Hydrogen compressor maintenance

Operating, inspecting, maintaining, and managing centrifugal compressors – which are large, complex, high-speed, high-pressure, and high-flow machinery – requires comprehensive inspection, maintenance, and management by all staff on a regular basis, including the following tasks. (i) Operational inspection and maintenance: Carry out tasks in strict accordance with operating procedures and post-specific maintenance guidelines. 1. Check the unit’s operating parameters, signal indications, and the parameters of the process gases at the inlet and outlet of the operating equipment (temperature, pressure, flow rate, pressure difference) ； Unit vibration values, shaft displacement, bearing temperature ； Valve openings for air, oil, and water circuits in the unit, as well as guide vane openings ； Check the pressure and temperature of the oil and water systems, as well as the pressure difference in the oil circuit, along with the microcomputer-controlled valves, operating electrical devices, and on-site panel indicators. Operation status of fans in factory buildings and soundproof enclosures. 2. On-site operational inspections, daily checks, weekly inspections, and comprehensive inspections: During normal operation of the unit, it is necessary to continuously monitor changes in its operation, pay close attention to trends in these changes, prevent accidents from occurring, and ensure safe operation. 3. Operation, maintenance, and adjustment of the cooling system: (1) Follow the operating procedures to properly adjust the valves and switches, as well as to regulate water volume, water pressure, and water temperature to normal levels. ⑵Maintenance and adjustment A, Air cooling: Mainly involves dust removal from the motor. B. In terms of water cooling, many problems often arise in daily operations, such as scaling on the water side of the intercooler, blockages on the water side, dirt on the air side, reduced water flow, and increased inlet water temperature. All of these issues can affect the heat exchange efficiency of the cooler. It needs to be repaired and cleaned. 4. Maintenance of the lubrication system: ⑴ Tank inspection: Oil level – Ensure that during the operation of each unit, the oil level in the main tank is above 2/3. For nitrogen compressors, since the main motor bearings are lubricated by oil in the bearing oil tank, it is important to top up the oil level in the motor oil tank promptly when it becomes low. Oil quality: According to regulations, the oil quality is tested once every 3 months. ⑵Oil pump inspection: No abnormal noises; the measured vibration speed should be < 2.8 mm/s. ⑶Oil cooler inspection: The oil temperature can be adjusted within the specified range; the oil cooler is operating properly, with no leaks or spills, and it is cleaned during annual maintenance. ⑷Oil filter inspection: The resistance of the oil filter should be < 0.15 MPa, and the filter element should be cleaned or replaced during annual maintenance. ⑸Pay attention to the effects of seasons and temperature differences between day and night on the temperature of the lubricating oil, and make adjustments gradually to avoid causing significant impacts on the vibration of the compression unit. ⑹Pay attention to the impact of leaks in the lubricating oil circuit system on operating parameters. In short, among the auxiliary devices of a compressor unit, the lubricating oil system plays an important role that cannot be ignored. As personnel responsible for operating and maintaining compression units, it is necessary to carry out a thorough and careful tuning of the lubrication system after the unit has been overhauled ； During normal operation of the unit, conduct thorough inspections, strengthen maintenance, and operate in accordance with the procedures. 5. Try to avoid emergency shutdowns while the unit is under load; during operation, emergency shutdowns should be avoided as much as possible, and such shutdowns should only be carried out in cases specified by the operating procedures. After taking emergency shutdown measures, inspections must be carried out strictly in accordance with the emergency shutdown procedures.

The most comprehensive manual for the installation and maintenance of air compressors – Chapter 1: General Provisions. Article 1: This section applies to the installation of positive displacement compressors such as reciprocating piston, screw, vane, and diaphragm types. Article 2: This document contains the specialized technical specifications for compressor installation projects. The general technical requirements for such installation projects shall be in accordance with the provisions set out in the \"General Provisions\" of these standards. The disassembly and cleaning of the compressor shall meet the following requirements ； I. Compressors installed as a whole generally require the following disassembly and cleaning tasks ； 1. For reciprocating piston compressors, the piston, connecting rod, air valves, and packing should be removed, and the surface of the equipment as well as the removed parts should be cleaned thoroughly; air valves and packing must not be cleaned with steam ； 2. For reciprocating piston compressors sealed with oil seals, when installed within the oil seal lifespan specified in the equipment’s technical documents, all components except the degassing valve can remain unremoved and unwashed. 3. For screw compressors and vane compressors, when installed within the oil seal lifespan specified in the equipment’s technical documents. It does not require disassembly for cleaning; those with special requirements should follow the provisions in the equipment’s technical documentation ； 4. The diaphragm compressor should have its bonnet, diaphragm, and suction and exhaust valves removed and cleaned. II. For compressors assembled on-site, the main units, components, and auxiliary equipment should be cleaned. Valve seats, packing, and other seals should not be cleaned with steam; after cleaning, any residual cleaning agents or moisture must be removed. It is also necessary to check for any damages or defects on the surfaces of the components and equipment. Once everything is in order, a thin layer of lubricant should be applied (components that come into contact with the medium in lubrication-free compressors should not be oiled). Chapter 2: Compressors Installed as a Whole – Article 3: The vertical and horizontal levelness of the compressor shall not exceed 0.2/1000. Measurements should be taken at the following locations: 1. For horizontal compressors (including those with symmetric balance), measurements are taken on the compressor body’s sliding surface or another reference surface ； II. For vertical compressors, remove the cylinder head and make measurements on the flat surface of the cylinder top ； III. For other types of compressors, measurements are taken on the exposed part of the main shaft or on other reference surfaces. Chapter 3: Reciprocating Piston Compressors Assembled on Site Article 4: The assembly of the casing and the main body shall meet the following requirements: 1. Fill the casing with kerosene up to the highest level of the lubricating oil; no leakage shall occur after 8 hours ； II. The longitudinal and transverse levels of the fuselage shall not exceed 0.05/1000. And it should be measured at the following locations ； 1. The longitudinal levelness of horizontal compressors (including those with symmetrical balance) is measured at two points, one in front of and one behind the slide, while the lateral levelness is measured at the bearing holes of the compressor body ； 2. Measure on the joint surface of the vertical compressor body. 3. The L-type compressor is measured on the flange surface of the fuselage. III. The misalignment of the axis lines of the main bearing holes in the two compressor housings shall not exceed 0.05 millimeters. Article 5: The assembly of the crankshaft and bearings shall meet the following requirements: 1. The oil passages of the crankshaft and bearings must be unobstructed and clean, and the oil plug on the crankshaft as well as the locking mechanism of the balance weight must be securely fastened ； II. The bond between the shaft bearing steel shell and the bearing alloy layer must be strong; there should be no delamination or abnormal noises ； III. The back side of the bearing shell should fit tightly against the bearing shell seat, with the contact area being less than 70% ； IV. The radial and axial clearances between the bearing shells and the main shaft journals shall comply with the specifications in the equipment’s technical documents ； V. The contact arc surface between the lower half of the split-thick-walled bearing shell and the shaft journal should be no less than 900, and the contact area should be no less than 70% of that contact arc surface ； For quarter-turn bearing shells, the contact area between the shaft journal and the lower and side shells should be no less than 70% of the area of each shell ； Thin-walled bearing shells do not require lapping during assembly, but their clearance must comply with the specifications outlined in the equipment’s technical documents ； VI. The levelness of the crankshaft should not exceed 0.1/1000; at positions every 900 degrees of rotation of the crankshaft, measure it on the main journal using a level ； VII. The deviation of the crankshaft axis from the slide way axis shall not exceed 01/1000 ； VIII. Check the distance between the cranks in the upper, lower, left, and right directions; the variation in this distance should comply with the specifications stated in the equipment’s technical documents. In the absence of such specifications, the variation should not exceed one ten-thousandth of the stroke length. IX. After the crankshaft is assembled, turn it a few times by hand; there should be no resistance. Article 6: The assembled cylinder shall meet the following requirements: 1. After the cylinder is assembled, its water circuit must undergo a leak test in accordance with the specifications provided in the equipment’s technical documents; no leaks are allowed ； II. The misalignment between the axis of the horizontal cylinder and the axis of the slide shall be within specified limits, and the direction of this misalignment shall be consistent with the inclination direction of the slide ； When adjusting the cylinder bore, gaskets should not be placed on the cylinder end face. III. When aligning a vertical cylinder, the clearance around the piston within the cylinder should be even, with the deviation being less than 1/2 of the average clearance between the piston and the cylinder. IV. The misalignment between the cylinder axis and the slide rail axis. V. Cylinder diameter (in millimeters); the radial displacement should not exceed (millimeters), and the inclination should not exceed ≤100; 0.05. Article 7: The connecting rod must meet the following requirements: I. The oil passages in the connecting rod must be unobstructed and clean ； II. The contact area between the thick-walled connecting rod big end bearing and the crank pin should be no less than 70% of the area of the big end bearing ； The thin-walled connecting rod big end bearings do not require lapping; the contact area between the connecting rod small end bearing (shaft bearing) and the crosshead pin should be no less than 70% of the area of the small end bearing (shaft bearing). III. The radial and axial clearances between the big end bearing of the connecting rod and the crank pin shall comply with the specifications stated in the equipment’s technical documents ； IV. The radial clearance between the connecting rod pin bushing (bearing) and the crosshead pin, as well as the axial clearance between the pin bushing (bearing) and the crosshead body, must all comply with the specifications stated in the equipment’s technical documents ； V. The linkage bolts and nuts should be tightened and secured evenly, using the tightening torque recommended in the equipment’s technical documents. Article 8: The assembly of the crosshead shall meet the following requirements: 1. The contact area between the crosshead slider and the slideway shall not be less than 60% of the area of the slider ； II. The clearance between the crosshead slider and the slideway must meet the specifications stated in the equipment’s technical documents at all positions along the stroke ； III. For symmetrically balanced compressors, the crossheads on both sides of the casing move in a symmetrical manner, and the forces acting on the sliders are different. During assembly, it is necessary to follow the markings provided by the manufacturer to prevent incorrect installation and ensure that the axis of the piston rod aligns with the axis of the slider track ； IV. The connecting bolts and locking devices of the crosshead pin must all be tightened and secured firmly. Article 9: The assembly of pistons and piston rods shall meet the following requirements. First, the piston rings must be inspected for light leakage inside the cylinder; there should be no more than two areas where light leaks occur along the entire circumference, each area should not cover an arc length of more than 45 degrees, and the distance from such areas to the opening of the piston ring should be greater than 30 degrees (except for plastic rings) ； II. The clearance between the piston ring and the end face of the piston ring groove, as well as the clearance at the opening where the piston ring is inserted into the cylinder, must all comply with the specifications stated in the equipment’s technical documents ； III. The piston rings should be able to rotate freely when touched by hand inside the piston ring groove; when pressure is applied to the piston rings, they should sink completely into the grooves. When the piston is installed in the cylinder, the openings of piston rings in the same group should be offset from each other, and all of these opening positions should also be offset from the valve holes ； IV. The clearance between the piston and the cylinder wall should comply with the specifications outlined in the equipment’s technical documents. For horizontal cylinders and pistons with bearing alloy poured at the bottom, the upper clearance may be about 5% less than the average clearance compared to the lower clearance ； V. The contact area between the piston bearing surface coated with piston bearing alloy and the cylinder wall surface should be no less than 60% of the arcuate surface of the piston bearing. VI. The piston rod and piston, as well as the piston rod and crosshead, must be firmly connected and locked in place ； VII. The clearance between the piston and the inner and outer dead centers in the cylinder shall comply with the provisions specified in the equipment’s technical documents. Article 10: The packing and oil scrapers shall meet the following requirements: 1. When assembling the packing, its oil, water, and gas passages must be unobstructed and clean ； II. The contact area between the end faces of each packing ring and the end face of the packing box should be no less than 70% ； III. The contact area between the packing, the wiper, and the piston rod should be no less than 70% of the area of that set of rings ； IV. When assembling the oil scraper, the cutting edge should not be rounded, and the direction of the edge must not be reversed ； V. After the filler and wiper are assembled, the gaps in all areas shall comply with the specifications stated in the equipment’s technical documents ； VI. The locking device of the packing gland must be securely locked. Article 11: The assembly of air valves shall meet the following requirements: 1. The elasticity of the valve spring shall be uniform, and there shall be no sticking or misalignment of the valve disc and the spring ； II. The gas valve control device and the valve disc lift shall comply with the provisions of the equipment’s technical documents. III. After the gas valve is assembled, kerosene should be injected to conduct a tightness test; only intermittent droplet-like leaks are permitted. Article 12: The assembly of the lubrication system shall meet the following requirements: 1. The oil pipes shall have no sharp bends, twists, or flattening ； II. The transmission mechanism connecting the crankshaft to the oil pump, or the crankshaft to the oil injector, should operate smoothly ； III. The pipelines, valves, filters, coolers, and other components of the lubrication system shall be subjected to a tightness test at the pressure specified in the equipment’s technical documents after assembly; if no such specification is provided, the test shall be carried out at the rated pressure, with no leakage allowed. IV. The oil pipe should first be vented and drained before being connected to the oil supply and lubrication points. Chapter 4: Auxiliary Equipment Article 13: Before installing the auxiliary equipment of the compressor (such as coolers, gas-liquid separators, buffers, dryers, air storage tanks, filters, vent tanks, etc.), it is necessary to check against the construction drawings to ensure that the positions of the pipe connections, the bolt holes, and the foundation are correct, and to verify that all pipelines are unobstructed. Article 14: Pressure-bearing auxiliary equipment shall undergo strength and tightness tests at the pressures specified in the technical documents. In the absence of such specifications, the strength test pressure shall be determined as per relevant regulations, while the tightness test pressure shall be the rated pressure. Determination pressure P (kgf/cm2); Test pressure PS (kg/cm2): 12, 1.5PP + 31.25P. According to Article 15, the strength test shall be conducted using water as the medium. The equipment must be held at the test pressure for 5 minutes, after which the pressure is reduced to the rated value. A thorough inspection is then carried out by gently tapping along both sides of the weld at a distance of 150 millimeters; no leaks or deformation should be present. Article 16: When conducting a tightness test using air or an inert gas as the medium, it is advisable to use the following methods for inspection: 1. Apply soapy water to the bolts and joints such as rivets and welds, and observe for any bubbles ； II. The leakage rate or pressure drop of the gas over one hour (with observation lasting at least 1 hour) shall comply with the specifications stated in the equipment’s technical documents. Article 17 Pressure-bearing auxiliary equipment may be exempted from strength testing and subjected only to a tightness test if it meets all three of the following conditions ； I. Strength tests have been conducted at the manufacturing plant, and a certificate of conformity is available ； II. No visible signs of damage on the surface ； III. Install within the period specified in the technical documents. Article 18: The levelness of the tubes in a spray-type cooler, as well as the verticality of their vertical surfaces, shall both comply with the specifications stated in the equipment’s technical documents ； If not specified, it shall not exceed 1/1000 ； The water overflow from the overflow tray is even. Article 19: The levelness of horizontal equipment and the verticality of vertical equipment shall comply with the provisions specified in the equipment’s technical documents ； If not specified, it shall not exceed 1/1000. Chapter 5: Commissioning Article 20: Before commissioning the compressor, the following requirements must be met. First, all fasteners such as those on the cylinder head, cylinders, frame, crosshead, connecting rods, and bearing caps must be thoroughly checked to ensure they are properly tightened ； II. The instruments and electrical equipment should be properly adjusted, and the rotation direction of the motor should meet the requirements of the compressor ； III. The specifications and quantity of lubricating grease shall comply with the requirements specified in the equipment’s technical documents, and the oil supply should be normal ； IV. The intake pipeline should be clean ； V. The water inlet and outlet pipelines should be unobstructed ； VI. Rotate the compressor a few times; it should move smoothly without any obstruction ； VII. Safety valves at all levels should be sensitive.

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