CHEVRON Compressors - Installation and Pre Commissioning

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700 Compressor Installation and Precommissioning

AbstractThis section contains general guidelines and checklists for installation and precmissioning 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

Chevron Corporation 700-1 December 1988

700 Compressor Installation and Precommissioning Compressor Manual

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710 IntroductionThese guidelines focus on new installations, although many aspects also applyexisting installations where equipment has been repaired, rerated, retrofitted, e

Proper compressor installation and precommissioning helps ensure trouble-freestartup and long-term reliability. Thorough inspection and critical review during each phase of the installation process eliminates “built-in” deficiencies or problewhich later result in equipment failures or poor performance. The checklists in tsection are intended to aid in this inspection/review process.

711 Installation/Precommissioning ChecklistsIn 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 applicato most common on-shore and off-shore installations.

The Precommissioning Checklists should be used immediately preceding startupThese checklists cover a final check of equipment readiness and general stepsfollowed during equipment run-in and startup. As with the Installation Checkliststhe Precommissioning Checklists cover general requirements applicable to mosinstallations.

These checklists are general, and do not include specific acceptance criteria (ament tolerances, pipe forces, vibration limits, etc.). These criteria should be devoped for the specific application based on the manufacturer's instruction manuaapplicable industry standards, project specifications, and local practice. Any discrepancies should be resolved prior to installation or start-up. Consult the mfacturer's instruction manual for detailed run-in/startup procedures specific to thequipment involved, and modify the final checklist accordingly.

712 SummarySuccessful startups depend on:

• Documented execution of maintenance/installation work during the turn-around/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 reviewtiming, communications during startup, contingencies, startup sequencing, other pertinent items.

713 ReferencesThe following provide additional information:

December 1988 700-2 Chevron Corporation

Compressor Manual 700 Compressor Installation and Precommissioning

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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 stan-dards, repair and operating procedures, and specific checklists).

• Total Alignment, V.R. Dodd (machinery alignment standards, procedures, angeneral background)

Note All of the startup data described in the following pages should be reduceduring 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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720 Reciprocating Compressor Installation ChecklistThe manufacturer's installation manual, equipment specifications, as-built data sheets, and the specific process requirements should be reviewed in detaiand modifications made to this checklist, as appropriate, to cover individual requirements.

Reciprocating Compressor Installation Checklist (1 of 10)

Initial Date

Step 1. 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 _____ __

As-built Equipment Data Sheets _____ ____

Performance Data _____ _____

Lubrication Chart _____ _____

Installation Drawings _____ _____

Shop Test/Inspection Records and Reports _____ ___

Safety Instruction Sheets _____ ____

Existing Installations:

Maintenance History _____ _____

Performance/Vibration History _____ _____

Inspection/Trouble Reports since last major turnaround _____ __

Step 2. Safety Precautions

Lock out and properly tag the main driver. _____ ____



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Insure all piping and hot surfaces (above 140°F) are suitably guarded or insu-lated 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). _____ _____

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. _____ _

Step 3. Equipment Condition (Before Installation)

As Received:

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

Insure all required spare parts and special tools received, and location docu-mented. Take immediate action on any shortages or damage. _____ _

Check internal/external cleanliness. _____ ____

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

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


Initial Date



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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. _____

Temporary Storage:

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.) _____ ____

Step 4. Foundations and Grouting

Concrete Foundations:

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

Check for properly rounded corners of soleplates or rails. _____ __

Confirm the mounting feet or base are free of burrs. _____ ___

Disconnect coupling before leveling. _____ ____

Level soleplates, rails, and compressor parts 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-MS-3907, Grouting of Machinery, for recommended procedures.) _____ ____

Insure proper grout material/thickness. _____ ____


Initial Date



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

Cure grout for at least three days. Piping should not be connected to equip-ment 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 manu-facturer's recommendation. _____ ____

Other Foundations (Structures):

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. _____ __

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 that no further foreign material can enter the system. _____ __

Piping

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. _____ ____

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

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._____ _____

Thoroughly drain all gas suction lines. _____ ____

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


Initial Date



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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. _____ ____

Pulsation Dampers/Separators

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. _____ _____

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 overlay, orient so that flow contacts mesh overlay first. _____ ___

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

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

Insure correct separator mesh material, with adequate corrosion resistance. _____

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

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. _____ ____

Vent all high points in liquid piping. _____ _____

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

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


Initial Date



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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 accor-dance with manufacturer's recommendations. _____ ___

Check cylinder-to-frame alignment by measuring piston rod runout in accor-dance with manufacturer's recommendations. _____ ___

Step 7. Compressor Valves/Cylinders

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

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

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

Confirm all valves are correct for the service intended. _____ ___

Inspect valves for correct installation in the cylinders. _____ ___

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. _____ _____

Check valve gaskets for correct type and material. _____ ___

Use torque wrench to insure valve cap holddown bolts are torqued to manufac-turer's recommended values to avoid valve seat distortion. _____ ____


Initial Date



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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

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. _____ ____

Static Cooling

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. _____ __

Thermosyphon Cooling

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. _____ _____

Forced Coolant System

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

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

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 high-point of the line. _____ _____

Shell-and-Tube Type Oil Cooler:

Run coolant through to confirm all connections are tight. _____ ___

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

Water- or Oil-Cooled Packing Assemblies:


Initial Date



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Check for external leaks, and vent air from system piping. _____ __

Step 9. Frame Lubrication

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 mate-rial, and clean as necessary. _____ ____

Flush the frame lubrication system in accordance with manufacturer's recom-mendations. (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. _____ _____

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 lines are connected. Bar the crankshaft through 90 degrees every 10-15 minutes during the flush cycle on each bearing. _____ ___

If special flush oil is used, completely drain frame, external piping and equip-ment 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. _____ ____

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

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. _____ _

Check internal piping for tightness. _____ ____

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.) _____ ___

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


Initial Date



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Step 10. Cylinder Lubrication—Lubricated Units

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. (Gener-ally, 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 lubrica-tors 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 crank-case). Clean, and apply a few drops of oil. _____ ___

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

Step 11. Non-lubricated Cylinders

Carefully examine all portions of cylinders, pistons, and rods for foreign mate-rial. _____ _____

Note It is extremely important that all components be thoroughly cleaned. _____ _____

Check suction filters, if any, for cleanliness. _____ ____

Step 12. Instrumentation and Controls

Check all safety valves for proper location and setting. _____ ___

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

Test all alarm, shutdown, and safety functions. _____ ___


Initial Date



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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.


Initial Date



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730 Reciprocating Compressor Precommissioning ChecklistUse the following checklist during run-in of the compressor for the first time, analso following major equipment overhauls. Review the manufacturer's installa-tion 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 oper-ating procedures/training has been implemented in accordance with local prac-tice. A Pre-startup Meeting of all concerned is highly recommended. _____ _____

Step 1. General

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. _____ ____


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

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

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

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

Insure outlets of crankcase and distance piece explosion relief doors, if any, are pointed 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, and remove all oil from floors or decking. _____ _____



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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. _____ ___

Step 3. Pre-Run-in Data Review

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 4. Pre-Run-in Installation Check

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

Insure all alarms and shutdown have been set and tested. _____ _

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

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

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

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


Initial Date



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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. _____ ___

For lubricated compressor cylinders:

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. _____ ___

Check lubricator oil level. _____ _____

Start lubricator motor (if separately driven). _____ ____

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. _____ __

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. _____ ___


Initial Date



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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 temper-atures. 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, pres-sures, temperatures, etc. Watch for smoke or other signs of overheating. Imme-diately 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 condi-tion 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. _____ _

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

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

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. _____ __


Initial Date



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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. _____ ___

Step 6. Run-in Under Load

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. _____ ___

☞ Caution Confirm that the specific run-in procedure developed insures that a non-reversing rod load condi-tion 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 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 accor-dance 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 recom-mendations on the maximum rate of pressure buildup for the particular packing material supplied. _____ _____


Initial Date



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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 config-uration 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, however, be detrimental for the short period of time it takes to put the machine on line.

1. 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. _____

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

1. Apply full load (open discharge and suction block valves) for approxi-mately 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. _____ _


Initial Date



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

1. 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. _____ _____

Step 7. Bringing the Unit On-stream

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. _____ ___

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. _____ __


Initial Date



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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



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740 Centrifugal Compressor Installation ChecklistThe manufacturer's installation manual, equipment specifications, as-built data sheets, and the specific process system requirements should be reviewedin detail, and modifications made to this checklist, as appropriate, to cover individual requirements.

Centrifugal Compressor Installation Checklist (1 of 9)

Initial Date

Step 1. 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 _____ ____

Existing Installations:

Maintenance History _____ _____

Performance/Vibration History _____ _____

Inspection/Trouble Reports done since last major turnaround _____ __



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Lock out and properly tag the main driver. _____ ____

Insure all piping and hot surfaces (above 140°F) are suitably guarded or insu-lated 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. _____ ___

Step 3. Equipment Condition (Before Installation)

As Received

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 docu-mented. _____ _____

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. _____ _


Initial Date



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Temporary Storage:

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 appro-priate. _____ _____

Confirm rust preventive/lubricant compatibility. _____ ____

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

Step 4. Foundations and Grouting

Concrete Foundations

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 recom-mended 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 manu-facturer's recommendation. _____ ____


Initial Date



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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. _____ _

Step 5. Alignment and Couplings

Install compressor and driver on foundation in accordance with the manufac-turer'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. _____ _____


Initial Date



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Step 6. Piping

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 mate-rial 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 appro-priate 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. _____


Initial Date



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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 refab-ricated, realigned, or anchors adjusted as required. _____ __

Insure suction strainers are accessible and removable without disturbing equip-ment 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 func-tional. _____ _____

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.


Initial Date



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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 overflushing 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 defin-able 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. _____ _____

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

Disassemble and thoroughly clean all components. _____ _____

Reassemble cleaned components in a clean work environment. _____ _


Initial Date



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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. _____ __

Step 8. Instrumentation and Controls

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. _____ _

Step 9. Drivers

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 equip-ment. _____ _____

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. _____ ___


Initial Date



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


Initial Date



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750 Centrifugal Compressor Precommissioning ChecklistUse the following checklist during run-in of the compressor for the first time, analso following major equipment overhauls. Review the manufacturer's installatiomanual 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 procdures and the specific objectives involved. A Pre-startup Meeting of all concerned is highly recommended.

Centrifugal Compressor Precommissioning Checklist (1 of 4)

Initial Date

Step 1. General

New equipment installations should first be checked in accordance with the Centrifugal CompressoInstallation 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. _____ ____


Step 3. Pre-Startup Data Review

As a minimum, the following data should be available:

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). _____ __



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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 tran-sition 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—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 manu-facturer 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. _____ _____

Step 4. Pre-Startup Installation Check:

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 opera-tion 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. _____ _


Initial Date



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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 extrac-tion valves trip on proper signals. _____ ____

Step 5. Startup

Revise the following general checklist for the specific installation and equip-ment involved, and incorporate detailed procedures from the manufacturers instruction manual(s), as appropriate.

Steam Turbine Drivers

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 tempera-ture 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. _____ ____

Motor Drivers

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


Initial Date



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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:

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. _____ _

Electronic Monitoring of Startup

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


Initial Date



Fig. 700-1 Recommended Startup Data for Major Turbomachinery

Data Type When Recorded

Slow RollMinimum Governor

Maximum Governor

500 RPM Intervals

During Speed

ChangeContin-

uous

1. Scope Photos x x x

2. Hand Logged Data x x x x

3. Probe Spectrums x x x

4. FM Tape Recording x x

5. Bode/Nyquist Plots x x

6. Raster Plots x x

7. Strip Chart x x

8. Velocity Spectrums x x

9. Acceleration Spectrums x x

Notes: 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 acceler-ometer. 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.


700 Compressor Installation and Precom

missioning

Compressor M

anual

December 1988

700-36Chevron Corporation

Fig. 700-2Turbom

achinery Hand-logged Data Sheet

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