Rotating Machine Test Procedures for Sipchem Complex

Date : Mar.
01, 2004
Rev :
ROTATING MACHINE TEST PROCEDURE
DocNo. :
CLIENT :
Page 1 of 69
SMJ-256-101
SAUDI INTERNATIONAL PETROCHEMICAL

COMPANY (Sipchem)
PROJECT TITLE : Sipchem COMPLEX AT JUBAIL

LOCATION :
AL-JUBAIL, THE KINGDOM OF SAUDI ARABIA
FOR CONSTRUCTION
CHIYODA CORPORATION
COMPANYs PROJECT No. :

CHIYODA PROJECT NAME :
CHIYODA JOB NO. :
12729700-10-K001 / 50-K003
SMJ PROJECT
11010
Revised as per companys comment
Mar. 01, 2004
S. W.
T. K.
A. M.
Original
Jan. 9, 2004
S. W.
T. K.
A. M.
Date
by
Checked
Approved
No.
Origination (0) / Revision ( )
Date : Mar. 01, 2004

Rev :
DocNo. :
Rev No
No.
.
0
Page 2 of 69
SMJ-256-101
ITEM
DESCRIPTION
REMARKS
Original Issue for Companys review
GENERAL
Revised as per companys comment
SMJ-T-SJ/CJ-700
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 3 of 69
SMJ-256-101
CONTENTS
1.
GENERAL
..............................................................................................................................
4
2.
PRE-COMMISSIONING/COMMISSIONING PROCEDURE
..............................................................................................................................
5
2.1
Centrifugal Compressors and Steam Turbine Drivers (10-C1101/10CT1101, 10-C1401/10-CT1401)
..................................................................................................................
5
2.2
Air Compressor Package (50-Z1701A/B/C)
..................................................................................................................
8
2.3
Horizontal Centrifugal Pumps
..................................................................................................................
10
2.4
Pump Drivers
..................................................................................................................
12
2.5
Reformer Fan Turbines
..................................................................................................................
13
2.6
Seawater Pumps (70-P1001A/B/C)
..................................................................................................................
15
2.7
BFW Pumps (10-P1901A/B/C, 50-P1402A/B/C)
..................................................................................................................
17
2.8
Fire Water Pumps (50-P1202A/B/C)
..................................................................................................................
20
2.9
Sundyne Pumps (10-P1508A/B)
..................................................................................................................
23
2.10 Sump Pumps
..................................................................................................................
25
2.11 Submersible Pumps
..................................................................................................................
27
2.12 Air Diaphragm Pumps
..................................................................................................................
29
2.13 Lube Oil System
Date : Mar. 01, 2004

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SMJ-256-101
..................................................................................................................
30
3.
RUN-IN PROCEDURE
..............................................................................................................................
32
3.1
Centrifugal Compressor and Steam Turbine Driver (10-C1101/10CT1101, 10-C1401/10-CT1401)
..................................................................................................................
32
3.2
..................................................................................................................
43
3.3
..................................................................................................................
47
3.4
Steam Turbines
..................................................................................................................
50
3.5
Reformer Fan Turbines (10-BT1201, 10-BT1202)
..................................................................................................................
53
3.6
..................................................................................................................
54
3.7
..................................................................................................................
56
3.8
..................................................................................................................
58
3.9
..................................................................................................................
60
3.10 Sump Pumps
..................................................................................................................
62
3.11 Submersible Pumps
..................................................................................................................
63
3.12 Air Diaphragm Pumps
..................................................................................................................
64
3.13 Lube Oil System
..................................................................................................................
65
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 5 of 69
SMJ-256-101
1. GENERAL
This document covers the activities, checks, preparations, and procedure(s) required for
the pre-commissioning / commissioning work for rotating machinery supplied for the
Sipchem Complex at Jubail.
The procedures contained in this document shall be used as a guide for the precommissioning / commissioning work and for the specific requirement/information for
certain subjects. The following documents shall be referred to as necessary;
-
Vendor's operation manuals

As built vendor prints
Process operation manuals
Lubricant list
Detail pre-commissioning, commissioning, and mechanical run in plan shall be prepared

and reviewed with Company prior to the commissioning process. All safety precaution
shall be highlighted in the plan.
Unless otherwise mutually agreed between Company and Contractor. All rotating
equipment driver shall be solo run for a minimum of two hours or more, as recommended
by the vendor, to confirm the driver rotation direction, vibration, bearing temperature,
proper lubrication and abnormality free before couple up to the driven equipment.
All secondary steam supply line, seal auxiliary lines, oil lines and process lines shall be
cleaned to equipment manufacturers warranty standard.
All alignment shall be confirmed before and after piping connection to comply with vendor
specification or project equipment installation specification, whichever is the more
stringent requirement shall be followed.
All oil lubricated bearing or gear reduction housings shall be flushed clean with oil and
charged with fresh oil for the mechanical run test. Old grease shall be purged with new
grease for the grease lubricated bearings.
A commissioning report shall be prepared by Contractor to record the commissioning
process, the alignment record, vibration readings, oil change record, temperature reading
etc. as appropriate for the equipment.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 6 of 69
SMJ-256-101
2. PRE-COMMISSIONING/COMMISSIONING PROCEDURE
2.1
Centrifugal Compressors and Steam Turbine Drivers (10-C1101/10-CT1101, 10C1401/10-CT1401)

1)
Confirm completion of mechanical check (Pre-commissioning)

Prior to commencement of commissioning work, completion of erection work shall
be checked/confirmed by the report prepared for mechanical completion.
The completion of the following activities shall be confirmed, but not limited to;
-
Setting/leveling of equipment on foundation

Grouting
Alignment
Piping alignment to equipment nozzle
Setting of suction strainer, where applicable
Installation of gland condensing unit
Installation of surface condenser, where applicable
Installation of vacuum ejector/condenser unit, where applicable
Installation of turbine exhaust relief valve
Installation of turbine exhaust duct, where applicable
Completion of auxiliary piping (drain, vent, cooling water, steam, condensate,
lube oil, seal gas, etc.)
Removal of temporary blind, etc. used during erection work
Installation of lube and dry gas seal system
Installation of coupling (*)
Installation of local panel, where applicable
Installation of local gages (instruments)(*)
Completion of instrument wiring/tubing installation
Status of rust preventative applied
(*) Note:
Coupling, local gages, etc. might be removed from compressor/oil unit skid and
be stored separately until certain commissioning activities are completed. On
such case, inventory check of the parts separately stored shall be carried out.
Followings are commissioning activities.
2)
Remove all rust preventatives, desiccant, oil used to protect equipment (bearing
housing, casing, and condensers)
3)
Commission lube and control oil system (refer to Section 2.13 PreCommissioning/Commissioning Procedure for Lube Oil System)
4) Commission oil purifier/clarifier (refer to vendor's manual)

It is recommended to use oil purifier/clarifier for oil filling to lube and control oil
system, and also to use during oil flushing.
Date : Mar. 01, 2004

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Page 7 of 69
SMJ-256-101
5)
Carry out oil flushing (refer to Oil Flushing Procedure, SMJ-256-102)

After completion of oil flushing, circulation oil to be drained completely from oil
system & oil reservoir, and fill specified lubricant to oil reservoirs. The charge
capacity, corresponding to the run-down level, is shown on vendor's operation
manuals.
Also fill/charge lube oil/grease to auxiliary equipment as required.
6)
Confirm that the following lines were cleaned by steam blow (refer to Steam Blow
Procedure). Silent stream blowing shall be done for steam turbine inlet & other
auxiliary steam lines cleaning purpose with required target plate before
commissioning steam lines.
-
Steam turbine inlet

Motive steam inlet to ejectors, etc.
Seal steam to turbine gland, where applicable
7)
Check that the compressor suction piping is cleaned, chemically or mechanically

as applicable, and that rust prevention is properly maintained until compressor
run-in. Sheet blasting and target blowing (with white cloth) of all suction lines,
seal gas primary and secondary buffer gas lines to be done in absence of
chemical cleaning.
8)
Check installation/connection of earth terminal/lugs of base plate, oil unit,

condenser, etc.
9)
Check freedom of all moving parts.

Check of free movement of compressor and turbine shaft shall be attempted only
when forced feed lubrication system is operated.
10)
Install coupling and coupling guard.

Before installing coupling guard, cold off set alignment reading between driver
and driven without piping & with piping should be confirmed.
11) Check line up of;

cooling water piping,
lube oil piping,
seal gas piping,
steam piping,
buffer gas piping, etc.
12)
Check that the surface condenser, where applicable, is tested for tightness by air
according to vendors instruction (refer to SOG0013680/4, Air Leak Test
Procedure). Surface condenser vacuum check should be done.
13)
Check that, where applicable, the condensate pumps (10-P1401A/B) and

condensate fan (10-B1401A-H) are commissioned and properly lined up. Make
sure that all the line around surface condenser is properly lined up. Refer to
vendors instruction (SOG0013761/4, Operation and Maintenance Specification).
14)
Check that the steam turbine exhaust relief valve is set to service.
Date : Mar. 01, 2004

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SMJ-256-101
15)
Check installation of instruments.

Instrument air tubing/piping shall be cleaned by air blow. Instruments logic
checking and all C/Vs stroke checking shall be completed before commissioning.
16)
Check that control and sequence check is completed.
17)
Check that continuity check, meggar check, and other required electrical checks
of instrument wiring and electrical power wiring/cable is completed.
18)
Check that instrument calibration is completed.

Steam turbine electric governor and governor valve shall be checked for proper
function remotely from the governor in the control room. Various pre-set values
for governor control shall be checked for those specified in steam
turbine/governor manual. Stroke checking of governor and extraction valves shall
be completed & recorded before commissioning.
Radial vibration: Probe to be installed while checking GAP voltage with monitor &
demodulator.
Axial Displacement: Probe to be installed while checking monitor reading. Probe
to be set in order monitor to get Zero reading at center of thrust float. Rotor
centering shall be checked mechanically and on control panel by setting axial
probes gap voltage.
19)
Fully energize instrumentation.
20)
Line up process piping/system.

Pipe routing/loop to be used for compressor mechanical running test (run-in) shall
be planned for each service (item).
Required piping/system line-up shall be, as a normal practice, provided by
marking up the relevant P&ID indicating all the pipe routing/loop to be used for
compressor mechanical running test including the following information, but not
limited to;
-
Valve position of all the valves included in the test loop.

Instruments, which shall be put into service during the test.
Temporary block/blind, bypass, etc. required for the test.
Lube oil and control oil pressure shall be checked, turning gear operation to be
checked, rundown tank over flow line to be checked for oil flow, all oil
accumulator N2 pressure to be checked before commissioning of compressor.
2.2
21)
Compressor Run-in (Mechanical Running Test)

(refer to Run-in Procedure for 10-C1101/10-C1401)
22)
Hot alignment will be conducted only when it is required by compressor vendor.

1)
Date : Mar. 01, 2004

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Page 9 of 69
SMJ-256-101
-

Grouting, where applicable
Alignment
Installation of inlet air filter/silencer
Installation of blow-off valve and silencer
Installation and setting of expansion joint
Installation of discharge check valve in proper flow direction and movement
Completion of auxiliary piping (drain, vent, cooling water, lube oil, etc.)
Installation of local panel
Installation of local gages (instruments) (*)
(*) Note:
Coupling, local gages, etc. might be removed from compressor/oil unit skid and
be stored separately until certain commissioning activities are completed. On
2)
housing, casing).
3)
Commission lube oil system (refer to Section 2.13 PreCommissioning/Commissioning Procedure for Lube Oil System).
4) Fill specified lubricant to oil reservoirs.

Also, fill/charge lube oil/grease to auxiliary equipment as required.
Oil flushing will not be conducted since no additional oil piping is provided at site.
5) Check that the compressor suction piping is cleaned, chemically or mechanically as
applicable, and that rust prevention is properly maintained until compressor runin.
Sheet blasting and target blowing (with white cloth) of all suction lines shall be
done in absence of chemical cleaning.
6)
7)
Check installation/connection of earth terminal/lugs of base plate.

Commission drivers (Refer to Section 2.4 Pre-commissioning/Commissioning
Procedure for Pump Drivers)
8)

Check of free movement of compressor shaft shall be attempted only when
forced feed lubrication system is operated.
Date : Mar. 01, 2004

Rev :
DocNo. :
SMJ-256-101
9)

Before installing coupling guard, cold off set alignment reading between driver
and driven without piping & with piping should be confirmed.
10)
Check line up of;

lube oil piping,
instrument air piping, etc.
11)

Instrument air tubing shall be cleaned by air blow.
12)
Check that control and sequence check is completed (including functional check
of inlet valve and blow-off valve).
Instruments logic checking and all C/Vs stroke checking shall be completed
before commissioning.
13)
14)

Set point for anti-surge control and surge protection shall be optimized and set at
site under the supervision/instruction of compressor vendor field supervisor (Elliott
Company).
15)
16)

Pipe routing/loop to be used for compressor mechanical running test (run-in) shall
be planned.
compressor mechanical running test including the following information, but not
limited to;
-
2.3
Page 10 of 69

Instruments which shall be put into service during the test.
17)
Compressor Run-in (Mechanical Running Test).

(refer to Section 3.2 Run-in Procedure for Air Compressor Package)
18)
Hot alignment will be conducted only when it is required by compressor vendor.
1)

Date : Mar. 01, 2004

Rev :
DocNo. :
Page 11 of 69
SMJ-256-101
-

Grouting
Alignment
Installation of turbine exhaust relief valve, where applicable
Completion of auxiliary piping (drain, vent, cooling water, steam, etc.)
Installation of constant level oiler(*)
Installation of coupling(*)
Installation of local gages (instruments), where applicable(*)
Status of rust preventative applied.
(*) Note:
Coupling, constant level oiler, local gages, etc. might be removed from pump skid
and be stored separately until certain pre-commissioning activities are completed.
On such case, inventory check of the parts separately stored shall be carried out.
2)
Remove all rust preventatives, desiccants, oil used to protect equipment (bearing
housing, casing)
3)
Where applicable, flush/clean pressurized dual seal piping/system and fill the seal
reservoir with specified barrier fluid to specified level.
Seal pot & its piping to double seals shall be flushed with water & then dry with
N2 blowing then fill with required barrier fluid.
4)
Install constant level oiler, where applicable.
5)
Flush bearing housing and fill specified lubricant to specified level.

Clean the bearing housing oil and flush with required oil for debris and dirt.
6)
Confirm that steam turbine inlet piping was cleaned by steam blow, where
applicable
7)

For pump utilizing forced feed lubrication system, check of free movement of
pump shaft shall be attempted only when forced feed lubrication system is
operated.
Check the free movement of pump rotor and for any abnormalities, check
bearings and casing wear rings.
8)
Commission forced feed lubrication system, where applicable (refer to Section

2.13 Pre-Commissioning/Commissioning Procedure for Lube Oil System).
9)
Commission driver (refer to Section 2.4 Pre-Commissioning/Commissioning

Procedure for Pump Drivers).
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 12 of 69
SMJ-256-101
10)

Before installing coupling guard, alignment reading for radial & axial misalignment
shall be checked. Maximum misalignment value should be within +-0.05 mm.
11)
Check line up of;

seal flushing piping, where applicable,
cooling water piping, where applicable,
lube oil piping, where applicable,
steam piping, where applicable, etc.
12)
13)
Check installation of instruments, where applicable.

(instrument installation, calibration, continuity check, etc.)
14)
Fully energize instrumentation
15)

Pipe routing/loop to be used for pump mechanical running test (run-in) shall be
planned for each service (item).
pump mechanical running test including the following information, but not limited
to;
-

Suction strainer of pumps should be wrap with fine SS wire mesh screen (up to
60 mesh screen) for collecting dirt & debris. After commissioning same can be
removed.
2.4
16)
Pump Run-in (Mechanical Running Test)

(refer to Section 3.3 Run-in Procedure for Horizontal Centrifugal Pumps)
In pre commissioning, if process permits pump trial can be taken with fire/service
water and system flushing can be done.
17)
Hot alignment will be conducted only when it is required by pump vendor.
Pump Drivers
1)
Electric Motor Driver

Prior to run-in of pump, all required Pre-Commissioning / Commissioning activities
shall be completed by Electrical group and be reported.
Mechanical Engineer in charge of pump Pre-Commissioning / Commissioning
shall check such report and confirm readiness of the motor driver.
(Refer to Pre-Commissioning / Commissioning procedure separately provided for
electric motor)
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 13 of 69
SMJ-256-101
Direction of rotation of the motor shall be checked/confirmed at motor run-in test

which shall also be completed prior to run-in test of the pump.
Solo run of motor shall be checked for direction checking and for any abnormality
check. Motor meger & amperes checking shall be done.
2)
Steam Turbine Driver (General Purpose Turbine)

(1)
Confirm completion of Pre-Commissioning / Commissioning activities

specified in Para. 1) to 6) and 9) to 14) of Section 2.3 Pre-Commissioning /
Commissioning Procedure of Horizontal Centrifugal Pumps, which shall be
checked together with its dedicated pump.
Turbine solo run shall be checked for over speed trip checking and for any
abnormalities check.
(2)
Steam Turbine Run-in (refer to Section 3.4 Run-in Procedure for Steam
Turbine).
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 14 of 69
SMJ-256-101
2.5 Reformer Fan Turbines

1)

-

Grouting
Alignment
Installation of gland condensing unit
Installation of turbine exhaust relief valve
Installation of turbine exhaust pipe
lube oil, etc.)
Installation of lube oil system
Installation of local panel, where applicable
Installation of local gages (instruments)(*)
(*) Note:
Coupling, local gages, etc. might be removed from turbine/oil system skid and be
stored separately until certain commissioning activities are completed.
2)
housing, casing, gear, gland condenser)
3)
Commission lube and control oil system (refer to Section 2.13 PreCommissioning / Commissioning Procedure for Lube Oil System)
4)
Carry out oil flushing (refer to Oil Flushing Procedure)

After completion of oil flushing, fill specified lubricant to oil reservoirs.
5)
Confirm that the following lines were cleaned by steam blow (refer to Steam Blow
Procedure). Silent stream blowing shall be done for steam turbine inlet & other
auxiliary steam lines cleaning purpose with required target plate before
commissioning steam lines.
-
Steam turbine inlet
Date : Mar. 01, 2004

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Page 15 of 69
SMJ-256-101
-
Motive steam inlet to ejectors
6)
Check installation/connection of earth terminal/lugs of base plate, oil unit, etc.
7)

Check of free movement of turbine and gear shaft shall be attempted only when
8)

Before installation of coupling, alignment checking shall be done and cold off set
value shall be achieved as per vendor cold off set value for alignment.

lube oil piping,
steam piping, etc.
10)
11)

Instrument air tubing/piping shall be cleaned by air blow.
12)
13)
14)

Steam turbine electric governor and governor valve shall be checked for proper
function remotely from the control room and from local P.B.
Various pre-set values for governor control shall be checked for those specified in
steam turbine/governor manual.
Stroke checking of electric governor shall be done. All instrument probes setting
and gap voltage shall be checked. For axial probes rotor centering shall be
checked. All instrument logic check shall be completed before start up.
15)
16)
Turbine Run-in (Mechanical Running Test)

(refer to Section 3.5 Run-in Procedure for Reformer Fan Turbine)
Turbine solo run shall be checked for over speed trip checking.
17)
Hot alignment will be conducted only when it is required by turbine vendor.
Date : Mar. 01, 2004

Rev :
DocNo. :
2.6
Page 16 of 69
SMJ-256-101

1)
Confirm completion of mechanical check. (Pre-commissioning)

-
Setting/leveling of equipment on foundation.

Grouting
Alignment.
Piping alignment to equipment nozzle.
Completion of auxiliary piping (drain, vent, cooling water, etc.), where
applicable.
Removal of temporary fixture used for transportation, if any.
Removal of temporary blind, etc. used during erection work.
Installation of motor on pump (motor mount bracket).
Installation of constant level oiler(*).
Installation of coupling(*).
Installation of local gages (instruments)(*).
Completion of instrument wiring/tubing installation.
(*) Note:
Coupling, constant level oiler, local gages, etc. might be removed from pump skid
and be stored separately until certain commissioning activities are completed. On
2)
housing, casing).
3)
Install constant level oiler, where applicable.
4)
Flush bearing housing and fill specified lubricant to specified level.

Clean the bearing housing oil and flush with required oil for debris and dirt.
5)
Check freedom of all moving parts, if possible.

6)

7)

Before installation of coupling and coupling guard, alignment reading for radial
and axial misalignment shall be checked. Maximum misalignment value should be
within +-0.05 mm.
Date : Mar. 01, 2004

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Page 17 of 69
SMJ-256-101
8)
Check line up of;

auxiliary piping,
cooling water piping, where applicable, etc.
9)
Where applicable, check installation of instruments which shall include the

following, but not limited to;
-
wiring continuity check.

calibration.
control logic check for auto start/stop.
10)
11)

to;
-

12)

(refer to Section 3.6 Run-in Procedure for Sea Water Pumps)
13)
No hot alignment will be conducted.
Date : Mar. 01, 2004

Rev :
DocNo. :
2.7
Page 18 of 69
SMJ-256-101

1)

-

Grouting.
Alignment.
Setting of suction strainer, where applicable.
Installation of turbine exhaust relief valve, where applicable.
lube oil, etc.).
Installation of lube system, where applicable.
Installation of coupling (*).
Installation of local panel, where applicable.
Installation of local gages (instruments)(*).
(*) Note:
Coupling, local gages, etc. might be removed from pump/oil unit skid and be
stored separately until certain commissioning activities are completed.
2)
housing, casing, etc.).
3)
Commission lube oil system (refer to Section 2.13 Pre-Commissioning /

Commissioning Procedure for Lube Oil System).
4)
Carry out oil flushing (refer to Oil Flushing Procedure).

After completion of oil flushing, fill specified lubricant to oil reservoirs and
degassing tank.
5)
Confirm that steam turbine inlet piping was cleaned by steam below.
Silent stream blowing shall be done for steam turbine inlet and other auxiliary
steam lines cleaning purpose with required target plate before commissioning
steam lines.
6)
Check that the pump suction piping is cleaned as applicable, and that rust
prevention is properly maintained until pump run-in.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 19 of 69
SMJ-256-101
60 mesh screen) for collecting dirt and debris. After commissioning same can be
removed.
7)
Check installation/connection of earth terminal/lugs of base plate, oil unit, etc.
8)
Commission drivers (Refer to Section 2.4 Pre-commissioning/Commissioning

Procedure for Pump Drivers)
9)

Check of free movement of pump and turbine shaft shall be attempted only when
10)

Before installation of coupling alignment checking shall be done and cold off set

auxiliary piping,
lube oil piping,
steam piping, where applicable, etc.
12)
13)

Instrument air tubing shall be cleaned by air blow.
14)

Stroke checking of electric governor shall be done. All instrument probes setting
and gap voltage shall be checked. For axial probes rotor centering shall be
checked. All instrument logic check shall be completed before start up.
15)
16)
17)
18)

planned.
to;
-

Date : Mar. 01, 2004

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DocNo. :
Page 20 of 69
SMJ-256-101
19)

(refer to Section 3.7 Run-in Procedure for BFW Pumps).
20)
Hot Alignment will be conducted only when it is required by pump vendor.
Date : Mar. 01, 2004

Rev :
DocNo. :
2.8
Page 21 of 69
SMJ-256-101

1)

-

Grouting.
Alignment.
Completion of auxiliary piping (drain, vent, fuel oil, etc.).
Installation of constant level oiler(*).
Installation of local fire pump controller.
Installation of local gages (instruments), where applicable(*).
Status of lubricant filling.
(*) Note:
Coupling, constant level oiler, local gages, etc. might be removed from
pump/diesel engine skid and be stored separately until certain pre-commissioning
activities are completed.
2)
Remove all rust preventatives, desicant, oil used to protect equipment (bearing
housing, casing).
3)
Fill specified lubricant to specified level into crankcase.

Clean the crank case housing oil and flush with required oil for debris and dirt.
4)
Check engine jacket coolant level.
5)
Commission driver (Diesel engine)

-
Check that instrument wiring between local panel and fire control room is
completed and all loop check is also completed.
Conduct pre-start inspection in accordance with vendors manual.
Conduct Engine Sole-Run Test as follows;
Date : Mar. 01, 2004

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SMJ-256-101
Place the Manual-Auto-Stop control switch on engine local panel in "Manual"
position.
Pull and hold one of the two manual start levers until engine starts; or for a
cranking period of approximately 15 seconds.
If engine fail to start, wait 15 seconds and repeat cycle with the alternate manual
start lever.
After starting the diesel engine, confirm that all operating conditions are normal.
If the engine speed will not be rated speed, adjust the governor to set the speed
about rated speed.
The diesel engine will be set at the rated speed and be kept this condition for one
hour after the diesel engine mechanical conditions is stabilized.
A great care shall be taken to check the oil leakage from the oil systems during
the running.
During this operation the items listed below will be measured and recorded every
30 minutes.
The readings shall be checked to be normal specified in vendor documents.
- Engine speed
- Engine lube oil pressure
- Engine fuel tank level
- Engine fuel pressure
- Engine coolant temperature
- Ammeter
- Any abnormal vibration
- Any abnormal sound
- Any coolant or oil leakage
Over speed trip test shall be carried out by overcoming the governor in order to
check the over speed trip mechanism.
After confirming that the diesel engine will run safely, turn the control switch on
engine control panel to Stop position and hold until engine comes to a complete
stop.
6)

Before installation of coupling alignment checking shall be done and cold off set
7)
Check line up of;

cooling water piping, where applicable,
lube oil piping, where applicable,
fuel line, etc.
8)
Check installation of instruments, where applicable.

9)
10)
Line up piping/system.
planned.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 23 of 69
SMJ-256-101
to;
-

removed.
11)

(refer to Section 3.8 Run-in Procedure for Fire Water Pumps)
Date : Mar. 01, 2004

Rev :
DocNo. :
2.9
Page 24 of 69
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1)

-

Grouting
Alignment
Completion of auxiliary piping (drain, vent, cooling water, seal flushing, etc.)
(*) Note:
Local gages, etc. might be removed from pump skid and be stored separately
until certain pre-commissioning activities are completed.
2)
Remove all rust preventatives, desiccants, oil used to protect equipment (bearing
housing, casing)
3)
Flush/clean pressurized dual seal piping/system and fill the seal reservoir with
specified barrier fluid to specified level.
Seal pot and its piping to double seals shall be flushed with water & then dry with
N2 blowing then fill with required barrier fluid.
4)
Flush gear box and fill specified lubricant to specified level.
5)

6)
Check line up of;

seal flushing piping,
lube oil piping, etc.
7)

8)
Fully energize instrumentation
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to;
-

removed.
10)

(refer to Section 3.9 Run-in Procedure for Sundyne Pumps)
11)
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SMJ-256-101
Sump Pumps
1)

-

Grouting
Setting of suction strainer
Installation of motor on pump (motor mount bracket)
(*) Note:
Coupling, etc. might be removed from pump skid and be stored separately until
certain commissioning activities are completed.
2)
housing, casing).
3)
Fill specified grease to specified quantity.
4)

For pump utilizing rigid coupling, check of free movement of pump shaft is
possible only after pump is coupled to motor shaft to a proper setting.
5)

6)
Install coupling and coupling guard (refer to vendor's manual for pumps utilizing
rigid coupling for setting of axial gap).
7)

to;
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removed.
8)

(refer to Section 3.10 Run-in Procedure for Sump Pumps)
9)
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Submersible Pumps
1)

-

Installation of local panel
Completion of electrical and instrument wiring installation
(*) Note:
Local gages, etc. might be removed and be stored separately until certain
commissioning activities are completed.
2)
housing, casing).
3)
Fill specified grease to specified quantity.
4)
5)
6)
Check that continuity check, meggar check, and other required electrical checks of
instrument wiring and electrical power wiring/cable is completed.
7)
8) Fully energize instrumentation.

9)

to;
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-

10)

(refer to Section 3.11 Run-in Procedure for Submersible Pumps)
11)
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SMJ-256-101
Air Diaphragm Pumps

1)
Confirm completion of mechanical check.(Pre-Commissioning)

-

Grouting.
Completion of auxiliary piping (motive air, etc.).
Installation of relief valve, where applicable.

2) Remove all rust preventatives, desiccant, oil used to protect equipment, where
applicable.
3)
Confirm that air inlet piping was cleaned by air blow.
4)
Check line up of:

motive air piping, etc.
5)
Pipe routing/loop to be used for pump mechanical test (run-in) shall be planned
for each service (item).
to;
-

Temporary block/blind bypass, etc. required for the test.
6)

(refer to Section 3.12 Run-in Procedure for Air Diaphragm Pumps)
7)
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SMJ-256-101
Lube Oil System

1)

-

Grouting.
Alignment of auxiliary oil pumps.
Completion of auxiliary piping (drain, vent, cooling water, steam, etc.).
Installation of run-down tank, where applicable.
Installation of interconnecting piping, where applicable.
Installation of local gages (instruments), where applicable (*).
(*) Note:
Local instrument, etc. might be removed from oil system and be stored separately
until certain commissioning activities are completed.
2)
Remove all rust preventatives, desiccant, oil used to protect equipment.
3)
Check proper installation/connection of earth terminal/lug on base plate and/or

equipment.
4)
Flush bearing housing and fill specified lubricant to lube oil pump & driver, as
applicable.
5)
Commission auxiliary pumps and drivers (refer to applicable procedures).
6)
Charge nitrogen to accumulator and reservoir to a required pressure, where

applicable.
7)
Check that temporary blind/caps, if any, used for transportation are removed.

oil piping,
steam piping, where applicable,
nitrogen piping, where applicable, etc.
9)
Check installation of instruments including the following, but not limited to;
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wiring continuity.
calibration.
function.
control and protection logic, etc.
10)
11)
Oil System Run-in and oil flushing

(refer to Section 3.13 Run-in Procedure for Lube Oil System, and Oil Flushing
Procedure, SMJ-256-102).
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3. RUN-IN PROCEDURE
3.1
Centrifugal Compressor and Steam Turbine Driver (10-C1101/10-CT1101, 10C1401/10-CT1401)
3.1.1. General
This document covers the general procedure of Gas Seal System Start-up, Oil System
Start-up, Turbine Solo-Run and Compressor Run-in for 10-C1101/10-CT1101, 10C1401/10-CT1401 at the commissioning stage.
3.1.2. Gas Seal System Start-Up Procedure
3.1.2.1 Preparation for Gas Seal System
1)
Piping
1.1)
Instrument air piping, flushing gas (N2) supply piping for pressurizing the
tertiary seals & intermediate chamber and seal gas piping have been cleaned.
Sheet blasting and target blowing with N2 (with white cloth) of all seal gas
primary and secondary buffer gas lines shall be done in absence of chemical
cleaning.
1.2)
The other piping has been cleaned per vendor service manual.
1.3)
N2 line will be connected to the tap on seal gas panel temporarily and N2 will
be injected to dry gas seal face for confirmation of cleanliness of dry gas seal
face.
2)
Valves
2.1)
All gas seal system manually controlled valves have been in their normal open
or closed position.
3)
Instruments
3.1)
Check whether the;

a) instrumentation is fully energized.
b) alarm and shut-down devices have been checked.
c) All instrument logic check shall be completed for alarm & trip before start
up.
3.1.2.2 Initial Start-up of the Gas Seal System

Compressor vendor advised that start-up seal gas, such as N2, is not required,
however, during initial start-up of compressor with N2 (refer to Section 3.1.5.
Compressor Run-In Procedure), using N2 as start-up seal gas might be effective,
since external N2 pressure will be higher than compressor system pressure. In this
case, temporary piping (with isolation valve & check valve) will be connected to the tap
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on seal gas panel temporarily and after start-up of compressor, start-up N2 seal gas
will be gradually switched over to discharge gas. Before starting commissioning
activity, the necessity of this operation should be discussed and mutually agreed
between Company and Contractor/Vendor.
The initial start-up must be carried out in accordance with the following schedule.
The schedule corresponds approximately to the time sequence.
1)
Preparation work described in the earlier section must be carried out.

2) Instrument Air Supply (Where applicable)
Turn on instrument air supply and check that all air pressure regulators are correctly
adjusted.
3) Check that the flushing gas (N2) supply for pressurizing the tertiary seals and
intermediate chamber is available.
4) Check that the isolating valves of the following control valve are open.
For 10-C1101: PDCV-11039
Pressure Differential Control Valve
For 10-C1401: PDCV-14051 & PDCV14041 Pressure Differential Control Valve
5) Check that the isolating valves of the seal gas lines to the compressors are open
6) Check that each main seal gas filter and the main flushing gas filter have the
isolating valves open and the vent and drain valves closed.
7) Check that each stand-by seal gas filter and the stand-by flushing gas filter have the
isolating valves and drain valve closed.
Check the seal gas filter differential pressure for cleanliness and if required change
over the filter for cleaning/replacement.
8) Check that the isolating valve on the primary vent lines are open.
9) Check that the isolating valves of pressure switches, pressure gauges, pressure
transmitters and pressure differential indicators are open.
10) Check the pressure in the lines bearing in mind that the flushing and seal (balancing
gas/seal gas) pressure should be as per vendors instruction.
11) Check the pressure in the intermediate chambers
12) Check that the adjusting flow orifice valves in the primary vent lines are fully open
and check the flow/ pressure also check the trip logic actuation for alarm & trip
before start up.
These valves should be adjusted after first start-up to give a low differential
pressure. These valves should be then be left in set position.
13) Check absence of oil in the compressor flushing chambers labyrinth seals opening
the proper drain valves.
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Note.
Before starting the lube oil system is necessary to pressurize by means of N2
the tertiary seal chambers situated between Dry Gas Seals and Bearings. If
the pressurized lube oil is supplied to bearing without barrier seal separation
gas, dry gas seal will be contaminated by lube oil.
3.1.3. Oil System Start-Up Procedure
3.1.3.1 Preparation for Lube Oil and Control Oil System
1)
Piping
1.1)
Oil flushing has been completed.
1.2)
Auxiliary parts and materials removed during flushing have been restored.
1.3)
Temporary blinds used during oil flushing have been removed and temporary
bypass piping has been restored to permanent line-up.
2)
Oil Reservoir
2.1)
Check reservoir for sufficient oil filling. Use only the specified oil type.
Thoroughly clean filling equipment and transport containers prior to use.
2.2)
Remove any water by means of the tank draining valve. Eliminate the cause
for water deposit.
2.3)
Check whether shut-off valves of the level indicators / switches are open.
2.4)
Check whether electric power is available for the lube oil heater.
3)
Oil Pumps
3.1)
Check if the shut-offs at the oil pumps are open.
3.2) Check whether operating and control voltage for the electric motor are
available.
3.3)
Check whether, for steam turbine of the main oil pump;

a) the rules for start-up in accordance with the instructions in the manual have
been noted, and
b) the steam conditions are in due order.
4)
Oil Coolers
4.1)
Check if the change-over devices at the twin coolers are connected in such a
way that the oil passes always only through one cooler.
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4.2)
In case of double cooler, check whether the shut-offs;

a) in the venting lines of the oil side are opened,
b) in the filling line are open,
c) of the cooler drains are closed.
d) The necessary orifices must be installed.
4.3)
Check if cooling water is available and if the water discharge shut-offs (possibly
provided for) are open and inlet shut-offs are closed.
4.4)
Check whether the temperature alarm sets comply with the designated values.
5)
Oil Filter
5.1)
Check if the change-over devices at the twin filters are connected in such a
way that the oil passes always through one filter unit only.
5.2)
Check the double filter. Are the shut-offs;

a) in the venting lines open,
b) in the filling line open,
c) in the filter drainage closed.
d) The required orifices must be provided.
6)
Control Valves
6.1)
Check if;
a) the shut-offs ahead of and downstream of the control valves are opened,
b) the hand control valve in the bypass is opened,
c) the shut-off in the impulse line is opened.
Check whether the valve ahead of the accumulator is open.
7)
Oil pressure lines at the machine
7.1)
Check if the adjusting orifices ahead of the bearings are open. (Where
applicable)
7.2)
Check if the wire screens possibly installed in the lines ahead of the bearings
between two flanges have been removed after flushing.
7.3)
Check whether the adjusting orifice ahead of the coupling is open.(Where

applicable)
8)
Rundown Tank
8.1)
Check whether the filling valve in the check valve by-pass line is open.
8.2)
Check that the atmospheric vent line is open. (Shipping plugs, blinds, etc., shall
be removed.)
9)
Bladder-type Accumulator
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SMJ-256-101
9.1)
Check whether the bladder type accumulator has the required pre-filling
pressure and whether the shut-off valve in the supply line is open.
10)
Instruments
10.1) Check whether the;

a) pressure gauge shut-off valves are open,
b) shut-off valves in the line of the pressure switches / transmitters are open
and the orifice (where applicable) is properly installed,
c) instrumentation is fully energized,
d) all instrument logics for alarm/trip have been checked before start up.
3.1.3.2 Initial Start-up of the Lube and Control Oil System
The initial start-up must be carried out in accordance with the following schedule. The
schedule corresponds approximately to the time sequence.
The following documents must be observed before the initial start-up:
a)
b)
Vendors manual describing; the oil system, and

preparation for initial start-up of the oil system.
1)
Preparation work described in the earlier section must have been carried out.
2)
Oil temperature adjustment.
2.1)
The oil should have a specified minimum temperature prior to start-up. If

required, start-up heating.
2.2)
An auxiliary pump can be put on line (bypass valve of PCV on return line to
reservoir may be open.) to reduce heating up time. Switch off pump and close
bypass line valve after temperature has been attained.
2.3)
Prior to start-up, the oil shall have a specified minimum temperature. As and
when required, operate both lube oil pumps at opened bypass valve of PCV on
return line to reservoir. Afterwards, cut out pumps and close bypass line valve.
3)
Oil pump start-up.
3.1)
Take auxiliary oil pump into operation. (Where necessary)
3.2) Put the main oil pump into operation, set auxiliary oil pump on automatic
control.
4)
Vent double cooler and double filter. Change over repeatedly, slowly from one
cooler and filter, respectively, to the other. Check sight glass in the common
return line (to do so, close all valves and then open them again, one after the
other).
5)
Oil pressure / temperature adjustment.
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SMJ-256-101
5.1)
Slowly close manual control valve in bypass line at all control valves, if it is
opened. L/O Control valves operation shall be checked and fine tuning shall be
done.
5.2)
Vent impulse line for control valve (PCV on return line to reservoir).
5.3)
Check and set all the other oil pressures / temperature in oil unit by adjusting
existing control valves.
Confirm that bypass valve of all control valves are closed.
5.4)
Vent impulse lines of all the measuring instruments.
5.5)
Check the sight glasses or flow indicators of the individual oil lines for oil flow.
6)
Check the automatic cutting-in of the auxiliary oil pump and its time taken to
develop full pressure to be noted.
7)
Check whether the rundown tank is filled (by oil flow in sight glass in elevated
tank overflow line). Filling valve on the by-pass line of check valve to be closed
after oil comes through overflow line.
8)
Compressor unit start-up.

Note:
Only warm oil of specified minimum temperature may enter the machine during
start-up.
Do not start-up compressor unit until the rundown tank are filled.
9)
Switch off or select auto position (where applicable) for electric heater, but only
after the oil in the bearings of the running compressor unit has warmed up to
normal oil temperatures.
10)
Open shut-off in cooling water supply line and adjust. Vent on waterside, until
water issues from the vent fittings, then close same.
11)
Readjust the oil pressures and temperature.
12)
Check the sight glasses or sight flow indicators in the oil discharges for proper
passage.
3.1.4. Turbine Solo Run Procedure (10-CT1101, 10-CT1401)

The turbine shall be tested by solo-run before making the coupling connection with the
compressor. Turbine governor and extraction valves stroke checking shall be done
prior to solo run.
The primary purpose of solo-run is to verify overspeed trip settings for overspeed trip
devices. In solo run, turbine mechanical trip, electrical trip and manual trip to be
checked.
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During these tests, vibration baseline data will be taken and the turbine shutdown
effect on the other equipment will also be checked.
Turbine shall be run at maximum continuous speed for half an hour and vibration,
bearing temperature to be noted for its maximum limit.
Turbine TTV (Trip & Throttle valve) shall be checked for its operation.
Surface condenser required vacuum to be achieved by running hogging ejector, in
case of problem, system leak test shall be done.
Before solo run warm up the steam inlet line up to required temperature and drain the
condensate.
Proper care to be taken for draining the condensate (by opening trap by pass line)
from steam supply to gland labyrinth area, if condensate enter to the turbine gland
labyrinth area it may damaged the turbine shaft (in form of bowing shaft) due to
condensate attack.
Check turbine turning gear operation prior to start up.
During speed up of turbine critical speed zone to be crossed quickly to avoid high
vibration.
All parameters recording to be done for initial start up / commissioning.
On line vibration monitoring device to be taken in line prior to start up / commissioning.
3.1.4.1. Preparation.
1)
Make sure that steam pipes are clean by steam blow.
3.1.4.2. Step-by-step Procedure

1)
Verify lube and control oil system is in service.
2)
The trip valve must be exercised prior to start-up to ensure proper operation
(cold test the trip valve).
After the test, confirm that trip valve is fully closed (trip condition)
3)
All monitoring devices, alarms and trips, must be put into operation.
4)
Prepare surface condenser as follows; (Applicable for 10-CT1401)

For operation of surface condenser(10-E1408), refer to vendors operation
manual and Operation and Maintenance Specification(SOG0013761/4).
4.1)
Check that all drain and vent valves are closed.
4.2)
Filling the water to condensate drum(10-D1406). Level inside condensate

drum(10-D1406) should be within maximum and minimum level: Start
the pump to remove the excess condensate or fill through the relevant
connection.
4.3)
Open or close the valve according to vendors instruction.
5)
Open drain from turbine and trip valve.
6)
Place turbine steam seal system preparation;
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SMJ-256-101
6.1)
Establish cooling water flow through to gland condenser.
6.2)
Put gland seal condenser ejector in service.
6.3)
Seal steam supply line shall be blocked until turbine rotor starts rotation by
turning gear.( Applicable for 10-CT1401)
7)
Establish vacuum in surface condenser as follows; (Applicable for 10-CT1401)
7.1)
Start hogging ejector.

Note) After sealing steam is available at turbine glands and motive steam to
vacuum unit, hogging ejector can be started.
7.2)
Start condenser fan motor.
7.3)
Line up condensate pumps through aftercondenser and LV to 10-D1406 & 10E1302.
7.4)
Start main condensate pump and put stand-by condensate pump in AUTO start
standby.
7.5)
Test standby pump for "Auto Start" by shutting down running pump and
verifying stand-by pump starts.
7.6)
Restart main condensate pump and shut-down stand-by condensate pump and
put hand switch in AUTO start position.
7.7)
Start holding ejector.
7.8)
Check out ejector condenser traps.
7.9)
Verify LIC of condensate drum is controlling the level properly.
7.10) When vacuum on surface condenser is holding at specified vacuum, shut-down

hogging ejector.
8)
Put turbine on solo-run as follows;

For start-up of steam turbine, refer to vendors operation manual and Control
System Functional Description(SOS0350722/4 & SOS0350721/4).
8.1)
Warm up the steam supply line to the trip valve as instructed below;
Confirm that warm up the steam supply line to the block valve.
Confirm that trip valve is fully closed position.
Check and open the line drain on the inlet of trip valve.
Slowly open the bypass around the steam supply block valve.
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When line is pressurized to system pressure, fully open the supply line block
valve and close the bypass.
8.2)
Check whether the pressure of gland condenser is within operating range.
8.3)
Check condition of steam drain of upstream of trip valve and where no

condensate is observed in the steam blown out of drain lines, inlet steam is
ready for operation.
8.4)
Check that no trip condition is active.
8.5)
Check that all permissive to start condition are active.
8.6)
Reset the electric governor and open trip valve(refer to Control System
Functional Description for detail).
8.7)
Ready to start lamp ON at local Start/Stop panel.
8.8)
Steam turbine start from local Start/Stop panel by operator.

Turbine shall be started /operated in the manner instructed in the vendors
operation manual and electric governor manual.
Note. :
After turning gear start-up, put seal steam line in service.
During acceleration, sustained operation at the critical speed must be avoided.
8.9)
Turbine will be operated at MCS for the specified duration. During operation,
vibration and bearing temperature shall be monitored and confirmed in good
order.
8.10) During operation, electrical overspeed test shall be performed.

8.11) During operation, mechanical overspeed test shall be performed, if applicable.
8.12) Turbine shall be stopped in the manner instructed in the vendors operation
manual and electric governor manual.
8.13) Maintain oil system operation until turbine rotor is safely cooled down.
8.14) Shut-down steam seal gland condenser and air ejector. Open all drain lines
and leave them opened.
8.15) Close steam inlet valves located in upstream of trip valve.
8.16) Open all drains (provided no air is drawn into the casings).
8.17) Open line switches to take electrical devices out of service.
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8.18) Leave the trip valve and trip device in the tripped condition until re-starting the
turbine.
8.19) When the turbine is shut-down, take every precaution to guard against steam
leaking into the turbine casing in order to prevent possible corrosion of the
internal parts.
3.1.5. Compressor Run-In Procedure
As the results of compressor performance study, the compressor will be run at the
following conditions;
3.1.5.1. Run-in gas
10-C1101 : Nitrogen (N2) Gas
10-C1401 : Nitrogen (N2) Gas
<10-C1101>
Reformer is heated-up by HT steaming with N2 circulation using the Feed Gas
Compressor(10-C1101). During this N2 operation, compressor run-in test will be
performed.
For detail operating condition and line-up of this N2 circulation operation, please
refer to other instructions.
<10-C1401>
During catalyst reduction operation, Syngas & Circulator Compressor (10C1401) will be operated by N2. During this N2 operation, compressor run-in test
will be performed.
For detail operating condition and line-up of this N2 circulation operation, please
refer to other instructions.
3.1.5.2. Run-in gas piping diagrams
The compressor will be run in the closed system.
3.1.5.3. Compressor running conditions
The compressor running conditions will be determined taking the following into
consideration;
1)
2)
3)
4)
5)
6)
7)
Suction gas temperature.

Anti-surge valve characteristic. (Where closed loop will be constructed by using
anti-surge line)
Run-in gas characteristic
Performance of gas heat exchanger
Discharge gas temperature limitation.
To avoid the compressor surging.
To keep separation margin of encroachment from the lateral critical speeds of
the compressor and steam turbine.
3.1.5.4. Preparation
Date : Mar. 01, 2004

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2)
3)
4)
gas.
5)
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SMJ-256-101
Make sure that process gas lines are clean and perform the line check.
The system is purged with specified run-in gas and pressurized up to the
designated pressure.
Put the heat exchanger in the closed loop into the service.
Compressor buffer gas supply line shall be connected with nitrogen/process
Lube oil & control oil system must be put into service.
3.1.5.5. Step-by-Step Procedure

1)
2)
3)
Refer to para 3.1.4.2.8.1) to 3.1.4.2.8.8) for starting up compressor up to

designated speed.
Continue to monitor vibration closely.
When satisfactory operation is established, hold for approximately 4 hours.
Monitor suction and discharge pressure and temperatures.
Note:
1) Discharge temperature alarm/trip setting shall be adjusted to suit run in gas
operation, if required and accepted by Vendor
2)
During the compressor start-up, acceleration, and continuous run, the

followings shall be carefully observed and, if necessary, corrective action
shall be taken.
Compressor discharge temperature shall be maintained to be less than

high alarm set . Suction and/or discharge pressure (pressure ratio) or
speed shall be adjusted as necessary. Compressor should be started with
minimum pressure ratio and pressure be adjusted after reaching test
speed (refer to compressor performance curve prepared for run-in gas
operation).
Acceleration around critical speed shall be observed so that critical speed
was quickly passed as programmed and that no harmful vibration occured.
4)
3.2
Compressor shutdown.
Refer to section 3.1.4.2.8.12)-3.1.4.2.8.19) for the shutdown procedure.
3.2.1. General
This procedure covers the general procedure for 50-Z1701A/B/C run-in (mechanical
running test).
Similar care to be taken as mentioned in centrifugal compressor and turbine (10C1401 / 10-C1101).
For the specific requirements, compressor performance, operating limit, test loop, etc.,
the following documents shall be referred to, but not limited to;
-
Compressor data sheet

Compressor performance curve
Motor data sheet
Date : Mar. 01, 2004

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P&ID prepared for test line up
3.2.2. Preparation Before Testing

The followings shall be checked/confirmed prior to commencement of compressor runin;
1)
Check for completion of pre-commissioning activities required prior to

compressor run-in (refer to Section 2.2 Pre-Commissioning Procedure for Air
Compressor Package).
2)
Process piping pressure test is completed.
3)
Cleaning of process piping is completed.
4)
Inlet air filter is commissioned and filter element is properly installed.
5)
Line-up of the test piping arrangement is completed.
3.2.3. Running Test Procedure

Compressor shall be run (tested) twice for the following purpose;
-
Test run with blow-off line.

A mechanical test run of several hours is carried out until steady-stage
operation is reached to make sure that the compressor was duly assembled.
Test run with blow-off line and discharge line.

This test run is primarily designed to set the control system and the surge limit.
1)
Test run with blow-off line (mechanical test run).
1.1)
Control system power up or reset to normal shutdown state.

All control outputs are forced to there off positions.
Main motor start/stop digital output is set to the stop state.
Auxiliary oil pump start/stop output is set to the stop state.
Compressor inlet air valve is forced 100% closed.
Compressor unloading valve is forced 100% open.
Alarms should be configured.
1.2)
Check cooling water is flowing to compressor intercoolers and oil coolers.
1.3)
Oil reservoir heater contactor output is energized when all of the following
conditions exist:
-
1.4)
Oil reservoir level is normal.

Oil heater thermostat is closed.
Turn on the air supply to the pneumatic control components and seal air piping
harness.
Check setting.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 45 of 69
SMJ-256-101
1.5)
Provided that oil reservoir level is not low and seal air is present the
compressor auxiliary oil pump will automatically start when a compressor start
command is issued via local control panel.
1.6)
Check tightness of piping (absence of leaks).
1.7)
Check inlet oil pressure to be above low alarm start permissive setpoint.
1.8)
Check inlet oil temperature to be above low alarm start permissive setpoint.
1.9)
If oil pressure and temperature permissives are met and no trip condition exists,
permissive start output is asserted.
1.10) Set blow-off valve to manual and set its position to OPEN
1.11) Check start-up position of inlet valve.
1.12) Bump start and observe smooth rotation/rundown and free from any abnormal
sound.
Start compressor.
Particular attention should be given to potential irregularities, unusual noise,
shocks and vibrations during machine start-up until steady-state conditions are
reached.
1.13) If inlet oil pressure is above auxiliary oil pump shutoff pressure setpoint,
auxiliary oil pump will be automatically switched off and unit will run on main oil
pump only.
1.14) Run the compressor for 1 hour in start-up position of inlet valve.
1.15) Check oil temperatures, in particular on bearings.
1.16) Check discharge temperatures and pressures.
1.17) Register all measured data in data sheets.
2)
Test run with blow-off line and discharge line.
2.1)
Follow procedure of 1.1) through 1.16) of above.
2.2)
Close blow-off or bypass valve slowly until the desired operating point is
reached.
2.3)
Check air temperatures and pressures.
2.4)
Register all measured data in data sheets.
2.5)
Set controlling devices and check function.
Date : Mar. 01, 2004

Rev :
DocNo. :
2.6)
Page 46 of 69
SMJ-256-101
Set anti-surge control system and check function.
If the test run with air is carried out directly after the mechanical test run, i.e. if
the compressor is still running, only close the bypass or blow-off valve slowly
until the desired operating point is reached. Monitor gas temperatures and
pressures as usual and register all measured data in the data sheets.
3)
Normal shutdown.
When shutting down the air compressor, compliance with the instructions
pertaining to the overall plant system is imperative.
Proceed as follows for compressor shut-down;
3.1)
A normal shutdown can be initiated from DCS or from local panel normal stop
switch.
3.2)
When normal stop is issued, unloading valve PID controller will be forced to
minimum output and unloading valve to go to fully open position (fail-open
valve).
3.3)
8 seconds after normal stop is issued, inlet valve PID controller will be forced to
minimum output and inlet valve to go to fully closed position (fail-closed valve).
3.4)
30 seconds after normal stop is initiated, stop signal will be issued to main
motor.
3.5)
Start signal will be issued to auxiliary oil pump at the same time the main motor
stop signal is issued.
3.6)
15 minutes after the main motor stops, auxiliary oil pump will be automatically
stopped.
3.7)
After compressor coast-down, make sure that compressor does not reverse.
3.8)
Close discharge valve.
3.9)
Slowly throttle water supply to oil cooler, keeping watch on oil temperature at
bearing outlets, then turn off completely.
3.10) Shut down seal air supply, if available.

3.11) Shut down power supply (only for longer standstill periods).
3.12) If there is the danger of frost, drain water from oil cooler and outlet pipes, or
keep cooling water system operating.
Note:
1) Vendors field supervisor shall attend the compressor run test and any
necessary adjustment of control set points, equipment shall be carried out
under the supervision of him.
Date : Mar. 01, 2004

Rev :
DocNo. :

SMJ-256-101
Page 47 of 69
Date : Mar. 01, 2004

Rev :
DocNo. :
3.3
Page 48 of 69
SMJ-256-101
3.3.1. General
This procedure covers the general procedure for horizontal centrifugal pump run-in
(mechanical running test).
For the specific requirements, pump performance, operating limit, test loop, etc., the
following documents shall be referred to, but not limited to;
-
Pump data sheet

Pump performance curve
Driver data sheet
In planning the pump mechanical test, the followings shall be checked to determine
the possibility of running the pump with water;
1)
Limitation of motor kW when the pump is operated with water.
2)
Discharge pressure limitation when the pump is operated with water.
3)
Available NPSH during the pump test.
4)
Possibility of operating the pump below minimum continuous flow.
5)
Restriction on pump operation caused by the difference in test and rated

suction (stuffing box) pressure.
6)
Availability of external flushing source, where applicable, to suit test condition.
7)
Restriction, from process reason, to introduce water into pump casing and/or
process piping.

The followings shall be checked/confirmed prior to commencement of pump run-in;
1)
Check for completion of pre-commissioning/commissioning activities required

prior to pump run-in (refer to Section 2.3 Pre-commissioning/Commissioning
Procedure for Horizontal Centrifugal Pumps).
2)
3)
Pump suction piping is flushed.
4)
Strainer(s) required for testing are prepared/installed.
5)
Test Loop is lined up.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 49 of 69
SMJ-256-101

1)
Fill up pump suction vessel, tank, reservoir, or sump to a required level and
open suction valve.
2)
Open pump casing vent to release trapped air or vapor (for self venting pump
casing, open vent connection on discharge piping or bleed connection provided
on PG block valve for this purpose).
3)
Select "Hand (manual)" position on local start switch or, where applicable, on
local switch stand. Also confirm that the start P.B. is in the locked-off position.
4)
Put lube oil system into service, where applicable (refer to Run-in Procedure for
Lube Oil System).
5)
Check smooth rotation of pump shaft by hand, if possible.
6)
Check that the minimum flow bypass (auto recirculation valve) is lined up for
service, where applicable.
7)
Check that the discharge valve is closed.
8)
Bump start and stop the pump and check that the rotor turned smoothly
(electric motor) (Allowable start-up of electric motor interval shall be checked in
advance).
9)
Start the pump (driver) (refer to Section 3.4 Run-in Procedure for Steam
Turbines for steam turbine driven unit).
10a) Motor driven pump.

Where acceleration is completed for the motor driven unit, then gradually open
the discharge valve and set to a planned operating point.
The operating point for run-in shall be selected in advance using the certified
pump performance curve taking into account the following factors;
-
Driver kW limit when run-in the pump by water.

Minimum continuous flow of the pump.
Discharge pressure limit when the pump is run-in by water.
NPSH av. limitation on test set up.
10b) Steam Turbine Driven Pump

After the turbine is put into slow roll/warm-up speed, pump discharge valve
shall be cracked open.
While continued on acceleration, discharge valve opening shall be adjusted to
avoid operation of extended period of time at the flow rate less that the pump
minimum continuous flow. When turbine speed reaches pump rated speed,
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 50 of 69
SMJ-256-101
discharge valve opening shall be adjusted to set the pump flow to a planned
point.
11)
Start Continuous Running Test.

Test duration shall be 2 hours unless otherwise specified.
12)
Bearing temperature and vibration shall be monitored and recorded during the
running test. (measuring/recording interval shall be 15 minutes for the first 1
hour and 30 minutes for the second 1 four unless otherwise specified.)
Date : Mar. 01, 2004

Rev :
DocNo. :
3.4
Page 51 of 69
SMJ-256-101
Steam Turbines
3.4.1. General
This procedure covers the general procedure for steam turbine run-in (mechanical
running test).
Similar care to be taken as mentioned in centrifugal compressor & turbine (10-CT1401
/ 10-CT1101).
For the specific requirements, steam turbine performance, operating limit, etc., the
-
Turbine data sheet

Turbine performance curve
This procedure is generally intended to be used for steam turbine no-load operation.
However, it can be also applied for the run-in of the driven equipment.
1)
Check completion of pre-commissioning/commissioning activities required prior

to turbine run-in (refer to Section 2.4 Pre-Commissioning/Commissioning
Procedure for Pump Drivers and Section 2.5 PreCommissioning/Commissioning Procedure for Reformer Fan Turbines).
2)
Check completion of pre-commissioning of steam piping including pressure test

and steam blow.
3)
Steam strainer, where applicable, shall be installed.
4)
Drain traps are provided as specified on P&ID and/or turbine drawing. Position
of valves shall be set to service position.
5)
Line up of steam line.
6)
Installation of exhaust relief valve and completion of testing shall be confirmed.
7)
When the turbine is to be used for driven equipment, run-in steam condition as
well as required KW shall be investigated in advance and the necessity of
using the hand valve(s), where applicable, shall be checked.
3.4.3. Turbine Running Test Procedure

1)
Verify lube and control oil system is in service, where applicable.

(refer to Section 3.13 Run-In Procedure for Lube Oil System)
2)
The trip and throttle valve (TTV) must be exercised prior to start-up to ensure
proper operation (cold test the TTV).
After the test, confirm that TTV is fully closed (trip condition).
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 52 of 69
SMJ-256-101
3)
All monitoring devices, alarm and trips, must be put into operation.
4)
Open drain from turbine and trip valve.
5)
Place turbine steam seal system preparation, where applicable;

a) Establish cooling water flow through to gland condenser.
b) Put gland seal condenser ejector in service.
6)
Warm up the steam supply line to the TTV as instructed below;

a) Confirm that warm up the steam supply line to the block valve.
b) Confirm that TTV is fully closed position.
c) Check and open the line drain on the inlet of the TTV.
d) Slowly open the bypass around the steam supply block valve.
e) When line is pressurized to system pressure, fully open the supply line
block valve and close the bypass.
7)
Check whether the pressure of gland condenser is within operating range,

where applicable.
8)
Check condition of steam drain of upstream of TTV and where no condensate

is observed in the steam blown out of drain lines, inlet steam is ready for
operation.
9)
Reset the electric governor, where applicable.
10)
All the causes of inhibiting start-up incorporated in start permissive logic shall
be cleared and contacts to be closed.
11)
All the causes of each trip contacts incorporated in the trip logic shall be
cleared.
12)
Reset trip logic and reset trip solenoid.
13)
Turbine shall be started /operated in the manner instructed in the vendors

operation manual and electric governor manual, where applicable.
14)
Turbine will be operated at MCS for the specified duration. During operation,
vibration and bearing temperature shall be monitored and confirmed in good
order.
15)
Run the turbine for 2 hours unless otherwise specified (as mechanical running
test).
16)
Bearing temperature, vibration and turbine speed shall be monitored and

recorded during the 2 hour running test (measuring/recording interval shall be
15 minutes for the first 1 hour and 30 minutes for the second hour, unless
otherwise specified).
17)
During operation, electrical overspeed test shall be performed, where
applicable.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 53 of 69
SMJ-256-101
18)
During operation, mechanical overspeed test shall be performed, where

applicable.
19)
Turbine shall be stopped in the manner instructed in the vendors operation

manual and electric governor manual.
20)
Maintain oil system operation until turbine rotor is safely cooled down, where
applicable.
21)
Shut-down steam seal gland condenser and ejector, where applicable.
22)
Open all drain lines and leave them opened.
23)
Close steam inlet valves located in upstream of TTV.
24)
Open all drains (provided no air is drawn into the casings).
25)
Open line switches to take electrical devices out of service.
26)
Leave the TTV and trip device in the tripped condition until re-starting the
turbine.
27) When the turbine is shut-down, take every precaution to guard against steam
leaking into the turbine casing in order to prevent possible corrosion of the
internal parts.
Note:
1) Vendors field supervisor shall attend the steam turbine run test and any
necessary adjustment of control set points, equipment shall be carried out
under the supervision of him.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.5
Page 54 of 69
SMJ-256-101
Reformer Fan Turbines (10-BT1201, 10-BT1202)
3.5.1. General
This procedure covers the general procedure for Reformer Fan Turbine run-in
Similar care to be taken as mentioned in centrifugal compressor & turbine (10-CT1401
/ 10-CT1101).
For the specific requirements, steam turbine performance, operating limit, etc., the
-
Turbine data sheet

Turbine performance curve
3.5.2. Oil System Start-Up Procedure

Refer to Section 3.13 Run-In Procedure for Lube Oil System.
3.5.3
Turbine Solo Run Procedure

Refer to Section 3.4 Run-In Procedure for Steam Turbines.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.6
Page 55 of 69
SMJ-256-101
3.6.1. General
This procedure covers the procedure for Sea Water Pump run-in (mechanical running
test).
For the requirements on pump performance, operating limit, test loop, etc., the
-
Pump data sheet

Motor data sheet

1)

Procedure for Sea Water Pumps).
2)
Piping pressure test is completed.
3)

1)
Confirm that sea water level is enough for pump operation for all 3 pumps.
2)
Select "Hand (manual)" position on local start switch of all 3 pumps.
3)
Check that the instrumentation is fully energized for all 3 pumps.
4)
Check that discharge isolation valve of all 3 pumps are closed

The followings are the procedure of filling sea water into the system / and initial
start-up.
Filling sea water into the system is done by using item 70-P1001A.
5)
Check that discharge isolation valve of 70-P1001A is closed.
6)
7)
(electric motor), if it is allowed. (Allowable start-up of electric motor interval shall
be checked in advance).
8)
Start the pump 70-P1001A(driver).
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 56 of 69
SMJ-256-101
9)
The discharge isolation valve (remote motor operated) will be opened after the
pre-set time to fill sea water into system.
10)
After finishing filling operation, the opening discharge isolation valve of 70P1001A shall be re-set to operate the pump at around rated condition.
11)
Set the discharge isolation valve of the pump to be next started at the same
opening position as 70-P1001A.
12)
After confirmation of 6 & 7), Start the pump (driver).
13)
The opening of discharge isolation valve of both of 70-P1001A and running

pump shall be re-set to operate each pump at around rated condition.
14)
Start Continuous Running Test. (2 pumps parallel running, one pump stand-by)
When the continuous running test of one of three running pumps has finished,
stand-by pump to be auto started to check auto start function by stopping one
pump (whose test has finished) and continuous running test of stand-by pump
to be started.
Auto start function of all 3 pumps shall be checked in the same sequence of
the above.
Duration of continuous running test of each pump shall be at least 2 hours.
15)
hour and 30 minutes for the second 1 hour unless otherwise specified.)
Date : Mar. 01, 2004

Rev :
DocNo. :
3.7
Page 57 of 69
SMJ-256-101
3.7.1. General
This procedure covers Oil System Start-up Procedure, Turbine Solo-Run Procedure
and Pump Run-in Procedure for BFW Pump.
-
Pump data sheet

Driver data sheet
1)
2)
3)
4)

5)
process piping.

1)

Procedure for BFW Pumps).
2)
3)
3.7.3. Oil System Start-Up Procedure (for 10-P1901A/B/C)

Refer to Section 3.13 Run-In Procedure for Lube Oil System.
3.7.4
Turbine Solo Run Procedure (for 10-P1901A, 50-P1402B/C)

Refer to Section 3.4 Run-In Procedure for Steam Turbines.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 58 of 69
SMJ-256-101
3.7.5. Pump Run-In

Refer to Section 3.3 Run-In Procedure for Horizontal Centrifugal Pump
Date : Mar. 01, 2004

Rev :
DocNo. :
3.8
Page 59 of 69
SMJ-256-101
3.8.1. General
This procedure covers the procedure for Fire Water Pumps (50-P1202A/B/C) run-in
-
Pump data sheet

Driver data sheet

1)

Procedure for Fire Water Pumps).
2)
3)
4)
5)

1)
Fill up Fire Water Tank to a required level.
2)
For 50-P1202A, place the Manual-Auto-Stop control switch on engine local

panel in "Manual" position.
For 50-P1202B/C, place the Manual-Auto-Stop control switch on engine local
panel in "Stop" position.
3)
4)
5)
Bump start and stop the pump and check that the rotor turned smoothly.
6)
Start the pump (driver) by pushing start button on engine local panel.
Where acceleration is completed, then gradually open the discharge valve and
set to a planned operating point.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 60 of 69
SMJ-256-101
7)

8)
9)
After continuous running test is finished, auto start test shall be conducted.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.9
Page 61 of 69
SMJ-256-101
3.9.1. General
This procedure covers the general procedure for sundyne pump run-in (mechanical
running test).
-
Pump data sheet

Motor data sheet
1)
Limitation of motor kW when the pump is operated with water.
2)
3)
4)
5)

6)
Availability of external flushing source, where applicable, to suit test condition.
7)
process piping.

1)

Procedure for Sundyne Pumps).
2)
3)
4)
5)
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 62 of 69
SMJ-256-101

1)
Fill up pump suction vessel, tank, reservoir, or sump to a required level.
2)
Open pump casing vent to release trapped air or vapor (for self venting pump
casing, open vent connection on discharge piping or bleed connection provided
on PG block valve for this purpose).
3)
Select "Hand (manual)" position on local start switch.

Also confirm that the start P.B. is in the locked-off position.
4)
5)
Check that the minimum flow bypass (auto recirculatio valve) is lined up for
service.
6)
7)
(electric motor) (Allowable start-up of electric motor interval shall be checked in
advance).
8)
Where acceleration is completed for the motor driven unit, then gradually open
the discharge valve and set to a planned operating point.
The operating point for run-in shall be selected in advance using the certified
pump performance curve taking into account the following factors;
-
Driver kW limit when run-in the pump by water.

Minimum continuous flow of the pump.
Discharge pressure limit when the pump is run-in by water.
NPSH av. limitation on test set up.
9)

10)
Gear box oil pressure to be noted it should be more than 2.5 barg, otherwise
stop the pump.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.10
Page 63 of 69
SMJ-256-101
Sump Pumps
Refer to Section 3.3 Run-in Procedure for Horizontal Centrifugal Pumps which shall
be commonly applied for vertical centrifugal pump with the following difference;
1)
Most vertical sump pumps are designed for automatic start/stop by pump sump
liquid level.
Such automatic start/stop sequence shall be checked during pump run-in.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.11
Page 64 of 69
SMJ-256-101
Submersible Pumps
3.11.1. General
This procedure covers the general procedure for submersible pump run-in
-
Pump data sheet

Motor data sheet

1)
Check for completion of Pre-Commissioning / Commissioning activities required

prior to pump run-in (refer to Section 2.10 Pre-commissioning Procedure for
Submersible Pumps).
2)
3)
Discharge relief valve is installed, tested at site, and set for service, where
applicable
4)

1)
Fill up pump sump to a required level.
2)
Select "MANUAL" position on local panel, where applicable.
3)
Check that the discharge valve is open.
4)
Start the pump (driver).
5)
Start Continuous Running Test (Minimum 30 min).
Date : Mar. 01, 2004

Rev :
DocNo. :
3.12
Page 65 of 69
SMJ-256-101
Air Diaphragm Pumps
3.12.1. General
This procedure covers the general procedure for air diaphragm pump run-in
-
Pump data sheet


1)
Check for completion of Pre-Commissioning / Commissioning activities required

prior to pump run-in (refer to Section 2.12 Pre-commissioning Procedure for Air
Diaphragm Pumps).
2)
3)
4)
5)
Discharge relief valve is installed, tested at site, and set for service, where
applicable
6)

1)
Fill up pump suction vessel, tank, reservoir, or sump to a required level.
2)
Check that the discharge valve is opened.
3)
Bump start and stop the pump and check that no abnormal noise and vibration
is occured.
4)
Start the pump.
5)
Start Continuous Running Test. (Minimum 30 min)

During continuous running, mechanical soundness in view of vibration and
noise shall be checked.
Date : Mar. 01, 2004

Rev :
DocNo. :
3.13
Page 66 of 69
SMJ-256-101
Lube Oil System
3.13.1. General
This procedure covers the general procedure for lube oil system run-in (mechanical
running test).
For the specific requirements, lube oil pump performance, operating limit, test loop,
etc., the following documents shall be referred to, but not limited to;
-
Lube oil pump data sheet

Lube oil pump performance curve
Driver data sheet
3.13.2. Preparation for Lube Oil System

1)
Piping
a) Oil flushing has been completed.
b) Auxiliary parts and materials removed during flushing have been restored.
c) Temporary blinds used during oil flushing have been removed and
temporary bypass piping has been restored to permanent line-up.
2)
Oil Reservoir
a) Check reservoir for sufficient oil filling.
Use only the specified oil type.
Thoroughly clean filling equipment and transport containers prior to use.
b) Remove any water by means of the tank draining valve.
Eliminate the cause for water deposit.
c) Check whether shut-off valves of the level indicators/switches are open.
d) Check whether electric power is available for the lube oil heater.
3)
Oil Pumps
a) Check if the shut-offs at the oil pumps are open.
b) Check whether operating and control voltage for the electric motor are
available.
c) Check whether, for steam turbine of the main oil pump, where applicable;
- the rules for start-up in accordance with the instructions in the manual
have been noted, and
- the steam conditions are in due order
Date : Mar. 01, 2004

Rev :
DocNo. :
4)
Page 67 of 69
SMJ-256-101
Oil Coolers
a) Check if the change-over devices at the twin coolers are connected in such
a way that the oil passes always only through one cooler.
b) In case of double cooler, check whether the shut-offs;
- in the venting lines of the oil side are open,
- in the filling lines are open,
- of the cooler drains are closed.
- necessary orifices are installed.
c) Check if cooling water is available and if the water discharge shut-offs
(possibly provided for) are open and the inlet shut-offs are closed.
d) Check whether the temperature alarm sets comply with the designated
values, where applicable.
5)
Oil Filter
a) Check if the change-over devices at the twin filters are connected in such a
way that the oil passes always through one filter unit only.
b) Check the double filter. Are the shut-offs and plugs;
- in the venting lines open,
- in the filling line open,
- in the filter drainage closed.
- The required orifices must be provided.
6)
Control Valves
6
7 Check if;
- the shut-offs ahead of and downstream of the control valves are open,
- the hand control valve in the bypass is open
- the shut-off in the impulse line is open.
7)
Oil pressure lines at the machine

a) Check if the orifices ahead of the bearings are properly installed as
indicated on vendor P&ID.
b) Check if the wire screens possibly installed in the lines ahead of the
bearings between two flanges have been removed after flushing.
c) Check whether the orifice ahead of the coupling is properly installed.
8)
Instruments
Check whether the;
- pressure gauge shut-off valves are open,
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 68 of 69
SMJ-256-101
-
shut-off valves in the line of the pressure switches/transmitters are open

and the orifice, where applicable, is properly installed,
instrumentation is fully energized,
alarm and shut-down devices have been checked.
3.13.3. Initial Start-up of the Lube Oil System

The initial start-up must be carried out in accordance with the following schedule. The
schedule corresponds approximately to the time sequence.
The following documents must be observed before the initial start-up:
-
Vendors manual describing; the oil system, and

preparation for initial start-up of the oil system.
1)
Preparation work described in the earlier section must have been carried out.
2)
Oil temperature adjustment.

a) Check if the oil temperature in the reservoir is above the specified minimum
temperature. If required, start-up heating.
b) An auxiliary pump can be put on line to reduce heating up time (bypass
valve of PCV on return line to reservoir may be open). Switch off pump and
close bypass line valve after temperature has been attained.
c) Prior to start-up, the oil shall have a specified minimum temperature, As and
when required, operate both lube oil pumps at opened bypass valve of PCV
on return line to reservoir. Afterwards, cut out pumps and close bypass line
valve.
3)
Oil pump start-up

a) Take auxiliary oil pump into operation, where necessary.
b) Put the main oil pump into operation, set auxiliary oil pump on automatic
control.
4)
Vent the oil cooler and oil filter. Change over repeatedly, slowly from one filter
to the other. Check sight glass in the common return line (to do so, close all
valves and then open them again, one after the other).
5)
Oil pressure / temperature adjustment.

a) Slowly close manual control in bypass line at all control valves, if it is open.
b) Vent impulse line for control valve, where applicable.
c) Check and set the oil pressures / temperature in the oil unit by adjusting
control valves.
Confirm that bypass valves of all control valves are closed.
Date : Mar. 01, 2004

Rev :
DocNo. :
Page 69 of 69
SMJ-256-101
d) Vent impulse lines of the measuring instruments.

e) Check the sight glasses or flow indicators of the individual oil lines for oil
flow.
6)
Check the automatic cutting-in if the auxiliary oil pump.
7)
Equipment to be lubricated start-up.
8)
Open shut-off fitting in cooling water supply line and adjust.

Vent on waterside, until water issues from the vent fittings, then close same.
9)
Set auxiliary lube oil pump on automatic control.

Readjust the oil pressures and temperature.
10)
Check the sight glasses or sight flow indicators in the oil discharges for proper
passage.

Rotating Machine Test Procedures for Sipchem Complex

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Rotating Machine Test Procedures for Sipchem Complex

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Date : Mar.

ROTATING MACHINE TEST PROCEDURE

SAUDI INTERNATIONAL PETROCHEMICAL

PROJECT TITLE : Sipchem COMPLEX AT JUBAIL

AL-JUBAIL, THE KINGDOM OF SAUDI ARABIA

COMPANYs PROJECT No. :

Revised as per companys comment

Mar. 01, 2004

Origination (0) / Revision ( )

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Original Issue for Companys review

Revised as per companys comment

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Vendor's operation manuals

Detail pre-commissioning, commissioning, and mechanical run in plan shall be prepared

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Centrifugal Compressors and Steam Turbine Drivers (10-C1101/10-CT1101, 10C1401/10-CT1401)

Confirm completion of mechanical check (Pre-commissioning)

Setting/leveling of equipment on foundation

4) Commission oil purifier/clarifier (refer to vendor's manual)

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Carry out oil flushing (refer to Oil Flushing Procedure, SMJ-256-102)

Steam turbine inlet

Check that the compressor suction piping is cleaned, chemically or mechanically

Check installation/connection of earth terminal/lugs of base plate, oil unit,

Check freedom of all moving parts.

Install coupling and coupling guard.

11) Check line up of;

Check that, where applicable, the condensate pumps (10-P1401A/B) and

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Check installation of instruments.

Check that control and sequence check is completed.

Check that instrument calibration is completed.

Fully energize instrumentation.

Line up process piping/system.

Valve position of all the valves included in the test loop.

Compressor Run-in (Mechanical Running Test)

Hot alignment will be conducted only when it is required by compressor vendor.

Air Compressor Package (50-Z1701A/B/C)

Confirm completion of mechanical check (Pre-commissioning)

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Setting/leveling of equipment on foundation

4) Fill specified lubricant to oil reservoirs.

Check installation/connection of earth terminal/lugs of base plate.

Check freedom of all moving parts.

Date : Mar. 01, 2004

ROTATING MACHINE TEST PROCEDURE

Install coupling and coupling guard.

Check line up of;

Check installation of instruments.

Check that instrument calibration is completed.

Fully energize instrumentation.