How to Commission a GD150 Compressor

The Guide

The GD150 Operating and Commissioning Guide provides a structured procedure for checking a GD150 installation and verifying compressor operation before the unit is placed into service.

The guide takes qualified personnel through pre-operating checks, PTO engagement, compressor speed, inlet restriction, pipework leak testing and relief valve verification. It also establishes critical operating limits for inlet vacuum and discharge pressure.

This can be used during commissioning to help verify that the compressor and supporting system have been correctly installed, tested and prepared for operation.

Download the GD150 Operating and Commissioning Guide

GD150 Operating and Commissioning Checklist Cover

Why GD150 Commissioning Starts Before the Compressor Runs

Commissioning isn’t simply a matter of starting the compressor and confirming that it operates.

The installation around the GD150 needs to be checked first.

Pipework should be clean following fabrication. Flanges, fasteners and mountings need to be secure. The correct testing equipment must be installed, and the vehicle and engine controls need to be properly configured for the application.

Completing these checks before startup gives commissioning personnel an opportunity to identify installation issues before pressure is introduced into the system.

Most importantly, never start the compressor against a pressurized tank or discharge line.

How to Prepare a GD150 for Commissioning

Before beginning the operating test, verify the installation and supporting system.

Pre-Operating Check	Requirement
Pipework	Clean flexible and welded pipe bores after fabrication
Mounting	Confirm flanges, fasteners and mountings are secure
PTO	Vehicle PTO disengaged before startup
Engine Management	Correctly configured for the application
Ball Valve	Open if starting against tank pressure
Testing Equipment	Fit a 1.5-2 in gate valve and silencer
Pressure Gauge	Fit a 0-43.5 PSI (0-3 bar g) discharge pressure gauge
Ancillaries	Confirm correct installation and sequencing

Once these checks are complete, confirm that the gate valve on the discharge pipework is open before beginning the operating procedure.

Start Within the Correct GD150 Operating Speed

Engage the PTO according to the truck manufacturer’s instructions and slowly raise the clutch.

Engine speed can then be adjusted so that the compressor operates at the speed required for the application.

The specified GD150 compressor input speed range is:

1,000-1,600 RPM

Before progressing with the commissioning test, check the inlet blockage indicator. It should not show red, which would indicate a blocked filter or inlet pipework condition.

While the compressor is operating, inspect the pipework for leaks. If leaks are found, stop the machine and tighten the fasteners as necessary before continuing.

Build Pressure Gradually and Check the System for Leaks

Commissioning should verify system integrity before testing the relief valve at its operating point.

Partially close the gate valve to increase discharge pressure to:

3 PSI (0.2 bar) below the relief valve’s full-bypass setting.

At this pressure, inspect the system again for leaks.

If corrective work is required, stop the machine and tighten the appropriate fasteners.

When the system is operating correctly, continue running the compressor until the total test time reaches 30 minutes, then perform another check for air leaks.

This process provides an opportunity to verify the installation under operating conditions before completing relief valve testing.

Verify Relief Valve Operation Before Commissioning Is Complete

The relief valve test establishes several specific acceptance points.

Pressure should be increased slowly beyond the setting stamped on the valve until the relief valve operates.

Relief Valve Check	Commissioning Requirement
Valve cracking	Should begin to lift/open/blow off within 10% below set pressure
Permitted leakage before cracking	Up to 7 PSI (0.5 bar g) below set pressure
Full opening / bypass	Within 5% of set pressure
Valve reseating	Before pressure falls 7 PSI (0.5 bar g) below full-bypass pressure

Once full-bypass operation has been verified, slowly reduce pressure and confirm that the relief valve reseats within the specified range.

After testing, check again that all fastenings remain tight and that flanges are leak-free.

Finish the GD150 Commissioning Procedure Safely

Once testing is complete, return the engine speed to idle before disengaging the PTO.

Then stop the engine.

Remove any commissioning test apparatus, disconnect the discharge hose and fit a blanking cap as required.

Commissioning personnel should also remain aware that pipework becomes hot during testing and operation.

Three operating limits from the checklist should remain front of mind:

Maximum inlet vacuum: 0.7 PSI (50 mbar)

Maximum discharge pressure: 36 PSI (2.5 bar g)

Compressor input speed: 1,000-1,600 RPM

The compressor should never be started against a pressurized tank or discharge line.

Following the complete commissioning sequence helps verify not just that the GD150 runs, but that the compressor, installation, pressure controls and supporting pipework are operating within the requirements established for the system.

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Frequently Asked Questions

Begin by checking the pipework, flanges, fasteners, mountings, PTO, engine management settings, testing equipment and ancillaries. The commissioning procedure then verifies compressor operation, inlet restriction, system leaks, operating pressure and relief valve performance before the unit is placed into service.