【Q&A Question 099】April 09, 2017
Thread Content
This post was last edited by liuquan1100 on 2017-4-9 at 19:55. [Q&A Question No. 099] April 9, 2017: What preparations are required before starting up a circulating hydrogen compressor unit? (Unless otherwise specified, all Q&A questions are based on hydrogenation units.) ) The reference answers will be visible after responding; points are awarded by identifying the key points. 1. Checks before startup 2. Activating the dry gas seal system 3. Starting up the lubrication oil system 4. Warming up the pipes with 1.0 bar backpressure steam 5. Warming up the pipes with 3.5 Mpa main steam 6. Activating the gas seal gas cooler 7. Warming up the turbine 8. Opening the quick shutdown valve 9. Cold-starting indoors 10. Controlling the turbine speed. Summary thread of Q&A questions for 2017 (updates ongoing): http://bbs.hcbbs.com/thread-1657793-1-1.html Summary thread of daily questions for 2017 (updates ongoing): http://bbs.hcbbs.com/thread-1657794-1-1.html Summary thread of Q&A questions for 2016 (already updated): http://bbs.hcbbs.com/thread-1597792-1-1.html Petrochemical sector – “Creative Ideas for Energy Saving” campaign (sponsors sought; highest returns ever offered): http://bbs.hcbbs.com/thread-1666758-1-1.html Sponsors are being sought for this campaign; those interested should contact the campaign coordinator. (Sponsors of the event are entitled to the policy allowing them to include promotional advertisements as sponsors in various events held in the petrochemical region for one year.) The Petrochemical Advanced Processing version – the event to share pictures of chemical processing equipment has begun! A vast amount of wealth, as well as HChuan coins, are waiting for you to claim them: http://bbs.hcbbs.com/thread-1760733-1-1.html. Notice regarding the collection of chemical engineering technical materials in the “Petroleum and Chemicals Section”: http://bbs.hcbbs.com/thread-1614796-1-1.html (Source: HChuan Chemical Forum)
Cleaning and commissioning of the oil station, activation of the dry gas seal, machine warming up, static tests
1) Lubricating oil system ① Check that local indicating instruments such as pressure gauges and thermometers are complete and in good condition. ②Check the condition of the lubricating oil in the engine’s oil tank; if the quality of the oil is unsatisfactory, it should be replaced with fresh oil. The oil level should be maintained at 1/2 to 2/3 of the mark on the oil sight gauge. ③Activate the lubricant flow and place the filter switch handle in the correct position. ④Open the inlet and outlet valves of the auxiliary pump, open the outlet valve of the main shaft pump, start the auxiliary lubricating oil pump. Once the oil pump is running steadily, check whether the oil temperature and pressure are within the specified range. Oil-cooled circulation water systems are used in the Taiwan Strait region as appropriate. ⑤Fill the spare filter and the spare oil cooler with oil slowly. (2) Airtightness check and nitrogen purging before driving: *A nitrogen seal should be applied before ensuring airtightness; the injection pressure for this nitrogen seal is generally 0.1~0.2 MPa. ①Check whether the compressor inlet valve, outlet valve, and vent valve are closed; if they are not properly closed, close them, and activate the safety valve at the same time. ②Open the pressure gauge valves for each line. ③Open all the vent valves and bottom drain valves of the unit, and put the oil collector into operation. ④Slightly open the nitrogen valve at the inlet, slowly introduce nitrogen into the compressor until the airtight pressure is reached, and then close it. ⑤Check the compressor, auxiliary equipment, and pipelines for leaks. ⑥Open the vent valve on the outlet pipeline to release the gas inside the machine, and then close it. ⑦After passing the airtightness test, replace the air with nitrogen following the airtight nitrogen filling procedure. ⑧During nitrogen purging, open each drain valve to drain the condensate and then close them
(1) Lubricating oil system: ① Check that local indicating instruments such as pressure gauges and thermometers are complete and in good condition. ② Inspect the lubricating oil in the oil sump of the machine; if the quality of the oil does not meet requirements, it should be replaced with fresh oil. The oil level should be maintained at 1/2 to 2/3 of the level indicated by the oil sight glass. ③ Ensure that the lubricating oil flow path is unobstructed, and set the filter switch lever to the correct position. ④ Open the inlet and outlet valves of the auxiliary pump, as well as the outlet valve of the main shaft pump. Start the auxiliary lubricating oil pump; once the pump is running steadily, check whether the oil temperature and pressure are within the specified ranges. The oil cooler’s circulating water should be activated as appropriate. ⑤ Slowly fill the spare filter and spare oil cooler with oil.
(2) Airtightness testing and nitrogen purging before startup: *Before conducting airtightness testing, a nitrogen seal should be established, with the injection pressure typically being 0.02 MPa. ① Check that the inlet valve, outlet valve, and vent valve of the compressor are closed; if they are not properly closed, close them immediately, and also activate the safety valve. ② Open the pressure gauge valves for each line. ③ Open the vent valves on the middle section of the machine and the bottom drain valves, and activate the oil collector. ④ Slightly open the inlet nitrogen valve and slowly introduce nitrogen into the compressor until the airtightness pressure is reached, then close the valve. ⑤ Check for any leaks in the compressor, associated equipment, and pipelines. ⑥ Open the vent valve on the outlet pipeline to release the gas inside the machine, then close it. ⑦ After confirming airtightness, perform another nitrogen purging process. ⑧ During nitrogen purging, open each drain valve to remove any condensate, then close them again.
(2) Airtightness testing and nitrogen purging before startup: *Before conducting airtightness testing, a nitrogen seal should be established, with the injection pressure typically being 0.02 MPa. ① Check that the inlet valve, outlet valve, and vent valve of the compressor are closed; if they are not properly closed, close them immediately, and also activate the safety valve. ② Open the pressure gauge valves for each line. ③ Open the vent valves on the middle section of the machine and the bottom drain valves, and activate the oil collector. ④ Slightly open the inlet nitrogen valve and slowly introduce nitrogen into the compressor until the airtightness pressure is reached, then close the valve. ⑤ Check for any leaks in the compressor, associated equipment, and pipelines. ⑥ Open the vent valve on the outlet pipeline to release the gas inside the machine, then close it. ⑦ After confirming airtightness, perform another nitrogen purging process. ⑧ During nitrogen purging, open each drain valve to remove any condensate, then close them again.
①Contact the reaction team to improve the process so that the check valve has sufficient opening; also contact the steam supply team to ensure a proper supply； ②Confirm that the lubricating oil system is operating properly, with a temperature of ≤30°C and normal oil pressure ； ③Confirm that the seal oil system is operating properly and that the liquid level in the high-level oil tank is stable ； ④The process parameters of the reaction system meet the requirements for starting up; it has been confirmed that all instruments are operational, and that the steam parameters used for pipe warming and machine warming are suitable for startup ； ⑤Once the machine replacement is complete, slowly open the inlet valve manually to balance the pressure inside the machine with that of the system, and then fully open the inlet and outlet valves using a pneumatic valve ； ⑥The auxiliary oil pump is set to automatic mode; 3-5 revolutions of the crankshaft were made with no abnormalities ； ⑦The shutdown button in the control room is reset, and the emergency shutdown system is also reset ； ⑧Turn the synchronizer knob to the minimum position, switch the speed control panel to manual mode, and set the air pressure to the lowest level ； ⑨Press down the throttle lever at the throttle end and secure it to keep the throttle fully open.
1) Clean the area and remove all items that are not related to starting up the equipment. (2) Prepare the tools needed for driving, such as wrenches and torque wrenches. (3) Check the freezing points of each row and ensure that all pipelines are unobstructed. (4) Coordinate the supply of water, electricity, steam, air, etc. to the equipment to ensure that all parameters meet the required standards. (5) Cooperate with instrument inspections to adjust the automatic protection, automatic control, alarm systems, as well as various measuring and control instruments of the unit, to ensure their flexibility and effectiveness. (6) After cleaning the lubricating oil tank and the like, use an oil filter to add qualified N46# rust-resistant turbine oil to the tank, ensuring that the oil level remains above 70%, and open the dehydration valve at the bottom of the tank to remove water.
Check that the circulating water, lubricating oil, inlet and outlet valves are fully open, the buffer tank is drained, the interlocks are reset, power is supplied, the pump is rotated manually, and startup is carried out
Apply lubricating oil! Turn the wheel! Dry gas seal in operation! Press stamping! Anti-surge valve opened!
1) Thoroughly clean the equipment and the surrounding area, removing debris. 2) Check whether the equipment, valves, and pipelines are installed correctly and firmly. 3) Prepare the tools and install pressure gauges and thermometers at each monitoring point. The shift handover records and operation logs are ready. 4) Check that the oil levels in the lubricating oil and seal oil tanks are within the acceptable range, and that the oil quality tests have passed. Dehydrate and prepare enough spare oil. 5) Relevant professionals shall be present to conduct a thorough inspection of all mechanical components of the unit, manual valves, control valves, electrical equipment, instruments, alarm interlock systems, and lighting, to ensure they are in proper working condition. 6) Contact the dispatching department and relevant units to supply water, steam, instrument air, nitrogen, etc.; conduct condensate drainage inspections as appropriate, and verify that all parameters are within normal ranges. 1.0MPa steam is led to the machine room. 3.5MPa steam is led to the unit, with condensate drained in front of the main steam valve. Increase the pressure at a rate of 0.1~0.15 Mpa per minute. N2 is led to the tank and the gas separator tank for pre-cooling. 7) All cooler water inlets are used to displace air for standby use. 8) The backpressure pipeline is opened, and steam is led in from the 1.0 steam network in the reverse direction to condense behind the outlet gate valve. 9) Adjust the charging pressure of the oil system accumulator. 10) Put into use various instrument level gauges, control valves, etc. 11) Add lubricating oil to the lubricating oil and seal oil tank heaters, and start the electric heaters. 12) The compressor body is purged with N2 via the inlet N2 branch line, and the outlet gas is discharged to the low-pressure pipeline network through the outlet flare.
1. Clean the site and remove all items that are not related to starting up the equipment； 2. Prepare the tools needed for driving, such as wrenches and tools for checking tightness ； 3. Check the freezing points of each row and ensure that all pipelines are unobstructed ； 4. Coordinate with the dispatching team to supply water, electricity, steam, wind, etc. to the equipment, ensuring that all parameters meet the required standards ； 5. Cooperate with instrument inspections to adjust the automatic protection, automatic control, alarm systems, as well as all the measuring and control instruments of the unit, to ensure their flexibility and effectiveness ； 6. After cleaning the lubricating oil tank and similar components, use an oil filter to add qualified anti-rust turbine oil to the tank, ensuring that the oil level remains above 70%; also open the dehydration valve at the bottom of the tank to remove water from the oil ； 7. Open each drain valve and vent valve before opening the turbine emergency shutdown valve to warm up the pipes. Note that the heating rate of the tubes should not exceed 200°C/h; heating should be carried out gradually along the flow path. When heating approaches the quick-close valve, attention should be paid to any steam leakage into the turbine casing, and the turbine should be rotated accordingly based on the actual situation ； 8. Draw circulating cooling water into the condenser and add desalinated water until the hot well is 80% full; start the condensate pump to initiate circulation. (9) Replace the air in all water cooler inlets by introducing water, open the upper drain valve, and once water is seen, close the drain valve and the water inlet valve. (10) Check that the fire-fighting equipment is flexible and functional.
(1) Clean the site and remove all items that are not related to starting up the equipment. (2) Prepare the tools needed for driving, such as wrenches and torque wrenches. (3) Check the freezing points of each row and ensure that all pipelines are unobstructed. (4) Coordinate the supply of water, electricity, steam, air, etc. to the equipment to ensure that all parameters meet the required standards. (5) Cooperate with instrument inspections to adjust the automatic protection, automatic control, alarm systems, as well as various measuring and control instruments of the unit, to ensure their flexibility and effectiveness. (6) After cleaning the lubricating oil tank and the like, use an oil filter to add qualified N46# rust-resistant turbine oil to the tank, ensuring that the oil level remains above 70%; also open the dehydration valve at the bottom of the tank to remove water from the oil