Field Commissioning Form
1.0 Package Datasheet
UNIT NUMBER: REPORT DATE:
1.1 CONTACT
Customer: Customer Contact:
Customer Office: Contact Title:
Contact eMail:
Contact Phone:
Valerus Office: Valerus Contact:
Contact Title:
Contact email:
Contact Phone:
1.2 SITE
Country: Closest City:
Offshore/Onshore: First Arrived:
Producing Field: First Run-SAT:
Providence/Area: First Loaded:
Platform/Location: Performed By:
1.3 ENGINE
Engine Make: Engine Hours:
Engine Model: Fuel Type:
Engine Serial.: Ignition Type:
Engine Spec/Arr: Fuel Regulator First:
Maximum Speed: Fuel Regulator Final:
Maximum Power: Optional Equipment:
1.4 COMPRESSOR
Compressor Make: Maximum Speed:
Compressor Model: Maximum Power:
Compressor Serial: Number of Throws:
1.5 COOLER
Cooler Mfg: IC2 Design Temp:
Cooler Model: IC2 Inlet Flange:
IC1 MAWP: IC2 Outlet Flange:
IC1 Design Temp: AC MAWP:
IC1 Inlet Flange: AC Design Temp:
IC1 Outlet Flange: AC Inlet Flange:
IC2 MAWP: AC Outlet Flange:
1.6 PRESSURE RELIEF VALVES
PRV 100 Location: PRV 301 Location:
PRV 100 Size: PRV 301 Size:
PRV 100 Setting: PRV 301 Setting:
PRV 101 Location: PRV E100 Location:
PRV 101 Size: PRV E100 Size:
PRV 101 Setting: PRV E100 Setting:
PRV 201 Location: PRV E101 Location:
PRV 201 Size: PRV E101 Size:
PRV 201 Setting: PRV E101 Setting:
1.7 COMPRESSOR CYLINDERS
Throw 1 Throw 2
Cylinder 1 Bore: Cylinder 2 Bore:
Cylinder 1 Stage: Cylinder 2 Stage:
Cylinder 1 Serial: Cylinder 2 Serial:
Cylinder 1 MAWP: Cylinder 2 MAWP:
Cylinder 1 Action: Cylinder 2 Action:
VVCP Equiped: VVCP Equipped:
Current VVCPSet: Current VVCPSet:
Throw 3 Throw 4
Cylinder 2 Bore: Cylinder 4 Bore:
Cylinder 2 Stage: Cylinder 4 Stage:
Cylinder 2 Serial: Cylinder 4 Serial:
Cylinder 2 MAWP: Cylinder 4 MAWP:
Cylinder 2 Action: Cylinder 4 Action:
VVCP Equipped: VVCP Equipped:
Current VVCPSet: Current VVCPSet:
Throw 5 Throw 6
Cylinder 1 Bore: Cylinder 1 Bore:
Cylinder 1 Stage: Cylinder 1 Stage:
Cylinder 1 Serial: Cylinder 1 Serial:
Cylinder 1 MAWP: Cylinder 1 MAWP:
Cylinder 1 Action: Cylinder 1 Action:
VVCP Equiped: VVCP Equiped:
Current VVCPSet: Current VVCPSet:
1.8 MISC DATA
Cooler Belts Part #: Qty. Required:
Fuel Filter Part #: Qty. Required:
Air Filter Part #: Manufacturer:
Engine Oil Filter Part #: Manufacturer:
Comp. Oil Filter Part #: Manufacturer:
Was the Unit grouted?
1.9 LIFTING
Total Package Weight: Overall Width:
With Transport Cage: Overall Length
Load Testing: Overall Height
Field Commissioning Form
2.0 Pre-Post Start-Up Checklist
Unit Number: Report Date:
2.1 COMPRESSOR
Yes No
Anchor bolts torqued? Value:
Crosshead support deflection checked?
Crosshead support torqued? Value:
Coupling torqued? Value:
Valve caps torqued? Value:
VVC Pockets torqued? Value:
VVC Pockets set?
Rod run out checked?
Crosshead clearances checked?
Piston end clearances checked?
Primed force feed lubrication system?
Lubricator Box Filled with oil?
Checked oil flow to crossheads with prelube pump?
Compressor pre-lube pump operational?
Compressor lubrication cycle time been set?
2.2 ENGINE
Yes No
Anchor bolts torqued? Value:
Crankshaft deflection checked?
Cold Alignment done?
Shipping protection removed from air filters?
ESM/ECM programmed with correct values?
Engine Timing Checked? Value:
Filled with oil?
Filled with coolant?
Pulley alignment checked?
Belt tension checked?
Checked oil flow to valve train with prelube pump?
2.3 SKID & PIPING
Yes No
Skid anchor bolts torqued? Value:
Fuel filter element inspected?
Clear of trash?
Flange bolts and U-bolts checked for tightness?
Unit ready for purge?
Coupling guards securely in place?
ASME coded vessels MAWP checked against PID?
PRV settings checked?
Valves positions for coolant and oil lines correct?
Valve position of drain and dump lines correct?
Block valves positions in suction lines correct?
Block valves positions in discharge lines correct?
Discharge check valve direction been checked?
Are all blind flanges removed?
Compressor and cooler be adequately purged?
Process system been leak checked?
Suction line been blown of debris?
Is a strainer installed in the suction line?
Are the sight glasses on the scrubbers open?
Block valve to the oil level controllers open?
2.4 SAFETY DEVICES
Yes No
Level control switch shutdowns checked?
Vibration switch shutdown checked?
Oil pressure shutdown set and checked?
High oil temperature shutdown set and checked?
Low & High suction pressure shutdowns set and checked?
Low & High discharge pressure shutdowns set and checked?
Stg 1 High temperature shutdown set and checked?
Stg 2 High temperature shutdown set and checked?
Stg 3 High temperature shutdown set and checked?
Have Pressure Transmitters been calibrated?
Have the compressor no flow shutdowns be checked?
Supply pressure to the level controllers checked and set?.
2.5 COOLER
Yes No
Fan blade torque checked? Value:
Cooler section MAWP matches P&ID?
Set screws in bearings torqued?
Clear of trash?
Field Commissioning Form
2.0A Pre-Post Start-Up Checklist - Older Units or Units in Idle for duration of 12+ Months
Unit Number: Report Date:
2.1 COMPRESSOR FRAME
Yes No
Check the crankshaft for rust
Check the pistons, piston rods and crosshead for rust
Ensure the oil pump spins (by hand via crankshaft)
Check the general condition of the rod packing
Check (and probably replace) the frame oil filters
TBD
TBD
2.2 ENGINE
Yes No
Check the engine crankshaft for rust
Borescope the combustion chambers for rust
Check the spark plugs for rust
Pull the valve covers and check the intake/exhaust valve areas for rust
Check the cam shaft for rust
Check the engine turbocharger compressor and turbine wheels
for rust and ensure it free spins
Check the water pumps and make sure they’re not locked up
Check the general condition of all of the sensors/transmitters and wiring
Check (and probably replace) the engine oil filters
TBD
TBD
2.4 SAFETY DEVICES
Yes No
PSV's checked for Debris or blockage
TBD
TBD
2.5 COOLER
Yes No
Cooler Belt checked for damage or dry rot
TBD
TBD
Field Commissioning Form
3.0 Engine Checklist - Initial Test A
Unit Number: Report Date:
3.1 COUPLING ALIGNMENT & BASE DEFLECTION
POSITION 0˚ 180˚ Total
RADIAL, VERTICAL 0.000 0.000 0.000 -005" or +.005 Max.
RADIAL, HORIZONTAL 0.000 0.000 0.000 -005" or +.005 Max.
AXIAL, VERTICAL 0.000 0.000 0.000 -005" or +.005 Max.
AXIAL, HORIZONTAL 0.000 0.000 0.000 -005" or +.005 Max.
Hot Alignment
THRUST, ENGINE 0.000 0.000 0.000 Free Floating
THRUST, COMPRESSOR 0.000 0.000 0.000 Free Floating
DIAL OR LASER? DIAL
2 same signs subtract example: -0.010 & -0.005 = 0.005
2 opposite signs add example: -0.010 & + 0.005 = 0.015
0.000 0.000
Soft Foot
ENGINE
0.000 0.000
Must not be more then .002” Cat 3600 – Wauk 12VHP & UP
Must also do Web Deflection
0.000 0.000
Soft Foot
COMPRESSOR
0.000 0.000
Must not be more then .002” GE Frame D - Ariel K/T & Up
Must also do Web Deflection
ALIGNMENT NOTES:
Field Commissioning Form
3.0 Engine Checklist - Second Test B
Unit Number: Report Date:
3.1 COUPLING ALIGNMENT & BASE DEFLECTION
POSITION 0˚ 180˚ Total
RADIAL, VERTICAL 0.000 0.000 0.000 -005" or +.005 Max.
RADIAL, HORIZONTAL 0.000 0.000 0.000 -005" or +.005 Max.
AXIAL, VERTICAL 0.000 0.000 0.000 -005" or +.005 Max.
AXIAL, HORIZONTAL 0.000 0.000 0.000 -005" or +.005 Max.
Hot Alignment
THRUST, ENGINE 0.000 0.000 0.000 Free Floating
THRUST, COMPRESSOR 0.000 0.000 0.000 Free Floating
DIAL OR LASER? DIAL
2 same signs subtract example: -0.010 & -0.005 = 0.005
2 opposite signs add example: -0.010 & + 0.005 = 0.015
0.000 0.000
Soft Foot
ENGINE
0.000 0.000
Must not be more then .002” Cat 3600 – Wauk 12VHP & UP
Must also do Web Deflection
0.000 0.000
Soft Foot
COMPRESSOR
0.000 0.000
Must not be more then .002” GE Frame D - Ariel K/T & Up
Must also do Web Deflection
ALIGNMENT NOTES:
Field Commissioning Form
4.0 Engine Checklist
Unit Number: Report Date:
4.1 CRANKSHAFT WEB DEFLECTION
Condition: Cold Web Deflection - Engine
Throw
Pos 1 2 3 4 5 6 7 8
1 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
2 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
3 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
4 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
5 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Condition: Cold Web Deflection - Compressor
Throw
Pos 1 2 3 4 5 6
1 0.000 0.000 0.000 0.000 0.000 0.000
2 0.000 0.000 0.000 0.000 0.000 0.000
3 0.000 0.000 0.000 0.000 0.000 0.000
4 0.000 0.000 0.000 0.000 0.000 0.000
5 0.000 0.000 0.000 0.000 0.000 0.000
Field Commissioning Form
5.0 Compressor Checklist
Unit Number: Report Date:
5.1 PISTON ROD RUN OUT CHECK
Cylinder Last
Throw Stage Vertical Horizontal
Size Checked
1 0.000 inch 0.000 inch
2 0.000 inch 0.000 inch
3 0.000 inch 0.000 inch
4 0.000 inch 0.000 inch
5 0.000 inch 0.000 inch
6 0.000 inch 0.000 inch
5.2 PISTON END CLEARANCES CHECK
Cylinder Last
Throw Stage Crank end Head end
Size Checked
1 0.000 inch 0.000 inch
2 0.000 inch 0.000 inch
3 0.000 inch 0.000 inch
4 0.000 inch 0.000 inch
5 0.000 inch 0.000 inch
6 0.000 inch 0.000 inch
5.3 CROSSHEAD CLEARANCES CHECK
Cylinder Last
Throw Stage Upper Lower
Size Checked
1 0.000 inch 0.000 inch
2 0.000 inch 0.000 inch
3 0.000 inch 0.000 inch
4 0.000 inch 0.000 inch
5 0.000 inch 0.000 inch
6 0.000 inch 0.000 inch
5.4 DISTANCE PIECE-CYLINDER SUPPORT DEFLECTION
Cylinder Last
Throw Stage Distance Piece Cylinder
Size Checked
1 0.000 inch 0.000 inch
2 0.000 inch 0.000 inch
3 0.000 inch 0.000 inch
4 0.000 inch 0.000 inch
5 0.000 inch 0.000 inch
6 0.000 inch 0.000 inch
** Pre-Load 0.002"- 0.005", Maximum Pulldown 0.001"
Field Commissioning Form
6.0 Instrumentation Checklist
Unit Number: Report Date:
6.1 SHUTDOWN / FUNCTIONALITY CHECKS
Annunciator Unit of Test Result Checked by Checked by
Tag ID Class Device Description Design Set Point
Channel Measure Pass / Fail VCS Customer
PSL2010 1 C LOW SUCTION PRESSURE 50 10 PSI Pass
PSL2020 2 C LOW 1ST STAGE DISCHARGE PRESSURE 190 130 PSI Pass
PSL2040 3 C LOW 2ND STAGE DISCHARGE PRESSURE 560 400 PSI Pass
PSL2060 4 C LOW 3RD STAGE DISCHARGE PRESSURE 1150 800 PSI Pass
PSL1001 5 B1 LOW FUEL GAS PRESSURE 30 15 PSI Pass
PSL1002 6 B1 LOW ENGINE OIL PRESSURE 50 25 PSI Pass
PSL1101 7 B1 LOW COMPRESSOR OIL PRESSURE 50 25 PSI Pass
PSL1003 8 B1 LOW ENGINE WATER PRESSURE 12 5 PSI Pass
PSL1004 9 B1 LOW AUX WATER PRESSURE 20 5 PSI Pass
FSL1102 10 B1 LUBE NO-FLOW (STROKES PER MINUTE) 12 120 SEC Pass
PSL1005 11 B1 LOW ENGINE MANIFOLD PRESSURE 3 -10 HG Pass
LSL2010 12 C LOW 1ST STAGE LIQUID LEVEL FIXED 5% FLOAT Pass
LSL2030 13 C LOW 2ND STAGE LIQUID LEVEL FIXED 5% FLOAT Pass
LSL2050 14 C LOW 3RD STAGE LIQUID LEVEL FIXED 5% FLOAT Pass
PSH2010 16 A HIGH SUCTION PRESSURE 50 70 PSI Pass
PSH2020 17 A HIGH 1ST STAGE DISCHARGE PRESSURE 190 275 PSI Pass
PSH2040 18 A HIGH 2ND STAGE DISCHARGE PRESSURE 560 650 PSI Pass
PSH2060 19 A HIGH 3RD STAGE DISCHARGE PRESSURE 1150 1250 PSI Pass
PSL1001 20 A HIGH FUEL GAS PRESSURE 30 15 PSI Pass
PSH1005 22 A HIGH ENGINE MANIFOLD PRESSURE 3 10 PSI Pass
LSH1001 23 A HIGH FUEL GAS SCRUBBER LIQUID LEVEL FIXED 20% FLOAT Pass
LSH2010 24 A HIGH 1ST STAGE SCRUBBER LIQUID LEVEL FIXED 20% FLOAT Pass
LSH2030 25 A HIGH 2ND STAGE SCRUBBER LIQUID LEVEL FIXED 20% FLOAT Pass
LSH2050 26 A HIGH 3RD STAGE SCRUBBER LIQUID LEVEL FIXED 20% FLOAT Pass
LSL1001 28 A LOW ENGINE OIL LEVEL FIXED 85% FLOAT Pass
LSL1101 29 A LOW COMPRESSOR OIL LEVEL FIXED 85% FLOAT Pass
LSL1002 30 A LOW ENGINE WATER LEVEL FIXED 95% FLOAT Pass
VSH1001 32 A HIGH ENGINE VIBRATION 1 1 Turn CW Pass
VSH1101 33 A HIGH COMPRESSOR VIBRATION 1 1 Turn CW Pass
TSH2020 35 A HIGH 1ST STAGE DISCHARGE TEMPERATURE 290 310 °F Pass
TSH2040 36 A HIGH 2ND STAGE DISCHARGE TEMPERATURE 260 280 °F Pass
TSH2060 37 A HIGH 3RD STAGE DISCHARGE TEMPERATURE 230 250 °F Pass
TSH1001 39 A HIGH ENGINE OIL TEMPERATURE 180 210 °F Pass
TSH1002 40 A HIGH ENGINE WATER TEMPERATURE 190 220 °F Pass
TSH1003 41 A HIGH TURBO WATER TEMPERATURE 130 165 °F Pass
PSL-1006 47 ESD LOW MASTER PANEL AIR PRESSURE 90 50 PSI Pass
ESD ESD ESD EMERGENCY STOP LOCAL PUSH NA BUTT Pass
Remark
* Class A =Point is always armed
* Class B1 =Point is armed after 3 minute Timer "Reset" VFS Representative Customer Representative
* Class C =Point is armed once condition has overcome set point
COMMISSIONING PROCEDURE
COMPLETE ALL PRE-COMMISSIONING PROCEDURES BEFORE CONTINING WITH STARTUP
UNIT NUMBER: REPORT DATE:
INSPECT INSTALLATION OF UNIT
INDICATE TYPE OF CHAT ROCK OR IF CONCRETE WHAT
FOUNDATION CONCRETE TYPE OF GROUT EPOXY OR CEMENT
SUPPORT OF OFF SKID
PIPING
FLANGE ALIGNMENT OF
INLET AND DISCHARGE
PIPING TO
COMPRESSOR
PACKAGE FLANGES
INSPECT LUBE AND
COOLANT SUPPLY
FOLLOW OEM CHECKLISTS ENGINE AND COMPRESSOR FOR INITIAL COMMISSIONING CHECKS AND
RECORD RESULTS
STARTUP PROCEDURE AFTER COMPLETION OF STARTUP AND COMMISSIONING CHECKS
1. OPEN BLOWDOWN AND BYPASS
2. OPEN SUCTION AND DISCHARGE BLOCK OR CONTROL VALVES
3. PURGE UNIT
4. SET DESIRED SPEED (ENGINE DRIVEN) MINIMUM 750 RPM
5. SET PANEL TIMER, INITIATE START TO PRELUBE AND START UNIT
6. WHILE UNIT IS WARMING UP TO OPERATING TEMPERATURE, INSPECT FOR LEAKS ON UTILITY
AND PROCESS SYSTEM, LISTEN FOR ANY UNUSUAL NOISE
7. ALLOW UNIT TO WARM UP TO OPERATING TEMPERATURE PRIOR TO CLOSING BYPASS SLOWLY
TO LOAD UNIT
8. ONCE UNIT IS LOADED CONTINUE TO MONITOR FOR LEAKS AND UNUSUAL NOISES
9. ON COMPLETION OF SUCCESSFUL ACCEPTANCE RUN, COMPLETE HOT ALIGNMENT, HAVE
CUSTOMER SIGN OFF ON UNIT FOR PERFORMANCE AND OPERATION
Field Commissioning Form
8.0 CONDITION MONITORING
Unit Number: Report Date:
8.1 MONITORING POINTS
Point Monitored 1 Hr 4 Hrs 8 Hrs 12 Hrs 24 Hrs
Compressor RPM:
Ambient Temperature F:
Flow Rate mmscfd:
Inlet Pressure:
Inlet Temperature:
Stg1 Discharge Pressure:
Stg1 Discharge Temperature:
Stg2 Discharge Pressure:
Stg2 Discharge Temperature:
Stg3 Discharge Pressure:
Stg3 Discharge Temperature:
Outlet Discharge Temperature:
Compressor Oil Pressure:
Compressor Oil Temperature:
Engine Timing BTDC:
Engine Oil Pressure:
Engine Oil Temperature:
Engine Manifold Pressure:
Engine Water Temperature:
Auxiliary Water Temperature:
Main Fuel Pressure:
Comments:
