78025839-CHEVRON-Compressors-Installation-and-Pre-Commissioning.pdf

700 700 Comp Comprresso essorr Inst Instal alllatio ation n and and Precommissioning Abstract This section contains general guidelines and checklists for installation and precommissioning of new compressors and recommissioning of existing ones.

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 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 Instal Installat lation ion/Pr /Preco ecommis mmissio sionin ning g Checkl Checklist istss 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 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.


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 Instal Installat lation ion/Pr /Preco ecommis mmissio sionin ning g Checkl Checklist istss 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 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.

Compressor Manual


•

Spec Specif ific icat atio ion n MACMAC-MS MS-2 -298 983, 3, Field Cleaning of Compressor Lube-Oil and Seal Oil Systems.

•

Spec Specif ific icaation tion MACMAC-EG EG-3 -390 907, 7, Grouting of Machinery.

•

Spec Specif ific icaation tion PIM PIM-M -MSS-2 2411, 411, Descaling and Cleaning Clean ing Steel Piping.

•

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

•

Machinery Reliability Reliabili ty 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)

st artup data described d escribed in the following fo llowing pages should sh ould be reduced Note All of the startup 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.


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

_____

_____

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

_____

_____

•

Project Specifications

_____

_____

Purchase Documents: •

Purchase Order

_____

_____

•

Quotation Request

_____

_____

•

List Sheets

_____

_____

•

Other Documents Referenced in Purchase Order

_____

_____

Compressor Manual


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.

_____

_____

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.

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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


Compressor Manual


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Insure baseplate/skid is straight and flat.

_____

_____

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

_____

_____

Confirm compressor/driver rotates freely.

_____

_____

Inspect condition of all bearings.

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

Confirm rust preventive/lubricant compatibility.

_____

_____

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.)

_____

_____

Temporary Storage:

Step 4.

Foundations and Grouting

Concrete Foundations:

Compressor Manual



Date

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

_____

_____

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

_____

_____

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

_____

_____

Back off leveling bolts.

_____

_____

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

_____

_____

Locate mounting plates at load bearing support beams.

_____

_____

Insure shims are of corrosion-resistant material.

_____

_____

Properly level baseplate/skid.

_____

_____

Tighten bolting using a torque wrench to recommended values.

_____

_____

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.

_____

_____

Thoroughly clean all lube systems as recommended below.

_____

_____

Isolate the system, and if possible, inert gas blanket it after cleaning to insure


Compressor Manual


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

_____

_____

Completely remove all grit from sandblasted lines.

_____

_____

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

_____

_____

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.)

_____

_____

Flush frame lube-oil and packing cooling oil piping.

_____

_____

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

_____

_____

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

_____

_____

_____

_____

Pulsation Dampers/Separators

Step 6.

Piping Installation/Support Systems/Alignment

Check all process and auxiliary piping valves, including safety valves, for proper location, position, flow direction, and tightness of supports and anchors. Inspect suction strainers, if used, for proper installation, correct orientation, and differential pressure gage, if applicable. If strainers have fine mesh

Compressor Manual



Date

Inspect auxiliary equipment for properly installed block valves.

_____

_____

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.

_____

_____

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

_____

_____

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

_____

_____

Insure suction and discharge piping is properly supported and clamped.

_____

_____

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

_____

_____

Insure provision is made for thermal expansion of discharge line.

_____

_____

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

_____

_____

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

_____

_____

Check alignment of all coupled equipment.

_____

_____

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

_____

_____

Check cylinder-to-frame alignment by measuring piston rod runout in accord ith f t ' d ti


Compressor Manual


Date

_____

_____

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

_____

_____

Avoid use of raw water due to its fouling tendency.

_____

_____

Properly inhibit any coolant to minimize rusting.

_____

_____

Completely fill cylinder jackets with appropriate coolant.

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

Replace all vent plugs.

_____

_____

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

Compressor Manual



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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:

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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.

_____

_____

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

_____

_____

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: 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


Compressor Manual


Date

Drain lubricator of all rust preventive oil unless compatible.

_____

_____

Fill the lubricator with the proper grade of cylinder oil.

_____

_____

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.

_____

_____

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.

_____

_____

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.

_____

_____

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.

_____

_____

Apply lubricating oil to the cylinder bore.

_____

_____

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

_____

_____

Step 10.

Cylinder Lubrication—Lubricated Units

Compressor Manual



Date

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

_____

_____

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.

_____

_____

Confirm that all manual unloaders are operating freely.

_____

_____

Step 13.

Drivers

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


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.

_____

_____

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.

_____

_____

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

_____

_____

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

_____

_____

Step 1.

Step 2.

General

Safety Precautions

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.

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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

_____

_____

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.

_____

_____

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

_____

_____

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

_____

_____

Step 3.

Step 4.

Pre-Run-in Data Review

Pre-Run-in Installation Check


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.

_____

_____

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

_____

_____

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.

_____

_____

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

_____

_____

Check that the lubricator reservoir is filled.

_____

_____

Confirm the proper break-in oil is being used.

_____

_____

Squirt oil on rods prior to initial run-in.

_____

_____

Flood the packing with lubricant.

_____

_____

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

_____

_____

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

_____

_____

Prime divider block type lubricator systems with a priming pump.

_____

_____

For lubricated compressor cylinders:

Compressor Manual



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.

_____

_____

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

_____

_____

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

_____

_____

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.

_____

_____

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.

_____

_____

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.

_____

_____

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.

_____

_____


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.

_____

_____

_____

_____

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.

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

Compressor Manual



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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.)

_____

_____



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,


Compressor Manual


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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.

_____

_____

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

Check piston rods and packing for overheating and adequate lubrication

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

Initial

Date

_____

_____

_____

_____


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

_____

_____

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.

_____

_____

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

_____

_____

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.

_____

_____

_____

_____

Step 2.

Step 3.

Safety Precautions

Equipment Condition (Before Installation)

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


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.

_____

_____

Temporary Storage:

Step 4.

Foundations and Grouting

Concrete Foundations

Compressor Manual



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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.

_____

_____

Step 5.

Alignment and Couplings

Check for proper shim installation on flexible coupling


Compressor Manual


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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.

_____

_____

Step 6.

Piping

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

Compressor Manual



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

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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.

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

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

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

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

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Confirm insulation and/or heat tracing 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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Vent all high points in liquid piping.

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


Compressor Manual


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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.

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Define goal of cleanliness, and establish criteria for measuring.

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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).

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

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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.

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

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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.

Compressor Manual



Date

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

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

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

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

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

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Recycle through the previous steps as necessary.

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Check all safety valves for proper location and setting.

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

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Test alarm, shutdown, and safety functions.

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

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Step 8.

Instrumentation and Controls

Complete required loop checks and other tests of Compressor anti-surge, it d t l t fi i ti


Compressor Manual

Centrifugal Compressor Installation Checklist (9 of 9) Initial Consult the Drivers Manual for more comprehensive installation checklists for drivers.

Date

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.

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

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Step 2.

Safety Precautions

Lock out and tag main driver. Insure all safety valves are installed properly set and tested


Compressor Manual

Centrifugal Compressor Precommissioning Checklist (2 of 4) Initial

Date

Overspeed trip setting (turbine drivers).

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Maximum turbine exhaust temperature (condensing turbines).

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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 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.

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

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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.

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Operation on Air—Initial 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

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.

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

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

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

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Close drain valves when condensate has been purged.

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

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

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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

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


Compressor Manual


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Process for excessively high flow or pressure demands.

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Improper electrical switchgear settings.

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Low system voltage during starting.

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Mechanical compressor problem such as bad bearing or internal rubbing.

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

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.

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

x

x x x x

x

9.

x

x

Notes:

Continuous

x

8. Velocity Spectrums Acceleration Spectrums

500 RPM Intervals

During Speed Change

1. Scope photos should be fully documented, and on X-Y probes, should include filtered and unfiltered orbits at speeds above s low 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 t ape 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 t he 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.

78025839-CHEVRON-Compressors-Installation-and-Pre-Commissioning.pdf

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