RECOMMENDED PROCEDURES FOR INSTALLATION, COMMISSIONING, START-UP & RELIABILITY TEST IN RECIPROCATING COMPRESSORS
FREQUENT QUESTIONS & ANSWERS
frequent questions and answers about the recommended procedures for installation, commissioning, and start-up of reciprocating compressors:
Q: What is the recommended procedure for installing a reciprocating compressor? A: The installation procedure for a reciprocating compressor should include a detailed review of the foundation design, as well as the alignment and installation of the compressor itself. It is important to ensure that the compressor is properly anchored to the foundation and that all piping and instrumentation connections are correctly installed.
Q: What is the recommended procedure for commissioning a reciprocating compressor? A: Commissioning a reciprocating compressor involves performing a series of tests to ensure that the compressor is operating correctly and safely. This typically involves checking the alignment and operation of the compressor, verifying that all safety systems are functioning properly, and conducting a series of performance tests.
Q: What is the recommended procedure for starting up a reciprocating compressor? A: Before starting up a reciprocating compressor, it is important to verify that all systems and components are operating correctly and safely. This includes checking that the lubrication system is functioning properly, verifying that all safety systems are functioning, and confirming that the compressor is properly aligned and connected to the process piping.
Q: What is the recommended procedure for conducting a reliability test for a reciprocating compressor? A: A reliability test for a reciprocating compressor typically involves running the compressor continuously for 72 hours under normal operating conditions. This test is usually performed two months after the compressor has been installed and commissioned, and is designed to verify that the compressor is capable of operating reliably over an extended period of time.
Q: Why is a reliability test necessary for reciprocating compressors? A: Reciprocating compressors are critical components in many oil, gas, and petrochemical processes, and a failure can result in costly downtime and production losses. Conducting a reliability test helps to ensure that the compressor is capable of operating reliably over an extended period of time, and can help to identify any potential issues that may need to be addressed before the compressor is put into service.
RECOMMENDED PROCEDURES FOR INST & COMM & START UP & RELIABILITY TEST
recommended procedures for installation, commissioning, and start-up of reciprocating compressors:
Installation:
- Make sure the foundation is suitable for the compressor and aligned properly.
- Ensure that all components are properly connected and tightened, such as piping, valves, and instrumentation.
- Check all the fasteners and make sure they are properly tightened.
- Perform a visual inspection to verify that all components are installed correctly.
Commissioning:
- Perform a functional check of all the components and ensure that they are working correctly.
- Perform a check of the control system and ensure that it is correctly programmed and functioning as intended.
- Verify that the compressor’s lube oil system is working properly and is providing adequate lubrication.
- Perform a leak test to verify that there are no leaks in the compressor, piping, valves, or instrumentation.
- Check that the safety systems are installed and functioning correctly.
Start-up:
- Verify that all safety systems are functioning correctly before starting the compressor.
- Start the compressor in accordance with the manufacturer’s recommendations.
- Monitor the compressor’s performance during start-up, paying close attention to the vibration levels and temperatures.
- Gradually bring the compressor up to operating speed and pressure.
- Once the compressor is operating at the desired conditions, monitor it for a period of time to ensure that it is operating correctly.
Reliability test:
- After the compressor has been operating for two months, schedule a reliability test for 72 continuous hours to verify its performance.
- During the test, monitor the compressor’s performance closely and verify that it is operating within the manufacturer’s recommended parameters.
- After the test, perform a detailed inspection of the compressor to identify any issues that may have arisen during the test.
It is important to note that these are general recommendations and specific procedures may vary depending on the manufacturer’s recommendations and the specific requirements of the installation. Proper training and supervision are critical to ensuring that the installation, commissioning, and start-up procedures are performed correctly and safely.
WHY, WHEN, WHERE & HOW TO APPLY PROCEDURES FOR I & C & SU & RT
To improve the reliability, availability, maintainability, and safety of reciprocating compressors and avoid critical failures in new projects and existing plants in the oil, gas, and petrochemical industries, the following procedures for installation, commissioning, start-up, and reliability testing can be applied:
Why: The procedures are applied to ensure proper installation, effective commissioning, smooth start-up, and reliable operation of reciprocating compressors. By following these procedures, potential issues and risks can be identified and addressed, leading to improved reliability, availability, maintainability, and safety.
When: The procedures should be applied at different stages of the compressor lifecycle:
- Installation: The procedures begin during the installation phase when the compressor is being positioned, aligned, and connected to the relevant systems and components.
- Commissioning: The procedures continue during the commissioning phase, which involves verifying the proper functioning of the compressor, conducting tests, and adjusting settings.
- Start-up: The procedures are crucial during the start-up phase to ensure a controlled and safe transition from idle to operational state.
- Reliability Testing: Reliability testing procedures are conducted periodically to assess the performance of the compressor, identify potential issues, and implement corrective actions.
Where: The procedures are applied in the specific location where the reciprocating compressor is installed, which can be in a new project or an existing plant within the oil, gas, and petrochemical industries. The procedures are typically implemented at the site where the compressor is installed, including the designated compressor area, control room, and associated systems.
How: The following are some key procedures to apply during installation, commissioning, start-up, and reliability testing:
Installation:
- Ensure proper positioning and alignment of the compressor according to manufacturer guidelines.
- Follow all safety protocols and regulatory requirements during the installation process.
- Perform thorough inspections of components and systems, including piping, valves, and instrumentation, to verify their integrity and compatibility.
Commissioning:
- Verify all connections, fittings, and valves to ensure they are properly installed and functioning.
- Conduct functional tests to check the operation of control systems, interlocks, and safety devices.
- Perform performance tests to verify the compressor’s efficiency and capacity.
Start-up:
- Gradually bring the compressor to its operating conditions, ensuring that all systems and components are properly monitored and controlled.
- Follow a predefined start-up sequence and monitor critical parameters, such as pressure, temperature, and vibration, to ensure stable operation.
- Address any abnormalities or deviations during the start-up process promptly and implement necessary corrective actions.
Reliability Testing:
- Define a comprehensive reliability testing plan based on industry standards and best practices.
- Conduct periodic inspections and assessments of the compressor’s condition, including performance, reliability, and safety aspects.
- Perform non-destructive testing, such as vibration analysis, oil analysis, and thermographic inspections, to detect potential issues.
- Implement condition monitoring techniques to track the health of the compressor and identify early signs of deterioration or failure.
By applying these procedures for installation, commissioning, start-up, and reliability testing, organizations can enhance the reliability, availability, maintainability, and safety of reciprocating compressors in new projects and existing plants within the oil, gas, and petrochemical industries.
