Page 373 - Improving Machinery Reliability

Chapter 8

Startup Responsibilities

Summary of Startup Preparations for Process Plant Machinery

A number of key elements are indispensable to ensuring successful commission-
ing of rotating machinery in process plants. These include the following mix of
mandatory and contingency actions.

1. Develop equipment lists for general reference and progress tracking.
2. Assign mechanics during the erection period to observe or execute:
a. Machine assembly:
Lifting and handling procedures.
Cleaning, inspection, and installation of bearings and seals.
Checking and recording critical clearances, and pre-operation settings and
adjustments.
Full inspection of most centrifugal pumps.
Machinery-related instrument installation and adjustments.
b. Correct shaft alignment.
c. Parallelism and gaskets for major flange connections.
d. External flush systems cleanup.
e. Piping system cleaning for:
Compressors.
Turbines.
3. Set up training program for special machinery operation and repair:
a. Consider vendor service representatives, as available.
b. Use classroom instruction together with practical demonstrations.
c. Use contract or on-loan startup advisors as time permits.
d. Verify soundness of auxiliary systems, starting interlocks, and shut-down
protection alarms, and provide routine checking and trouble-shooting during
machinery operations.
e. Review vendor’s instruction books, cross-sectional drawings, and inspection
procedures. Verify completeness of records.
f. Expose mechanics to the same training as operators in such key subjects as:
Steam-turbine operation.
Centrifugal-compressor shaft seal system.
e Recognizing machinery distress.

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