Safe running-in method for labyrinth compressor

Abstract

The invention relates to the technical field of compressor running-in, in particular to a safe running-in method for a labyrinth compressor. A safe running-in method for a labyrinth compressor comprises the following steps that S1, all valve decks, valve frames and exhaust valves are detached, and a cylinder cover and a stainless steel wire filter screen are installed; s2, an N2 feeding line on the inlet side of the compressor is opened; cooling water is put into use, and the flywheel is rotated for several circles; s3, an auxiliary oil pump is started, and the lubricating oil pressure is checked; s4, monitoring the temperature of the bearing; s5, installing an outlet valve to purge the pipeline; s6, a compressor is started; s7, the exhaust temperature is kept, and the back pressure of a bearing and a safety valve is adjusted; s8, the sealing performance of the oil scraper ring is checked; s9, adjusting and detecting each part; and S10, all the valves are detached, and valve cavities and gas pipelines are cleaned and blow-dried. The running-in method has the following effects that the running-in safety and reliability of the compressor are improved, and the probability of equipment failures is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of compressor running-in, and in particular to a method for safely running-in a labyrinth compressor. Background Art

[0002] Compressors play a vital role in petrochemical, natural gas processing and other fields. They are mainly used to transport and compress flammable and explosive process gases. With the continuous development of these fields, the demand for compressors is increasing. Their stable and reliable operation is of great significance to ensuring the normal progress of production and the safety of personnel and equipment.

[0003] In the existing technology, compressor running-in is usually carried out using air or process gas. Directly using process gas for running-in has the advantage of not requiring additional gas supply, but there is a risk of explosion. Using air for running-in is less expensive, but may cause combustion due to the presence of oxygen.

[0004] In recent years, with the improvement of safety standards, the industry has gradually tended to use nitrogen for running-in, but there are problems such as irregular operation and lack of systematic processes, which can easily lead to equipment failure. Summary of the Invention

[0005] In order to improve the safety and reliability of compressor running-in and reduce the probability of equipment failure, the present application provides a labyrinth compressor safe running-in method.

[0006] The present application provides a method for safely running in a labyrinth compressor, which adopts the following technical solution: comprising the following steps: S1. Remove all valve covers, valve racks and exhaust valves, and install the cylinder cover and stainless steel wire filter; S2. Open the nitrogen feed line on the compressor inlet side; use the cooling water in the compressor and cooler, and manually rotate the flywheel several times in the direction of operation; S3. Start the auxiliary oil pump and check the lubricating oil pressure. When the pre-lubrication time is satisfied, start the main motor, check the rotation direction, and then turn off the auxiliary oil pump and check the oil pressure again. S4. Monitor bearing temperature: Check bearing temperature after the compressor has been running for 5, 10, and 20 minutes; S5. Install the outlet valve to purge the pipeline; S6. Start the compressor and continuously increase the outlet pressure to reach the exhaust temperature within about 3 hours by throttling the outlet gas; S7. Maintain the exhaust temperature for at least 1 hour, adjust the bearing and safety valve back pressure, and adjust the back pressure of the lubricating oil safety valve installed on the flywheel side of the bearing housing to approximately 4 barg; S8. Check the sealing of the oil scraper ring; S9. Adjust the safety protection instrument and check whether it is operating normally; check the piston clearance, and check whether the piston nut, the key connecting the crosshead and the piston rod, and the connecting rod bolt are in the correct position; S10. Remove all valves, clean and blow dry the condensate in the valve cavity and gas pipeline.

[0007] By adopting the above technical solution and executing these steps in a specific order, the compressor running-in is completed safely and in a standardized manner, avoiding risks caused by the flammable and explosive properties of process gases. At the same time, the equipment status is monitored in real time, equipment vibration is effectively controlled, and pipeline damage is prevented, thereby improving the safety and reliability of the compressor running-in and reducing the probability of equipment failure.

[0008] Preferably, the lubricating oil pressure checked in S3 is in the range of 2.5 to 4 barg.

[0009] By adopting the above technical solution, appropriate oil pressure can ensure the normal operation of the lubricating oil system and provide good lubrication for the various bearings and piston rods of the compressor.

[0010] Preferably, the purging in S5 comprises the following steps: S51, close the air intake and exhaust valves; S52, open the bypass valve to reduce the pressure, and then close the valve; S53. Open the nitrogen feed line at the compressor inlet end.

[0011] S54, continuously pressurize the components between the intake and exhaust valves with dry nitrogen; S55. Stop delivering nitrogen and slowly discharge the gas remaining in the system through the exhaust valve at the outlet end until the pressure indicated on the system pressure gauge is the same as the external pressure; S56. Repeat S53, S54 and S55 until the exhaust gas analysis shows that the process gas content in the machine reaches the required value.

[0012] By adopting the above technical solution, such a purge process can effectively remove impurities and process gases in the pipeline, reducing the risk of explosion and fire.

[0013] Preferably, each purge repeated in S56 does not exceed 3 minutes.

[0014] By adopting the above technical solutions and standardizing the operating procedures, the controllability and repeatability of the running-in process can be ensured, and the probability of human error can be reduced.

[0015] Preferably, the mesh size of the stainless steel wire filter installed in S1 is 0.3 mm.

[0016] By adopting the above technical solution, the fine mesh can effectively filter out impurities, preventing them from entering the compressor and damaging the piston or cylinder.

[0017] Preferably, the inspection of the oil scraper ring sealing in S8 needs to ensure that the oil leakage does not exceed 5 drops per minute.

[0018] After a period of operation, a thin film of oil forms on the guide bearing. Abrasive components in the process gas can enter the spacer cavity or crankcase, damaging the oil scraper ring and piston rod surface. Scratches on the piston rod and oil scraper ring sliding surfaces can also affect oil scraping effectiveness. Rapid and wide fluctuations in intake pressure can also affect oil scraping. If intake pressure drops, crankcase gas can leak through the spacer cavity to the intake port. By using this technical solution, the efficiency of the oil scraper ring can be monitored in real time.

[0019] Preferably, if the oil leakage exceeds 5 drops per minute, the oil scraper ring is not working properly, check as follows: S81. Check whether the oil scraper ring is assembled correctly; S82, check whether the opening slot sequence is correct; S83. Check whether the annular coil spring is properly tensioned; S84. Check whether the surface condition of the piston rod is good; S85. Whether there are any abrasive components in the process gas; S86. Check whether the intake pressure changes rapidly and widely.

[0020] If the oil leakage exceeds 5 drops per minute, the oil scraper ring cannot work normally. By adopting the above technical solution, the above detection steps can provide real-time feedback on the status of the oil scraper ring to ensure the efficiency of the oil scraper ring. Good sealing of the oil scraper ring can prevent lubricating oil leakage and ensure the cleanliness and normal lubrication of the inside of the compressor.

[0021] Preferably, the throttling method in S6 is: increasing the temperature of the exhaust gas by 10-15° C. every 15 minutes.

[0022] By adopting the above technical solution, a reasonable throttling and boosting process can simulate the actual working state of the compressor, allowing the compressor to gradually adapt to different working conditions during the running-in process; at the same time, it is convenient for the monitoring system to detect the temperature in real time and trigger an emergency shutdown in case of abnormality.

[0023] Preferably, the compressor needs to be inspected before running-in, including the following steps: S01. Check the cleanliness of gas pipelines, coolers, and buffer tanks; S02. Check the tightness of the cooling system and lubricating oil system; S03. Manually rotate the flywheel several times to check whether the compressor rotates freely; S04. Install the emergency stop switch and test its performance.

[0024] By adopting the above technical solution, before starting the compressor for the first time, make sure that the inlet and outlet pipelines have been cleaned. If there is foreign matter on the inlet side, the valve or piston will be damaged; fill the cooling system with coolant and check whether the coolant system is unobstructed; use a sponge to clean the crankcase, add lubricating oil until the oil level reaches 3 / 4 of the lubricating oil window, turn the flywheel several times by hand to fill the oil circuit, and turn the flywheel until oil seeps out of the bearing; before operation, check the performance of the emergency stop switch to ensure that the compressor can be stopped immediately in an emergency during operation.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. Significantly improve the safety of the compressor's initial startup and running-in, avoiding risks caused by the flammable and explosive properties of process gases; 2. Ensure the controllability and repeatability of the running-in process through standardized operating procedures, reducing the probability of human error; 3. Real-time monitoring of equipment status enables timely detection and handling of abnormal situations, reducing the risk of equipment damage; 4. Effectively control equipment vibration during the running-in process to prevent pipeline rupture or weld damage, thereby extending equipment service life; 5. Use nitrogen running-in and systematic inspection to reduce subsequent maintenance costs and improve equipment operating efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the inspection process before the safe running-in method of a labyrinth compressor of the present application; Figure 2 This is a flow chart of a safe running-in method for a labyrinth compressor of the present application; Figure 3 This is a schematic diagram of a purge process in a safe running-in method for a labyrinth compressor of the present application; Figure 4 This is a schematic flow chart of inspecting an oil scraper ring in a safe running-in method for a labyrinth compressor of the present application. DETAILED DESCRIPTION

[0027] The present application is further described in detail below with reference to the accompanying drawings.

[0028] The present application discloses a labyrinth compressor safe running-in method, which is used to improve the safety and reliability of compressor running-in and reduce the probability of equipment failure.

[0029] refer to Figures 1-4A safe running-in method for a labyrinth compressor includes a series of running-in steps, which are performed in a specific order to achieve a safe and standardized running-in of the compressor, avoid risks caused by the flammable and explosive properties of process gases, and simultaneously monitor the equipment status in real time, effectively control equipment vibration, and prevent pipeline damage.

[0030] First, the compressor needs to be inspected before running in, including the following steps: S01. Check the cleanliness of gas pipelines, coolers, and buffer tanks; Before starting the compressor for the first time, make sure that the inlet and outlet pipelines have been cleaned. If there is foreign matter on the inlet side, the valve or piston will be damaged. The nitrogen used when running the compressor should be as clean and dry as possible. Before the compressor is running, the air inlet pipeline, the compressor cooler and the pulsation buffer tank should be blown dry.

[0031] S02. Check the tightness of the cooling system and lubricating oil system; Check that all pipeline bolt connections are tight. Fill the cooling system with coolant and check that it is flowing freely. Remove the top cover of the engine to allow the coolant to circulate and check the system's tightness. Use a sponge to clean the crankcase. Add lubricating oil until the oil level reaches 3 / 4 of the lubricating oil sight glass. Manually rotate the flywheel several times to fill the oil passages. Rotate the flywheel until oil seeps from the bearings. Check all crankshaft bearing lubrication points and the crosshead for lubrication.

[0032] S03. Manually rotate the flywheel several times to check whether the compressor rotates freely; Before starting the compressor for the first time, use the manual turning lever to turn the flywheel several times to check whether the compressor and the motor rotor can rotate freely. When turning the flywheel, lubricate the part of the piston rod below the guide bearing with lubricating oil.

[0033] S04. Install the emergency stop switch and test its performance. Before operation, check the performance of the emergency stop switch to ensure that the compressor can be shut down immediately in an emergency during operation.

[0034] Specifically, the running-in process includes the following steps: S1. All valve covers, valve racks and exhaust valves need to be removed, and then the cylinder cover and stainless steel wire filter are installed. The mesh size of the stainless steel wire filter is 0.3mm. Its structural feature is that the fine mesh can effectively filter out impurities, preventing impurities from entering the compressor and damaging the piston or cylinder. In other embodiments, other corrosion-resistant metal filters can also be used to replace the stainless steel wire filter, as long as the same filtering effect can be achieved. When installing the cylinder cover, ensure that it fits tightly against the top of the cylinder to prevent gas leakage.

[0035] S2. Open the N2 feed line at the compressor inlet to allow nitrogen to enter the compressor. Simultaneously, apply cooling water to the compressor and cooler, and manually rotate the flywheel several times in the direction of rotation. This allows for preliminary lubrication and operation of the compressor components, and checks for any abnormalities such as jamming. When opening the N2 feed line, ensure that the pipe connections are secure to prevent nitrogen leaks. The coolant in the cooling water can be selected based on the compressor model to achieve optimal cooling.

[0036] S3. Start the auxiliary oil pump and check the lubricating oil pressure. The lubricating oil pressure range is 2.5 to 4 barg. A suitable oil pressure ensures the proper functioning of the lubricating oil system and provides good lubrication for the compressor's bearings and piston rods. After the pre-lubrication time has expired, start the main motor, check the direction of rotation, and then shut down the auxiliary oil pump and check the oil pressure again to ensure that the oil pressure remains stable while the main motor is running. The starting sequence of the auxiliary oil pump and main motor is critical; incorrect sequence may result in equipment damage. For example, an electronic oil pressure sensor can be used to monitor the lubricating oil pressure in real time and connected to a monitoring system to provide a prompt alarm when the oil pressure exceeds the normal range.

[0037] S4. Monitor bearing temperature. Check bearing temperature after the compressor has been running for 5, 10, and 20 minutes. The maximum allowable bearing temperature is approximately 60°C. Real-time bearing temperature monitoring can promptly detect abnormal heating and prevent bearing damage due to excessive temperatures. Temperature sensors can be installed at the bearings to transmit temperature data to the monitoring system in real time.

[0038] S5. Install the outlet valve to purge the pipeline. Purging includes closing the inlet and exhaust valves, opening the bypass valve to reduce the pressure and then closing the valve, opening the nitrogen feed line at the compressor inlet, and continuously pressurizing the components between the inlet and exhaust valves with dry nitrogen. After stopping the nitrogen supply, slowly discharge the gas remaining in the system through the exhaust valve at the outlet until the pressure indicated on the system pressure gauge is the same as the external pressure. Repeat the above steps until the exhaust gas analysis shows that the process gas content in the machine reaches the required value. Each purge should not exceed 3 minutes. This purge process can effectively remove impurities and process gases in the pipeline, reducing the risk of explosion and fire.

[0039] S6. Start the compressor and continuously increase the outlet pressure to reach the exhaust temperature within about 3 hours by throttling the outlet gas. The throttling method is to increase the exhaust temperature by 10-15° every 15 minutes. Reasonable throttling and pressure increase process can simulate the actual working state of the compressor, allowing the compressor to gradually adapt to different working conditions during the running-in process.

[0040] S7. Maintain the exhaust temperature for at least one hour. Adjust the bearing and safety valve back pressures. Adjust the back pressure of the lubricating oil safety valve, installed on the flywheel side of the bearing housing, to approximately 4 barg. Stable exhaust temperature and appropriate safety valve back pressure ensure stable compressor operation and improve equipment reliability. A high-precision pressure sensor can be used to monitor safety valve back pressure in real time.

[0041] S8. Check the oil scraper ring for tightness, ensuring that oil leakage does not exceed 5 drops per minute. If oil leakage exceeds 5 drops per minute, the oil scraper ring will not function properly. Check the following: Check that the oil scraper ring is correctly assembled, the slot sequence is correct, the annular coil spring is properly tensioned, the piston rod surface is in good condition, the process gas contains any abrasive components, and check for rapid, wide fluctuations in intake pressure. A good oil scraper ring seal prevents lubricating oil leakage, ensuring cleanliness and proper lubrication within the compressor.

[0042] S9. Adjust the safety protection instrument to check for proper operation. Check the piston clearance and ensure the piston nut, the key connecting the crosshead to the piston rod, and the connecting rod bolt are in the correct position. Proper operation of the safety protection instrument ensures that the protection mechanism is triggered promptly in the event of an equipment anomaly, preventing further damage. Checking the piston clearance and the position of related connectors ensures proper piston movement and prevents problems such as sticking. A displacement sensor can be used to monitor the piston clearance in real time.

[0043] S10. Remove all valves, clean and blow dry the condensate in the valve cavity and gas pipeline to ensure the cleanliness of the valve cavity and pipeline, and prevent the condensate from corroding and clogging the equipment. Use professional cleaning agents and tools for cleaning, and ensure that the moisture is completely removed when blowing dry.

[0044] The implementation principle of a safe running-in method for a labyrinth compressor in an embodiment of the present application is as follows: during the running-in process, nitrogen enters the compressor through a filter to prevent impurities from damaging the piston or cylinder; the cooling system circulates coolant to control the equipment temperature; the lubricating oil system ensures lubrication of the bearings and piston rods; the monitoring system detects the bearing temperature and vibration in real time, and triggers an emergency shutdown when an abnormality occurs. Strict regulations and monitoring are implemented from the inspection before running-in to every link during the running-in process. The use of nitrogen for running-in avoids the risk of explosion and fire. The standardized process ensures the repeatability and controllability of the operation. Real-time monitoring can promptly detect and handle abnormal situations, effectively control equipment vibration and prevent pipeline damage, thereby significantly improving the safety and reliability of compressor running-in and reducing equipment failure rate and subsequent maintenance costs.

[0045] The embodiments of this specific implementation method are all preferred embodiments of the present application and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A labyrinth compressor safe running-in method, characterized by: The following steps are involved: S1. Remove all valve covers, valve racks and exhaust valves, and install the cylinder cover and stainless steel wire filter; S2, open the N2 feed line on the compressor inlet side; Put the cooling water in the compressor and cooler into use, and manually rotate the flywheel several times in the direction of operation; S3. Start the auxiliary oil pump and check the lubricating oil pressure. When the pre-lubrication time is satisfied, start the main motor, check the rotation direction, and then turn off the auxiliary oil pump and check the oil pressure again. S4. Monitor bearing temperature: Check bearing temperature after the compressor has been running for 5, 10, and 20 minutes; S5. Install the outlet valve to purge the pipeline; S6. Start the compressor and continuously increase the outlet pressure to reach the exhaust temperature within about 3 hours by throttling the outlet gas; S7. Maintain the exhaust temperature for at least 1 hour, adjust the bearing and safety valve back pressure, and adjust the back pressure of the lubricating oil safety valve installed on the flywheel side of the bearing housing to approximately 4 barg; S8. Check the sealing of the oil scraper ring; S9. Adjust the safety protection instrument and check whether it is operating normally; Check the piston clearance, check whether the piston nut, the key connecting the crosshead and the piston rod, and the connecting rod bolt are in the correct position; S10. Remove all valves, clean and blow dry the condensate in the valve cavity and gas pipeline.

2. A labyrinth compressor safe running-in method according to claim 1, characterized in that: The lubricating oil pressure in S3 is checked in the range of 2.5 to 4 barg.

3. A labyrinth compressor safe running-in method according to claim 1, characterized in that: The purging in S5 includes the following steps: S51, close the air intake and exhaust valves; S52, open the bypass valve to reduce the pressure, and then close the valve; S53, opening the nitrogen feed line at the air inlet end of the compressor; S54, continuously pressurize the components between the intake and exhaust valves with dry nitrogen; S55. Stop delivering nitrogen and slowly discharge the gas remaining in the system through the exhaust valve at the outlet end until the pressure indicated on the system pressure gauge is the same as the external pressure; S56. Repeat S53, S54 and S55 until the exhaust gas analysis shows that the process gas content in the machine reaches the required value.

4. A labyrinth compressor safe running-in method according to claim 3, characterized in that: Each purge repeated in S56 does not exceed 3 minutes.

5. A labyrinth compressor safe running-in method according to claim 1, characterized in that: The mesh size of the stainless steel wire filter installed in S1 is 0.3 mm.

6. A labyrinth compressor safe running-in method according to claim 5, characterized in that: Check the oil scraper ring sealing in S8 to ensure that the oil leakage does not exceed 5 drops per minute.

7. A labyrinth compressor safe running-in method according to claim 6, characterized in that: If the oil leakage exceeds 5 drops per minute, the oil scraper ring is not working properly. Check as follows: S81. Check whether the oil scraper ring is assembled correctly; S82, check whether the opening slot sequence is correct; S83. Check whether the annular coil spring is properly tensioned; S84. Check whether the surface condition of the piston rod is good; S85. Whether there are any abrasive components in the process gas; S86. Check whether the intake pressure changes rapidly and widely.

8. The labyrinth compressor safe running-in method according to claim 1, characterized in that: The throttling method in S6 is to increase the exhaust gas temperature by 10-15°C every 15 minutes.

9. The labyrinth compressor safe running-in method according to claim 1, characterized in that: The compressor needs to be inspected before running in, including the following steps: S01. Check the cleanliness of gas pipelines, coolers, and buffer tanks; S02. Check the tightness of the cooling system and lubricating oil system; S03. Manually rotate the flywheel several times to check whether the compressor rotates freely; S04. Install the emergency stop switch and test its performance.

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