How to Commission a GD150 Compressor

The Checklist

The Gardner Denver GD150 Pre-Operation & Commissioning Checklist provides qualified installation and commissioning personnel with a structured process for checking a newly installed GD150 before first operation.

The complete process from verifying the installation and preparing the system through initial operation, pressure testing, relief valve verification and final shutdown.

Rather than discovering an installation or system issue after the truck enters service, the checklist gives technicians a defined opportunity to identify and address potential problems during commissioning.

Why Proper GD150 Commissioning Matters

A compressor does not operate independently of the system around it.

The PTO, engine controls, inlet and discharge piping, valves, silencer, pressure protection and mounting all have to work together once the GD150 begins operating.

That means a successful installation isn’t confirmed simply because the compressor starts.

The commissioning process helps qualified personnel answer more important questions:

Is the compressor operating within its specified speed range?
Is the inlet free from excessive restriction?
Is the pipework leak-free under pressure?
Is the relief valve operating at the correct pressure?
Did the installation remain secure throughout the test?

Verifying these conditions before regular operation can help identify problems while the truck is still in a controlled commissioning environment.

How to Prepare a GD150 for Commissioning

Before engaging the PTO, the installation should be inspected and prepared according to the checklist.

This includes confirming that flexible and welded pipe bores are clean following fabrication, flanges and fasteners are secure, mounting points are tight and ancillary equipment has been installed in the correct sequence.

Verification that the PTO is disengaged before startup and that the engine management system has been configured for the application.

The commissioning system should include the specified 1.5 to 2 inch gate valve, silencer and 0 to 43.5 PSI (0 to 3 bar g) discharge pressure gauge.

One particularly important startup requirement is that the GD150 should never be started against a pressurized tank or discharge line.

Know the Operating Limits Before You Start

Qualified personnel should know the GD150’s operating limits before beginning the commissioning test.

Commissioning Requirement	GD150
Compressor input speed	1,000 to 1,600 RPM
Maximum inlet vacuum	0.7 PSI / 50 mbar
Maximum discharge pressure	36 PSI / 2.5 bar g
Total commissioning test duration	30 minutes

Pipework can also become hot during testing and operation, so the safety precautions identified in the checklist should be followed throughout commissioning.

How to Check the GD150 Under Operating Conditions

Once the initial installation checks have been completed, the compressor can be operated within the specified 1,000 to 1,600 RPM input speed range.

The inlet blockage indicator should be checked before increasing system pressure. If the indicator is red, the checklist directs personnel to investigate a blocked inlet filter or restriction in the inlet pipework.

Pipework should then be inspected for air leaks.

For pressure testing, the gate valve is gradually closed until discharge pressure reaches 3 PSI (0.2 bar) below the relief valve’s full-bypass setting.

The system is inspected again for leakage and the compressor is operated for a total test duration of 30 minutes.

This is why commissioning is valuable. The technician isn’t simply confirming that the GD150 can produce air. The procedure tests how the compressor and its supporting installation perform together under operating pressure.

How to Verify the GD150 Pressure Relief Valve

The pressure relief valve is another critical part of the commissioning process.

The checklist provides specific acceptance criteria:

Relief Valve Check	Requirement
Begins to crack	Within 10% below set pressure
Slight leakage	Permitted up to 7 PSI / 0.5 bar below set pressure
Full bypass	Within 5% of set pressure
Reseats	Before reaching 7 PSI / 0.5 bar below full-bypass pressure

If the valve does not operate as specified, commissioning should not simply continue.

Personnel should stop commissioning if a required step cannot be completed or abnormal operation occurs. The unit should not be placed into service until the condition has been addressed with Gardner Denver Technical Support or an authorized Gardner Denver service provider.

What Does the GD150 Checklist Cover?

The downloadable checklist provides a field reference for qualified personnel completing the initial GD150 commissioning process, including:

Pre-operation installation checks
PTO and engine management verification
Inlet and discharge system preparation
Operating speed and pressure limits
Inlet restriction checks
Pipework leak inspection
30-minute commissioning test
Pressure relief valve testing
Final fastener and flange inspection
Proper shutdown and removal of commissioning equipment

Once the procedure has been successfully completed, the checklist also guides personnel through reducing the engine to idle, disengaging the PTO, stopping the engine, removing the test apparatus and preparing the installation following commissioning.

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Frequently Asked Questions About GD150 Commissioning

GD150 commissioning begins with verifying the installation, pipework, mounting, PTO and supporting components before operating the compressor. The commissioning procedure then checks operating speed, inlet restriction, system leaks, discharge pressure and pressure relief valve operation. The complete test should follow the sequence provided in the Gardner Denver GD150 Pre-Operation & Commissioning Checklist.