What maintenance tasks are required when the equipment is shut down for a long period of time?
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This post was last edited by quanyu502 on 2015-10-14 09:27. Due to external factors, the chemical plant will be shut down for an extended period (more than half a year), and all pump and chemical processing equipment will also cease operating for a long time. What maintenance tasks need to be carried out on these pump devices in such a situation? Especially for some critical equipment, it is necessary to ensure that each start-up is successful; what regular tasks are essential in this regard? For example, regular trial runs, as well as the removal of cooling water, condensate, and similar fluids. For example, centrifugal air compressors, screw air compressors, screw ammonia compressors, calcium chloride brine systems, etc. If anyone has good successful experiences in these areas, please feel free to share them! I’d like to thank everyone one by one first!
I don’t have much experience with this, but based on my understanding, the materials need to be emptied and flushed with nitrogen. The oil system of the equipment should remain in operation, and the pumps should be rotated periodically or tested. Winter is approaching, so measures such as anti-freezing and anti-condensation treatments for the cooling water system are necessary.
Drain the cooling water from the pump, apply lubricant to the rotating parts, clean and replace the equipment, carry out anti-corrosion treatment on the pipelines, lock in the measuring instruments, and arrange for regular shaft rotation as necessary
(1) Check the pump, pipelines, and joints for any signs of looseness. Turn the pump by hand to see if it moves smoothly. (2) Add bearing lubricating oil into the bearing housing; ensure that the oil level is at the center line of the oil gauge. The lubricating oil should be replaced or topped up in a timely manner. (3) Unscrew the priming plug on the pump body and fill it with priming water (or slurry). (4) Close the gate valve on the outlet pipeline, as well as the outlet pressure gauge and inlet vacuum gauge. (5) Start the motor intermittently to check whether its rotation direction is correct. (6) Start the motor; once the pump is running properly, open the outlet pressure gauge and the inlet vacuum pump. Once an appropriate pressure is indicated, gradually open the gate valve, while simultaneously checking the motor load. (7) Try to keep the pump’s flow rate and head within the ranges specified on the nameplate, so that the pump operates at its highest efficiency point and maximum energy savings can be achieved. (8) During operation, the bearing temperature of the pump must not exceed the ambient temperature by 35°C, and the maximum temperature shall not exceed 80°C. (9) If abnormal noises are heard from the pump, stop it immediately to check for the cause. (10) To stop using the pump, first close the gate valve and pressure gauge, then shut down the motor. (11) Within the first month of operation, the lubricating oil should be changed after 100 hours; thereafter, it should be changed every 500 hours. (12) Regularly adjust the packing gland to ensure normal dripping in the packing chamber (dripping in drops is appropriate). (13) Regularly check the wear of the shaft sleeves; replace them promptly if the wear is significant. (14) When the pump is used in cold winter seasons, after it is stopped, the drain plug at the bottom of the pump body must be unscrewed to drain all the medium. Prevent frost cracking. (15) When a pump is not in use for an extended period, it must be completely disassembled, all moisture removed, the moving parts and joints lubricated with grease, and then stored properly.
Pumps that are not in use for extended periods should have their power cut off, be protected against corrosion, and have their shafts rotated regularly; in terms of process safety, isolation from the system is necessary
Valve and pipeline metering instruments. . . .
1. Provide nitrogen padding protection for the process system and monitor it; if the pressure drops, contact the dispatch team and the air compressor workshop promptly to refill nitrogen； 2. The pump ensures that the lubricant level remains constant, and the shaft is rotated regularly ； Large units undergo regular oil drainage and barring operations. 3. Fill the compressor and turbine interiors with nitrogen to provide pressure maintenance protection ； 4. Apply butter to the bolts and nuts of the unit for protection ； 5. Space heaters should be installed in electrical equipment such as generators and motors ； 6. Regularly inspect the equipment for its appearance and internal condition
Agree with the person above! ! ! ! ! ! ! ! ! ! ! ! ! ! !
All material pipelines and equipment must be kept under nitrogen pressure to prevent air from entering and causing corrosion； Electrical equipment is powered off ； The equipment should be rotated regularly, with trial operations conducted on a monthly basis ； ； An important point is that for all air shut-off valves (which are fully open when power or air supply is cut off), the manual valve in front of them must be closed.
I learned it! I have a question: How can atmospheric-pressure equipment (equipment that cannot be sealed with nitrogen) be protected?