule shall include size,
type, and location of all pneumatic and electrical connections.
Instruments that require field installation and items that are
shipped loose shall be identified on the schedule, drawings, and
packing list.
11.2.3.2
Vendor shall include ISA or purchaser-supplied specification

sheets for all instruments. Information included on specification
sheets shall include calibrated ranges of instruments, set points
for alarm and trip switches, and control valve sizing calculations.
11.2.3.3
Vendor shall provide control logic details and associated

programming when the vendor provides the unit controls. These
details shall include unit fail-safe action in the event of an
instrument or related component failure.
11.2.3.4
Vendor shall provide an estimate of total air and electric power

consumption required for both normal and upset conditions.
Rotary Compressor Control and Instrumentation

11.3.1 Vibration detectors, when specified, shall be externally mounted.
11.3.2 Bearing temperature probes, when specified, shall be sealed and suitable for
casing differential pressure.
11.3.3 The control system shall be electronic.
11.3.4 Condition monitoring shall operate on dual level of alarm and shutdown.
11.3.5 Any special control and monitoring instrumentation required because of use
of rotary screw compressor shall be provided as part of package.
11.4
Centrifugal Compressor Control and Instrumentation

11.4.1 Compressor capacity control shall be accomplished by the most efficient
means to meet system requirements.
11.4.2 Capacity control method shall be detailed in the proposal.
11.4.3 Centrifugal compressors shall have automatic surge control system. Flow
shall not be controlled by throttling of condenser cooling water.
11.4.4 Compressor motor overload shall override process set point to operate inlet
guide vanes to prevent motor overload.
11.4.5 Compressors shall have two vibration probes in the x-y position adjacent to
each radial bearing and shall have two axial position probes on the rotor
shaft if specified on the data sheet.
11.4.6 Thermocouples or RTDs shall measure bearing temperature at each radial
bearing and in thrust bearings, if specified. Temperature indication shall be
by vendor in the microprocessor control panel.
Page 17 of 26
PIP RESR001
January 2002
12.
13.
Control Panel
12.1
The control and monitoring panel shall be mounted on the driveline skid unless
otherwise specified.
12.2
The panel shall be stainless steel and shall meet the requirements of the area
classification. Panel shall be NEMA 4X as a minimum.
12.3
All pressure tubing and control wiring to sensing points shall be completed by
vendor.
12.4
Panel penetrations shall have bulkhead fittings.
12.5
Each terminal strip shall have 20% spare terminals for purchaser connections.
12.6
Process fluids and lube oil shall not be allowed into panel.
12.7
Panel-mounted gauges, indicators, and switches shall each be labeled for function
with engraved labels having black letters that are at least 3/8 inch tall on white
background. Labels shall be attached with stainless steel screws or rivets.
12.8
A manual pushbutton or keypad shall initiate an automatic startup sequence.
12.9
The control panel shall have low-watt-density space heaters, if required. Space
heaters shall maintain instrument manufacturers recommended minimum
temperature inside the cabinet at specified minimum site temperature.
12.10
Pressure transducers or transmitters and differential pressure transmitters that can be

calibrated in the field shall be provided.
Electrical
13.1
General
13.1.1 Motor starters and disconnects shall be provided by purchaser and installed
in remote motor control center (MCC).
13.1.2 Two diagonally opposite ground lugs on each skid shall be provided for
purchaser connection to facility grounding.
13.1.3 A hermetic compressor shall be wired at the factory with starting equipment
selected to match motor and system requirements of vendor.
13.2
Wiring and Terminations

13.2.1 Electrical terminations shall be made only on labeled terminal strips.
13.2.2 Electrical wiring interconnecting with purchasers system shall be run to a
common junction box located at skid edge.
13.2.3 Power and instrument wiring shall be run in a separate conduit and
terminated in separate boxes.
13.2.4 Liquid-tight, flexible steel conduit as long as 18 inches may be used. Lengths
greater than 18 inches shall be in a rigid conduit.
13.2.5 Low-point conduit drains shall be provided.
Page 18 of 26
PIP RESR001
January 2002
14.
15.
Pipe, Valves, and Fittings

14.1
Fluorocarbon-based refrigerant system piping and valves shall conform to

ASME B31.5 and ASHRAE 15.
14.2
Hydrocarbon and ammonia-based refrigerant systems shall be per ASME B31.3.
14.3
Threaded connections in refrigerant service shall not be larger than NPS 3/4.
14.4
Threaded connections shall be limited to instrumentation connections and

compressor casing oil connections NPS 1/2 and smaller.
14.5
Vent and drain connections or valves shall be socket-weld by threaded and have
plugs or blinds of the same material as the connection or valve.
14.6
Individual system components shall have isolation and vent valves to permit
maintenance with minimum depressuring of the system and/or piping.
14.7
All valves shall have a stainless steel identification tag. Purchaser shall provide tag
numbers.
14.8
All refrigerant isolation valves shall be back seat design with seal caps and socketweld or flanged connections.
14.9
The allowable forces and moments for purchaser connections shall be shown on the
outline drawing by vendor.
14.10
Interconnecting piping shall be designed and installed so that maximum stress

(pressure, vibration induced, thermal, etc.) is within allowable limits for the
materials selected.
14.11
Where piping and/or equipment shall be assembled and disassembled in vendors

shop, purchaser retains the right to inspect and approve shop fit-up.
14.12
If required and approved by purchaser, vendor shall provide flexible expansion joints
to avoid excessive loads on the compressor.
14.13
The use of copper pipe and tubing shall not be acceptable without written approval
from purchaser.
14.14
Interconnecting piping between skids shall be provided by purchaser unless

otherwise specified. If vendor is supplying interconnecting piping, the piping shall be
match-marked for easy installation.
Pressure-Relieving Devices
15.1
Vendor shall supply pressure-relieving devices as required by ASME, ASHRAE 15,

and as specified by purchaser.
15.2
Vendors sizing basis as well as inlet pressure-drop calculations shall be provided for
purchasers approval.
15.3
The inlet pressure drop to the relief valve shall be calculated and shall meet
Paragraph M-7 of ASME Code, Section VIII, Division 1, Appendix M (i.e., shall be
less than 3%). In addition, for compressible fluid systems, the irreversible pressure
Page 19 of 26
PIP RESR001
January 2002
losses in the relief valve inlet piping shall not exceed 3% of set pressure based on a
flow rate equal to the relief valve ASME-rated capacity (nameplate capacity).
15.4
16.
17.
Relief valve mounting locations and inlet and outlet piping requirements for
refrigerants that are toxic or hazardous may require special design considerations to
avoid liquid accumulation or undesirable discharges to the atmosphere. In such
applications, purchaser will advise relief valve mounting locations, piping layout,
pressure drop, and maximum back pressure (for relief valves piped to a closed
system).
Insulation
16.1
Insulation shall be provided by purchaser unless otherwise specified on the

PIP RESR001 Data Sheet.
16.2
Space shall be provided for purchaser-supplied and -installed insulation system.

Careful attention to spacing for valve actuation, equipment maintenance, and other
component functionality must be maintained.
16.3
Vendor shall indicate on the system flow diagram which items shall be insulated and
shall recommended thicknesses of insulation.
Structural Steel Skids

17.1
Vendor shall provide the structural steel base upon which all system equipment shall
be mounted.
17.2
The common structural steel base shall be sufficiently rigid to provide for
satisfactory performance of the system when installed at purchasers site. Vendor
shall specify anchor points and foundation requirements.
17.3
Vertical jack bolts located next to anchor boltholes shall be provided for the
structural baseplate(s).
17.4
Vendor shall provide stainless steel shim packs for leveling of compressors and main
drives mounted on a structural steel skid. Shims shall be a minimum of 1/8 inch and
shall straddle boltholes.
17.5
Equipment shall be arranged for accessibility and ease of maintenance.
17.6
Spreader bars, if required, shall be provided by vendor.
17.7
Structural steel shall be seal welded in accordance with AWS D1.1.
17.8
Skids shall be designed for mounting on a concrete foundation.
17.9
Equipment, piping, and conduit shall not extend below the top of structural skid
beams. Piping and conduit shall not protrude beyond the outer perimeter of skid
beams.
17.10
Machined mounting blocks for compressor and driver shall be provided.
17.11
Ends of tubular steel members shall be capped and seal welded.
17.12
Horizontal alignment bolts shall be provided for driver.
Page 20 of 26
PIP RESR001
January 2002
18.
17.13
System shall be provided with lifting lugs for a minimum four-point lift.
17.14
Individual system components shall have eyebolts to facilitate lifting during

maintenance. Weights of individual components shall be provided.
17.15
Vendor shall provide a drawing that indicates system lifting points, rigging
requirements, center of gravity of each skid, and the weight at each point.
Noise
Vendor shall provide a best estimate for the noise level at a distance of 3 feet from each skid.
Where the sound pressure level exceeds PIP RESR001 Data Sheet requirements, vendor shall
include information indicating additional sound treatment required to obtain the conditions
specified.
19.
20.
Compressor Vibration and Critical Speeds

19.1
Vendor shall assume full responsibility for the performance of necessary torsional
studies and the elimination of any lateral or torsional vibrations that may affect the
operation of the system. Vendor shall be responsible for the total system including
the drive motor.
19.2
Torsional and lateral critical speeds or system resonances shall be 20% above or
below any operating speed.
19.3
Peak unfiltered vibratory velocity (with compressor installed on the vendors

baseplate and within the specified operating range) in any plane measured on the
bearing housing relative to a radial bearing shall not exceed: 0.4 inch per second for
a reciprocating compressor, 0.25 inch per second for a screw compressor, and
0.1 inch per second for the centrifugal compressor and drive motors.
Painting
20.1
Unless otherwise specified, the painting shall be the vendors standard. The proposed
paint system shall be detailed in vendors proposal.
20.2
Components that are inaccessible after fabrication shall be primed and coated with
paint acceptable for service conditions for the component before installation.
20.3
Paint systems shall be shop-applied.
20.4
Surfaces that cannot be accessed for painting after assembly shall be prepared and
primed before final assembly.
20.5
Top or final coat shall not be applied until all fabrication and assembly is complete
and all surfaces are primed in areas to be coated.
20.6
Primer(s) shall be applied the same day as surface preparation and before oxidation.
20.7
Paints and coatings shall be stored, mixed, catalyzed, thinned, and applied according
to manufacturers instructions.
Page 21 of 26
PIP RESR001
January 2002
20.8
21.
Exposed alloy equipment shall not be painted. However, alloy equipment shall be
painted before being insulated.
Inspection
21.1
Vendor Quality Requirements

21.1.1 Quality surveillance by purchasers representative of items furnished on this
order is required. The purchasers representative will contact vendor to
schedule surveillance visits.
21.1.2 Vendor will make available to purchasers representative a complete set of
approved drawings for use at the time of the surveillance activities.
21.1.3 When major components or services are obtained from subvendors,
purchasers representative shall be notified and given the option of
inspecting these items at the point of manufacture. The prime vendor shall
include purchaser surveillance and notification requirements in suborders.
The prime vendor shall arrange for approved drawings to be used by the
purchasers representative at the subvendors location.
21.1.4 Vendor or subvendors shall perform the inspections that are necessary to
ensure conformance to the purchase order specification and referenced
documents. Additional inspections of the equipment by the purchasers
representative do not relieve vendor or subvendors of responsibility for
meeting specification requirements.
21.1.5 Final release by the purchasers representative is required before shipment of
material or equipment.
21.2
Special Considerations
21.2.1 Vendor shall provide a safe work area and testing equipment for purchasers
representative.
21.2.2 The intent of purchasers surveillance activity is to monitor and audit
vendors quality control (QC) effort to assure compliance with purchase
order specification and drawings so that quality requirements are attained
and verifiable. The purchasers representative will participate and witness
surveillance activities as deemed necessary.
21.2.3 All fasteners in a pressure/process containment application that are supplied
by vendor shall conform to ASTM/ANSI standards for chemical and
physical properties. In accordance with ASTM/ANSI, the fasteners shall
bear the manufacturers symbol (stamp) and the applicable specification
grade. Any fastener found without the above-mentioned features shall be
cause for rejection.
21.3
Documentation
The following documents/records shall be made available by the vendor/subvendor
for review by the purchasers representative:
Page 22 of 26
PIP RESR001
January 2002
1. Manufacturers pressure vessel data reports

2. Certified mill test reports
3. Certification of hydrostatic/pneumatic testing, including pressures, time held,
type and location of any leaks and methods of repair; microprocessor shop
logs; and certification of compressor run test
4. Compressor assembly records
21.4
Prefabrication Meeting
A prefabrication meeting shall be held when specified on data sheet PIP RESR001D
to review all order requirements with vendors responsible personnel. Site and design
personnel are encouraged to attend.
21.5
Surveillance Schedule
The following surveillance activities shall be conducted by purchaser as a minimum:
1. Preliminary - Inspection of shop before start of fabrication
2. Intermediate - Witness hydrostatic/pneumatic tests of all pressure vessels
3. Intermediate - Inspect motor at motor vendors facility
4. Intermediate - After blast cleaning but before painting, accomplish electrical
check-out and witness functional test of all controls
5. Final - Witness mechanical run (if specified) and leak test
22.
Testing and Preparation for Shipment

22.1
Purchaser shall be notified at least 5 days before any testing, including testing of
parts or assemblies in subvendors facilities.
22.2
Purchaser reserves the right to conduct a field performance test with the participation
of the vendors representative. If this test is to be conducted, purchaser and vendor
shall agree beforehand on the acceptance criteria.
22.3
Before assembly on system skid, pressure vessels and/or heat exchangers shall be
pneumatic-tested or hydro-tested at fabrication facilities. Hydro-tested components
shall be thoroughly drained in accordance with the applicable purchase order
specifications.
22.4
After assembly, refrigerant piping shall be pressure-tested in accordance with

ASME B31.5 or ASME B31.3, whichever applies.
22.5
Compressors shall be given manufacturers standard pressure and running tests. Test
procedure shall be provided to purchaser at least 2 weeks before test.
22.6
Microprocessors shall be functionally tested.
22.7
After final assembly, oil system shall be tested by operation for 1 hour at design flow
rate. Compressor and bearings shall be bypassed during oil system run test.
Page 23 of 26
PIP RESR001
January 2002
22.8
Oil system filter and screens shall be visually inspected after test for identification of
foreign particles. Test shall not be considered accepted until no particles are visible
on the screens or are detectable by touch.
22.9
A continuity test shall be performed on all electrical circuits before final inspection.
22.10
All shutdown and safety devices, except relief valves and rupture disks, shall be
functionally tested by simulating the conditions required for actuation.
22.11
Assembled refrigeration system shall be evacuated to 2-mm Hg for a minimum of

2 hours. System shall then be sealed with the vacuum pump off, and vacuum shall
hold for a minimum of 6 hours with less than 2-mm Hg rise. If refrigeration system
fails to hold vacuum, vendor shall identify and repair leaks and shall repeat vacuum
test.
22.12
If system consists of more than one skid, each skid shall hold vacuum on the
refrigerant side as listed in Section 22.11 of this Practice.
22.13
Vacuum shall be broken with dry nitrogen, and system shall be pressurized to 15 psi
for shipment.
22.14
Pressure gauges shall be provided to monitor pressure during shipment and

placement of unit.
Page 24 of 26

January 2002
23.
PIP RESR001
Documentation
Item
With Proposal Review and Comment
1. Drawing List
2. Noise Data Sheets
3. Completed Equipment Data Sheets
4. Maintenance, Operation, and Instruction Manuals

5. Spare Parts List
6. Layout Drawings
7. Outline Drawing and Weights
!
!
8. Allowable Forces on Nozzles

9. Fill Quantities (Oil, Refrigerant, Water)
10. Exceptions to Specification
11. P&ID (Refrigerant Flow Diagram)
12. One-Line Electrical Drawing
!
!
!
13. Schematic Wiring Diagram

14. Foundation Grouting and/or Mounting Instructions
15. Instrument List
16. Material List
17. Nozzle and Piping Orientation Drawing
18. Center of Gravity (C.G.), Bolt Location
19. Field Panel Layout
20. Instrument Schematic Drawing
21. Valve List
!
!
!
!
!
!
!
!
!
26. Supervisory Per Diem Rate
!
!
!
!
!
!
!
!
!
!
!
29. Vessel and Heat Exchanger Drawings

30. Control Panel Outline
35. Instrument Data Sheet

36. Items to Be Shipped Loose
!
!
!
!
!
32. Lifting and Rigging Instructions
34. Relief Valve Calculations
!
!
!
!
!
28. Instrument IOM Manual
33. Pressure-Enthalpy Cycle Diagram
27. Special Tools List
31. Data Sheet PIP Heat Exchanger
!
!
23. Test Procedures
25. Fabrication and Delivery Schedule
!
!
22. Equipment and Accessories Catalogs, Cut Sheets
24. Quality Control Procedures
Certified
!
!
!
!
!
!
!
Page 25 of 26
PIP RESR001
January 2002
Table Monitoring System Instrumentation

Unit
Evaporator
System Instrumentation
Alarm
Shutdown
Local
Panel
Process Inlet Temperature

Process Outlet Temperature 1
High/Low
Process Inlet Pressure 2

Process Outlet Pressure 2
Level Indication
Condenser
Cooling Water Outlet Temperature 2
High
High
Low
Low
Cooling Water Outlet Pressure 2

Cooling Water Inlet Temperature 2
Cooling Water Inlet Pressure 2
Refrigerant Outlet Pressure

Refrigerant System
Compressor
Receiver Liquid Level
Dryer Moisture Content
Suction Pressure
Low
Discharge Pressure
Low
Suction Temperature
Low
Low
Discharge Temperature
High
High
Bearing Temperature
High
High
Reservoir Level
Low
Low
!
!
Vibration
Oil System
Reservoir Temperature
Pump Discharge Temperature
Low
Low
Return Oil Temperature
High
High
Cooling Water Return
High
Filter Differential Pressure
High
Low-Pressure Switch
Low
Oil Separator
Level Indication
Receiver
Level Indication
Motor (if appl.)
Bearing Temperature
High
Vibration Probes
High
Winding Temperature
!
!
Low
!
!
!
!
!
Gear Box (if appl.)

NOTES: 1) Low-process-outlet-temperature alarm and shutdown may be required to prevent freeze damage.
2) By Purchaser.
Page 26 of 26
PIP RESR001
January 2002
Appendix - Surveillance Instructions

A.1
In-Process
A.1.1
Witness hydrostatic/pneumatic test of all pressure vessels. Verify

material and thickness of tubesheets. Witness/verify tube expansion
procedures on all heat exchangers.
A.1.2
Review all mill test reports, certificates of compliance, ASME Code data
reports, microprocessor shop logs, pressure test results on vessels,
compressor assembly records, and certification of compressor run test.
A.1.3
Visually inspect all welding before painting, including baseplate, piping,

vessels, and peripherals. Spot-check piping internal diameter, where
possible, for burn through, excessive protrusion, or unremoved slag.
A.1.4. Review vendors dimensional records for the package. At discretion of

quality representative, accomplish check of critical dimensions,
including location and elevation of field connections, runout, and
alignment with compressor and drive motor.
A.2
A.1.5
Check for satisfactory results of blast cleaning per vendors standard

procedure. Ensure proper application of all pipe dope and/or joint
compound on all threaded connections and conduit before paint
application. Verify that all thermocouples, probes, and other instrument
appurtenances are adequately taped and protected from spray painting
and that small gages and panel devices are removed before painting if
they cannot be adequately protected from paint.
A.1.6
Check all bolting for proper identification and markings (see

Section 21.2.3). Replace any fasteners not in compliance with
Section 21.2.3.
A.1.7
Witness compressor mechanical run test and leak testing of the complete
system before painting.
Electrical Check-out
A.2.1
Verify panel material, type, configuration, dimensions, welds, cutting,

bolting, shaping, type of cable entry and exit door pad-locking and
hinge, access openings for field use, lifting means, workmanship, and
painting.
A.2.2
Verify type and arrangement of pushbuttons, selector switches, pilot

lights, terminal blocks, raceways, and color-coding.
A.2.3
Verify instrument model number, chart or dial range, calibration, and

specified identification tag.
A.2.4
Verify alarm operation sequence, alarm acknowledge, test, reset, horn,

alarm position description, and interdevice wiring.
A.2.5
Verify circuit and equipment ground provisions, electrical power

disconnect, padlocking, interlocking, or any other safety device. Verify
Page A-1
PIP RESR001
January 2002
that danger tag states that more than one voltage source is within the
panel, if applicable.
A.2.6
Verify guards or covers for line voltage terminations of under 250 volts
to ground; verify fully enclosed housings for terminations of 250 volts
and more to ground.
A.2.7
Verify the following:

1 Proper raceway fill
2. Correct terminal blocks
3. Wire type
4. Insulation
5. Labeling at both ends
6. Adequate space for field wiring
7. Devices wired to terminal do not have splices
8. Two conductors per terminal
9. No vendor wiring on field side of terminal blocks, tight
connections, separation of power, and signal wiring
A.2.8
Verify circuit and equipment ground provisions.
A.2.9
Verify any special features as specified in the order.
A.2.10 Verify correct tubing and piping runs, valve locations, air supply, spot
check of fittings, and tubing supports.
A.3
Motor Inspection
A.3.1
Check the dimensions of the following items, using the vendors

approved drawings:
1. Shaft diameter
2. Keyway location and key length
3. Base support
4. Size and location of base mounting holes
5. Main terminal box size and location
6. Accessory terminal box size and location
Page A-2
A.3.2
Ensure that the nameplate agrees with the specification requirements.
A.3.3
Check for correct motor rotation.
A.3.4
Check for correct bearing type and lubricant.
A.3.5
Check space heater size and voltage.
A.3.6
Check ground bolt per specification.
A.3.7
Ensure that all electrical leads are identified.
PIP RESR001
January 2002
A.3.8
Ensure that motor leads are undamaged and that compression lugs are
installed.
A.3.9
Ensure that temperature sensor and space heater leads are terminated on
terminal blocks in accordance with drawings.
A.3.10 Check the number of temperature sensors and ensure that the
temperature sensors have the correct operating temperature.
A.3.11 Identify spare temperature sensors and check all temperature sensors for
operation.
A.3.12 Ensure that airflow openings have stainless steel screens.
A.3.13 Verify proper sizing and installation of cooling fans.
A.3.14 Check shaft end float, as specified.
A.3.15 Ensure that copies of vendors standard commercial test results are
provided.
A.3.16 Ensure that shaft was stress relieved before final machining.
A.3.17 Review shipping preparations with vendor. Ensure that the motor is
mounted on a rigid skid.
A.4
Final
A.4.1
Inspect paint for proper coverage and application per specified paint
system.
A.4.2
Verify nitrogen make-up after evacuation. Unit shall be conspicuously

marked so the purchaser knows to maintain the make-up. Red
WARNING notices are to be provided on all major openings.
A.4.3
Review/check preparations for shipment, including protective covers on

all flanges, plugs, and/or caps in all openings, rust preventive on all
machined surfaces, and installation of suitable inhibitor within
electro/micro controller enclosure. Lifting points (as applicable) shall be
conspicuously marked.
Page A-3
PIP RESR001
January 2002
This page is intentionally blank.
Page A-4
RESR001D
Specification for Skid-Mounted Industrial

Process Refrigeration Systems
Data Sheet
Job No.:
Req./Spec. No.:
Item No.:
/
Purchase Order No.:

Inquiry No.:
" Purchaser
# Manufacturer
Information to be Completed by:
Applicable to:
" Proposal
" Purchase
" As Built
" For:
" Site:
" No. Req.:
" Manufacturer:
Date:
By:
Manufacturer if Not Given by Purchaser

"
"
"
#
Unit:
Service:
Type:
Model:
# Serial No.:
" MATERIALS OF CONSTRUCTION
" PROCESS CONDITIONS

Rated
Page 1 of 2
January 2002
Max
Norm
Min
Flow Rate (Lb./Hr)
Condenser
Evaporator
Channels
Tubes
Inlet Temp. (F)
Tubesheets
Outlet Temp (F)

Sp. Gravity @
Shell
Other Requirements:
Freezing Point (F)

Molecular Weight
Inlet Pressure (Psia)
Viscosity (Cp)
Specific Heat (Btu/Lb)
Thermal Conductivity (Btu/Hr-Ft-F)
Latent Heat of Vap. (Btu/Lb)
TEMA Class
Fouling Factor (Hr-Ft2-F/Btu)
Reservoir Mtrl. of Construction:
Mfg. Standard
SS
Comments:
Hazardous:
Yes
No
Flammable:
Corrosive:
Comments:
Yes
Yes
No
No
Elec. Classification: Class

Ambient Temp. Range:
Range of Rel. Humidity:
Indoor
Altitude, (Ft)
Group
Other
" OPERATING CONDITIONS

Min
Max
Design Capacity (Btu/Hr)

Percent Turndown
Upset Conditions (Btu/Hr)
" SITE CONDITIONS

Location:
CS
Capacity vs. Time (Btu/hr-Oper Hrs):

Outdoor
Division
Max (F)
Summer
Min (F)
Winter
Case 1
Case 2
Preferred Refrigerant
Operating Hr/Year
Comments:
Comments:
" NOISE CONTROL
Allowable Noise Limit
Comments:
" UTILITIES
dBA @ 3 Ft
# DESIGN DATA
Refrigerant
Capacity (tons)
Turndown to
Turndown by:
Sliding Valve
Compressor Type:
Centrifugal
Open
Discharge Muffler:
%
Valve Loaders
Screw
Hermetic
Yes
Other
Reciprocating
Other
Semi-hermetic
No
Power Reqts
Cooling Water Reqts
Comp. Air Reqts
Flow (GPM)
Press (Psig)
Inert Gas Reqts
Press (Psig)
Refrigerant Chg. Cap

Make-up Water Reqts
Steam Reqts:
Press (Psig)
Electrical Class
Utility Equivalents:
Aux. Oil Pump Reqts:
Make/Type:
Comments:
Temp (oF)
Flow (CFM)
Flow (CFM)
(Lbs.)
(GPM)
Class
Power
Water
Voltage
Temp (oF)
Group
Flow (CFM)
Division
$/BHP
$/GPM
Flow
Pressure:
Specification for Skid-Mounted Industrial

Process Refrigeration Systems
Data Sheet
Job No.:
Req./Spec. No.:
Item No.:
/
Purchase Order No.:

Inquiry No.:
RESR001D
Page 2 of 2
January 2002
Date:
By:
" INSPECTION AND SHOP TESTING
" CONDENSING MEDIA
Required
Witnessed
Pre-fabrication Meeting
Shop Inspection
Mfg. Standard Shop Tests
Vacuum Leak Test
Mechanical Run Test
Lube System Test
Vessel(s) Hydro Test
Instruments Systems Test
Condensing Media
Air
Temperature (oF)
Min
Inlet Pressure (Psia)
Max. Allowable Pressure Drop (Psi)
Max Outlet Temperature (oF)
Min/Max Velocity (FPS)
Comments:
Water
Max
" SAFETY ALARMS AND SHUTDOWN
Comments:
" INSTRUMENTATION AND CONTROLS
Voltage:
Other
Alarm
Phase:
Hertz:
Preferred Vendors List, Attached
Number of Points
Annunciator
Fist-Out
Yes
Yes
Required Alarm List Attached

Required S/D List Attached
Shutdown
High Oil Temperature

Low Oil Pressure
No
No
" LUBE OIL SYSTEM
High Refrigerant Discharge Pressure

Low Refrigerant Suction Pressure
High Refrigerant Discharge Temperature
High Suction Trap Liquid Level
Motor Overload (Signal by Purchaser)
Comments:
Mfg. Standard
API 614
Dual Oil Coolers
Other
" MONITORING
Centrifugal Compressor:
Comments:
Radial
" DRAWING AND DATA REQUIREMENETS

Drawings and Data Requirements Per Section 23
and Attached:
Yes
Include Timeline:
Yes
Comments:
Temperature
No
No
Rotary Compressor:
Vibration Detection
" DRIVER INFORMATION

Drive Type:
Motor Volts/Phase/Hz:
Direct
/
/
Temperature Detection
Belt Driven
Encl.
Gear Service Factor:
AGMA Ratio:
Forced Lube System?

Comments:
Cooling Water Reqd?
Temperature Axial
Comments:
" PRESSURE/TEMPERATURE INDICATIONS
Pressure and Temperature Indications per Section 23
and Attached:
Yes
# COUPLINGS
Mfg.
No
Comments:
Model
" SAFETY VALVES
Type
Low Speed
High Speed
Main/Aux Oil Pump
By Purchaser
By Mfg.
Comments:
Other
by Purchaser
Charged
Dry
W
Per ANSI B9.1

ASME UG135, App M-7
Sizing per
Preferred Mfg.
" ACCESSORIES
# MISCELANEOUS
Paint:
Mfg. Standard
Insulation:
by Mfg.
Total System Weight:
Maximum Component Weight:
Approximate Floor Space:
L
Maintenance Space Required:
Comments:
3
Axial
Vibration
Purge Unit
Filter Dryer with Indication
Other (Describe Below)
Comments:
Economizer
2
1
REV
DATE
REASON FOR REVISION
BY
CHECK
APPROVED

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EDITORIAL REVISION/TECHNICAL REVISION

Process Industry Practices

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

Process Industry Practices (PIP), Construction Industry Institute, The

EDITORIAL REVISION/TECHNICAL REVISION

Process Industry Practices

Process Industry Practices

7. Heat Exchangers ......................... 8

9. Oil System .................................. 11

10. Purge System ............................13

RESR001D - Specification for SkidMounted Industrial Process

12. Control Panel ............................18

14. Pipe, Valves, and Fittings.........19

Vendor Quality Requirements ..........22

22. Testing and Preparation for

Process Industry Practices

EDITORIAL REVISION/TECHNICAL REVISION

The refrigeration package shall provide liquid refrigerant to its chiller(s)

The refrigeration system shall consist of a complete package with all

A single skidded system is preferred. Multiple baseplates designed to

Process Industry Practices (PIP)

Process Industry Practices

PIP VESV1002 - Vessel/S&T Heat Exchanger Fabrication Specification,

Industry Codes and Standards

Subvendors and subcontractors used by vendor shall be subject to written approval

The system shall be suitable for 4 years continuous operation.

Process Industry Practices

EDITORIAL REVISION/TECHNICAL REVISION

Performance, capacity, and operating conditions are as indicated on attached process

The refrigeration system shall be designed to operate continuously at the maximum

Refrigeration packages shall be completely assembled at the factory before shipment.

Unless specifically approved in writing by purchaser, no substitution for material,

Fluorocarbon systems shall have a replaceable-element desiccant filter dryer with

System refrigerant shall be supplied by purchaser unless otherwise specified.

The refrigeration system high-pressure side maximum allowable working pressure

Process Industry Practices

Compressor(s) shall be provided with seals to prevent the loss of refrigerant

Complete compressor casing, including all welded connections (unless

Compressor inlet pressure shall be greater than atmospheric pressure when

Compressors shall conform to ASHRAE 15.

If multiple compressors are to be used, isolation valves and controls shall be

The compressor(s) may be open, semi-hermetic, or hermetic as specified on

Compressors shall have a method to prevent liquid refrigerant accumulation

If flooded evaporator is used in refrigeration cycle, the compressor(s) shall

The compressor shall have a discharge muffler if required to meet noise

Process Industry Practices

EDITORIAL REVISION/TECHNICAL REVISION

Layout shall provide sufficient room around and above-mentioned

Compressors below 25 hp shall have feet supplied with vibration isolation

Vendor shall provide a detailed description of the compressor-unloading

Open compressors shall be directly connected through a coupling. Drive

Hermetic and semi-hermetic compressors shall have the following features:

The compressor shall be helical rotor, screw compressor type.

Pipe vibration levels shall be less than 0.5 inch/sec.

Unit shall be oil flooded for operation with refrigerant.

Capacity control from full load down to purchaser-specified minimum of full

Oil separation in compressor discharge shall be vendors recommended

Drive coupling shall be per PIP RESE003.

The compressor(s) proposed may be open or hermetic and single or

Purchaser shall provide applicable gear specification for gear boxes, if