78025839 CHEVRON Compressors Installation and Pre Commissioning

700 Compressor Installation and Precommissioning Abstract This section contains general guidelines and checklists for installation and precommissioning of new compressors and recommissioning of existing ones.

Chevron Corporation

Contents

Page

710

Introduction

700-2

720

Reciprocating Compressor Installation Checklist

700-4

730

Reciprocating Compressor Precommissioning Checklist

700-14

740

Centrifugal Compressor Installation Checklist

700-22

750

Centrifugal Compressor Precommissioning Checklist

700-31

700-1

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700 Compressor Installation and Precommissioning

Compressor Manual

710 Introduction These guidelines focus on new installations, although many aspects also apply to existing installations where equipment has been repaired, rerated, retrofitted, etc. Proper compressor installation and precommissioning helps ensure trouble-free startup and long-term reliability. Thorough inspection and critical review during each phase of the installation process eliminates “built-in” deficiencies or problems which later result in equipment failures or poor performance. The checklists in this section are intended to aid in this inspection/review process.

711 Installation/Precommissioning Checklists In general, the Installation Checklists cover items to be done well in advance of, and in preparation for the initial equipment run-in and startup. They are applicable to most common on-shore and off-shore installations. The Precommissioning Checklists should be used immediately preceding startup. These checklists cover a final check of equipment readiness and general steps to be followed during equipment run-in and startup. As with the Installation Checklists, the Precommissioning Checklists cover general requirements applicable to most installations. These checklists are general, and do not include specific acceptance criteria (alignment tolerances, pipe forces, vibration limits, etc.). These criteria should be developed for the specific application based on the manufacturer's instruction manual, applicable industry standards, project specifications, and local practice. Any discrepancies should be resolved prior to installation or start-up. Consult the manufacturer's instruction manual for detailed run-in/startup procedures specific to the equipment involved, and modify the final checklist accordingly.

712 Summary Successful startups depend on: •

Documented execution of maintenance/installation work during the turnaround/construction phase.

•

Startup procedures developed for each unique startup (with follow-up and documentation support).

•

Clearly defined startup tasks and responsibilities.

•

Communicated tasks and responsibilities in a Pre-startup Meeting to review timing, communications during startup, contingencies, startup sequencing, and other pertinent items.

713 References The following provide additional information:

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•

Specification MAC-MS-2983, Field Cleaning of Compressor Lube-Oil and Seal Oil Systems.

•

Specification MAC-EG-3907, Grouting of Machinery.

•

Specification PIM-MS-2411, Descaling and Cleaning Steel Piping.

•

Integrated Machinery Inspection Candidate Manual (data acquisition and condition monitoring procedures).

•

Machinery Reliability Procedures—El Segundo Refinery (machinery standards, repair and operating procedures, and specific checklists).

•

Total Alignment, V.R. Dodd (machinery alignment standards, procedures, and general background)

Note All of the startup data described in the following pages should be reduced during and immediately after the startup, then filed in the appropriate machine binder. Instructions are covered in detail in the CUSA Mfg., IMI Candidate Manual. This standard startup information is used routinely and successfully in all CUSA refineries.

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700-3

December 1988


Compressor Manual

720 Reciprocating Compressor Installation Checklist The manufacturer's installation manual, equipment specifications, as-built data sheets, and the specific process requirements should be reviewed in detail, and modifications made to this checklist, as appropriate, to cover individual requirements. Reciprocating Compressor Installation Checklist (1 of 10)

Step 1.

Initial

Date

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Documentation

The following documents covering all major compressor train components should be available. Review as applicable: Manufacturer's instruction manual for the equipment involved. Equipment specifications, as applicable: •

API Equipment Standards

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•

Project Specifications

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Purchase Documents: •

Purchase Order

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•

Quotation Request

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•

List Sheets

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•

Other Documents Referenced in Purchase Order

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As-built Equipment Data Sheets

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Performance Data

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Lubrication Chart

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Installation Drawings

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Shop Test/Inspection Records and Reports

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Safety Instruction Sheets

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Maintenance History

_____

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Performance/Vibration History

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Inspection/Trouble Reports since last major turnaround

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Existing Installations:

Step 2.

Safety Precautions

Lock out and properly tag the main driver.

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Reciprocating Compressor Installation Checklist (2 of 10) Initial

Date

Insure all piping and hot surfaces (above 140°F) are suitably guarded or insulated for personnel protection.

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Verify all relief valves are installed, properly set, and tested. Notify the proper equipment inspector that the valve exists so that his database can be updated.

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Confirm no block valves are located between the source of pressure and safety valves, unless locked open.

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Insure outlets of crankcase and distance piece explosion relief doors point downward away from personnel.

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Insure suitable guards meeting OSHA requirements are in place around all exposed rotating parts such as couplings, belts, etc.

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Eliminate tripping/slipping hazards or mark clearly as hazards. Remove oil from floors or decking.

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Insure suction and discharge valves are correct and properly placed in compressor cylinders.

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Relieve pressure within unit (cylinders, piping, bottles, etc.) before any tie-in work is performed. Install blinds per local procedures.

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Isolate compressors handling toxic or flammable gases from process piping and purge or evacuate, as applicable.

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Open piston vent holes and confirm piston does not contain pressure (when removing a cylinder head).

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Bar-over unit more than one complete revolution before any startup/re-start to insure there are no mechanical interferences, nor any liquid in cylinders.

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Check all bill of materials for completeness of material received. Insure all “tagged” materials are correctly labeled.

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Insure all required spare parts and special tools received, and location documented. Take immediate action on any shortages or damage.

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Check internal/external cleanliness.

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Inspect cylinder bore, pistons, rods, bearing journals, etc. for corrosion, pitting, or damage.

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Confirm integrity of preservative per manufacturer's recommendations and local practice.

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Step 3.

Equipment Condition (Before Installation)

As Received:

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Compressor Manual


Date

Insure baseplate/skid is straight and flat.

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Insure baseplate/skid mounted compressor/driver not bolt-bound (free to move for alignment, as necessary).

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Confirm compressor/driver rotates freely.

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Inspect condition of all bearings.

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Check alignment shim (number, material, condition) acceptability.

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Insure coupling condition is acceptable and all components have been received.

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Insure storage protection requirements met (refer to the General Machinery Manual and manufacturer's installation manual).

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Blanket equipment with inert gas or dry air/inert gas purge as appropriate.

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Confirm rust preventive/lubricant compatibility.

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Schedule and perform inspection of equipment condition at regular intervals during storage. (Check condition of equipment and storage protection if stored for more than one month. Follow-up required.)

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Clean or coat metal surface of soleplates, rails, or compressor parts (crankcase or crosshead frame).

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Check for properly rounded corners of soleplates or rails.

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Confirm the mounting feet or base are free of burrs.

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Disconnect coupling before leveling.

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Level soleplates, rails, and compressor parts in accordance with manufacturer's recommended procedure and local standards.

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Cure concrete foundation for at least 14 days before grouting preparation.

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Properly roughen and clean (free of oil, grease and other foreign substances) concrete surface. If cementitious grout is used, saturate concrete surfaces with water for 24 hours prior to placement of grout. Remove any free standing water before grouting (Refer to Specification MAC-MS-3907, Grouting of Machinery, for recommended procedures.)

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Insure proper grout material/thickness.

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Temporary Storage:

Step 4.

Foundations and Grouting

Concrete Foundations:

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Date

Confirm anchor bolt cavities in foundation are not filled with grout.

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Cure grout for at least three days. Piping should not be connected to equipment until grout has thoroughly cured.

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Check there are no hollow areas or major cracks in grouting.

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Back off leveling bolts.

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Tighten anchor bolts using a torque wrench to values in accordance with manufacturer's recommendation.

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Locate mounting plates at load bearing support beams.

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Insure shims are of corrosion-resistant material.

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Properly level baseplate/skid.

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Tighten bolting using a torque wrench to recommended values.

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Other Foundations (Structures):

Step 5.

Cleaning of Piping, Pulsation Dampers and Separators—New Construction

Check cleanliness of all cylinder suction vessels and piping to protect against damage to compressor valves and cylinder walls during/after startup.

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Thoroughly clean all lube systems as recommended below.

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Isolate the system, and if possible, inert gas blanket it after cleaning to insure that no further foreign material can enter the system.

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Chemically clean steel process gas and lube-oil system piping internally, in accordance with appropriate procedures. PIM-MS-2411 is available in the Piping Manual as a cleaning specification.

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Clean alloy piping in accordance with applicable project or local procedures.

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Note When chemically cleaning the frame lube-oil system, clean all of the piping from the discharge of the oil pump, through the oil cooler and oil filters and up to the inlet of the compressor (generally, only the oil cooler shell and filter bodies should be pickled; tube bundles and filter cartridges removed). Mechanically clean the cooler shell and filter bodies if they are large enough.

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Thoroughly drain all gas suction lines.

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Protect piping against oxidation by jetting oil using high- pressure air or inert gas blanket, as applicable.

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Piping

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700-7

December 1988


Compressor Manual


Date

Check inlet line to air compressor for corrosion protective coating of internal surface (except stainless steel).

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Completely remove all grit from sandblasted lines.

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Cover the ends of all intake piping and fittings, and vessel nozzles to insure that no foreign material can enter during construction/turnaround.

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Clean interstage piping mechanically. Blow clean. (Do not blow back into the compressor cylinder unless piston rods and valves are removed and packing area is blanked off.)

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Flush frame lube-oil and packing cooling oil piping.

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Remove inspection covers on pulsation dampers/separators and inspect vessels for cleanliness and integrity of all internals.

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Insure wedge-type supports used on discharge pulsation dampers are loose when cold.

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Check all process and auxiliary piping valves, including safety valves, for proper location, position, flow direction, and tightness of supports and anchors.

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Inspect suction strainers, if used, for proper installation, correct orientation, and differential pressure gage, if applicable. If strainers have fine mesh overlay, orient so that flow contacts mesh overlay first.

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Insure insulation and heat tracing is installed in accordance with installation drawings.

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Confirm there are no pockets or low spots in the gas piping which cannot be drained.

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Insure correct separator mesh material, with adequate corrosion resistance.

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Drain all separators/K.O. pots to a safe location. (Hazardous service.)

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Check all piping against final installation drawings and P&ID's for correct material and installation. Confirm necessary pressure gages, block valves, and control valves are provided.

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Vent all high points in liquid piping.

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Insure oil piping on frequently used vents/drains properly routed to prevent spraying oil over equipment.

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Confirm pipe plugs are not installed in packing case drain valves.

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Pulsation Dampers/Separators

Step 6.

Piping Installation/Support Systems/Alignment

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Date

Inspect auxiliary equipment for properly installed block valves.

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Use proper thread sealant for screwed piping. (Sealant should not be used when connection is seal welded.) Do not use teflon tape for lube-oil pipe threads.

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Insure nitrogen or dry air purge to reservoirs, sump, bearing housings, etc., is connected and functional.

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Inspect all drain lines for proper slope (1/4-inch/foot minimum).

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Insure suction and discharge piping is properly supported and clamped.

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Confirm that no significant strains have been introduced on the compressor cylinder(s) during erection and bolt up of process piping.

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Insure provision is made for thermal expansion of discharge line.

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Insure cylinder supports installed and adjusted in conformance with design drawings. Under no circumstances should a cylinder be supported by its piping.

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Inspect all bolted connections for tightness. Tape flanges for sniffer inspection.

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Check alignment of all coupled equipment.

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Check alignment of frame by measuring crankshaft web deflection in accordance with manufacturer's recommendations.

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Check cylinder-to-frame alignment by measuring piston rod runout in accordance with manufacturer's recommendations.

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Inspect the cylinder bore and gas passageways for dirt and foreign material. Clean each cylinder as necessary.

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Check piston-to-head clearance on cylinder head-end and crank-end.

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Insure suction ports of each cylinder are free of all foreign material.

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Confirm all valves are correct for the service intended.

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Inspect valves for correct installation in the cylinders.

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Note Valve strips or plates in the suction valves open toward the cylinder bore. Strips or plates in the discharge valves open away from the bore.

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Check valve gaskets for correct type and material.

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Use torque wrench to insure valve cap holddown bolts are torqued to manufacturer's recommended values to avoid valve seat distortion.

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Step 7.

Compressor Valves/Cylinders

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700-9

December 1988


Compressor Manual


Date

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Insure all thermosyphon, static, and closed-loop forced circulation cylinder cooling systems contain treated water and/or antifreeze type fluids where necessary.

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Avoid use of raw water due to its fouling tendency.

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Properly inhibit any coolant to minimize rusting.

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Completely fill cylinder jackets with appropriate coolant.

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Check that the stand pipe or expansion chamber and vent extends above the top of the cylinder to accommodate expansion of the coolant.

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Remove high-point vent plugs and fill cylinder jackets with coolant.

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Fill the expansion tank to the proper level, leaving room for the level to rise as the system temperature increases.

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Replace all vent plugs.

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Disconnect water lines at cylinder and cooler outlets, and thoroughly flush the system with clean water.

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Open all cylinder and piping vents to remove air, completely fill the system, and replace plugs.

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Run coolant through to confirm all connections are tight.

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Vent the coolant side of exchanger and all auxiliary piping to remove all air.

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Remove one or more suction valves (and their covers) from each end of each cylinder to reduce load during initial run-in. Step 8.

Cylinder Cooling System

Static Cooling

Thermosyphon Cooling

Forced Coolant System

Cylinder Cooling System Design/Other Compressor Cooling Systems Occasionally, there is a portion of the hot coolant outlet system where it is difficult to obtain good circulation due to air entrainment. To remove the air and thus restore circulation, an “air expelling trap” can be installed on the highpoint of the line. Shell-and-Tube Type Oil Cooler:

Water- or Oil-Cooled Packing Assemblies:

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Date

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Thoroughly clean frame lubricating system before startup. After cleaning all newly installed piping and auxiliary equipment as outlined previously in step 5, the following additional cleanup steps are recommended:

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Drain rust preventive from the frame lubrication system, as applicable.

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Check frame oil filter elements for proper micron rating. Check for dirt and lint. Clean as necessary.

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Remove frame and frame extension inspection covers, inspect for foreign material, and clean as necessary.

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Flush the frame lubrication system in accordance with manufacturer's recommendations. (If auxiliary oil pump is available, bypass crank driven main frame oil pump and circulate flush oil through oil cooler, oil filter and all piping.) Check external piping for leaks.

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Circulate flush oil with bearings bypassed until no foreign material is detected ahead of the oil filters.

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Connect the oil lines to the first main bearing and flush for approximately one hour. Then continue, connecting to other main bearings one at a time until all lines are connected. Bar the crankshaft through 90 degrees every 10-15 minutes during the flush cycle on each bearing.

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If special flush oil is used, completely drain frame, external piping and equipment after flushing is completed. For any oil, check for foreign material in oil filter housings. Remove any accumulated material and clean or replace oil filter elements, as appropriate.

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Fill the frame oil sump to the proper level with the proper grade of oil.

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Circulate oil and completely fill the frame lubrication system using the motor driven or hand pump, as appropriate. Add oil to the crankcase as required.

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Check internal piping for tightness.

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Inspect the crankshaft oil seals, clean, and apply a few drops of oil, if possible. (May be impractical on units with flywheels or large couplings.)

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Confirm that correct size flow control orifices are installed in oil supply to bearings (pressure systems).

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Check for external leaks, and vent air from system piping. Step 9.

Frame Lubrication

Circulate flush oil through bearings using the following procedure to achieve similar cleanliness:

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700-11

December 1988


Compressor Manual


Date

Drain lubricator of all rust preventive oil unless compatible.

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Fill the lubricator with the proper grade of cylinder oil.

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Install special lubricant if a new cylinder or cylinders and packing have been installed and the final lube-oil to be used is not suitable for break-in. (Generally, lubricants required for normal operations will be suitable for break-in.) During the break-in periods, oil feed to both cylinders and packing should be adjusted to a heavy feed rate, as recommended by the manufacturer.

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With the oil lines disconnected at the check valve, operate the lubricator by hand, or use an oil filler pump, to eliminate all air in the system. Pump the system until oil is forced out of the line, indicating tubing is full.

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Reconnect piping and operate the lubricator or hand pump for one minute more to inject oil into the cylinder and packing cases. Confirm that the lubricators are adjusted to deliver feed rates, as recommended by the manufacturer.

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When it is not possible to adjust the lubrication rate to an individual packer, additional oil can be added to the rod by mounting a temporary lube reservoir on the distance piece. This reservoir can then provide drops of oil on the rod.

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Apply lubricating oil to the cylinder bore.

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Inspect the oil seal on lubricator drive shaft (where it emerges from the crankcase). Clean, and apply a few drops of oil.

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Carefully examine all portions of cylinders, pistons, and rods for foreign material.

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Note

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Check all safety valves for proper location and setting.

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Confirm that all indicating gages are properly installed, and are oriented to be clearly seen by an operator when making control adjustments.

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Test all alarm, shutdown, and safety functions.

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Step 10.

Cylinder Lubrication—Lubricated Units

If used, insure synthetic oils are compatible with materials of construction. Some synthetic oils attack aluminum bearing components. Step 11.

Non-lubricated Cylinders

It is extremely important that all components be thoroughly cleaned.

Check suction filters, if any, for cleanliness. Step 12.

Instrumentation and Controls

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Date

Insure alarms and shutdowns are operating and arranged to permit testing while the compressor is on line.

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Confirm operation and sequencing of pneumatic valve unloaders, if the unit is provided with them. This is extremely important. A crossed connection could result in compressor damage.

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Confirm that all manual unloaders are operating freely.

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Step 13.

Drivers

Refer to the Drivers Manual for Installation Checklists for compressor drivers.

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700-13

December 1988


Compressor Manual

730 Reciprocating Compressor Precommissioning Checklist Use the following checklist during run-in of the compressor for the first time, and also following major equipment overhauls. Review the manufacturer's installation manual and the specific process system in detail and modify this checklist, as appropriate, to cover individual requirements. Reciprocating Compressor Precommissioning Checklist (1 of 8) Initial

Date

Review the final modified checklist with the operators and all other personnel involved in the precommissioning to insure that everyone understands the procedures and the specific objectives involved.

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Confirm that operators are familiar with new equipment and required operating procedures/training has been implemented in accordance with local practice. A Pre-startup Meeting of all concerned is highly recommended.

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New equipment installations should first be checked in accordance with the Reciprocating Compressor Installation Checklist.

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Reconfirm checks previously completed if there has been extended time between installation and startup and/or additional work has been performed on the unit.

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Review existing installation overhaul/repair records for completeness of repairs and repair documentation.

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Lock out and properly tag the main driver, and complete all checks.

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Do not operate any equipment in excess of its rated capacity, speed, pressure, compression ratio, or temperature.

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Confirm all safety relief valves are installed, properly set, and tested.

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Confirm no block valves are located between the source of pressure and the safety relief valves, unless locked open.

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Insure outlets of crankcase and distance piece explosion relief doors, if any, are pointed downward away from personnel.

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Insure suitable guards meeting OSHA requirements are in place around all exposed rotating parts such as couplings, belts, etc.

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Eliminate tripping/slipping hazards or mark clearly as hazards, and remove all oil from floors or decking.

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Step 1.

Step 2.

General

Safety Precautions

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700-14

Chevron Corporation

Compressor Manual


Reciprocating Compressor Precommissioning Checklist (2 of 8) Initial

Date

Check that all vent lines (including packing and distance piece vents) are open and purge gas, if required, is properly connected to the distance piece and/or wiper packing.

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When overheating is suspected, the crankcase should not be opened until components have cooled sufficiently.

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Avoid creation of flammable mixtures in compressor cylinders, in suction and discharge piping, and in interstage equipment.

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Define data acquisition requirements and develop list (or data sheets) covering specific data to be recorded during precommissioning.

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Review the final run-in procedure to be certain that non-reversing rod load conditions cannot occur in any cylinder.

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Check all interstage pressure switches or differential switches, if provided, to insure that the shift in interstage pressure when bringing the unit on line will not cause a shutdown.

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For motor drivers, determine how many restarts are permitted during one hour's time. Do not exceed these limits.

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Review manufacturer's instructions for loading and unloading compressor cylinders.

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Check that all appropriate blinds are in place and that suction and discharge line block valves are closed.

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Insure all alarms and shutdown have been set and tested.

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Insure monitoring systems, including all alarms and shutdowns, are in service and not bypassed during initial operation and startup.

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Insure gas lines are drained and prewarmed, if applicable, by turning on heat tracing before operation of the compressor.

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Confirm that suction and discharge valves are correct and properly placed in compressor cylinders.

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Confirm that at least one suction valve and valve cover has been removed from each end of each cylinder.

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Step 3.

Step 4.

Pre-Run-in Data Review

Pre-Run-in Installation Check

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700-15

December 1988


Compressor Manual


Date

Bar the unit over manually at least one complete revolution before any startup/restart for a few revolutions to confirm that all components are working freely and that lube-oil is distributed to all running surfaces and there is no liquid in the cylinders.

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Check the direction driver of rotation by bumping it. Check rotation of all auxiliary system motor drivers. Resolve conflicts.

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Check the oil level of the crankcase. If a separate motor-driven frame oil pump is provided, start the pump to pressurize the lubrication system.

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When the unit is not equipped with a separate motor-driven pump, manually prelubricate the running gear for approximately five minutes.

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Check that the lubricator reservoir is filled.

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Confirm the proper break-in oil is being used.

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Squirt oil on rods prior to initial run-in.

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Flood the packing with lubricant.

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Check that both cylinder and packing lubricators are set at correct rate.

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Manually turn shaft-driven lubricators to confirm that oil is being fed.

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Prime divider block type lubricator systems with a priming pump.

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Check lubricator oil level.

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Start lubricator motor (if separately driven).

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Turn on coolant to compressor cylinders, packing, etc.; and start closed coolant system pumps and air cooler as applicable. Vent trapped air from cylinder jackets or any other parts of the cooling system.

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For lubricated compressor cylinders:

Note Avoid turning on cooling water to the frame lube-oil cooler until the oil is almost up to normal operating temperature. (In colder climates it may be necessary to initially heat the lube-oil.) This completes the specific pre-check prior to equipment run-in. Make one final walk completely around the unit making sure that all equipment is ready for operation. Confirm that all personnel are in a safe position and are aware that the unit is about to be started. Step 5.

No-Load Run-in

Start the driver in accordance with manufacturer's instructions. If possible, the unit should be run-in at reduced speed.

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Date

When the unit comes up to speed, note the frame oil pressure, check the cylinder lubricator for proper feed rate and check all coolant flows and temperatures. Adjust as necessary.

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For motor-driven units, record the no-load amperage.

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Run the unit for approximately one minute and stop it. Record the time it takes the compressor to roll to a stop.

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During the initial startup, operators should be alert for abnormal noises, pressures, temperatures, etc. Watch for smoke or other signs of overheating. Immediately shut the unit down if overheating is indicated. If an auxiliary frame lube-oil pump is provided, and it has started on unit shutdown, keep it running to facilitate cooldown.

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If overheating is suspected or smoke is coming out of the frame oil sump breather, do not open any crankcase inspection cover for at least 15 minutes. Sufficient time must elapse for the hot parts to cool. Opening a cover allows an inrush of fresh air and may trigger a crankcase explosion.

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If overheating is not indicated, open crosshead and frame covers as soon as the compressor stops turning. Check all bearings (main, thrust, and crankpin), crosshead pin bushing, and crosshead shoe temperatures. Eliminate any condition causing overheating in these parts. Replace inspection covers.

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Restart the unit and run it for approximately five minutes. Check driver and driven unit for abnormal vibration. Stop the unit and repeat internal inspection.

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Examine compressor cylinders. (Remove valve covers and inspect cylinder bore condition.)

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On lubricated cylinders, check for satisfactory lubrication of cylinder bores. Check temperature and lubrication of piston rods and packing.

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_____

Check temperatures in non-lubricated cylinders for indication of overheating.

_____

_____

Run the compressor at no load for at least a 15-minute period as long as no overheating or other signs of distress are noted. Repeat bearing and lubrication checks.

_____

_____

Reinstall suction valves and covers previously removed from each end of each cylinder. Clean parts thoroughly before installing.

_____

_____

Purge all air from compressor cylinders and piping inside process piping block valves.

_____

_____

When process gases are toxic or noxious, pressurize the cylinders with nitrogen to approximately 50 psi and check for leaks in flanged piping joints and valve covers. Use portable gas sniffers. Correct leaks.

_____

_____

Chevron Corporation

700-17

December 1988


Compressor Manual


Date

Alternately for non-toxic gases, check for leaks by gradually pressurizing the system by opening unit block valves to admit process gas.

_____

_____

Apply full suction pressure (using nitrogen or process gas) to each cylinder and recheck for leaks.

_____

_____

Blow piping and cylinders down through vent valves.

_____

_____

There are a variety of ways to run-in new packings and rings. The basic idea is to allow working parts to adjust and to seat satisfactorily without overheating or overstressing. Gradual load application is recommended to avoid burned spots on rings and packing. This damage will appreciably reduce overall life.

_____

_____

Be sure manufacturer's instructions for loading and unloading cylinders are available and have been reviewed.

_____

_____

_____

_____

Open discharge-to-suction bypasses. (Be sure bypass cooler, if any, is operational.)

_____

_____

2.

Open discharge vents (not interstage) to blowdown.

_____

_____

3.

Unload suction valves on one end of each cylinder.

_____

_____

With the compressor unloaded, start the unit and allow it to warm up in accordance with manufacturer's recommendations (at least 15 minutes).

_____

_____

Closely observe gas temperature indication for each cylinder. Do not exceed the manufacturer's recommended maximum allowable temperature in any cylinder.

_____

_____

Turn on purge gas, if any, to rod packers, distance pieces and wiper packing.

_____

_____

During the following loading procedure it is particularly important that piston rod packing be properly run-in. The rate of pressure buildup in a cylinder depends on piston rod packing leakage. Follow specific manufacturer's recommendations on the maximum rate of pressure buildup for the particular packing material supplied.

_____

_____

Step 6.

Run-in Under Load

☞

Caution Confirm that the specific run-in procedure developed insures that a non-reversing rod load condition will not occur in any cylinder.

Open all fixed and variable volume clearance pockets on each cylinder (to the maximum allowable volume). With all cylinder valves in place, unload the compressor as much as possible by one or more of the following methods: 1.

December 1988

700-18

Chevron Corporation

Compressor Manual



Date

Depending on the particular installation, it may be necessary to make special provisions for gradual partial loading until the packing seals properly. This is especially true for high-pressure applications.

_____

_____

For units equipped with discharge-to-suction bypass capability, gradually load the unit by slowly opening the discharge block valve, closing the bypass, and then slowly opening the suction block valve.

_____

_____

Note If the bypass stream is not cooled, some intake gas must be admitted to maintain safe gas temperatures.

_____

_____

For units equipped with discharge vents only, slowly open the discharge block valve and while opening it, close the vents.

_____

_____

Open the suction block valve slowly.

_____

_____

If design permits, utilize suction valve unloaders on the crank end of the cylinder to minimize pressure on the rod packing. (First, verify that the configuration of unloading will not cause non-reversing rod loading.)

_____

_____

Load the last stage (highest pressure cylinder) by opening the discharge block valve, then the suction block valve on that stage.

_____

_____

2.

Load the next highest pressure cylinder as above.

_____

_____

3.

Continue to load each succeeding lower pressure stage in a similar manner.

_____

_____

Apply full load (open discharge and suction block valves) for approximately one minute. Remove the load entirely for approximately 15 minutes to permit rings and packing to cool.

_____

_____

2.

Apply full load for two minutes and remove it for 15 minutes.

_____

_____

3.

Repeat initial step for five minutes.

_____

_____

4.

Apply full load and leave it on unless severe heating occurs in the packing.

_____

_____

☞

Caution Suction block valves must be opened fast enough to avoid rod overloads caused by an excessive compression ratio.

For multi-stage compressors, the following loading procedure is recommended: Note When stages are loaded in the following manner, no gas will be pumped. Cylinder pressures will be reduced during each stroke. This will not, however, be detrimental for the short period of time it takes to put the machine on line. 1.

Use the following procedure to break in new rings and packing on each new stage: 1.

Chevron Corporation

700-19

December 1988


Compressor Manual


Date

Packing for overheating and leakage. If severe heating occurs or the packing blows by excessively, shut the unit down, determine and correct the cause. If the packing blowby rate is low but persists for more than a few hours, shut the unit down and correct the problem.

_____

_____

2.

Suction valve temperatures by checking valve covers for excessive heating.

_____

_____

3.

Valve leakage using an ultrasonic transducer or an electronic engine analyzer.

_____

_____

Following initial break-in of rings and packing the unit may be put in service. Re-check adequacy of cooling and lubrication system operations.

_____

_____

After the unit has been in operation long enough for temperatures to stabilize, supports under compressor cylinder and pulsation dampers should be adjusted in accordance with manufacturer's recommendation.

_____

_____

Shut down the compressor after a few hours of service (or after unit has reached thermal stability).

_____

_____

Remove inspection covers and check bearings, bushings, and crosshead shoes for overheating.

_____

_____

Check piston rods and packing for overheating and adequate lubrication.

_____

_____

Remove valve covers and check for satisfactory lubrication of cylinder bores (lubricated cylinders). Check bores of non-lubricated cylinders for proper condition.

_____

_____

Retighten to manufacturer's recommended torque (or stretch) all bolting including external frame bolting, packing gland nuts, piston rod crosshead nuts, main bearing nuts, foundation bolts, driver holddown bolts, pulsation dampers, and cylinder flange mounting bolts, etc.

_____

_____

During the run-in period, make sure lubricator feed rates are properly set. In addition, check the following items: 1.

Step 7.

Bringing the Unit On-stream

After the unit has run for approximately two days, shut down the unit and perform the following steps: 1.

Check alignment of the compressor, driver, and gearbox (if any).

_____

_____

2.

Retorque holddown bolts for compressor, driver and gearbox (if any).

_____

_____

3.

Remove several valves and check each cylinder bore for proper condition.

_____

_____

4.

Check piston rod alignment.

_____

_____

5.

Check piston rod crosshead nuts for proper tightness.

_____

_____

December 1988

700-20

Chevron Corporation

Compressor Manual


Reciprocating Compressor Precommissioning Checklist (8 of 8)

6.

If a special break-in oil is used, drain oil from the frame oil system including sump, filters, coolers, pump, and piping. Fill the sump to the proper level with the lube-oil recommended for the service intended. Fill the cylinder and packing lubricator reservoir with the proper oil. Replace or clean oil filters, as applicable.

Gradually reduce the lubricant rate to cylinders and packing to the feed rate recommended by the manufacturer.

Initial

Date

_____

_____

_____

_____

Note Caution should be used in operating at maximum lubricator feed rates for extended periods to avoid excessive lube-oil accumulation in cylinders.

Chevron Corporation

700-21

December 1988


Compressor Manual

740 Centrifugal Compressor Installation Checklist The manufacturer's installation manual, equipment specifications, as-built data sheets, and the specific process system requirements should be reviewed in detail, and modifications made to this checklist, as appropriate, to cover individual requirements. Centrifugal Compressor Installation Checklist (1 of 9)

Step 1.

Initial

Date

_____

_____

Documentation

As applicable, review the following documents which cover all major compressor train components: Manufacturer's instruction manual(s) Equipment Specifications, as applicable: •

API Equipment Standards

_____

_____

•

Project Specifications

_____

_____

Purchase Documents: •

Purchase Order

_____

_____

•

Quotation Requests

_____

_____

•

List Sheets

_____

_____

•

Other documents referenced in Purchase Order

_____

_____

As-built Equipment Data Sheets

_____

_____

Performance Data/Curves

_____

_____

Lubrication Chart

_____

_____

Installation Drawings

_____

_____

Shop Mechanical/Performance Reports, and Inspection Reports

_____

_____

Shaft Alignment Chart

_____

_____

Safety Instruction Sheets

_____

_____

Maintenance History

_____

_____

Performance/Vibration History

_____

_____

Inspection/Trouble Reports done since last major turnaround

_____

_____

Existing Installations:

December 1988

700-22

Chevron Corporation

Compressor Manual


Centrifugal Compressor Installation Checklist (2 of 9) Initial

Date

Lock out and properly tag the main driver.

_____

_____

Insure all piping and hot surfaces (above 140°F) are suitably guarded or insulated for personnel protection.

_____

_____

Confirm all safety valves are installed, properly set, and tested.

_____

_____

Insure no block valves are located between the source of pressure and the safety valves, unless locked open.

_____

_____

Insure suitable guards meeting OSHA requirements are in place around all exposed rotating parts.

_____

_____


_____

_____

Relieve all pressure within the unit before any work is performed.

_____

_____

Isolate compressors handling toxic or flammable gases from process piping and purge or evacuate, as applicable.

_____

_____

Check all bill of materials for completeness of material received. Insure all tagged materials are correctly labeled.

_____

_____

Confirm required spare parts and special tools received, and location documented.

_____

_____

Take immediate action on any shortages or damage.

_____

_____

Check internal/external cleanliness.

_____

_____

Insure baseplate/skid straight and flat.

_____

_____

Insure baseplate/skid mounted compressor/driver not bolt-bound (free to move for alignment, as necessary).

_____

_____

Confirm that compressor/driver rotates freely.

_____

_____

Inspect condition of all bearings.

_____

_____

Confirm alignment shims (number, material, condition) are acceptable.

_____

_____

Confirm coupling condition is acceptable and all components received.

_____

_____

Step 2.

Step 3.

Safety Precautions

Equipment Condition (Before Installation)

As Received

Chevron Corporation

700-23

December 1988


Compressor Manual


Date

Insure storage protection requirements met (refer to the General Machinery Manual and Manufacturer's installation manual).

_____

_____

Confirm equipment inert gas blanketed or dry air/inert gas purged, as appropriate.

_____

_____

Confirm rust preventive/lubricant compatibility.

_____

_____

Schedule and perform inspection of equipment condition at regular intervals during storage.

_____

_____

Clean and properly coat metal surface of soleplates or baseplate/skid.

_____

_____

Confirm corners of soleplates or baseplate/skid are properly rounded.

_____

_____

Insure mounting feet or base are free of burrs.

_____

_____

Disconnect coupling before leveling.

_____

_____

Level soleplates or baseplate/skid in accordance with manufacturer's recommended procedure and local standards.

_____

_____

Cure concrete foundation for at least 14 days before grouting preparation.

_____

_____

Properly roughen and clean (free of oil, grease and other foreign substances) concrete surface. If cementitious grout is used, saturate concrete surfaces with water for 24 hours prior to placement of grout. Remove any free standing water before grouting. (Refer to Specification MAC-EG-3907, Grouting of Machinery for recommended procedures.)

_____

_____

Insure proper grout material/thickness.

_____

_____

Confirm anchor bolt cavities in foundation are not filled with grout.

_____

_____

Cure grout for at least three days.

_____

_____

Piping should not be connected to the equipment until grout has thoroughly cured.

_____

_____

Confirm no hollow areas or majors cracks in grouting.

_____

_____

Back off leveling bolts.

_____

_____

Tighten anchor bolts using a torque wrench to values in accordance with manufacturer's recommendation.

_____

_____

Temporary Storage:

Step 4.

Foundations and Grouting

Concrete Foundations

December 1988

700-24

Chevron Corporation

Compressor Manual



Date

Other Foundations (Structures)

_____

_____

Insure mounting plates are located at load bearing support beams.

_____

_____

Use shims of corrosion-resistant material.

_____

_____

Dowel driver after successful solo (uncoupled) run.

_____

_____

Dowel compressor after hot alignment check confirms proper alignment.

_____

_____

Install compressor and driver on foundation in accordance with the manufacturer's recommendations and local procedures.

_____

_____

Check for correct axial spacing between compressor and driver shaft ends.

_____

_____

Check axial float of motor driver.

_____

_____

Confirm that motor driver is properly positioned. (Limited end float coupling.)

_____

_____

Review and finalize the compressor train Shaft Alignment Chart.

_____

_____

For existing installations, use historical data as a basis for determining cold alignment settings necessary to achieve the desired running (hot) alignment.

_____

_____

Lubricate bearings before rotating shaft for cold alignment.

_____

_____

Install coupling per manufacturer's instructions.

_____

_____

Check for proper shim installation on flexible coupling.

_____

_____

Check for proper coupling lubrication.

_____

_____

Check alignment of all coupled equipment.

_____

_____

Install hot alignment tooling/equipment, as applicable.

_____

_____

Check hot alignment only after the compressor has been operated for several hours and stable operating temperatures reached.

_____

_____

Make final alignment moves based on a thorough review of data obtained during the hot alignment.

_____

_____

Install coupling guard.

_____

_____

Step 5.

Alignment and Couplings

Chevron Corporation

700-25

December 1988


Compressor Manual


Date

Thoroughly clean all piping and vessels which are on the suction side of any compressor to protect against damage of compressor internals during/after startup. Also thoroughly clean all lube systems as recommended below. Precautions must be taken after cleaning to insure that no further foreign material can enter the system. Cleaning of piping usually requires chemical or mechanical means, or both. Appropriately seal all component parts following cleaning.

_____

_____

Compressor flanges should remain sealed until the final piping is to be connected.

_____

_____

Mechanically clean steel piping for suction gas and blow down with air.

_____

_____

Chemically clean steel piping for lube-oil systems in accordance with appropriate procedures. Sandblasting may be appropriate for some installations.

_____

_____

Clean alloy piping in accordance with applicable project or local procedures.

_____

_____

Drain all gas suction lines thoroughly.

_____

_____

Remove all grit from sandblasted lines.

_____

_____

Confirm that piping interior is free from all dirt, scale, rust, weld slag and other foreign material.

_____

_____

Braces on expansion joints and pins in spring supports should remain in place during installation, and any subsequent testing, such as hydrotesting.

_____

_____

Piping should not be connected to the equipment until grout has thoroughly cured.

_____

_____

Confirm flange bolt holes are in line and flanges are parallel within specified tolerance.

_____

_____

Check the equipment installation (including auxiliary systems) against final drawings to insure correct location and orientation of safety valves, block valves, check valves, recycle lines, etc., as required by the specific system. Check all piping and components for proper material.

_____

_____

Check the location and setting of pipe anchors, fixed supports and spring hangers to insure they are in accordance with drawings and specifications, and properly set and anchored to avoid any casing strains.

_____

_____

Check spring supports after removal of pin to insure springs freely carry the pipe load.

_____

_____

Provide adequate allowance for expansion of suction and discharge piping.

_____

_____

Step 6.

Piping

December 1988

700-26

Chevron Corporation

Compressor Manual



Date

Maintain angular offset of expansion joints within manufacturer's prescribed limits (expansion joints not used to correct misalignment of pipe).

_____

_____

Maintain compressor and driver movement within allowable limits during piping bolt-up. If movement exceeds limits, piping must be loosened and refabricated, realigned, or anchors adjusted as required.

_____

_____

Insure suction strainers are accessible and removable without disturbing equipment alignment.

_____

_____

Inspect screen for adequate construction, compliance with specification and proper orientation.

_____

_____

Verify that strainers are installed and that piping is provided with pressure taps both upstream and downstream of the strainer.

_____

_____

Check inlet line to air compressor for corrosion protective coating of internal surface, or that line is stainless steel.

_____

_____

Confirm insulation and/or heat tracing installed in accordance with installation drawings.

_____

_____

Confirm there are no pockets or low spots in the gas piping which cannot be drained.

_____

_____

Vent all high points in liquid piping.

_____

_____

Route oil piping on frequently used vents/drains away from equipment to prevent spraying oil over equipment.

_____

_____

Inspect auxiliary equipment for properly installed block valves.

_____

_____

Insure proper thread sealant used for screwed piping. (Sealant not used when connection is seal welded.) Do not use teflon tape to seal threads on lube-oil piping.

_____

_____

Confirm purge gas to reservoirs, bearing housings, etc., connected and functional.

_____

_____

Inspect all drain lines for proper slope (l/4-inch/foot minimum).

_____

_____

Step 7.

Special Notes for Lube and Seal Systems

Since centrifugal compressor trains are often among the last items to be started up, cleanup of the lube and seal system is usually on the critical path to plant startup. Refer to MAC-MS-2983, Field Cleaning of Compressor Lube and Seal Oil Systems, and PIM-MS-2411, Descaling and Cleaning Steel Piping for additional information.

Chevron Corporation

700-27

December 1988


Compressor Manual


Date

Substantial time savings can be realized by proper planning prior to the start of flushing. Historical records from previous projects indicate revised procedures and improved planning can reduce overall flushing from five-six weeks to less than two weeks. Consider the following areas: Pre-plan approach—Put one individual in charge and familiarize all personnel with objectives.

_____

_____

Define goal of cleanliness, and establish criteria for measuring.

_____

_____

Initial startup of flush—A very effective way to expedite cleanup is to initially remove all screens, filters, orifices, or any other removable restrictions and sweep all foreign material through the system into the reservoir (make sure filters are removed and the compressor and driver seals/bearings, turbine control system and overhead seal oil tank are bypassed).

_____

_____

Schedule around-the-clock flushing right from the start.

_____

_____

Heat the oil—Optimum flushing temperatures are in the order of 160°-180°F. Permanently installed reservoir heaters will probably not be adequate. Plan to make special provisions for temporary heating of the oil.

_____

_____

Shock the system every way possible—This includes sudden changes in flow velocity, hammering on all the piping and components, and thermal shock.

_____

_____

Plan for adequate flushing velocity—Oil flushing velocity should be at least twice the normal operating velocity. Walk the piping, count fittings and definable pressure drops, determine the system curve and plot on pump curves. Consider alternate methods of maximizing flow (parallel pumps, series pumps, operate steam driven pump above its rated speed, temporarily replace positive displacement pumps with centrifugal, etc.). Check to make sure any pump bypasses back to the reservoir remain closed.

_____

_____

Maintain close and continual DAILY communication with all parties involved. Immediately resolve problems and develop a revised course of action.

_____

_____

Do not assume the system or components are clean because they were “cleaned at the factory.”

_____

_____

Do not install anything that isn't clean.

_____

_____

Disassemble and thoroughly clean all components.

_____

_____

Reassemble cleaned components in a clean work environment.

_____

_____

The key to an efficient cleaning program is recognizing that lube-oil is a very inefficient rust, slag, scale or paint remover. Timely completion therefore relies heavily on thorough cleaning of individual components and piping prior to assembly. Specifically:

December 1988

700-28

Chevron Corporation

Compressor Manual



Date

Stainless steel systems often include carbon steel block valves, slip-on flanges, coolers, filters, switch valves, and pumps.

_____

_____

Remove carbon steel components, dismantle and clean mechanically before starting flushing.

_____

_____

Carefully analyze all material that appears on the flushing screens (identify and remove source of contamination).

_____

_____

Make prompt decisions to remove contaminates or to live with them.

_____

_____

Do the previous steps concurrently with the final piping assembly and testing for the most efficient use of time.

_____

_____

Recycle through the previous steps as necessary.

_____

_____

Check all safety valves for proper location and setting.

_____

_____

Insure all indicating gages are installed, and oriented to be clearly seen by an operator when making control adjustments.

_____

_____

Test alarm, shutdown, and safety functions.

_____

_____

Confirm alarms and shutdowns are operating and arranged to permit testing while the compressor is on line.

_____

_____

Complete required loop checks and other tests of Compressor anti-surge, capacity and process control systems, confirming proper operation.

_____

_____

Consult manufacturer's instruction manual for specific installation instructions.

_____

_____

Operate turbines uncoupled and check the actual trip speed three times before coupling to the driven equipment. Trip speeds should be non-trending and all within ±1%.

_____

_____

Also confirm that trip setting is within the allowable range for all driven equipment.

_____

_____

Operate motors uncoupled from compressor to check rotation and general operation. Provide supplementary lubrication for motors normally lubricated by a shaft driven oil pump on the driven equipment.

_____

_____

Coordinate mechanical checks, such as air gap and magnetic center, with appropriate electrical personnel.

_____

_____

Check for proper rotation of all auxiliary system motor drivers.

_____

_____

Step 8.

Step 9.

Instrumentation and Controls

Drivers

Chevron Corporation

700-29

December 1988


Compressor Manual


Date

Consult the Drivers Manual for more comprehensive installation checklists for drivers.

December 1988

700-30

Chevron Corporation

Compressor Manual


750 Centrifugal Compressor Precommissioning Checklist Use the following checklist during run-in of the compressor for the first time, and also following major equipment overhauls. Review the manufacturer's installation manual and the specific process system in detail, and modify this checklist, as appropriate, to cover special requirements. Review the final modified checklist with the operators and all other personnel involved in the precommissioning to insure that everyone understands the procedures and the specific objectives involved. A Pre-startup Meeting of all concerned is highly recommended. Centrifugal Compressor Precommissioning Checklist (1 of 4) Initial Step 1.

Date

General

New equipment installations should first be checked in accordance with the Centrifugal Compressor Installation Checklist. Reconfirm checks previously completed if there has been extended time between installation and startup and/or additional work has been performed on the unit.

_____

_____

For existing installations the overhaul/repair records should first be reviewed for completeness of work and recording of pertinent data.

_____

_____

Lock out and tag main driver.

_____

_____

Insure all safety valves are installed, properly set, and tested.

_____

_____

Confirm no block valves are located between the source of pressure and safety valves, unless locked open.

_____

_____

Insure suitable guards meeting OSHA requirements are in place around all exposed rotating parts.

_____

_____


_____

_____

A list (or data sheets) covering specific data to be recorded during startup.

_____

_____

Critical speeds for all train components.

_____

_____

Any maximum temperature/pressure limits.

_____

_____

Minimum and maximum governor speed settings (turbine drivers).

_____

_____

Step 2.

Step 3.

Safety Precautions

Pre-Startup Data Review

As a minimum, the following data should be available:

Chevron Corporation

700-31

December 1988


Compressor Manual

Centrifugal Compressor Precommissioning Checklist (2 of 4) Initial

Date

Overspeed trip setting (turbine drivers).

_____

_____

Maximum turbine exhaust temperature (condensing turbines).

_____

_____

For motor drivers, determine how many restarts are permitted during one hour's time. Do not exceed these limits.

_____

_____

Review the precommissioning procedure with the appropriate operating and startup personnel, to insure a safe, reliable initial operation, and a smooth transition from startup conditions to normal operation.

_____

_____

Resolve any conflicts between precommissioning checklist and manufacturer's instruction manual procedures.

_____

_____

Define data acquisition requirements, and schedule appropriate personnel and monitoring equipment. (See Figure 700-1 for data recommended for all major machinery startups.) For turbine drivers, define the specific speed steps at which data will be taken during startup.

_____

_____

Operation on air or inert gas, when permitted, requires special precautions. Both discharge temperature and/or seal operation may be limiting factors. Specifics of the proposed operation should be reviewed in detail, and the manufacturer consulted for any recommendations or limitations on the specific equipment involved.

_____

_____

Run-in on air should only be done with an open loop for flammable gas machines with oil seals—never with a closed loop, this can be extremely dangerous.

_____

_____

Removal of all liquids from gas suction piping is mandatory. Be sure lines are drained and prewarmed, if applicable, by turning on heat tracing before operation of the compressor.

_____

_____

Confirm that the coupling and coupling guard are properly installed.

_____

_____

Remove any rust preventive, as appropriate.

_____

_____

Confirm that all instrumentation (including vibration, thrust, and temperature probes) has been calibrated, and is operational.

_____

_____

Confirm that all alarms and shutdowns have been properly set and tested.

_____

_____

Confirm that monitoring systems, including all alarms and shutdowns, are in service and not bypassed during initial operation and startup.

_____

_____

Operation on Air—Initial Startup

Step 4.

Pre-Startup Installation Check:

December 1988

700-32

Chevron Corporation

Compressor Manual



Date

Check the lube and seal system for proper oil supply pressure, temperature, and flow; and confirm that all system alarms, trips, and the auxiliary pump startup are functioning properly.

_____

_____

For turbine drivers—confirm that the main trip-throttle valve and any extraction valves trip on proper signals.

_____

_____

Open drains to remove condensate from the turbine casing and steam lines.

_____

_____

Warm the turbine by cracking open the steam supply block valve or the warmup bypass valve.

_____

_____

Close drain valves when condensate has been purged.

_____

_____

Open sealing steam lines, when provided, at both low and high pressure ends.

_____

_____

Manually begin turbine rotation up to slow roll speed (approximately 500 RPM) by further cracking open the main steam supply valve.

_____

_____

Allow the unit to warm up while monitoring operation. Watch exhaust temperature on condensing units to make sure it does not exceed the specified limit while at reduced speed.

_____

_____

Manually trip overspeed mechanism in accordance with local procedures to check for proper action. Reset and continue startup.

_____

_____

Gradually increase speed in steps as previously defined. Record required data at each step. Pass through criticals rapidly without stopping.

_____

_____

Monitor unit operation as speed is increased to minimum governor. Increase to approximately 100% speed on governor control. Check that the governor is controlling to proper speed.

_____

_____

Step 5.

Startup

Revise the following general checklist for the specific installation and equipment involved, and incorporate detailed procedures from the manufacturers instruction manual(s), as appropriate. Steam Turbine Drivers

Motor Drivers Determine how many restarts are permitted in one hour's time and follow those limits.

Chevron Corporation

700-33

December 1988


Compressor Manual


Date

Process for excessively high flow or pressure demands.

_____

_____

Improper electrical switchgear settings.

_____

_____

Low system voltage during starting.

_____

_____

Mechanical compressor problem such as bad bearing or internal rubbing.

_____

_____

☞

Caution Do not frequently push the “Stop” button before motor has reached full speed, particularly on larger motors. Do not push the “Start” button until motor has coasted to a complete stop. Such actions may trip or even damage the electrical equipment.

If motor repeatedly trips on start attempts, check:

Electronic Monitoring of Startup Note The following information is applicable to electronic monitoring of centrifugal-compressor start-ups.

December 1988

700-34

Chevron Corporation

Compressor Manual

Fig. 700-1


Recommended Startup Data for Major Turbomachinery

Data Type

When Recorded

Slow Roll

Minimum Governor

Maximum Governor

1. Scope Photos

x

x

x

2. Hand Logged Data

x

x

x

3. Probe Spectrums

x

x

x

4. FM Tape Recording

x

5. Bode/Nyquist Plots

x

6. Raster Plots

x

7. Strip Chart

x

During Speed Change

Continuous

x

x x x x

8. Velocity Spectrums

x

x

9. Acceleration Spectrums

x

x

Notes:

500 RPM Intervals

1. Scope photos should be fully documented, and on X-Y probes, should include filtered and unfiltered orbits at speeds above slow roll. All photos must be done in real-time. 2. Hand logged data should be logged as often as possible during the run as outlined above. Do not try to hand log data within the critical range, which must be traversed rapidly. (Refer to Figure 700-2 for a hand-log form.) 3. Probe spectrums should be recorded on each probe as outlined above. Averaging is not necessary if the spectrum is stable. (i.e., no pulsating amplitudes, etc.) 4. FM tape recordings should include a known reference calibration signal and a tape log. At a minimum, the X-Y probes on each side of each coupling, one of the X-Y probes at the end of the machine opposite the coupling, and the key-phasor probe should be recorded for each machine casing. (This will require more than one 8-channel recorder if the train consists of more than two machine cases.) Under no circumstances should the recordings be interrupted for any reason. 5. Bode/Nyquist plots should be made for all radial probes. Normally, one probe is done in real-time during startup and the others are done from the tape recorded signals. 6. Raster plots should be made at 500 RPM intervals for each X-Y probe. These may also be done from the tape. 7. Strip chart recordings should be made for any radial probe(s) not being tape recorded, and as a minimum should include speed and unfiltered amplitude. If all radial probes are being tape recorded, a strip chart recording of axial position versus speed should be recorded. 8. Velocity spectrums should be made at all points on the bearing caps for each machine as outlined previously. A minimum of eight linear averages should be done, and each spectral line's frequency identified. 9. Acceleration spectrums should be made on turbine casings and gearboxes as previously outlined, using a stud-mounted accelerometer. These must also be averaged at least eight times and each spectral line over 0.5 G's should have the frequency identified on the plots.

Chevron Corporation

700-35

December 1988

Turbomachinery Hand-logged Data Sheet


Fig. 700-2

December 1988

700-36

Compressor Manual

Chevron Corporation

78025839 CHEVRON Compressors Installation and Pre Commissioning

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