Single-unit test plan for the pump

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Before starting up the plant, the performance of each new pump must be tested to check for any defects. During the testing process, a temporary filter screen should be installed on the pump’s inlet pipeline. The pump commissioning is also a process of cleaning the associated pipelines and equipment. The closed circulation loop should have as long a normal flow path as possible; the entire process system can be divided into several sections for circulation, or all pumps can be activated at the same time. Operators should be familiar with the information provided by the pump and motor manufacturers, and should comply with some of the specific regulations therein. 1. Individual testing of the motor 1.1 Preparation work ⑴ All installation tasks have been completed and approved, and the site has been cleaned. ⑵ Compare with the construction drawings to check whether the motor and its associated electrical equipment meet the relevant technical requirements; only after confirming there are no issues can testing begin. ⑶ Clean the motor bearing housing and replace the lubricating grease. ⑷ Manually turn the shaft to check whether the motor rotates smoothly and without any jamming. ⑸ Remove the idler wheel that connects the pump and the motor. ⑹ Prepare a thermometer to measure the bearing temperature. ⑺ Prepare a notebook and reports. 1.2 Individual testing of motors J0205A/B/ and J0206A/B: (1) Check the motor insulation; once it is satisfactory, supply power to the motor. ⑵ According to the requirements of the starting motor, start the motor and stop it immediately (i.e., test the motor). Check whether the rotation direction of the motor is consistent with the direction indicated on the motor, and look for any abnormal noises or other unusual phenomena. ⑶ Restart the motor; once it reaches its rated speed, check for any vibration in the motor, ensure that the electrical equipment and the motor are operating properly, and monitor the temperature rise of the bearings. If there is a problem, stop immediately, address it, and then try again. ⑷ After operating continuously for 4 hours without any vibration, and with the motor’s temperature rise as well as the electrical equipment meeting the specified technical requirements, the test can be considered successful; the motor was then shut down. ⑸ Record the test run conditions at regular intervals, such as current, temperature rise, and any problems that occur during the test. III. F0210 Flushing: 1. Remove all flow orifice plates from the desalinated water pipeline, shut down all pressure and flow switches, and inspect the sampling valve at the root. 2. Close the valves leading to L0205 and L0206, as well as those for the jacket water, distillation, compression, and makeup of deionized water. 3. Disassemble FV-1224, and the inlet ports of C0211, C0208, and F0210. 4. Shut off the cut-off valves before and after PV-1227 along with their associated lines, and close the cut-off valves from L0205, L0206 to F0210. 5. Close all drain valves of F0210, and close the inlet and return valves of J0204A/B, J0205A/B, and J0206A/B. 6. Open the vent valve at the top of F0210. 7. The pressure of the demineralized water used for flushing should be above 0.4 Mpa. IV. Flushing 1. Disconnect the pipe end behind the demineralized water-to-methanol interzone isolation valve, and repeatedly flush the pipeline entering the interzone; once it meets the requirements, reconnect it. 2. Segment by segment, repeatedly rinse the openings at item “3” of the preparation work; after one segment is found to be satisfactory, proceed to rinse the next segment. The flow rate of the rinsing water is controlled by the cut-off valve in the inlet area. The front and rear cut-off valves of FV-1224 are closed, and the branch line valves are fully open. 3. Raise the liquid level in F0210 to above 50%, then open the bottom drain valve for flushing. 4. When the liquid level of the F0210 glass level gauge is above 90%, disassemble the outlet end of the gas-liquid shut-off valve for cleaning. 5. Disassemble the dosing isolation valves L0205 and L0206, and flush these two sections of pipeline. 6. After the flushing is successful, close the feedwater inlet isolation valve, drain the water accumulated in F0210, open the manhole, and manually clean F0210 (the O2 level should be analyzed before entering the container). 7. Open all flow orifice plates, pressure and flow transmitter switches within the recovery range, as well as the root valve for analysis sampling. V. Flushing of the pump inlet pipeline: 1. F0210 and its inlet pipelines have been successfully flushed; all instruments and glass level indicators for F0210 have been restored, and the main control system can display and adjust values properly. 2. Remove the flow orifice plate from the pipeline and turn off all transmitter switches. 3. Remove the pump inlet filter, use the inlet valve to control repeated flushing of the inlet pipeline, and install a temporary filter screen once it is satisfactory. 4. Disassemble the check valve at the pump outlet, open the inlet valve of the pump to flush it, and reinstall it once it is satisfactory. Disassemble FV-1215, 1216, 1217, 1218. Open the inlet valve of the pump. 2. Individual testing of pumps J0205A/B and J0206A/B: (1) The individual testing of the pumps is carried out after the equipment and pipelines have been properly purged and flushed. ⑵ Use cooling water or circulating water for testing. A temporary water source is required for pump testing; multiple temporary water sources can be considered to allow for flexible selection based on the conditions at the time of testing. ⑶ The preparation work, methods, and requirements for testing all pumps are the same; the only difference lies in the location where water enters the pump and the discharge point. Apart from the specific requirements that need to be described separately, everything else is explained once only without repetition. ⑷ This plan should be read in conjunction with the flowchart. ⑸ Since the design of this project had not been finalized at the time this plan was prepared, the cleaning of pipelines/equipment, as well as the selection of water inlets and outlets, should be adjusted appropriately according to the on-site conditions. 2.1 Inspection: Compare with the construction drawings to check whether the inlet and outlet pipes, fittings, as well as indicating and measuring instruments of each pump are in accordance with the drawings. Check the tightness of the pump’s foot bolts to ensure that the pump is installed in accordance with the specified requirements. 2.2 Preparation work for individual pump testing ⑴ A temporary filter screen should be installed on the pump’s inlet pipeline. ⑵ Connect the idler wheels of the pump and the motor. Clean the bearing housing of the pump and replace the lubricating grease. ⑶ Clean the motor bearing housing and replace the lubricating grease. ⑷ Open the seal water and cooling water valves of the pump. ⑸ Prepare a thermometer to measure the bearing temperature of the pump. ⑹ First, manually turn the crank to check whether it rotates smoothly and if there is any sticking. ⑺ Remove the flow orifice plate and turbine flow meter from the pump outlet pipe. ⑻ Open the pump inlet valve to introduce water into the pump, and open the pressure gauge cock and drain valve at the pump outlet to discharge the gas inside the pump. ⑼ Power is supplied to the motor. ⑽ Open the valves and related pipelines associated with the mechanically sealed pump. 2.3 Individual testing of the pump ⑴ Close the pump outlet valve and open the return line flow control valve. After exhausting air from the pump and performing a rotation check to confirm there are no issues, start the pump in accordance with the operating procedures, then stop it immediately. Check whether the pump’s operating direction is consistent with the direction indicated on the pump. Start the pump and conduct a 8-hour continuous operation test. ⑵ Start the pump again; once it reaches normal operating speed, gradually open the pump outlet valve to control the outlet flow rate and prevent the motor from overloading. ⑶ Check the operating conditions, such as vibration and bearing temperature rise, for any abnormalities; also verify whether the pressure and flow rates at the pump’s inlet and outlet are stable, and whether the motor is operating above its rated current. If any abnormalities are detected, the pump should be stopped immediately for treatment. ⑷ During operation, if the inlet pressure drops, the pump should be stopped to clean the filter before attempting to restart it. ⑸ Each pump must run continuously for at least 4 to 6 hours without any abnormalities before it can be considered to have passed the testing, and only then can the pump be stopped. ⑹ . After 8 hours of continuous operation without issues, stop the pump, remove the temporary filter screen, and install the permanent one. ⑺ During the testing period, pay attention to maintaining the pressure at the pump’s inlet and outlet, and replenish water as needed to prevent damage to the pump due to vacuum conditions. ⑻ Record the test run data and any issues that occur every half hour. VI. Flushing of the pump outlet pipeline 1. Notify the water treatment station to supply qualified deionized water to maintain the level in F0210, and use LIC-1208 to control the level at 80%. Run the pump in intermittent mode to check whether its rotation direction is correct. 2. Restart the pump intermittently, and open the valves of the return line flow control valves (FV-1215, 1216, 1217, 1218) to flush them until the flushing is satisfactory. (During the flushing process, closely monitor the level of liquid in F0201 to prevent pump damage due to vacuum; also monitor the motor current – if there is an overcurrent, reduce the outlet valve opening). Install a flow control valve on the return line, and remove the check valve behind the control valve. 3. Start the pump intermittently and repeatedly flush the area behind the return flow control valve and at the location where the check valve is removed until it meets the requirements. Install a check valve. After opening the check valve, close the rolling valve, disconnect the F0210 connection to the main pipeline, start the pump to perform flushing until the required standard is met, and then reattach the disconnected part. Streamline the import and export processes for J0205 and J0206. Last edited by zjx1973 on 2008-1-4 22:20.]