120201

PETRONAS TECHNICAL STANDARDS

Field Inspection Prior to Commissioning of Mechanical Equipment

PTS 12.02.01 June 2015

© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 2 of 56

FOREWORD PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge, experience and best practices of the PETRONAS group supplementing National and International standards where appropriate. The key objective of PTS is to ensure standard technical practice across the PETRONAS group. Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all phases of work activities. Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of work, goods and services meet the required design and engineering standards. In the case where specific requirements are not covered in the PTS, it is the responsibility of the Contractors/manufacturers/suppliers to propose other proven or internationally established standards or practices of the same level of quality and integrity as reflected in the PTS. In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall ensure accuracy and completeness of the PTS used for the intended design and engineering requirement and shall inform the Owner for any conflicting requirement with other international codes and technical standards before start of any work. PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or otherwise) or be disclosed by users to any company or person whomsoever, without the prior written consent of PETRONAS. The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to PETRONAS that this requirement is met.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 3 of 56

ANNOUNCEMENT Please be informed that the entire PTS inventory is currently undergoing transformation exercise from 2013 - 2015 which includes revision to numbering system, format and contents. As part of this change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7 digit numbers. All newly revised PTS will adopt this new numbering system, and where required make reference to other PTS in its revised numbering to ensure consistency. Since the PTS inventory is being revised in stages there could be cases where a referenced PTS has not been revised and may retain in its original number in the AXIS system. In such cases users are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at [email protected]

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 4 of 56

Table Of Contents 1.0

2.0

3.0

INTRODUCTION ..................................................................................................... 5 1.1

SCOPE ............................................................................................................................. 5

1.2

GLOSSARY OF TERM ....................................................................................................... 5

1.3

SUMMARY OF CHANGES ................................................................................................ 5

INSPECTION OBJECTIVE ......................................................................................... 6 2.1

GENERAL ......................................................................................................................... 6

2.2

MATERIAL IDENTIFICATION ............................................................................................ 6

PRESSURE TEST PROCEDURES ................................................................................ 7 3.1

GENERAL ......................................................................................................................... 7

3.2

HYDROSTATIC TESTING .................................................................................................. 7

3.3

PNEUMATIC TESTING ..................................................................................................... 8

4.0

MECHANICAL EQUIPMENT INSPECTION CHECKLIST ................................................ 9

5.0

BIBLIOGRAPHY .................................................................................................... 10

APPENDIX 1: CHECKLIST .................................................................................................. 11

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 5 of 56

1.0

INTRODUCTION This PTS specifies the minimum requirements for field inspection of mechanical equipment prior to commissioning based on industrial practices, lesson learnt and best practices.

1.1

SCOPE

1.1.1

The scope covers the required field inspection to be executed for new and rejuvenation projects during commissioning, and existing equipment following maintenance or plant modifications. The scope covers field inspection of static and rotating equipment including furnaces, boilers etc. as well piping.

1.1.2

The inspection of the electrical and instrumentation associated with the mechanical equipment are excluded from this PTS for which PTS 13.02.01 and PTS 14.10.07 respectively shall apply.

1.2

GLOSSARY OF TERM

1.2.1

General Definition of Terms & Abbreviations Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS 00.01.03 for General Definition of Terms & Abbreviations.

1.2.2

Specific Definition of Terms None

1.2.3

Specific Abbreviations None

1.3

SUMMARY OF CHANGES This PTS 12.02.01 replaces PTS 61.10.08.11 (September, 2012).

.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 6 of 56

2.0

INSPECTION OBJECTIVE

2.1

GENERAL

2.1.1

The objective of the inspection prior to commissioning is to ensure that the system is ready to accept the fluid in all respect and there is no pending items and all punch lists are attended and completed. The inspection records/ punch list are made during receipt of material at site and during construction to ensure the following: i.

The equipment has delivered to site in accordance with the purchase order.

ii.

All required documentation has been completed and as built drawings, inspection and test reports, manuals etc. are available.

iii.

The equipment has been installed correctly.

iv.

All necessary data and information related to the equipment are adequately acquired for future integrity studies (e.g. P-RBI, P-ALS, etc.)

2.1.2

Handover procedures shall be agreed between the Owner and the Contractor before precommissioning commence and shall include the respective responsibilities of the Contractor, the Manufacturer and the Owner. Inspection check list shall be developed to ensure all the essential data are recorded to facilitate ‘as built ‘information and baseline measurement.

2.2

MATERIAL IDENTIFICATION

2.2.1

In order to identify the correct material for a critical service, a minimum inspection requirements are as follows: i.

Full traceability of all materials used, i.e. transfer and recording of heat numbers or other unique identifiers.

ii.

Random alloys verification prior to installation (only for alloys and alloy steels such as 5 Cr-1/2 Mo steel).

iii.

A 100% alloy verification check, including all elements, after completion of erection of these systems (only for alloys and alloy steels such as 5 Cr- ½ Mo steel).

Note: Any components that are accidentally installed or if do not meet the materials selection/ welding consumable etc. shall be inspected and documented. Any rejection/ rectification shall be corrected by Contractor/ manufacturer timely.

2.2.2

All design changes during the manufacturing period shall be recorded and documented.

2.2.3

Any modification on site shall be performed in such a manner that the Manufacturer's guarantees are not invalidated. The equipment shall be subject to the same inspection requirements as for the original equipment.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 7 of 56

3.0

PRESSURE TEST PROCEDURES

3.1

GENERAL

3.1.1

Equipment pressure test requirement shall comply with the code and standard specify in the design. Local regulations shall be strictly adhered to unless exemption has been obtained. If these regulations are less stringent than the design code, the latter shall prevail.

3.1.2

Equipment shall be re-test to the original test pressure after any major repairs such as nozzle replacement, shell plate replacement are carried out. All non-destructive testing and stress relieving shall be completed with acceptable before pressure testing

3.1.3

Any major repair to the equipment shall, be retested, NDT in accordance with the original design specification.

3.1.4

The equipment to be pressure tested shall be properly vented during filling to avoid air pockets. A pressure relief valve and pressure gauge shall be installed at the highest point of the equipment and on the test pump

3.1.5

Examination for leakage shall be made of the joints and connections and of all regions of high stress, such as head knuckles, regions around openings, and thickness transition sections

3.1.6

Pressure testing of shop and field fabricated piping shall be as per PTS 12.30.05 and for new pipeline it shall be in accordance with PTS 11.34.01.

3.2

HYDROSTATIC TESTING

3.2.1

General The water quality for hydrostatic test depends on the material(s) from which the equipment to be tested. Hydro test area shall be barricaded with signs to inform others that hydrostatic test is in progress. After testing, the equipment shall be drained and dried to prevent corrosion. Do not leave systems filled with water. During draining a vent valve shall be open at the highest point of the equipment to prevent vacuum.

3.2.2

Carbon steel and low-alloy steel May be tested with portable, brackish or salt water. If portable is not used, the test water shall be completely drained and flushed with portable water immediately after testing. It should be thoroughly dried with hot air or steam.

3.2.3

Austenitic stainless steel/ ferritic stainless steels and medium/high nickel alloys The water shall not contain chlorides that may cause stress corrosion cracking or pitting. It should be tested with boiler feed water or demineralized water having chloride content of no more than 2mg/kg. Alternatively may be tested with portable water provide the test water is drained or dried immediately after testing, or flushed with boiler feed water or demineralised water immediately after testing.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 8 of 56

Steam tracing line shall be tested and flushed with demineralised water prior to the functional testing of the tracing. Stainless steel below shall be isolated from the system during hydrostatic test. 3.2.4

Duplex stainless steel Duplex stainless steel is highly susceptible to crevice corrosion when in contact with oxygencontaining water. Use portable water for hydrostatic test medium and rinse immediately with boiler feed water or demineralised water follow by thorough drying. Fill the equipment with nitrogen to removed oxygen from the system.

3.2.5

9 % Nickel alloy steel Test water shall be have neutral pH value, clear and free from sulphides. The equipment shall be thoroughly cleaned and dried.

3.2.6

Aluminium and aluminium alloys Test water shall be have neutral pH value free from ions of heavy metals. The equipment shall be thoroughly cleaned and dried.

3.3

PNEUMATIC TESTING Pneumatic test may considered with approval of Owner if hydrostatic test is impractical. Procedure for pneumatic test and safety distances calculation in accordance with PTS 12.30.05 shall be furnished for Owner‘s review before conducting such test.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 9 of 56

4.0

MECHANICAL EQUIPMENT INSPECTION CHECKLIST The inspection checklist is detailed out for various equipment, however if any mechanical equipment is not listed it shall be prepared by Contractor for Owner’s review. The Vendor’s recommendation for inspection shall also be complied with in addition to this PTS.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 10 of 56

5.0

BIBLIOGRAPHY In this PTS, reference is made to the following Standards/Publications. Unless specifically designated by date, the latest edition of each publication shall be used, together with any supplements/revisions thereto: PETRONAS TECHNICAL STANDARDS Index to PTS

PTS 00.01.01

Requirements, General Definition of Terms, Abbreviations & Reading Guide

PTS 00.01.03

Hydrostatic Pressure Testing Of Pipelines

PTS 11.34.01

Refractory Bricks and Shapes

PTS 12.04.01

Standard Vertical Tanks – Field Erection and Testing

PTS 12.22.03

Piping General Requirements

PTS 12.30.02

Field Commissioning and Maintenance of Electrical Installations and Equipment

PTS 13.02.01

Inspection and Functional Testing Of Instruments

PTS 14.10.07

Cleaning Of Equipment

PTS 15.05.01

Equipment History Record

PTS 15.06.01

The Preservation of Old and New Equipment and Piping Standing Idle

PTS 15.44.01

Interlocking System for Relief Valves

PTS 16.53.03

STANDARD DRAWINGS Installation of thermocouple on furnace tubes

D.12.92.161

Sieve for Y type strainer

D.12.92.303

Temporary strainer for compressors

D.12.92.310

AMERICAN STANDARDS Lubrication, shaft-sealing, and control-oil systems and auxiliaries for petroleum, chemical and gas industry services

API 614

Issued by: American Petroleum Institute Publications and Distribution Section 1220 L Street Northwest,Washington DC. 20005 USA

Process piping Issued by: American Society of Mechanical Engineers 345 East 47th Street ,New York, NY 10017 ,USA

ASME B 31.4

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 11 of 56

APPENDIX 1: CHECKLIST 1.0 STATIC EQUIPMENT

1.1 No 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15

16 17

18

GENERAL Description All packing material and protective devices are removed from the equipment prior to installation. Special Tool and instruction manual are available. Name plate is in accordance with specification. Foundation bolts are straight and vertical. Approved grouting material to be applied at baseplate and support. Insulation and fireproofing in accordance with specification. Any deviation or modification made during plant construction and erection are inspected. All material certification, NDT requirement are available and recorded Wall thickness measurements of shell, heat exchanger and furnace tubes, and nozzle in accordance with specification and datasheet. Flanges, gaskets, flange face, stud bolts and nuts are in accordance with specification. Internal cleaning check before final box up. Painting and coating protection in accordance with specification. Earthing connection for lightning protection is available at site. Ladders, stairways, platforms, walkways are installed correctly and accessible. Any imperfections, e.g. dents, out of roundness, bulge and etc. on the equipment are inspected.

NDT is carried out on field welds and results is recorded. Hydrostatic test is conducted on equipment in accordance with design code and local regulation.

Check ergonomic for valve accessibility and maintenance work.

Yes

No

Remarks

Layers of shim plates is not recommended.

If any imperfections were found, rectification procedures shall be agreed with Owner.

Field erected equipment shall be hydrostatic test at site. Hazards shall be removed or permanently mark at site.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 12 of 56

1.2 No 1

2 3 4 5 6 7 8 9 10

1.3 No 1 2 3 4 5 6 7 8

9

VESSELS, COLUMNS, REACTORS AND THEIR INTERNALS Description Yes Internal dimensions and clearances are correct in accordance with approved drawing and specification. Beam fastening are securely tightened. Tray installation are in accordance with approved drawing and specification. Stiffening ring weldment for weld defect is inspected by Dye penetration. Internal lining for defect at shell, manway, nozzle and flanges is inspected. The reinforcement pads are tested. Any interferences that may cause from expansion or contraction is inspected. Equipment verticality tolerance is in accordance with specification. Leaks test for installed tray is conducted in accordance with specification. Joint internal inspection with operation and construction team before equipment box up.

SHELL AND TUBE HEAT EXCHANGERS Description Correct material is used for drain and vent plugs. Anodes or sacrificial plate is correctly installed if any. Tell tale holes on the reinforcement plate is provided. Plug off the treaded holes for pulling eyes with dummy bolts. The impingement plate is correctly installed. Extended bolts ends (internal and external) are properly protected for bolt tensioning. The test flange or test ring are properly stored. Verticality and horizontality tolerance for heat exchangers is in accordance with approved drawing. Pneumatic testing at 1 bar (g) for floating head and channel flanges to test the tightness.

Yes

No

Remarks

No

Remarks

Equipment which have been tested at the manufacturer’s shop may not require to be retested, Unless required by local regulation.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 13 of 56

10

11 12 13

1.4 No 1

2 3 4

5 6 7 8 9 10

Hydrostatic test for heat exchanger which have been subjected to cleaning, removal of shell, cover, channel or floating heat cover. Tube to tube sheet connection is tested with full pressure test after replacement of tube bundles. Bellow are installed correctly as per drawing. All gasket is removed and replaced with new gasket before system leak test is carry out.

AIR-COOLED HEAT EXCHANGERS Description The following general checks shall be made for the air cooled exchanger. Check:  The sealing between cooler bundles;  The correct sloping of the horizontal parts of the air plenum and tube bundles;  Alignment of belt pulleys;  Rigidity of fan and belt guards;  Proper tension of belt drives;  Tube vibration check at maximum airflow;  Guards protecting personnel from hot surfaces;  Proper alignment of process piping to headers to ensure no excessive nozzle loading;  Full priming of grease lines between grease nipple and bearing house;  Tightness of fan blade securing bolts;  Vibration of fan and motor as a baseline for further degradation of bearings. Blade tips, fan ring clearance and pitch angle setting for all fan blades is checked. Tube fins condition is inspected for any damage or dent. Material used for drain and vent plugs is in accordance with approved drawings and specification. Sliding support are correctly installed and ensure free for movement. Louver mechanism are functioning. Fans bearing and drives is lubricated Fan rotation and blade setting is checked for correct setting and alignment. Air cooled heat exchanger is tested in accordance with the design code. Air blowing is require to dry the water after the hydrostatic test.

Not exceeding 110 % of the design pressure.

Yes

No

Remarks

Automatic lubricators shall be considered.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 14 of 56

11

1.5 No 1 2 3 4 5 6 7 8 9 10

11

12 13

14 15

1.6 No 1 2 3 4

Motor capacity is in accordance as per datasheet and drawing.

BOILERS Description Boiler structure are properly welded and painted. Air and flue gas ducting are sufficiently supported to allow expansion. Fuel and gas supply is ensure leakage free. Steam drum internal, down comer and riser tubes is checked. Properly fastened and free from debris. Air preheater is checked Intermittent blow down lines are adequately support and clamped. Blow down valve functionality is checked i.e. fail to close. Boiling and cleaning procedures is in accordance with PTS 15.05.01. Comply with Local regulation i.e. DOSH The burner throats, burner tips, side wall tubes, rear end tubes and super heater are visible through the observation doors. Inspect the burner installation, air register, fuel gun and its accessories are properly position is in accordance with drawings. The soot blower equipment are working within the full range of operations. Pressure test the equipment in accordance with design code or local regulation.

Yes

No

Remarks

Test water shall be from boiler feed water.

Smoke bomb test is conducted to check tightness of the firebox, ducting, dampers, etc. All pressure safety valves shall be check i.e. set pressure, relief and reseating pressure and adjusted accordingly at working temperature.

FURNACES Description Radiant and convection tubes support for proper alignment. Tube clearance for expansion and contraction is in accordance with approved drawings. Return fitting plugs is properly bolted. Both oil and gas fuel supply system is checked for leakage.

Yes

No

Remarks

Tubes should be straight

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 15 of 56

5 6

7 8 9 10 11

12 13 14

Expansion joint shall be allowed for expansion and contraction. Furnace structure, beam, roof and accessories are installed in accordance with the approved drawings. Dampers installation and position are correctly aligned. Ducting tightness and support for expansion is inspected. Provisions for spade removal in flue gas ducting is checked. Burner installation is in accordance with OEM specification Observation windows are provided to view burner throat and ignition burners are visible during operation. Heater access door is inspected for any obstruction. Snuffing steam to fire box and header boxes is inspected. Soot blower equipment is inspected and tested for full range operation.

15

Internal concrete lining or refractory for crack and void is inspected.

16

Tightness test on air preheaters, flanges and cleaning devices on preheaters is conducted. Smoke bomb test is conducted to check tightness of the firebox, ducting, dampers, etc. Hydrostatic test to furnace coils is carry out for a minimum of 30 minutes. Horse shoe type fittings are to be tested for leak by medium pressure steam Hydrostatic test is conducted if tunes or fitting has been repaired.

17 18 19 20

Steam for soot blowing and burners. Check on expansion, purge facilities, steam supply, valves tightness. For further checks on refractory, see PTS 12.04.01 and Vendor’s recommendation.

The test pressure is 1.3 times the design pressure multiplied by a factor S/S' where S and S' represent the allowable material stress values at ambient temperature and design temperature respectively.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 16 of 56

21 22 23

1.7 No 1 2 3 4 5

6

1.8

Thermocouple installation is in accordance with the standard drawing D.12.92.161. Air purge to the observation windows on the radiant cell. All spring hanger locking pin are removed. The cold and hot setting support condition is inspected.

DESUPERHEATERS STEAM TEMPERATURE CONTROL EQUIPMENT Description Yes No The injection point are correctly installed. The injection nozzle and venturi size is in accordance with approved drawings. Bolts and nuts is in accordance with specification. Flange connection are within the acceptance tolerance. Equipment is adequately supported. Piping connection, valves, instrumentation, straight lengths upstream and downstream of the injector are in accordance with the approved drawings. Inner tube installation make from low-alloy carbon steel.

Remarks

ATMOSPHERIC STORAGE TANKS, TANKS FOR SOLIDS AND SILOS PTS 12.22.03 shall be used for tank inspection work.

1.9 GRE OR GRP EQUIPMENT GRE or GRP equipment is brittle and easily damaged. No Description 1 Metallic edges is avoided on GRE or GRP equipment. 2 GRE or GRP material shall be properly stored and covered. 3 GRE flange shall be protected not to dent the gasket surface that may cause potential leak.

1.10 RUBBER AND GRE/GRP-LINED EQUIPMENT No Description 1 Cover plate is provided to every flange prior to installation. 2 Flange facing shall be check for defect and scratches etc. 3 Type of gasket shall be in accordance with specification.

Yes

No

Remarks

Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 17 of 56

4

5 6 7 8

9 10 11

12 13

Check piping supports to GRE equipment prior to installation. Soft packing material between support and equipment shall be checked. Bolt tension is in accordance with manufacturer’s values. Filler rings shall be used for raised face steel flanges. Installation of GRE equipment shall be accessible to allow pipe connection to be attached easily. The gaskets, piping connection, and equipment are resistant to the process fluids in accordance with specification. The allowable torques require for flange tightness is in accordance with OEM specification. GRE equipment shall not be used as piping support. Piping connection to the GRE equipment shall not exert any strain, stress or bending moment to the equipment. Bellow shall be installed adequately. The piping size and equipment nozzle size is correctly matched. Tie rods are tensioned and within the limit indicated by the manufacturer.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 18 of 56

2.0 PIPING 2.1 No 1 2 3 4

5 6 7 8 9 10 11 12

13 14 15 16

17

18

PIPING Description Materials for pipe and fitting is in accordance with specification. Wall thickness for pipes and fittings is in accordance with specification. Bolting, gaskets, flanges, flange finish and bolts length is inspected. Flanges tolerance is in accordance with PTS 12.01.01. Nozzle forces and movement are within the acceptable limit in accordance with specification. GRP piping or cast iron are correctly installed Low point and high point connection for drain and vent are inspected. Piping system shall be supported adequately when pressure testing is carried out. Uninsulated lines for personnel protection are safely provided Insulation are correctly installed to ensure no water ingress. Globes and check valve are correctly installed. Underground and above ground transition connection are protected against water ingress Welded and treaded nipples are installed in accordance with drawings. Insulation gasket shall be provided for dissimilar piping connection. Piping system shall be hydrostatic tested in accordance with the design code. Sloping requirement for flare line is in accordance with the approved drawing. Radiographic examination and stress relief of welds is not a substitute for pressure testing. Any deviation shall be subjected to Owner approval. All piping system shall be adequately supported for hydrostatic test pressure. Pressure testing on piping shall be conducted with welds connection not painted. Visual inspection is required to check weldment before apply painting.

Yes

No

Remarks

Threaded nipples shall not be seal welded.

Any deviation shall be consulted to owner for approval.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 19 of 56

19

20

2.2 No 1 2 3 4 5

2.3 No 1

2 3 4 5 6

7

8

Hydrostatic test water shall be immediately remove from the piping system after the test is conducted. The piping system shall be preserved if left idle longer than one month in accordance with PTS 15.44.01

VALVES Description Valve type, pressure class, material is in accordance with specification. Valve direction is correctly installed especially globe and check valve. Ensure valve end covers are provided before installation. Valves accessibility shall comply to PTS 12.30.02 Check whether full handle stroke/turn is possible.

SAFETY/RELIEF VALVES Description The following general precautions shall be made when handling safety/relief valves:  Proper handling of safety/ relief valves are required during handling. Safety/relief valves handling procedure shall be adhered.  Flanges and gasket facings shall be protected from ingress of foreign material.  Valve internals shall not be coated with corrosion inhibitor or protection Valve type, pressure rating, set pressure and material is in accordance with specification. Valve internal cleanliness is checked. All safety/ relief valves shall be bench tested to ensure the correct set pressure before installation. All safety/relief valve are installed in accordance with the approved drawings. Ensure the line size leading to the inlet of the safety/relief valve is at least of the same size or larger than the inlet flange size of the safety/relief valve. Where the valve has been installed to relieve directly to atmosphere, the outlet line shall be vertical. Drain hole shall be provided at the lowest point. Adequacy of pipe support and vibration is checked.

Yes

No

Remarks

Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 20 of 56

9 10 11 12 13

Piping misalignment prior to valve installation is checked. The piping are free from mill scale or debris prior to valve installation. Interlocking system are provided and correctly installed in accordance with PTS 16.53.03 Safety valve testing shall be witnessed by Owner or Owner representative. Availability of heat tracing required foe safety/relief valve in accordance with the approved drawing.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 21 of 56

3.0 ROTATING 3.1 GENERAL 3.1.1 Rotating equipment shall be installed in accordance with PTS 12.01.01. 3.1.2 For each type of equipment, a checklist shall be drawn up of any checks required in addition to, or as verification of, the checks described in PTS 12.01.01, which are to be performed prior to commissioning. No Description Yes No Remarks 1 All Manufacturers’ commissioning/operating instructions shall be adhered to. 2 After welding, any pressure-tested part shall be Rotating equipment retested in accordance with the requirements as parts, which have described in Sections 3. been tested in the shop, shall not be retested. 3 The line-up and instrumentation are checked in accordance with the relevant design documents. 4 All packing materials and protective devices used These include shock during transport and handling have been removed absorbent materials from the equipment before hook up. from machined faces, desiccants, blanking plates from orifices, restraining devices from instruments, safety devices and dummy parts e.g. bearings or seals. 5 Special maintenance tools and instruction manuals have been supplied if any. 6 The nameplate rating is compare with the Equipment Record Card and any variations is recorded. 7 The nameplate is attached to the equipment in accordance with the specification. 8 The foundation bolts and dowelling are securely tightened and check for free thermal expansion of equipment. 9 The insulation and winterising have been applied in accordance with the specification and precautions taken to prevent the ingress of water. 10 The equipment for internal cleanliness before final sealing is checked.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 22 of 56

11

The lubrication system has been properly flushed and is clean.

12

The quality and grade of the applied lubricants are in accordance with specification.

13

Lubrication, filters, strainers and lubricant levels throughout system is checked. N2 pre-charge pressure in accumulators is checked as applicable. The proper mesh size is installed in the suction line strainer/filter of the equipment and that the sieve is fitted correctly and is a close fit with the pipe wall and flush with the cover flange.

14 15

16

17 18

During plant/system flushing and pressure testing the rotating equipment shall be positively isolated from the system. Equipment nozzles shall be blinded off in such a way that no flushing or testing liquid can enter. Process and utility lines leading to and from the equipment is checked. Relative shaft movement when (re)-connecting piping is checked. Alignment tolerances shall not be exceeded.

During flushing the bearings/seals shall be bypassed. The machine may have been shipped with preservation oil.

During the initial start-up, commissioning and initial operating phase the sieve shall be covered with a primary mesh and for reciprocating compressors also with a secondary mesh. Details are given in Standard Drawing D.12.92.303 and D.12.92.310. The fine mesh gauze may be removed after the initial operating phase if fouling has ceased. This can be determined by means of a suitable differential pressure method or visual inspection.

The maximum deviation of flanges from parallel shall be in accordance with PTS 12.01.01. The use of heat or mechanical means to help in achieving

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 23 of 56

acceptable parallel flange deviation shall be subject to approval by the Owner. Alloyed steel materials may require heat treatment to maintain system integrity. 19 20

Cold setting position of spring hanger after filling the system with liquid is checked. Easy removal of locking pin and remove lock pins is checked.

21

Shaft alignment between driving and driven unit is checked.

22 23 24

Ensure baseplate is horizontal Shaft alignment shall include a ‘soft foot’ check. After alignment and prior to coupling with driver, electric motors shall be subjected to a 4 hour ‘solo run’. Direction of rotation and check/record vibration levels. Pay attention to any excitation of natural frequencies of foundation. An arrow, indicating the direction of rotation, should be an integral part of the equipment. The process or steam lines to the equipment are cleaned, flushed or blown out in accordance with the specifications. Adequate drain and venting facilities have been installed. The direction of rotation of drivers prior to coupling up with driven equipment. Coupling is clean and lubricated, if required. Coupling guard and flexible connections is checked. The applied surface protection system is in accordance with specified requirements. Earth bosses are connected and in electrical contact with the equipment.

25

26 27

28 29 30 31 32 33

If easy removal of pin is not possible take adequate corrective action. Any misalignment radially and axially should not exceed the limits specified by the Manufacturer or PTS 12.01.01 whichever is stringent or as per approval by Owner.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 24 of 56

34

Warm-up line of multi-stage and large simple stage pumps is properly installed to avoid channelling and in accordance with the Manufacturer's recommendations. 35 The presence and condition of start-up and insurance spares is checked. 3.2 CENTRIFUGAL COMPRESSORS 3.2.1 Lube oil/seal oil or seal gas system No Description 1 The gaskets fitted are of the correct material and pressure class. 2 Verify the cleanliness of any temporary systems (reservoirs, pumps filters) used for flushing.

3

The system is filled with the correct volume of flushing oil compatible with the operational lube and seal oils.

4

System flushing is started by following special instruction by the Manufacturer (e.g. bypassing bearings and/or seals, heating of oil, max oil flow etc.) if any.

5

The flushing oil is completely drained, including heat exchangers, filters and pump strainers.

6

Clean and inspect oil reservoirs and run down tanks after the flushing procedure. Dual filter housings is cleaned and filter elements is replaced. All oil piping and fittings is reinstate using correct gaskets. Check that the buffer gas/ buffer airlines to the gas seals have been flushed and are clean. Nitrogen pre-charge pressure of accumulators (precharge pressure on nameplate) is inspected. The lube and seal oil system is filled with the correct volume of oil of the specified type and grade. Positive verification of venting is possible (sight glass or open-ended vent line).

7 8 9 10 11

12

Yes

No

Remarks

Prior to circulating oil through the centrifugal compressor lube oil and seal oil systems. Ensure that the expansion vessel is filled to the appropriate level. Continue flushing until no debris or particle observed on wire mesh. Wire mesh placement on lube system shall be agreed with Owner. After the lubrication and sealing system has been properly flushed

Prime and vent heat exchangers and filter bodies

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 25 of 56

13

Fully commission oil systems. Full operating range of level control, checking LL, L and HH safeguarding settings is ensured and the levels throughout the system (overhead system properly filled/vented) is inspected. 14 Lube/seal oil systems safeguarding instrumentation (i.e. auto-start stand by pump) is inspected. 3.2.2 Process piping No Description Yes 1 Piping flanges is line up properly with the equipment flanges. 2

This includes filling the overhead seal oil vessel (if any) following agreed procedures.

No

Remarks For parallelness of flanges see PTS 12.01.01. The use of heat or mechanical means to achieve acceptable parallel flange deviation shall be subject to approval of the Owner. The requirement for heat treatment for alloyed-steel materials shall be investigated.

No

Remarks

The following checklist shall be done after completion of the hydrotest and system flushing:  All process piping in between suction strainer/filter and compressor nozzle is clean (no mill scale etc.). If the line diameter is too small for a proper visual inspection, the line sections concerned shall be removed and chemically cleaned and passivated.  The start-up strainer/filter is properly constructed and fitted in accordance with Standard Drawing D.12.92.310.  The alignment shall be checked during final connection of the process piping to the equipment with all supports (fixed and spring loaded) completed and set-up according to the design.

3.2.3 Utilities No Description 1 The cooling water system has been properly flushed and is clean. 2 Verify the changeover function The system is properly treated with antifreeze and corrosion inhibitor. 3.2.4 Safety devices No Description 1 The instruments and safety devices are correctly installed and in accordance with instrument data sheets and flow diagrams. 2 Ensure all safety devices is functioning.

Yes

If double coolers are installed For closed cooling water system

3

Yes

No

Remarks

Safety devices, which cannot be tested when the machine is not running, should be checked during the initial run.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 26 of 56

3.2.5 Function testing of compressor No Description Prior to initial run: 1 The foundation bolts are securely tightened. 2 The axial and transverse keys are properly located and secured.

3

No process piping is connected prior to compressor alignment.

4

During the tightening of the piping, the dial indicators should be watched in order to highlight the cause of any distortion. If the alignment of the compressor after all process piping has been completely tightened is within Manufacturer's tolerance, data can be recorded and filed and the unit can be accepted for further commissioning. The following should be verified prior to during the final alignment checks:  proper pipe supports and pipe anchors installed;  locating pin for spring hangers has been removed and check for cold setting;  casing hold down bolts properly tightened;  casing positioning screws loose. The auxiliary lube oil/seal oil pump cuts in at correct pressure. Supply of buffer gas/ buffer air to the gas seals is available. Proper action (air fail close/open) and actuator travel on all PSD/ESD and BDV valves. All alarm and trip/safety device settings is functioning properly by simulation of the alarm-trip condition/signal from the sensing device.

5

6

7 8 9 10

Yes

No

Remarks

The casing can expand with increasing temperature When the alignment is within the Manufacturer's requirements, connect the process piping to the compressor with the alignment clocks still in place.

Simulation of the alarm-safety system from the relay/junction base in the auxiliary room is not allowed, as this does not test the field wiring. Verification of

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 27 of 56

alarm/trip device settings, which require actual running of the installation, shall be done during the initial run (e.g. surge protection system). 11

10

11 12

After satisfactory completion of the alarm-safety checks, the compressor can be coupled to the driver provided that the drive safety program including its safety checks under running condition, e.g. overspeed, has been completed. If the coupling is a gear coupling, check the following after it has been fitted:  Axial float of the coupling, and adjustment in accordance with Manufacturer's instructions;  Position and direction of spray of the oil nozzles;  Quantity and pressure of lubricating oil at the spray nozzles. Proper installation of coupling guard is ensured. Initial operation of the compressor Sometimes a compressor is used to dry and clean the process installation using air. The molecular weight and the K value of air may differ from those of the process gas in the compressor.

13

Nitrogen is purged prior to starting the unit on process gas.

14

Lube and seal oil systems is started prior to Nitrogen purging.

The Manufacturer should be consulted if such operation is foreseen or required, as the compressor may have to be operated at reduced speed and pressure; for example, seals may have to be modified temporarily to prevent equipment damage. Purging shall include all associated process piping. Capacity control and surge control recycle valves shall be cycled during purging to ensure no air remains anywhere in the system.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 28 of 56

15

16 17 18

Pressurising the compressor with process gas is started when lube and seal oil flows, levels, pressure and temperature are found to be satisfactory. Any gas leakage is verified. The compressor is started. Oil supply and return temperatures, bearing temperatures, and transient vibration levels is closely monitored until stabilised.

19

The machine is stopped and visually inspect the journal and thrust bearings including the shaft journal and thrust collar before releasing machine for further operation.

20

All readings are recorded regularly and confirm that the readings are within specified limits.

21

Inward leakage rate of shaft seals is monitored.

22

The process parameters like oil/gas flows, pressures and temperatures regularly, particularly after a change in operating conditions are recorded. The surge protection system is inspected in accordance with pre-agreed procedures once the unit is up to rated conditions.

23

NOTE: Stop the unit immediately if abnormalities are observed.

Closely monitor in particular vibration levels for any abnormalities at speeds below the normal operating range. Unless RTDs are installed in bearing pads. This constitutes the final confirmation that machines can confidently be left in the care of Operations for uninterrupted start up activities. Particularly after a change in operating conditions. NOTE: Pre calibration of sightglass or level instruments on oil traps shall be considered for this verification process.

NOTE: Use the Manufacturer’s predicted performance data for the air/gas used for this test. Verifying the settings of this protection system may result in surging of the compressor, and therefore shall be carried out by

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 29 of 56

qualified personnel only. 24

25

26

27

When satisfactory operation is obtained and all outstanding matters have been dealt with, the unit is ready for the plant performance test. Conditions for the test shall be mutually agreed between the equipment Manufacturer, Contractor and Owner. The unit shall be stopped and the strainer cleaned.

After successful completion of the test the unit may be stopped for adjustment of safety devices or inspection of certain parts. With compressor and driver at or close to normal operating temperature a hot alignment check shall be considered at this point. When laser alignment gear is used the coupling does not need to be disconnected. Warm air circulation across the laser beam e.g. caused by a hot turbine casing can influence readings. A shield can be used to minimise this risk. Take an oil sample and check it for presence of water and any other foreign matter. Once it can be safely assumed that the system is clean, the fine mesh shall be removed. The perforated cone, however, remains in place. When sufficient operating experience has been gained to indicate that the total system is free of foreign matter (this can take up to several months) the entire screen can be removed. However, in order not to disturb the piping alignment the flange of the conical strainer shall be recovered and reinstalled.

3.3 RECIPROCATING COMPRESSORS/VACUUM PUMPS No Description 1 The crankcase and crossheads is inspected for cleanliness. 2

3

4

NOTE: Whenever the differential pressure across the start-up strainer reaches 1.5 bar, NOTE: After each plant overhaul a temporary strainer made of perforated plate shall be installed for equipment protection.

The crankshaft deflection before and after coupling-up of driver is in accordance with the Manufacturer’s tolerance. The levels of cylinder liners and crosshead slides are in accordance with the Manufacturer’s tolerance The rod run outs, both vertical and horizontal, are in accordance with the Manufacturer’s tolerance.

Yes

No

Remarks NOTE: make sure the crankcase is properly vented.

NOTE: Horizontal run out will indicate bent

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 30 of 56

inaccuracies of rebored conrod bearings after major overhaul) 5 6 7 8 9

The line-up of lube oil system is in accordance with flow diagram. The entire lube oil system has been properly flushed and is cleaned. The line-up of cooling water system is in accordance with flow diagram. Cooling water system section can be isolated to facilitate maintenance activities The cooling water system has been properly flushed and is clean.

10

Line-up of vent and drain system of cylinder pressure packing compartment and distance piece compartments is examined.

11

Line-up of purge system to cylinder pressure packing compartment or distance piece compartments is examined. The barring gear is functioning correctly. ‘rider ring clearance’ with piston in TDC position (liner to piston clearance) is examined The suction and discharge valve assembly and valve housing for cleanliness and valve lift are examined. Valves are assembled correctly.

12 13 14

15

16 17

Functioning and sequence is correct. Hydraulic control system is examined. Develop Commissioning protocol.

18

The piston end clearance at both sides of each cylinder is examined. Cylinder and suction volume bottle is examined for cleanliness.

19

NOTE: (e.g. cylinder head removal). NOTE: Water of closed circuit system shall be treated with suitable inhibitors. NOTE: Taking into account local safety regulations for disposal of hazardous or very toxic gases (the definition of which is given in PTS 16.50.01.

NOTE: Remove valves for initial run NOTE: If valve unloaders are mounted, check clearance of spindle with valve assembly. NOTE: If Hydraulic Capacity Control (Hydro COM) is installed.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 31 of 56

20

The clearance pockets is properly functioning.

21

Cleanliness of the compartments in the distance piece is examined.

22

The safety devices are properly installed and in accordance with the data sheets and flow diagram. The crankcase contains oil up to the correct level. The lubricator is filled with oil and check proper supply to all lubricated points by rotating the crank by hand.

22 23

24 25 26 27 28 29

30

No 1 2 3

No

NOTE: If clearance pockets for capacity control are installed NOTE: If the compressor is driven by means of V-belts, check the correct tension of these belts and the pulley alignment. NOTE: check set pressure NOTE: Run lubricator and adjust lubrication rate according to the Manufacturer’s recommendation.

Correct water/glycol mixture and level in expansion vessel is examined. Alignment prior to and following hook-up of process piping is examined. Oil grade and level in gear drive and auxiliary bearings is examined. Immersion heater coils for lubricator reservoir is examined. Cooling water system is functioning properly. The reservoir and cylinders are filled with glycol and correct level in the reservoir examined.

NOTE: If cylinders are cooled by thermosyphon cooling, NOTE: Safety devices that cannot be tested when machine is not running should be checked during the initial run.

All safety devices and safeguarding instrumentation is functioning properly.

Utilities Description The cooling water system has been properly flushed and is clean. Verify the changeover function The system is properly treated with antifreeze and corrosion inhibitor. Safety devices Description

Yes

No

Remarks

If double coolers are installed For closed cooling water system Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 32 of 56

1

2 No 1

No 1

2 3 4

5

The instruments and safety devices are correctly installed and in accordance with instrument data sheets and flow diagrams. Ensure all safety devices is functioning. Piping Description Process suction piping is clean (no mill scale etc.) and the pipe shall be chemically cleaned and passivated. Initial run (without valves) Description The molecular weight, suction pressure and Kvalue of air or nitrogen will most probably differ from those of the process gas. Follow the Manufacturer's recommendations for air or nitrogen operation. The suction should be unrestricted and the discharge temperature should not exceed the maximum as specified by the compressor Manufacturer. Suction or discharge valves from each cylinder is removed. Lube oil, lubricator and cooling water system is started. The barring gear is in a safe position after the compressor has been barred over for at least one full revolution.

Motor is isolated and temperature of all bearings and other friction parts is examined.

Yes

No

Remarks

Yes

No

Remarks NOTE: Not applicable if valves are not installed.

NOTE: If abnormal resistance is encountered during barring, refrain from starting the compressor until the cause of the resistance has been found and remedied. Bump start compressor and monitor slow roll down to standstill. Next run for 5 minutes. Observe oil pressure, V belts and vibrations. NOTE: If no excessive temperature is observed start the compressor again and let it run for about 2 to 4 hours or until temperatures have stabilised

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 33 of 56

6 7

8

9 10 11 12 13 14 15 16

17

3.4 No 1 2 3 4 5

Motor and machine is observed, vibration levels and lubricators is examined for leakage, etc. Isolate motor and repeat checks of bearings including lubricator effectiveness and valves is reinstalled. Capacity control system with respect to unloading sequence and cylinder load. Let it run for a prolonged period unless observations indicate the presence of a defect.

NOTE: (Check rods and liners). NOTE: After the mechanical run-in period, the valves should be refitted and the compressor can be started again with valves unloaded. It should be loaded in accordance with the specified sequence.

The oil pressures and temperatures of all bearings and seals is examined. The lubricator is functioning properly and cooling system is examined for abnormal loss of coolant. Differential pressure across suction strainer is monitored. The gas pressures and temperatures is monitored regularly. Any gas leakage, vibration of machine and piping is examined. The automatic loading and unloading device is examined, if installed, for smooth operation. Noise exceeds the specified limits. Oil is changed after 100 hours of operation (if sump volume is relatively small, flush out any conservation oils used). Once it can be safely assumed that the system is clean, the fine mesh shall be removed.

ROTARY TYPE COMPRESSORS Description The bearings and bearing housings is examined for cleanliness. The lube oil system is in accordance with the flow diagram. The entire lube oil system has been properly flushed and is clean. Separate seal oil is in accordance with the flow diagram. The entire seal oil system has been properly flushed and is clean.

Yes

NOTE: For instrument air compressors

NOTE: The perforated cone, however, remains in place.

No

Remarks

NOTE: If a separate seal oil system is installed,

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 34 of 56

6 7

8

9 10

11 12

13 14 15 16

17

18 19 20 21

22 23 24 25

The cooling water system is in accordance with the flow diagram. Cooling water system has been properly flushed and is clean.

The seal buffer gas system is in accordance with the flow diagram and has been properly flushed and is clean. The tension of the V belts and the pulley alignment is examined. The suction line is examined for absolute cleanliness.

The discharge line is examined for cleanliness and valve orientation is checked. Safety devices are properly installed and in accordance with data sheets and flow diagram. Safety/relief valve is installed and the set pressure is checked. The lube oil tank contains oil up to the correct level. The seal oil tank contains oil up to the correct level. The overhead seal oil accumulator contains oil up to the correct level and is properly vented. The gearbox contains oil up to the correct level. The auxiliary lube oil pump cuts in at the correct oil pressure. The auxiliary seal oil pump cuts in at the correct oil pressure. All safety devices and safeguarding instrumentation is functioning properly. Safety devices, which cannot be tested when the machine is not running, should be checked during the initial run. The loading/unloading system is examined. The direction of rotation is examined before coupling up. Over speed /under speed protection is examined. Alignment prior to and following hook-up of process piping is examined.

NOTE: Water of dedicated cooling water system shall be treated with suitable inhibitors. NOTE: If gas seals are used.

NOTE: If the compressor is driven by means of V belts, Any dirt or welding scale from the suction line is disastrous for a screw compressor.

NOTE: If a gearbox is installed with its own lube oil pump

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 35 of 56

26 27 28

29

30 31 32

33 34 35

36

37

Before the initial run, the free rotation of the unit is verified normally. Initial run (normally on air or nitrogen) The molecular weight, suction pressure and K-value of air or nitrogen will most probably differ from those of the process gas. Therefore, the compressor may have to be operated at a reduced speed and discharge pressure. Follow the Manufacturer's recommendations for air and nitrogen operation. The suction should be unrestricted and the discharge temperature should not exceed the maximum, as specified by the compressor Manufacturer. Vibration and noise levels is examined. Shut down and check for excessive bearing temperature. Start the compressor again and let it run for a period of about 4 hours.

The oil pressures and temperatures of the bearings and seals is examined regularly. Differential pressure of start-up strainer is examined. The gas pressures and temperatures is monitored regularly. The interstage cooling and knock-out facilities is examined. Any gas leakage is examined. Vibration is examined and recorded. The automatic loading and unloading devices is examined, if installed, for smooth operation. Hot check of the coupling alignment is performed as soon as the machine has come to a standstill following a running period of some hours at design temperature. Once it can be safely assumed that the system is clean, the fine mesh shall be removed. The perforated cone, however, remains in place.

NOTE: Purge all relevant process piping, lubricating oil and seal oil systems with nitrogen before the unit is put into operation. When lube oil, and where applicable seal oil, flows and pressures are found to be satisfactory, start the compressor and allow the compressor to attain full speed.

NOTE: For instrument air compressors

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 36 of 56

3.5 No 1

2 3

4

5

6 7

8

9

10

BLOWERS/FANS Description The bearing and bearing housings is examined for cleanliness.

The correct position of the constant-level oiler is examined, if applicable. The bearing housings contain oil up to the correct level or are properly greased and the presence of correct re-greasing facilities is examined. Installation records is checked to ensure correct clearances have been achieved and the thrust rings are installed in the drive end bearing housing. Through the inspection cover on the casing, the radial and axial clearance between the impeller and the inlet cone is examined. Cooling water lines is flushed. Alignment, DBSE (Distance Between Shaft End) and coupling spacer length, DBSE shall be measured while motor shaft is in its magnetic position (sleeve bearing type motor). For fans with variable pitch, correct pitch angle settings is examined.

Initial run  The temperatures and pressures is examined regularly.  Vibration levels is within acceptable levels.  Noise is within the specified limits.  The correct position and function of inlet guide vanes is examined if installed.  Cooling and purging facilities on the shaft sealing area.  The housing drain facilities is examined. For ID and FD fans for furnaces and boilers:  Inlet guide vanes is functioning properly. Record their movement degrees versus instrument output. Make sure that the operating mechanism is strong enough and has less than 5 to 20 degrees hysteresis.

Yes

No

Remarks Where bearings are oil lubricated, check that the lubricating rings have adequate free movement. NOTE: If bearings are oillubricated.

If tapered bore spherical roller bearings are used,

NOTE: While rotating by hand, check correct bearing position and dowels.

NOTE: For fans with adjustable louvers, check freedom of movement of louver linkage system.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 37 of 56

   

3.6 No 1 2 3

4

No 1 2

3

4

No 1 2 3

No

Make sure that greasing facilities are installed. Make sure that an adjustable minimum and maximum stroke stop is installed. Hot ID fans: check free movement when hot. Dual drive FD fans, check (overriding) clutch.

CENTRIFUGAL PUMPS Lubrication Description The lubricating rings and/or lubrication system is functioning properly. The correct position and level of the constant-level oiler is examined. The bearing housing contains oil up to the correct level or is properly greased.

Presence of proper regreasing facilities is examined Sealing Description The type of mechanical seal and its material are in accordance with specification. The seal piping arrangement is correctly installed in accordance with the specified API plan. Soft packing rings in the stuffing box are of correct material and the packing and gland are properly installed. The location and connections of the lantern ring is examined and proper seal liquid is used, if applicable. Utilities Description The cooling water system has been properly flushed and is clean. Verify the changeover function The system is properly treated with antifreeze and corrosion inhibitor. Safety devices Description

Yes

No

Remarks

If oil-mist lubrication is applied, check that the system is lined up correctly and is clean.

Yes

No

Remarks

Yes

No

Remarks

If double coolers are installed For closed cooling water system Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 38 of 56

1

2 No 1

2

3

The instruments and safety devices are correctly installed and in accordance with instrument data sheets and flow diagrams. Ensure all safety devices is functioning. Function Testing Description Yes Prior to initial run (E-motor de energised)  The free axial movement of the gear coupling spacer is examined, if applicable.  The free movement of pump rotor/electric motor is examined.  The correct rotation of motor (perform a bump test) is examined. Initial run (on water or flushing liquid) if applicable  Ensure start-up strainer is installed properly (fine mesh strainer) [see (18)].  Where necessary, supply cooling water, start the lube oil unit and seal liquid supply.  Check N2 pre-charge pressure in accumulators if applicable.  Open the suction valve and vent the pump casing and seal chamber.  Start the pump with the discharge valve cracked open and check the shut off head.  Open the discharge valve gradually and check the power consumption (ammeter) at the same time.  Also check correct operation of minimum flow protection device, if applicable.  Check the mechanical performance of the pump on the duty point, e.g. bearing temperature, vibration levels.  Inspect start-up strainer. Final start-up on product If a bypass or equalizing line is installed for warming-up purposes, open the valve in this line and warm up the pump for a sufficient length of time.  Start the pump as for water.  Check and record vibration. If vibrations are excessive make a hot check of the coupling alignment, if necessary.

No

Remarks

NOTES: 1. Ensure that vacuum pumps are not started when full of liquid. Vacuum pump suction piping shall be (mechanically) cleaned downstream of suction strainers. Absolute cleanliness shall be

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 39 of 56



3.7 No 1 2 3

4

5 6 7

No 1

assured prior to start-up. Recirculation line shall join system upstream of strainer. 2. For high speed pumps, follow the start-up procedure of the Manufacturer. Ensure minimum flow bypass volume sufficient to prevent vaporising of pumped liquid. 3. Multi-stage pumps with balancing disc should always operate at the specified differential head and design process conditions. Low discharge heads could destroy the balancing disks.

Check whether noise levels exceed the specified limits.

RECIRPOCATING PUMPS Lubrication Description The line-up of the lube oil system is examined. The crankcase contains oil up to the correct level. The lubricator contains oil up to the correct level and proper oil supply to all lubricated points by rotating the crank by hand is examined. Oil in the gearbox is up to the correct level or is properly greased. The correct position and level of the constant-level oiler is examined. The bearing housing contains oil up to the correct level or grease. If oil mist lubrication is applied, the system is lined up correctly and is clean. Sealing Description Soft packing rings in the stuffing box are of correct material and the packing and gland are properly installed.

Yes

No

Remarks NOTE: If forced-feed lubrication is applied,

If a gearbox is installed,

Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 40 of 56

2

No 1

No 1

No 1

2

The location and connections of the lantern ring is examined and proper seal liquid is used, if applicable. Utilities Description The nitrogen pre charge pressure is as per specified. Safety device Description A safety/relief valve is installed and the set pressure is verified. Function Testing Description Prior to initial run  The free axial movement of the gear coupling spacer is examined, if applicable.  Free movement of pump rotor/electric motor is examined.  The suction and discharge valve assembly and valve housings for cleanliness is examined and the valves are correctly assembled.  If the pump is driven by means of Vbelts, the tension of these belts and pulley alignment is examined.  If the pump is steam-driven, the steam supply and exhaust lines have been connected to the equipment so that strain-free operation is assured. Flange bolts, gaskets, pipe supports and drain lines is examined.  The valve gear and re adjust where necessary. Initial run (on product or flushing liquid)  Any specific Manufacturer instructions is checked. If stroke adjusting devices are installed the Manufacturer's handling instructions shall be followed (in principle the start-up should be at a minimum capacity).  Supply the specified utilities, e.g. steam, cooling water.  Supply, if applicable, steam to heating jackets.  Start the lube oil unit and seal liquid supply.

Yes

No

Remarks NOTE: If a bladder type pulsation damper is installed,

Yes

No

Remarks

Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 41 of 56



3

3.8 No 1

2 3

4

1 2

Verify suction strainer is properly installed, with fine mesh cover [see (18)].  Open the suction and discharge valves.  Start the pump.  The mechanical performance of the pump and its lubrication is examined.  Vibration of pump and piping is examined and recorded.  Check whether noise exceeds specified limits.  Mechanical performance of the pump at the duty point, e.g. bearing temperature, vibration levels is examined and recorded.  Start-up strainer is inspected. Final start-up on product  If a bypass or equalizing line is installed for warming-up purposes, open the valve in this line and warm-up the pump for a sufficient length of time.  Start the pump.  Check and record vibration. In case of excessive vibrations make a hot check of the coupling alignment, if necessary.  Check whether noise exceeds specified limits. ROTARY POSITIVE-DISPLACEMENT PUMPS Lubrication Description The bearings and the bearing housings is examined for cleanliness and ensure that lubricating rings have adequate free movement. Ensure correct position and level of the constant level oiler. Ensure that the bearing housing contains oil up to the correct level or is properly greased. If oil-mist lubrication is applied, the system is lined up correctly and is clean. Sealing The type of mechanical seal and its material are in accordance with specification. The seal piping arrangement is correctly installed in accordance with the specified API plan.

Yes

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 42 of 56

3

4

1

1

2

3.9 No 1

2

Soft packing rings in the stuffing box are of correct material and the packing and gland are properly installed. The location and connections of the lantern ring is examined and proper seal liquid is used, if applicable. Utilities Safety device  Safety/relief valve is installed and the set pressure is verified. Function Testing Prior to initial run  The suction line and filters for absolute cleanliness is examined.  The free axial movement of the gear coupling spacer is examined, if applicable.  The free movement of pump rotor/electric motor is examined.  Shaft coupling, bolting and bolt securing devices is examined.  Suction strainer is examined Initial run (on flushing liquid or product)  Supply the required utilities.  Start the oil lubrication and seal flush/quench system.  Start the pump with the suction and discharge valves open.  The mechanical performance of the pump is examined and bearing temperature is monitored.  Vibration is examined and recorded.  Hot check of the coupling alignment is performed, if necessary.  Check whether noise exceeds specified limits.

MIXERS Lubrication Description The bearings and the bearing housings is examined for cleanliness and ensure that lubricating rings have adequate free movement. Ensure correct position of the constant level oiler, if applicable.

Yes

No

Remarks

NOTE: If the axial bearing is oil-lubricated.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 43 of 56

3 4 5 6 7

No 1

2

3 4

No 1

2

No 1

The axial bearing housing contains oil up to the correct level or is properly greased. Check that it contains oil up to the correct level or is properly greased. Ensure correct position and level of the constant level oiler. Ensure the bearing housing contains oil up to the correct level or is properly greased. If oil-mist lubrication is applied, the system is lined up correctly and is clean. Sealing Description Yes Soft packing rings in the stuffing box are of correct material and the packing and gland are properly installed. The location and connections of the lantern ring and proper seal liquid is used, if applicable. The type and material of mechanical seal are in accordance with specification. The seal piping arrangement is correctly installed in accordance with the specified API plan. Utilities Description Yes Safety device  Safety/relief valve is installed and the set pressure is verified. Bottom bearing Manufacturer's drawings, instructions etc. shall be consulted.  Dimensions and materials used for sleeve and bushing is verified.  Flush system is examined.  Bearing can be operated with test liquid.  Use clean feed lines and clean vessel and bearing before initial start. Function Testing Description Yes Prior to initial run  The inlet lines and filters is examined for absolute cleanliness.  The general condition of the stirrer is examined for damage which might have occurred during transport.  Mark parts such as seal cartridges, bushes and sleeves of bearing. In the

NOTE: If a gearbox is installed,

No

Remarks

No

Remarks

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 44 of 56

No 1

event of a failure or problem (e.g. wear in the bottom bearing) this information can be helpful in tracing the cause. During this stage the electric drive is still uncoupled from the main and the main switch is locked.  The alignment and bolts of different parts of the drive is examined.  The alignment criteria for the coupling shaft between gear box and main shaft, after installation is verified. Limits should be given by the Vendor.  Ensure the shaft can be rotated by hand without obstruction.  Mark positions on mixer set-up and vessel for vibration and shock pulse measurements (3 directions on drive, gear box, bearings, mechanical seal, top nozzle of vessel, bottom of the vessel and construction).  Alignment of the main shaft to be checked by measuring the run-out at three different heights along the shaft by means of a gauge.  The position of the main shaft relative to the middle of the vessel at the same positions as for the run out measurements.  Ensure that the operating procedure for the mechanical seal has been added to the plant operating manual.  After this stage the vessel shall be cleaned and all inlets to the vessel shall be flushed or the lines shall be cleaned later without drainage into the vessel. Take photographs of the different parts of vessel and mixer set-up, both inside and outside. Initial run Description Yes From this point on the manhole is open for visual observations during tests at ambient conditions. No construction work near the manhole is permitted. Glasses, helmets and tools shall likewise be kept away from the manhole. The Vendor should be present at this stage.

No

Remarks

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 45 of 56

2

3

4

5

Run the motor uncoupled for 3 hours (check whether this is allowed!).  Ensure the directional rotation of the motor in relation to the proper pumping action of the impellers.  Measurement of absorbed power (kW, volts, amperage, control room.  Measure stirrer speed with tachometer and check in control room.  Carry out vibration and shock pulse measurements at marked positions.  Carry out noise measurements near drive, gear box, mechanical seal and bottom of vessel. Connect drive to the gearbox and run for 2 hours in an empty vessel. (If applicable: check whether bottom bearing needs to be submerged).  Accurate measurement of absorbed power (kW, volt Measure stirrer speed with tachometer and check in control room.  Carry out vibration and shock pulse measurement at marked positions.  Carry out noise measurements near drive, gear box, mechanical seal and bottom of vessel.  The seal unit (leakage, pressure and temperature) is functioning properly.  Observe deflections of the main shaft via top man hole. Liquid can be used for initial run with regard to both the material and drive rating of the unit. Test run with water level with the top tangent line for 12 hours. During the test the following shall be monitored:  Absorbed power.  Stirrer speed (if variable speed, vary at least twice from minimum to maximum and check with tachometer and in control room).  Temperature of drive, bearings (drive and gearbox) and seal.  Proper function of seal unit.

NOTE: Charge vessel with a measured quantity of clean water to the operating level with the stirrer at stand still.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 46 of 56



6

Movement ("wobbling") of pedestal (indicative of low frequency vibration).  Observe deflections of the main shaft.  Observe noises around mixer set up. At the start, halfway point and end of the test run, carry out:  Vibration and shock pulse measurements at marked positions. Vibrations shall not exceed the maximum given by the Vendor before installation.  Noise measurements near drive, gear box, mechanical seal and bottom of reactor.  Empty and clean vessel.

3.10 ROTARY FILTERS No Description 1 Manufacturer's instructions, drawings, etc., shall be consulted for any additional checking not mentioned below. 2 The quality and grade of the applied lubricants are in accordance with the specification. 3 Filter tank expansion facilities is examined. 4 The filter tank is inspected for cleanliness after filter cloth is installed and damage of packing between hood and tank before tank is closed is observed. 5 The hood hydraulic lifting device for leakage is functioning properly. 6 When the hood is lifted, the assembly of safety bars is examined. 7 The drum is examined for proper installation of grids and the dividing strips for sharp edges or burrs is checked. 8 The drum for proper installation of wire fasteners and movement of adjustable fasteners. 9

10

When tank is filled with water, carry out pressure test of drum at approximately 0.35 bar (ga) and check for leakage. Flush trailing and leading pipe after pressure test and check for cleanliness.

Yes

No

Remarks

NOTE: The wire guide grooves at the drum ends for correct angle and smooth finish.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 47 of 56

11

12

13

The drum-shaft journals for cleanliness and proper location of lube oil supply holes is examined. Soft packing rings in the stuffing box are of correct material and whether packing, lantern ring and gland are properly installed. Valve head and wear plate surfaces are perfectly clean.

14

The bearing bushing in the valve head for cleanliness.

15

Ensure the correct pressure of springs and the sealing bellows is examined for damage. Straightness of the conveyer shaft by turning the conveyer by hand is examined. The setting of deflector blades is examined after filter cloth has been installed. The outer and intermediate bearings of scroll shaft is inspected for cleanliness. Soft packing rings in the stuffing boxes of scroll shaft are of correct material and whether packing, lantern ring and gland are properly installed. The tightness of bolts of conveyer flanges is inspected. Lube oil or grease system is correctly installed and all connections are tight and inspect for cleanliness. Ensure proper supply of lube oil or grease to all lubricating points when lubricator is operated. The electric drum drive motor and speed variator are rigidly supported. The drum drive coupling alignment and that slip coupling and limit switch are correctly adjusted. Cleanliness of worm wheel, worm and worm shaft bearings is examined. Speed variator is functioning properly, and ensure the correct direction and free rotation of drum.

16 17 18 19

20 21

22 23

24 25

26

27

Geared scroll drive electric motor is rigidly supported and the coupling alignment is examined. Ensure correct direction and free rotation of the scroll.

NOTE: Apply grease to surfaces while valve head is being installed. NOTE: That oil supply holes to the bearing and to the circumferential grooves in valve head are clean. NOTE: During installation of the valve head

NOTE: When the speed variator has been filled with oil and the lube oil system is operated,

NOTE: When the scroll drive motor gearing has been

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 48 of 56

28

Ensure product lines, inert gas lines and solvent lines are properly installed and all connections are tight.

28

Ensure correct position of spray nozzles and check for cleanliness. All pipes leading to the equipment is examined for cleanliness before they are connected. Ensure the length of the cloth is correct and the cloth is free of mildew. Ensure whether sufficient winding wire is available on the spools for a complete winding run. Ensure sufficient and correct caulking material. The wire winding machine is properly supported on its foundation and whether the threaded shaft, bearing, wire guides, sprockets and driving chain are properly installed. The filter cloth and caulking material is applied to the drum in accordance with Manufacturer's instructions. Ensure that the filter cloth has not been damaged during this procedure and that caulking bars are flush with cloth surface. The wire winding procedure is performed in accordance with Manufacturer's instructions. Ensure the winding procedure that the correct wire tension is constantly maintained. The wire cannot be drawn into the caulking at the drum ends. The set pressure of relief valves is verified. When installed, the line-up of the inert gas supply to the bail-out device connection is in accordance with the applicable drawing. Ensure all view port connections for tightness. The cold insulation material is properly applied and the parts are properly steam traced.

29

30

31

32

33

34

35

36 37 38

39 40

filled with lubricant to the correct level and the lube oil system is operated, NOTE: Special attention should be paid to flexible hoses at valve head, ensuring that no pipe strain is transmitted to the valve head.

NOTE: Before installation of the filter cloth.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 49 of 56

41 42

43

Instruments are properly installed and are in accordance with the instrument data sheet. Ensure the oil grade and level in the lubricator, worm wheel housing, speed variator of drum drive, and geared electric motor of scroll drive. Ensure that neither scroll drive nor drum drive can be started before the lube oil system is operated and that the drum drive cannot be operated before the scroll drive is operated.

NOTE: The starting sequence of equipment.

3.11 STEAM TURBINES 3.11.1 Since construction details and auxiliary equipment can vary widely from Manufacturer to Manufacturer, it is important to consult the Manufacturer's instruction manual for any additional checking not mentioned below. It is assumed that steam blowing of supply lines to turbines has been carried out in accordance with appropriate standards; steam strainers are installed; stress free piping is connected to turbines and auxiliaries; piping anchors and spring hangers have been checked and accepted after steam blowing; and final alignment has been carried out. No Description Yes No Remarks 1 The schedule of auxiliary and associated equipment is examined for correct calibration and operation. 2 Casing expansion is not obstructed, and NOTE: Transverse that keys and dowels are correctly installed movement of the casing and will not influence shaft alignment at centreline shall be operating temperatures prevented. The casing foundation bolts on the non drive end shall not be too tight to obstruct expansion of the casing. 3 Bearings and bearing housings is examined NOTE: If applicable, check for cleanliness. that bearing lubricating rings have adequate movement. 4 Ensure correct position of constant-level oiler. 5 The lube oil system is in accordance with the flow diagram. 6 Ensure that the entire lube oil system has been properly flushed and is clean. 7 The control oil system is in accordance with the flow diagram. 8 Ensure that the entire control oil system has been properly flushed and is clean.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 50 of 56

9 10 11 12 13 14

15 16 17 18

19 20

21

22

23

24

The cooling water system is in accordance with the flow diagram. The piping arrangement and shaft seals is examined. Vent and drain piping of casing, steam lines, trip/throttle valve is examined. Ensure proper line-up of piping and control of sealing steam. The line-up of vacuum equipment is in accordance with the applicable drawings. Safety devices are properly installed and in accordance with data sheets and flow diagram. The safety/relief valve is installed and the set pressure is verified. Ensure the bearing housings contain oil up to the correct level. Ensure the lube oil tanks contain oil up to the correct level. Depending on the type, ensure the governor contains oil up to the correct level. Auxiliary lube oil pump cuts in at correct oil pressure. The line-up of the governing system is in accordance with the applicable drawings.

The automatic cut-in turbines are properly preheated and that the cut in device is properly set. All safety devices is functioning properly.

The lever-holding mechanism of the over speed trip device is examined while the turbine is not running. Barring gear for proper operation and automatic cut-in and/or -out, if applicable Initial run

NOTE: If a gland steam condenser is installed,

NOTE: If possible, operate the system and check for proper functioning of relay valves, control valves and main stop valve after correct control oil pressure is obtained. If the main stop valve is operated without oil pressure, check proper functioning manually.

NOTE: Safety devices, which cannot be tested when the machine is not running, should be checked during the initial run.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 51 of 56

No 1

2

Description All steam drains and condensate traps is functioning properly.

Yes

No

Remarks NOTE: Consult Manufacturer's instruction manual for start-up procedure of unit.

Start turbine, control speed with throttling valve 3 Vent governor oil system of air before bringing turbine to minimum governor speed. Check trip valve manually. 4 Observe steam pressures and temperatures, bearing temperatures and vibration levels. Check that lube oil flow to bearings is adequate. 5 The over speed trip device is examined by increasing the turbine speed to the correct trip speed, 3 times in succession. 6 Vibration levels is examined and recorded. 7 For automatic cut-in turbines, cut-in device is examined for correct operating condition. 8 For condensing turbines, vacuum equipment is functioning properly and whether the required vacuum can be obtained. 9 All condensate drains and steam traps is examined for proper operation. 10 Ensure whether the noise exceeds specified limits. 3.11.2 If no abnormalities are observed during the initial run, the turbine can be coupled to the driven machine and the complete unit started up, taking into consideration the process conditions and start-up procedure for the driven machine. Second run No Description Yes No Remarks 1 Run the complete unit for a long period, if NOTE: During this test, all possible under normal operating observations carried out conditions, until smooth operation is during previous test, with obtained and no abnormalities are the exception of the over observed. speed test, shall be repeated. Additional Checks during test No Description Yes No Remarks 1 When loading the turbine, the control NOTE: If the turbine is valves respond and open gradually. equipped with backpressure control valves, check that they respond and function properly.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 52 of 56

2

Hot check of the coupling alignment is performed as soon as the set has come to a standstill following a running period of some hours at design temperature. 3 Oil reservoir is inspected for water content and take oil sample for analysis. 3.12 GAS TURBINES 3.12.1 Since construction details and auxiliary equipment can vary widely from Manufacturer to Manufacturer, it is important to consult the Manufacturer's instruction manual for any additional checking not mentioned below. No Description Yes No Remarks 1 The equipment supplied against the schedule of auxiliary and associated equipment for correct calibration and settings. 2 Ensure the casing, shaft and exhaust duct NOTE: However, transverse can expand with increasing temperatures. movement of the casing should be prevented. The casing foundation bolts should have adequate clearance under their heads to allow for expansion of the casing. 3 The cooling system is in accordance with the flow diagram. 4 Ensure the entire cooling system has been properly cleaned. 5 Ensure the entire lube oil system has been properly flushed and is clean. 6 Ensure the entire hydraulic oil system has been properly flushed and is clean. 7 The fuel supply system is in accordance with the flow diagram. 8 Ensure the entire fuel supply system has been properly flushed and is clean. 9 Ensure the correct functioning and setting of the gas fuel supply system pressure regulators and isolating/venting valves. 10 Operate the fuel control system statically and check for correct equipment response. 11 After commissioning the compressor washing system, ensure that it operates correctly according to the Manufacturer's manual. 12 All air intake bypass doors and mechanized shutters is examined for cleanliness particularly just before the first start up and correct operation.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 53 of 56

13

14 15 16

Safety devices are properly installed and in accordance with the data sheets and the flow diagram. Ensure the lube oil tanks contain oil up to the correct level. Ensure the auxiliary lube oil pump cuts in at the correct oil pressure. The line-up of the governing system is in accordance with the drawings.

17

All safety devices is functioning properly.

18

Fire protection and gas detection systems is examined for correct operation according to the Manufacturer's manual. Initial run (non-fired) All pre-commissioning runs shall take place under the supervision and responsibility of the Supplier's engineer and in accordance with the Manufacturer's instructions. Second motoring run

19 20

21 22

NOTE: If possible, operate the system and check the proper functioning of relay valves, control valves and the main stop valve after correct hydraulic oil pressure is obtained. If the main stop valve is operated without oil pressure, check proper functioning manually. NOTE: Safety devices which cannot be tested when machine is not running should be checked during the initial run.

Repeat item (10) but with gas start selected. Commissioning run 3.12.2 This run shall take place under the supervision and responsibility of the Supplier's engineer and in accordance with the Manufacturer's instructions. No Description Yes No Remarks 1 Ensure whether noise exceeds specified limits. 2 Vibration frequency is taken for analysis as future reference. 3 Take an oil sample. 4 Compile a checklist of safety devices to be calibrated. This checklist shall include all test information.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 54 of 56

3.13 DIESEL ENGINES 3.13.1 Since construction details and auxiliary equipment can vary widely from Manufacturer to Manufacturer, it is important to consult the Manufacturer's instruction manual for any additional pre-commissioning checks not mentioned below. No Description Yes No Remarks 1 Ensue whether the crankcase, oil pump and lubricating lines have been properly flushed and are clean. Ensure that the crankcase can be vented. 2 Ensure the cleanliness of oil filters and oil coolers. 3 The fuel oil system is in accordance with the Manufacturer's drawing. 4 Ensure the entire fuel oil system has been properly flushed and is clean. 5 Filter and separators is examined. 6 Cooling water lines are installed in accordance with the Manufacturer's drawings. 7 The entire cooling water system is properly flushed and is clean. 8 The line-up of starting equipment is NOTE: If an electric starting examined. system is fitted, check the electrical installation and battery condition. 9 The line-up of compressor, starting air NOTE: If an air starting vessel, and all pipe connections are in system is fitted accordance with the Manufacturer's instructions. 10 Ensure that the starting-air vessel is equipped with a safety/relief valve (and check the set pressure) and that the vessel can be drained. 11 An air inlet filter is installed. 12 Ensure the oil sump contains oil up to the correct level. 13 Ensure the barring functions correctly. 14 Ensure the lubricator contains oil up to the NOTE: If a lubricator is correct level and check for proper supply to installed, all lubricated points by rotating the crank by hand. 15 Ensure the fuel oil tank is filled with fuel oil.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 55 of 56

No 1 2

3 4

Description Consult Manufacturer's instruction manual for start-up procedure of engine. Regular observations should be made of temperatures, lube oil pressure, speed regulation, vibration, etc. Ensure whether noise exceeds specified limits. Hot check of the coupling alignment is performed, if necessary.

3.14 ROTARY STOP VALVES No Description 1 Seals between rotor axis and side plates are of the specified material. 2 Ensure that the gas purge of seals is functioning, if applicable, before solids are introduced into the valve. 3 Ensure correct alignment of the rotor in the housing. 4 The system leading to the valve for absolute cleanliness to avoid damage by foreign matter during start-up operation. 5 Ensure the chain drive is secure, if applicable. 6 Ensure presence of a shear pin, if applicable. 7 Trial run while empty.

Yes

Yes

No

No

Remarks

Remarks

3.15 EXTRUDERS 3.15.1 Since construction details and auxiliary equipment can vary widely from Manufacturer to Manufacturer, it is important to consult the Manufacturer's instruction manual for any additional pre-commissioning checks not mentioned below. 3.15.2 Extruders may be subdivided into small extruders for laboratories and large extruders for commercial production. No Description Yes No Remarks 1 Manufacturer's instructions, drawings, etc. shall be consulted. 2 Additional precommissioning procedures is specified by the Owner. 3 Ensure the entire lubrication system is clean and correctly installed in accordance with the flow diagram. 4 The quality, grade and levels of lubricants are in accordance with requirements.

PTS 12.02.01 FIELD INSPECTION PRIOR TO COMMISSIONING OF MECHANICAL EQUIPMENT

June 2015 Page 56 of 56

5

6 7 8 9

10 11

12

13

Ensure the entire cooling system is clean and correctly installed in accordance with the flow diagram. The equipment alignment and couplings for compliance with specified tolerances. Ensure the tightness of connections to specified torques. Safety valves are installed and set pressures is verified. Ensure the bearing housings are supplied with oil to correct levels or are properly greased. Ensure internals for absolute cleanliness. Safety devices are correctly installed and in accordance with data sheets and flow diagrams. All safety devices is functioning properly.

The initial run shall take place under the supervision and responsibility of the Manufacturer in accordance with the Manufacturer's instructions.

NOTE: Safety devices which cannot be checked when the equipment is not running should be checked during the initial run.