Plan 3 for individual testing of carbon dioxide compressors

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(1) Purpose of load testing: To comprehensively evaluate the design, manufacturing, and installation quality of the compressor, as well as the sealing performance of all pipelines. 1. The medium for the load test is air. 2. The pressures and temperatures for each section are as follows:
Name, Unit: I, II, III, IV, V
1. Outlet pressure, MPa: 0.05, 0.25, 0.7, 1.7, 4.0; 0.12, 0.5, 1.5, 3.4, 8.0; 0.15, 0.6, 1.8, 4.3, 10.0; 0.18, 0.7, 2.0, 4.7, 12.0; 0.2, 0.8, 2.5, 5.7, 15.0
Inlet temperature, °C: 40, 40, 40, 40
Outlet temperature, °C: 150, 150, 150, 150, 100
1. Before testing, the inlet and outlet valves connected to the system should be closed (the inlet valve No. 1, the outlet valve No. 5, the outlet valve No. 2, and the inlet valve No. 3). The inlet pipe should be disconnected from the inlet of Section 1 and a filter should be installed there. All interlock alarm signals have been tuned and are sensitive and reliable. 2. Commissioning steps: (1) Open the main return valve for cooling water, with a water pressure of 0.2–0.3 MPa. Check whether the return water valves on the cylinder jackets, stuffing boxes, and coolers of each section are open, and what the water flow rate is. ⑵Check whether the valves in the oil system are in the correct open or closed position, as well as the quality and level of the oil. Start the circulating oil pump; maintain the oil pressure at 0.3–0.4 MPa, and check the oil supply to each lubrication point. Testing pump, oil pressure interlock. ⑶Turn on the oil injector and check whether the oil injection volume at each point is normal. ⑷Rotate the pump for 2–3 minutes. ⑸ Check the system valves: ensure that the one-way valve for each stage, the exhaust valves for stages 4 and 5, the 2–3 direct-through valves, and the oil-water discharge valves for stages 1–4 are all fully open. After opening the on-site drain valves of each cooler and oil-water separator to drain the accumulated water, close them. ⑹Contact the electrician to check the motor; once the excitation is adjusted properly, start the carbon brush box fan and inform the electrician to supply power. ⑺Run the host idly for 1 hour; once there are no issues, proceed with the load test. ⑻After the load test proceeded normally, the pressure was increased to 4.0 MPa for the first time. Run for 1 hour. Pressurized to 8.0 MPa for the second time. Run for 1 hour. Pressurize for the third time to 10.0 MPa. Run for 1 hour. Pressurized to 12.0 MPa for the fourth time. Run continuously for 2 hours. The pressure was increased for the fifth time to 15.0 MPa. Operate continuously for 8 hours. Check whether the machine vibrates during operation and if there are any abnormal noises. Check the temperature of the main bearing < 65°C, the motor bearings < 65°C, as well as the temperature of the motor rotor and the upper and lower slides of the crosshead. The temperature of the piston rods in each section should be below 80°C; the temperature rise in the stuffing box, as well as current and voltage levels, need to be checked. Additionally, it is necessary to examine the conditions of the foundation and pipeline vibrations, as well as the system’s sealing performance. If a problem is detected, contact us promptly to resolve it. After the load test is completed, relieve pressure to reduce the compressor load to the minimum, then shut down the main unit and the oil injector. After 20 minutes, stop the oil pump and cooling water, and close the inlet valve. Open the on-site drain valves for each section of cooler and oil separator, and keep them open during shutdown. Testing was carried out using a CO2 gas load, with the pressures and temperatures at each stage as follows: Name, Unit: I, II, III, IV, V. Suction pressure, MPa: 0.05, 0.25, 1.16, 3.67, 8.0. Exhaust pressure, MPa: 0.25, 1.16, 3.67, 8.0, 20.0. Suction temperature, °C: 40, 40, 40, 40, 40. Exhaust temperature, °C: 140, 145, 145, 120, 120