(5) pq questionnaire part iii gs & gc system 1 july 2014

35
8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014 http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 1/35  Page 1 of 35  Tech: GS & GC System  –  July 2014 KUWAIT OIL COMPANY (K.S.C.) PRE-QUALIFICATION QUESTIONNAIRE CATEGORY: GAS SWEETENING GAS COMPRESSION SYSTEM  ___________________________________________________________________________________ TECHNICAL SECTION  –  PART III Subcategory A: GAS Sweetening System Complete the following questionnaire relating to your current Technical, Manufacturing and other related facilities. (If space provided is insufficient, attach additional sheets) 1. SPECIALISATION: 1.1 Confirm that your present ability and field of specialisation includes:  Pre-Engineered Package [ ] YES [ ] NO  Manufacturing [ ] YES [ ] NO  Assembling/Packaging [ ] YES [ ] NO  FAT Inspection & Testing [ ] YES [ ] NO  Installation & pre-Commissioning [ ] YES [ ] NO  Supply & Delivering [ ] YES [ ] NO  Commissioning & Performance Testing [ ] YES [ ] NO  Operation & Maintenance [ ] YES [ ] NO 1.2 Confirm if your main line of field of specialisation (manufacture/assembling/packaging/ business) is: a) Pumps: i.  Pump [ ] YES [ ] NO ii. w/ Driver (see b below) [ ] YES [ ] NO  b) Driver (Gas Engine/ Electric Motor) i. Gas Engine [ ] YES [ ] NO ii. Electric Motor [ ] YES [ ] NO iii. Gas Turbine [ ] YES [ ] NO c) Sulfur Recovery Unit (SRU) [ ] YES [ ] NO d) Acid Gas Disposals (Incinerators) [ ] YES [ ] NO e) Tail Gas Treatment Unit (TGTU) [ ] YES [ ] NO f)  Sulfur Handling Systems [ ] YES [ ] NO g) Pressure Vessels (e.g. Absorbers, Columns & Towers) [ ] YES [ ] NO

Upload: 2904

Post on 07-Aug-2018

213 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 1/35

 

Page 1 of 35  Tech: GS & GC System  –  July 2014

KUWAIT OIL COMPANY (K.S.C.)PRE-QUALIFICATION QUESTIONNAIRE

CATEGORY: GAS SWEETENING GAS COMPRESSION SYSTEM 

___________________________________________________________________________________

TECHNICAL SECTION – 

 PART IIISubcategory A: GAS Sweetening System

Complete the following questionnaire relating to your current Technical, Manufacturing

and other related facilities.

(If space provided is insufficient, attach additional sheets)

1.  SPECIALISATION: 

1.1  Confirm that your present ability and field of specialisation includes:

  Pre-Engineered Package [ ] YES [ ] NO

  Manufacturing [ ] YES [ ] NO

  Assembling/Packaging [ ] YES [ ] NO

  FAT Inspection & Testing  [ ] YES [ ] NO

  Installation & pre-Commissioning [ ] YES [ ] NO

 

Supply & Delivering [ ] YES [ ] NO

  Commissioning & Performance Testing [ ] YES [ ] NO

  Operation & Maintenance [ ] YES [ ] NO

1.2  Confirm if your main line of field of specialisation(manufacture/assembling/packaging/ business) is:

a)  Pumps:

i. 

Pump [ ] YES [ ] NOii.  w/ Driver (see b below) [ ] YES [ ] NO

 b)  Driver (Gas Engine/ Electric Motor)

i.  Gas Engine [ ] YES [ ] NO

ii.  Electric Motor [ ] YES [ ] NO

iii.  Gas Turbine [ ] YES [ ] NO

c)  Sulfur Recovery Unit (SRU) [ ] YES [ ] NO

d)  Acid Gas Disposals (Incinerators) [ ] YES [ ] NO

e)  Tail Gas Treatment Unit (TGTU) [ ] YES [ ] NO

f) 

Sulfur Handling Systems [ ] YES [ ] NOg)  Pressure Vessels (e.g. Absorbers, Columns & Towers) [ ] YES [ ] NO

Page 2: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 2/35

 

Page 2 of 35  Tech: GS & GC System  –  July 2014

h)  Air Cooler/ Fin-Fan Coolers [ ] YES [ ] NO

i)  Regeneration / Chillers (Heat Exchanger-Shell & Tube) [ ] YES [ ] NO

 j)  Complete System (incl. Structural Steel Skids) [ ] YES [ ] NO

1.3 Confirm the list of “Main / Typical / Standard / Pre-engineered” Supplied Skid-

mounted Modules indicating its Major Equipment or Long Lead Items.

1.4 Please outline the Modules Assembling Procedure /framework / Workflow

1.5 Please specify available Delivery Options:

a.  EX Works

 b.  FOB

c.  CIF-Kuwait Port

2.  MAJOR EQUIPMENT / LONG LEAD ITEM DETAILS

State the type/types of Major Equipment / Long Lead Items (LLIs)

details normally supplied within your Modules/ Packaged for which

 pre-qualification is sought:

2.1  PUMP(S)

2.1.1  Centrifugal Pumps (Thick in the appropriate box)

2.1.1.1  Horizontal

a) Single stage (volute) [ ]

 b) Multistage [ ]

c) End suction [ ]

2.1.1.2  Vertical

a) Non-clog [ ]

 b) Sump [ ]

c) Vertical turbine/canister [ ]

d) Submersible [ ]

2.1.1.3  Large Vertical [ ]

2.1.1.4  Self-priming  [ ]

2.1.1.5  High Pressure [ ]

2.1.1.6  Others:(specify the

type):_____________________ [ ]

Page 3: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 3/35

 

Page 3 of 35  Tech: GS & GC System  –  July 2014

2.1.2  Rotary Pumps

a) Screw (single rotor) [ ]

 b) Screw (multiple rotor) [ ]

c) Progressive cavity type [ ]

d) Rotary vane type [ ]

e) Gear type [ ]

f) Vacuum Type [ ]

g) Rotor-jet type [ ] 

h) Other (state the type) _______ ______________________ [ ]

 

2.1.3  Reciprocating Pumps

a) High pressure [ ]

 b) Horizontal plunger [ ]

c) Vertical plunger [ ]

2.1.4  Controlled Volume Pumps (for metering, chemical

dosing & injection)

a) Diaphragm type [ ]

 b) Piston/Plunger type [ ]

c) Simplex/Duplex type [ ]

d) Others (specify the type ________________________ [ ]

2.1.5  Special Effect Pumps (for special application)

a) Jet (Eductor Pumps) [ ] b) Gas Lift-Pumps [ ]

c) Hydraulic Turbine Driven Pumps [ ]

2.2  MOTORS

a)  Induction Squirrel Motor (TEFC) [ ]

 b) 

Other Specify [ ]

2.3  SRU(s)

a) 

Clauss [ ] b)  Others [ ]

3.  Oil & Gas Industry ExperienceState your experience with the following:

a) 

Chemical / Petro-Chemical Industries [ ]

 b)  Hydrocarbon Process [ ]

c) 

Fuel Gas [ ]

d)  Refrigeration Service [ ]

e) 

Hydrocarbon (Sour Service in accordanceWith NACE : MR-01-75 / ISO 151 56-1) [ ]

f)  Others (State the type______________________________)

Page 4: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 4/35

 

Page 4 of 35  Tech: GS & GC System  –  July 2014

4.  CLIENT INFORMATION 

State the client to whom you supplied various types of GAS Sweetening

System, complete the following table separately for each type of GAS

Sweetening system for last five (5) years.

Client

Country

Gas

Sweeting

Systems(pumps type,

motor types,

insulation, and

other Tech.

details) 

Note 1& 2 

Service(incl. Sour

Service in

accordance with

NACE MR-

0175/ ISO 15156

Part I, II & III)

Operating

Conditions(Pressure, flow

etc.)

Year  Installed

capacity

total Plant

/ Modules

(e.g.MMSCFD; Power;

KW;

Molten/Sol

id/

Granular

Sulfurs

MTPD) 

Quantity

incl. #

modules 

 Notes:1.  Actual in Rental skid-mounted fleet (sour/non-sour)

2. 

 Number of sold skid-mounted fleet (sour/non-sour), designing, fabrication,inspection, testing, packaging & supply:

a.  As per Vendor Specs b.  As per Purchaser Specs

  Please inform details of your oldest in operation owned / designed /

supplied Sweetening Skid-mounted Modules / Facility

  Please indicate average / mean Useful Life of the Skid-mounted Modules

& under which conditions, Operating & Maintenance System.

5.  CODES

5.1 

State the number of GAS Sweetening Systems supplied in accordancewith the listed Codes/ Standard/ Specifications:

International Standard / RP/ Publ. a) b)  c)

API Std 610

Centrifugal Pumps For Petroleum, Heavy Duty Chemical and GasIndustry Services 

API Std 660Shell-and-Tube Heat Exchangers

API Std 661Petroleum, Petrochemical, and Natural Gas Industries — Air-Cooled Heat

ExchangersAPI Std 662Plate Heat Exchangers for General Refinery Services, Part 1 — Plate-

 

Page 5: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 5/35

 

Page 5 of 35  Tech: GS & GC System  –  July 2014

and-Frame Heat Exchangers

API Std 662Plate Heat Exchangers for General Refinery Services, Part 2 — Brazed

Aluminium Plate-Fin Heat Exchangers 

API Std. 670

Machinery Protection Systems 

API Std. 671Special Purpose Coupling for Refinery Service 

API Std 672

Packaged, Integrally Geared Centrifugal Air Compressors for

Petroleum, Chemical, and Gas

Industry Services 

API Std. 674

Positive Displacement Pumps - Reciprocating 

API Std. 676

Positive Displacement Pumps - Rotary 

API Std. 677General-Purpose Gear Units for Petroleum, Chemical and Gas Industry

ServicesAPI Std 680

Packaged Reciprocating Plant and Instrument Air Compressorsfor General Refinery Services 

API 682Shaft Sealing System for Centrifugal and Rotary Pumps

ISO 8010

“Compressors for the Process Industry-Screw ……” 

BS 7316

Specification for Design & Construction of Screw related typecompressors PIPASME B73.1M

Horizontal,End Suction Centrifugal Pumps 

ASME B73.2M

Vertical In-line Centrifugal Pumps 

API Std. 613

Special Purpose Gear Units for Refinery Services

API Std. 614

Lubrication, Shaft-Sealing and Control Oil Systems for Special Purpose

Application 

API Std. 615

Sound Control of Mechanical Equipment for Refinery Services 

API RP. 684

API Standard Paragraphs Rotor dynamic Tutorial: Lateral CriticalSpeeds, Unbalance Response,

Stability, Train Torsional, and Rotor Balancing 

API Std. 685

Sealless Centrifugal Pumps for Petroleum, Petrochemical, and Gas

Industry Process Service

API RP 688

Pulsation and Vibration Control in Positive Displacement Machinery

Systems for Petroleum, Petrochemical, and Natural Gas IndustryServices

BS 5500

Specification for unfired fusion welded pressure vessels

BS 5169Specification for unfired fusion welded steel air receiver

Page 6: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 6/35

 

Page 6 of 35  Tech: GS & GC System  –  July 2014

API 12 J

Specification for oil & gas separators

API 510

Pressure Vessel Inspection Program

WRC Bulletin # 107Local Stresses in Spherical & Cylindrical Shell due to External Loading

WRC Bulletin # 297Local Stresses in Spherical & Cylindrical Shell due to External Loading

on Nozzles

IEC 34 Part 1/ 5/6/7/8/9 & 14

Rotating Electrical Machines 

ISO 8528

Reciprocating Internal Combustion Engineer Driven A/C Generating Set

BS 4999

General requirement for Rotating Electrical Machines: Specification for

Rating & Performance

BS 5000

“Generator…….to be driven by Reciprocating Internal CombustionEngines” 

BS 5501/ IEC79

Electrical Apparatus for Potentially Explosive Atmospheres

IEC79

Electrical Apparatus for Explosive Gas Atmospheres 

ASME

Section II

Materials Specifications

  Part A Ferrous Materials

  Part B Non-Ferrous Materials

  Part C Welding Rods, Electrodes and Filler Metal

  Part D Properties

Section V Non-Destructive Examination

Section VIII

Pressure Vessels

  Division 1

  Division 2

Section IX

Welding and Brazing Qualifications

Columns stand for:

a)  Within the last 2 years

 b)  Within the last 10 years

c)  At Middle East last 20 years

For each Standard please specify main details & features selected by the purchaser (eithervendor or final user).

Please indicate full compliance with each international Standard / RP/ PIP/ Code, ifnegative, please provide deviations list and implemented option / alternative designfeature.

Page 7: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 7/35

 

Page 7 of 35  Tech: GS & GC System  –  July 2014

5.2  Also, state any experience with other Codes, Standards & Specification

Codes/ Standards Within last 2 years Within last 5 years

API RP 686

Machinery Installation andInstallation Design 

API Std. 689

Collection and Exchange of

Reliability and Maintenance

Data for Equipment

API Std. 752

Management of Hazards

Associated with Location ofProcess Plant Permanent

Buildings

API Std. 753

Management of Hazards

Associated with Location ofProcess Plant Portable

Buildings

API Std. 754Process Safety Performance

Indicators for the Refining and

Petrochemical Industries

API TR 949-A

Research Report on

Characterization and

Monitoring of Cracking in Wet

H2S Service

API TR 949-B

Repair and RemediationStrategies for Equipment

Operating in Wet H2S Service

API RP 945

Avoiding Environmental

Cracking in Amine Units

API RP 2218

Fireproofing Practices in

Petroleum and Petrochemical

Processing Plants

API Publ 4679

Amine Unit Air Emissions

Model and User‟s Guide,

AMINE Calc, Version 1.0

API Publ 4679

Amine Unit Air Emissions

Model Evaluation 

Others

5.3 Submit valid copies of API / ISO and /or BS or any other certificate,which you may hold for the manufacture of any of the major equipment.

Page 8: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 8/35

 

Page 8 of 35  Tech: GS & GC System  –  July 2014

5.4  State whether Driver of Rotating / Positive Displacement Equipmenthave been supplied in accordance with the following standards.

a)  Drive Motors: BS 4999 [ ]BS 5000 Part 2 [ ]BS 4683 [ ]

 NEMA7 [ ]

 b)  Drive Turbines API 611 [ ]API 612 [ ]API 616 [ ]

c)  Gas Engine API 7B-11C [ ]BS 5514/ISO 3046 [ ]

d)  Others _____________________________________________

i) Please list out the other reference standards applied for the major

items of the Compressor system supplied by you. ___________________________________________________________ 

 ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ________________________________________________________

6  QUALITY ASSURANCE/CONTROL 

6.1 Do you have a formally documented quality system? [ ] YES [ ] NO

6.2 

Do you have a Quality Assurance Manual/If yes, to which National/ International Standard is it developed?

-ISO 90001-BS 5751-If other, please specify.

6.3 Is your quality assurances system approved by any inspection/certifying agency?Such as Lloyds, TUV, B. Veritas or by any large well known Agency or Co.;such as Major oil Companies. Attach copies of letter the above, if any.

6.4 Are quality plans used as controlling documents on the shop floor?-if not

State the reason

6.5 Is your manufacturing plant approved by ISO 9000 series or BS 5750 series?Specifically state the approval status & provide documentary evidence.

7.0 MATERIAL 

7.1  Submit typical sectional views for each type of Major Equipment / LLIsmanufactured by you, showing all design features. The views shouldclearly state full compliance to API/BS standard specified above. If thereare deviations/exception to above standards, these are to be clearlyhighlighted.

Page 9: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 9/35

 

Page 9 of 35  Tech: GS & GC System  –  July 2014

7.2  The sectional views should also be marked with appropriate material(ASTM/AISI/BS/ any other) grades for individual components& size.

7.3  Are defective castings/forgings always returned to the foundry/forge shopfor repair or replacement or are some or all repair performed in- house?

 _____________________________________________________________ 

 _____________________________________________________________

7.4 Are weld repairs (including foundry repairs) routinely documented? _____________________________________________________________  _____________________________________________________________

7.5 Are repair records available for review? _____________________________________________________________  _____________________________________________________________

7.6 Are castings for „Sour Service‟ treated differently or segregated?  _____________________________________________________________ 

 _____________________________________________________________

7.7  Is supplementary heat treatment provided for sour service? State the heattreatment process used. ________________________________________________________

7.8 Are casting thicknesses routinely checked?

 _____________________________________________________________  ___________________________________________________________

7.9 Can material test certificates be provided for compressor components ifrequired? _____________________________________________________________ _____________________________________________________________

7.10 What supplementary tests can be additionally performed on materials for

sour service & on surfacing treatments on request?

7.11 Submit catalogues for each type of Motor manufactured by you, showing all

features. This should clearly state full compliance to the applicableIEC/BS/ISO or any other applicable standard. Any deviations to the

specified standard, should be clearly highlighted.

7.12 

Do you manufacture Motors for special services? If yes; state applicablecode/standard, e.g.

1. Suitable for hazardous areas [ ] YES [ ] NO 

2. Any other (specify) [ ] YES [ ] NO 

Page 10: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 10/35

 

Page 10 of 35  Tech: GS & GC System  –  July 2014

7.13 Provide your statement of compliance/limitation/exceptions to the relevant portions of the attached KOC Standard Specification No.: KOC-E-001 

Compliance [ ] Limitation [ ]State limitations, if any (Provide complete details)

7.14 Do you supply refurbished/reconditioned products.[ ] YES [ ] NO

If Yes, please provide details _____________________________________________________________

 _____________________________________________________________

7.15 Indicate your experience with material specification for the following

Major Equipment / LLIs / Part / Component:

AIR COOLED HEAT EXCHANGER (FIN-FAN COOLER/ ACHE)

Part Material Specifications (API/ASTM/BS) DIN or others

2 Years 5 Years

Shell

Header

 Nozzles

Tubes

Fin

FansSpeed reducer

PRESSURE VESSELS

Specification/Standard Within last 2 years Within last 5 years

API

ASME

ASTM

BS

DINBuyers Own ( Give detail)

Vendors Own ( Give detail)

Other National Standards

(Pl. Specify which)

8.0 DESIGN

Complete the following questions as applicable for the each Major Equipment /LLIs for which approval is sought.

Page 11: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 11/35

 

Page 11 of 35  Tech: GS & GC System  –  July 2014

8.1 Provide design details in respect to the each types of Major Equipment /LLIs in your production range.

8.2 What design work is normally or always contracted out? ___________________________________________________________  ___________________________________________________________

8.3 Are typical Major Equipment / LLIs sectional views provided, clearlyshowing all design features for all sizes? ___________________________________________________________ 

 ____________________________________________________________

8.4 Are the bearings anti-friction type or sleeve type? Can alternative bearings be provided, if required? What is your experience regarding magnetic bearings? ___________________________________________________________ 

 ____________________________________________________________

8.5 Is Critical Speed Verification &Tensional Analysis carried out for allCompressors?

 ___________________________________________________________  ___________________________________________________________

8.6 Is standardization and inter-changeability of components practiced between Major Equipment / LLIs of same types but for different duties?

 ___________________________________________________________  ___________________________________________________________

8.7 Advise the type of surface protection provided on un- machined exteriorsurface and on machined& threaded surfaces. ___________________________________________________________ ___________________________________________________________

8.8  Provide the details of marking provided on the Major Equipment / LLIs.

State the method of marking and also provide a typical Nameplatedrawing incorporating the marking. ___________________________________________________________ 

 ___________________________________________________________

8.9  What design approaches do you use for pulsation and vibration control.Can you carryout acoustic and mechanical system response analysis or do

you get a third party to do it?

8.10  All Electrical Equipment shall be suitable rated for hazardous areas

classification in accordance with IEC 60079 on NFPA 70. Specify Exd,Exe, Exn and any other categories

8.11  For reciprocating compressor, advise your specific construction details forthe following item:

- Cylinder & Cylinder appurtenances ____________________________- Cylinder Cooling (Air/ water both) ____________________________- Valve& Unloaders_________________________________________

- Piston & Crankshaft________________________________________-Pulsation Suppression Devices_________________________________

Page 12: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 12/35

 

Page 12 of 35  Tech: GS & GC System  –  July 2014

8.12  Engineering / Design Capability:

a.  Please explain and provide evidence of your StandardizedSystem / pre-Engineered for ModularDesign/Transportable, skid-mounted gas processingequipment fully instrumented/ automated

 b. 

Proprietary Design, please explain & provide evidencesc.  Please indicate the Engineering for Customized Modules,

limitations and its interfaces on your standardizedmodules, if any.

d.  Specialized Software & handing over the native files:i.  Pressure Vessel Design (e.g. PVElite, Codecalc)

ii.  CAESAR or equivalentiii.  3-D Modelingiv.  PDMS/PDS & Intelligent P&IDsv.  Structural Steel Design for Modules Skids

vi.  ETAPvii.  Hysis, Promax

viii. 

Smart & Intelligent Documentationsix.  Optimum Plant Footprint according with

international acceptable risk level for People &Assets (specify your reference levels), preferablesupported by a third party report like QRA-quantitative risk analysis.

x.  Vendor‟s Best Practice / Lessons Learned

Systeme.  Are any of your equipments specify as a Lethal Service?

If yes, please provide details.f.  Please detail the Internals Selection Procedure & key

decision parameters, in terms of why, when used them,for:

i.  Trays

ii.  Structured Packing

9.0  INSPECTION AND TESTING 

9.1  For each Major Equipment / LLIs please list all the components forwhich material test certificates are furnished.Submit sample test certificate for Chemical Composition, PhysicalProperties etc.

9.2  Provide detailed of “Positive Material Identification” Procedure 

9.3 

Furnish detailed procedure for all the main shop tests carried out.9.4  Confirm that third party inspection will be permitted if required,

and specify limitations, if any.9.5  Specify the NDE of fabrication welds and body castings normally

carried out with respect to the standards adopted, technique, areasconsidered critical, extent of examination, acceptance criteria,

repair procedures etc.9.6  Are safe facilities available for high pressure gas pneumatic

testing?

9.7  Are facilities available for sensitive leak testing? Which techniquesand fluids are used?

9.8 

Are facilities available for test running of Major Equipment / LLIsPackages under load?

Page 13: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 13/35

 

Page 13 of 35  Tech: GS & GC System  –  July 2014

9.9  Are facilities available to test the Major Equipment / LLIs withshop driver?

9.10  Submit sample inspection and test certificates & performancecurves.

9.11  Detail what services are available for Third PartyInspection/Testing

9.12 

State whether the type tests are carried out[ ] In house [ ] Third Party.

9.13  List testing facilities available In-house

Factory-built modular units 

9.14  Manufacturing of Major Equipment or Long Lead Itemsa.  Please provide details & evidences of the In-house fabrication

facilities for:i)  LLIs,

ii) 

Modular construction / assembles b.  Others means / arrangements, explain

9.15  Is it workshop owned by you?9.16  Is it on Rented?9.17  Other agreements e.g. Joint Ventures, Process Licensor, Long-

Term relationship with sub-vendor and so on? Explain

9.18  Are your Modularized solutions 100% (or a near value) fabricated before gas composition or site identified? How, explain?, pleasespecify features of your standardized / pre-engineered packaged /modules.

Compliance with the ASME Performance Test Codes, please specify

their uses and details as applicable

 PTC 1 General Instructions PTC 2 Definitions and Values

 PTC 4.1 Steam Generating Units PTC 8.2 Centrifugal Pumps PTC 9 Displacement Compressors, Vacuum Pumps and Blowers

 PTC 10 Compressors and Exhausters PTC 22 Gas Turbine Power Plants

10.0  OPERATION & MAINTENANCE

Amine Management System:

10.1  Sour gas inlet specifications:

i.  Please specify the / brief about acceptable contaminants levels in

order to prevent / minimize foaming, corrosion, solid particles

entrained, and other contactor / absorption process upsets.

ii.  Please indicate the optimum range temperature of stripping /

contacting sour gas & lean amine

10.2  Amine Absorption & Amine Type as per sour gas predominant

composition:iii.  Specify Amine Selective Type normally used for H2S-rich Sour Gas

& the max handling (v/v) % capacity installed by you

Page 14: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 14/35

 

Page 14 of 35  Tech: GS & GC System  –  July 2014

iv.  Specify Amine Selective Type normally used for CO2-rich Sour Gas

& the max handling (v/v) % capacity installed by you

v.  Specify Amine Non-selective Balanced Type (generic) and the max

handling (v/v) % capacity installed by you

10.3  Established limits of the Amine Quality:

vi.  Please provide Amine Supplier Management System in term of

optimum process parameter (inputs) & recommendation of the Amine

handling

vii.  Please indicate the average of contaminated amine circulation,

monitoring, control and preventive measurements

10.4  Annual mean amine losses

10.5  Based on your experience please establish the impact on the AminePlant Performance of seasonal changes i.e. Kuwait Extreme

Weather

Integrity Management System:

10.6  Furnished the applicable Material selection diagram, PMI &encountered / identify corrosion types / phenomena

10.7  Furnished detailed Piping Class (specs for piping/ pipes, valves,fittings, connections, design & testing)

10.8  Main features & details for Material Used for LLIs10.9  Please indicate the overall corrosion rate for each system as

follows:10.9.1

 

Saturated Sour Rich Gas-Wet Sweet Gas Circuit includingoutlet KOD

10.9.2  Rich Amine Circuit10.9.3  Acid Gas Circuit10.9.4  Lean Amine Circuit10.9.5  Absorber Column / Tower10.9.6  Regenerator Tower

10.10  Minimal consideration for Turndown Ratio / Low Flow OperationCondition

Reliability, Constructability, Availability, Maintainability &

Functionality please specify

10.11  Main Plant Failures as follows :10.11.1  Failure to meet specification10.11.2  Foaming10.11.3  Amine Losses10.11.4  Corrosion

10.12  Mean Time Between Failure (MTBF)10.13  Mean Time to Repair (MTR)10.14  Average Operating Availability, as defined in ISO/IEC Std.

10.15 

Availability Features:10.15.1  Promptly Diagnostic / Root Cause Failure Analysis

Page 15: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 15/35

 

Page 15 of 35  Tech: GS & GC System  –  July 2014

10.15.2  Repair Order & Crew for pre-Repair & Post-Repairtasks

10.15.3  Availability of Spare Parts:10.15.3.1  At Job Site10.15.3.2  At nearby Vendor Workshop

10.15.4  Critical items contributing with high plant

availability & sustainable full throughput:10.15.4.1  Lean Amine Circulating Pumps:

1.  Main Pumps2.  Booster Pumps

10.15.4.2  Acid Gas Disposal / Incinerator / Emissions10.15.4.3  Control of Amine Contamination & Foaming10.15.4.4  Absorption Temperature10.15.4.5  Flash Tank Operational Upsets10.15.5 Recommended Spare Parts inventory10.15.5.1  Commissioning10.15.5.2  3 Year in Operation

10.15.6  Please specify operation & maintenance philosophy

& control system10.15.7  Planned / Major Maintenance, explain

10.15.8  Preventive / Proactive Maintenance, Inspection &Monitoring System, explain

10.15.9  Precaution during Start-up & Shutdown10.15.10 Warming Period up to get Sweet Gas on full

specification

11.0  PERSONNEL

State names, numbers, qualifications and experiences of following

categories of personnel employed (as applicable).

-  Design/ Specialist engineer/s

-  Welding engineer/s

-  Metallurgist

-  Quality Assurance/Quality Control engineer/s

-  Provide the Organisation chart showing thesefunctions

12.0  PURCHASING

12.1  State which materials do you purchase from-  Mills-  Stockists-  Foundry

-  Others(Specify)

12.2  State your regular sources of purchase of castings, forgings, bars, plates and normal delivery time.

12.3  State your regular source of purchase of fittings, gears, actuators,etc.

Page 16: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 16/35

 

Page 16 of 35  Tech: GS & GC System  –  July 2014

12.4  State how your purchase orders for bought-out items are expeditedand the nature of inspection that is carried-out at sub-vendor‟s

works.12.5  State how you undertake QA/QC auditing on material suppliers

(mills, stockists, foundry, others).

13.0  JOB RECORDS 

State how long after a purchase order has been completed that thedocumentation is retained in your records.

State techniques of recording (microfilms, floppies etc.)

 ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ______________________________________________________

14.0  UPDATED VENDOR INFORMATION 

The vendor is requested to submit with this questionnaire all literaturethat will define the scope of the vendors facilities.

Updated literature to be sent to KOC as it becomes available.

15.0 

SPARES

15.1  Are spares stocked or manufactured to order? Give lead time forsupply of parts, particularly major components such as rotors, piston, rings, valves, bearings, seals, couplings etc.

15.2  How long do you guarantee availability and supply of spares fromthe date of supply of Major Equipment / LLIs?

15.3  Do you have any facility to stock spares in Kuwait or Gulf-region?[ ] YES [ ] NO

15.4 

Provide address of your Spares Supply Facility (If not in Kuwait/Gulf Area, the nearest one)

 ____________________________________________________  ____________________________________________________  ____________________________________________________

16.0  SERVICE FACILITY

16.1  Do you have a Technical Representative in Kuwait or Gulf region?[ ] YES [ ] NO

If YES, give contact details.

Page 17: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 17/35

 

Page 17 of 35  Tech: GS & GC System  –  July 2014

16.2  Do you have any Service/ Repair Shop facility in Kuwait or Gulf

region?[ ] YES [ ] NO

16.3  Provide address of your Service/ Repairs Facility (if not in Kuwait /

Gulf Area, the nearest on). _____________________________________________________  _____________________________________________________

17.0  HEALTH AND SAFETY 

17.1  Is Health and Safety related information always marked on or sent

with goods?

17.2  Are checks performed to ensure no radioactive contamination is present in the finished product originating from scrap?

17.3 

Please specify environmental regulation compliances Local orInternational (EPA or similar)

HSE Management System

a.  Identified Major Risks / Hazards & provide write-up evidences:i.  Hazardous flames

ii.  Emissions Measurementiii.  Control toxic chemical usage

 b.  Define the Critical Safety Elements

c. 

Furnished Hazardous Areas Classificationd.  Explain implementation of the Passive & Active Barrierse.  Main HSE Management System & Lessons Learned System details of

established proceduref.  List of your Major Accidents or Incidentsg.  HSE Statistics

18.0  PROCESS GUARANTEE / PERFORMANCE

GUARANTEE, LIABILITY & WARRANTY

Advise the standard warranty offered by you for the main compressorunit/ spares.

 ___________________________________________________________  ___________________________________________________________

18.1  Process Guarantee / Performance Guarantee:

a.  Provide the Protocol of testing b.  Product / Material / Manufacturer Supplier Role

c.  Guarantee Periodd.  Limitations as per following condition:

i.  If the Modules / Packaged Facility is installed by

Third Parties

Page 18: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 18/35

 

Page 18 of 35  Tech: GS & GC System  –  July 2014

ii.  If the Modules / Packaged Facility is pre-commissioning, commissioning and start-up by

Third Partiesiii.  If the Performance Test for Modules / Packaged

Facility is conducted by Third Parties18.2  Liability & Warranty:

18.2.1 

How is transferred to end users?18.2.2 

Page 19: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 19/35

 

Page 19 of 35  Tech: GS & GC System  –  July 2014

19.0  CLIENT UP-DATE/ AFTER SALES SERVICES

Do you distribute all relevant Technical, Operating and Maintenance up-

dates and Bulletins routinely and automatically to all your customers?

After Sales Service, Capabilities at Middle East, parts supply, retrofit,safety notice & Setup

Training Services, Operator Training‟s Programs including real timeoperation simulator.

Completed by (Name) :

Designation :

Signature :

Date :

Company Seal

Page 20: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 20/35

 

Page 20 of 35  Tech: GS & GC System  –  July 2014

KUWAIT OIL COMPANY (K.S.C.)PRE-QUALIFICATION QUESTIONNAIRE

CATEGORY: GAS SWEETENING GAS COMPRESSION SYSTEM

 

___________________________________________________________________________________

TECHNICAL SECTION –  PART III

Subcategory B: GAS Compression System

Complete the following questionnaire relating to your current Technical, Manufacturingand other related facilities.

(If space provided is insufficient, attach additional sheets)

1.0 SPECIALISATION: 

1.1 Confirm that your present ability and field of specialisation includes:

  Pre-Engineered Package [ ] YES [ ] NO

  Manufacturing [ ] YES [ ] NO

  Assembling/Packaging [ ] YES [ ] NO

  FAT Inspection & Testing  [ ] YES [ ] NO

  Installation & pre-Commissioning [ ] YES [ ] NO

  Supply & Delivering [ ] YES [ ] NO

  Commissioning & Performance Testing [ ] YES [ ] NO

  Operation & Maintenance [ ] YES [ ] NO

1.2 Confirm if your main line of field of specialisation (manufacture/assembling/packaging/ business) is:

a)  Compressors:i.  Compressor [ ] YES [ ] NO

ii. 

w/ Driver (b select below) [ ] YES [ ] NO

 b)  Driver (Gas Engine/ Electric Motor)

i.  Gas Engine [ ] YES [ ] NO

ii.  Electric Motor [ ] YES [ ] NO

iii.  Gas Turbine [ ] YES [ ] NO

c)  Pressure Vessels (e.g. Scrubbers/Coalescer Filter /Strainers) [ ] YES [ ] NO

d)  Air Cooler/ Fin-Fan Coolers [ ] YES [ ] NO

e)  Complete System (incl. Structural Steel Skids) [ ] YES [ ] NO

1.3 

Confirm the list of “Main / Typical / Standard / Pre-engineered” Supplied Skid-mountedModules indicating its Major Equipment or Long Lead Items.

1.4 Please outline the Modules Assembling Procedure /framework / Workflow

Page 21: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 21/35

 

Page 21 of 35  Tech: GS & GC System  –  July 2014

1.5 Please specify available Delivery Options:

a.  EX Works

 b.  FOB

c.  CIF-Kuwait Port

2.0 MAJOR EQUIPMENT / LONG LEAD ITEM DETAILS

State the type/types of Major Equipment / Long Lead Items (LLIs)

details normally supplied within your Modules/ Packaged for which

 pre-qualification is sought:

2.1 COMPRESSOR(S)

2.1.1  Centrifugal Compressor:

a)  Barrel type: [ ]

 b)  Horizontally split: [ ]

c) 

Single stage [ ]d)  Multi stage [ ]

e)  Recycle type [ ]

2.1.2  Rotary Type Positive Displacement Compressors 

a)  Screw(single rotor) [ ]

 b)  Screw (multiple rotor) [ ]

c)  Straight Lobed [ ]

d) 

Helical Screw [ ]

e)  Scroll [ ]

f) 

Oil Flooded [ ]

g)  Oil Free (Dry) [ ]

h)  Others (state the type____________)

2.1.3  Reciprocating Compressors 

a)  Horizontal Cylinder [ ]

 b)  Vertical Cylinder [ ]

c)  Multi Cylinder [ ]

2.2 

ENGINE (S)

a)  Horizontal cylinder block (opposed position) [ ]

 b)  Vertical in-line /V-type cylinders [ ]

c)  Two/Four stroke engine [ ]

3.0 Oil & Gas Industry ExperienceState your experience with the following:

a)  Chemical / Petro-Chemical Industries [ ]

 b) 

Hydrocarbon Process [ ]

c)  Fuel Gas [ ]

Page 22: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 22/35

 

Page 22 of 35  Tech: GS & GC System  –  July 2014

d)  Refrigeration Service [ ]

e)  Hydrocarbon (Sour Service in accordance

With NACE : MR-01-75 / ISO 151 56-1) [ ]

f)  Others (State the type______________________________)

4.0 CLIENT INFORMATION 

State the client to whom you supplied various types of GAS Compression

Systems, complete the following table separately for each of GAS

Compression Systems for last five (5) years.

Client

Country

Gas

Compression

Systems(driven by,

compressors

type,

engine/turbine

/types and

other Tech.

details) 

Note 1& 2 

Service(incl. Sour

Service in

accordance with

NACE MR-

0175/ ISO 15156

Part I, II & III)

Operating

Conditions(Pressure, flow

etc.)

Year  Installed

capacity

total Plant

/ Modules

(e.g.MMSCFD; Power) 

Quantity

incl. #

modules 

 Notes:3.  Actual in Rental skid-mounted fleet (sour/non-sour)4.   Number of sold skid-mounted fleet (sour/non-sour), designing, fabrication,

inspection, testing, packaging & supply:a.  As per Vendor Specs b.  As per Purchaser Specs

  Please inform details of your oldest in operation owned / designed /supplied Gas Compression Skid-mounted Modules / Facility

  Please indicate average / mean Useful Life of the Skid-mounted Modules

& under which conditions, Operating & Maintenance System.

5.0 CODES

5.1 State the number of GAS Compression Systems supplied in accordance withthe listed Codes/ Standard/ Specifications:

International Standard / RP/ Publ. a) b)  c)

API Std 610

Centrifugal Pumps For Petroleum, Heavy Duty Chemical and Gas

Industry Services 

API Std 660Shell-and-Tube Heat Exchangers

Page 23: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 23/35

 

Page 23 of 35  Tech: GS & GC System  –  July 2014

API Std 661Petroleum, Petrochemical, and Natural Gas Industries — Air-Cooled Heat

Exchangers

API Std 662Plate Heat Exchangers for General Refinery Services, Part 1 — Plate-and-Frame Heat Exchangers

API Std 662Plate Heat Exchangers for General Refinery Services, Part 2 — Brazed

Aluminium Plate-Fin Heat Exchangers 

API Std. 670

Machinery Protection Systems 

API Std. 671

Special Purpose Coupling for Refinery Service 

API Std 672Packaged, Integrally Geared Centrifugal Air Compressors for

Petroleum, Chemical, and Gas

Industry Services 

API Std. 674

Positive Displacement Pumps - Reciprocating 

API Std. 676

Positive Displacement Pumps - Rotary 

API Std. 677General-Purpose Gear Units for Petroleum, Chemical and Gas Industry

Services

API Std 680

Packaged Reciprocating Plant and Instrument Air Compressorsfor General Refinery Services 

API 682Shaft Sealing System for Centrifugal and Rotary Pumps

ISO 8010

“Compressors for the Process Industry-Screw ……” BS 7316

Specification for Design & Construction of Screw related type

compressors PIPASME B73.1M

Horizontal,

End Suction Centrifugal Pumps 

ASME B73.2M

Vertical In-line Centrifugal Pumps 

API Std. 613Special Purpose Gear Units for Refinery Services

API Std. 614

Lubrication, Shaft-Sealing and Control Oil Systems for Special PurposeApplication 

API Std. 615

Sound Control of Mechanical Equipment for Refinery Services 

API RP. 684

API Standard Paragraphs Rotor dynamic Tutorial: Lateral Critical

Speeds, Unbalance Response,

Stability, Train Torsional, and Rotor Balancing 

API Std. 685

Sealless Centrifugal Pumps for Petroleum, Petrochemical, and GasIndustry Process Service

API RP 688

Pulsation and Vibration Control in Positive Displacement Machinery

Systems for Petroleum, Petrochemical, and Natural Gas Industry

Services

Page 24: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 24/35

 

Page 24 of 35  Tech: GS & GC System  –  July 2014

BS 5500

Specification for unfired fusion welded pressure vessels

BS 5169

Specification for unfired fusion welded steel air receiver

API 12 J

Specification for oil & gas separators

API 510Pressure Vessel Inspection Program

WRC Bulletin # 107

Local Stresses in Spherical & Cylindrical Shell due to External Loading

WRC Bulletin # 297

Local Stresses in Spherical & Cylindrical Shell due to External Loading

on Nozzles

ASME

Section II

Materials Specifications  Part A Ferrous Materials

  Part B Non-Ferrous Materials

 

Part C Welding Rods, Electrodes and Filler Metal  Part D Properties

Section V

 Non-Destructive Examination

Section VIII

Pressure Vessels

  Division 1

  Division 2

Section IX

Welding and Brazing Qualifications 

Columns stand for:a)  Within the last 2 years b)  Within the last 10 years

c) 

At Middle East last 20 yearsFor each Standard please specify main details & features selected by the purchaser (eithervendor or final user).Please indicate full compliance with each international Standard / RP/ PIP/ Code, ifnegative, please provide deviations list and implemented option / alternative design

feature.

5.2 Also, state any experience with other Codes, Standards & Specification

Codes/ Standards Within last 2 years Within last 5 years

API RP 686

Machinery Installation and

Installation Design 

API Std. 689

Collection and Exchange of

Reliability and Maintenance

Data for Equipment

API Std. 752

Management of HazardsAssociated with Location of

Process Plant Permanent

Buildings

Page 25: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 25/35

 

Page 25 of 35  Tech: GS & GC System  –  July 2014

API Std. 753

Management of Hazards

Associated with Location ofProcess Plant Portable

Buildings

API Std. 754

Process Safety Performance

Indicators for the Refining andPetrochemical Industries

API TR 949-AResearch Report on

Characterization and

Monitoring of Cracking in Wet

H2S Service

API TR 949-B

Repair and Remediation

Strategies for Equipment

Operating in Wet H2S Service

API RP 2218

Fireproofing Practices in

Petroleum and Petrochemical

Processing Plants

Others

5.3 Submit valid copies of API / ISO and /or BS or any other certificate,which you may hold for the manufacture of any of the major equipment.

5.4 State whether Driver of Rotating / Positive Displacement Equipmenthave been supplied in accordance with the following standards.

a)  Drive Motors: BS 4999 [ ]

BS 5000 Part 2 [ ]BS 4683 [ ] NEMA7 [ ]

 b)  Drive Turbines API 611 [ ]API 612 [ ]

API 616 [ ]c)  Gas Engine API 7B-11C [ ]

BS 5514/ISO 3046 [ ]

d)  Others _________________________________________________

i) Please list out the other reference standards applied for the major

items of the Compressor system supplied by you. ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ___________________________________________________________  ________________________________________________________

Page 26: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 26/35

 

Page 26 of 35  Tech: GS & GC System  –  July 2014

6.0 QUALITY ASSURANCE/CONTROL 

6.1 Do you have a formally documented quality system? [ ] YES [ ] NO

6.2 Do you have a Quality Assurance Manual/If yes, to which National/ International Standard is it developed?

-ISO 90001

-BS 5751-If other, please specify.

6.3 Is your quality assurances system approved by any inspection/certifying agency?Such as Lloyds, TUV, B. Veritas or by any large well known Agency or Co.;

such as Major oil Companies. Attach copies of letter the above, if any.

6.4 Are quality plans used as controlling documents on the shop floor?-if notState the reason

6.5 Is your manufacturing plant approved by ISO 9000 series or BS 5750 series?Specifically state the approval status & provide documentary evidence.

7.0 MATERIAL 

7.1 Submit typical sectional views for each type of Major Equipment / LLIsmanufactured by you, showing all design features. The views shouldclearly state full compliance to API/BS standard specified above. If there

are deviations/exception to above standards, these are to be clearlyhighlighted.

7.2 

The sectional views should also be marked with appropriate material(ASTM/AISI/BS/ any other) grades for individual components& size.

7.3  Are defective castings/forgings always returned to the foundry/forge shopfor repair or replacement or are some or all repair performed in- house? _____________________________________________________________  _____________________________________________________________

7.4  Are weld repairs (including foundry repairs) routinely documented?

 _____________________________________________________________  _____________________________________________________________

7.5  Are repair records available for review? _____________________________________________________________ 

 _____________________________________________________________

7.6  Are castings for „Sour Service‟ treated differently or segregated? _____________________________________________________________  _____________________________________________________________

7.7  Is supplementary heat treatment provided for sour service? State the heattreatment process used. _____________________________________________________________ 

 _____________________________________________________________

Page 27: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 27/35

 

Page 27 of 35  Tech: GS & GC System  –  July 2014

7.8  Are casting thicknesses routinely checked? _____________________________________________________________ 

 ___________________________________________________________

7.9  Can material test certificates be provided for compressor components ifrequired?

 _____________________________________________________________ _____________________________________________________________

7.10  What supplementary tests can be additionally performed on materials forsour service& on surfacing treatments on request?

7.11  Do you supply refurbished/reconditioned products.[ ] YES [ ] NO

If Yes, please provide details _____________________________________________________________ _____________________________________________________________

7.12 

Indicate your experience with material specification for the followingMajor Equipment / LLIs / Part / Component:

AIR COOLED HEAT EXCHANGER (FIN-FAN COOLER/ ACHE)

Part Material Specifications (API/ASTM/BS) DIN or others

2 Years 5 Years

Shell

Header

 Nozzles

Tubes

Fin

Fans

Speed reducer

PRESSURE VESSELS

Specification/Standard Within last 2 years Within last 5 years

API

ASME

ASTM

BS

DIN

Buyers Own ( Give detail)

Vendors Own ( Give detail)

Other National Standards

(Pl. Specify which)

Page 28: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 28/35

 

Page 28 of 35  Tech: GS & GC System  –  July 2014

8.0 DESIGN

Complete the following questions as applicable for the each Major Equipment /LLIs for which approval is sought.

8.1 Provide design details in respect to the each types of Major Equipment /

LLIs in your production range.

8.2 What design work is normally or always contracted out? ___________________________________________________________  ___________________________________________________________

8.3 Are typical Major Equipment / LLIs sectional views provided, clearlyshowing all design features for all sizes? ___________________________________________________________ 

 ____________________________________________________________

8.4 Are the bearings anti-friction type or sleeve type? Can alternative bearings be provided, if required? What is your experience regarding magnetic bearings? ___________________________________________________________ 

 ____________________________________________________________

8.5 Is Critical Speed Verification &Tensional Analysis carried out for allCompressors? ___________________________________________________________ 

 ___________________________________________________________

8.6 Is standardization and inter-changeability of components practiced between Major Equipment / LLIs of same types but for different duties? ___________________________________________________________  ___________________________________________________________

8.7 Advise the type of surface protection provided on un- machined exteriorsurface and on machined& threaded surfaces. ___________________________________________________________ ___________________________________________________________

8.8  Provide the details of marking provided on the Major Equipment / LLIs.State the method of marking and also provide a typical Nameplatedrawing incorporating the marking. ___________________________________________________________  ___________________________________________________________

8.9  What design approaches do you use for pulsation and vibration control.Can you carryout acoustic and mechanical system response analysis or do

you get a third party to do it?

8.10  For reciprocating compressor, advise your specific construction details for

the following item:

- Cylinder & Cylinder appurtenances ____________________________

Page 29: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 29/35

 

Page 29 of 35  Tech: GS & GC System  –  July 2014

- Cylinder Cooling (Air/ water both) ____________________________- Valve& Unloaders_________________________________________

- Piston & Crankshaft________________________________________-Pulsation Suppression Devices_________________________________

8.11 

Engineering / Design Capability:

a.  Please explain and provide evidence of your Standardized System / pre-Engineered for Modular Design/Transportable, skid-mounted gas processing equipment fully instrumented/ automated

 b.  Proprietary Design, please explain & provide evidencesc.  Please indicate the Engineering for Customized Modules, limitations

and its interfaces on your standardized modules, if any.d.  Specialized Software & handing over the native files:

i.  Pressure Vessel Design (e.g. PVElite, Codecalc)ii.  CAESAR or equivalent

iii.  3-D Modeling

iv. 

PDMS/PDS & Intelligent P&IDsv.  Structural Steel Design for Modules Skids

vi.  ETAPvii.  Hysis, Promax

viii.  Smart & Intelligent Documentationsix.  Optimum Plant Footprint according with international

acceptable risk level for People & Assets (specify your

reference levels), preferable supported by a third party reportlike QRA- quantitative risk analysis.

x.  Vendor‟s Best Practice / Lessons Learned System

9.0 INSPECTION AND TESTING 

9.1 For each Major Equipment / LLIs please list all the components for whichmaterial test certificates are furnished.Submit sample test certificate for Chemical Composition, PhysicalProperties etc.

9.2  Furnish detailed procedure for all the main shop tests carried out.9.3  Provide detailed of “Positive Material Identification” Procedure 9.4  Confirm that third party inspection will be permitted if required, and

specify limitations, if any.9.5  Specify the NDE of fabrication welds and body castings normally carried

out with respect to the standards adopted, technique, areas considered

critical, extent of examination, acceptance criteria, repair procedures etc.9.6  Are safe facilities available for high pressure gas pneumatic testing?

9.7  Are facilities available for sensitive leak testing? Which techniques andfluids are used?

9.8  Are facilities available for test running of Major Equipment / LLIsPackages under load?

9.9  Are facilities available to test the Major Equipment / LLIs with shopdriver?

9.10  Submit sample inspection and test certificates & performance curves.9.11  Detail what services are available for Third Party Inspection/Testing9.12  State what Material testing facilities are available In-house.

Page 30: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 30/35

 

Page 30 of 35  Tech: GS & GC System  –  July 2014

Factory-built modular units 

9.13  Manufacturing of Major Equipment or Long Lead Itemsa.  Please provide details & evidences of the In-house fabrication

facilities for:i.  LLIs,

ii) 

Modular construction / assembles b.  Others means / arrangements, explain

9.14  Is it workshop owned by you?9.15  Is it on Rented?9.16  Other agreements e.g. Joint Ventures, Process Licensor, Long-Term

relationship with sub-vendor and so on? Explain9.17  Are your Modularized solutions 100% (or a near value) fabricated before

gas composition or site identified? How, explain?, please specify featuresof your standardized / pre-engineered packaged / modules.

Compliance with the ASME Performance Test Codes, please specify

their uses and details as applicable

 PTC 1 General Instructions

 PTC 2 Definitions and Values PTC 4.1 Steam Generating Units PTC 8.2 Centrifugal Pumps PTC 9 Displacement Compressors, Vacuum Pumps and Blowers PTC 10 Compressors and Exhausters

 PTC 22 Gas Turbine Power Plants

10.0 OPERATION & MAINTENANCE

Integrity Management System:

10.1 Furnished the applicable Material selection diagram, PMI &encountered / identify corrosion types / phenomena

10.2 Furnished detailed Piping Class (specs for piping/ pipes, valves, fittings,connections, design & testing)

10.3 Main features & details for Material Used for LLIs10.4  Please indicate the overall corrosion rate for each system as follows:

10.4.1 Saturated Sour Rich Gas-Wet Sweet Gas Circuit including outletKOD

10.4.2 Rich Amine Circuit10.4.3 Acid Gas Circuit

10.4.4 

Lean Amine Circuit10.4.5 Absorber Column / Tower10.4.6 Regenerator Tower

10.5 Minimal consideration for Turndown Ratio / Low Flow OperationCondition

Reliability, Constructability, Availability, Maintainability & Functionality

please specify

10.6 Please indicate the Main Plant Expensive Failures, downtime experience

and preventive measurements.

10.7 

Mean Time Between Failure (MTBF)10.8 Mean Time to Repair (MTR)

Page 31: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 31/35

 

Page 31 of 35  Tech: GS & GC System  –  July 2014

10.9 Average Operating Availability, as defined in ISO/IEC Std.10.10  Availability Features:

10.10.1 Promptly Diagnostic / Root Cause Failure Analysis10.10.2 Repair Order & Crew for pre-Repair & Post-Repair tasks10.10.3 Availability of Spare Parts:

10.10.3.1  At Job Site

10.10.3.2 

At nearby Vendor Workshop10.10.4 Critical items contributing with high plant availability &

sustainable full throughput:10.10.5 Recommended Spare Parts inventory

10.10.5.1  Commissioning10.10.5.2  3 Year in Operation

10.10.6 Please specify operation & maintenance philosophy &control system

10.10.7 Planned / Major Maintenance, explain10.10.8 Preventive / Proactive Maintenance, Inspection &

Monitoring System, explain10.10.9 Precaution during Start-up & Shutdown

10.10.10 

Warming Period up to get Sweet Gas on fullspecification

11.0 PERSONNEL

State names, numbers, qualifications and experiences of followingcategories of personnel employed (as applicable).

-  Design/ Specialist engineer/s- -  Welding engineer/s- 

Metallurgist- -  Quality Assurance/Quality Control engineer/s- -  Provide the Organisation chart showing these

functions

12.0 PURCHASING

12.1 State which materials do you purchase from

-  Mills-  Stockists

Foundry-  Others(Specify)

12.2  State your regular sources of purchase of castings, forgings, bars, plates and normal delivery time.

12.3  State your regular source of purchase of fittings, gears, actuators, etc.

12.4  State how your purchase orders for bought-out items are expedited andthe nature of inspection that is carried-out at sub-vendor‟s works. 

12.5  State how you undertake QA/AC auditing on material suppliers (mills,

stockists, foundry, others).

Page 32: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 32/35

 

Page 32 of 35  Tech: GS & GC System  –  July 2014

13.0 JOB RECORDS 

State how long after a purchase order has been completed that the

documentation is retained in your records.

State techniques of recording (microfilms, floppies etc.)

 ___________________________________________________________  ___________________________________________________________ 

 ___________________________________________________________  ___________________________________________________________ 

 ___________________________________________________________  ______________________________________________________

14.0 UPDATED VENDOR INFORMATION 

The vendor is requested to submit with this questionnaire all literature that willdefine the scope of the vendors facilities.

Updated literature to be sent to KOC as it becomes available.

15.0 SPARES

15.1 Are spares stocked or manufactured to order? Give lead time for supplyof parts, particularly major components such as rotors, piston, rings,valves, bearings, seals, couplings etc.

15.2  How long do you guarantee availability and supply of spares from the

date of supply of Major Equipment / LLIs?

15.3 

Do you have any facility to stock spares in Kuwait or Gulf-region?[ ] YES [ ] NO

15.4  Provide address of your Spares Supply Facility (If not in Kuwait /GulfArea, the nearest one)

 ____________________________________________________  ____________________________________________________  ____________________________________________________

16.0 SERVICE FACILITY

16.1 Do you have a Technical Representative in Kuwait or Gulfregion?

[ ] YES [ ] NO

If YES, give contact details.

16.2  Do you have any Service/ Repair Shop facility in Kuwait or Gulfregion?

[ ] YES [ ] NO

16.3  Provide address of your Service/ Repairs Facility (if not in

Kuwait / Gulf Area, the nearest on). _____________________________________________________ 

 _____________________________________________________

Page 33: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 33/35

 

Page 33 of 35  Tech: GS & GC System  –  July 2014

Page 34: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 34/35

 

Page 34 of 35  Tech: GS & GC System  –  July 2014

17.0 HEALTH AND SAFETY 

17.1 Is Health and Safety related information always marked on or sent

with goods?

17.2 Are checks performed to ensure no radioactive contamination is

 present in the finished product originating from scrap?

17.3 Please specify environmental regulation compliances Local orInternational (EPA or similar)

HSE Management System

a.  Identified Major Risks / Hazards & provide write-up evidences:i.  Hazardous flames

ii.  Emissions Measurementiii.  Control toxic chemical usage

 b.  Define the Critical Safety Elementsc.

 

Furnished Hazardous Areas Classificationd.  Explain implementation of the Passive & Active Barrierse.  Main HSE Management System & Lessons Learned System details of

established proceduref.  List of your Major Accidents or Incidentsg.  HSE Statistics

18.0 PROCESS GUARANTEE / PERFORMANCE

GUARANTEE, LIABILITY & WARRANTY

Advise the standard warranty offered by you for the main compressor

unit/ spares.

 ___________________________________________________________  ___________________________________________________________

18.1 Process Guarantee / Performance Guarantee:a.  Provide the Protocol of testing b.  Product / Material / Manufacturer Supplier Rolec.  Guarantee Periodd.  Limitations as per following condition:

i.  If the Modules / Packaged Facility is installed by

Third Partiesii.  If the Modules / Packaged Facility is pre-commissioning, commissioning and start-up byThird Parties

iii.  If the Performance Test for Modules / PackagedFacility is conducted by Third Parties

18.2 Liability & Warranty:

18.2.1  How is transferred to end users?

Page 35: (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

8/21/2019 (5) PQ Questionnaire Part III GS & GC SYSTEM 1 July 2014

http://slidepdf.com/reader/full/5-pq-questionnaire-part-iii-gs-gc-system-1-july-2014 35/35

 

19.0 CLIENT UP-DATE/ AFTER SALES SERVICES

Do you distribute all relevant Technical, Operating and Maintenance up-dates and Bulletins routinely and automatically to all your customers?

After Sales Service, Capabilities at Middle East, parts supply, retrofit,safety notice & Setup

Training Services, Operator Training‟s Programs including real time

operation simulator.

Completed by (Name) :

Designation :

Signature :

Date :

Company Seal