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NGBC Assembly and Installation Timeline Cogen Project

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NGBC Assembly and Installation Timeline Cogen Project


Civil foundations complete

Assembly and Installation Preparation


Verification of skid anchor bolt locations before setting bolts in the concrete Set the anchor bolts at the time concrete is poured Ensure leveling of the slab surface Wash all loose concrete and dirt from the top of the slab Check anchor bolts for any burrs or concrete Install a sleeve around the portion of the anchor / jack bolt which will be in contact wilth the grout Install plates under internal anchor bolts (refer to AG Installation Dwg step-2) Check for capabilities and fitness of rigging equipment for lifting of skid (Rigging study approval) Assembly and Installation Preparation for PLC/Control Panel 3900A Rigging and Welding works on PLC/Control Panel 3900A

Installation of Compressor Skid, Cooler Skid,Motor and PLC/Control Panel 3900A


Lowering the skids over the anchor bolts and installation of timbers under the skid Install round plates under each jack bolt Grease the jack bolts Add foam sleeves around the jack bolts Remove the timbers and slowly lower each skid supported by jack bolts Verify that each skid is setting securely on its jack bolts and check level Installation the Motor and its Junction Box Installation of Power/Control Cables on Main motor and Lube Oil Motor Installation of the PLC/Control Panel/NGC MCCs Laying of Interconnecting Cables from JB's 3913 & 3915 Laying of Interconnecting Cables from/to DCS Panels Laying of Interconnecting Cables from/to MCC Connection of UPS Power supply Cables Terminations of the Cables as per Termination Schedule Termination of Grounding/Shielding Cables Installation and Wiring of HMI module Connection of Ethernet Switch and DeviceNet modules

Alignment Checks
Use the jack bolts to level / align the frame within 0.005" longitudinally and side to side Ensure all jack bolts have uniform loading Ensure 50.8 mm of grout between bottom of the skid and top of concrete AG serviceman to conduct pre-grouting alignment check AG service man to fill out compressor pre-start up checklist and misc clearance checks Check coupling for preliminary alignment

Grouting
Build a FORM that is 50.8MM - 101.6 mm higher than the botton flange of the skid Grout the Skid using high strength epoxy grout Run 3 chains under each skid to eliminate all voids under the skids Pour the grout from one side of the skid only Allow the grout to cure

Post-Grouting
Install the plate washers over the interior anchor bolts of the main skid Weld the plate washers in place Torque the interior anchor bolts to the torque values determined by foundation design Torque all anchor bolt nuts Install the process piping, start-up strainers, pipe clamps, relief valves, misc piping/conduits etc

Installation of Piping, supports and misc structure


Installation of Off-skid pipe supports and shims where necessary

Installation of clearance pockets, 3rd stage suction scrubber and pipe btw scrubber and suction bottle Installation of misc screwed piping and electrical connections to the scrubber

Final Alignment / Installation Mechanical Checks


Remove main drive coupling spider Verify motor's direction of rotation Final Alignment must be completed by AG Service A hot alingment must be carried out by AG service technician Drive motor instrumentation must be connected to the MCC Verify that bearing/stator temp indicators are connected properly Anchor bolt nuts and coupling bolts must be torqued weekly during the first 30 days of operation Fill out and verify for check holes by running pre-lube for 1 hr Check and record piston TDC and BDC clearances after setting up VVCP Check and record piston ring clearances Check freedom of piping and supports as per drawing Check wire harnesses and ensure all openings closed Ensure proper housekeeping and signing off of all permits Set the initial lube rates to compressor cylinders Set final lube rates after 30 days

Pre-commissioning/Commissioning
Performing Continuity checks on the installed cables

Perform pre-commissioning checks on the Software Perform pre-commissioning checks and parameterization on the HMI Perform the wiring terminations' verification and other integrity checks on the PLC Panel / Skid Verify the integrity of Interconnect signals with DCS & MCC Perform all other pre commissioning checks as per vendor standard/recommendations Perform dry run of the machine in coordination with the client E&I/Operation Team Perform the Test Run on the machine (compressor) Tuning of Controls and final parameterization of the program/HMI during commissioning Overall test run of the Co-Gen Plan Providing password of all levels (E&I/Operation) Providing complete Software back-up of the program along with the latest PLC & HMI software versions to the cli Providing final as built drawings / documentation's Any other scope required for the pre commissioning and commissioning of the NGC Packages and its integration

Reference: Operation and Maintenance Manual - AG Equipment Co Shipping and Re-assembly-Installation InstallationStepsRevision2 Location in shared drive: Project/ General / Natural Gas Compressor Manual

Aug-11 Duration
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ions to the client

s integration with the rest of the plant

Sep-11
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