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Carbon monoxide compressor commissioning plan

2009-03-20View Original

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I. Conditions required before testing 1. The compressor oil system is operating properly. 2. The main motor has passed the individual test run. 3. The individual compressor test has been completed, and it meets the design requirements. 4. The production system connected to the compressor has completed its purging and airtightness testing, and is fully ready for operation. 5. The compressor passed the air trial run. 6. The test drive organization has been established, and safety measures have been implemented. II. Preparations before driving 1. Contact the electrical department to supply power to all electrical devices. 2. Open the cooling water return valve. 3. Connect the instrument and test the interlock. 4. Connect to the PSA-CO system and prepare to start the machine. 5. Prepare the tools and recording equipment to be used during the operation. 6. Contact the dispatch team to ensure a supply of water and electricity. III. Pre-driving preparation 1. Open the outlet vent valve of the compressor and close the inlet and outlet valves. 2. Connect a temporary nitrogen hose at the backflow port behind the compressor inlet valve, use N2 to purge the equipment; after purging for a certain period of time, take samples at the sampling point on the compressor outlet pipeline for analysis – a N2 concentration of ≥98.5% is considered acceptable. 3. Disconnect the N2 hose and open the compressor inlet valve. IV. Commissioning Steps 1. Starting up 1.1 The compressor should first be tested using air following the steps below; only after passing the inspection should it be tested with carbon monoxide gas. 1.2 Before the load test, all valves in the gas circuit should be opened (except the water release valve), while the oil and water release valves should be closed. 1.3 When operating with carbon monoxide, the air in the containers and pipes must be removed under vacuum. 1.4 Start the cooling system and check the return water condition at each sight glass. 1.5 Start the circulating oil system. 1.6 Turn the shaft. 1.7 Start the motor, check whether the oil and water systems are functioning properly, and whether the machine has any abnormal vibrations; run it under no-load conditions for about half an hour. 1.8 Increase the pressure in gradual steps until it reaches the final outlet pressure of 1.2 MPa; the operating time for each step shall be no less than 1 hour, and the full-load operating time shall be no less than 24 hours. 2 During and after operation, the following items shall be inspected: 2.1 Whether the lubricating oil pressure and temperature meet the requirements, and whether the signal control system is sensitive and functions properly to provide protection. 2.2 Whether the inlet pressure and temperature meet the requirements, and whether the signals and control protections are sensitive and function properly. 2.3 The temperature of the friction surface shall not exceed 60°C. 2.4 There are no abnormal noises. 2.5 Whether the gas pressures at various levels and the inlet and exhaust temperatures meet the specified requirements. 2.6 The outlet temperature of the cooling water shall not exceed 40°C for each stage of cooler, and shall not exceed 50°C for each cylinder stage. 2.7 Ensure that the connection surfaces of the gas, water, and oil circuits are airtight and that all leaks are eliminated. 2.8 After the load test run, each friction surface should be inspected to ensure there is no abnormal wear; any such abnormal wear must have its causes identified and promptly eliminated or repaired. 2.9 During the loading process, it is also necessary to check the vibration of the machine foundation and the sealing condition at various points along the pipelines, addressing any issues that are found promptly. 3 Parking 3.1 Open the control valve and its bypass valve to reduce pressure, and open the compressor outlet vent valve. 3.2 Stop the main motor, close the outlet valve and the outlet vent valve. 3.3 For maintenance, close the inlet valve and purge with N2 until it is qualified. 4 Stop the machine immediately in the following situations: 4.1 When the temperatures and pressures of the compressor exceed the specified limits significantly. 4.2 The compressor or motor makes a noise. 4.3 The oil pressure is below the specified value. 4.4 The ammeter reading is above the normal value. 4.5 Other production accidents occur. 5 Emergency shutdown steps 5.1 Fully open the three-way and one-way valves, and shut down the main motor. 5.2 Open the final vent valve and close the outlet valve. V. Precautions 1. Those who drive the machine should be familiar with its structure, characteristics, and all the requirements of this plan. 2. The compressor must be operated by a designated person; unauthorized personnel are not allowed to enter the site. 3. During driving, if any abnormal situation occurs, contact the production system first and stop the vehicle to handle it. 4. Take precautions against CO poisoning, fires, and electrical hazards.

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