PK-301 Labyrinth Compressor Commissioning

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:) PK-301 Maze Compressor Commissioning 5.15 Pre-commissioning of the compressor equipment 5.15.1 Prerequisites Emergency stop for the commissioning procedure In order to enable immediate shutdown of the compressor during the commissioning procedure, the electrician must install an emergency stop button, equipped with a cable long enough to reach around the compressor. We strongly recommend that the commissioning of the compressor be carried out under the supervision of experts from Burckhard Compression AG. Burckhard Compression shall bear no responsibility for any damage resulting from non-professional debugging. Operator instructions: Our assembly staff will guide the personnel responsible for monitoring to exert their best efforts. 5.15.2 Coolant system: Check that all screw connections of the pipes are firmly tightened. Inject coolant into the cooling system and ensure that the coolant system is drainable. Never operate any equipment under conditions beyond those specified on the nameplate. General recommendation: In all installations, make sure to minimize or eliminate the transmission of pulses as well as mechanical vibrations affecting the cooler. Avoid thermal shock • Open all discharge valves. • First, turn on the cold medium. To ensure optimal formation of the protective layer, the cooling water should be circulated continuously (even when the compressor is not running). Bolt connections: All external bolt connections can be required to be retightened after installation, and if necessary, after the cooler has reached its operating temperature. Performance: When the performance does not meet the specified requirements, investigate the following situations: • Dirt on the tube surface causing deposits or scale. • Air is trapped due to improper emissions or the lack of exhaust outlets. • The pipe connectors are incorrect. • Do not operate under the designed conditions; check the performance data sheet. Cylinder cooling: The cylinder and the crosshead block are cooled separately. The orifice plate (diameter 10 mm) is installed on the pipe fitting at the cylinder outlet (Figure: 5-81); if there is a large temperature difference between the coolant outlets, it must be minimized by drilling holes in the orifice plate. See page 1560172 for the image: Figure 5-81 Standard view of the cylinder cooling orifice plate. 1. Orifice diameter: 10 mm. 5.15.3 Lubrication equipment: Use a sponge to clean the crank drive mechanism (do not use any fabric that contains fibers or fluff). Fill the compressor’s oil tank with lubricating oil until the oil baffle is covered by about 30 mm. The quality and viscosity of the oil must meet the technical specifications mentioned in the section on \"Lubrication Equipment\" in Appendix Chapter 13. Turn on the pre-lubrication pump and immediately check the rotation condition as well as whether the lubrication equipment is securely fastened. Turn the flywheel several times by hand in the direction of rotation. Check whether the lubricant has been distributed to all bearing points of the crank drive and the crosshead. The pressure of the lubricating oil must rise to approximately 0.35 to 0.4 MPa g. Check the tightness of the lubrication equipment. If the lubrication device is tight, fill the observation hole about 3/4 full with oil. Required amount of lubricating oil: See Section 8.6.5 “Oil Replacement”. 5.15.4 Checking the cleanliness of gas equipment Before initially starting the compressor, it is essential to ensure that the suction and discharge pipelines, as well as all accessories (shock absorbers, coolers, separators), are completely clean (see section 5.12.4 “Pickling and passivating pipelines”). Small foreign objects (solder beads) on the inlet side can cause damage to the valve and piston. To prevent foreign objects from entering the compressor through the suction inlet, a robust conical suction filter is installed in the suction line up to the first stage. 5.15.5 Installing valves (with nylon-radius valve discs) – See page 1560174 for diagrams: Valve installation and removal – Valves should not be used when they are wet. - It should not be exposed to air and/or sunlight for long periods of time. Figure: 5-82 Labels to note for plastic seals on valves. If the valves are shipped separately, assemble them onto the compressor just before turning the piston. 1. On the cylinder, remove all the valve covers. 2. Carefully open the valve from the cardboard and plastic seal. Do not expose them to moisture and direct sunlight. 3. Install the valves in their correct designated positions as shown in Section 9.6 “Suction Valves and Discharge Valves” (see Appendix, Chapter 13, “Compressors”). 4. Thoroughly purge the compressor with dry nitrogen. 5. Fill the compressor with dry nitrogen or immediately run the piston continuously as described in section 5.15.8. 5.15.6 Rotating Flywheel Warning: Unlubricated crankshaft drive components. Damage to bearings and guide bearings. a The compressor must never be rotated by an electric motor. Use the crank device properly, or manually rotate the flywheel with a rod! Before turning on the compressor for the first time, manually rotate the flywheel several times in the direction of rotation. Ensure that everything is in proper mechanical condition. While rotating the flywheel, apply sufficient compressor operating oil to the piston rod beneath the guide bearing. Figure: Stopping the initial startup of the 5.15.7 compressor 1. Allow coolant to flow into the compressor and cooler. 2. Rotate the flywheel several times in the direction of rotation. 3. Start the coolant pump: • Turn on the pre-lubrication pump and check the lubricating oil pressure, which should be around 0.35 to 0.4 MPa g. • After the pre-lubrication time has passed, turn on the motor (=start the compressor). Check the direction of rotation immediately (the arrow is on the gear oil pump housing). The lubricating oil pressure should reach approximately 0.35 to 0.4 MPa g. 4. Check the temperature of the bearings: • Listen carefully to the sound of the crank drive. Turn it off after about 3 minutes and check the temperature of all bearings. • The bearing temperature check was repeated after 5 minutes, 10 minutes, and finally after the compressor had been running for 20 minutes. The highest bearing temperature is about 60°C. 5.15.8 The setting of the vibration switch for the trial operation piston must be determined in accordance with the advice of our experts during the commissioning of the compressor equipment. A detailed description of this instrument can be found in the “Instruments” section of the appendix in Chapter 13. The commissioning procedure can be applied to new pistons after replacement (except for bearing temperature checks and pipeline purging). See the “Control Description” section in the appendix of Chapter 13. Compressor—piston—must be tested under operation using dry, oil-free nitrogen. Measure the piston clearance before commissioning (see Section 8.8.3 “Piston”). Ensure that the pipe is installed on the cylinder without stress. The piston must be tested under operation up to the highest temperature during normal use. Due to the very small diameter gap between the cylinder and the piston, labyrinth pistons require a very careful commissioning method. During the trial run, the piston and cylinder rub against each other; for this reason, nitrogen is used in this process. Due to the pulses that cause compressed gas to be conveyed through pipes and coolers, large forces and vibrations can be generated, especially in long gas pipelines with several bends. This can lead to operational failures of the compressor and cause damage in the welds. If necessary, additional pipe supports must be installed before starting up the equipment (for examples of securing pipes, see Section 5.12.6 “Recommendations for Pipe Supports”). Refer to Section 5.15.9 “Vibration Assessment” in the event of vibration. Listen for any abnormal noises coming from the compressor frame during a short period of time. The emergency stop button should be at hand. Before each increase in pressure, the temperature and pressure of the gas must be recorded. Over a period of about 3 hours, the discharge pressure is initiated and gradually increased. Throttling is applied to the gas in the discharge pipeline until the outlet temperature exceeds the highest temperature reached by approximately 10°C under extreme conditions. See also the “Instruments” section in the appendix of Chapter 13. At the same time, closely monitor the operation of the compressor. Throttling in this manner results in the discharge temperature of the stage increasing from 10°C to 15°C every 15 minutes. If the piston begins to rub against the cylinder wall during trial operation, stop the compressor immediately. Friction can be detected through irregular noises generated inside the compressor. To continue with the trial operation procedure, wait for the piston to cool down (15 minutes) before restarting. See page 1560178 for the diagram: 1. Spring guide block; 2. Washer; 3. Valve sleeve; 4. Spring; 5. Valve body; 6. O-ring for the bearing bracket; 7. Bearing bracket; 8. Valve seat; 9. Gasket for the valve seat; 10. O-ring for the bearing bracket. Diagram: 5-83 Safety valve installed on the bearing bracket. 1. After the final stage reaches the operating temperature, keep the compressor under this load for at least 1 hour. During this period, a final bearing inspection must be carried out. The lubricating oil pressure of the safety valve installed in the bearing bracket at the drive end must be adjusted to approximately 0.4 MPa g using warm lubricating oil. 2. The oil scraping knife must be properly sealed. In the case where oil leakage exceeds the oil shield and enters the piston rod, the oil scraper must be inspected in accordance with what is described in Section 8.7.6 “Guiding Bearings”. According to this procedure, the corresponding piston must be removed from the compressor. 3. The oil leakage in the shaft seal should not exceed 3-5 drops per minute. If there is an oil leak in the crank drive, see section 8.7.2 “Sealing of the Crank Drive”. 4. Adjust the safety instruments as described in the “Instruments” section of the appendix to Chapter 13, and check whether they are functioning properly. 5. Use a feeler gauge to check the piston clearance according to the clearance table (see the “Compressor” section in the appendix of Chapter 13). The piston nut, the crosshead connector with the piston rod, and the connecting rod bolts must be checked to ensure they are properly tightened. Check the tightening torque of the piston nut as described in the \"Compressor\" section of the appendix to Chapter 13. 6. It is recommended to remove all valves in order to clean and dry out any condensate in the valve chambers, flash tanks, and gas pipes. All flange connections and pipe fixings must be retightened. As gas pulses are transmitted through pipes and coolers, strong forces are generated, resulting in significant vibrations, especially in long gas pipelines with several bends. In addition to damaging the welds, this can also damage the compressor’s smooth operation. If necessary, additional pipe supports must be installed before the equipment is started up. 7. Inject dry, oil-free nitrogen into the compressor or the entire compressor system. From shutdown until operation (see Chapter 6), the equipment/compressor must be continuously purged with nitrogen, maintained at a slight overpressure of 0.020 MPa g respectively. 5.15.9 Evaluation of vibration – Terminology explanation: Based on the explanations below, a difference will be shown between pipes with and without stress concentration devices. Tube with possible stress concentration device • Pipe fitting from a smaller tube into a larger tube (large diameter difference). • The valve is equipped with a large driving element. • Install safety valves and similar devices on the pipes. Example of a pipe with a stress concentration device (Figure: 5-84): Figure 5-84: Pipe with a stress concentration device. Pipe without a stress concentration device • A long pipe that is not connected to other pipes with a large diameter difference, or • A pipe that does not have any large additional devices (safety valves, instruments, etc.). Tube example without a stress concentration device (Figure: 5-85): Figure 5-85 shows a tube without a stress concentration device; accessories include coolers, shock absorbers, and separators. Although the diameter difference between the fittings and the connected pipes is usually large, resulting in \"pipes with stress-relief devices,\" a high vibration viscosity is acceptable because the fittings are reinforced to prevent increased stress. The maximum allowable vibration viscosity for compressors is according to ISO 10816-6. The maximum value for the labyrinth piston compressor is indicated on the base diagram. These values are used by civil engineers as the basis for the final determination. The compressor can be considered as a rigid body. With these considerations in mind, the given amplitude values are used for the measurements taken on the cylinder bores and are lower than the values specified in ISO 10816-6. Vibrations that affect installation: The maximum acceptable vibration level specified must not be exceeded under normal conditions; see Figure 5-86. The Burckhardt compressor takes into account and studies the internal pulses and vibrations that occur during installation, to ensure the specified values are met. However, it is also possible for excessive vibration viscosity to be measured during and after debugging. Given this situation, pulse-driven gas or mechanical excitation requires corresponding countermeasures, namely: installing additional orifice plates or pipe supports (examples of pipe supports are provided in section 5.12.6, \"Recommendations for Pipe Supports\"). This is the general practice, and the work involved is unpaid. Measurement of vibrational viscosity: For each measurement, check whether the instrument displays veff(RMS) or v. Veff = the square root of RMS, representing the square of viscosity; unit: mm/s. V = vibration viscosity, unit: mm/s. Veff = v/√2. For example: (see Figure 5-86) when the cylinder speed n is 600 rpm, Veff = 3.5 mm/s and RMSv = 4.95 mm/s. Figure 5-86: Allowable vibration levels for piston compressors (next page). 1. Veff: the square root of RMS, representing the square of viscosity. 2. V: vibration viscosity. 3. Examples; see pages 1560181 for the original text and tables on page 1560181. 1. Allowable vibration levels for piston compressors and their components mounted on a rigid foundation. 2. RMS: the square root of viscosity. 3. Limits: According to VD12063, for compressors, RMS = 45 mm/s. 4. Pipes without stress-relief devices have an RMS of 35 mm/s. 5. Accessories that are not directly fixed to the compressor cylinder. 6. Pipes with stress-relief devices have an RMS of 20 mm/s. 7. Compressor cylinders and pipes that are directly fixed to them. 8. Displacement. Allowable vibration levels for piston compressor components mounted on a rigid foundation. 2. RMS: the square root of viscosity. 3. Limits: According to VD12063, for compressors, RMS = 45 mm/s. 4. Pipes without stress-relief devices have an RMS of 35 mm/s. 5. Accessories that are not directly fixed to the compressor cylinder. 6. Pipes with stress-relief devices (in mm). 9. Limits: According to ISO 10816-6, hardness grade 11. 10. Mechanical device in operation*. 11. Mechanical device operating. 12. Acceleration. 13. Compressor fixation. 14. Damage is impossible to occur on a solid building structure. 15. *ISO 10816-6 Compressors, mechanical vibration class 4. 16. Vibration viscosity. 17. Frequency. 18. Frequency. 5.15.10 Inspection of compressor equipment: After the entire gas piping system, including shock absorbers, coolers, and all accessories, has been assembled, a leak test of the system is carried out at the designed pressure in accordance with local regulations. All safety and monitoring instruments must be connected. Their functionality must be tested and confirmed. Following the successful experimental operation of the compressor, all flange connections and pipe fastenings should be retightened thoroughly using the appropriate tightening torque, as specified in the “Compressor” section of the appendix in Chapter 13. If tube vibration occurs, refer to 5.15.9 “Evaluating Vibration”. It is recommended to check the following items: • The suction filter in the gas pipeline • Some of the intake and exhaust valves • Visual inspection of the piston • Visual inspection of the crank drive mechanism. 5.15.11 Protection of compressor equipment after installation If the compressor equipment cannot be put into operation more than two months after installation, appropriate measures should be taken to protect the compressor and its associated equipment over a certain period of time to prevent damage that may result from prolonged downtime. Warning: Possible damage from shutdown! Due to the many installation possibilities and the use of our compressors, the guidance on protection varies depending on the application. a Please contact our Customer Support Service (CSS); the address is listed in section 1.3 “Contact Addresses”. General procedures: The procedures below are used to provide general recommendations. Depending on your application, our guidance on protection can be easily revised or supplemented at any time. 1. Cooling chamber and cooler of the discharge compressor. The drain valve remains open. 2. Inject lubricant into the crank drive mechanism. During shutdown periods, a specialized anti-corrosion oil provided by a renowned supplier can be used. 3. Carefully apply oil to the piston rod by hand up to the oil shield. Spin the flywheel a few times. In general, compressor components and equipment parts that involve gas conduction should not be protected with oil or grease (keep the surfaces dry and untreated). 4. Inject dry, oil-free nitrogen into the compressor or the entire compressor system. In general, compressor components and equipment parts that involve gas conduction should not be protected with oil or grease (keep the surfaces dry and untreated). Note: Leaking valves with nylon radius valve discs. Nylon radius valve discs can deform due to humidity/moisture and exposure to sunlight. As a result, the valve leaks, which can cause a pressure drop and high gas temperatures. a When handling the loading and unloading valves, avoid exposing them to humid and sunny areas. If the humidity is >30% RH, use a dehumidifier if possible. 5. Inject dry, oil-free nitrogen into the compressor or the entire compressor system. Throughout the entire shutdown period, the equipment/compressor must be continuously purged with nitrogen, maintained at a slight overpressure of 0.020 MPa g respectively. Under all conditions, prevent air from entering the compressor/system. Danger: Health hazard! Risk of suffocation! Nitrogen is a gas that causes asphyxiation and poses health risks by displacing oxygen in the atmosphere. At high concentrations, it can cause loss of consciousness or death. a Reduce the pressure before turning on the compressor. a When operating on the compressor, ensure there is sufficient fresh air circulation. a Be aware of any signs of dizziness or fatigue. Exposure to lethal concentrations of nitrogen can occur without any obvious warning symptoms. a During emergency response, before entering the area, check whether there is a lack of oxygen in the atmosphere. 6. Selecting the solution: To prevent corrosion near the cylinder and to avoid affecting the guide bearings below, desiccants—namely VCI packets (volatile anti-rust agents)—are inserted into the cylinder, valve diaphragms, and partitions. Experience has shown that it is not necessary to place absorbents in the lubricated crank drive area. Note: Forgetting to place the absorbent pack may damage the compressor! a Records the number and location of the absorbent bags/packs placed in the compressor. a Ensure that the flywheel can be rotated manually. 5.15.12 Equipment maintenance during downtime 1. Check the condition of the absorbent every six months and replace it if necessary. 2. To protect the bearings, turn on the pre-lubrication pump for about 5 to 10 minutes per week while simultaneously rotating the flywheel (about 10 revolutions). Attention should be paid to the adsorbent component in the cylinder. 3. In situations with large temperature differences between day and night, condensation may occur inside the motor. Attention should be paid to this situation during shutdown and before restarting (drying, heating, ventilation, checking insulation resistance, etc.). For descriptions of motors, please refer to the documents provided by the motor manufacturers. 4. Inspect the entire compressor system annually as appropriate. 5.15.13 Re-debugging the equipment: Before re-debugging, carefully inspect the entire compressor system. • In particular, the functions and operation of mechanical and electrical safety devices. • All cooling chambers shall undergo hydrostatic testing using the specified pressure test data. For descriptions of motors, please refer to the documents provided by the motor manufacturers. :)