RECOMMENDED PROCEDURES FOR INSTALLATION, COMMISSIONING, STARTUP & RELIABILITY TEST

CENTRIFUGAL COMPRESSORS

GAS TURBINES

SPECIAL STEAM TURBINES

CENTRIFUGAL COMPRESSORS

The recommended procedures for the installation, commissioning, and start-up of centrifugal compressors are crucial to ensure their reliable operation, maintainability, and safety in oil, gas, and petrochemical industries. Here are some steps that can be taken:

  1. Installation: The installation process should be carried out by experienced personnel following the manufacturer’s recommendations and industry standards. The foundation, piping, and electrical connections must be designed and installed to meet the specified requirements.

  2. Commissioning: Before starting the compressor, all systems, components, and instrumentation should be checked and tested. The commissioning process includes checking the alignment of the compressor, verifying the proper operation of the control system and protective devices, and ensuring that all piping, valves, and instrumentation are functioning correctly.

  3. Start-up: The start-up process should be gradual, following the manufacturer’s recommended procedure. The operator must monitor the compressor’s operation during the start-up phase to detect any abnormal vibrations, noises, or temperatures.

  4. Reliability test: A reliability test for 72 continuous hours, scheduled two months after having gas available in the plant, can be performed to ensure that the compressor is operating at its rated capacity and efficiency. During the test, the performance parameters such as suction and discharge pressures, temperatures, and flow rates should be monitored and recorded. The results of the test can be used to verify the compressor’s performance, identify any issues, and make necessary adjustments.

  5. Regular maintenance: Regular maintenance activities such as cleaning, lubrication, and inspection should be carried out according to the manufacturer’s recommendations and industry standards. The maintenance activities should include checking the condition of the bearings, seals, and other components that are subject to wear and tear. The data obtained from the regular maintenance activities can be used to identify potential issues and prevent unscheduled shutdowns.

  6. Training and documentation: The operators and maintenance personnel should be trained on the proper operation and maintenance of the compressor. The documentation of the installation, commissioning, and maintenance activities should be properly recorded and updated to ensure that the compressor’s history is well-documented.

By following these recommended procedures, the installation, commissioning, and start-up of centrifugal compressors can be carried out safely, reliably, and efficiently, minimizing the risk of critical failures and unscheduled shutdowns in oil, gas, and petrochemical industries.

GAS TURBINES

The recommended procedures for installation, commissioning, and start-up of gas turbines in new projects and existing process plants are critical for ensuring reliable and safe operation and avoiding critical failures and unscheduled shutdowns. Here are some general steps that should be followed:

  1. Pre-installation and planning phase: This involves assessing the site conditions and requirements, selecting the appropriate turbine, designing the foundation and support systems, and identifying any special requirements or challenges.

  2. Mechanical installation phase: This involves preparing the site, installing and aligning the gas turbine, assembling the auxiliary systems, and conducting quality checks.

  3. Electrical and control installation phase: This involves installing and connecting the electrical and control systems, conducting cable and insulation tests, and performing functional tests.

  4. Commissioning and start-up phase: This involves checking and adjusting the operational parameters, testing the protection systems, and ensuring proper synchronization with the grid or process systems.

  5. Reliability test phase: This involves conducting a 72-hour continuous test after two months of having gas available in the plant, as specified in the question.

In addition to these general steps, there are several specific procedures and checks that should be followed during each phase to ensure that the gas turbine is installed, commissioned, and started up safely and reliably. These procedures and checks can vary depending on the specific gas turbine model and the site conditions, but some of the key considerations include:

  • Ensuring proper alignment and clearance of all components during mechanical installation.
  • Conducting vibration and noise measurements during mechanical and electrical installation.
  • Verifying the correct installation and connection of all electrical and control systems, including grounding and insulation checks.
  • Conducting functional tests of all systems, including fuel supply, oil supply, cooling systems, and fire protection systems.
  • Conducting a commissioning test run to check the overall performance and stability of the gas turbine.
  • Checking and adjusting the operational parameters, such as the fuel flow rate, temperature, and pressure, to ensure optimal performance and efficiency.
  • Verifying the proper functioning of all protection systems, including over-speed protection, temperature and pressure alarms, and emergency shutdown systems.
  • Conducting a reliability test after two months of having gas available in the plant, as specified in the question, to ensure that the gas turbine can operate continuously and reliably for extended periods.

Overall, following these recommended procedures for installation, commissioning, and start-up, including the reliability test, can help to ensure that gas turbines operate safely, reliably, and efficiently in power generation, oil, gas, and petrochemical industries.

SPECIAL STEAM TURBINES

The recommended procedures for installation, commissioning, and start-up of special steam turbines in new projects and existing process plants are critical to ensure their reliability, maintainability, and safety. Here are some general steps to consider:

  1. Transportation and handling: The steam turbine and its components should be transported and handled carefully to avoid any damage. The manufacturer’s instructions and best practices should be followed.

  2. Foundation: The steam turbine should be installed on a solid foundation designed to meet the manufacturer’s requirements, which should include an appropriate level of vibration isolation.

  3. Piping: Piping should be designed, installed, and tested to ensure proper alignment and minimum strain on the steam turbine. Valves and fittings should be installed according to the manufacturer’s instructions.

  4. Lubrication and control oil systems: These systems should be installed and tested according to the manufacturer’s instructions. Cleanliness is critical to ensure the reliability of the steam turbine.

  5. Instrumentation and control system: The instrumentation and control system should be installed and tested to ensure that the steam turbine operates safely and efficiently.

  6. Alignment: The steam turbine should be aligned to the manufacturer’s specifications to ensure that it operates smoothly and efficiently. Alignment should be checked before and after installation.

  7. Commissioning: After installation, the steam turbine should be commissioned in stages to ensure that it operates as intended. The commissioning process should include verifying the performance of the steam turbine under load.

  8. Reliability test: The reliability test should be conducted for 72 continuous hours, scheduled two months after the steam turbine has been installed and gas is available in the plant. The purpose of the test is to demonstrate the reliability of the steam turbine under continuous operation.

  9. Operation and maintenance: Once the steam turbine is in operation, it is important to follow the manufacturer’s recommendations for operation and maintenance to ensure its reliability and safety.

It is important to note that each steam turbine is unique, and the manufacturer’s instructions and best practices should be followed. Additionally, local regulations and standards should be considered when developing installation, commissioning, and start-up procedures.

FREQUENT QUESTIONS & ANSWERS

Here are some frequent questions and answers about the recommended procedures for installation, commissioning, and start-up of centrifugal compressors, gas turbines, and special steam turbines:

  1. What is the purpose of the reliability test for 72 continuous hours? Answer: The reliability test is performed to ensure that the turbine or compressor can operate continuously for a prolonged period without any failure or interruption. This test helps to identify any potential problems and correct them before the equipment is put into operation.

  2. Can the reliability test be skipped? Answer: It is not recommended to skip the reliability test as it is an essential part of the start-up process. Skipping the test can lead to unforeseen problems during operation, resulting in costly repairs and downtime.

  3. How can I ensure that the installation is done correctly? Answer: It is important to follow the manufacturer’s installation instructions and hire experienced and qualified personnel to handle the installation process. Proper alignment, foundation, and piping installation are critical for the smooth operation of the equipment.

  4. What are some common start-up issues with turbines and compressors? Answer: Some common start-up issues include inadequate lubrication, improper alignment, and incorrect operation of control systems. These issues can lead to equipment failure and downtime.

  5. What maintenance procedures should be followed after start-up? Answer: Regular maintenance procedures such as inspection, lubrication, and cleaning should be followed as per the manufacturer’s recommendations. Any abnormalities or problems should be addressed promptly to prevent unscheduled downtime and critical failures.

  6. Can I use different installation procedures for different types of turbines and compressors? Answer: Each type of turbine and compressor has unique installation, commissioning, and start-up procedures. It is important to follow the manufacturer’s recommendations for each type of equipment to ensure safe and reliable operation.

  7. What training is required for personnel involved in the installation and start-up of turbines and compressors? Answer: Personnel involved in the installation, commissioning, and start-up of turbines and compressors should have adequate training and experience to handle the equipment. This includes knowledge of safety procedures, installation techniques, and operation of control systems.

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