Turbine centrifugal compressor

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This post was last edited by liuquan1100 on 2017-12-15 at 16:50. Air Compressor Operating Manual 1. Pre-start checks file:///C:/Users/ADMINI~1/AppData/Local/Temp/msohtmlclip1/01/clip_image001.gif Block diagram for starting the compressor (right image) file:///C:/Users/ADMINI~1/AppData/Local/Temp/msohtmlclip1/01/clip_image002.gif 1.1 Preparation for operation 1.1.1 Routine inspections 1.1.1.1 Ensure that the equipment is clean and free of any residual rags； 1.1.1.2 The bolts of the observation hole and the fastening bolts of the housing have all been tightened ； 1.1.1.3 Coupling bolts have been tightened ； 1.1.1.4 All accessories such as instruments have been reinstalled. 1.1.2 Pipeline System 1.1.2.1 Ensure that pipelines, valves, blind flanges, etc., have been reinstalled in their original positions after maintenance, and that the flange fastening bolts are tightened ； 1.1.2.2 Proper connection of serviced instruments ； 1.1.2.3 The discharge valve or other normally closed valves shall be closed ； 1.1.2.4 The normally open valve is open. (It is necessary to confirm which valves specifically) 1.1.3 Electricity 1.1.3.1 The low-voltage start panel is in normal condition ； 1.1.3.2 In case of repair to the power cable of the equipment, check its connections. 1.1.4 Control System 1.1.4.1 Power to the field control panel is turned on ； The test light is in the “LAMP TEST” PB state ； 1.1.4.2 Verify that there are no alarm lights flashing on the local control panel, instrument panel, or controller. 1.1.5 The lubricating oil supply system is used to drain any remaining oil from the gearbox, oil tank, oil cooler, and oil filter discharge valves; a sponge-like material should be used to clean the oil tank (old rags are not allowed). When changing the oil, follow these steps: 1.1.5.1 Place the new oil next to the oil tank ； 1.1.5.2 Open the oil filling hole ； 1.1.5.3 Fill with oil using an oil pump ； 1.1.5.4 Add oil to the required level ； Project: Standards used for oil grades; Remarks: Grade, filling quantity. Lubricating oil for compressors: ISO VG46, Shell Turbo 46; Quantity: 2000 L. Series 1.1.6: Inspection notes – Check whether the on-site display instruments function properly. 1.2 Preparation of utilities; 1.2.1 Electricity; 1.2.1.1 380V low-voltage oil supply pump ； 1.2.1.2220VUPS for on-site control panel ； 1.2.1.3220V for sockets, lights, air conditioners, etc ； 1.2.2 Steam at 410°C and 3.5 Mpa (A) is supplied to the steam turbine; 1.2.3 Cooling water is provided for the outlet cooler ； 1.2.4 Compressed air for the instrument air supply control valve ； 1.3 Lubricating Oil System 1.3.1 Electric Heating of Lubricating Oil: If the oil tank temperature is below 20°C, set the oil heater button to “AUTO” for automatic electric heating (heating stops at 38°C) ； 1.3.2 Operate the cooling water inlet and outlet valves of the oil cooler for the CCW to supply cooling water to the oil cooler, and open the air release valve (the exhaust port of the cooler tube bank) to release air ； 1.3.3 Start the oil pump – Start button for starting the oil pump ； Keep the lubricating oil pressure within 0.1–0.15 MPa ； The normal value is 0.14 MPa. 1.3.4 Confirm that oil enters KC-201 (through the sight glass). 1.3.5 Verify that the gearbox oil level is normal. 1.4 Outlet cooler 1.4.1 Open the inlet and outlet valves for the cooling water of the outlet cooler to supply cooling water to it ； 1.4.2 Open the exhaust valve of the cooler ； 1.4.3 Open the pressure balance valve ； 2 Driving 2.1 Steps for driving: Start the general program. Starting the compressor using this program is based on a routine procedure. Some steps can be run automatically in the control system. Warning: Only personnel who have received training on compressor operation may start the compressor. Incorrect operations can lead to serious injuries or death. 2.1.1 Follow the manufacturer’s instructions to install the drive controller and the recommended pre-startup program. 2.1.2 Check that the oil level is at the center line of the oil sight glass. 2.1.3 If necessary, use instrument air to test the control panel, control valves, and transmitters. 2.1.4 Open the inlet and outlet valves of the circulating water for the oil cooler and aftercooler to supply cooling water to them. 2.1.5 Open the tank’s exhaust system (air ejector or electric vacuum pump) and adjust it properly. 2.1.6 Power on the compressor control system. 2.1.7 Provide air (or the required electrical energy) to the tank’s ventilation system. 2.1.8 Start the auxiliary oil pump; before system loading, the auxiliary oil pump must run for at least 20 minutes. This step ensures that all bearings, bushings, and gears are thoroughly lubricated. 2.1.9 Check whether the inlet guide vanes can be adjusted properly, and confirm that they are in a closed position before the compressor is started. 2.1.10 Check and confirm that the bypass valve or vent valve is in the open position before starting the compressor. 2.1.11 Check the pressure and temperature of the lubricating oil. The normal operating pressure of the lubricating oil system is 20 PSI (1.38 BAR, 0.14 Mpa). Under normal operating conditions, the oil temperature at the gears is measured to be 33–55°C. The minimum oil temperature for starting the compressor is 21°C. 2.1.12 Start the steam turbine; refer to Section 2.1.13 for the starting procedures. Check for any air or oil leaks in the compressor. Note: Abnormal noises or excessive vibration indicate internal friction, bearing wear, or improper alignment of the coupling. If abnormal noises indicate a machine malfunction, immediately stop the compressor. 2.1.14 Switch the compressor to the operating mode in accordance with the control system’s instructions. 2.1.15 Set the surge controller to a slight position at the surge flow rate condition. There is ample time to carry out proper debugging during operation. 2.1.16 Check the pressure and temperature of the lubricating oil. Adjust the flow rate of the cooling water to keep the oil temperature between 33 and 55°C. The oil outlet temperature must not exceed 87.8°C. Adjusting the pressure setpoint: During normal operation, operators can modify the performance characteristics of the compressor by making fine adjustments to system setpoints such as pressure offsets. Warning: Do not start the compressor at a pressure exceeding the design pressure indicated on the nameplate. If operating under overpressure can cause equipment damage or injury to personnel. 2.2 Compressor pressure increase 2.2.1 Inlet guide vane valve fully closed ； 2.2.2 Full closure of the vent valve (anti-surge control) ； 2.2.3 Manually open the inlet guide vanes slowly ； 2.2.4 Set the outlet pressure valve to the AUTO mode (set at MPaG); under the automatic control of the vent valve, the compressor’s discharge pressure rises to MpaG. 2.3 Once the pressure and flow at the outlet of the air compressor supplying air to the device are normal, slowly open the outlet valve until it is fully open (air supply to ). 3 Shutdown 3.1 Shutdown diagram: file:///C:/Users/ADMINI~1/AppData/Local/Temp/msohtmlclip1/01/clip_image003.gif 3.2 Shutdown steps: The routine procedure for shutting down the compressor involves using the following steps under normal conditions. 3.2.1 Depressurize the compressor in accordance with the instructions provided by the control system. 3.2.2 Close the outlet valve completely. 3.2.3 Open the anti-surge control valve of the compressor. 3.2.4 Slowly close the inlet guide vane valve. 3.2.5 Stop the main motor. After the compressor stops operating, the auxiliary oil pump must run for at least 30 minutes before it can be turned off in order to dissipate the heat from the gearbox. 3.2.6 Stop the supply of instrument air to the control panel, control valves, and oil tank drains. 3.2.7 After the compressor stops, the cooling water and oil circulation must continue for at least 30 minutes to allow the temperature to drop; thereafter, the inlet and outlet cooling water valves of the outlet cooler should be closed to cease the supply of cooling water. 4. When restarting the machine after an emergency stop, check the indicator lights; absolutely do not start the compressor if the “SHAFT VIBRATION HIGH” or “L.O. PRESSURE ABNORMALLY LOW” lights are on ； The compressor is not allowed to be started until it is confirmed that the damaged components have been repaired and the cause of the incident has been identified ； After confirming that all work has been completed, press the reset button ； After 4.2 to 3 seconds, manually turn the shaft to confirm that the shaft vibration is normal. 5. Issues to note during operation and maintenance: ① Replace the lubricating oil filter monthly, check for blockages, and clean it if necessary ； ②Open the low-point drains of the fuel tank and oil cooler every month to ensure that no water has entered ； ③Test and analyze oil samples once a month ； ⑤Inspect and calibrate measuring instruments annually, such as those for pressure measurement, temperature measurement, and pressure switches ； ⑥The stop valves and control systems must be disassembled for inspection within two years of their arrival at the site, and thereafter every four years. They must be cleaned thoroughly, with particular attention being paid to the adjustment parts and emergency interlock devices, which need to remain clean over the long term ； ⑦Before closing the stop valve, it is necessary to ensure that all drain (bleed-off) valves are fully open, so that any leaking steam can be released into the atmosphere; otherwise, the blades and rotor will be corroded. It is also important to pay attention to the steam system to ensure that this problem does not occur there as well ； 6. Analysis of Abnormal Incidents: Phenomenon, Inspection, Cause, Solution. Increased vibration and noise: Detect vibration; conduct vibration analysis; if the vibration frequency is high, there may be dust on the impeller – clean it off; perform dynamic balancing if necessary. Bearing wear: Replace the bearings. If the frequency is low, bolts or nuts may be loose – disassemble, check, and tighten them. Abnormalities in the coupling: Adjust it repeatedly, align it, and check the flexible coupling. Abnormal lubricating oil pressure: Is the oil pressure control valve malfunctioning? If so, disassemble it, clean it, and readjust it. Abnormal safety valve in the lubricating oil pump: If the safety valve is faulty, disassemble it, clean it, and readjust it. Abnormal noises from the lubricating oil pump: The pump may be damaged – clean it and repair it. Leaks at the connections between the oil cooler and oil pipelines: The O-rings or gaskets may be worn out, or the connections may be loose – clean them, replace the O-rings and gaskets, and tighten the loose bolts. Is the oil level in the oil tank normal? If not, air may be entering the pump – fill it with lubricating oil. Abnormal lubricating oil temperature: What is the opening degree of the cooling water valve? Adjust the amount of cooling water used. Has the temperature at the cooling water inlet changed? What is the temperature difference between the inlet and outlet of the cooler? If the oil cooler is blocked, clean it. Is the temperature control valve functioning properly? If not, check and readjust it. Is the anti-surge controller working correctly? If not, check the controller. High temperature at the compressor inlet: The air cooler may be blocked – clean it. Is the operation of the vent valve smooth? If not, repair the vent valve. Increase in lubricating oil level: Is there a mixture of oil and water in the oil tank? The heat exchange tubes in the oil cooler may be damaged or blocked – clean those tubes. Leakage in the tube sheet of the oil cooler: Re-seal it. Abnormal readings on the gauge: Are the measurement tubes functioning properly? If they are damaged, replace them. The liquid level plug is closed: Open the liquid level plug. Are the cables connected properly? If not, repair them. 7. Maintenance: Cooper air compressors do not require frequent attention. However, monitoring usage on a daily basis is a good habit, as it allows users to detect potential problems earlier by becoming familiar with the smooth operation of the machine. As with other machines, changes in the environment, mechanical wear, or human negligence can all affect the operation of air compressors. For example: clogged drain valves, unusual noises, increases in temperature or vibration levels, changes in the color of the lubricating oil, or abnormal fluid leaks are all signs of potential problems. Identifying any changes in operations and taking appropriate actions can prevent unnecessary losses. Warning: Do not perform any maintenance on the air compressor using methods other than those described in this operating manual. Even minor adjustments can result in serious damage if performed incorrectly. Since centrifugal air compressors are high-tech products, all other maintenance procedures must be carried out by repair technicians approved by Cooper. The daily inspections require only a short amount of time, and the compressor is very easy to operate for the operator; it is possible to develop sensitivity to the machine in terms of its appearance, sound, or other operating conditions. Preventive measures can be taken before any changes cause problems. Table 5-1 lists the items that must be monitored daily (or at shift changes). Operator’s daily inspection checklist Warning: Be cautious in areas with high surfaces, high gas levels, and high voltages. Mark warning symbols (!) on the operating procedures ) requires special attention. Operation data recording ˇ Operating data recording under design conditions ˇ Recording of set points Gearbox (high surface temperature) ˇ ★Surfaces should be wiped clean ˇ No abnormal noises or vibrations ˇ No oil leaks ˇ No water leaks ˇ ★No old or worn wires and cables Intermediate cooler and rear cooler (high-pressure gas, high surface temperature) ˇ ★Surfaces should be wiped clean ˇ ★Water shut-off valves should function properly ˇ No cooling water leakage ˇ No air leaks Lubrication system (pay attention to high-pressure oil heaters and oil pumps) ˇ Surfaces should be wiped clean ˇ Verify that the oil level in the tank is at the appropriate level ˇ Verify that the oil cooler is functioning properly ˇ No oil mist should be emitted from the vacuum system ˇ No water leaks from the oil cooler ˇ No oil leaks ˇ ★No old or worn wires and cables Air compressor drive motor (only visual inspection – high voltage, temperature) ˇ ★Surfaces should be wiped clean ˇ Ensure proper air circulation ˇ No abnormal operations or excessive noise levels ˇ ★No old or worn wires and cables ˇ It is necessary to follow the manufacturer’s recommendations regarding inspections and maintenance. Table 5-2 lists the maintenance schedules for the various components mentioned above, such as filter checks or adjustments to the oil system. However, these maintenance intervals can vary depending on operating conditions and the actual hours the machine has been in use. For some items, special attention is given or the frequency is reduced according to actual requirements. Maintenance schedule: When repairing centrifugal air compressors, please have authorized Cooper dealers obtain genuine Cooper original replacement parts and guidance. Weekly: (or approximately 150 hours after startup) ˇ Check the inlet air filter; replace it if necessary ˇ Check the vacuum pump filter in the oil system; replace it if necessary ˇ Check the bypass valve filter (if purchased) Every six months: (or approximately 4000 hours after startup) ˇ Replace the element of the vacuum pump filter in the oil system ˇ Replace the oil system filter ˇ Test the lubricating oil; replace it if necessary ˇ Conduct chemical tests on the coolant ˇ Lubricate the bypass valve (if necessary – as indicated) ˇ Lubricate the drive screw of the intake guide vane assembly ˇ Lubricate the ball bearings of the motor with the recommended lubricating oil* ˇ Lubricate the motor of the lubrication pump with the recommended lubricating oil ˇ Check the exhaust check valve *The replacement timing is determined according to the operating instructions for the motor. Filter maintenance: The filters in various parts of the air compressor ensure that both air and oil remain clean as they pass through the system. For operators, the optimal approach is to regularly check the condition of these filters and clean or replace them as needed. The following lists the recommended inspection times for various filters and the appropriate responses in normal operating conditions. Filter maintenance schedule: Filter: Inspection: Cleaning or replacement: Inlet air filter *Every week or after 12 months. Bypass valve filter *Every week or after 12 months. Vacuum pump filter *Every week or after 6 months. Oil system filter *When the pressure drop exceeds 20 psig or after 6 months. *Cooper’s original filter components are to be used. Lubrication system: The following lists the various parts within the air compressor that require lubrication and the intervals for inspection. Air compressor lubrication system schedule – Maintenance intervals for components: Lubricant: The oil tank should be inspected daily; it needs to be replaced only when necessary. Cooper Air Compressor TurboBlendTM lubricant. Bearing of the oil pump motor: Every six months. Chart 2-2: Main coupling: Every six months. Lubricant for Cooper Air Compressor couplings: Ball bearings of the motor: Chart 2-2. Sleeve bearings of the motor: Cooper Air Compressor TurboBlendTM lubricant. Drive rod of the inlet guide vanes: Every six months. High-quality synthetic grease. Bypass valve (applicable only to models with 3000/6000 horsepower or less): Every six months. Molycoat® 33. Note: Only lubricants recommended by Cooper should be used. Refer to the replacement schedule recommended by the motor manufacturer. A professional inspection and preventive maintenance plan includes professional inspections as well as the replacement of regular maintenance parts at regular intervals. Unplanned and/or prolonged downtime can severely impact production. Thorough inspection is particularly important; Table 5-3 lists the specialized maintenance required for the components under any environment or operating conditions. More detailed professional information can be obtained from maintenance personnel trained and certified by Cooper. Maintenance Service Checklist – To be carried out by agents authorized by Cooper. Gearbox* ˇ Clean the blades, inlet pipes, and diffuser ˇ Inspect the blades, inlet pipes, and diffuser ˇ Visually inspect the gears ˇ Measure the gear clearance ˇ Check the sliding condition of the axial pinion ˇ Check the gap between the inlet and the blades. Intermediate cooler* and rear cooler* ˇ Inspect the water tubes in the tube bundle box; clean them if necessary ˇ Inspect the fins in the tube bundle box; clean them if necessary ˇ Inspect and clean the holes in the cooler. Lubrication system* ˇ Check for leaks in the pipe connections ˇ Visually inspect the quality of the oil ˇ Inspect the oil cooler. Filters ˇ Inspect all filter components. Control panel ˇ Check that all functions are operating properly. Control valves ˇ Inspect the inlet guide vane control valves ˇ Inspect the bypass valves ˇ Inspect the exhaust check valves. Reducer gearbox ˇ Inspect the couplings and reapply lubricant ˇ Conduct inspections in accordance with the recommendations of the reducer gearbox manufacturer. *Parts need to be replaced. Only use original Cooper parts or purchase them through Cooper-authorized dealers.