Those interested can take a look at our compressor maintenance plan for the installation

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Pump maintenance plan (draft): The rich gas compressor C1101 in my workshop has been operating unstably recently, with the main issues being high steam flow and difficulty in increasing its rotational speed. Upon analysis, the main possible cause is scaling on the turbine blades, which reduces the steam flow area within the flow channels; as a result, there is an insufficient amount of steam supplied. Due to the possibility of short-term shutdowns of this machine, the following plan has been formulated. 1. Shutdown: Upon receiving the shutdown command from the dispatch, proceed with the shutdown in the following order: 1.1 Before shutting down, notify the relevant personnel to conduct inspections and confirm the situation, and then inform the power station to pay attention to any changes in the medium-pressure steam pipeline network and the boiler ； 1.2 Gradually reduce the rotational speed to 5500 rpm, then shut down the machine using either the ESD, 505, or emergency shutdown device; follow the operating procedures for all other operations ； 1.3 Test the idle time of the steam turbine after shutdown, determine and record the time it takes for the speed to drop by 100 r/min, and plot it as an idle curve ； 1.4 Close the main steam isolation valve, and open the drain valves on the steam inlet pipeline and the cylinder balance pipe ； 1.5 Cooling water for steam seal cooler ； 1.6 Once the rotor has stopped, it is necessary to turn it manually; this should be done every 5 minutes. After the machine has been shut down for 1 hour, turning the rotor manually should be carried out every 30 minutes. This process continues until the bearing temperature drops to 40°C and the temperature inside the cylinder falls below 90°C, at which point turning the rotor manually can be stopped. 2. Maintenance tasks 2.1 Refer to the \"Detailed List of Turbine Maintenance Tasks.\" The maintenance tasks are determined based on the downtime; if the downtime is long (24 hours or more) and sufficient materials are available, it is recommended to carry out all the tasks. If the time is short (3–4 hours), the items marked with “*” are mandatory. 3. Startup 3.1 The relevant parties shall sign the \"Turbine Startup Conditions Confirmation Form\"; 3.2 The startup of the turbine must be carried out in strict accordance with the requirements of the startup system. The operator in the control room shall slowly open the control valve to start the turbine, maintaining its speed at around 600 revolutions per minute. On-site personnel must check whether the speed indicated by the tachometer matches the speed set in the control room. At the same time, it is necessary to comprehensively check changes in the turbine’s vibration, temperature rise, thermal expansion, secondary oil pressure, control oil pressure, shaft displacement, etc ； Close attention must also be paid to the thermal expansion of pipes in the steam system, particularly in the medium-pressure steam system, as well as to changes in supports and hangers ； The steam seal extraction system must also operate properly, with no steam leakage at the turbine’s steam seal. Maximum temperature rise rate during startup: The maximum allowable temperature rise rate for turbine components is in °C/min. For the main steam valve and control steam valves, it is 6; for the cylinder block, it is 4. The maximum temperature differences are as follows: Maximum allowable temperature rise rate for turbine components in °C – between the upper and lower parts of the cylinder: 50; between the cylinder wall and the outer edge of the flange: 140; between the cylinder flange and bolts: 45. After all parts of the turbine are functioning properly, it should be maintained at 600 revolutions per minute for 30 minutes, while simultaneously controlling the opening degree of the second-stage valve for medium-pressure steam. Then increase the speed to 1,000 revolutions per minute and maintain it for 60 minutes. In the future, each time the speed is increased, it is necessary to monitor changes in the turbine shafting, instrumentation, steam pipelines, secondary oil pressure, control oil pressure, etc. If everything is normal, the speed can be increased according to the acceleration curve: increase the speed to 3000 r/min and let it run steadily for 10 minutes ； Increase the rotation speed to 4000 r/min and run steadily for 10 minutes ； When the rotation speed reaches 5000 r/min, run stably for 10 minutes ； When the rotation speed reaches 6000 r/min, run steadily for 10 minutes ； When the rotational speed reaches 7000 r/min, run stably for 10 minutes ； When the rotational speed reaches 8000 r/min, run it stably for 10 minutes. When the rotational speed drops to 0.7 times the critical speed (9100 r/min), operate the machine stably for 30 minutes, and conduct a thorough inspection of the temperature, vibration, shaft displacement at all bearings in the machine, as well as the sound emitted by the rotor inside the machine. Continue to increase the speed using the governor until it reaches the rated speed of 9850 r/min. Once operation is stable, carefully monitor the temperature of the bearings, vibration levels, shaft displacement, and thermal expansion of the machine’s components. At the same time, check the operating status of all auxiliary equipment and keep detailed records of everything. Note: At any time, if there are abnormalities with the turbine, the speed-up time can be extended ； The machine can be stopped directly in case of an emergency. 3.4 After normal operation, gradually integrate into the system. 3.5 Closely monitor the turbine speed, steam flow rate, and steam backpressure, and keep records. List of Turbine Maintenance Tasks
Serial Number | Maintenance Task | Materials Needed | Category | Contractor | Timing | Remarks
---|---|---|---|---|---|---
1 | Replace the inlet valve filter screen | Filter screen | 1 | Blacksmith | Available in the material warehouse |
2 | Remove scale from the speed control valve spool | – | Blacksmith |
3 | Stop oil leakage from the speed control valve | Seal the leak | Blacksmith |
4 | Replace the filter screen on the compressor exhaust | – | Blacksmith |
5 | TIA1546 and TIA1547 are malfunctioning; replace them | Instruments |
6 | TI1501 is malfunctioning; replace it | Instruments |
7 | FI1503 is malfunctioning; replace it | Instruments |
8 | Leakage at the thermocouple connection at the rich gas outlet; replace the gasket | Instruments |
9 | Oil leakage due to sand holes in lubricating oil Pump B; seal the leak | Blacksmith |
10 | Seal all oil leaks in the oil station | Blacksmith |