High-pressure pump start-stop process

To start the operation: a) Rotate the pump for two weeks, paying attention to any abnormal noises inside the pump and whether its rotation is smooth. After turning the shaft, install the coupling guard immediately. b) For centrifugal pumps, the inlet valve should be opened first and the outlet valve closed before starting the pump. Once the pressure at the pump’s outlet has stabilized, the outlet valve should be slowly opened to adjust the flow rate. With the outlet valve closed, the pump should not operate for an extended period of time. c) When starting positive-displacement pumps such as reciprocating pumps, gear pumps, and screw pumps, the inlet and outlet valves must be opened first. d) For pumps used to transport chemical media during commissioning, the requirements regarding filling, purging, venting, etc. shall be carried out in accordance with the provisions of the technical documents. e) During the trial operation of the reciprocating pump, the pressure should be increased in accordance with the following specifications: operation at no load (with the outlet valve fully open) should last for at least 15 minutes ； After returning to normal, operate in stages at 1/4, 1/2, and 3/4 of the operating pressure; the operation time for each stage should be no less than 0.5 hours. Thereafter, it should operate continuously at the operating pressure for more than 4 hours. Operation at the next pressure level should not be carried out until the trial run at the previous pressure level is successful. f) During the commissioning of pumps made of brittle materials, sudden cooling and heating must be prevented; abrupt temperature changes of more than 50°C are not allowed.

1. Preparatory work before starting the high-pressure water pump: Verify the initial condition of the high-pressure water pump – Ensure that the protective cover of the coupling is in place – Confirm that the mechanical, instrumentation, and electrical components of the high-pressure water pump are in good condition – Ensure that the pump can rotate smoothly when manually turned – Verify that the sealing flush water system is functioning properly – Ensure that the oil tank level is between 70% and 80% – Close the inlet and outlet valves of the high-pressure water pump – Open the drain valve and vent valve of the pump – Ensure that the communication system is working properly. Power on the high-pressure water pump system – Contact an electrician to power on the auxiliary systems associated with the pump – Contact an electrician to power on the pump’s motor. Power on the control panel – Check that the indicators indicate that it’s time to start the pump – Ensure that the outlet valve of the high-pressure water pump opens, and that the valve status indicators on the control panel are correct – Verify that the pressure gauges and other instruments are functioning properly – Ensure that the main control panel displays normal readings – Verify that the alarm and interlock systems are working correctly. Activate the lubricating oil system – If the lubricating oil pressure is low, the corresponding alarm light will turn on – If the pressure is even lower, another alarm light will turn on – The high-pressure water pump should be shut down due to low oil pressure – Open the main valve for the lubricating oil supply – Ensure that the safety valve is functioning properly – Start one lubricating oil pump manually, while keeping the other in automatic mode – Fill the filters and oil coolers with oil and remove any air from them – Ensure that there are no leaks in the oil circuit (if any issues are found, inform the supervisor to arrange repairs); the indicator on the filter handle should point to the filter that is currently in use. - Turn on the electric heater to maintain the lubricating oil temperature at 40±2°C. Start the high-pressure water pump – close the drain valve and vent valve of the high-pressure water pump. Ensure that the liquid level in the upper water tank is above 70%. Fully open the inlet valve of the high-pressure water pump; open the pump’s vent valve to release air. Once ventilation is complete, close the pump’s vent valve. The three-way valve should be in bypass mode, with the bypass inlet valve open and the outlet valve also open. The drain valve at the low point of the three-way valve should be closed. Select the carbon tower for coking removal – press the “Select Tower” button to choose the desired tower, then press the “Confirm” button. The indicator light for the selected tower will turn on, while those for the unselected towers will remain off. The “Open” indicator light for the isolation valve of the selected tower will be on, while the “Closed” indicator light will be off; for the other carbon towers, the “Closed” indicator light will be on and the “Open” indicator light will be off (if there are any abnormalities, inform the shift supervisor and take action accordingly). Contact the personnel at 46 meters to verify that the selected carbon tower is correct and that the high-pressure water isolation valve is in the proper position. Inform the control room.

2. Start the high-pressure water pump. Activate the oil cooler to supply cooling water. Communicate with the operators in relevant positions. Open the inlet and outlet valves of the pump. Start the motor. Stop the pump immediately if any of the following occur: abnormal leaks, unusual vibrations, strange odors, abnormal noises, sparks, smoke, or persistently high current levels. The outlet pressure of the high-pressure water pump should be no less than 28 MPa, with a normal value of 30 MPa. The motor current should be within normal limits. The controls and instruments should show normal readings, and all data should be carefully recorded.

3. Adjustments and verification after starting the high-pressure water pump
3.1 High-pressure water pump and associated equipment: The vibration of the high-pressure water pump should be normal. The temperature of the bearing bushes should be normal. The liquid level in the lubricating oil tank should be above 70%. The pressure of the lubricating oil should be normal. Turn off the heater; maintain the lubricating oil temperature at 40±2°C by adjusting the cooling water from the oil cooler. The return flow of lubricating oil should be normal, with no leaks. The seal water level should be normal. The differential pressure across the oil filter should be within normal limits. The gearbox should be functioning properly.
3.2 Instrumentation and electrical equipment: The current in the motor should be normal. The motor driving the lubricating oil pump should be functioning properly. All instruments on the control panel should show normal readings.
3.3 Process system: The inlet pressure of the pump should be no less than 0.06 MPa. The outlet pressure should be stable, with a minimum of 28 MPa. The liquid level in the upper water tank should remain above 70%

The operating procedures are too complicated. As long as it is properly maintained and kept in standby mode, and the key points are addressed, it can be started quite easily