5.

3 - COMMISSIONING

5.3.1. Preliminary tests

5.3.1.1. Lube oil system commissioning

5.3.1.2. Control and safety oil system commissioning
5.3.1.3. Compressor sealing system commissioning
5.3.1.4. Steam gland condenser commissioning
5.3.1.5. Final check of sequences
5.3.1.6. Turbine no-load test / Overspeed test
5.3.1.7. Installation of coupling
5.3.1.8. Leak test of the process loop

5.3.2. Full load tests

5.3.2.1. Test run on anti-surge loop

5.3.2.2. Commissioning on process loop
5.3.2.3. Putting into commercial operation
 The operator shall check that there are no personnel working on the
equipment or any item of equipment before starting the relevant system
or compression unit.

5.3.1. Preliminary tests

5.3.1.1. Lube oil system commissioning

Refer to: - IPLSH001747 (IPLSH000747 P&ID) Lube Oil Console System P&ID
(VP-18-102-C-231-002-SK-021)
- IPLSH011747 (IPLSH000747 P&ID) Lube Oil Shaft Line P&ID
(VP-18-102-C-231-002-SK-021)
- IPLSH012747 (IPLSH000747 P&ID) Control Oil System P&ID
(VP-18-102-C-231-002-SK-021)

CHECK THAT ALL COUPLING GUARDS ARE PROPERLY INSTALLED.

Checks to be made before initial start-up.

Before starting the system, be sure that it is clean and ready for operation.
. The oil reservoir is filled with oil up to the required level.
. All flushing equipment is removed.
. Correctly position all valves (open or close) for operating the system.
. Inspect flanges for loose bolts and missing gaskets
. The main switch of the electric power for motors, heater, control and instrumentation is
“ON” and power available.
. Energize the oil immersion heater (C-231-002-H1). Check the oil temperature in the
reservoir (TI-5603).
. Heating ON below 35° C, heating OFF above 40° C
. Vent off air of all instruments.
. Test of alarms and shutdowns
. Check the correct position of the transfer valve of the oil filters and the oil coolers, and then
open the corresponding vent valve.
If needed open the filling valve, so that the standby oil filter is filled up with oil, when
starting the oil pump and will be ready for immediate use in case of emergency.
Oil heater operation is automatically sequenced to ensure safe operation
of the heater. Operating the oil tank heater if lube oil low level alarm is
inhibited creates a fire hazard.

Initial start-up

Refer to the specification RNTIC072747 (VP-18-102-C-231-002-SK-009).

. Carry out a final check of the whole oil system; especially check for readiness of control
valves PCV-5601 and PCV-5602.
. Check that the manual valves at the pumps discharge are fully open (2”)
. Close the hand valve upstream of PCV-5601.
. Open the bypass valve of PCV-5601.
. Check that the pump, cooler and filter vent valves are open.
. PUT THE NITROGEN BUFFER GAS IN OPERATION. Check the nitrogen pressure
(PI-5609). The pressure control valves PCV-5603 shall maintain this pressure at 4 Bar.G.
. Start the main pump and slowly increase the pressure, by gradually closing the bypass
valve of PCV-5601 until the nominal pressure is reached (12.5 Bar.G).
. Open the valve upstream of the valve PCV-5601 and fully close the bypass valve.
. When the bypass valve is closed, check the oil pressure at PI-5604. The pressure control
valve PCV-5601 shall maintain this pressure at 12.5 Bar.G. If necessary, adjust the
pressure by setting PCV-5601.
. Wait until the oil piping system is filled up with oil. Check the tightness of the oil circuit.
. Make sure that the oil side of the oil cooler and the oil filter are properly vented. A constant
oil flow must be visible in the flow glass. Close the vent valves.
. Inspect for oil leaks.
. Inhibit the alarms.
. Check that the lube oil rundown tank (C-231-002-TK2) is properly filled. A constant oil
bleeding shall be visible in flow glass of the overflow line.
The filling time of the tank can be shortened by opening the filling valve W341 (3/4”).
Close the valve after the tank has been filled.
. Check the lube oil flow to the shaft line bearings. The oil must be visible in the drain flow
glasses (FG-5602 / FG-5603 / FG-5604 / FG-5605).
. Check the lube oil supply pressure at PI-5602. The pressure control valve PCV-5602 shall
maintain this pressure at 1.5 Bar.G.
. Check operation of valve TCV-5601.
. Monitor filter clogging by means of differential pressure gauge PDIT-5601.
 Cold oil will temporarily produce a high differential pressure in the filters.
Checks to be made with the lube oil system in operation

. Lube oil system in operation.

. Check that all alarms lights are off.
. Check that all pressure gauges are working.
. Check that PAL-5604 and PAL-5603 cause the standby pump to start.
. Note oil pressure at start-up of the stand-by pump (PG-5603 and PI-5603).
. Check that PALL-5602 stops the compressor.
. Note oil pressure at PI-5602.
. Check that all analog transmissions to the UCP are correct.
. Check the lube oil supply to the shaft line bearings. The oil must be visible in the drain
flow glasses.

5.3.1.2. Control and safety oil system commissioning

Refer to : - RNTIC072747 Functional Analysis (§7)

(VP-18-102-C-231-002-SK-009)
- IPLSH012747 (IPLSH000747 P&ID) Control Oil System P&ID
(VP-18-102-C-231-002-SK-021)

The control oil system and safety oil system are supplied from the lube oil system; the supply
of these circuits is then subject to the good operation of the lube oil system.

An orifice plate (FO 5613) supplies safety oil to the trip valve.

. Check the pressure at PG-5607.

. Energize the solenoid valves SOV-5602 / SOV-5603 and check that the oil safety
pressure is correct (PG-5608 / PG-5609).
. Check the opening of trip valve.

NOTE : The three way hand valve is used for trip solenoid test SOV-5602 / SOV-5603
In normal operation this one is in middle position.
For the test it is necessary to have limit switch ZSL-5602 “ON” to test SOV-
5602 or ZSL-5603 “ON” to test SOV-5603.

By de-energising the corresponding solenoid valves, check on the pressure gauges PG-
5608 or PG-5609 that the pressure has dropped.
5.3.1.3. Compressor sealing system commissioning

Refer to: IPLSH021747 (IPLSH000747 P&ID) Seal Gas System P&ID

(VP-18-102-C-231-002-SK-021)

Prior to the gas leak test, all supply piping of seal gas from compressor to gas filters and to
compressor limit flanges shall be air blown.

- Make sure that the pressure gauge panel is available.

- Nitrogen buffer gas available. The line upstream of TP-311 shall be air blown prior to its
connection.
- PCV-5603 in operation, adjust the pressure to 4 Bar.G at PI-5609.
- Check all orifices diameters FO-5621, FO-5622, FO-5623, FO-5624, FO-5625 and FO-
5626.
- Gas filters in normal position.
- Check that all utilities are available.
- Vent off air of all instruments.

Checking
Commissioning of sealing system will be performed during the leak test of the
process loop.
- Pressurize the compressor in steps of 25 % until reaching full operating pressure.
- Check all pipe connections for leaks.
- Check that all alarm lights are off.
- Verify that seal gas flow is normal.
- Test alarms and shutdowns: each safety device can be tested by simulation for
compressor emergency stop (pressurized and depressurized shutdowns).
- Check that the seal gas system operates normally. Check the good operation of PCV-
5603.

5.3.1.4. Steam gland condenser commissioning

Refer to: IPLPR101747 (IPLSH000747 P&ID) Gland Condenser System P&ID

(VP-18-102-C-231-002-SK-021)

- Make sure of the proper connection of openings, which must be connected and correct
closing of those that are left unconnected.
- Start the cooling water; all tubes must be full of circulating water, which implies that water
boxes should be filled completely and permanently.

NOTE: Never feed a condenser with steam, unless its tubes are full of water.

- Drain the air from the water boxes making sure they are full of water.

- Start the gland condenser ejector and check the good operation.
5.3.1.5. Final check of sequences

NOTE: Ensure system wiring conforms to the electrical schematic, interconnecting

and wiring diagrams.

- Inspection of alarms and shutdowns devices.

This step obligatorily takes place before the commissioning of the turbo-compressor and
after the completion of all connections.
It consists in systematically and separately verifying each alarm and each shutdown
pertaining to the protection of the machines and the auxiliaries.
Each safety device can be tested on a real basis or by simulation of its outcome and its
result.
Particular attention should be taken to the safety devices, which provoke an emergency stop
of the turbo-compressor train.

- Verification of the logic sequences and anti-surge regulation.

NOTE: Check all cabling and wiring against the available documentation before
starting PLC checkout. It is very easy to cross-wire cables and connections
in these systems.

All of this operation consists in verifying, by simulation, each regulation loop and the
sequential logics, which ensue.
Particular attention should be given to the satisfactory functioning of the compressor anti-
surge regulation by causing the flow rate / pressure / temperature parameters to vary.
The opening times of the anti-surge valve shall be verified for the compressor emergency
stop.

5.3.1.6. Turbine no-load run / overspeed test

- Uncoupled running (steam turbine only)

The purpose of these tests is :

* To check the turbine starting sequence,

* To check the mechanical reliability
* To check all turbine operating parameters.

The mechanical overspeed tests shall be carry out with the compressor uncoupled and
when the shaft line is ready to be set into service, and in particular:

* The oil circuits are set.

* The regulation is checked, take over by the governor has been tested.
* All safety devices are in operation.

- Start-up normally and set the turbine into speed regulation.

* As soon as the oil, steam, metal temperatures and possibly the vibration is stabilised,
run at rated or maximum speed.
 * Increase the speed manually. The speed should be up with a maximum acceleration
of 50 RPM thus without any racing of the turbine.

NOTE: WOODWARD governor overspeed will be the first one tested (lowest
overspeed). For the second one, it will be necessary to inhibit the first
overspeed (WOODWARD).

* Make 2 tests for each overspeed.

5.3.1.7. Installation of coupling

Rotate equipment shafts in normal direction of rotation only. Reverse

rotation of the equipment can cause seal damage.
Refer to the chapter 5.1.3 and for detailed instructions.

The placement and installation of the flexible coupling spacer shall take place after the
following:

- Inspection and final acceptance of the machines alignment by the customer or by his
representative.
- Final verification of the distance between the coupling hubs.

Refer to the coupling supplier's drawing to determine the number of shims to be positioned to
respect the "prestress" linked to the expansion of the mobile elements.

Refer to: ACC012747 COUPLING DRAWING

- Coupling the shafts and tighten all coupling bolts to specification.

5.3.1.8. Leak test of the process loop

General

This test is carried out in the final phase after completion of installation and assembly of the
whole equipment, including control and regulation equipment.
The procedure to be used is at the discretion of the customer who will have to determine the
test pressure and the fluid to be used for the test.

In some cases, the process gas is used as the test fluid and the loop tightness is checked at
the compressor nominal suction pressure.
In other cases, an alternative gas is used (Nitrogen). Then, the tightness test is performed at
a pressure to be defined by the Customer as a function of the characteristics of the loop.
Several methods may be used for leak detection. The method being the most commonly
used consists in wrapping each set of flanges with adhesives tape containing a small hole on
which soapy water will be applied once the test pressure is reached.
Another method consists of using a portable gas detector.

Never attempt to check gas leaks by feeling the suspected area using a
hand. THIS METHOD CAN BE VERY DANGEROUS as gas pressures can
exceed 10 bar.

- Before pressurizing :
. Carry out an ultimate check of the loop
. Start oil and seal systems
. Check instruments for readiness condition
. Put the nitrogen buffer gas system in operation.

- Pressurize the loop at about 3 bar. Check and repair the leaks. Then step by step increase
the pressure and repair any further leaks.
- Maintain the maximum pressure for one hour and check for any pressure drop.
If there is any pressure drop, repair the leaks.
Then depressurize the loop and purge with nitrogen if necessary.
- Drain the compressor casing by opening the drain valves. After draining, close the drain
valves.

Check for zero system pressure before disconnecting any system lines.
5.3.2. Full-load tests

5.3.2.1. Test run on anti-surge loop

Refer to : RNTIC 072747 Control System Functional Description

(VP-18-102-C-231-002-SK-009)
RNTIC 061747 Functional Logic Diagram
(VP-18-102-C-231-002-SK-016)

NOTE : THERMODYN’S RECOMMENDATIONS :

In order to prevent any damages on anti surge valves during the first starting, THERMODYN
recommend to install a spool provided with an orifice plate in place of the anti surge valve.

- The purpose of these tests is :

. to check the good functioning of the complete start-up and shutdown sequences
. to check the mechanical reliability of the shaft line,
. to check operation of the anti surge control loop,
. to check the control stability of oil systems, seal and process systems in operation during
the test
. to check all turbo-compressor operating parameters (pressure, temperature, vibration
level and speed),
. to carry out any modifications and adjustments, as required
. Start the sequence by the local push-button,
. Start up sequence : refer to unit start sequence,
. At completion of the sequence, keep turbo-compressor running at mini governing speed
and operate for 2 hours.

NOTE : Drain compressor casing during pressurisation,

- When the equipment is rotating :

. Check for proper mechanical behaviour of the whole unit and stability of lube oil and gas
seal systems.
. Observe unit vibration amplitudes and bearing temperatures.
. Check dry seal gas pressure and flow.
. Check flow and temperature of oil returning from journal and thrust bearings.
. Rapidly detect any abnormal noise.
. Check absence of liquid at compressor drain pipes.
. Check that all operating parameters are stable throughout duration of this phase.
. Observe gas pressures and temperatures.
. Then, increase the turbine speed step by step. Stop to increase the speed when the
operating conditions are reached.
. Run the unit at the speed reached during 2 hours.
 . Observe gas pressures and temperatures.

After completion of this test, remove temporary strainer located at compressor

suction for cleanliness inspection.
Additional clean up run if requested.
Remove the spool and re-install the anti-surge valve.

5.3.2.2. Commissioning on process loop

Make sure that all process valves are in the proper start up position and are functioning
normally.

Unit permissive OK:

- Press local start pushbutton.
- Start-up sequence proceeds.

 Check for proper mechanical behaviour of the whole unit and control stability of lube
oil and gas seal systems.
 Observe unit vibration amplitudes.
 Check dry seal gas pressure and flow.
 Check flow and temperature of oil returning from journal and thrust bearings.
 Check immediately source of any abnormal noise detected.
 Check for absence of liquid at compressor drain pipes (casing valves).
 Check that all operating parameters are stable throughout the duration of this phase.

5.3.2.3. Putting into commercial operation

The train operates at normal and stable condition.

The unit can be put into commercial operation after all tests and adjustments for proper
operation of the turbo-compressor and its associated equipment have been completed,
including those in relation with the process.

NOTE :
Generally, it is substantiated by a hand-over certificate or a provisional acceptance
certificate to be countersigned by the customer to whom the special instructions for
unit start-up, operation and shutdown are given.

5.3.2.3.1. Monitoring during operation

General recommendation

During the first days of train operation log every two hours all parameters (vibrations - oil
temperatures - oil pressures - process gas pressures and temperatures - dry gas seal
pressures and flow – steam flow, pressure and temperature).
See RECORD SHEETS.

Under normal operating conditions the compressor does not require any control or
adjustment by the operators. As can be seen from cause/effect chart (RNTIC063747 / VP-
18-102-C-231-002-SK-005), the abnormalities that could occur and affect the train during
operation are alarmed and the source of danger signalized. However, in order to prevent an
unprepared shutdown by any one of the safety devices, we recommend a regular
supervision of the train.
A log-book should be kept in which all readings of instruments as well as any observations
regarding operation, starting and shutting-down times, data of cooler and filter cleaning and
overhauling should be recorded. The variation of the noted figures gives a picture of the
performance of the machine and allows a quick detection of any abnormality.

During normal operation, log all below parameters once a day if they are not recorded by
PLC :

. vibrations, axial displacement,

. bearing temperatures,
. lube oil pressure and temperature,
. differential pressure across lube oil filters,
. cooler outlet oil temperature,
. gas temperature and pressure at compressor suction and discharge,
. gas pressure before seal gas filters,
. gas flow at compressor suction,
. steam temperature and pressure,
. turbine speed.

Periodically check for :

. proper oil level in rundown tank
. proper oil level in the reservoir
. oil, gas or steam leakage which, if any, should be suppressed

Identify any abnormal noise emitted by the equipment since it is a premonitory warning of
malfunction.

It is not permitted to run the turbo-compressor with any mandatory trip

by-passed. When a machine is shut down by one of its protective trip
functions, it is not to be restarted until the reasons have fully been
investigated.
5.3.2.3.2. Shutdown

"Lube oil system, electric motors and heaters remains on duty in case of
emergency shutdown".
Refer to: RNTIC061747 Functional Logic Diagram
(VP-18-102-C-231-002-SK-016)
RNTIC063747 Cause and Effect Chart
(VP-18-102-C-231-002-SK-005)
RNTIC072747 Control System Functional Description
(VP-18-102-C-231-002-SK-009)

5.3.2.3.3. Normal compressor shutdown

General
When there is no problem with the process, the compressor can be stopped by gradually
reducing the speed of turbine (normal stop commands).
This action will enable to check that the anti-surge valve operate properly.

NOTE: The lubrication of the compressor train in case of a power failure is

guaranteed with the overhead oil tank. In case of oil pump failure due to any
other reason than power failure we recommend stopping the train on the
next possible occasion in order to repair the damaged oil pump.

Once shutdown has been initiated:

. Check that the anti-surge valve is fully open

. Keep the loop either pressurized or depressurized depending on Plant Operator's
requirements.
. When the loop is pressurized, check that the buffer gas is in service. The utilities stay in
operation.

5.3.2.3.4. Compressor shutdown upon a fault

General

When any shutdown device stops the compressor, the Plant Operator has no control over
the shutdown.
The turbo-compressor will stop according to the data entered in the shutdown program and
the relevant sequences.
It should be checked that the shutdown sequence has been performed normally for both the
process and the turbo-compressor.
 After shutdown:

. Investigate for the cause of the shutdown. Evaluate how serious it is and what the
consequences are. If needed, schedule a maintenance operation.
. Depending on the diagnostic, take all necessary measures in order to determine the
actions to be made for either a short or a long duration shutdown.
. Determine whether the oil system should be stopped or not.

5.3.2.3.5. Compressor maintained in continuous operational availability

- In this configuration :

. The oil system is operational. Oil pressures and temperatures are at their nominal
values. Oil is kept flowing through the shaft line bearings.
. The compressor is kept pressurized at the nominal value.
. The anti-surge valve is open
. The buffer gas system is in operation
. The turbine is ready to start
. All alarms and shutdowns have been cleared

5.3.2.3.6. Long duration shutdown

- Measures to be taken :

. Depressurize the compressor. Open the casing drain valve. Isolate the compressor
from the process system
. Isolate the buffer gas system
. Stop the oil system. Keep the oil heater in the reservoir in operation to avoid a long
warm-up time and to prevent water condensation in the oil reservoir.

For a longer than one week shutdown period, every week operate an oil pump for
one hour approximately.
 ANNEX 3

RECORDS FOR : TEMPERATURES

PRESSURES
VIBRATIONS / AXIAL DISPLACEMENT
 Customer :
Job N° :
Equipment N°:

PARAMETERS RECORD
“Temperature”

Date – Time

Speed
TAG NUMBER
 Customer :
Job N° :
Equipment N°:

PARAMETERS RECORD
“Pressure”

Date - Time

Speed
TAG NUMBER
 Customer :
Job N° :
Equipment N°:

PARAMETERS RECORD
“Vibration – axial displacement”

Date – Time

Speed
TAG NUMBER