Synthetic Ammonia Process Technology Exchange Area [Daily Question 2009-03-04]

Initial startup purging procedure for the compressor system: Check whether the oil circuit is functioning properly, then purge each section of the pressure oil pipeline sequentially (without bypassing pipes or valves). While purging, tap the outer walls gently and adjust the flow rate, varying it from high to low, repeating this process multiple times. Once the gas emitted shows no contamination when tested using a test plate coated with butter or covered with a white cloth, it is considered satisfactory. During the purging process, after each section is purged, the appropriate blind flange is removed immediately, a valve is installed, and then the next stage of purging proceeds. Note that it is strictly prohibited to use iron tools to strike the outer wall during the cleaning process, and it is also strictly forbidden to try to wipe away the debris using hands at the flange separation area.

I: Plan for purging the water system 1. Water supply valves on each cylinder. Filler water supply valve. All water-cooling supply valves are in the closed position. 2. The end blind plates of the main pipe branches have been removed. Remove the baffle from the flanges of the water coolers in sections 1–3 and the inlet pipe joints. 3. Open the main water inlet valve; blow out all debris, sludge, etc. from within the main pipes and branch pipes, then close the main water inlet valve. 4. Install the end blind flanges on the main pipe and branch pipes, reopen the main water inlet valve, open the water supply valves for sections 1–3 of the water coolers one by one, blow air through them and then close the valves; subsequently, open the water supply valves for each cylinder and packing unit, blow air through them as well and then close those valves. II: Purging and testing of the oil circuit system 1. Wash the tank in the light oil station, purge the oil pipelines, start the circulation oil pump, determine the rotation direction of the high-pressure oil injection pump, and fill it with the specified amount of lubricating oil according to the oil level indicator. 2. Purging method 2.1 Oil filter: Remove all the pipes at the connection to the compressor, purge them with an air pump, pass oil through them once, and then reinstall them. 2.2 Remove all the oil supply lines for the bearing bushes inside the fuel tank; install blind flanges on the flanges of the oil supply branches for the slides, as well as on the flange at the inlet of the main oil pump. Remove the flanges connecting the crankcase return oil pipes to the light oil station, and use baffles to direct the recovered oil into the waste oil tank. 2.3 Start the circulating auxiliary oil pump for 5–10 minutes, then stop it; simply reinstall all the removed flanges.

Compressor purge testing plan: Objectives and requirements: Objective: Before a newly installed compressor is put into operation after all installation work is completed, it must undergo a period of testing to verify the quality of the installation (equipment, electrical systems, instruments, safety devices, etc.), to ensure that its performance and technical specifications meet the required standards, and to allow the transmission components, moving parts, operating mechanisms, and sealing elements to undergo the necessary running-in process. At the same time, any defects or potential risks that arise during the testing process are promptly eliminated to improve the system, ensuring reliable normal operation during testing, the prevention of accidents, and full compliance with technical requirements. Requirement: The single-unit testing time must be strictly followed, and any issues must be addressed promptly. No component, no control point, no weld, and no sealing point shall be missed; absolute assurance is provided for quality monitoring. Test drivers must absolutely obey commands; it is strictly prohibited to violate labor discipline. Any instances of insufficient personnel or leaving one’s post will be dealt with severely once discovered. During testing, each component, control point, weld, and seal point must be monitored and inspected by a dedicated person, with accurate and clear original records kept. Be careful during testing, pay attention to each other when carrying out cross-tasking, and implement protective measures for areas that are toxic or harmful. The commissioning of a compressor involves six main steps: 1. Pre-commissioning preparations; 2. No-load testing; 3. Purging of the compressor’s pipelines; 4. Load testing (Part 1); 5. System purging; 6. Load testing (Part 2). I. Pre-commissioning preparations: 1. Establish a unified command team for commissioning, with each member responsible for their own tasks, and there must be a clear commissioning plan in place. 2. Projects that are interrelated with the compressor testing must be completed, and the site must be thoroughly cleaned and rinsed with water. 3. The installation, inspection, testing, and adjustment records for the compressor and its auxiliary equipment as well as valves are complete and have passed verification. 4. For the commissioning of the lubricating oil system, cleaning work must be completed first before commissioning the compressor. The trial operation of the oil system was completed; the system’s sealing performance and cleanliness met the requirements for operation, new oil was installed, and the cylinder packing lubrication system is in good condition. 4.1 Before testing and cleaning the circulating lubricating oil system, it is necessary to disconnect the fuel supply connector of the fuselage and use a short rubber tube to direct the fuel directly to the bottom of the fuselage compartment. The oil temperature should be maintained at around 30°C, while the oil pressure should be kept at 0.2 Mpa. The oil pump should be operated for 8 hours to check the sealing performance and cleanliness of the system. After cleaning, the contaminated oil should be removed, the oil filter should be cleaned, and any defects found should be rectified. Replace it with clean lubricant and connect the fuel supply connector to the airframe. Then start the oil pump to maintain the oil pressure at 0.2 Mpa (gauge pressure), rotate the compressor to check the condition of each oil supply point, and make any necessary adjustments. 4.2 When lubricating and cleaning the cylinder packing, first disconnect the oil injection pipe connector, use compressed air to clean the pipe, inject lubricant into the oil injector, and then start the injector. At each oil supply point of the pipes, check the oil output and the degree of cleanliness, and conduct adjustment tests for the oil supply volume at each point. Check the operation of the check valve; once it is confirmed to be functioning properly, connect the oil injection connector and supply oil to the injection point. At the same time, rotate the compressor to check and adjust the performance of the oil injector. Generally, an increased oil supply volume is required during the initial operation of a new unit. 5. For the water circulation test of the cooling water system, open all the return valves and turn on the valve of the main water supply pipe to fill the entire cooling system with water. Check the pressure in the main pipes (around 0.25 Mpa) as well as the water volume, and verify that the return flow is unobstructed. Close the return valves one by one, paying attention to any changes in water pressure. After the inspection, close the water supply valve, and open the return water valve and the backwash valve. 6. Trial operation of the main motor. Disconnect the couplings at both ends, remove the thrust ring, push the crankshaft outward to the end, and secure it. The main motor is operated alone for 2 hours, and experiments and inspections are carried out on it in accordance with oil-related standards and technical regulations. The inspection items include: impulse test, ventilation conditions, noise level, bearings, current and voltage, temperature, vibration, etc. Any faults or defects must be addressed promptly before the motor can be used. 7. The testing of the protection device shall follow the instructions. Check the start conditions and ensure that the interlock circuit for shutdown due to operation protection alarms is functioning properly, making any necessary adjustments. 8. Check whether the measuring instruments are installed correctly and completely, and review the signal instruments and adjustments. The instruments are complete and in good condition. II. No-load test run – Preparations before starting the compressor: 1. Thoroughly inspect the stability of each stage as well as the reliability of the anti-loosening devices. 2. Check whether the cylinder support is installed correctly and firmly. 3. For the dynamic circulation oil pump and the main oil supply unit, once the pressure of the circulating oil stabilizes at 0.3 Mpa–0.4 Mpa and the oil supply unit is functioning properly, rotate the compressor more than three times; no abnormalities such as collisions or obstructions should occur. 4. Open the water supply valve and the air cock; wait until the water pressure stabilizes above 0.2 Mpa and the water supply and return flow are normal. 5. Remove all the intake and exhaust valves from the cylinders at each level. Then, wrap the valve openings with oil-copper (or steel) wire cloth (40 mesh), and install coarse wire mesh (about 20 mesh) at the connections of the intake and exhaust pipes of each cylinder to prevent large particles of impurities that have not been removed from entering the cylinders. 6. Start the ventilator for the main motor. Start the main motor: 1. Verify that the compressor is ready for operation; contact the on-duty electrician to supply power. Only after inspection reveals no issues can the switch be closed, and the indicator light will then signal that the motor can be started. 2. Start the main motor in jog mode to check the movement of each component; only when there are no obstructions or abnormal noises should the main motor be started for 10 minutes. Listen for any abnormal noises and observe the vibration of the unit. After stopping, check for overheating or wear on the bearing piston rods. Check the crosshead window and valve ports for metal particles carried along with the oil. 3. Once all the above checks show normal results, the main motor can be started for the third time to operate under no-load conditions for 30 minutes, followed by a stoppage for inspection. Only after three such repeated inspections show no abnormalities or faults can the compressor be allowed to run continuously under no-load conditions for a period of not less than 8 hours. 4. During no-load operation, it is necessary to closely monitor the heating level of various friction areas and adjust the oil supply volume accordingly. Check the sound and vibration of the compressor during operation, address any faults promptly, and keep track of the temperature of various components as well as the detailed process of handling incidents and making repairs. 5. Precautions during no-load operation. The temperature of the main bearings should not exceed 55°C, and the temperature of the slip rings in the packing should not exceed 60°C. Ensure that the circulating oil pressure remains stable at 0.4 Mpa. Check the oil supply at the oiling points at any time; during the testing phase, the oil supply should be 50% higher than the normal level – 30 drops per minute for high-pressure fillers, 20 drops per minute for low-pressure fillers, and 20 drops per minute for cylinders. The noises and vibrations of all components during operation are normal, and the lubrication system is functioning properly. Keep the cooling water flowing and pay attention to changes in water temperature. Pay attention to checking the sound of all moving components, the vibration of the unit, and the temperature rise of the main bearings and piston rods. III. Purging operation: Before starting the compressor under load, a purging operation must be carried out first to thoroughly clean any debris and residues in the main unit and pipelines, thereby ensuring proper operation of the compressor. 1. Preparatory work before cleaning: Check that the wooden hammers, hand hammers, lead paint, white cloth, wire mesh, blind plates (movable blind plates), baffles, as well as the personal protective equipment required for cleaning, are all available and meet the specified requirements. Check whether the gland covers of each intake and exhaust valve have been removed, whether they are supported and tightened properly, and whether wire mesh as well as baffles that do not interfere with air intake are in place at the inlet pipes of each cylinder. Remove the flanges and instrument connections related to the buffers, coolers, and oil-water separators at all levels; take out the valve cores of the check valves; and install a pressure gauge on the pipeline to be purged. The pressure ranges applicable during cleaning are as follows: One outlet – four inlets: 0 – 0.6 Mpa; Four inlets – seven inlets: 0 – 1.6 Mpa; Seven outlets: 0 – 2.5 Mpa. During cleaning, the inlet pipes of each cylinder are separated from the cylinders, while the outlet pipes continue to be connected to them. Once cleaning is complete, the equipment, pipelines, valves, and instruments are restored to their normal state, and the air valves are cleaned and replaced. Before cleaning, there must be a clear division of tasks, responsibilities assigned to specific individuals, and unified command. The equipment must be monitored by a dedicated person, and the movable blind plates should be secured and under supervision. Be careful and keep records while blowing out. 2. Methods and steps for cleaning by blowing: Primary cleaning – The inlet pipe is manually tapped to dislodge slag and debris, which then fall into the water reservoir at the bottom of the separator. Check the tightness of the wire mesh installed at the inlet flange, clean and install the inlet and exhaust valves, remove the blind plate on the secondary inlet, remove the one-way valve, and remove the valve at the base of the primary cooling oil-water separation system as well as the valve at the base of the pressure gauge. The above handling is correct; start the compressor to perform a cleaning cycle. To clean it thoroughly, continuously strike the pipe welds with a wooden hammer or hand hammer, adjust the pressure by using a removable blind flange, and repeat the process of venting. Blow from the outlet of one cylinder to the inlet of one or two cylinders; use a white damp cloth to inspect the circuits, drain lines, and the valves upstream of the pressure gauges at the same time – if no debris is found, it is considered acceptable, and the machine should be shut down for a second cleaning process. Second-stage purging: This is the same as first-stage purging. Third-stage purging: Connect the third-stage inlet pipe, install the third-stage inlet and exhaust valves; remove the flange in front of the valve and install a blind plate or a movable baffle (a baffle can also be installed after the third outlet valve). Place a baffle in front of the three-outlet-one-valve as well, leaving an air outlet open. Remove the three-way-four-way valve and install a blind plate. Once everything is ready, start the compressor. After checking that everything is functioning properly, use the one-in-one and two-in-one valves to control the purging pressure. Continue purging until the three-way-four-way connection meets the required standards; then install the third outlet valve head and remove the blind plate from that connection. Purge up to the fourth-stage inlet, following the same steps as during the previous purging process. The pipelines in front of each circuit valve, drain valve, and pressure gauge valve are also purged simultaneously. 3. Purging at other levels: The purging process for other levels is the same as mentioned above; the purging time for each level should be no less than 2 hours, with completion of purging serving as the criterion. Time obeys mass. 4. The equipment pipelines that have been cleaned should be restored promptly, and valves, instruments, and check valves should be installed in a timely manner. 5. During the blowing process, someone should be assigned to carry out inspections, monitoring equipment, electrical components, instruments, sounds, vibrations, pressure, temperature rises, and current changes; any abnormalities or potential hazards identified must be addressed promptly. IV. Load Testing (I) 1. Preparations for load testing: Load testing is the most important phase of compressor testing, aimed at thoroughly evaluating the performance of the compressor unit, identifying any defects, and making necessary improvements to create the conditions for the compressor to operate properly. The working medium for the load test is air, with a maximum exhaust pressure of 10 MPa. 2. The load test is divided into three pressure-raising stages, with the stable pressure duration for each stage being no less than 1 hour, in order to examine and assess the compressor’s performance under the load conditions of that stage. The pressure distribution across various sections and levels is as follows: (unit: Mpa) First phase (1 hour): Outlet 1: 0.03; Outlet 2: 0.078; Outlet 3: 0.16; Outlet 4: 0.3; Outlet 5: 0.5; Outlet 6: 1.3; Outlet 7: 3.5. Second phase (2 hours): Outlet 1: 0.06; Outlet 2: 0.16; Outlet 3: 0.33; Outlet 4: 0.58; Outlet 5: 1.05; Outlet 6: 2.69; Outlet 7: 7.0. Third phase (2 hours): Outlet 1: 0.088; Outlet 2: 0.22; Outlet 3: 0.47; Outlet 4: 0.88; Outlet 5: 1.5; Outlet 6: 3.7; Outlet 7: 10.0. Pressure control and adjustment can be achieved using the valves in each circuit, the main return valve, and the vent valve; temperature control can be accomplished by adjusting the water flow rate. 3. Load testing: Open all circuit valves, bypass valves, vent valves, oil and water discharge valves, and pressure gauge valves. Start the cooling water and lubricating oil systems in accordance with the normal startup procedures. Check and adjust the pressures, start the ventilators, turn the shaft several times using a shaft turning rod, and then contact the electrician to supply power. After a thorough inspection with no issues found and everything confirmed to be in order, making it suitable for operation, the main engine can be started only after approval by the test drive leadership team. After the main unit has been air-shipped for 30 minutes, and once it is confirmed that everything is normal, the voltage can be increased gradually, at a rate of 0.3–0.5 Mpa per minute. When the system reaches half load (typically at a pressure of 5–10 Mpa), a gas-tightness test is carried out simultaneously (pressure testing and leak detection). Soap water is applied to the welds and joints of the equipment and pipelines to thoroughly check for leaks; any leak points identified are marked for prompt repair. If there are no obvious leaks at this stage, a shutdown pressure retention test can be conducted. It is considered successful if the pressure does not drop within 30 minutes of parking; the pressure testing must be conducted rigorously, with no overpressure allowed and no leaks permitted. During the load test, inspection records are made every half hour, and oil and water are drained simultaneously; any abnormal phenomena that occur are addressed promptly. The pressures and temperatures at each stage during the load test did not exceed the design specifications; after the pressure at the final stage was increased to 10 Mpa, the machine operated without any abnormalities for 2 hours. During the load testing, attention should be paid to tightness and anti-loosening measures, as well as to heating conditions. It is necessary to closely monitor the sealing performance of all connections in the equipment and pipelines at each stage, as well as the sealing quality of the packing and the degree of heating. The safety valves and the security interlock systems must also be checked to ensure that these safety devices function properly. 4. Main inspection items and technical requirements for load testing: inlet and exhaust pressures at various stages, temperature, and compression ratio. Motor current, voltage, temperature, and insulation condition. Cooling water pressure and flow rate. The oil pressure, oil volume, oil quality, and oil supply and return conditions of the lubricating oil. Temperature rise of the main shaft bearings, noises from the moving and frictioning parts, and temperature conditions. Operation and status of main and auxiliary equipment. Displacement, shaft power, motor efficiency. The solid foundation at each connection point, the vibration of the equipment pipelines, and the smoothness of machine operation. The sealing of the equipment, leakage, cooling and separation effects of air and water, etc. The safety and reliability of safety devices and common interlock devices, etc. 5. Inspections and evaluations are required after the load test: Once the load test is completed, the main components of the compressor are disassembled and inspected. These components include the main shaft journal and bearings, the crankshaft, connecting rods, large and small end bearings, the crosshead slide, the crosshead lock, the packing, piston rod, piston, piston rings, cylinder liners, as well as the intake and exhaust valves at various stages. It is necessary to check for any signs of burning, scuffing, or deformation, and to assess the degree of wear as well. After the test run, all intake and exhaust valves must be removed, inspected and cleaned or replaced; the crankcase and oil tank should be cleaned, and new oil should be installed. After comprehensive evaluation by the Equipment Department, Production Department, Technology, Safety and Installation Departments, as well as the Supervision Department. It fully meets the production requirements. V. System Purging 1. Requirement: Before putting the system into operation, the air within the compressor and related equipment as well as pipelines must be purged using qualified inert gas, so that the O2 content measured at the outlet of the final stage is ≤0.5%, which is considered acceptable. Method steps: Start the compressor following the normal driving procedure, and use an inert gas to purge the compressor system. The pressurization process must be carried out step by step without any circulation of the gas. The pressure for pressurized displacement can be set at 1/3 of the pressure used in normal production. The replacement must be thorough and complete. Leave no blind spots. VI. Load Testing (II) 1. After the compressor system has been purged with inert gas, it is then purged with semi-water gas, followed by a second load test. The pressurization is carried out in accordance with a moderate load-testing procedure, until the system reaches the design pressure. It is important to operate the system for 2 hours after each pressurization before proceeding to the next one. Increase to the maximum pressure and operate continuously for 72 hours, following the requirements for normal operating pressure. During this pressurized operation, the pressure in each section is adjusted using the return valve, with the aim of minimizing or eliminating any venting. During operation under pressure, inspections should be carried out once per hour with proper recording, and any abnormalities or faults that occur must be addressed promptly. 2. After the secondary load operation is completed, it is integrated into the production system to carry out production operations.

Check whether the oil circuit is functioning properly, then blow out each section of the hydraulic pipeline sequentially (without bypassing pipes or valves). While blowing, tap the outer wall gently and adjust the flow rate, varying it between high and low, repeating this process several times until no gas is emitted. To conduct a test, apply butter to a test plate or cover it with a white cloth; if no contamination is detected, it is considered acceptable. During the purging process, after each section is purged, the appropriate blind flange is removed immediately, a valve is installed, and then the next stage of purging proceeds. Note that it is strictly prohibited to use iron tools to strike the outer wall during the cleaning process, and it is also strictly forbidden to try to wipe away the debris using hands at the flange separation area. :handshake

1. Once the compressor testing is complete and it is confirmed by the manufacturer and relevant personnel to be satisfactory, disconnect the instrument pipelines and safety valves and install blind flanges with labels; close all bypass valves, create a 20 mm gap, disconnect the front flanges of coolers sections 1–3, and insert blind flanges there as well, again creating a 20 mm gap； Disconnect the front flange of the gas separator in sections 1-3 and apply a thermal blind plate ； Disconnect the front flanges of 2–3 sections of the inlet buffer, install blind plates, create a 20 mm gap to disconnect the inlet flange of one cylinder section; create a gap of more than 50 mm and fit wire mesh in that area. Install all the inlet and outlet valves. 2. Start the compressor according to its startup procedure in order to perform purging. While the gas is blown from the inlet flange of the Section 1 outlet cooler, a dedicated person taps on the pipe welds between Section 1 of the cylinder body and the Section 1 outlet cooler; the blowing process continues until the area is clean enough as per the specified standards

1. After the compressor is installed, all installation tolerances must be carefully checked; only upon passing these checks can testing begin. 2. The commissioning of the compressor can be carried out in the following sequence. (1) Trial operation of the electrical system: The trial operation of the electrical system is carried out in accordance with the special instructions for the electrical control panel and relevant technical specifications. (2) Trial operation of the cooling water circuit: Open the main inlet and outlet valves, as well as the branch valves connecting the cylinders to the coolers. At a pressure of around 0.5 MPa, carefully check for any leaks or blockages in the pipelines, and also verify the water pressure and the proper functioning of the electrical interlock system; any defects found should be corrected promptly. (3) Trial operation of the circulating oil circuit: (A) It should be carried out after the pipes and accessories have been thoroughly cleaned. First, disconnect the connections at each oil inlet point to prevent oil from reaching the friction surfaces, that is, to stop it from returning to the oil suction station in the aircraft body. Then, use a wooden hammer to strike various parts of the pipes for a continuous period of no less than four hours. After that, clean the filters and the coarse oil filters, fill them with new oil, and then send the oil to each oil inlet point. (B) The requirements for the trial operation of the circulating oil circuit are as follows: a: Adjust the working pressure of the oil pressure control circuit to 0.25 MPa, and check the oil circuit for any leaks or blockages. and eliminate it. b: Check the oil pump’s oil delivery capacity, temperature rise, noise level, and for any leaks, and adjust it to normal conditions. c: Check the operation of the oil filter; the normal pressure drop should be below 0.08 MPa. d: Adjust the oil pressure and the operation of the electrical interlock system. e: Generally, 4–6 hours of separate testing for the circulating oil circuit is sufficient. (4) Testing of the cylinder and packing oil injection system: a: Pull apart the end of the oil injection tube to check whether the oil injection point is unobstructed. b: After inspection, start the oil injection pump and check whether its driving components are working properly, whether the oil volume can be adjusted smoothly, and whether there are any leaks in the pipelines. (5) Individual testing of the main motor: With the crankshaft in place, align the main motor and the crankshaft to ensure they are concentric, after which the main motor can be tested individually. The testing of the main motor is carried out in accordance with the relevant procedures for electrical systems; test items are checked, electrical performance indicators and interlock devices are inspected, and the temperature rise of each bearing is also monitored. (6) No-load test run of the compressor: The no-load test run of the compressor can be carried out after conducting separate tests on the water, oil, motor, electrical components, etc., and after resolving any faults that may have occurred during operation. B: Remove the inlet and exhaust valves for each section, open the inlet and exhaust pipes of each section, and install protective metal screens at the pipe ends to prevent other substances from entering. Check for debris on all friction surfaces and remove it. This post was last edited by Anhua Ren on 2009-3-5 20:06.]