Commissioning of the compressor after major repair

The process should include activities such as purging, replacement, sampling, airtightness testing, switching of processes, and recording of various data during commissioning. The commissioning plans are divided into single-unit commissioning and integrated commissioning； Generally, the single-unit test is prepared by the construction unit, while the integrated test is prepared by the production department and approved by relevant authorities.

Given that your title refers to testing after a major overhaul of the compressor, it seems it has already been in operation before; therefore, it would be safer to discuss the testing plan together as part of the process evaluation:)

Based on my understanding of your request, your equipment is undergoing trial runs after a major repair, and this can be carried out in collaboration with the process engineers. Conduct a single-unit test run of the compressor. During testing, some plans or standardized procedures can be established to prevent oversights during the process.

After the major repair, the construction unit shall prepare a commissioning plan; the process aspects should be coordinated during commissioning, and once the requirements are met, it shall be handed over to the user unit.

For maintenance, process coordination for the areas where equipment maintenance is carried out is provided, along with a commissioning plan prepared for the maintenance work.

If the compressor is being installed for the first time, the manufacturer, process equipment, and instrumentation must work together to determine the commissioning procedure. For a compressor that is already in operation and has undergone major repairs, it is generally connected directly to the driving mechanism, and startup is carried out in accordance with the compressor startup procedures; no separate testing is required. At this time, the relevant maintenance teams need to ensure service continuity.

The commissioning plan should be prepared through thorough inspection, and the process parameters must be coordinated accordingly. After starting up, the process parameters (such as temperature and pressure) should be recorded in detail; in particular, during the compressor pressure-rise testing, it is essential to ensure that the temperature and pressure remain within the specified limits. The inspection and testing time for specific equipment should be determined by the maintenance team.

In the case of a major overhaul, a comprehensive commissioning plan should be prepared based on the process specifications (it is the installation company that provides the commissioning plan for installation work). The test run is led by the process team.

The process system should have operational procedures and commissioning plans related to the process; commissioning plans prepared by maintenance or installation units cannot be used as substitutes. The two parties should communicate with each other and review the plans together to ensure safe and proper commissioning.

The test run is planned by the process team, with maintenance providing support. The commissioning plan after major repairs can be prepared with reference to the original commissioning plan.

First conduct a no-load test, then a load test! First conduct a no-load test, then a load test!

For compressors installed for the first time, it is necessary for the manufacturer, process equipment, and instrumentation to work together to determine the procedures for commissioning and mechanical performance testing; first, the drive motor is tested individually, and then the other components are tested one by one. The commissioning plan is generally prepared by the installation unit. However, since the workshop equipment managers are familiar with both the equipment and the manufacturing processes, at our facility, the commissioning plans are all prepared by these managers and submitted to relevant departments (such as the Maintenance Department) for review before being put into action. For compressors that are already in operation and have undergone major repairs, they are generally connected directly to the driving mechanism, and startup is carried out in accordance with the compressor startup procedures, without the need for separate testing. During the startup process, it is necessary to record the parameters of the unit’s shafting system as well as other process-related parameters; once the operation stabilizes after 2–4 hours, the unit can be integrated into the system. At this time, the relevant maintenance teams need to ensure service continuity.

Our factory is responsible for developing the process procedures, while the maintenance team handles the coordination tasks. The maintenance team determines that the commissioning is successful after the compressor has been running at full load for 72 hours

After the major repair of our plant, the plant’s mechanical department takes charge of organizing the production and operation units as well as the maintenance units to carry out trial operations. The commissioning plan is prepared by the production and operation unit, coordinated by the mechanical department, while the maintenance department is responsible for recording the parameters during the compressor’s trial operation and preparing the completion report ； I heard that in some organizations, the maintenance department is responsible for everything throughout the process, including testing, and hands the unit over to the user once it is operating properly.

The relevant standards should be checked; those such as API are quite detailed

The test run plan is prepared by the process team, while its implementation is carried out by the mechanical team

The commissioning plan must be prepared using process procedures, which include the sequence of starting up the equipment, the order in which materials are fed in, and the steps for operation and debugging; mechanical, electrical, and instrumentation aspects can only ensure proper operation. It concerns the rights and interests of Party A and Party B; Party A is the owner, and it carries out the tests using its own proven processes ； Party B is the maintenance party, and Party B has no right to touch the operating equipment; work can be considered complete only after approval from Party A. Now, in many petrochemical companies, maintenance work and process operations are separated, with even more detailed divisions of labor.