CHEVRON Compressors Installation and Pre Commissioning PDF

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

In general, the Installation Checklists cover items to be done well in advance of,
and in preparation for the initial equipment run-in and startup. They are applicable
to most common on-shore and off-shore installations.
The Precommissioning Checklists should be used immediately preceding startup.
These checklists cover a final check of equipment readiness and general steps to be
followed during equipment run-in and startup. As with the Installation Checklists,
the Precommissioning Checklists cover general requirements applicable to most
installations.
These checklists are general, and do not include specific acceptance criteria (align-
ment tolerances, pipe forces, vibration limits, etc.). These criteria should be devel-
oped 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 manu-
facturer's instruction manual for detailed run-in/startup procedures specific to the
equipment involved, and modify the final checklist accordingly.
712 Summary
Successful startups depend on:
Documented execution of maintenance/installation work during the 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 review
timing, communications during startup, contingencies, startup sequencing, and
other pertinent items.
713 References
The following provide additional information:
December 1988 700-2 Chevron Corporation

Compressor Manual 700 Compressor Installation and Precommissioning
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 ProceduresEl Segundo Refinery (machinery stan-
dards, repair and operating procedures, and specific checklists).
Total Alignment, V.R. Dodd (machinery alignment standards, procedures, and
general background)
Note All of the startup data described in the following pages should be reduced
during and immediately after the startup, then filed in the appropriate machine
binder.
Instructions are covered in detail in the CUSA Mfg., IMI Candidate Manual. This
standard startup information is used routinely and successfully in all CUSA refin-
eries.

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)

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. _____ _____


Initial Date
Insure all piping and hot surfaces (above 140F) 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
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
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 SeparatorsNew 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
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
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
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
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
Step 10. Cylinder LubricationLubricated 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
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.

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 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. _____ _____
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. _____ _____


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. _____ _____
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
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
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
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
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
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
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.

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)

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 _____ _____


Initial Date
Lock out and properly tag the main driver. _____ _____
Insure all piping and hot surfaces (above 140F) 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. _____ _____
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
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
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
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
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
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 approachPut one individual in charge and familiarize all
personnel with objectives. _____ _____
Define goal of cleanliness, and establish criteria for measuring. _____ _____
Initial startup of flushA 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 oilOptimum flushing temperatures are in the order of 160-180F.
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 possibleThis includes sudden changes in flow
velocity, hammering on all the piping and components, and thermal shock. _____ _____
Plan for adequate flushing velocityOil 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
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.

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 proce-
dures 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 Compressor
Installation Checklist.
Reconfirm checks previously completed if there has been extended time
between installation and startup and/or additional work has been performed on
the unit. _____ _____
For existing installations the overhaul/repair records should first be reviewed
for completeness of work and recording of pertinent data. _____ _____
Lock out and tag main driver. _____ _____
Insure all safety valves are installed, properly set, and tested. _____ _____
Confirm no block valves are located between the source of pressure and safety
valves, unless locked open. _____ _____
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). _____ _____


Initial Date
Overspeed trip setting (turbine drivers). _____ _____
Maximum turbine exhaust temperature (condensing turbines). _____ _____
For motor drivers, determine how many restarts are permitted during one
hour's time. Do not exceed these limits. _____ _____
Review the precommissioning procedure with the appropriate operating and
startup personnel, to insure a safe, reliable initial operation, and a smooth 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 AirInitial 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 sealsnever 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
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 driversconfirm 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
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.

Fig. 700-1 Recommended Startup Data for Major Turbomachinery

Data Type When Recorded
During
Minimum Maximum 500 RPM Speed Contin-
Slow Roll Governor Governor Intervals Change 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.

Fig. 700-2 Turbomachinery Hand-logged Data Sheet

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