Safety Operating Procedures for Oxygen Production Stations
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Safety Operating Procedures for Oxygen Production Stations 1] General Provisions 1. The oxygen storage tanks and pipelines must be cleaned before use; all welded joints, rust, scale, dust, and other impurities must be removed to keep the pipelines clean. For the pneumatic testing of storage spheres and pipelines, oil-free air or nitrogen should be used. The test pressure should be 1.15 times the working pressure. 2. The pipes of the control valve assembly, as well as the pipes before and after the quick shut-off valve, should be made of copper or stainless steel. 3. Oxygen storage and delivery must not exceed the rated operating pressure. To prevent overpressure, the overpressure alarm system and pressure self-regulation system should be inspected regularly to ensure that the pipes can release pressure automatically in case of overpressure. Various safety valves, pressure relief valves, automatic control valves, etc. should always remain sensitive and reliable, and must not be removed arbitrarily. If any abnormality is detected, report it immediately and take action. 4. Oxygen pipelines must not be laid in the same trench as oil pipes and cables. During oxygen delivery, the opening and closing of valves should be done slowly. This is especially important under high stress. 5. Oxygen storage tanks, pipelines, valves, etc. should be inspected regularly to ensure there are no leaks or cracks; flammable materials should not be present in their vicinity. Oxygen release must not occur indoors, and if it does take place outdoors, it must be directed to a safe location. When checking for leaks, it is absolutely forbidden to use an open flame; instead, soap water should be used to detect them. 6. The oxygen storage and delivery areas should be considered hazardous areas. Open flames are strictly prohibited in this area. Do not wear shoes with nails, and no metal objects may collide. Open flames and smoking are strictly prohibited within 20 meters of the machines, bottling area, warehouse, and oxygen station; barriers should be installed along with warning signs stating “No Smoking or Open Flames”. The air separation tower and its associated equipment and devices shall have measures in place to prevent static electricity accumulation, and it is necessary to regularly check whether they are in good condition. 7. For equipment containers and pipelines that require welding repairs, approval from the relevant departments is necessary, and the matter must be reported to the fire department for record-keeping. Before starting any work involving open flames, it is necessary to test the air in that area to ensure that its concentration is below the explosive limit; at the same time, sufficient fire-fighting equipment must be available. Assign a dedicated person to supervise during work as a precaution. 8. Gloves worn by staff at oxygen stations must not be contaminated with oils. The shift handover system must be strictly followed; one must not leave the area at any time, and flammable items are not allowed to be stored there. Unrelated persons are strictly prohibited from entering. 9. Staff are entitled to prevent the use of oxygen as a medium for pressure testing, leak testing, cleaning equipment, or for cooling purposes in workshops and all departments, in order to avoid accidents involving personnel. 10. The station should be kept clean; the floors and areas around the machines must be free of oil, and no oil drops are allowed to fall on the foundation. 11. When cleaning the oxygen production equipment with carbon tetrachloride, ensure good ventilation in the room – keep doors and windows open. The operator must wear a gas mask, work clothes, and gloves. 12. All measuring instruments should be calibrated regularly to ensure good performance. The pressure gauge should be calibrated at least 2 times per year. Pressure vessels and pipelines shall undergo regular inspections as specified, and be equipped with inspection marks. 13. The acetylene content in liquid oxygen should be analyzed daily; when it reaches the alarm limit, part of the liquid oxygen must be released, and a large amount of liquid air from the lower column must be sent to the upper column to dilute the liquid oxygen until its acetylene content meets the specified requirements. When taking liquid oxygen, liquid nitrogen, or liquid air from the facility and placing them into a Dewar flask, approval is required and supervision must be provided. The discharge of liquid oxygen or liquid nitrogen must be carried out through dedicated pipelines and ditches; it must not be dumped arbitrarily around workshops or equipment. 14. Staff must remain vigilant to prevent damage by bad actors. Persons who are not staff of the oxygen station and do not possess special access permits are prohibited from entering. Staff of this station and those permitted to enter the station must register as required and abide by the safety regulations when entering or leaving the station building. Oxygen production worker: 1. Oxygen production operators must receive safety and technical training, understand safety knowledge, master preventive measures and operating procedures, and only after passing the relevant examinations may they carry out operations. 2. All instruments, valves, and safety protection devices must be complete, sensitive, and reliable. Meters and safety valves should be calibrated regularly, while pressure vessels and pipelines must undergo regular hydrostatic and airtightness tests. 3. Strictly follow the equipment operation procedures. While the equipment is in operation, the operator must closely monitor changes in pressure and temperature across all components, and operating under conditions of excessive pressure or humidity is strictly prohibited. 4. When operating oxygen compressors, distillation towers, filling stations, and other equipment and valves that come into contact with oxygen, the tools and gloves used must not contain any grease at all; oil drums, oil containers, and similar items must not be placed near such equipment. 5. When the oxygen compressor is in operation, the supply of distilled water should be checked regularly; it is not allowed to have a shortage or interruption in water supply ； Regularly check the sealing performance of the upper and lower seals on the oxygen press, and repair any issues found promptly. Prevent oil from being carried into the cylinder by the piston rod. 6. Regularly analyze the acetylene concentration in liquid oxygen to keep it below the specified level. When using adsorption methods to remove impurities such as water, carbon monoxide, and acetylene, it is necessary to frequently check whether the adsorber is functioning properly. If the filter is regenerated together with the acetylene adsorber, the liquid contained within it should be drained before regeneration. After regeneration, tightly close the inlet and outlet valves of the adsorber. Repair work on equipment and pipelines should be carried out after the load has been removed. It is absolutely forbidden to tighten screws or similar under pressure. 7. Whenever equipment, containers, pipes, etc. that come into contact with oxygen need to be repaired by welding, they must first be purged and replaced; only after testing shows that the oxygen content in the air is below 22% and the relevant department has been informed can the work proceed. Someone should be present to supervise when working with fire. 8. When repairing or installing components that come into contact with oxygen, degreasing should be performed. 9. The use of oxygen for pressure testing, leak detection, and purging is prohibited. 10. When carrying out alkali treatment and degreasing with carbon tetrachloride, protective goggles and rubber gloves should be worn to avoid burns from caustic soda; good ventilation should be ensured, and protective masks should be used to prevent poisoning by carbon tetrachloride. When cleaning with gasoline, it is necessary to wear multiple layers of protective masks and rubber gloves; after the work is completed, any exposed skin areas should be washed promptly with soapy water. 11. When draining the liquid from the vacuum distillation tower, care and attention should be exercised to avoid frostbite. There must be no grease in the pipes and passages through which the liquid flows; welding operations are prohibited inside the factory building under such conditions. 12. The inlet temperature of the heating gas for the distillation tower must not exceed 70°C. 13. When a low-temperature valve leaks, it must be dealt with after it freezes. 14. Open flames and smoking are strictly prohibited inside the oxygen production station and within 20 meters of it. Fire should not be used to check for leaks, and care must be taken to prevent sparks from being generated by metal objects hitting each other. 15. Fire-fighting equipment on site should be complete, and it should be inspected regularly. 16. In the event of an accident such as a fire inside the station building, rescue efforts should be carried out immediately. At the same time, the scene should be protected and reported to the supervisor. 17. Personnel who are not employees of this site are not allowed to enter the factory building without permission. Visitors from external organizations must obtain approval from the relevant departments and be accompanied by someone to enter. 1. Personnel operating the oxygen compressor must carry out the preparatory work before startup, and check whether the distilled water, cooling valves, oil level gauges, oil pressure gauge, bypass valves, oxygen supply valves, etc. are safe and reliable. They must also conduct a crankshaft rotation test, with each rotation lasting no less than 30 minutes, and check the oil pressure as well as whether the mechanical operation is normal. 2. Once the machinery is operating properly, the bypass valves on the circuits of stages I and III can be gradually closed. It is necessary to ensure that the oxygen supply valve for stage III is in the fully open position; the vent valve for stage III should also be gradually reduced in size, so that the pressure can increase to the specified normal level. At the same time, it is important to check that the compression ratios between each stage are normal. After the machinery is running properly, the oxygen vent valve should be closed. 3. When the oxygen compressor is operating normally, check the oxygen pressure and temperature; the pressure and temperature of the oxygen after compression at each stage must not exceed the specified values. During operation, ensure that the surface temperature of the moving parts does not exceed 50°C, and the exhaust temperature at each stage should not be higher than 170°C. 4. Regularly check the supply of distilled water, and make sure that the temperature of the water entering the cooler does not exceed the specified value. The water in the oil-water separator is often removed. 5. Pressure gauges, safety valves, and thermometers must be calibrated regularly; the pressure gauge of the oxygen compressor must not be used interchangeably with that of air compressors. 6. The oil level in the crankcase should be kept at an adequate height; if it is too low, it should be topped up to 1/2 of the gauge’s mark. 7. When the gauge pressure is between 294 and 49 kPa, oil must not enter areas where oxygen is present. Special attention should be paid to the sealing performance between the piston rod and the sealing surface; if oxygen comes into contact with grease, degreasing should be carried out promptly. 8. Unrelated personnel are prohibited from entering the oxygen pressure room; smoking and the use of open flames for heating are forbidden inside, and adequate ventilation measures must be implemented. 9. Emergency shutdown in case of accident: (1) Stop the motor ； (2) Open the tray-level vent valve ； (3) Close the oxygen inlet valve, (4) Close the stage III oxygen supply valve ； (5) Stop supplying fuel and water after half an hour or as appropriate. 10. After the work is completed, turn off the power and clean up the area. Gas Cylinder Room 1. Operators must maintain a high sense of responsibility; smoking and bringing in open flames are strictly prohibited. It should be kept at a distance of over 10 meters from open flames, and it is prohibited to operate valves with oily hands or gloves. 2. In the gas cylinder room, various types of gas cylinders must be stored separately as required; hydrogen and acetylene cylinders are prohibited from being placed in oxygen cylinder storage areas, oxygen filling rooms, or oxygen stations. Gas cylinders should be placed upright and marked clearly. They must be placed neatly, and secured with railings or supports to prevent rolling. Appropriate-width passages should be left in the storage area. 3. Operators must regularly inspect pressure gauges and gas pipelines; if any abnormalities are detected, they must take appropriate action immediately and report to the relevant personnel. 4. When freezing occurs at the outlet of the gas cylinder in winter, it is only allowed to use steam or hot water to heat and dissolve it. The use of open flames for heating is strictly prohibited. Cylinder Oxygen Filling Operator 1. Must be familiar with the filling equipment, processes, and safety operating procedures. 2. Before filling the oxygen cylinder, it must be inspected by a designated person; filling is not allowed without such inspection. During inspection, technical examinations shall be carried out strictly in accordance with the provisions of the \"Regulations on Safety Supervision of Gas Cylinders\" ； Before filling, the gas composition inside the bottle should also be analyzed and identified ； During filling, the gas flow rate should not be too fast to prevent the gas cylinder from overheating. 3. Pressure gauges and safety valves should be calibrated regularly to ensure they remain sensitive and accurate. To check for air leaks, use soapy water; testing with fire is prohibited. 4. The temperature of the gas cylinder must not exceed 45°C; otherwise, oxygen filling must be stopped immediately. 5. Cylinders with any of the following conditions shall not be filled with gas: (1) The cylinder is covered in grease, or the nozzle is frozen ； (2) The paint color, markings on the cylinder do not match the gas contained therein ； Unguished color, with faded markings, making it difficult to identify the type of gas cylinder ； Stamp marks are incomplete or unreadable ； (3) Gas cylinder leakage, faulty gas valve, and no residual gas in the cylinder ； (4) Incomplete, damaged safety accessories, or those that do not meet the requirements ； (5) Bottles with defects detected during visual inspection that cannot ensure safe use ； (6) Those that have exceeded the inspection deadline. 6. If a fire breaks out during the filling of gas cylinders, the valve should be closed promptly. After cutting off the gas supply, extinguish the fire using fire-fighting equipment. 7. In the bottle filling room, the bottle storage room, and during operations, it is necessary to prevent gas cylinders from toppling over, and all bottles should be handled gently; attention must also be paid to leaving safe passages. 8. The inflated clamps should be flexible to ensure reliable locking. 9. The gloves, tools, fixtures, etc. being used should be protected from getting contaminated with oil. ——Excerpt from “Safety Operating Procedures for Machine Operators” (Responsible editor: Deng Changhuang)
Operating Standards for Air Separation Posts I. Preparation for Operation: 1. Wear protective equipment properly； 2. Conduct thorough inspections, check the equipment operation records to understand its operating status, as well as keep track of maintenance and testing activities, equipment defects, accident handling, instructions from higher authorities, and other relevant matters ； 3. Listen carefully to the details of the handover and verify whether they are consistent. II. Implementation of tasks: 1. Precautions for job performance: A. Operators must hold valid certificates to work; illegal operations are strictly prohibited, as are leaving one’s post, switching posts, or sleeping at work ； B. Open flames are strictly prohibited within the enclosure; a fire permit is required for any work involving open flames. The oxygen concentration in the area where work is carried out must be 23% O2, and fire prevention measures must also be in place ； C. Tools and gloves that come into contact with oxygen pipelines, valves, and equipment must be thoroughly degreased ； D. It is strictly prohibited to strike pipes and valves with metal, as well as to open and close valves forcefully ； E. When discharging cryogenic liquids, there must be someone on duty to supervise, and this supervisor shall not leave their post casually ； F. To thaw the valve, use steam or boiling water; heating with an open flame is strictly prohibited ； G. Any adjustment to operating conditions must be carried out gradually and slowly after a thorough analysis, to avoid neglecting one aspect while focusing on another ； H. In winter, the equipment must be insulated to prevent it from being damaged by freezing ； I. Be strict in preventing asphyxiation by high-concentration nitrogen gas. 2. Equipment inspection and operation: A. To be carried out once per hour: (1) Starting 5 minutes before the scheduled time, complete the filling out of the operation report within 10 minutes, ensuring neat handwriting and a clean report ； (2) Emit non-condensable gases, remove free water at the bottom of the purifier, reverse-blow the brake fan, and open V1253 to check for free water ； (3) Conduct a routine inspection of the equipment to check for any signs of leakage, abnormal operation of the machinery, as well as changes in the oil temperature and pressure of the expansion unit, the various pressures and seal gas pressure of the chiller unit, and various levels, flow rates, and purities. Also, verify whether the instrument readings are accurate ； (4) For problems that occur in the own shift, adjustments should be made promptly; serious issues must be reported to the station and the Equipment Management Department without delay, along with detailed records (time, operating conditions and equipment symptoms, measures taken, person responsible for handling the issue, outcome of the handling, person who reported it, and recipient of the report). B. Once a week: (1) Check the operation of each switching butterfly valve and any leakage issues ； (2) Perform a jog test on the standby equipment to check whether it functions as a standby unit. C. Once a month: (1) Inspect the equipment and the lubrication of valves, and add oil as specified ； (2) Check for poor purity of liquid oxygen and gaseous oxygen; inspect and analyze each heat exchanger for leaks or cross-leaks ； (3) Inspect and replenish the bead finish sand in the cold box ； (4) Check whether there is ice formation or rust on the safety valve seal. 3. System operation stability indicators: (1) Air pressure entering the purifier is 0.54 MPa, the temperature is 8–12°C, and the flow rate is ~12,800 m3/h. (2) Oxygen flow rate ≥ 2400 m3/h, purity 99.6% ； Nitrogen flow rate ≥ 5300 m3/h, purity 99.9% ； Regenerated gas flow rate ≥ 2500 m3/h; temperature: alarm set at N ≤ 175 oC, with the electric heater engaging in interlock when the temperature reaches ≥ 250 oC. (3) PIAS-1103: An alarm is triggered when the pressure of air exiting the air-cooled tower is 0.54 MPa ≤ 0.4 MPa; the water pump stops operating and the chiller shuts down when the pressure is ≤ 0.35 MPa. (4) Main cryogenic liquid oxygen level: 2600 mmH2O; liquid-to-air ratio: 400 mmH2O. (5) CO2 content in the air exiting the molecular sieve: <2 PPM. (6) Analysis of the liquid air coming from the lower column: 36–38% O2. III. Operation of monomer production equipment: 1. Startup: Activate the standby instrument air compressor and supply air to the instrument system gradually, with a pressure of 0.5 MPa. 2. Start up the pre-cooling system operation: (Model UF-12800/5.5) (1) Startup: A. Check the process pipelines, ensure that all normal-temperature and low-temperature water pumps, as well as instruments and control systems, are functioning properly; then notify personnel to supply water and electricity ； B. Check whether each switching butterfly valve in each purification system is closed ； C. Open the discharge valves of the air-cooled tower and the water-cooled tower fully, start the water pump to flush the air-cooled tower; after that, maintain a water level of 300–500 mmH2O. Stop the water pump and close the discharge valves (note that V1183 cannot be put into operation yet; it will operate automatically once the air flow in the air-cooled tower is adjusted and the water level is stabilized manually) ； D. Slowly introduce gas into the air-cooled tower until the pressure reaches 0.54 MPa. Once pressurization is complete, start the normal-temperature and low-temperature water pumps and open the return water valve. After the liquid level in V1183 is stabilized through manual adjustment, switch it to automatic mode. Monitor the liquid level to prevent it from rising too high, thereby avoiding water from flowing into the molecular sieve system’s pipelines. (2) Stop: A. Stop the low-temperature water pump ； B. Fully open the inlet and outlet valves ； C. Open the discharge valve fully to drain the water in the tower, then close it ； D. Observe the air-cooled and water-cooled towers to check if the water level is rising, and inspect the system valves to prevent water from entering the air compressor and molecular sieve system pipelines. 3. Operation of the purification system: (HXK-12800/5.5 model) (1) Startup: A. Check the operation of each switching butterfly valve, ensure that the heating system is functioning properly, and prepare for the regeneration process ； B. Review the original records of the two purifiers to determine their respective operating status, and check whether V1224 is fully closed ； C. Once the pre-cooling system is operating stably, manually pressurize the purifier to be used to 0.54 MPa, and then close the manual pressure filling valve ； D. Check whether each switching butterfly valve is leaking air, adjust the operating sequence of each purifier, and switch to automatic mode ； E. Adjust the flow rate and temperature of the stabilized regenerated gas. (2) Stop: A. After the system is depressurized, close all switching butterfly valves ； B. Stop the purifier operation timer and the heater power supply ； C. Record the purifier’s operating status. 4. Operation of the heater: (1) Startup: First, introduce air, then supply power, and control the heating temperature properly ； (2) Stop: First cut off the power, then the gas, and finally shut off the power supply. 5. Chiller operation: (Strictly follow the equipment operation and maintenance instructions.) (1) The water flow rate at startup must be ≥5 T/H; before starting, the equipment should be powered on 3–4 hours in advance. The compressor oil must be heated before starting, and attention should be paid to changes in pressure at various points ； (2) Stop: First, stop the operation of the unit, then stop the water pump from supplying water. 6. Operation of the turbine expansion unit (PLPK-36.7/5.15×0.45 type) (strictly follow the equipment operation and maintenance instructions). IV. For the startup, shutdown, and heating/purging operations of the KDON-2400/1000 air separation system equipment, it is necessary to strictly follow the operation manual and safety procedures for the KDON2400/1000 air separation unit. 1. Operational requirements: (1) Starting and stopping must follow the instructions of the factory management and the Technical Production Department ； (2) The operators shall follow the instructions of the team leader, and keep detailed records during the operation process for reference by the incoming staff and workshop technicians ； (3) Conduct a thorough inspection before operation to ensure that electrical instruments and remote-controlled valves are in normal condition ； (4) Adjustments should be made slowly; large changes in pressure, flow rate, or resistance are strictly prohibited. V. Shift handover: 1. It is strictly prohibited to conduct shift handovers under false operating conditions ； 2. Explain the equipment’s operating status to the person taking over and answer their questions ； 3. Only after both parties have signed the shift handover log can the person handing over the shift leave their post. VI. Operation Records: 1. Operation records of KDON-2400/1000 air separation units ； 2. Air separation unit inspection form ； 3. Shift handover record of the shift supervisor ； 4. Record of the pre-shift meeting, with signatures from operators in each position ； 5. Records of routine operational adjustments by the main control operator. Operating Standards for Air Compressor Position I. Taking Over the Shift: 1. Wear appropriate personal protective equipment ； 2. Take over in person to understand the equipment’s operating status and fault handling. II. Preparation for operation: 1. Inspect the main body of the unit as well as all auxiliary equipment, pipelines, electrical systems, and instruments; ensure they are in good condition and functioning properly before preparing to start operation ； 2. Check whether the oil level and oil temperature in the tank are normal. If the oil temperature is too low, the electric heater can be activated to heat the oil; the oil temperature should be no lower than 25°C, and the oil quality must meet the standards (L-TSDA46 turbine oil, GB11120-89) ； 3. The measuring instruments and safety control interlock systems are sensitive, complete, and reliable ； 4. Close the inlet guide vane regulator (set to 5 degrees at startup) and the water inlet valve of the oil cooler ； 5. Open the drain valve on the compressor outlet pipeline, the oil supply valve for the lubricating oil pipeline, the gate valve on the main cooling water pipeline, the inlet gate valve of the intercooler, all the return water pipeline valves, and the exhaust valve on the water side of the intercooler (close it after exhaust) ； 6. Check that the cooling water flows smoothly, and maintain the water pressure at 0.35 MPa ； 7. Start the main oil pump, turn on the exhaust fan, adjust the safety valve, and check again the oil level in the tank as well as whether there is oil in the return pipe of the upper oil tank; also check the oil filter on the oil side of the oil cooler ； 8. Stop the operation of the main oil pump; when the oil pressure drops to 0.12 MPa (gauge pressure), an alarm is triggered, and the auxiliary oil pump starts automatically to maintain the oil pressure at 0.15–0.2 MPa (gauge pressure). When the oil pressure exceeds 0.2 MPa, the auxiliary oil pump stops automatically. This indicates that the automatic interlock system for the oil pumps is functioning properly. If there are any issues, they must be resolved before restarting the equipment ； 9. When the crank is turned, there are no abnormal noises inside the machine, and it rotates smoothly ； 10. Conduct a test drive; start the vehicle once everything is normal. III. Operation Implementation 1. Starting the machine: (1) Start it in accordance with the motor’s operating procedures, paying attention to the values indicated on the ammeter ； (2) Listen carefully to the sounds coming from inside the compressor and the speed increase gearbox. The temperature of each bearing should not exceed 65°C. It is standard for the bearing temperature to be 10°C to 20°C higher than the oil temperature; however, the temperatures of different bearings may vary. It is acceptable if a bearing’s temperature is 30°C higher than the oil temperature. Pay attention to any changes in the vibration amplitude as monitored by the compressor’s online shaft vibration monitoring system – if the vibration is too high, the machine needs to be stopped for inspection ； (3) When the outlet temperature reaches between 35°C and 45°C, open the gate valve at the outlet of the oil cooler, adjust the water flow rate, and maintain the oil temperature within the range of 35°C–45°C; meanwhile, keep the water pressure in the oil cooler below the oil pressure ； (4) Check the water volume, water pressure, and water temperature of each cooler, as well as the oil pressure in the lubrication system ； (5) Run the unit without load for 5–10 minutes before starting operation under load. Gradually open the control vanes to 90° to increase the air flow rate. Shut off V1015 completely, and then slowly close the compressor outlet vent valve to raise the pressure. The increase in outlet pressure should be done in steps of 0.2, 0.3, 0.4, and 0.5 MPa respectively. After each increase, stop the unit for a few minutes to observe the operating conditions, changes in current levels, thermal expansion, and variations in the unit’s compression flow rate ； (6) After 30 minutes of operation under load, once normal operation is confirmed, gradually open the compressor outlet gate valve, close the vent valve, and resume normal production operations to supply gas. 2. Conduct the inspection of the air compressor strictly in accordance with the contents of the daily inspection sheet. 3. Take readings once per hour, including: the exhaust pressure at stages 1–4 of the compressor, inlet vacuum level, inlet flow rate, cooling water volume, water pressure, and inlet water temperature for the main water inlet pipe; as well as oil temperature, oil pressure, bearing temperatures at each stage, shaft vibration levels at each stage, and current and voltage values. 4. Each shift must wipe the equipment and auxiliary devices once to keep them shiny; the operation surfaces of all equipment at the site should be free of dust and oil stains, and kept clean. 5. Normal shutdown: (1) Open the vent valve slowly until it is fully open ； (2) Close the inlet guide vanes to 40-50 degrees ； (3) Stop the main motor ； (4) Record the time from when the motor is turned off until the unit rotor comes to a complete stop ； (5) The oil pump can be stopped only 20 minutes after the main motor stops and when the shaft temperature is below 45°C ； (6) Stop the range hood after the oil pump has stopped ； (7) Close the inlet gate valve, and pay attention to the increase in pressure in the water system ； (8) Open the valves of the water chambers in the intercooler and oil cooler to drain the water accumulated in the cooling pipes. 6. Emergency shutdown: (1) First, remotely open the emergency vent valve (V1015) ； (2) Shut down the main motor immediately ； (3) Quickly open the compressor outlet vent gate valve ； (4) Carry out the necessary procedures as for a normal shutdown. 7. Emergency stop signal: The compressor must be stopped immediately under any of the following conditions while it is in operation: (1) When there is sudden intense vibration in the compressor or motor, or when there are sounds of collision and friction inside the casing ； (2) When the oil pressure in the oil inlet pipeline drops to 0.07 MPa (gauge pressure), and normal operating pressure cannot be restored even after starting the auxiliary oil pump, resulting in a failure of the interlock system ； (3) If the temperature of any bearing rises suddenly by more than 80°C, causing the interlock to fail, or if smoke appears at any bearing or sealing area ； (4) When sparks appear from the motor ； (5) When a certain component of the unit is in a dangerous condition ； (6) When there is a sudden power or water outage, and the control system automatically cuts off the circuit. 8. Signal for immediate normal shutdown: The compressor must be shut down immediately under any of the following conditions during operation. (1) If the temperature of either bearing exceeds 75°C and various measures prove ineffective ； (2) When the oil level in the tank drops to the minimum level line, and adding more lubricant oil still does not stop the drop ； (3) The water pressure in the main water inlet pipe is below 0.13 MPa (gauge pressure), or the oil temperature or air temperature continues to rise continuously due to insufficient water flow ； (4) When any inlet water or oil pipeline becomes blocked, causing a sudden and significant increase in oil pressure or water pressure. IV. Detailed specifications of the H275-6.5/0.97 type centrifugal compressor; strict compliance with all the requirements outlined in the operation manual is necessary. V. Shift handover: 1. Clean the workplace to maintain a clean environment; ensure that the floors of the air compressor room and the surfaces of all equipment control panels are free from dust and oil stains, and that everything is neatly arranged according to the designated locations ； 2. Conduct face-to-face handover, explaining the operation status of the equipment and any issues that have been resolved during the shift. VI. Operation Records: 1. Operation records of each unit in the air compressor station ； 2. Records of daily operational condition adjustments for position personnel ； 3. Daily inspection form ； 4. Shift handover record. Operating Standards for Oxygen Pressure Posts I. Taking Over Shift: 1. Wear appropriate personal protective equipment ； 2. Conduct face-to-face handovers to understand the equipment’s operating conditions and any issues that have been resolved. II. Preparation for operation: 1. Inspect the main unit as well as all auxiliary equipment, pipelines, electrical systems, and instruments; ensure they are in proper condition and functioning correctly before proceeding with startup ； 2. Check whether the oil level in the crankcase is normal and whether the oil quality meets the standards (68# mechanical oil) ； 3. The measuring instruments and safety control systems are sensitive and complete ； 4. Close the return water valve of the oil cooler ； 5. Open the vent valve on the outlet pipeline of the oxygen compressor, close the oxygen supply valve, open the gate valve on the cooling water inlet pipeline as well as the return water valves of each stage of coolers; also open the exhaust valves on the water side of the oil coolers (close them after exhaust) ； 6. Check that the cooling water flows smoothly, and maintain the water pressure at 0.25–0.3 Mpa ； 7. Manually rotate the oxygen pressure oil pump to force oil supply, turn the unit several times; no abnormal noises are heard inside the machine ； 8. Conduct a thorough inspection of the tightening and anti-loosening conditions of all moving and stationary components of the compressor ； 9. During the first trial run, it is necessary to conduct thorough inspections of various tasks such as the installation, adjustment, dielectric strength testing, and drying of each motor. Special attention should be paid to the tightening, positioning, and anti-loosening of the motors. And pay attention to whether the motor rotation direction is correct ； 10. Clean the area around the oxygen compressor unit, and remove all tools and parts that are located near the machine or on it ； 11. Once everything is ready, conduct a no-load test run; once it proceeds normally, carry out a full test run before switching to normal operation. III. Operation Implementation: 1. Starting the machine: (1) No-load test run (test operation after installation or major/mid-term repairs): A. Remove all intake and exhaust valves ； B. Unscrew the nut of the oil pump, rotate the oil pump using the pump crank to supply oil to all lubrication points ； C. Start the motor in accordance with its operating procedures, pay attention to the reading on the ammeter, stop it as soon as its speed stabilizes for inspection; the unit should not produce any abnormal noises ； D. Start the main motor for the second time and run it for 5–10 minutes, while checking the sound, temperature, and vibration of various parts of the compressor. Special attention should be paid to whether the oil pressure is normal after the main oil pump starts operating, as well as whether the lubrication parts are receiving adequate oil supply. Then, adjust the lubricating oil supply pressure of the main oil pump to 0.2–0.3 Mpa; if any abnormalities are detected, stop the machine immediately to address them ； E. After the above checks are successful, run the compressor unit under no-load conditions for 4–8 hours, while checking whether the oil temperatures in all components are normal. The oil temperature should not exceed 60°C, and the lubricating oil supply pressure should be no less than 0.15 Mpa; at the same time, it is necessary to check that all fasteners are securely tightened. (2) Load testing: Dry air or nitrogen is used for the load testing of oxygen compressors. Compressor load testing steps: A. Spin the compressor several times to check for any abnormalities ； B. Open the valves on the cooling water circuit to check the water supply ； C. Rotate the oil pump using its crank handle to supply sufficient oil to all lubrication points ； D. Fully open the vent valve and the test intake valve; fully close the intake and exhaust valves ； E. Start the compressor and let it run idly for 30 minutes; thereafter, the load can be increased gradually using the relief valve. First, increase the pressure to 0.5 MPa and let the compressor run for 1 hour. Then increase the pressure to 1.0 MPa and let it run for another 1 hour. Finally, raise the pressure to the rated exhaust pressure, with the compressor operating under these conditions for no less than 4 hours ； F. Park and conduct a thorough inspection. During the testing process and after shutdown, the following inspections and recordings should be carried out: A. Lubricating oil pressure and temperature, as well as the oil supply to each lubrication point ； B. Sealing of various components of the compressor (including any signs of air, water, or oil leakage) as well as the temperature and vibration levels of various friction areas ； Check for any looseness at the connection points, as well as for any abnormal noises from the moving parts ； C. Pressure and temperature of intake and exhaust valves at various levels, inlet and outlet temperatures of each heat exchanger, and the operating condition of the compressor’s intake and exhaust valves ； D. Compressor displacement ； E. Current, voltage, and temperature rise of the main motor ； F. Is the operation of the instrumentation and control system sensitive? ； G. The above items shall be checked and recorded every half hour, and any issues that arise during testing must be addressed promptly. (3) Normal driving: A. Turn the engine several times to check for any abnormalities ； B. Check whether each pipeline system meets the requirements of the process flow ； C. Open the supply and return valves on the cooling water pipeline to check the water supply situation ； D. Fully open the vent valve and intake valve; fully close the intake valve and exhaust valve for testing ； E. Rotate the oil pump using the pump handle to supply oil to various lubrication points ； F. Start the main motor; once oxygen has filled the system and the unit is operating under load, verify that everything is functioning properly. Then open the exhaust valve fully while closing the vent valve, and proceed with normal production to supply gas to the customer. (Note: The oxygen supply valve should be opened slowly to prevent a large pressure difference on either side of the valve, which could increase the oxygen flow rate and generate high-voltage static electricity, leading to an explosion.) G. Adjust the oil pressure to 0.2–0.3 MPa. (4) Normal shutdown and precautions: A. Open the vent valve and close the discharge valve ； B. Press the stop button to stop the main motor ； C. Close the intake valve ； D. Cut off the power to the control circuit ； E. Stop the water supply 10 minutes after the main motor stops ； F. During winter parking (when the temperature is <5°C), the water remaining in the cylinders at various levels and in the heat exchangers should be drained to prevent the equipment from being damaged by freezing ； G. If the compressor is left running for an extended period, anti-rust treatment should be applied to it. Dry nitrogen should be introduced through the testing intake pipeline, and the compressor should be rotated slowly to allow the nitrogen to fill the air passages. Afterwards, the vent valve and the intake valve in the testing pipeline should be closed ； H. During parking, perform several manual turns of the crankshaft per shift. 2. Conduct inspections strictly in accordance with the daily inspection checklist for ZW-38/16 type oxygen compressors, and keep detailed records. 3. Take readings once per hour, including: suction and exhaust pressures at various levels, temperature, inlet flow rate, oil temperature, oil pressure, current, voltage, etc. 4. Each shift must wipe the operating equipment and its associated facilities once to keep them shiny; all control panels should be clean, free of dust and oil stains. There should be no clutter of items or tools in the equipment’s working area, and the production site must be well-organized. 5. Emergency shutdown of the oxygen compressor: (1) Immediately shut down the main motor ； (2) Quickly open the vent valve ； (3) Handle it as a normal stop. 6. The oxygen compressor must be stopped immediately in an emergency if any of the following conditions occur during operation. (1) When there is sudden intense vibration in the oxygen pressure unit and the main motor, or when there are collisions and friction inside the unit ； (2) When the oil pressure drops and the oil temperature is >60°C, adjust the oil pump pressure; if increasing the cooling water flow does not work ； (3) When the motor produces sparks ； (4) In the event of a power or water outage, when the control system automatically cuts off the circuit ； (5) In the case of a fire or cylinder collision in the oxygen compressor ； (6) When the oxygen outlet valve failed, the unit’s return valve started to allow flow in reverse, resulting in negative pressure in the buffer tank ； (7) When the exhaust pressure ratios at all levels increase, affecting the safe operation of the unit ； (8) When oil is carried along the piston rods at all levels due to a fault with the oil scrapper. 7. Shift handover: (1) Clean the work area to maintain hygiene and cleanliness ； (2) Conduct face-to-face handover, introducing the operation status of the equipment and the handling of any faults during the shift. 8. Work record: (1) ZW-38/16 oxygen compressor daily inspection form ； (2) ZW-38/16 operation record. 9. Operating parameters during normal driving: Sequence Number, Parameter, Unit, Level 1, Level 2, Level 3: 1. Intake pressure, MPa: 0.02, 0.221±0.02, 0.716±0.05; 2. Exhaust pressure, MPa: 0.221±0.02, 0.716±0.05, 1.6; 3. Intake air temperature, °C: 30, 38, 38; 4. Exhaust gas temperature, °C: ≤160 (before cooling), ≤40 (after cooling); 5. Oil temperature inside the engine, °C: ≤60; 6. Circulating oil pressure, MPa: 0.2–0.3; 7. Pressure of water supply for cooling, MPa: 0.35; 8. Temperature of water supply for cooling, °C: ≤32; 9. Temperature of return water for cooling, °C: ≤40. Standards for operating at nitrogen pressure: I. Taking over the shift: 1. Wear appropriate personal protective equipment ； 2. Conduct face-to-face handovers to understand the equipment’s operating conditions and any issues that have been resolved. II. Preparation for operation: 1. Inspect the main unit as well as all auxiliary equipment, pipelines, and electrical control systems to ensure they are in good condition and functioning properly before preparing to start operation ； 2. Check whether the oil level in the crankcase is normal and whether the oil quality meets the standards (46# mechanical oil) ； 3. The measuring instruments and safety control systems are sensitive, reliable, and intact ； 4. Close the return water valve of the oil cooler ； 5. Open the vent valve on the outlet pipeline of the nitrogen compressor, close the nitrogen supply valve; open the gate valve on the cooling water inlet pipeline, as well as the return water valves for each stage of cooler. Also open the exhaust valves on the cooling water side of each cooler (close them after exhaust) ； 6. Check that the cooling water flows smoothly, and maintain the water pressure at 0.25–0.3 MPa ； 7. Rotate the oil pump by hand to supply oil to all lubrication points; turn the unit several times to check for any abnormal noises inside the machine ； 8. Thoroughly inspect the tightening and anti-loosening conditions of all moving and stationary components of the compressor ； 9. During the first trial run, it is necessary to conduct thorough inspections of various tasks such as motor installation and adjustment, insulation resistance testing, and drying. Special attention should be paid to the tightening, positioning, and anti-loosening of the motor, as well as to ensuring that its rotation direction is correct ； 10. Clean the area around the nitrogen pressure unit, and remove all tools and parts that are located near the machine or on it ； 11. Once everything is ready, conduct a no-load test run; once it proceeds normally, carry out a load test run before switching to normal operation. III. Operation implementation: 1. Starting the machine: (1) No-load test run (test run after installation or major/mid-scale repairs): A. Remove all exhaust valves at each stage ； B. Unscrew the nut at the back of the oil pump, rotate the oil pump using its crank handle to supply oil to all lubrication points ； C. Start the motor in accordance with its operating procedures, pay attention to the reading on the ammeter, stop it as soon as its speed stabilizes for inspection; the unit should not produce any abnormal noises ； D. Start the main motor for a second time and run it for 5–10 minutes; meanwhile, check the sound, temperature, and vibration levels in various parts of the compressor. Then adjust the lubricating oil supply pressure of the main oil pump to 0.2–0.3 MPa. If any abnormalities are detected, stop the machine immediately to address them ； E. After the above checks are successful, run the compressor unit under no-load conditions for 4–8 hours, while checking whether the temperatures of all components are within normal ranges. The oil temperature should not exceed 60°C, and the lubricating oil supply pressure should be no less than 0.15 MPa. Additionally, verify that all fasteners are securely tightened. (2) Load testing: Steps for compressors’ load testing: A. Spin the compressor several times to check for any abnormalities inside and outside the unit ； B. Open the valves on the condensate lines and check the water supply ； C. Fully open the exhaust valve, fully close the intake and exhaust valves ； D. Rotate the oil pump using its crank handle to supply sufficient oil to all lubrication points ； E. Start the compressor and let it run idly for 30 minutes. Then, use the vent valve to gradually increase the pressure in stages: increase the pressure to 0.5 MPa and let it run for 1 hour; increase it to 1.0 MPa and let it run for another 1 hour; finally, raise the pressure to the rated exhaust pressure, with the compressor running under these conditions for no less than 4 hours ； F. Park and conduct a thorough inspection. During the testing process and after shutdown, the following inspections and recordings should be carried out: A. Lubricating oil pressure and temperature, as well as the oil supply to each lubrication point ； B. Sealing at various parts of the compressor (including any signs of air, water, or oil leakage), as well as the temperature and vibration levels of various friction points; whether there is any looseness at the connection points, and whether any abnormal noises are present from the moving parts ； C. Exhaust and intake temperatures and pressures at various stages, inlet and outlet temperatures of each heater, and the operating condition of the compressor’s exhaust and intake valves ； D. Compressor displacement ； E. Current, voltage, and temperature rise of the main motor ； F. Is the instrumentation and control system responsive in operation? ； G. The above items shall be checked and recorded every half hour, and any issues that arise during testing must be addressed promptly. (3) Normal driving: A. Turn the engine several times to check for any abnormalities ； ； B. Check whether each pipeline system meets the requirements of the process flow ； C. Open the supply and return valves on the cooling water pipeline, and check the water supply situation ； D. Fully open the air valve and intake valve, fully close the exhaust valve ； E. Rotate the oil pump using the pump handle to supply sufficient oil to all lubrication points ； F. Start the main motor; once the unit is filled with nitrogen, gradually close the vent valve while opening the discharge valve, and then adjust the discharge valve to gradually increase the pressure. (4) Normal shutdown and precautions: A. Open the vent valve and close the discharge valve ； B. Press the stop button to stop the main motor ； C. Close the intake valve ； D. Cut off the power to the control circuit ； E. Stop the water supply 10 minutes after the main motor stops ； F. During winter parking (when the temperature is <5°C), the water stored in the cylinders at various levels and in the heat exchangers should be drained to prevent the equipment from being damaged by freezing ； G. During the shutdown period, perform manual turning of the shaft 3 times a day, with a certain number of rotations per shift. 2. Conduct inspections strictly in accordance with the contents of the daily inspection sheet for ZW-1816 type nitrogen compressors, and keep detailed records. 3. Take readings once per hour, including: suction and exhaust pressures at various levels, temperature, inlet flow rate, oil temperature, oil pressure, current, voltage, etc. 4. Each shift must wipe the operating equipment and auxiliary devices to keep them shiny; all control panels should be clean, free of dust and oil stains. There should be no items or tools left scattered around in the machine area, and the site must be kept tidy and orderly. 5. Emergency shutdown of the nitrogen compressor: (1) Immediately shut down the main motor ； (2) Quickly open the vent valve ； (3) Handle it as a normal shutdown ； 6. The nitrogen compressor must be stopped immediately in an emergency if any of the following situations occur during operation: (1) Sudden severe vibration in the nitrogen compressor unit and the main motor, or collisions and friction inside the unit ； (2) When the motor generates sparks ； (3) When oil pressure drops, oil temperature > 60°C, and measures taken prove ineffective ； (4) In the event of a power or water outage, when the control system automatically cuts off the circuit ； (5) When cylinder collision occurs in the unit ； (6) When the nitrogen outlet valve of the product fails and gas supply is interrupted, causing negative pressure at the primary suction pressure of the unit ； (7) When the exhaust pressure ratio at all levels increases, posing a threat to the safe operation of the unit. 7. Shift handover: (1) Clean the work area to maintain hygiene and cleanliness ； (2) Conduct face-to-face shift handover, explaining the operating status of the equipment and any issues that have been resolved during the shift. 8. Operation records: (1) Daily inspection form for ZW-18/16 type nitrogen compressors ； (2) Operation record of ZW18/16 type. 9. Operating parameters during normal driving: Sequence Number, Parameter, Unit, Level 1, Level 2, Level 3: 1. Intake pressure, MPa: 0.105 (A), 0.180±0.02, 0.588±0.05; 2. Exhaust pressure, MPa: 0.180±0.02, 0.588±0.05, 1.6; 3. Intake air temperature, °C: 30, 38, 38; 4. Exhaust gas temperature, °C: ≤160 (before cooling), ≤40 (after cooling); 5. Oil temperature inside the engine, °C: ≤60; 6. Circulating oil pressure, MPa: 0.2–0.3; 7. Pressure of water supply for cooling, MPa: 0.35; 8. Temperature of water supply for cooling, °C: ≤30; 9. Temperature of return water from cooling, °C: ≤40
Both system and stand-alone versions are explained. It was explained very well