Factory inspection of compression unit

Spares and auxiliary systems – I think they’re actually not very useful even if they’re brought along. Compressors are supplied as spares when they’re purchased; they are then assembled and installed based on the operating conditions. There are purchase orders detailing the spares and auxiliary systems to be received, which are installed on-site and tested. After installation is complete, the compressor manufacturer will conduct tests on-site at the time of commissioning. Once the equipment is running properly, and after your staff have received adequate training, they can leave, and it’s then time for you to pay the remaining balance

Are relevant documents and mechanical operation tests not checked during the factory inspection?

It mainly involves mechanical property tests and overall machine performance tests; visual inspection isn’t very meaningful

During performance tests, are the relevant AIP standards used to determine whether the tests are successful? Is it necessary to open the bearing housing after the tests to check the condition of the bearings? I have not participated in such inspections, so I am not familiar with the exact procedures

API617 provides detailed specifications regarding performance tests. Here is a technical specification document prepared some time ago that you can refer to: 5. Inspection and Testing 5.1 General Requirements 5.1.1 The bidder is responsible for the inspection and testing. The tenderer has the right to conduct inspections at any time during equipment construction, as well as to witness mechanical operation tests, performance tests, and gearbox performance tests. The mechanical operation test prior to leaving the factory is witnessed on-site by the tenderer (7 persons) over a period of 2 weeks, with the costs borne by the bidder. 5.1.2 The bidder shall submit inspection procedures and inspection points for review. 5.1.3 The inspection shall be carried out by the tenderer or a representative designated by the tenderer. They have the right to enter factories, including those of subcontractors, to inspect the work in progress or witness equipment tests. The right to reject any equipment that does not meet the specifications or order requirements. 5.1.4 The bidder shall submit a detailed schedule for inspections and tests to the tenderer 6 weeks prior to the start of the testing procedures. 5.1.5 The bidder shall control all stages, including design, material procurement, construction, and assembly, in accordance with the requirements of the quality assurance manual approved by the tenderer. The quality control manual should include detailed procedures for testing and non-destructive testing, as well as the required qualifications for non-destructive testing operators. 5.1.6 The material tracking system shall include all major structural components. 5.1.7 The scope of non-destructive testing, as well as the procedures and contents for repeat acceptance tests, must be approved by the tenderer. 5.2 Test contents: The testing of the compressor skid will be carried out in accordance with the requirements of this standard and API Std 617, Edition 7. As a minimum requirement, each compressor skid is subjected to the following tests: ☆ Hydrostatic test ☆ Impeller overspeed test ☆ Seal leakage test ☆ Mechanical operation test. 5.3 Test reports and acceptance certificates: The bidder must submit complete reports for all tests, indicating any observed discrepancies found by the tendering party’s inspectors. If any of the tests performed are not accepted, modifications should be made and the tests repeated. Within 4 weeks after the delivery of the skid blocks, 4 sets of test certificates must be provided to the tenderer. 5.4 Hydrostatic testing: All pressure-bearing parts shall be subjected to hydrostatic testing at 1.5 times the maximum allowable operating pressure. The inspection and testing of pressure vessels are carried out in accordance with the requirements of Section I, Part VIII of ASME. 5.5 Impeller overspeed test: Each impeller shall be subjected to an overspeed test at a speed not less than 115% of the maximum continuous speed, for a duration of at least 1 minute. Unless approved by the tenderer, the impeller shall be subjected to a separate overspeed test. The speed test needs to be repeated until no new defects appear. 5.6 Mechanical operation test 5.6.1 The bidder shall submit to the tenderer at least 6 weeks prior to the scheduled first operation test detailed procedures for the mechanical operation test and all required optional operation tests, including the acceptance criteria for all monitoring parameters, for the tenderer’s review and verification. 5.6.2 The compressor shall be operated from zero to its maximum continuous speed in increments of approximately 10%, and run at the maximum continuous speed until the bearing metal temperature and shaft vibration have stabilized. 5.6.3 Increase the rotational speed to the maximum continuous speed and run it continuously for 4 hours. 5.7 Leak test: After completing the mechanical operation test, the compressor skid should be pressurized to the rated pressure using an inert gas for at least 1 hour, and leaks should be checked using soap or other approved methods. The gas leakage rate shall meet the requirements of API Std 617. 5.8 On-site acceptance testing 5.8.1 On-site acceptance testing is conducted separately for each unit, with the participation of the tenderer, the designer and bidder, as well as the variable frequency drive subcontractor. On the basis of its success, jointly sign the on-site acceptance report for each unit. 5.8.2 After on-site installation and commissioning are completed, the bidder shall be responsible for conducting a mechanical operation test of the complete set of units, including all systems and protection functions, for 24 consecutive hours. Verify that the mechanical components and installation of the complete unit are of good quality, with no abnormal vibrations, and no leaks of lubricating oil, CO gas, or air. 5.8.3 During on-site testing, the compressor flow rate and power consumption should be recorded and analyzed. 5.8.4 After the mechanical operation test, the bidder shall be responsible for conducting a full-load performance test for 72 consecutive hours. 5.8.5 Tests should be conducted under actual operating conditions, as closely as possible to normal operating conditions. 5.8.6 The purposes of the testing are as follows: ☆ To determine the efficiency of the entire plant. ☆ To assess the performance of the drive unit under actual field conditions. ☆ To identify the actual surge line under field conditions. 5.8.7 The bidder shall provide detailed field acceptance criteria in the bid document, which will be approved by the tenderer. 5.9 Plant Performance Tests 5.9.1 Compressor performance tests shall be conducted in accordance with the ASME power test standards, by carrying out PTCl0 Class II closed-loop tests on the compressor skids (one unit of each model). Six weeks before starting the tests, the bidder must submit a complete test procedure and schedule for the tenderer’s review. 5.9.2 Based on the test records, a speed curve shall be plotted from 50% to the maximum continuous operating speed in increments of 10%. The vertical axis of the curve represents the multi-pressure head, while the horizontal axis represents the flow rate. Draw the equal efficiency curves within the operating range, as well as the equal power curves at each operating speed.

Thank you so much. Are there any additional materials available? I would appreciate it if you could share them

Mainly mechanical property tests and overall machine performance tests