CENTAC C700 Start-Up Services Notes: (1) This packet includes: (a) the Centac Start-up form used by the Field Technician during start-up services; (b) the Installation Planning Checklist that is used prior to start up to assure the user is informed with regard to installation requirements and to assure the unit is ready for start-up. (2) Start-up services will be performed by a Field Service Technician. This service includes 5 days of start-up support and operator training.
CENTAC START-UP REGISTRATION FORM I. CUSTOMER INFORMATION CUSTOMER: ADDRESS : CITY : COUNTRY: ZIP CODE : CUSTOMER CONTACT: PHONE #: FAX #: II. COMPRESSOR INFORMATION MODEL #: SERIAL #: START-UP DATE: DESIGN DISCHARGE PRESSURE: III. MAIN DRIVER INFORMATION TYPE: MOTOR / TURBINE / ENGINE: SERIAL#: FRAME #: H.P.: VOLTS: AMPS: STYLE: S.F: TYPE OF MAIN DRIVER OIL / GREASE: MAIN DRIVER OIL / GREASE MEETS SPECIFICATIONS OF THE VENDOR: YES NO INSTRUCTION MANUAL ON SITE: YES NO MOTOR STARTER TYPE: MOTOR STARTER SERIAL NUMBER: TURBINE DRIVER STEAM SUPPLY PIPE BLOWN CLEAN: YES NO MAIN DRIVER ROTATION CHECKED AND VERIFIED CORRECT TO THE ROTATION ARROW ON THE COMPRESSOR GEAR CASE: YES NO IV. GENERAL INFORMATION (GROUT NOT REQUIRED ON CV UNITS) UNIT LEVEL AND GROUTED: YES NO FOUNDATION BOLTS TIGHT: YES NO INLET AIR FILTER LOCATION: INSIDE OUTSIDE INLET PIPE MATERIAL: INLET PIPE INSPECTED AND CLEANED: YES NO
IV. GENERAL INFORMATION (continued) CHECK VALVE INSPECTED: YES NO DESSICANT BAGS REMOVED FROM INLET & DISCHARGE: YES NO OIL SUMP INSPECTED AND CLEANED: YES NO TYPE OF COMPRESSOR OPERATING OIL: OIL MEETS SPECIFICATIONS OF THE INSTRUCTION MANUAL: YES NO COOLING WATER SUPPLY SOURCE: COOLING WATER INLET PRESSURE: OUTLET PRESSURE: AIR COOLERS HYDROTESTED: YES NO AIR COOLER HYDROTEST PRESSURE / TIME: CONTROL AIR (C.A.) SOURCE: C.A. PIPE MATERIAL: C.A. DRIP LEG: YES NO INSTRUMENT AIR (I.A.): I.A. PIPE MATERIAL: I.A. FILTER INSTALLED: YES NO ALL ELECTRICAL CONNECTIONS CHECKED: YES NO COMPRESSOR OPENED FOR INSPECTION: YES NO IF YES, DESCRIBE BRIEFLY CONDITION AS FOUND: V. COUPLING ALIGNMENT (NOT REQUIRED FOR CV UNITS) NOTE: Compressors with sleeve bull gear bearings MUST be on mechanical center; Motors with sleeve bearings MUST be on magnetic center; Turbines MUST be on mechanical center when spacing is checked and set; MOTOR ALIGNMENT SPACE BETWEEN SHAFTS: VERTICAL OFFSET: HORIZONTAL OFFSET: COUPLING FACE TO FACE OPEN AT BOTTOM; DRIVER HOT ALIGNMENT CHECKED: YES NO DRIVER DOWELED AFTER HOT ALIGNMENT CHECKED: YES NO
V. COUPLING ALIGNMENT (continued) ENGINE/GEAR BOX OR TURBINE / GEAR BOX RADIAL VERTICAL OFFSET: RADIAL HORIZONTAL OFFSET: ANGULAR VERTICAL OFFSET: ANGULAR HORIZONTAL OFFSET: ENGINE/ TURBINE VERTICAL OFFSET TO GEAR BOX: ENGINE / TURBINE HOT ALIGNMENT CHECKED: YES NO ENGINE / TURBINE DOWELED AFTER HOT ALIGNMENT CHECKED: YES NO TYPE COUPLING GREASE: COUPLING HAND-PACKED: YES NO EXCESS GREASE REMOVED FROM COUPLING: YES NO Vl. IMPELLER CLEARANCES NOTE: NOT REQUIRED IF THRUST BEARINGS COVER BOLTS ARE WIRED PRESSURE TIP CLEARANCES CHECKED: YES NO 1ST STAGE PRESSURE TIP CLEARANCE: 2ND STAGE PRESSURE TIP CLEARANCE: 3RD STAGE PRESSURE TIP CLEARANCE: 4 th STAGE PRESSURE TIP CLEARANCE : 5 th STAGE PRESSURE TIP CLEARANCE : ADDITIONAL STAGES: Vll. PROTECTIVE FUNCTION VALUES OIL PRESSURE: LOW OIL TEMPERATURE: HIGH OIL TEMPERATURE: 1ST STAGE VIBRATION: 2ND STAGE VIBRATION: 3RD STAGE VIBRATION: 4 TH STAGE VIBRATION : 5 TH STAGE VIBRATION: S1 DISCHARGE AIR TEMP: S2 DISCHARGE AIR TEMP: ACTUAL UNLOADED ACTUAL (LOADED) ALERT SHUTDOWN S3 DISCHARGE AIR TEMP: S4 DISCHARGE AIR TEMP: FINAL DISCHARGE AIR TEMP: LOW SEAL AIR SWITCH Shutdown Only
VlIl. CONTROLS CMC MIRCOCONTROLLER SYSTEM PRESSURE SETPOINT : MAX LOAD (HLL), AMPS : MINLOAD USER SETPOINT (TL), AMPS/ FT : INDEX ACCUMULATOR, FT : PROCESS SETPOINT, AMPS / FT : SURGE INDEX INCREMENT AMPS / FT : SURGE ASBORBER ENABLED : YES NO SURGE SENSITIVITY : INLET VALVE PRESSUSE MINLOAD (TL) MAXLOAD (HLL) BYPASS VALVE PRESSURE PB IT REP/SEC D SEC AUTO DUAL SETPOINTS RELOAD PRESSURE, % OF SETPOINT : UNLOAD POINT, BV % OPEN : UNLOAD DELAY TIMER, SECONDS : STARTING TIMER : COASTING TIMER : CT RATIO : MOTOR FAILURE TRIP ENABLE: YES NO INLET UNLOAD POSITION % : SETPT RAMP RATE, PRESS/SCAN : AUTO HOT START ENABLE : YES NO AUTO HOT START PRESSURE : INLET VALVE STROKED: YES NO BYPASS VALVE STROKED: YES NO CHECK VALVE INSPECTED: YES NO DESSICANT BAGS REMOVED FROM INLET & DISCHARGE: YES NO
IX. OTHER VALUES/FUNCTIONS OIL HEATER THERMOSTAT TEMPERTURE SETTING: OIL HEATER CONTACTOR CONTROLLED BY THERMOSTAT: YES NO OPERATING OIL TEMPERATURE : MAIN OIL PUMP PRESSURE AT OPERATING OIL TEMPERATURE: PRELUBE PUMP PRESSURE AT OPERATION OIL TEMPERATURE: LOW SEAL AIR PRESSURE SWITCH SHUTS OFF PRELUBE PUMP: YES NO NATURAL SURGE PRESSURE: WATER TEMPERTURE : RH % : INLET TEMPERTURE : SURGE SENSITIVITY CHECKED AND VERIFIED AT NATURAL SURGE: YES NO INSTRUMENT AIR PRESSURE: FULL LOAD AMPS: UNLOADED AMPS: ENGINE DRIVEN UNITS OVERSPEED TRIP SETPOINT: UNDERSPEED TRIP SETPOINT: ENGINE OPERATING SPEED: BULLGEAR SPEED (not to exceed rated design speed): OVERSPEED AND UNDERSPEED TRIPS VERIFIED: YES NO
X. OTHER VALUES/FUNCTIONS (continued) ADDED PROTECTIVE FUNCTIONS (specify) ALERT SHUTDOWN Xl. VALVE CALIBRATION INLET VALVE STROKED: YES NO BYPASS VALVE STROKED: YES NO INLET VALVE (MA OR PSI): BYPASS VALVE (MA OR PSI): Xll. ADDITIONAL INFORMATION INSTRUCTION MANAUAL ON SITE: YES NO CUSTOMER TRAINING REQUIRED: YES NO SPARE PARTS REQUIRED: YES NO RECOMMENDED SPARE PARTS LIST PROVIDED TO CUSTOMER: YES NO UNRESOLVED PROBLEMS: YES NO CUSTOMER INSTRUCTED TO FIRST CONTACT YOUR OFFICE FOR SERVICE OR WITH ANY PROBLEMS OR QUESTIONS: YES NO GENERAL : STARTUP LOCATION (IRCC, DISTRIBUTOR or DCC) SERVICE TECHNICIAN SIGNATURE: CERTIFICATION NUMBER: DATE:
Installation Planning Checklist Customer Name Customer Location Centac Model & Horse Power Centac Serial Number Date Date Date Date Check Order Complexity Level: 1&2 3&4 Attached a copy of this document to asset in Siebel. a:prestrt.doc 11/1/2011 FORM # RAW-2193 The proper installation of any CENTAC compressor is important for reliable operation. The following checklist is provided as a guide to conduct a PRE-INSTALLATION meeting with the people who will be responsible for the Centac's installation and operation. After review, the names of the Customer's Representative and Ingersoll-Rand Representative who conducted the review are to be inserted on page 1.
Installation Planning Checklist Delivery / Receipt Requirements DESCRIPTION 1. Review of GA drawings for weight, lifting requirements, dimensions 2. Review freight on board (FOB) shipping terms and responsibilities. 3. Review lifting & rigging equipment requirements 4. Customer trucking / off-loading requirements ( ex. low-boy for clearance) 5. Review all equipment & potential ship loose items. 6. Installation timeline & storage requirements 7. Plan equipment path. PRE-SHIPMENT INSTALLATION COMPLETED Equipment Layout Site Specifics DESCRIPTION 1. What is around? Describe environment. (Air, water, airborne particles) 2. The foundation should be checked for outside vibration before the machine arrives. 3. The machine is leveled to the specification in the Installation Guide. 4. The base must have full contact with the foundation and must be bolted to the foundation & grouted where required. PRE-SHIPMENT INSTALLATION COMPLETED 5. Leave at least 3' around the machine for maintenance. 6. Remind the customer that an overhead lifting device is strongly recommended for major maintenance. Must be load tested & certified.
Installation Planning Checklist 7. Insure the customer knows that the machine is prepared for 120 day storage if kept in a controlled environment. If the 120 days has expired, the machine must be inspected by an IR qualified Centac Service Technician. Advise the customer if the motor is not prepared for LTS. Does Long term storage need to be purchased? Safety Requirements DESCRIPTION 1. If climbing above 4 ft, a secure tie off point must be provided. 2. Provide the capability to lock out tag out all power sources. ( power, water, air) 3. Ingersoll Rand Technicians are provided with PPE. Identify site specific requirements. 4. Is there any site specific safety training? PRE-SHIPMENT INSTALLATION COMPLETED 5. Remind the customer that an overhead lifting device is strongly recommended. Must be load tested & certified. Installation Requirements DESCRIPTION 1. Inlet Air Filter Indoor or outdoor installation? For outdoor installation is filter 2- stage minimum with weather hood? Verify the filter will not be mounted near a cooling tower, steam vent, or in a location where it can draw in unwanted foreign substances? Is the filter mounted 6-8 FT above roof? PRE-SHIPMENT INSTALLATION COMPLETED
Inlet filter model number and flow capacity? 2. Inlet Pipe Is the pipe sized correctly for the Inlet CFM of the machine? Is the pipe made of non-ferrous material? Plastic pipe should be minimum Schedule 80. Verify all elbows are long-radius type. Total drop of filter and pipe should not exceed 0.3 PSI. The inlet pipe must be suitably flanged for 100% visual inspection for cleanliness. Distance to first elbow ( min 4 pipe diameters) Is there a spool piece installed at the inlet flange of the machine to facilitate maintenance? Does the pipe have a drip leg installed at its lowest point? Is the pipe supported properly? (Do not use the machine as support) 3. Discharge Pipe Does the pipe meet the minimum size pressure and temperature rating? Verify all elbows are long-radius type. Verify discharge pipe entry into main air header is on WYE angle (30-45 degree) not 90 degree tee Is the distance to the first elbow at least (3) pipe diameters? Is the pipe supported properly and does not rely on the machine flange for support? Is there a drip leg for moisture removal? Is there a block valve installed? Is there a safety relief valve installed between the check valve and the block valve? Is there a spool piece installed to facilitate maintenance? Is the discharge of the Centac isolated from other compressors? Installation Planning Checklist
Installation Planning Checklist What material is the pipe made out of? If this is a hot air discharge machine, an expansion joint must be installed. 4. Bypass Air Piping If this is a hot air discharge machine, an expansion joint must be installed. Verify all elbows are long-radius type. Is the pipe supported properly and does not rely on the machine flange for support? Is there a drip leg for moisture removal? Silencer exhausted must be mounted horizontal or raincapped Is there a spool piece installed to facilitate maintenance? Discharge back pressure from silencer must be 5psi or less Expanded metal recommended to be installed at the end of the silencer pipe to prevent large objects & animals from entering DESCRIPTION 5. Control Air Piping (CA) Minimum pipe size is 1/2" for first 50 FT. Increase pipe size 1/4" for every 50 FT. additional. Non-ferrous material If in a horizontal run mount CA connection on top of discharge pipe. Is drip leg installed in lowest point of pipe? Is the pipe connected at least 10 pipe diameters from the check valve and inside the block valve? 6. Instrument Air (IA) What is the auxiliary source for instrument air? Is the air source 10 CFM per stage @ 80-120 PSI? PRE-SHIPMENT INSTALLATION COMPLETED
Installation Planning Checklist Is the air source instrument quality? Instrument air dryer installed? Filter should be absolute filter capable of filtering to 5 microns. Non-ferrous piping material, minimum size 1/2". Is there a drip leg installed at the lowest point in the line? 7. Water System Source of cooling water? (city, well, river (filtered?), open tower, closed tower, water/glycol?) Does cooling water meet IR specification in the installation guide? Is cooling water to compressor filtered or strained? Is the piping sized correctly? Is the drop across the water manifold 10-12 PSI, maximum of 15 PSI? Is the water pressure at least 35 PSI and does not exceed 75 PSI? It is recommended a flow regulating valve Be installed in the water discharge line. Pipe casing vents to open drain or water return line It is recommended the casing vents have flow indicators installed in the vent lines. If closed loop system, are the vent lines piped back to discharge of the water system? Pressure and temperature gauges must be installed on water inlet and outlet? Will glycol be introduced to the system? If so, location of surge tank? What is the mixture of the gycol (50/50)? 8. Condensate Piping Are the traps piped to a nonpressurized open drain? Can you see the trap discharges?
Is there a trap bypass line installed? Do not pipe trap drains below any water level. 9. Power Source / Communication Other equipment on same feeder or transformer? Is the breaker correctly sized? Is there a separate breaker for control panel? Is a compressor main power disconnect installed within eyesight? Is Ethernet / modbus connection line available? Will equipment be controlled / monitored remotely? Panel mounted / remote starter? If remote starter, what is CT size? (ex. 100amp = 0->200CT ) For remote starter must have auxilary dry N.O. contact Installation Planning Checklist
Installation Planning Checklist After installation inspection is completed and form is attached to asset information. Reference materials to be used to answer questions about installation are: Customer Specific Drawings (found on customer site) Field Service Manual/ Operator's Manual Installation Guide Pre-Installation Meeting Signatures Customer Representative IR Account Manager/IRAC Salesman Installation Contractor Installation Inspection Meeting Signatures Customer Representative IR Account Manager/IRAC Salesman Installation Contractor Revised 1 November 2011 Document owner: Marketing Product Manager Published: Sales Library & irtechpubs 8