Catalytic main fan

1 Scope (Contents of commissioning) This commissioning plan is applicable to the load testing of the main fan unit in the 2.8 million tons per year heavy oil catalytic cracking unit at the Refining and Chemicals Company. 2 Equipment Overview 2.1 Structure and Technical Features The main fan unit of the 2.8 million tons/year heavy oil catalytic cracking plant operated by the Refining and Chemicals Company was designed and assembled technically by the Shaanxi Turbine Machinery Research Institute. The mechanical components include a flue gas turbine, an axial flow main fan, gearboxes, electric/generator sets, and a lubricating oil station (with auxiliary oil pumps). The commissioning plan and technical measures for this unit were prepared in accordance with the general provisions of the \"Code for Construction and Acceptance of Compressor, Fan, and Pump Installation Projects\" (GB50275-98), the design drawings related to the main fan provided by Sinopec Engineering Corporation, as well as the technical requirements specified in the accompanying documents from Shaanxi Turbine Machinery Research Institute. These plans and measures were then discussed and approved by all three parties involved. 2.2 Main technical parameters 3 Conditions required for commissioning 3.1 All mechanical, electrical, instrumentation equipment as well as auxiliary equipment and process pipelines of the unit must be installed, with complete and satisfactory installation records available. 3.2 The unit’s lubricating oil lines were restored after acid washing and passivation treatment. 3.3 Once the process pipelines have been purged, those sections that cannot be purged (such as the area from the fan inlet to the filter) should be cleaned manually. And it has been inspected and deemed qualified by the relevant personnel. 3.4 The steam pipeline purging and target testing meet the requirements. 3.5 The cooling water pipeline purging is satisfactory. 3.6 The supply of water, electricity, and gas to the equipment is adequate and functioning properly. 3.7 The commissioning plan has been approved and reviewed by the relevant personnel. 4 Commissioning Procedures 4.1 Flushing and running-in of the unit’s oil system. 4.2 Static commissioning of the unit control system. 4.3 Single-unit test rotation of the motor/generator. 4.4 Joint commissioning of the motor/generator—gearbox—main air blower (low load)—flue gas turbine (under load). Due to the limited capacity of Hainan Refining and Chemicals’ power grid, the unit motors cannot start automatically to carry out single-motor load tests. Additionally, because the moment of inertia of the main fan differs significantly from that of the motors, it is not possible for the motors to initiate and accelerate the unit. The unit shall immediately undergo a load test operation with the smoke generator involved, as well as the flushing and running-in of the oil system. 5.1 Preparations before oil transportation 5.1.1 All lubricating oil pipelines and valves must be subjected to acid washing, passivation, and air drying. Thoroughly clean all valves such as those on the fuel tank, oil cooler, and oil filter. It is strictly prohibited to use fluffy rags or cotton yarn for cleaning. 5.1.2 Install the temporary pipelines and valves for external circulation ； Install the temporary pipelines and valves for external circulation ； Install the oil filter. Install a 150-mesh temporary filter at the fuel pump outlet and at the fuel tank return line. 5.1.3 Check the flushing and circulation processes; install blind flanges on the oil inlet and outlet branches of each bearing to isolate them from the system. Close the valves of all instrument connections; route the control valve around, and ensure that the positions of the other valves in the system are correct. Install 150-mesh temporary filters at the outlet of the oil station, at the oil tank return pipe, and at the crossover point of the bearing housing drain pipe. Close the valves of all instrument connections; route the control valve around, and ensure that the positions of the other valves in the system are correct. 5.1.4 A blind plate is installed in front of the gearbox oil drain sight glass to prevent oil from flowing into the gearbox. 5.1.5 Use an oil filter to add L-TSA46 turbine oil to the oil tank; install a temporary 150-mesh filter at the outlet of the oil filter. Check whether the low liquid level alarm and its deactivation in the test tank are functioning correctly. 5.2 Commissioning of the lubricating oil pump motor 5.2.1. The motor shall be operated under no-load conditions for 2 hours; the rotation direction of the motor must be consistent with the direction required by the pump. 5.2.2 Bearing temperature (rolling bearings): The temperature rise shall not exceed 40°C. 5.2.3 The vibration values meet the specifications. 5.2.4 After the motor has passed the trial run, recheck that the concentricity between the pump and the motor meets the manufacturer’s specifications, and connect the coupling between the motor and the pump. 5.3 Trial operation of the main oil pump steam turbine: 5.3.1. Warm up the pipes up to the steam turbine inlet valve, with a warming rate of ≤ 50°C per minute. 5.3.2 Open the steam turbine drain valve, slightly open the feed valve, close the turbine grid connection valve, and open the outlet vent valve. For turbine preheating, cooling water is supplied to the bearing housing. 5.3.3 Gradually open the inlet valve to impulse the turbine rotor and slowly increase the speed, keeping the turbine running at its operating speed for 2 hours; check whether the temperature rise and vibration of the turbine bearings are normal (the normal operating speed is 3000 r/min). 5.3.4 Test for the turbine emergency shutdown device: the shutdown speed is 3360 r/min. The test shall be conducted twice, and in each case the value must remain within the specified range; the turbine’s speed control range is 2950–3150 r/min. 5.3.5 Stop the turbine, open the drain valve, and recheck the concentricity of the oil pump and the turbine; thermal alignment should be achieved, after which the turbine and the oil pump should be connected. 5.4 Oil Circuit Circulation 5.4.1 Check that the anchor bolts of the pump and motor are not loose. 5.4.2. The pump bearing housing should be filled with qualified lubricating oil (L-TSA46 turbine oil) to a level of 1/2–2/3 of its height. 5.4.3 Check the mechanical seal to ensure that it allows for easy turning of the shaft; any signs of sticking or uneven wear should be addressed. 5.4.4 Fully open the cooling water inlet valve, and slightly open the cooling water outlet valve. 5.4.5 Fully open the pump inlet and outlet valves to fill the pump with oil, then close the outlet valve. Other valves on the pump outlet pipeline, fully open. 5.4.6 Connect the power supply, activate all instruments and start the motor; immediately check the pressure in the pump’s outlet pipeline. If the pressure rises normally, slowly open the outlet valve and adjust the outlet flow rate within 3 minutes. Otherwise, stop the pump for inspection. 5.4.7 Drain the air from the system through all exhaust valves, and gradually increase the amount of oil in the system until the maximum flow rate is reached. 5.4.8 Operate all oil pumps in the system for more than 4 hours during the oil flushing process, and conduct the following checks: Whether oil flows through all pipelines, and whether there are any leaks ； ? Is there any blockage in the pump inlet coarse filter, and are there any abnormalities in the oil temperatures and pressures? ； ? Are the pump and motor operating properly? ? Replace the filter element in a timely manner based on the filter pressure difference. 5.4.9 Start from one end of the system and move towards the oil tank, striking the pipelines with a wooden tool (or copper hammer), focusing on the welded areas. 5.4.10 Switch the flow paths through the cooler and filter every hour. 5.4.11 The oil flow passing through the control valve will be switched to flowing through all the bypasses on a periodic basis. 5.4.12 Criteria for satisfactory oil flushing and circulation. The qualified standards for flushing oil shall meet the following requirements: visually, there must be no hard particles in the filter screen, and there shall be no more than 2 soft contaminants per square centimeter. The oil quality test report for the lubricant must be satisfactory. 5.4.13 After the oil flushing is deemed satisfactory, all flushing oil in the oil system must be drained. The oil tank within the oil system should be cleaned of dirt using dough; the oil filters and the inlet filter of the oil pump should be cleaned with kerosene. 5.4.14 Re-add lubricating oil, remove the blind flanges installed on the oil inlet and outlet branches of each bearing, remove the blind flange in front of the gear box oil drain sight glass, and remove the 150-mesh temporary filters located at the outlet of the oil pump station, on the oil tank return pipe, and at the junction of the bearing box oil drain pipe. Start the lubricating oil pump to establish circulation in the oil system. 5.4.15 All circuits in the oil system must be circulated to the proper position and sampled for analysis to confirm compliance. The acceptance criteria for oil circulation shall meet the following requirements: Check the operating condition of the oil filter; after 24 hours, the pressure difference across the oil filter should not exceed 0.01–0.015 MPa. If this limit is exceeded, oil circulation must continue until the criteria are met. 5.5 Quality standards for the trial operation of lubricating oil pumps – Bearing vibration: Double amplitude of bearings in μm. For oil pump motors, this value should be ≤25; for oil pumps, it should be ≤20; for oil pump turbines, it should be ≤25. Bearing temperature: The temperature of the bearings in the pump and motor should be equal to the ambient temperature plus 40°C. Mechanical seals must not exhibit any leakage. 5.6 Running-in of the power oil system: Follow the procedures for running in the lubricating oil system. After the oil system has completed its running-in period, start the auxiliary oil pump to continue the oil circuit circulation. 6 Static calibration tests of the unit’s instruments and electrical systems (for details, see the sections on instruments and electrical tests for the main motor). 7 Combined operational test of electric/generator – gearbox – main fan (at low load) – exhaust fan (at full load). 7.1 Electric/generator. 7.1.1 Once the conditions at the test site are ready, and all the measuring instruments required for the unit’s operational test are available and have passed inspection, they are prepared for use at the site. 7.1.2 Commissioning personnel must be proficient in the operating procedures of their posts. 7.1.3 The connection between the unit and various external systems is ready, with smooth communication. 7.1.4 Ensure continuous supply of water, electricity, steam, and air. 7.1.5 The commissioning and calibration documents for all equipment in the unit are complete and reliable, in compliance with relevant regulations, and have been approved through joint signing by all relevant parties. 7.1.5 All construction trades and relevant parties have completed co-signing at the commissioning meeting. 7.1.6 Prepare the trial operation record. 7.1.6 Install the following instruments and equipment: ? Water supply for air coolers ； Leak detector ； ? Motor shaft vibration, bearing temperature, monitoring instruments. ? Motor stator temperature thermocouples and instruments. ? Motor relay protection. 7.1.7 Two persons are assigned to each of the control room, machine room, and power distribution room for testing and recording, while the substation is monitored and recorded by the main operator. 7.1.8 Disconnect the coupling between the motor and the gearbox, and check that the oil circuit system is functioning properly. 7.1.9 The electrical technician should conduct a jog test on the motor to determine its rotation direction. 7.1.10 After it is back to normal, connect the coupling between the motor and the gearbox. 7.2 Gearbox 7.2.1 Recheck whether the gearbox itself, as well as the electrical, instrumentation, and equipment pipelines, have been installed correctly, and whether the construction records are complete and accurate. 7.2.2 Check whether the barring gear box and motor are properly lubricated. (C90 high-grade gear oil for the pinion gearbox) 7.3 Main fan 7.3.1 Carefully check whether all the process pipelines related to the main fan have been installed and whether there are any missing items. 7.3.2 Thoroughly clean the inlet pipeline of the main fan and related equipment; after joint inspection and acceptance by the relevant parties, seal the manholes. 7.3.3 Thoroughly inspect all components of the main fan inlet filter to ensure there is no looseness. 7.3.4 The instrument control system for the main air system equipment and valves has been completed. 7.4.4 The actuator for the stator blades operates reliably, allowing the stator blades to be manually adjusted to the closed position. 7.4.5 Start up the following devices for use: shaft vibration, shaft displacement, and key phase monitoring instruments ； ? Control instruments for inlet and outlet flow, pressure, and temperature of the main fan. ? Check that the flash alarm button and all light displays are functioning correctly. 7.5 Smoke Extractors 7.5.1 The inspection and installation of the smoke extractors have been completed, with complete and satisfactory installation records, which have been signed and approved by the on-site representative of the mechanical engineering company. 7.5.2 The inlet and outlet pipelines of the flue gas machine have been constructed; all supports and fixings are reliable and appropriate, and the expansion/contraction values of all compensators meet the design specifications. 7.5.3 The inlet pipe of the flue machine (from the triple spinner to the flue machine inlet) shall be cleaned thoroughly, and after inspection and approval by the relevant parties, the hole shall be sealed. 7.5.4 The electrical and instrumentation components associated with the flue gas fan have been installed; static simulation tests were conducted and the operations were correct. The butterfly valve at the inlet of the flue gas fan has also been adjusted properly. 7.5.5 The steam cooling and seal air system pipelines for the flue gas turbine have been successfully purged. 7.5.6 Recheck the concentricity of the main fan and the exhaust fan, and connect their couplings. 7.5.7 Closing of the flue gas inlet butterfly valve (manual or electric). 7.5.8 Open each drain valve on the smoke extractor’s cooling steam line to thoroughly drain water. 7.5.9 Starting instruments: Instruments related to the unit’s bearing temperatures, vibration, shaft displacement, key phase, rotational speed, etc ； ? Indicators for each valve position, alarm instruments, indicators for the opening degree of the main fan’s stationary blades, etc ； 7.5.10 Introduce buffer air to the flue gas extractor seal, with an air pressure of 0.4 MPa. 7.5.11 Start the lubricating oil station to supply the unit with lubricating oil and power oil that meet the required temperature and pressure specifications. 7.5.12 Start the lift oil pump and the barring gear, and check that there are no metallic friction sounds from the rotors of the unit. 7.6 Unit shutdown interlock test: The unit’s trip procedure is activated when either of the following conditions is met: ? The emergency stop button is pulled. ? Smoke extractor trips due to overspeed ； ? Tripping due to low lubricating oil pressure ； ? PLC power outage ； ? Unit power outage ? Excessive shaft displacement: After the trip procedure is activated, the following devices should operate: ? Electric/generator circuit breaker opens ； ? Close the smoke machine inlet valve ； ? Open the anti-surge valves FCV-1, FCV-2. ? Close the main air outlet check valve. ? Main air stator vanes fully closed. Remarks: This test is conducted prior to the startup of the standby unit. 7.7 Coordinated start-up of the main blower and flue gas turbine units. 7.7.1 Verify that the anti-surge valve, outlet check valve, and high-temperature butterfly valve are in the operating state. The anti-surge valve is fully open, the check valve at the fan outlet, the electric valve at the fan outlet, and the high-temperature butterfly valve are all closed, and the water seal at the flue gas exhaust is in good condition. 7.7.2 Drain the cooling steam and buffer air of the flue gas extractor, and lead them to in front of the control valve or the final manual valve. Slightly open the shell drain valve; close it after draining is complete. 7.7.3 Once the pressure of the lubricating oil and power oil returns to normal, contact the electrical department to supply power to the jacking oil pump and start it. Start the electric barring gear. 7.7.4 Activate the smoke machine to cool the steam, and activate the bearing buffer air to maintain PI at 7 kPa. Check the flue gas cooler steam PIC—at 600 kpa. Cooling water for the range hood base has been put into use. 7.7.5 Reset shutdown button PB – Check the conditions required for startup; once the readiness light comes on, any conditions that are not met are resolved. The conditions that must be satisfied for startup are as follows: ① The auxiliary oil pump is stopped. ③The pressure in the lubricating oil main pipe is normal. ④Lubricating oil pressure is normal. ⑤ Auxiliary power oil pump is shut down. ⑥The power oil pressure is normal. ⑧The jacking oil pressure is normal. ⑨The main lift oil pump is operating. ⑨The stator blades are in the starting position. ⑩Anti-surge valve A is fully open. ⑾Anti-surge valve B is fully open. ⑿The check valve at the fan outlet is closed. ⒀High-temperature butterfly valves A and B are closed. ⒁All shutdown conditions have been resolved. ⒂The motor/generator circuit breaker is selected for local start. 7.7.6 Drainage from the water seal tank at the flue gas exhaust. 7.7.7 When the start-up permission is set to “yes”, the regeneration process proceeds smoothly. The catalyst content at the flue gas sampling outlet of the three-spinners (>10 μm) does not exceed 3%, and the concentration does not exceed 200 mg/Nm³. These values meet the operating standards for the flue gas turbine, indicating that it is ready for operation. A drain valve is placed in front of the butterfly valve at the inlet of the fully open flue gas extractor to warm the pipes with the flue gas. Switch to the high-temperature butterfly valve controller screen; set Controller A for the high-temperature butterfly valve to \"Manual\" mode, and open Butterfly Valve A fully. Switch to manual control on-site to prevent accidental operation of the butterfly valve. Drain valve in front of the butterfly valve at the smoke extractor inlet. 7.7.8 Slowly open butterfly valve B at the smoke inlet to warm up the unit at a low speed, relying on the smoke leakage for this purpose. 7.7.9 During low-speed warm-up, the unit’s speed should be kept within the range of 500–1000 rpm. By adjusting the butterfly valve B at the inlet of the exhaust fan, the rate of increase in the temperature of the exhaust fan housing is controlled to be ≤100°C/h, and the temperature of the exhaust fan rotor is kept within the normal range. The unit is operated at 500–1000 rpm for 1 hour during warm-up, during which the various pipelines, supports, and expansion conditions of the unit are inspected, and close attention is paid to ensure that the operating parameters are normal. 7.7.10 Re-establish contact at the corresponding position, slightly open the butterfly valve at the inlet of the smoke extractor, gradually increase the speed to ~1500 rpm, operate for 30 minutes, and then conduct a check. 7.7.11 Open the inlet butterfly valve and quickly raise the unit to approximately 85–90% of its rated speed (3162–3348 rpm), exceeding the critical speed of the axial flow fan, which is 2850 rpm. Run it for 5 minutes; after checking that there are no abnormalities, prepare to close the motor circuit. 7.7.12 Once the motor meets the conditions for closing, notify the main substation; upon approval, start the main motor on-site. By pressing the “Start Main Fan Unit” button, the “Main Fan Start Approved” indicator light will turn on. Pay attention to the decline in the motor’s starting current. 7.7.13 Stop the lifting oil pump, as well as the disk drive motor and the power supply for the lifting oil pump. 7.7.14 After the unit is operating at its rated speed of 3720 rpm without any abnormalities, increase the static blade angle of the axial flow fan from 22° to 26–28°, and monitor all operational parameters of the unit for 10 to 30 minutes. 7.7.15 Conduct a thorough inspection of the unit’s motors, gearboxes, fans, and exhaust fans; there should be no friction or abnormal noises in any part of the unit. 7.7.16 Increase the position of the stator blades to 70–80% of full load, run the unit for 4 hours, and carry out various inspections and take records. The specific items and normal operating parameters are listed in the attached table. 7.7.17 Reduce the butterfly valve at the inlet of the smoke exhaust fan, increase the motor power, and work together with the staff from Shaanxi Turbine Machinery Research Institute to determine the performance curve of the fan, ensuring that the smoke exhaust fan operates with minimal effort and without overloading the motor. 7.7.18 After the unit’s operational trial run, the on-site trial run leadership team analyzes and discusses the results of the trial run. If no issues are found, and after obtaining the signatures of the relevant parties, the construction party hands over the project to Party A upon completion. 7.7.19 Prepare a commissioning summary report. Note: After confirmation by the commissioning leadership team, the unit switch-over is carried out in accordance with the regulations. 7.8 Shutdown during normal operation 7.8.1 Upon receiving a shutdown notification, get ready to shut down the system. 7.8.2 Contact the reaction shift to slowly close the stator vanes in order to reduce the main air flow rate; at the same time, slowly close butterfly valve B at the exhaust fan inlet, controlling the cooling rate of the exhaust fan to be ≤ 100°C/h, until it is fully closed. The main air outlet vent valve is fully open. 7.8.3 During the process, pay close attention to the operation and power status of the motor to prevent it from operating under overload conditions. 7.8.4 Close the smoke extractor inlet isolation butterfly valve. 7.8.5 Press the normal stop button, and the motor/generator circuit breaker opens. 7.8.6 After parking, start the lift oil pump to rotate the shaft, continuing to circulate the lubricating oil until the bearing outlet temperature is also <49°C; then stop the shaft rotation first, and subsequently stop the oil pump. 7.8.7 Install a water seal at the smoke extractor outlet, stop the cooling steam for the smoke extractor, and activate the drain at the bottom of the smoke extractor. 7.8.8 As the machine temperature decreases, appropriately reduce the cooling steam to the smoke extractor wheel. When the temperature of the smoke extractor body is <200°C, stop the cooling steam and seal air to the wheel disc. 7.9 Emergency Shutdown: When a fault occurs in the unit, posing a threat to its safe operation and unable to be resolved, an emergency shutdown should be initiated. Immediate contact should be made with the relevant personnel, and the situation reported to the appropriate departments. 7.9.1 Emergency shutdown conditions? When the unit experiences severe vibration and measures taken to address it prove ineffective. ? There were sounds of metal impact and friction inside the unit, as well as smoking at the shaft seal. ? In the event of a severe leak in the oil system, preventing the oil level in the tank from being replenished. ? The bearing temperature rose suddenly, exceeding the shutdown threshold, and measures taken were ineffective. ? When the shaft displacement of the unit increases and exceeds the shutdown value, and measures taken prove ineffective. ? When there is an overreport of high motor stator temperature and measures taken prove ineffective; or when the unit meets the conditions for automatic shutdown but the safety protection system does not activate. ? Steam failure in the wheel; it’s difficult to control the wheel temperature. ? Failure of the high-temperature butterfly valve. 7.9.2 Shutdown Method: Pull the emergency stop button, the dedicated shutdown circuit breaker is de-energized, and the emergency stop logic is activated. ? Motor circuit breaker is disconnected ； High-temperature butterfly valve closed ； Open the anti-surge valve ； Close the main air outlet check valve ； Stator blade valve. ? Check the operation of each valve in item A; if they are not functioning, take action immediately. ? Reset all emergency shutdown conditions for the next startup, and maintain the lubricating oil pressure between 180 and 200 KPa. ? Others are treated as normal parking. 8 Safety measures for unit trial operation 8.1 Before the unit trial operation, all instruments, interlocks, controls, etc. must be ensured to be functioning properly. 8.2 The oil inlet and outlet in the bearing housing of the unit are unobstructed, and the lubricating oil has passed the quality tests. 8.3 During the commissioning phase, all relevant personnel must follow instructions, fulfill their duties diligently, and not leave their posts without permission. They are required to closely monitor various operational parameters of the unit, and report any abnormalities to the commissioning leadership team immediately. During the commissioning process, the commissioning leadership team has the authority to initiate an emergency shutdown, and must report the reasons for the shutdown as well as the measures taken to address it. 8.4 During the test run, personnel unrelated to the test run are strictly prohibited from staying in the control room to watch. 8.5 Sufficiently bright lighting facilities shall be available for night tests.

Main Fan Commissioning Plan I. Basis for preparation: 1. Documentation included with the equipment. 2. \"Construction Technical Specifications for Axial Flow Compressors and Flue Gas Turbines in Catalytic Cracking Units\" SHT3516-2001. II. Conditions to be met prior to commissioning: 1. All installation work on the unit must be completed, in compliance with the technical documents and relevant standards, with complete installation records. 2. The pipeline installation is complete, and the pressure testing and purging have passed. 3. Both the secondary grouting and finishing of the unit shall reach the design strength. 4. The common facilities related to the trial operation are ready for use. 5. The electrical and instrumentation installation work is complete, and it has been tested successfully; it is now ready for trial operation. 6. The oil system has been flushed and tested successfully. 7. The on-site roads are unobstructed, the environment is clean and safe, and the fire protection facilities are complete and reliable. 8. The trial operation plan has been approved. III. Preparatory work before the trial operation: 1. Establish a leading group for the trial operation, determine the trial operation plan, assign responsibilities to all personnel participating in the trial run, and ensure they carry out operations in accordance with the plan. 2. All personnel participating in the trial operation must be familiar with the equipment manual and relevant technical documents, understand the structure and performance of the equipment, and master its operating procedures and safety rules. 3. A technical briefing must be conducted prior to the trial run, so as to become familiar with the unit’s characteristics and to clarify operating procedures and safety regulations, etc. 4. Prepare all tools and safety protective equipment required for the trial operation. 5. All the various record forms required for the trial operation are ready. 6. The following preparatory work should be carried out before starting the unit: 6.1 Rotate the unit manually, and use a listening rod to check that there are no sounds of collision or scraping inside any of the unit’s casings. Any abnormal noises should be addressed immediately. 6.2. Make the necessary preparations before starting the motor in accordance with the instructions provided in the motor’s manual. 6. 3. Check that all bolts of the unit are tightened, and verify that everything is in order. 6.4 Check that the lubricating oil meets the specified main physicochemical properties of No. 46 turbine oil; the oil level in the tank should be 30–40 mm above the maximum level line, and an appropriate amount of spare lubricating oil should be kept on hand. 6.5 Check that the cold water pipeline is unobstructed and free of leaks. 6. Check the configuration and sensitivity of all measuring instruments. 6. 7. Check whether the manual parts of the valves installed on the gas pipelines are flexible. The throttle plate in the intake duct should be adjusted to a position of 5–10°. The gate valve in the exhaust pipeline should be closed, and the gate valve in the bypass pipeline should be opened. 6. 8. Check and adjust all interlock devices of the unit. (1) Interlock between the main motor and the electric oil pump. The main motor can be switched on only after the electric oil pump starts ； (2) When the bearing temperature is ≥80°C, audible and visual warning signals are emitted ； When the bearing temperature is ≥90°C, an audible and visual emergency signal is emitted, and the main motor stops automatically via interlock. (3) When the oil pressure in the main oil inlet pipe of the lubrication system is ≤ 1.5 kgf/cm²G, audible and visual warning signals are issued ； Chain-driven automatic start of standby oil pump ； If the oil pressure in the main oil inlet pipe of the lubrication system is ≤ 1.0 kgf/cm2G, an audible and visual emergency signal is generated, and the main motor stops automatically as a result of interlocking. Commissioning procedures and technical requirements IV. Commissioning procedures and technical requirements: 1. Oil system trial operation 1.1 Start the electric heater in the lubricating oil tank to heat the oil to 25°C. 1. 2. After the preparatory work is completed, start the main oil pump of the lubricating oil system to establish circulation in the oil system. 1. 3. Adjust the lubricating oil pressure so that the pressure at the oil inlet manifold is 0.245 MPa. 1. 4. The lubricating oil system shall undergo the following self-protection tests: (1) When the oil pressure at the oil inlet manifold is gradually reduced to 0.15 MPa, a low oil pressure alarm signal shall be generated and the auxiliary oil pump shall start automatically ； (2) When the oil pressure is further reduced to 0.1 MPa, an alarm should be triggered and the machine should be shut down urgently; 1.5 Test operation of the lubricating oil system: After the above tests are successful, the lubricating oil system is put into operation for a minimum of 72 hours, with the condition that the quality of the oil meets the specified standards. 1. 6. If the oil quality analysis shows satisfactory results after 72 hours of operation, and all interlocks function correctly, the oil system can be considered to have passed its trial operation. After the oil system passes the trial operation, clean the filters and bearing shells, and remove the temporary filters from the oil inlet pipes. 2. No-load test run of the motor 2.1 Preparatory work before the test run: (1) Check the motor’s insulation resistance and the wiring of the high-voltage components in accordance with relevant electrical regulations ； The setting, testing, and calibration of high and low voltage power distribution equipment as well as electrical devices such as motors have all been completed ； (2) The tightness of all bolts should be thoroughly checked to ensure it meets the requirements ； The half coupling should be securely fixed ； (3) Rotate the rotor by hand to check it; there are no abnormal noises and it rotates smoothly ； (4) Monitoring and control instruments ； (5) Start the main lubricating oil pump in accordance with the operating procedures to establish a normal working cycle for the lubricating oil system. 2. After all preparatory checks have been passed, start the motor manually using the switch (that is, stop it before the rotor reaches its rated speed) in order to check the direction of rotation and the behavior of the rotor. 2. 3. After the steering is verified to be functional, start the motor again. 2. 4. Record the starting current and voltage; during operation, record the current, voltage, bearing temperature, stator temperature, and amplitude every half hour. If any abnormalities are detected, the machine must be stopped for treatment. 2.5 After running continuously for two hours without any abnormalities, and with all parameters meeting the requirements specified in the table below, the motor is considered to have passed the no-load test run; it can then be shut down, and the idling time should be recorded. 2. 6. Carefully record the magnetic center line of the motor, and compare it with the data provided by the manufacturer; if there is a significant deviation, the axial distance and alignment of the motor should be adjusted again. 2. 7. The lubricating oil pump can be stopped only when the temperature difference between the inlet and outlet lubricating oil is less than 5°C. 2. 8. The number of times the motor may be started shall comply with the following regulations: Two consecutive starts are allowed when the motor is cold ； Hot start is allowed only once. 2. 9. After the motor is tested under no-load conditions, the electrical system must be carefully inspected. The high-voltage power supply lines and the distribution room require strict management, with a designated person in charge to ensure that the motor is in good condition ready for operation. 3. No-load test run of the gearbox 3.1 Preparatory work before the test run ； ⑴The motor has passed the testing ； ⑵Conduct a thorough inspection to ensure that all components of the gearbox have been properly installed ； ⑶, Connect the coupling between the motor and the gearbox. ⑷, Recheck the shaft alignment data. ⑸, Verify that the manual crank device functions properly. ⑹, Disconnect the coupling between the gearbox and the compressor 2. ⑺, Power on the control panel; all control and monitoring instruments should be activated ； ⑻The lubricating oil system has been put into operation; the system pressure has been adjusted to the appropriate level, and a normal operating cycle has been established. The inlet temperature of the lubricating oil should be between 40° and 50°. 3.2 Start the electric barring gear, check the direction of rotation (adjust it if necessary), verify the self-protection interlock system, and check for any abnormalities in the barring gear and gearbox. In case of any problems, stop the equipment immediately for troubleshooting. The operation time of the electric turntable shall be no less than 5 minutes. When the barring stop is activated, ensure that the handle is in the “Stop Barring” position and locked. 3.3 Start the motor: Closely monitor the temperature and vibration of each bearing, etc. During operation, records should be taken every half hour. In the event of any abnormalities, the machine must be stopped for troubleshooting. It can be stopped only after running continuously for two hours with no abnormalities, and all parameters meeting the requirements specified in the table below; at that time, the idling time should also be recorded. 3. 43. 5. After shutdown, check the gear meshing condition through the gearbox inspection window; if any abnormalities are found, corrective measures must be taken and a test run conducted again. 3. 6. After parking, if no issues are detected, it is considered that the gearbox operates mechanically without load successfully. 4. Test run of the centrifugal main blower
4.1 Preparatory work before the test run:
(1) Conduct a comprehensive inspection of the electrical system and the insulation resistance of the motor; also install an oscilloscope ； ⑵Power supplied to the dashboard; all control and monitoring instruments are activated ； ⑶, Coupling and guard between the main fan and gearbox ； ⑷Conduct a thorough inspection of the main fan unit itself, as well as all equipment and pipeline valves in the system, to ensure that they have all been installed and tested properly ； ⑸The lubricating oil system has been put into operation; the system pressure has been adjusted to the proper level, and a normal operating cycle has been established. ⑹ Start the electric barring gear and check whether there are any abnormal noises inside the main blower. If no abnormalities are detected, let it run for at least 5 minutes. 4.2 The main fan unit can be started only after the preparatory work is completed and passes inspection. ⑴Pre-startup check: Press the “Pre-startup Check” button; at this point, the relevant devices or valves should be in the following positions: the angle of the inlet butterfly valve should be α = 15%, the electric butterfly valve and check valve should be fully closed, and the anti-surge valve should be fully open. Once the “Ready to Start” light comes on, it indicates that the above conditions have been met, and startup is permitted. ⑵Start: Press the main motor switch manually; once the unit’s speed reaches the rated value, the start is complete. Listen immediately (for any abnormal noises) and check (bearing temperature, shaft vibration, etc.); if anything is abnormal, stop the machine immediately for inspection. 4. 3. Trial operation: (1) The centrifugal main fan was operated continuously for four hours with the inlet butterfly valve at 15% openness; no abnormalities were observed, and all parameters met the requirements specified in the table below, whereby it can be considered that the low-load mechanical operation trial was successful. ⑵For the load test, gradually increase the angle of the inlet butterfly valve to 30°, and then slowly reduce the anti-surge valve, aiming to achieve an outlet pressure of 0.4 MPa (abs) for the main fan (depending on the motor power). If it can operate stably for 24 hours under these conditions and all parameters remain within the values shown in the table above, then the trial operation is considered successful. ⑶Record: Carefully monitor the operation of the unit during operation, and record the relevant process and mechanical parameters (every half hour). ⑷If the unit operates without any abnormalities within the specified operating time, it can be shut down following these steps: (a) Open the anti-surge valve fully ； (b) Press the main motor stop button ； (c) After the motor stops rotating, start the electric turning gear to perform low-speed rotation; stop the turning once the outlet temperature of the centrifugal compressor drops to normal temperature ； (d) Stop the lubricating oil pump when the temperature difference between the lubricating oil entering and leaving the bearing is less than 5°C ； (e) Systems such as cut-off control, etc. (5) Perform inspection work on the following items after shutdown ； (a) Open the gearbox viewing window to check for gear mesh marks ； (b) Inspect the wear condition of the bearing shells. 4.3 If no abnormalities are found during the vehicle inspection, it is considered that the main fan has passed the trial operation. 5. Normal shutdown 5.1 Reducing the load of the main fan: In accordance with the requirements of the process operations, the flow rate and outlet pressure of the main fan are gradually reduced. Once they reach a certain level, the anti-surge valve is opened, the outlet check valve is closed, and the electric butterfly valve at the outlet of the main fan is shut off, thereby stopping the supply of air to the unit. 5.2 Stop the main motor. 5.3 After the unit stops rotating, start the barring gear until the lubrication system is shut down. 5.4 Other: All systems such as water supply, electricity, instrumentation, and ventilation; the water seal tank at the exhaust end of the flue gas turbine should be filled with water, and the gate valve at the inlet of the flue gas turbine should be switched to manual operation. All the clot discharge valves on the machine are opened. 6. Emergency Shutdown 6.1. Situations requiring emergency shutdown: Sudden drop in lubricating oil pressure (and failure to return to normal levels even after the backup pump is started); pressure that is too low ； When the unit speed exceeds 105% and measures taken prove ineffective ； Self-protection shutdown of the motor itself ； Manual button for emergency shutdown (i.e., when the operator believes there is a fault with the unit and immediate shutdown is necessary) ； The displacement of a certain single shaft is excessive. 6.2 Methods of emergency shutdown: Apart from the shutdown via the manual button, the other methods mentioned are all automatic shutdowns. 6.3 Post-shutdown procedures: (1) Start the electric turntable until one minute before the lubrication system is shut down; (2) Stop the turntable mechanism, and one minute later, stop the lubrication pump; (3) Shut down various systems such as those for water, electricity, instrumentation, and ventilation. (4) Open all drain valves of the fully operational unit. 6.4 Analysis of the reasons for shutdown: After an emergency shutdown, it is necessary to immediately analyze the cause of the incident, identify the source of the fault, and take prompt action to enable restart as soon as possible. 6.5 After the trial operation is completed, the trial operation leadership team shall conduct a quality assessment of the results of the trial operation. V. Procedures for starting, operating, and shutting down the unit, as well as related matters: 1. The procedures for starting, operating, and shutting down the unit should be followed in accordance with the equipment manual and the operating instructions for the blower. 2. Detailed operation records should be kept during the unit’s trial operation. VI. Safety measures for testing: 1. Personnel participating in the testing must first receive safety training; they should be familiar with the testing plan and safety requirements, and adhere to them strictly. 2. On-site safety protection facilities and protective equipment must be fully available. 3. A designated operating area should be set up for testing, with warning signs posted; unauthorized personnel are not allowed to enter. 4. Repairing the equipment while it is in operation is not allowed. If repair is necessary, the power supply must be turned off; repairs can only be carried out after the equipment has stopped operating. 5. Do not use hands, feet, or objects to force the equipment to stop before it has come to a complete halt. 6. Before commissioning the equipment, it must be carefully inspected. It is strictly prohibited to leave any debris or tools inside the machine. VII. Commissioning organization design: Members of the commissioning leadership team