Table of Contents
| Section | Title | Page |
| Purpose | 2 | |
| Scope | 2 | |
| Related Documents | 2 | |
| Responsibilities | 3 | |
| Reports | 3 | |
| Equipment Unloading | 4 | |
| Job Review Meeting | 4 | |
| Inspection and Preservation | 4 | |
| Foundation Requirements | 5 | |
| Compressor Base Frame Installation and Erection | 6 | |
| Compressor and Motor Commissioning | 10 | |
| Compressor Test Runs | 12 | |
| Acceptance | 14 | |
| Change Log | 14 | |
| Expansion Joint Detail Utilizing the Secondary Seal Design | 9 | |
| Anchor Bolt and Leveling Screw Assembly | 9 |
1. PURPOSE
1.1 This global specification defines the minimum requirements for the design and installation of the foundation for an oil flooded screw compressor for process, flammable, and/or toxic gas compression. Section 9, “Foundation Requirements,” of this specification is intended to be used by the project civil engineer to design the foundation. It is also intended that Section 9 of this specification be used as part of the civil construction package. Additionally, this specification defines the minimum requirements for the installation, erection, commissioning, and start-up of such an oil flooded screw compressor. This specification is intended to be used as part of the mechanical construction package for the compressor.
2. SCOPE
2.1 This specification applies to oil flooded screw compressors in process, flammable, and/or toxic gas compression service.
2.2 This specification also outlines the scope of work split for performing those tasks in a guideline form and serves as a work checklist for those tasks.
2.3 Scope of Work
2.3.1 The installation includes the foundation installation and preparation, equipment unloading, job review, preservation, setting, compressor systems assembly, level and anchor, preliminary alignment and grouting, installation, and connecting of all equipment associated with the compressor.
2.3.2 The compressor erection includes installing any components of the base frame assembly removed for shipping.
2.3.3 System commissioning includes piping blow-out, instrument, unloading and recycle system checkout, lube oil system checkout, including pre-lube logic and cooling water system flush.
2.3.4 Compressor start-up includes mechanical run-in on nitrogen.
3. RELATED DOCUMENTS
3.1 Company Engineering Documents (Worldwide Facilities) 4CS02001A Anchor Bolt Design and Selection
3.2 Company Engineering Documents (European Facilities or European Engineered Facilities Worldwide Only) M10 Concrete and Reinforcement 4ECE-M13 Grouting of Equipment and Structures
3.3 Company Engineering Documents (U.S. Facilities or U.S. Engineered Facilities Worldwide Only) 4ACS-640102 Concrete Work 4ACS-640106 Grouting of Equipment and Structural Steel 4WCE-600500 Crane and Lifting Procedures
4. RESPONSIBILITIES
Note: The Company machinery representative referenced in this document will either be the machinery engineer or the Product Supply Organization (PSO) mechanical technician or supplier representative.
4.1 The Company representative, usually the Construction Superintendent, has overall responsibility for the construction contract and will implement these procedures and the proper installation of the machine. The Company representative will coordinate the construction contractor’s effort, and ultimately be responsible to accept the machine from the construction contractor, hereafter referred to as “the contractor.”
4.2 The Company representative might delegate technical area authority to the following people as required: Company Machinery Engineer Company PSO Mechanical Technician Company PSO Mechanical Engineer Supplier representative
4.3 The Company machinery representative will be present on-site for a job review, before the beginning of the contractor’s installation work.
4.4 The Company machinery representative and/or supplier representative will assist the Company representative in technical areas such as installation, inspection, and certain running clearance checks, as required.
4.5 The contractor shall perform all work in accordance with the contract. This includes material, labor, and labor supervision.
4.6 The Company machinery representative will ensure that each of the tasks in this procedure has been properly completed. Each task shall be completed one time, unless otherwise required to be repeated for technical reasons. Items in the procedure followed by a “(W)” shall be witnessed by an Company machinery representative.
4.7 The Company machinery representative will prepare data sheets to record erection and start-up data. These will be supplied to the Company PSO mechanical technician or supplier representative before equipment arriving on site.
5. REPORTS
5.1 The Company machinery representative will maintain the following logs and reports:
5.1.1 Daily log showing machinery work activity.
5.1.2 Data log on clearances and alignment according to erection procedure.
5.1.3 Weekly report on the status of the machinery erection and commissioning.
5.2 Before leaving the site, the Company machinery representative or supplier representative will ensure that the requirement in paragraph 5.1.2 is complete. The Company machinery representative will ensure that copies of items in paragraphs 5.1.2 and 5.1.3 are distributed to the Company Project Engineering, Machinery Engineering, Construction Engineering, and PSO Departments. A copy of the item in paragraph 5.1.2 shall also be provided to the plant manager.
6. EQUIPMENT UNLOADING
6.1 All equipment lifts shall be according to 4WCE-600500. Before off-loading of any equipment, all lifts shall be approved by the Company representative. After the equipment has been received and off-loaded on site by the contractor, the Company representative will notify the Company machinery representative. The equipment to be off-unloaded shall include any components required to be removed from the compressor base frame assembly to meet shipping constraints.
6.2 The Company machinery representative will inform the Project Engineering and Machinery Engineering department representatives of any variances in the required machinery inventory, so in-house action can be initiated to resolve shortages in the shortest time possible to avoid delays later in the construction phase.
7. JOB REVIEW MEETING
7.1 Just before equipment arriving on site, the Company machinery representative will call and chair a meeting with the appropriate Company personnel from Construction Engineering, Project Engineering, Machinery Engineering, and PSO Department. The contractor and epoxy grout representative (if applicable) shall also be included in this meeting. This procedure shall be reviewed in detail. Any equipment lifts shall be reviewed and tentatively approved at this time. Proper anchor bolt placement and machine centerline locations shall be certified by the contractor at this time. Proper foundation preparation for epoxy grouting shall be certified by the epoxy grout representative. Proper sealing of the foundation to grade level shall be confirmed by the contractor at this time.
8. INSPECTION AND PRESERVATION
8.1 The Company machinery representative will ensure that the compressor assembly is still sealed up and internally protected from the effects of corrosion due to rain, humidity, or dirt.
8.2 The Company machinery representative will supervise removal of one process piping protective cover by the contractor and thoroughly examine the visible interior surfaces for rust or contamination.
8.3 The Company machinery representative will inspect the compressor assembly to verify that all connections, both plugged and flanged, are sealed airtight to prevent the escape of preservative vapors. If vapor pressure inhibitor (VPI) capsules are not used for preservation of the compressor base frame assembly, the contractor shall maintain a nitrogen blanket on the compressor, process gas system, and associated and lube oil system components until commissioning and start-up. The nitrogen blanket shall be checked daily and recorded in a log by the contractor. During installation and erection, the nitrogen blanket shall be re-established at the end of each day’s work shift.
8.4 Main Drive Motor
8.4.1 The contractor shall run temporary power wiring and energize motor space heaters, verify that all motor conduit box covers are sealed, and rotor shaft apertures are covered and sealed. The contractor shall install a termination box on the temporary power circuit with indication light adjacent to each motor space heater so that power to the circuit can be easily confirmed. The Company machinery representative shall check the heaters on a weekly basis and record their status in the site log book.
8.4.2 The contractor shall cover the motor to protect it from any moisture.
9. FOUNDATION REQUIREMENTS
9.1 Foundation Design
9.1.1 The compressor base frame foundation pad shall rise 50 to 100 mm (2 to 4 in) above the finished grade level or finished paving surface. It shall be designed and installed according to 4CS02001A, M10, and 4ACS-640102 as applicable. For facilities within Europe or European engineered facilities worldwide, the closest SI or DIN equivalent to that specified in 4CS02001A may be used. The foundation pad shall extend beyond the base frame structural steel support members adequately to meet the minimum anchor bolt free edge distance requirements outlined in 4CS02001A. The foundation shall be designed to allow for a 25 mm (1 in) grout depth. Actual grout depths in the field shall not exceed 37.5 mm (1 1/2 in).
9.2 Anchor Bolts and Sleeves
9.2.1 The compressor base frame anchor bolts shall be Unisorb Jakebolt heavy duty anchor bolts with 620,000 kPa (90,000 psi) tensile strength or Company approved equal. The anchor bolts shall have a 150 mm (6 in) vertical adjustment. Note that the entire internal anchor assembly can be adjusted laterally as well as vertically. After installation, the top of the anchor bolt shall be adjusted vertically allowing two to four full threads exposure after torquing. On spot faced anchor bolt locations, a 6 mm (1/4 in) thick hardened washer shall be installed under the anchor bolt nut. A hardened spherical contact washer shall be installed under the anchor bolt nut for unfinished structural steel members. The minimum top tube length shall be as specified by the compressor supplier or as shown in Figure 2 of 4CS02001A. The top tube length shall be the sum of dimensions “E” and “F” for Type “3S” anchor bolts. The top tube length is defined as the distance from the top of the tube (top of the foundation) to the top of the steel housing containing the internal anchor assembly.
9.2.2 Minimum free edge distance from the centerline of the anchor bolts to the edge of the foundation shall be as listed in 4CS02001A. In no case shall the distance from the edge of the steel housing (containing the internal anchor assembly) to the edge of the foundation be less than 100 mm (4 in).
9.2.3 Anchor bolt holes on compressor base frame shall have a 3 mm (1/8 in) annular clearance for bolts below 37.5 mm (1 1/2 in) diameter. Bolts 37.5 mm (1 1/2 in) diameter and above shall have a 6 mm (1/4 in) annular clearance.
9.3 Foundation Installation
9.3.1 Anchor bolt sleeves shall be covered or filled with a non-bonding-moldable foam to prevent entry of concrete.
9.3.2 Anchor bolts for the compressor base frame shall be accurately located with the use of a wooden or steel template. The anchor bolts shall be suspended from the template. Care shall be taken to ensure they project above the foundation level as specified on the foundation drawing. The bottom of the anchor bolts shall be securely tied to reinforcement bars running on top of the box section. This is to ensure the anchor bolts remain plumb and in the proper position throughout the pouring of the concrete. These reinforcement bars shall run parallel to both sides of the foundation, forming a cross at the bottom of each anchor bolt. The reinforcement bars shall be a minimum #6 (or DIN equivalent) size. The reinforcement bars shall then be tied to the reinforcement bars that form the exterior cage of the foundation. (W)
9.3.3 Materials, mixing, handling, and placement of mass concrete shall be according to M10 or 4ACS‑640102 as applicable. Adequate procedures shall be given to the control of the concrete temperature at the point of depositing.
9.3.4 Stainless steel plug bench marks shall be embedded in the foundation at each of the four corners. Their elevation shall be accurately recorded for future reference for settling or shifting of the foundation.
10. COMPRESSOR BASE FRAME INSTALLATION AND ERECTION
10.1 Foundation Preparation Before Compressor Base Frame Installation
10.1.1 Allow concrete foundation to cure for a minimum of 28 days before sealing or grouting.
10.1.2 The foundation table top and supporting surfaces shall be smooth and free of any hard concrete, sludge, oil, or grease.
10.1.3 Seal the entire foundation that is above finished grade. Use clear ITW Philadelphia Resins IMPAX Water Based Epoxy Primer/Sealer followed by a topcoat of clear ITW Philadelphia Resins IMPAX HPU High Performance Urethane or Company approved equal. For horizontal surfaces that will extend more than 150 mm (6 in) beyond the compressor base frame edges, the top coat of clear ITW Philadelphia Resins IMPAX HPU High Performance Urethane shall have the optional anti-slip additive mixed in just prior to application.
10.1.4 The contractor shall accurately mark the compressor base frame centerlines on the foundation. Before setting the compressor base frame, the contractor shall check the foundation for dimensional accuracy. The contractor shall measure the anchoring hole locations and verify all anchor bolts are free in their sleeves. The contractor shall check the length and arrangement of the anchor bolts. (W)
10.1.5 All concrete areas in contact with grout must be chipped to expose aggregate to ensure grout adhesion. Chipping guns shall be used, not jack hammers. Chipping shall stop 10 to 15 mm (1/2 to 3/4 in) short of the grout forms or final grout line. Blow all dust from prepared concrete. Air for blowing dust must be oil-free. An oil separator/filter must be used on the air supply. Protect concrete from dirt and oil before grouting. For epoxy grout, in addition, protect concrete from moisture.
10.1.6 For epoxy grout, after the concrete is prepped and before the compressor base frame is placed, cut and glue 1-inch wide Styrofoam expansion joints to concrete using clear silicone caulk, or a mixture of sand and ITW Philadelphia Resins Expansion Joint Compound when more support is required. Ensure drain channels through grout are in place. Place expansion joints on 1 to 1.25 m (3 to 4 ft) centers. Refer to Figure 1 for expansion joint details. (W)
10.1.7 Isolate at least the top 12 anchor bolt diameters with foam pipe insulation or moldable foam to protect bolts from grout adhesion and provide free length stretch of the bolt during torquing. (W)
10.2 Setting Compressor Base Frame on the Foundation
10.2.1 All rigging and lifts shall be according to 4WCE-600500. The Company representative will ensure that the proper rigging is available for lifting of compressor base frame and associated parts by the contractor. This includes ensuring that the contractor will provide the proper size crane and proper size rigging hardware (e.g., slings, shackles, eyebolts, and spreader, if required). The Company representative will inspect and approve the rig before any lift by the contractor. (W)
10.2.2 Surfaces on compressor in contact with grout shall be coated with a compatible epoxy primer, Carboline Carbozinc 11 inorganic zinc primer or ITW Philadelphia Resins Rust Inhibitive Primer. Factory paint on the compressor in contact with the grout must be tight and free of all dirt, oils, and grease. Wipe grout contact areas down with clean rags and ITW Philadelphia Resins IMPAX IXT-59 Solvent to ensure cleanliness. All corners on the machinery to be grouted shall be rounded. All sharp edges shall be broken by the installing contractor. Touch up any damaged primer. The equipment supplier shall ensure that the outside corners of skids have a 2-inch radius to avoid stress concentration and resultant cracking in the grout. All base frames shall have jack bolts to level the unit before grouting. Jack bolts shall be provided by the equipment supplier. Jack pads under the jack bolts shall be provided by the installing contractor. (W)
10.2.3 Apply Non-Melt grease or duct tape to all jack bolts in contact with grout. Use round bar as jacking pads. Refer to Figure 2 for details. (W)
10.2.4 The contractor shall lift and set the compressor frame on its foundation, sliding the frame onto the anchor bolts, and allowing it to rest on the jacking bolts. The contractor shall provide minimum 3 inch diameter x 1/2 inch thick carbon steel plates cut from bar stock for the jack bolts to bear against.
10.2.5 Remove any temporary supports that were necessary for shipment. The contractor shall install any components removed for shipment. This includes items like overweight pressure vessels (suction separators, bulk and final oil separators, adsorbent vessels), drive motor and/or motor top hat, motor junction boxes, couplings, and guards.
10.2.6 The contractor shall level the compressor frame using the jacking bolts along both sides of the frame. A machinist’s level or laser transit shall be used to check for base frame levelness.
10.2.7 At this point anchor bolts should be snugged up. The contractor shall torque the base frame anchor bolts to a nominal 100–200 ft-lbs to ensure that the frame is completely down on the jacking bolts. Care shall be taken not to over torque the bolts at this point, or distortion of the frame might occur.
10.2.8 The contractor shall verify that the compressor base frame is level in both directions (parallel to and perpendicular to the compressor drive shaft) and record the final level readings. The coupling alignment shall be checked according to the manufacturer’s installation manual to ensure the frame is not distorted. (W)
10.3 Grouting the Compressor Base Frame
10.3.1 The compressor base frame shall be grouted to the foundation with either non-shrink-cement grout or epoxy grout as indicated in the project grouting schedule. Grouting shall be according to 4ECE-M13 or 4ACS-640106 as applicable. When epoxy grout is specified, Philadelphia Resins Chockfast Red epoxy grout systems shall be used to grout the compressor base frame to its foundation. Areas under full depth structural members only shall be grouted. Drain channels through the grout shall be provided to prevent pocketing of moisture, oil, or debris within the base frame.
10.3.2 For epoxy grout, construct leak-proof wooden forms. These shall be located within 25 to 50 mm (1 to 2 in) of the full depth members. Seal forms with silicone caulk. Apply Johnson’s or Butcher’s paste wax to inside of forms to facilitate their future removal. All internal and external corners of the form shall be fitted with a 45-degree chamfer. To help facilitate the grout pour, strategically form 100 by 300 mm (4 by 12 in) head boxes. The head boxes should be located inside the base frame whenever possible. Mask areas adjacent to where the grout will be poured to protect the base frame from grout splashing.
10.3.3 Before grouting the base frame, align the compressor and lube oil pump(s) to the motor(s) according to the manufacturer’s installation manual. (W)
10.3.4 After the motor and compressor are aligned, the compressor base frame shall be grouted to the foundation. For epoxy grout, ensure the grout forms are adequately supported to prevent collapse or movement under the hydraulic pressure of the grout. The Company machinery representative shall inspect any grout forms before pouring, as well as witness the actual placement or pouring of grout. Every effort shall be made to ensure a quality grouting is done with no voids in the grouted areas. For epoxy grout, arrange (to the account of the contractor) to have a Philadelphia Resins representative present to ensure a proper grout pour. The compressor and foundation shall be tented to shade from direct sunlight during pour and cure (or placement and cure for non-shrink-cement grout) of the grout. A back-up mixer shall be on hand before starting an epoxy grout pour. (W)
10.3.5 Precondition all grout materials between 18–27°C (65–80°F) for 48 hours before use.
10.3.6 For epoxy grout, mix two part resin with a power mixer at 250 to 300 rpm. When handling or mixing grout, use appropriate Personal Protective Equipment (PPE) such as goggles, respirators, and gloves. Take care not to ingest air into the resin. Mix resin with the aggregate. For Chockfast Red, the ratio is normally one can resin to four bags aggregate. For larger base frames, this shall be reduced to 3 1/2 bags of aggregate to improve its flow properties. Construct head boxes to facilitate grout pour. Pour grout under compressor base frame. Start at one end and completely fill grout area before moving on. Go back and top off old section to keep grout “head” in contact with the bottom of the base frame. Do not vibrate the grout as a means of helping it flow as this tends to separate the aggregate from the resin binder. Use push tools with flat ends to help distribute the grout, using long strokes rather than short jabs. Violent ramming of the grout shall not be permitted.
10.3.7 After epoxy grout pouring, brush all exposed grout areas using a paintbrush with ITW Philadelphia Resins IMPAX IXT-59 Solvent to provide a smooth, glass-like finish. Repeat as necessary.
10.3.8 Non-shrink-cement grout shall be cured with wet burlap or other approved curing compound for a minimum of three days. Allow non-shrink-cement grout to cure for minimum of seven days before tensioning anchor bolts. Allow epoxy grout to cure a minimum of 48 hours before removing grout forms and tensioning anchor bolts.
10.3.9 For epoxy grout, remove forms and grind all sharp corners.
10.3.10 For epoxy grout, remove Styrofoam expansion joints 1/2 inch below grout surface. Pour ITW Philadelphia Resins Expansion Joint Compound in this groove. Allow material four hours of initial cure time.
10.3.11 Back out all jack bolts. Anchor bolts shall be torqued to 207,000 kPa (30,000 psi) tensile stress with lubricated threads. An alternate approach, considering the yield strength of the bolt, is to torque to 1/3 of the yield strength for lubricated bolting or to 2/3 of yield strength for dry bolting. The bolt stretch required may be obtained by use of torque wrenches or by considering bolt thread pitch and turning the nut a specific number of flats.
10.3.12 Check for grout softness with a dial indicator. Equipment movement at each anchor bolt shall not exceed 0.001 inch after torquing.
10.3.13 Seal off all anchor bolts and jack bolt holes with silicone caulk.
Figure 1 Expansion Joint Detail Using the Secondary Seal Design
| ITW Philadelphia Resins Repair Compound should only be poured half as deep as the expansion joint is wide. |
Figure 2 Anchor Bolt and Leveling Screw Assembly
10.4 Installation and Erection of Piping and Auxiliary Systems
10.4.1 Any vapor pressure inhibitor (VPI) capsules used for preservation of the compressor base frame assembly shall be removed.
10.4.2 Install the main cooling water supply and return line to the compressor base frame cooling water supply and return headers. Ensure this piping is thoroughly cleaned and free of weld slag.
10.4.3 Install the main suction and discharge process piping.
10.4.4 Following the fit-up of the process piping, it shall be removed and thoroughly cleaned to remove all scale and foreign material from both the inside and outside. Following the cleaning, a nitrogen purge shall be established on the piping.
10.4.5 Run the nitrogen purge and vent lines to the compressor base frame assembly.
10.4.6 Install all compressor base frame assembly electrical power connections. Install all compressor and auxiliary instrumentation not yet installed according to the General Arrangement Drawing and the flowsheet. The contractor shall also install any valves required for instrument taps. Instrumentation should be easily accessible when possible. Install any heat tracing/insulation that is required by the installation drawings.
10.5 Equipment Preservation After Erection
10.5.1 Plug any holes that will allow dirt or rain to enter.
10.5.2 Maintain a nitrogen blanket on the compressor and all process gas components until commissioning and start-up.
11. COMPRESSOR AND MOTOR COMMISSIONING
11.1 Pre-Commissioning Activities
11.1.1 Before the start of commissioning, the Company machinery representative will verify that all systems on the compressor base frame assembly are consistent with the flow diagram.
11.1.2 The cooling water circuit will be flushed coincident with commissioning of the cooling tower/cooling water system. The circuit will be checked for leaks, air bled off at high point vents, and low points blown down to remove trash.
11.1.3 The contractor shall assist Company in checking the installation of all instruments and gauges. Perform function tests on all instrumentation and control logic. Set points shall be reviewed. Proper operation of all control valves and compressor slide valve shall be verified.
11.1.4 Before compressor motor commissioning the contractor shall disconnect the motor space heater(s) temporary power supply and connect the permanent power supply.
11.2 Commissioning the Lube Oil System
11.2.1 The Company machinery representative will verify that the lube oil system is consistent with the flow diagram.
11.2.2 Open the bulk oil separator and ensure the coalescer elements are installed properly, having not worked loose during shipment. (W)
11.2.3 If not previously checked and recorded, check the alignment of the oil pump. A record of the final alignment readings shall be kept and given to Company. (W)
11.2.4 Bump the oil pump motor to verify proper rotation. Install the coupling and guard. (W)
11.2.5 The contractor shall provide and fill the lube oil reservoir with oil as stated on the lubrication schedule. Unless otherwise specified in the contract documents, the initial charge of compressor lube oil shall be furnished by the compressor supplier and shipped with the compressor. In some cases the oil is shipped in the compressor lube oil reservoir. In this case the contractor shall verify the oil has not been contaminated during shipment. If a certified shop oil flush has not been previously accomplished or contamination is observed in the field, an oil flush shall be done. A 100 mesh screen shall be installed in the pump suction. The small bore SS tubing connections from the extreme end of the oil manifold to the compressor shall be temporarily disconnected during the oil flush. Install as a temporary jumper a large bore hydraulic hose from the extreme end of the oil manifold and route it back to the bulk oil separator setting up the oil system for a flush through all of the oil piping from the oil reservoir, pump(s), oil cooler(s), filter(s) and oil manifold. A 100 mesh screen shall be installed on the temporary jumper outlet to act as a temporary filter.
11.2.6 Turn on the reservoir oil heater. When at minimum allowable temperature, circulate oil with the oil pump. It might be necessary to bypass the oil pump time out circuit (protection to prevent oil flooding if the main drive motor has not started) in the DCS to accomplish the oil flush. Attempt to achieve an oil temperature as close as possible to 50°C (120°F). At about four-hour intervals, inspect the temporary filters and renew them. The oil flushing is complete when the temporary oil filters are clean after four hours of continuous circulation. Renew the cartridge oil filters (supplied by Company) after completion of the oil flush. Remove temporary filter screen and jumper after flush. Reconnect all small bore SS tubing connections to the compressor. If the compressor discharge is not free draining to the bulk oil separator, drain any trapped oil from this leg of the discharge piping. (W)
11.2.7 Check piping for lube oil leaks and repair as needed.
11.3 Commissioning the Control, Instrumentation, Purge, and Process Gas Systems
11.3.1 The contractor shall assist Company in checking the installation of all instruments. Set the oil pump pressure control valve as required, and function check the high temperature switch, temperature control valve, and low oil pressure switch.
11.3.2 Commission all nitrogen purge systems for the compressor, making sure that an adequate supply of nitrogen is attained. Leak test and repair piping as required.
11.3.3 Before starting any unloaded or loaded runs, functional tests of any instrumentation and control circuits not yet done must be completed. This includes shutdown, alarm, and permissive start circuits. Ensure the lube oil differential control valve is properly set and the recycle valve and slide valve operate over their entire range. (W)
11.3.4 Set points of all alarm and shutdown switches shall be checked. (W)
11.3.5 The vibration switches (if installed) will be set by the Company machinery representative during the unloaded run-in. Ensure proper operation and set up of any vibration transmitters or position transmitters.
11.3.6 The Company machinery representative will function test the recycle valve, slide valve, and controllers.
11.3.7 Inspect all of the gas suction filters and the discharge oil coalescers/adsorbers. Install the coalescer elements if shipped separately. Load the adsorbent (if applicable).
11.4 Commissioning Compressor Motor
11.4.1 The contractor shall assist in performing the final compressor motor inspections and checkouts.
11.4.2 Check baffling and fans to see that motor receives proper air flow. (W)
11.4.3 Visually and manually inspect for loose fan blades, loose support bolts, loose shroud bolts, and debris in motor. (W)
11.4.4 For medium voltage motors, check all internal motor instruments (temperature switches, level switches, RTDs). Calibrate and function check each device. (W)
11.4.5 For medium voltage motors, megger motor, perform polarization index. Record results on proper forms. (W)
11.4.6 Megger motor feeders. (W)
11.4.7 If applicable, megger lightning arrestors and capacitors in motors terminal box. (W)
11.4.8 Verify compression-type lugs on all connections. (W)
11.4.9 Verify connections of ground loop on entire motor compressor system. (W)
11.4.10 Verify all electrical power connections to the motor. (W)
11.4.11 For medium voltage motors, ensure that the motor bearings have the proper lubrication. (W)
11.4.12 If not previously checked and recorded, check the alignment of the compressor/motor. Stainless steel shims shall be used under the motor feet for alignment. After final alignment and a successful compressor run in, dowel the motor feet. A record of the final alignment readings shall be kept and given to Company. (W)
11.4.13 Bump the uncoupled compressor motor to verify proper rotation. When proper rotation is established, restart the motor and scribe a line on the motor shaft to indicate magnetic center. Turn over the compressor by hand to ensure it turns freely. Install the coupling and guard. (W)
12. COMPRESSOR TEST RUNS
12.1 Compressor 30 Minute No-Load Nitrogen Test Run
12.1.1 Before starting the compressor test runs, start the cooling water system and allow it to circulate continuously.
12.1.2 The contractor shall assist in the No-Load Compressor Run on Nitrogen. The slide valve and recycle valve shall be in their minimum capacity position during the test.
12.1.3 Ensure that compressor is completely isolated from the process gas by using the block valves around each service. Follow Plant lock-out/tag-out procedures. Purge the compressor piping over to nitrogen. (W)
12.1.4 Verify that lubrication system is running. (W)
12.1.5 Turn the compressor over at least two complete revolutions before starting.
12.1.6 Run the compressor for one minute. Ensure the lube oil system is operating during the start sequence. Observe lube oil temperature, coolant temperature, and listen for odd noises. Check the scribed line on the motor shaft to ensure it is operating on its magnetic center. (W)
12.1.7 Shut down the unit using the vibration switch (if installed). This is done by turning the set screw until machine trips. After the machine has stopped, the set screw shall be backed off one complete turn. (W)
12.1.8 If the motor shaft is not running at its magnetic center, the motor position will need to be adjusted. Be sure to rack out starters (or breakers as applicable) and lock out motor before doing any work on the motor or the compressor. Repeat the initial start-up until accomplished. (W)
12.1.9 After the motor position is acceptable, run the compressor unloaded for 30 minutes observing all the information mentioned previously. Record operating data half way through and before the end of the test. Shutdown the unit using another shutdown device. (W)
12.1.10 Additional no-load test runs on nitrogen shall be completed as necessary to check out all shutdown devices. Ample time must be allowed between motor starts as defined by the motor supplier. Each test run shall be shut down using a different shutdown device. (W)
12.2 Compressor 4-Hour Loaded Run-In Test on Nitrogen
12.2.1 Before starting the compressor test runs, start the cooling water system and allow it to circulate continuously.
12.2.2 The contractor shall assist in performing the 4-hour Loaded Run-In Test on Nitrogen.
12.2.3 As applicable, inspect the suction filter elements, suction scrubber demister pad, and individual suction strainers for cleanliness/integrity and clean/replace as necessary. (W)
12.2.4 Perform a final static pressure test of compressor system, spray leak detector (Snoop) around all covers, heads, oil ports, and flanged connections. (W)
12.2.5 Blow down all instrument tubing using nitrogen pressure in system. Place gauges, transmitters, and switches in service. (W)
12.2.6 Verify that all local PIs and TIs are installed and functional.
12.2.7 Blow down all drains lines, vent valves, blow down all condensate drain lines.
12.2.8 Verify that all instrument signals are checked to the DCS.
12.2.9 For medium voltage motors, function test all shutdown devices to actually trip the motor breaker.
12.2.10 Function test all recycle valve and slide valve controllers.
12.2.11 Close all suction and discharge block valves to isolate the compressor.
12.2.12 Open manual recycle valve and automatic recycle valve. Ensure slide valve is in its minimum capacity position.
12.2.13 Verify that all bleed points in the system are open.
12.2.14 Verify that coolant and lubrication systems are functioning properly.
12.2.15 Pressurize the system with nitrogen using the suction make-up line. Initially keep suction pressures relatively low to keep the power consumption down. (W)
12.2.16 All low pressure shutdowns shall be placed in bypass.
12.2.17 Start the compressor and allow it to run for 15 minutes before loading it. Close all open bleed points and vent valve. Increase nitrogen suction pressure to design pressures by providing make-up nitrogen at the suction.
12.2.18 Increase discharge pressure by loading the compressor with the slide valve and gradually closing the recycle valve and increasing capacity while providing make-up nitrogen at the suction.
12.2.19 Run the compressor on nitrogen for four hours at design suction pressure and design discharge pressure or maximum discharge temperature at or below the normal high discharge temperature alarm set point. Due to recycle cooler sizing, it might be necessary to run at minimum capacity slide valve position during the four-hour loaded run-in test on nitrogen.
12.2.20 Blow down coalescer.
12.2.21 Put the automatic recycle valves in service and tune the recycle controller.
12.2.22 Measure and record the operating data at 15-minute intervals during the test.
12.2.23 Leak test all flanges and threaded connections.
12.2.24 Reduce machine capacity with the slide valve while opening recycle valve and vent valve to relieve pressure in system. Shut down the machine.
12.2.25 As applicable, remove the suction filter elements, suction scrubber demister pad, and individual compressor suction screens for inspection and clean/replace as necessary before reinstalling.
13. ACCEPTANCE
13.1 Company’ acceptance of the compressor will be by signature of the Company site manager or his designee.