Dri en 800

CAUTION: Based upon the publication date, this document may not contain the latest
guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
user’s specific case.
800 Inspection and Testing
Abstract
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This section discusses the purpose of and general principles for shop inspection and
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testing of drivers (and electric generators). It covers several quality-control tests,
giving general guidance on when the respective tests may be cost-effective and
appropriate.
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Contents Page
810 General Comments 800-2
820
830
840
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Nonwitnessed (Required), Witnessed, and Observed Tests
Motor and Generator Inspections
Motor and Generator Tests
800-2
800-3
800-5
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850 Reciprocating I/C Engine Inspections 800-6
860 Reciprocating I/C Engine Tests 800-7
870 Combustion Gas Turbine Inspections 800-8
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880 Combustion Gas Turbine Tests 800-10

881 General Information
882 Factory Testing
883 Field Tests
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890 Special-Purpose Steam Turbine Test Checklist 800-15

Revision History 800-20
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April 2011 (E)  1989–2011 Chevron U.S.A. Inc. All rights reserved. 800-1
800 Inspection and Testing Driver Manual
810 General Comments

Inspection at the point of manufacture is normally done by the Quality Assurance
(QA) section of the Purchasing Department or by an inspector contracted by
Purchasing QA to inspect the equipment. The purpose of shop inspection is to
ensure that the equipment meets specification and order requirements, displays good
workmanship, and is free from significant defects or damage before it is shipped. A
key reason for inspection and testing is to avoid problems during the at-site equip-
ment startup.
The degree of inspection varies widely. Small, low-speed drivers in noncritical
service which drive equipment in nonflammable/nontoxic service usually do not
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warrant the expense of any shop inspections. Large, high-speed drivers in critical
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service, on the other hand, may call for several inspection visits during manufac-
ture. Inspection may also involve a Company machinery specialist and/or a mechan-
ical or electrical specialist from the client’s maintenance organization. Typically, the
machinery engineer or Company specialist would always witness mechanical run or
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performance tests for large machines, and one of them might also witness:
• Final rotor balancing for high-speed motors, generators, and gas turbines
• Final assembly
•
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Dismantling after mechanical or performance testing and reassembly
820 Nonwitnessed (Required), Witnessed, and Observed Tests

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Inspection and testing of a driver or parts of a driver by the manufacturer may be
nonwitnessed, witnessed, or observed:
Nonwitnessed (Required) means that the manufacturer does the required test and
certifies the results; the test results are reviewed by the Purchaser’s inspector if the
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driver is inspected. Production is not stopped as it is for “witnessed” tests.

Witnessed means that a hold is applied to the production schedule and the test
carried out with the Purchaser’s inspector present. This may result in a double test.
The vendor will include in his bid a cost extra for witnessing a test.
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Observed means that the Purchaser requires notification of the test’s timing.
However, the test is performed as scheduled, and if the Purchaser’s inspector is not
present, the vendor may proceed with the test. A hold is not placed in the produc-
tion schedule. Because only one test is scheduled, the Purchaser’s inspector can
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expect to be in the factory longer than for a witnessed test, while debugging of the
driver or test stand equipment is done. The vendor will include a cost extra for
observing a test that is about half the cost of witnessing a test.
The differential cost between observed and witnessed tests can be more than offset
by increased inspector’s time for observed tests; observed tests may also be missed
because of insufficient advance notification by the vendor. Specifying an observed
test is therefore not recommended. If a test is important enough to warrant the pres-
ence of an inspector or engineer, a witnessed test should be specified on the driver
data sheet or elsewhere in the order documents.
800-2  1989–2011 Chevron U.S.A. Inc. All rights reserved. April 2011 (E)
Driver Manual 800 Inspection and Testing
830 Motor and Generator Inspections

The principal inspection points are listed below in normal manufacturing sequence.
The cost of the in-process inspections or tests is usually added to the cost in the
motor or generator quotation. See DRI-MS-3547, Inspection and Testing of Large
Electric Motors and Generators, in Volume 2 of this manual for more details on
motor and generator inspections.
1. Preinspection Meeting. This meeting is held shortly after an order has been
placed to review specifications and order requirements and to coordinate any
interface between driver equipment or auxiliary systems. The preinspection
meeting will help resolve ambiguities that may delay final shipment and also
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verify that the manufacturer understands our inspection and test requirements
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and is aware of the required witness points. These meetings should be held for
all motors or generators except “general purpose” type. Manufacturers’ stan-
dard inspections and routine tests are commonly accepted for general-purpose
machines and medium induction motors (less than approximately 500 HP and
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600 V).
2. Examination of Stator Core Before Vacuum Pressure Impregnation (VPI)
Treatment. This visit is only made for large critical machines that have a
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voltage rating of 6600 V or above. It is a visual inspection that ensures high
standards in insulation taping and winding mechanical bracing have been met
before defects are masked by the VPI process, which solidifies the winding
assembly with an epoxy resin. Cost is minimal, except for the inspector’s
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charges for 1 day in the manufacturer’s plant.
3. Winding Penetration Tests. These tests are usually applied to large, critical
machines with voltage ratings 6600 V or above. At or above this voltage rating,
voids in the taped-insulation system of the coils could lend to “corona”
discharge within the void, with accelerated breakdown of the winding insula-
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tion. Nondestructive electrical tests are made, along with physically cutting a
sample coil open to check for proper penetration during the VPI process. The
cost of this inspection may be $1000 to $2000, but is worth the cost to ensure
the integrity of the windings on the large machines to which these high-voltage
windings are applied.
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4. Winding Immersion Test. Recommended for all “special-purpose,” critical

motors to prove a sealed winding insulation system. The stator assembly is
completely immersed in a tank of water, and high voltage is applied to prove
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the capability of the insulation system. Manufacturers do a more careful job in

the winding taping when this inspection is specified, which usually ensures
longer service life for the machine. The cost varies from nothing to $1000 or
more depending on the vendor’s perceived risk of failing the test.
5. Electrical Inspection Documentation. An inspector would review the

following electrical inspection documentation either during a visit for some
other test or inspection or prior to run-testing of the machine. This inspection is
not usually witnessed.
– Surge-comparison test of the internal turn-to-turn insulation of each stator
winding coil
– Synchronous machine rotor turn-insulation tests
See DRI-MS-3547 in Volume 2 of this manual for more details.
6. Mechanical Inspection Documentation. This inspection is not usually
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witnessed. An inspector would review the following mechanical inspection
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documentation during a visit for some other test or inspection or prior to run-
testing of the machine.
– Rotor shaft, bearing journal, and rotor core dimensions, fits, and runout
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measurements
– Rotor bar locking methods for induction machines
– Fit tolerances on stator and rotor windings
– Fit tolerances on the machine frame and rotor assemblies
–
–
–
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Dimensions and fits of bearings, including the fit with the frame bearing
housing and the clearance between the shaft and bearing
Rotor balance documentation
Air gap between the stator and rotor
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– Vibration probe calibration, if applied
See DRI-MS-3547 in Volume 2 of this manual for more details.
7. Review of Nonconformance Reports. The inspector should request the
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records of all nonconformances, whether corrected or uncorrected. All uncor-

rected nonconformances should be documented and be approved through the
vendor engineering department.
8. Residual Unbalance Verification. This is a procedure that is usually
“required” for machines 600 HP (450 kW) and larger with speed ratings
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1800 RPM and higher. Specification MAC-EG-3546 in the General Machinery

Manual is used to verify the rotor is balanced to within acceptable tolerances
and that the balancing machine is sensitive enough to balance a rotor. This
procedure provides documentation for future checks of rotor balance and saves
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time on subsequent test and inspector efforts in case an out-of-calibration

balancing machine is revealed. The cost of this inspection is usually $500 to
$750.
9. Mechanical and Electrical Run and Performance Tests. These are usually
specified on all “special-purpose” machines to verify the mechanical integrity
and electrical performance and efficiency. See Section 840 for further informa-
tion. Usually these are “witnessed” tests.
10. Dismantling After Test. The bearings are removed and inspected, along with
the shaft journals, for any metal transfer between the shaft and bearing or any
bearing-bore dimensional change. The inspection is normally done by a
machinery specialist who witnessed the run and performance tests.
840 Motor and Generator Tests

The following tests, applied to motors and generators, are covered in detail in
DRI-MS-3547 in Volume 2 of this manual and are highlighted here. Motors and
generators are often applied in critical applications and convert electrical energy to
mechanical energy (or vice-versa for generators) at an operating-expense cost (or
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revenue income) of two to four times the purchase price of the machine per year.
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These tests deserve considerable attention.
1. Routine Electrical Tests. These tests are recommended for all machines and
include:
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– Measurement of no-load quantities (current, speed, and power input)
– High-potential and insulation resistance tests
– A measurement of winding resistances
2.
–
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A measurement of bearing insulation for machines with insulated bearings
or end-to-end shaft voltage for those with uninsulated bearings
Complete Electrical Tests. Apply these tests to “special-purpose” machines
larger than 1000 HP (750 kW) and to one machine of a group ordered at the
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same time rated 1000 HP or less:
– Determination of efficiency
– Measurement of locked-rotor (zero speed, shaft locked) quantities for
motors
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– Heat run (rated-temperature test) of the machine’s windings

The efficiency test verifies the quoted performance of the machine and, due to high
operating-expense-to-purchase-cost ratio, a penalty is imposed if the test efficiency
is less than quoted. The temperature test verifies the temperature limits imposed on
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the electrical windings to ensure a long winding service life. There are other special-
ized tests described in the IEEE test standards, depending on the type of machine.
See DRI-MS-3547 in Volume 2 of this manual and IEEE Standards 112 and 115,
included as part of this manual, for more details.
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3. Routine Mechanical Tests. Apply these tests to all machines. This test
sequence includes:
– No-load mechanical vibration tests
– Measurement of bearing temperatures
– Inspection for oil leaks
4. Complete Mechanical Tests. Apply the following to “special-purpose”

machines and all two-pole (3600 RPM) induction machines 600 HP (450 kW)
and larger:
– Rated-temperature mechanical vibration tests
– Across-line starts and vibration performance for motors
– Rotor overspeed tests for 3600-RPM induction motors and all generators
– Rotor unbalanced-response test for selected machine ratings
In most cases, the rated-temperature vibration test is done at the same time as the
heat run for the “Complete Electrical Tests.” Large 3600-RPM induction motors,
commonly applied for high-speed centrifugal pumps and compressors, should be
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subjected to this test sequence to avoid problems after installation. They are much
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more susceptible to mechanical problems than lower-speed motors.
850 Reciprocating I/C Engine Inspections
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Reciprocating engines are mass-produced machines that are manufactured on an
assembly line out of parts bins. The components (and sometimes the entire engine)
are not assigned to a specific order until late in manufacture. As such, they do not
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lend themselves well to complete inspection during manufacture.
Inspection during assembly is beneficial only on large, low-speed engines (usually
integral compressor engines). See the Compressor Manual for more information on
integral engine compressors. Engines below 1000 HP should require little or no
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inspection. When engines are packaged by a machinery packager, the inspection
budget is better spent on fabrication of skids and appurtenances than on witnessing
assembly of the bare engine at the manufacturer’s plant.
Inspections For Large Engines

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At the end of this section Figure 800-1 is a checklist of inspection points for large
stationary engines. A preinspection meeting should be held at the manufacturer’s
plant to define “witness” and “observe” points from the checklist. Any special
requirements of the order can be reviewed during the meeting.
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A final inspection can be performed after the engine testing is complete, but before
painting. The final inspection includes:
• Equipment review against specifications
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• Equipment review against outline drawings

• Verification of presence of all appurtenances
• Visual inspection for damage and defects
860 Reciprocating I/C Engine Tests

There are three basic tests applicable to large stationary reciprocating engines.
These are:
• Factory test
• Packager’s shop test (generator sets)
• Field test
Unfortunately, most engine manufacturers are not equipped to perform comprehen-
sive tests on large stationary engines. This is usually due to lack of a large enough
fuel supply or a large enough load device in their test facilities. As a result, many
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engine tests are either performed in the field or waived by the user.
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A. Factory Test
Due to limited facilities, factory tests are usually standardized, and few if any
customer special tests are performed. The standard factory tests may be witnessed at
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the purchaser’s option. Tests are performed on the bare engine using test cell lube
system, cooling system, controls, etc. The engine load is usually a water brake.
Factory test procedures include a run-in after the initial start, variable load testing
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(within shop capabilities), overspeed trip setting, and limited post-test dissembly for
inspection. A typical load test might be performed as follows:
• Full rated load—1 hour
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• 110% rated load—30 minutes
The main objective of the load test is to determine brake-specific fuel consumption.
Other operating conditions such as firing pressures and temperatures, as well as
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temperatures throughout the engine are recorded.

A posttest disassembly for inspection is only warranted for the most critical
machines. It should include the following:
• Record bearing clearances and web deflections
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• Boroscopic inspection of cylinder liners

• Visual inspection of one or two piston/connecting rod assemblies (requires
removal from engine)
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• Record valve lash

• Visual inspection of valves in one head
• Remove and inspect one main bearing
• Retorque all main bearing caps
• Inspect crankcase and filter for metals or babbit
• Pressure test water jacket for 30 minutes
Witness of specific inspection points may be negotiated with the engine manufac-
turer. Depending on amount of disassembly, it is sometimes appropriate to run the
engine at full-rated load for 1 hour after reassembly.
B. Packager’s Shop Test

On generator sets it is sometimes possible to shop test the entire machinery train on
its skid complete with job auxiliary systems and controls. The benefit of performing
a packager’s shop test is that all of the auxiliaries and controls can be tested (and
debugged if needed) in the shop. Problems are discovered and solved prior to accep-
tance in the packager’s shop where all the resources for correction are available.
Such problems tend to be time consuming and costly if left for discovery in the
field.
The primary factors that limit packager’s shop tests are:
• Fuel availability
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• Lack of heat exchange equipment
• Load bank and electrical system limitations
A typical packager’s shop test will include the same load test durations as the
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factory test. In addition the test might include a heat-run at full load for 4 hours to
allow for thermal stabilization. A comprehensive record of temperatures and pres-
sures is logged during the heat-run, recordings taken every 10 to 15 minutes.
C. Field Tests
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Field performance tests on engines are cumbersome and of limited value. It is often
difficult to measure and control the engine load and difficult to accurately measure
the fuel flow rate and its heating value. When a field performance test is done to
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demonstrate guaranteed performance, the manufacturer should have a representa-
tive present, and the test procedures and conditions should be agreed upon prior to
commencing.
It is usually necessary to perform third-party emission tests on all internal combus-
tion engines to obtain operating permits from the local air pollution control authori-
ed
ties. More information on these tests can be found in Section 300 of the General
Machinery Manual.
870 Combustion Gas Turbine Inspections

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The following principal inspection points are listed in normal manufacturing

sequence. The inspection points listed apply to radially split, small industrial-type
CGTs. The cost of the in-process inspections or tests may be included as cost adders
in the quotation.
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A. Preinspection Meeting
Hold shortly after an order has been placed to review specifications and order
requirements and to coordinate any interface between driven equipment or auxiliary
systems. The preinspection meeting will help resolve ambiguities that may delay
final shipment and also verify that the manufacturer understands our inspection and
test requirements and is aware of the required witness points; it will also help to
reveal any deviations from the specifications that the manufacturer failed to cover in
his quotation. These meetings should be held for all combustion gas turbines.
B. Compressor and Power Turbine

Witness Nondestructive Examination (NDE) of the turbine “wheels” for both the
compressor section and the power turbine section after overspeed testing. Check
manufacturer’s records of dimensions taken before and after overspeed testing to
verify no yielding or distortion has occurred. Record the serial number of each part
or identify in some manner to verify parts are not switched with other jobs during
assembly. Witness NDE of any other parts for which witness is specified.
C. Balance of Rotors
Witness final dynamic balance of assembled rotor or rotors. Visually inspect all
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blades, and verify blade fit is correct and blade retaining means is properly installed.
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At this time (or during the prior visit) visually inspect all other major engine compo-
nents for casting quality, weld quality, obvious machining errors, and damage;
record serial numbers on parts or otherwise identify them.
D. During Engine Assembly
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Visit during engine assembly to ensure that previously inspected parts are in fact
being used (manufacturer’s frequently switch parts.) Verify to the extent possible
that assembly procedure is in compliance with the manufacturer’s standards. Verify
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that running clearances are measured and checked against the manufacturer’s toler-
ances. Two separate visits may be necessary (one for the compressor section and
one for the power turbine) but the inspector does not normally witness the entire
CGT assembly process.
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E. CGT Performance
Witness performance test of the CGT, following approved test procedure.
F. CGT Final Inspection
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Final inspect the CGT to verify that all components and appurtenances that belong
to the engine are installed (most CGT’s are tested using test cell equipment
including fuel control valves, gages, and filters.) This inspection can be accom-
plished during final inspection of the equipment package if the CGT is part of a
package that includes the driven equipment.
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G. String Test
Witness “string test” of the completely assembled equipment package if a string test
is specified.
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H. Shipping and Packing

Inspection for proper shipping preparation and packing may be warranted.
880 Combustion Gas Turbine Tests

This section discusses functional testing of combustion gas turbines, what the
testing criteria entail, and the possible roles of the vendor and purchaser in effec-
tively carrying out the tests. It is beyond the scope of this manual to include finite
details of each test procedure, because each turbine installation is unique and may
require specific engineering. Consult the Mechanical and Electrical Division, ETD,
or a local specialist for help in determining those details.
Numerous standards have been prepared over the past 25 years in an effort to guide
the turbine manufacturing industry and its users toward common goals for safety
and environmental compliance. An industry committee was formed to consolidate
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and recognize the necessary technical disciplines while providing a comprehensive
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gas turbine procurement standard under the auspices of the American National Stan-
dards Institute (ANSI).
In 1982 the American National Standards Committee B133 reorganized itself as the
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“ASME Standards Committee B133 on Procurement Standards for Gas Turbines.”
Standard B133.6-1978 relates to gas turbine ratings and performance under speci-
fied site conditions under which the turbine is intended to run. This standard forms
the basis by which a purchaser can specify and understand test results as they relate
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to the turbine’s specific site conditions.
Recognizing the specialized nature of petrochemical installations, the American
Petroleum Institute (API) published its own standard in 1982, Type H Industrial
Combustion Gas Turbines For Refinery Services, API Standard 616. As the title
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suggests, this standard addresses petroleum industry needs; therefore, many differ-
ences will be found between it and ASME B133. However, 133 and 616 compli-
ment each other—616 simply addresses API needs more fully.
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881 General Information

Standard testing criteria for gas turbines will include the following areas:
1. Power output of generator
2. Heat rate
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3. Exhaust energy
4. Emissions
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5. Noise
6. Vibration
7. Proper function of auxiliary systems
Testing criteria, over and above the standard testing procedures that the manufac-
turer performs, are primarily specified by the purchaser at the time of contract
agreement. The tests are usually in the form of performance guarantees that the
purchaser requires to ensure that the plant, operating under normal conditions, will
be in compliance with the operating design basis and all regulatory laws.
Verifying the guaranteed heat rate of gas turbines is less prone to error than veri-
fying the emissions output. The manufacturer’s experience allows for precise heat
rate and power output predictions that will satisfy the most stringent purchase speci-
fications. However, the same cannot be said for predictability of emissions. Emis-
sions output is extremely difficult to conclusively verify. For this reason the
manufacturer requires that the purchaser supply a detailed analysis of the intended
fuel supply(s), operating parameters, and heat recovery system specifics before a bid
can be intelligently formulated. For an example of the purchaser-supplied informa-
tion, refer to API 616.
When a contract is written with specific performance guarantees in the above areas,
the turbine must perform within the specified limitations or the purchaser may find
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that the plant operating permit may be violated. Care must be taken to ensure that
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the negotiated operating permit limitations are not too close to the performance
guarantee levels for emissions and noise.
Power Output of Generator
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Power output is expressed as kilowatts generated by the generator unit being driven
by the gas turbine under specified rating conditions. For example, a large industrial
gas turbine unit may be specified to provide an output of 38,740 kW at base load
Barometric pressure
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under the following conditions.
Compressor inlet temperature 63F
14.65 psia
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Relative humidity 71%
Steam injection 28,840 lb/hr @ 500F & 300 psia
Exhaust pressure drop 16 inches of water
Natural gas fuel (900 BTU/scf LHV)
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The rating conditions in this case take into account the site conditions as an average,
rather than stating International Organization for Standardization (ISO) standard
conditions. Conversion curves are used by the manufacturer to convert and compare
empirical data to ISO conditions.
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Heat Rate and Exhaust Energy

Heat rate and exhaust energy are verified under the same operating conditions at the
same time. Heat rate is usually expressed as gross BTU/kWh, lower heating value
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(LHV). Exhaust gas energy is expressed simply as the total BTU per hour.
Emissions
Emissions or compliance testing is one of the most difficult and exacting proce-
dures that can be carried out. Depending on the local regulatory laws and the
operating conditions under which the turbine will operate, emissions levels may be
mandated at such a low level that detection instrumentation and analyzers are inca-
pable of carrying out the specified tasks at the specified levels of accuracy. It is
highly recommended that an outside consultant or Company specialist be contracted
early in the project planning stage to assist with the emissions compliance planning.
Section 300 contains references on where to get additional guidance on emissions.

Section 400 contains information on CGT emissions.
Typical controlled emissions are:
1. Oxides of nitrogen
2. Carbon monoxide
3. Particulates
4. Ammonia (If a selective catalytic unit is used)
5. Noise
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6. Reactive organic compounds
7. Sulfur dioxide
Sulfur dioxide emissions are usually at a minimum due to the controlling laws for
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sulfur content in combustion fuels.
An example of a highly regulated area, such as Southern California, will exhibit
stack emissions limits in the range of:
Oxides of nitrogen
Carbon monoxide
at24-Hr. limit —300 lb
15-Min. Ave. limit—9 PPM
24-Hr. limit—49 lb
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15-Min. Ave. 10 PPM
Particulate matter 175 lb per day
Noise 85 dB—3 ft from the
enclosure
Reactive Organic 75 lb per day
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Compounds
Vibration Testing
Vibration testing is primarily performed in the factory at the time of rotor construc-
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tion. However, for large industrial turbines, this is usually done on each component
rather than on an assembled turbine generator train. The completed installation will
be observed for proper vibration levels during the initial startup if that has not
already been done in the factory.
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882 Factory Testing

Factory testing is only performed by those who have facilities to support the actual
firing of a turbine. It is usually only with small industrial turbines, such as aero-
derivatives, that the factory can conduct a complete package test of the turbine
generator or compressor as specified in the purchase contract.
Few companies can package test a large industrial turbine due to the amount of
support facilities required and the difficulties encountered dealing with the large
amounts of electricity generated by the generator packages. Large industrial turbines

are typically tested as a single component on a dynamometer device, such as a water
brake. This test is designed to verify the turbine power, heat rate, acceleration rate,
vibration characteristics, and the integrity of some of the skid-mounted support
systems integral to the operation of the turbine. Obviously, this test is not as desir-
able as a complete package test, because a package test is designed to run the entire
turbine generator train through its paces just as it is intended to be in its final instal-
lation. Package testing also provides the opportunity to debug and repair the entire
system before it leaves the factory.
Typical tests and requirements that would be required at the factory are:
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1. Acceleration rate
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2. Speed range control
3. Demonstrated stable operation for at least 4 hours
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4. Contract seals and bearings are used during tests
5. Lubrication system operates within design spec during testing sessions
6. Operation free of all leaks and safety hazards
7.
8.
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Protective and control devices checked
Auxiliary gear units included in tests
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9. Vibration amplitudes and frequencies recorded
10. Control system functions verified
Depending on the scope of the turbine purchase, several supplemental tests are
available to check load gears, noise, starting means, etc. The preceding list is an
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abbreviated description of tests that require clarification of specifics for the turbine
package being purchased and tested.
Standards that would be appropriate to apply to these tests are listed in API, NEMA,
IEEE and ASME guidelines. An example of this application would be API 670, to
govern the vibration probe installation specifications or API 614 utilized as the
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governing tool for the lubrication system. Company DRI-MS-3547 and IEEE 115
Standards are appropriate for many of the generator tests that are required. The
purchaser must become familiar with these standards to formulate a purchase speci-
fication that protects the client’s interests and minimizes costly downtime.
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Chevron has considerable experience in this field, and it is highly recommended that
a Company specialist be consulted for preparing a test plan/specification.
883 Field Tests

Tests performed at the completed installation are usually compliance tests that are
required by the local air quality management agency. This also depends on the
scope of the tests completed at the factory. Assuming that the factory was only
capable of firing the turbine as a single component, the following tests should be
expected in the field:
Preliminary checks
1. Appropriate hi-pot and megger tests (for generators)
2. Loop check of all control and protection circuits
3. Function testing and adjustment to all control and protection devices
4. Single component testing of the starting means and hydraulic system
5. Functional test of the fire protection system
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6. No-load turbine running checks, vibration, cooling, fuel supply, overspeed trips
7. Functional test of the D.C. backup system(s)
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Presynchronization checks (for those trains driving generators)
1. Verification of phase sequence at the generator output and from the utility
feeder line
2. Verification of proper protection relay coordination, calibration, and settings
3.
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Voltage regulator and excitation controls testing
Load tests
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Functional testing consists of testing of the turbine generator or mechanical drive
package under various operating conditions, for example, underexcited, overex-
cited, base load, peak load, power factor control, and VAR control.
The preceding field tests are time consuming and require precise coordination
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with the operating personnel, interfacing utilities, and regulatory agencies.

Many of the tests are performed at load levels that create operating conditions which
produce emissions in excess of the plant operating permit conditions. An example of
this would be the period of time taken to boil out a heat recovery steam generator.
This procedure, depending on the size of the turbine, requires the turbine to be oper-
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ated at very low exhaust temperature levels for several hours. A plant operation that
requires catalytic devices to reduce emissions for compliance will not be able to
achieve sufficient temperature to activate the catalysts during the boilout period.
Care must be taken to ensure that the negotiated operating permit allows for tran-
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sient operating conditions, startups, shutdowns, and low load.

Generators that are paralleled with the local utility grid can be disruptive should a
mishap occur. Representatives of the local utility will require close communication
during initial synchronization and the load tests that follow.
Field performance testing is the final step toward verifying that the purchaser has
received what was contracted for. The performance tests, governed by ASME B-133
guidelines, are usually conducted with a minimum amount of running time on the
turbine or following a turbine wash to ensure optimum performance. It should be
noted that this test may not be necessary if the manufacturer and purchaser have
agreed upon the results of a series of factory tests. However, factory tests do not
have the site conditions, the fuel and supply system, nor the steam or water injec-
tion system that the final installation does. Therefore, it is highly recommended that
these tests be carried out to verify that the installation satisfies all contract obliga-
tions.
The field performance tests, as described in Section 881, are performed by a team of
Company and turbine manufacturer personnel. The tests are conducted under
precisely controlled conditions following a series of calibration checks on the
measurement instrumentation. This includes removing and measuring the orifice
plates for accuracy, recalibration of the transmitters, fuel analysis, and the installa-
tion of additional trend monitors, if necessary. For an example of the level of detail
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included in a field performance test, refer to the attached sample test procedure for a
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large turbine generator.
Keep in mind that each turbine package is unique and is intended for specific site
conditions. The type of equipment it is driving must be appropriately accounted for
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in the contract agreement and all subsequent performance test procedures. For any
further details, refer to the applicable ASME power test code or consult with a
Company specialist.
For sample Combustion Gas Turbine Performance Test Procedures refer to ASME
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PTC 22, “Performance Test Code on Gas Turbines.”
890 Special-Purpose Steam Turbine Test Checklist

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Introduction
A sample checklist at the end of this section provides a detailed list of items to be
checked when mechanically testing a special-purpose steam turbine (Figure 800-2).
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Special-purpose turbines, as defined by American Petroleum Institute (API), are

those horizontal turbines used to drive equipment that is usually not spared, is rela-
tively large in size, or is in critical service—such as drives for centrifugal compres-
sors, air blowers, reciprocating compressors, or generators. Testing can take place
either in the manufacturer’s plant or while being installed in the field. Wording,
herein, is presented in terms of testing a new turbine on the manufacturer’s test
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stand. But minor editorial interpretation makes this a useful field testing checklist
also.
This checklist also provides a systematic means of collecting initial data on
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machinery characteristics for later comparison and troubleshooting.
Recommended Use
The checklist is presented in sequential order. Each step is intended to be self-
explanatory. As each step is completed, a notation can be made on the line at the
right. All blanks should be filled in.
Fig. 800-1 Inspection Checklist for Large Stationary Reciprocating Engines

1. Engine Component Inspection
Visual inspection of castings and forgings_______________________________________________________
Cleanliness______________________________________________________________________________
bed and cylinder block___________________________________________________________________
internal lube lines and passages___________________________________________________________
Surface finish____________________________________________________________________________
cylinder liners_________________________________________________________________________
crankshaft journals_____________________________________________________________________
piston pins____________________________________________________________________________
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main bearings_________________________________________________________________________
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connecting rod bores____________________________________________________________________
Visual inspection of valves and seats__________________________________________________________
Component discrepancy records_____________________________________________________________
2. Manufacturer’s Assembly Records
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Main bearing journal outside diameters________________________________________________________
Connecting rod journal outside diameters______________________________________________________
Main bearing inside diameters_______________________________________________________________
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Connecting rod___________________________________________________________________________
bearing inside diameters_________________________________________________________________
side clearance_________________________________________________________________________
Cylinder liner inside diameters_____________________________________________________________
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Piston__________________________________________________________________________________
outside diameters_______________________________________________________________________
pin fits________________________________________________________________________________
ring to groove clearance__________________________________________________________________
Crankshaft_______________________________________________________________________________
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web deflection__________________________________________________________________________
thrust_________________________________________________________________________________
Camshaft thrust___________________________________________________________________________
Piston to head clearance____________________________________________________________________
Water/oil pump drive runout__________________________________________________________________
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Intake and exhaust valve timing_______________________________________________________________

Injection timing____________________________________________________________________________
Ignition timing_____________________________________________________________________________
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3. Assembly Inspections
Main and rod bearing clearances (plastigage)___________________________________________________
Main bearing crush (plastigage)______________________________________________________________
Connecting rod bearing crush (plastigage)______________________________________________________
Post assembly cleanliness__________________________________________________________________
4. Appurtenances Inspections
Fabrication quality and cleanliness of lube, water fuel and air piping 
and manifolds____________________________________________________________________________
Fabrication quality of vessels and exchangers___________________________________________________
Fig. 800-2 Checklist for Conducting an API Special-Purpose Steam Turbine No-Load Run Test (1 of 3)
1. Documents to have on hand
API 612 (Edition in effect at time of purchase) _______
API 670 (Edition in effect at time of purchase) _______
DRI-EG-3664 (Edition in effect at time of purchase) _______
Final purchase order _______
Contractor’s purchase specification _______
As-built design data sheet _______
Coordination meeting notes _______
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Critical speed map and response analysis (See Section 800 for recommendations.); must include _______
effects of coupling used for test (if not the contract coupling)
John Sohre’s paper on testing of steam turbines _______
2. Before Test
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Review API 612 (Purchase edition) _______
Review DRI-EG-3664 (Purchase edition) _______
Review manufacturer’s Operating Manual, if available _______
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Discuss manufacturer’s prerun test experience with Chevron inspector, if any, Contractor’s
inspector and manufacturer’s engineering, quality assurance, and test floor personnel (Manufac-
turer should already have run subject turbine to anticipate outcome of witnessed test. A full or
partial load test may have also been run.)



_______
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Develop list of last-minute “problems” discovered by the manufacturer _______
Each problem has been satisfactorily rectified (Use purchase specification, manufacturer’s specifi- 
cation, and own best judgment as guides. Put yourself in the place of the plant operator.) _______
Using a copy of the critical speed map, plot the manufacturer’s calculated 1st and 2nd criticals [The 
critical(s) found during testing is within  5% of critical speed(s) predicted by the manufacturer.] 
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_______
Have design data sheet available _______
The Contractor’s inspector is normally the official Company spokesman. Work with and through 
him. _______
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3. Pretest Inspection
Check with test foreman to make sure job bearings are installed. _______
Check to be sure that contract proximity probes, including axial probe(s), are installed, gapped, and 
calibrated _______
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Check to see that contract coupling half and idling adaptor are in place. Adaptor must weigh about 
1/2 of contract spacer spool. If contract coupling is not available, shop coupling of same weight and 
center gravity can be substituted. Critical speed map and response analyses must be rerun to 
include effects of substitute coupling _______
If substitute coupling is of different size, record weight and center of gravity of substitute coupling
and adaptor combined
weight_______________lb
c.g._________________in. from_____________________end
Steam supply temperature does not exceed design condition. Ratio of inlet to discharge pressures 
approaches design value as closely as possible. Inlet steam pressure may be lowered to avoid 
overheating casing exhaust end. (See API 612 Paragraph on Standard No-Load Running Test.) 
_______
All vibration readouts are hooked up to an oscilloscope and are calibrated. Readout voltage should 
be about mid-range, 7 to 8 V, D.C. (Scale-and-pointer type readouts may have suppression and 
could read differently from scope especially if nonsynchrous vibrations are present.) _______
Test stand oil is:
150 ssu @ 100F. The brand name is _______________________________,
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type_______________, vis.______________________________________.
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Clean 10-micron nominally rated lube-oil filter is in place. _______
4. Test Run (without Vibration Analysis Travel Kit)
Maximum allowable runout (mechanical and electrical combined) determined at slow roll does not 
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exceed 0.25 (12,000/nmc)0.5 mils _______
Bearing and lube-oil temperatures have reached equilibrium; this normally takes an hour at 
maximum continuous speed _______
Oil inlet temperature and pressure are as specified by the manufacturer on data sheet (Should also 
be within allowable range in Operating Manual.
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Machine has no steam leaks at labyrinth seals or flanges
Gland condenser (if any) cooling water temperature is as specified
_______
_______
_______
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Gland condenser (if any) cooling water pressure drip is less than 5 psig _______
There are no oil leaks at fittings, along the shaft, at the hydraulic servo (if fitted), or at the governor 
_______
Temperature rise across any bearing is about 40F maximum during this no-load test. (An oil 
temperature rise of 50F, with 110F ambient—"under worst conditions"—will be the maximum 
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allowable in the field.) _______

(If bearing oil temperature is too high, check for overly restrictive orifice or passage in oil supply 
line and bearing clearances which are too tight.) _______
Vibration level as measured at any probe position does not exceed (12,000/nmc)0.5 mils, peak-to- 
peak (This allowable incudes all runout.) _______
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Vibration amplitude at any bearing is not affected adversely as oil supply temperature is varied 
within operating manual limits (If amplitude increases, use tunable filter or real time analyzer to 
look for fractional-frequency whirl.) _______
If maximum operating speed is above the first critical speed, find the first critical by vibration ampli- 
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tude peaking or by a clear-cut phase shift; unbalance the rotor if necessary—mid-span unbalance 
is best, but coupling unbalance is okay if mid-span is inaccessible (Try to get Vendor to use an 
unbalance weight equivalent to one gravity (maximum) at maximum continuous speed. Use the 
formula below.) _______
Wu  ru = 35,200  Wr/n2mc
Wu = Unbalanced weight, lb
ru = Radius of unbalance weight, in.
Wr = Rotor weight, lb
nmc = Maximum continuous speed, RPM
(Document unbalance weight location, amount of weight, radius from shaft center line.)
There is no rapidly increasing vibration amplitude as the machine reaches trip speed (If there is, 
this may be an indication that machine is running too close to its 2nd critical.) _______
Governor is properly set to provide smooth (no hunting) control from minimum to maximum contin- 
uous rated speed as control air signal is varied from 3 to 15psig and is repeatable _______
All control linkages are free to move without binding, but not too sloppy _______
Overspeed trip functions between -1% and +2% of manufacturer’s trip set point (RPM) on each of _______
three successive tries (No trends up or down in successive trips.)
1.____________ RPM 2.____________ RPM 3.____________ RPM
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All safety trips function at specified points (A reasonable allowance for adjustment above and 
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below this point should be provided.) _______
All required (if any) noise data has been taken and recorded _______
All test results have been properly recorded and certified on manufacturer’s SHOP TEST REPORT _______
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5. Posttest Run Inspection
All journal bearing and thrust pad surfaces are in like-new condition or satisfactorily restored with 
minimal efforts (The use of abrasive coated cloth (such as emery or crocus cloth) is strongly 
discouraged for this task) _______
a. Light scratches acceptable at
b. Shiny areas indicate uneven bearing surface preparation; this is normally the result of hand
scraping (If found, the bearing should be further scraped and blue-dye checked until most of the
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bearing surface shows contact with the journal.)
c. If bearing is wiped, check clearances and adequacy of oil supply passages (Normally, the
bearing should be honed and retested.)
d. If bearing is scored or cracked, lubrication system has failed or allowable bearing loading has
been exceeded and the test must be rerun
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If turbine has to be disassembled to make a correction, the entire test must be rerun. (See API 612 
Paragraph on Standard No-Load Running Test.) _______
6. Electronic Analysis
If the Vibration Analysis Travel Kit (or manufacturer’s equivalent) is available, the following addi-
tional tests should be performed before and during the mechanical running test:
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Get slow roll data at less than 500 RPM (Confirm that run-out (mechanical and electrical combined) 
is no more than 0.25 (12,000/nmc)0.5 mils) _______
Simultaneously record vibration amplitude and phase versus RPM on an X-Y-Y' plotter (Do this on 
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run up to trip and coast down from trip.) _______

Repeat above step as bearing oil temperature is varied _______
If temperature sensors are available, record oil and other temperatures on a multipoint recorder _______
Use Real Time Analyzer and X-Y-Y' plotter at 250 to 500 RPM intervals from slow roll to trip speed
to look for the frequency of vibration peaks (Watch carefully for frequency of 40 to 50% RPM 
RPM, first critical speed and multiples of RPM up to blade or vane passing frequency.) _______
Try to determine mode shape of shaft at critical(s) using phase information from both ends of shaft
(Use shaker on spare rotor (if available) to find natural frequencies and mode shapes.) _______
Plot D.C. voltages (X and Y) versus RPM for each journal to determine no-load running position of
journals within bearings (This can be compared later to fully loaded operation in the field to monitor
bearing deterioration.) _______
Revision History
Date Description Author Sponsor
1989 Initial release PSHA PSHA
April 2011 (E) Errata change: MWFS MWFS
In Section 883, replaced:

“A sample Combustion Gas Turbine Performance Test
Procedure is included in Appendix B.”
with:
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“For sample Combustion Gas Turbine Performance Test
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Procedures refer to ASME PTC 22, “Performance Test
Code on Gas Turbines.”
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800 Inspection and Testing

880 Combustion Gas Turbine Tests 800-10

890 Special-Purpose Steam Turbine Test Checklist 800-15

810 General Comments

820 Nonwitnessed (Required), Witnessed, and Observed Tests

driver is inspected. Production is not stopped as it is for “witnessed” tests.

830 Motor and Generator Inspections

4. Winding Immersion Test. Recommended for all “special-purpose,” critical

the capability of the insulation system. Manufacturers do a more careful job in

5. Electrical Inspection Documentation. An inspector would review the

records of all nonconformances, whether corrected or uncorrected. All uncor-

1800 RPM and higher. Specification MAC-EG-3546 in the General Machinery

time on subsequent test and inspector efforts in case an out-of-calibration

840 Motor and Generator Tests

– Heat run (rated-temperature test) of the machine’s windings

4. Complete Mechanical Tests. Apply the following to “special-purpose”

850 Reciprocating I/C Engine Inspections

Inspections For Large Engines

• Equipment review against outline drawings

860 Reciprocating I/C Engine Tests

temperatures throughout the engine are recorded.

• Boroscopic inspection of cylinder liners

• Record valve lash

B. Packager’s Shop Test

870 Combustion Gas Turbine Inspections

The following principal inspection points are listed in normal manufacturing

B. Compressor and Power Turbine

H. Shipping and Packing

880 Combustion Gas Turbine Tests

881 General Information

Power Output of Generator

Heat Rate and Exhaust Energy

Section 300 contains references on where to get additional guidance on emissions.

882 Factory Testing

amounts of electricity generated by the generator packages. Large industrial turbines

883 Field Tests

with the operating personnel, interfacing utilities, and regulatory agencies.

sient operating conditions, startups, shutdowns, and low load.

890 Special-Purpose Steam Turbine Test Checklist

Special-purpose turbines, as defined by American Petroleum Institute (API), are

machinery characteristics for later comparison and troubleshooting.

Fig. 800-1 Inspection Checklist for Large Stationary Reciprocating Engines

Intake and exhaust valve timing_______________________________________________________________

allowable in the field.) _______

run up to trip and coast down from trip.) _______

In Section 883, replaced:

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