Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-061-1730-0520S_0_0040
Limited Liability Company
Nghi Son, Vietnam
Rev. 0

Employer Contract No.: Contractor JOB Code: Date: 23/DEC/16

Detail Commissioning Procedure for

061-A-301 (Recycle Gas Compressor)
Unit.: 061
Unit Abbreviation: PPU
Rev Date Page Description Prepared by Checked by Approved by
0. 02 Original Mostafa
29/DEC/2016
Refaat

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by

NSRP Mostafa Refaat
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 2 of 8

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

CONTENTS

1. Application…………………………………………………………………..1
2. Field Test Running Procedure ……………………………………………1
2-1. Preparation before operation……………………………………………1
2-2. Confirmation of the rotating direction…………………………………..4
2-3. Break in operation (No Load Operation)……………………………....4
2-4. Cleaning operation ………………………………………………………5
2-5. Pressurizing operation…………………………………………………...5
2-6. Continuous operation…………………………………………………….7
3. Measuring……………………………………………………………………8
4. Instruments and Materials to be Prepared……………………………….8
5. Others………………………………………………………………………...9
Attachment -1 ……*Temporary Suction Filter drawing (1st & 2nd stage).
Attachment -2…….*Time Schedule for Pressurizing & Continuous Operation.
Attachment -3…….*Recommended Time Schedule for Process Gas Operation.
Attachment -4…….*Field Test Running Schedule.
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 1 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

1. Application
This procedure applies to the test running at job site of the 061-K-301 Recycle Gas
Compressor (Model: J4D250-2M).

2. Field Test Running Procedure

GENERAL NOTICE:
Test running shall be conducted in accordance with the Instruction herein and supervising
From JSW.

2.1 Preparation before operation

(1) After completion of the installation and confirmation on the Compressor that
There is no irregularity, test running of the compressor shall be performed in the
Following order.
(2) Detail procedure and operation duration at each step may be subject to Re-arrange
depending on the existing conditions and referring Attachment-4
"Field Test Running Schedule".
Supervisor will make adjustment, if necessary.
(3) NOTICE
All personnel who will attends to test running should;
-1. Know the meaning of "Safety First"
-2. Read safety instruction in the operation and maintenance manual.
-3. Have safety equipment, hear protector, safety cap, safety shoes, Etc.
-4. Not touch Motor ON/OFF switch without a permission of Supervisor.
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 2 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

(4) Prior to starting the operation, field operators who must operate and switch the
Motor under supervising of JSW should be qualified.
Other personnel should be for only assistance of the qualified operator.
(5) An electrical operator who should be responsible for the complete power off the
Main motor at MCC should also be qualified.
(6) If main motor solo-run is required, the purchaser should execute before
Compressor test running.

2-1 .Items to be checked and confirmed in the presence of Supervisor.

(1) Make cleaning of the area for operation. Confirm that there is no oil on the access
area.
(2) Confirm that safety interlock system has been well prepared.
NOTICE
Particularly, barring devise interlocking (to be de-coupled at Starting) is important.

(3) Confirm that the utilities to be used for test running are available and it supply
conditions are in compliance with the data sheet and specification.
(4) Supply cooling water to compressor jackets, lube oil cooler And each stage gas
Coolers. Vent air accumulation and Confirm that water is running normally.
(5) Confirm that oil flushing of lube oil line is completely finished.
(6) Completion of cleanliness should be judged by supervisor.

Criterion: Check oil filter cartridge and confirm if no other Particle is on cartridge and filter
Casing.
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 3 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

NOTE: Ultrasonic cleaning is necessary for sufficient cleaning of filter than 25μ, m oil filter
(40 μ, m oil filter in this case) is applied to the compressor, and ultrasonic cleaner shall be
prepared at oil Flushing work.
If ultrasonic cleaner is not available, then prepare paper filter which is throwaway type
instead of ultrasonic cleaning oil Flushing is completely finished.

(7) Confirm that specified lubricants are filled.

(See "Lubricant List") Doc. No.: VP2158- 202-A-751 (LTC130111-06)

NOTICE: Oil level should be higher than level gauge centerline.

(8) Remove the suction piping for each stage and set temporary filters supplied by JSW to
The suction opening of each stage Cylinder.

Detail drawings of temporary filter are attached. Attachment-1

(9) Confirm cylinder valves are set correctly on each suction and discharge valve port.
(10) Remove the safety valves, gas pressure gauges and gas thermometers for each stage.
(11) Confirm Instrument Air supply and valve un-loaders on/off are well activated.

Method: Confirm indicator, if arranged.

Confirm sound On-Off (Air in /Air exhaust)
(12) Fully open by-pass valves (on 2D-1S by-pass line).
Also fully open each drain valves.
(13) Switch-on lube oil pumps motor for 3 seconds running and then switch-off.
Confirm pump rotation direction and others. If no abnormality has been observed, lube
Oil pump motor should be started for pre-lubrication.
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 4 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

(14) Turn the compressor with Barring Devise and make turning more than 5 turns and
Confirm the rotation is normal.
WARNING
After completion of turning, Barring Devise should be removed from flywheel and
Return to bar holder on flywheel cover.
After completion of turning, barring devise shall be de-engaged from flywheel and
Return back to applied position.

2-2. Confirmation of the rotating direction

Momentary switch on the main motor and confirm that the rotating direction of
Compressor.
Direction of CW seeing from motor opposite load Side is acceptable.

2-3. Break in operation (No load operation)

(1) Operating time
Standard step: 30 (sec), 3 (min), 10 (min), 20 (min) and 60 (min)

NOTICE; at starting for every steps, valve un-loader should be 0 %, and then step up to
50 and 100 % after starting.

(2) Stop operation at each step and inspect the heating condition of each bearing and
Crosshead shoe. Compare with the JSW shop running test records and if there is
Nothing unusual, extend the operating time to a maximum of 60 minutes.
(3) During operation, pay attention to abnormal noise, vibration and movement of
Motor ammeter.
 Employer Doc. No.
Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 5 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

2-4. Cleaning operation

(1) Watching the operating condition of various sections, execute "Cleaning

operation" of piping (main gas piping, by-pass piping, drain piping, safety valve

piping and gas pressure gauge piping/tubing), starting from lower stages.

(2) Hammer, if necessary, the piping thoroughly during the cleaning operation.

Supervisor should check and confirm the cleanness.

(3) After checking the cleanliness of 2nd suction piping, install piping, safety valves,

discharge check valve, gas pressure gauges and thermometers from lower

stages.

(4) The temporary filter of 1st suction should remain attached to the cylinder opening

during cleaning operation.

NOTE:

Suction piping should be cleaned well before test operation because it cannot be

Cleaned with this compressor.

2-5. Pressurizing operation

After completion of cleaning operation, perform pressurizing operation according to the

Followings.
 Employer Doc. No.
Rev. 0
NSRP Complex Project
Title: Detail Commissioning Procedure for 061-A-301 Contractor Doc. No.
6 of 9
(Recycle Gas Compressor) S-061-1730-0520S_0_0040

Pressurizing Operation with Nitrogen

WARNING

Never use process gas (Hydrocarbon Gas) for the pressurizing operation.

Pressurizing Step Attachment – 2

Pressurize by throttling the manual valve on 2D-1S by-pass line.

1. Assemble the suction gas piping before the operation.

2. Charge Nitrogen at 1st Suction before starting to be around 0.05MPag.

3. Start under 0 % valve un-loader. And if no abnormality has been observed, shift up load

to N2 mode (N2 mode = 1st:50% + 2nd: 100% load).

4. And then, re-charge Nitrogen and maintain 1st suction pressure to be around 0.05MPag.

5. Pressuring steps are as following:

Remarks

*1). 2D-1 S by-pass valve: Fully open

*2). Pressurize by means of 2D-1 S by-pass valve: Gradually choke

Employer Doc. No.

Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 7 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

NOTE

1. This operation shall be carried out in accordance with supervisor’s Advice taking

account of discharge pressure and temperature balance.

2. If discharge temperature raises over 145 °C at 1st stage, 140 °C at 2nd stage stop

operation.

3. Above pressurizing steps shows a reference case. If it is difficult to operate at site,

supervisor of JSW may modify and/or skip the step(s) according to actual operating

condition.

4. For depressurizing for stoppage compressor at each steps, use purge valve.

Do not open by-pass valve before full de-pressurizing.

2-6. Continuous operation

If no abnormality has been observed during pressurizing operation, execute continuous

operation with [ ] Dry Air or [X] Nitrogen or [ ] Process Gas.

• Standard time: 3 - 4 hrs. Attachment -2

After continuous operation,

(1) Remove the frame cover and inspect bearings and driving parts from outside.

(2) Remove the cylinder cover and inspect the condition of the cylinder.

(3) In case any abnormality is observed, inspect and adjust the abnormal section as

Employer Doc. No.

Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 8 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)
necessary.

(4) The compressor shall be accepted by the customer if no abnormality has been

Observed.

3. Measuring

Measure the following reading during and after pressurizing and continuous

Operations and compare them with the design conditions.

Items to be measured and criteria are attached.

(1) Power (if required)

The compressor break-horsepower shall be obtained by the motor input and motor

Efficiency data.

(2) The pressure and temperature of gas, lube oil and cooling water.

(3) Vibration.

(4) Functional confirmation of alarm and interlock, where applicable (Pressure alarm

& Shutdown, etc.)

(5) Others, as applicable

4. Instrument and Materials to be prepared

The following instrument and materials shall be prepared by the purchaser.

(1) Gas (Nitrogen) for field test running

(2) Lube Oil (Initial charge 380L I 1 unit)

(3) Flushing Oil (Initial charge 380L I 1 unit)

(4) Other, as applicable

Employer Doc. No.

Rev. 0
NSRP Complex Project

Contractor Doc. No. Page 9 of 9

Title: Detail Commissioning Procedure for 061-A-301
S-061-1730-0520S_0_0040
(Recycle Gas Compressor)

5. Others

(1) After the test running is completed, replace the lube oil by new

One.

(2) Spare parts shall be checked in presence of the customer for

Items and quantities against the SPARE PARTS LIST and

Accepted thereon.

(3) For pressurizing operation by Process Gas,

Time Schedule Attachment-3 is recommendable.