1. Equipment selection and installation stage
Reasonable selection:
Select a suitable model and specification of reciprocating Hydrogen Compressor based on process parameters such as hydrogen flow rate, pressure, temperature, and working environment. Ensure that the performance parameters of the compressor can meet the actual production needs, avoid long-term overload or inefficient operation of the compressor due to improper selection, and reduce the possibility of failure.
Considering the material of the compressor, for hydrogen compressors, due to the permeability of hydrogen and the potential for hydrogen embrittlement, hydrogen resistant materials such as special alloy steel should be selected to prevent material performance degradation and failure.
Correct installation:
The installation foundation of the compressor should be solid, flat, and have sufficient load-bearing capacity. Design the foundation based on the weight and vibration characteristics of the compressor to ensure that it can effectively absorb and isolate vibrations. During the installation process, it is necessary to strictly follow the equipment installation instructions to ensure that the levelness and verticality of the compressor are within the allowable range.
During installation, attention should be paid to the assembly accuracy of various components, such as crankshafts, connecting rods, pistons, etc., to ensure that their connections are firm and the fit clearance is appropriate. At the same time, it is necessary to install the pipeline system correctly to avoid the transmission of pipeline stress to the compressor, which may cause component damage.
2. Daily operation and maintenance
Regular inspection and maintenance:
Establish a strict equipment inspection system and regularly inspect various components of the compressor. Including checking the opening and closing of the air valve, as well as the wear of the valve plate and spring; Wear and sealing of pistons, piston rings, and piston rods; Wear and deformation of crankshaft and connecting rod. For vulnerable components, a reasonable replacement plan should be developed based on their service life and degree of wear.
Regularly maintain the compressor, including cleaning the body and cooling system, replacing lubricating oil and filters, checking and adjusting belt tension (if any), etc. Maintenance work should be strictly carried out in accordance with the equipment manufacturer's recommendations to ensure that the compressor is in good operating condition.
Lubrication management:
Select appropriate lubricating oil, based on the working conditions of the compressor (such as working temperature, pressure, speed, etc.) and the properties of hydrogen gas, choose lubricating oil with good anti-wear, anti-oxidation, anti emulsification, and anti-corrosion properties. Strictly control the quality of lubricating oil and avoid using unqualified or deteriorated lubricating oil.
Regularly inspect the lubrication system, including the working status, oil level, oil pressure, and oil temperature of the oil pump. Ensure sufficient supply of lubricating oil, smooth oil circuit, and normal oil pressure and temperature. If there are any abnormalities, they should be dealt with in a timely manner to prevent component wear and failure caused by poor lubrication.
Cooling system maintenance:
Regularly inspect various components of the cooling system, such as coolers, water pumps, water pipes, and cooling towers (if water-cooled). Check the heat transfer efficiency of the cooler, clean the dust and dirt on the surface of the cooler, and prevent scaling from affecting the cooling effect. Check whether the water pipes are leaking or blocked, and whether the water pump and cooling tower are working properly.
Control the quality of cooling water to prevent impurities, microorganisms, and other contaminants from corroding and blocking the cooling system. Reasonably add water treatment agents or carry out water purification treatment according to the water quality situation.
3. Monitoring and Control of Operating Parameters
Parameter monitoring:
Install advanced monitoring equipment to monitor key operating parameters of the compressor in real-time, such as intake pressure, exhaust pressure, intake temperature, exhaust temperature, oil pressure, oil temperature, vibration, and noise. By monitoring these parameters, abnormal situations of the equipment can be detected in a timely manner, and measures can be taken in advance to avoid further expansion of the fault.
Establish parameter record files to record and analyze the monitored data. By analyzing historical data, we can understand the operating trend of the compressor, predict possible faults, and provide a basis for equipment maintenance and upkeep.
Operation control:
Reasonably control the operating parameters of the compressor according to production process requirements and equipment performance. Avoid prolonged operation of the compressor under abnormal conditions such as overpressure, overtemperature, overspeed, or excessive flow. For example, by adjusting the opening of the intake or exhaust valve, the flow and pressure of hydrogen can be controlled; By adjusting the cooling water volume or the speed of the cooling fan, control the exhaust temperature, etc.
When abnormal parameters are detected, there should be complete alarm and interlocking devices. Once the parameters exceed the normal range, an alarm can be issued in a timely manner to remind operators to take measures. In severe abnormal situations, the interlocking device can automatically shut down to prevent equipment damage.
4. Personnel training and operational standards
Personnel training:
Provide professional training to compressor operators to familiarize them with the working principle, structure, performance, and operating methods of compressors. The training content includes knowledge and skills in equipment startup, shutdown, operation adjustment, fault handling, and other aspects. Operators can only operate the compressor independently after receiving training and passing the assessment.
Regularly retrain operators to understand new technologies, methods, and maintenance requirements of the equipment. At the same time, strengthen the safety awareness training of operators, make them aware of the dangers of hydrogen compressors, strictly follow operating procedures, and ensure operational safety.
Operating standards:
Develop detailed and strict operating procedures, specifying the operating steps and precautions for the compressor before start-up, during operation, and after shutdown. For example, before starting, check whether the various connection parts of the equipment are tightened, whether the lubricating oil and cooling water are normal, etc; Regularly inspect the equipment during operation and record the operating parameters; After shutdown, equipment maintenance and upkeep should be carried out according to the prescribed procedures.
Operators must strictly follow the operating procedures during the operation process to avoid equipment failure caused by misoperation. At the same time, supervision and inspection of the implementation of operating procedures should be carried out, and any violations should be promptly corrected and educated.
Specific operational steps for daily operation and maintenance of reciprocating hydrogen compressors
Pre operation inspection
1. Lubrication system inspection:
Check the oil level in the lubricating oil tank, which should be within the range specified by the oil gauge, generally maintained at 1/2 to 2/3 of the oil gauge. If the oil level is too low, it is necessary to add lubricating oil of the same model.
Check the quality of the lubricating oil, which should be clear, free of emulsification, obvious impurities, and odors. If the oil quality deteriorates, the lubricating oil should be replaced in a timely manner.
Open the lubricating oil pressure gauge valve, shake the oil pump or start the auxiliary oil pump to increase the oil pressure to above 0.2 MPa, ensure that all lubrication points (such as crankshaft, connecting rod, crosshead, piston, etc.) are supplied with oil, and observe whether the flow of lubricating oil is normal.
2. Cooling water system inspection: Open the cooling water valve and check whether the cooling water system is unobstructed, whether the water flow in various parts (such as cylinder water jacket, cooler, etc.) is normal, and whether there is any leakage. At the same time, check the pressure and temperature of the cooling water. The pressure should meet the equipment requirements, generally between 0.2-0.4 MPa, and the temperature should be within the specified range. The inlet water temperature is usually not higher than 30 ℃.
3. Inspection of the pneumatic system:
Confirm whether the switch status of inlet and outlet valves, bypass valves, vent valves, etc. is correct. The inlet valve and outlet valve should be in the closed state, and the bypass valve and vent valve should be in the open state.
Check if the connection parts of the gas pipeline are tight and if there are any signs of leakage.
For compressors with top valves, check if the air pressure of the top valve is within the range of 0.4-0.45MPa, if there is any air leakage from the diaphragm head, and place the handle in the unloaded position.
4. Electrical system inspection: Notify the electrician to check the insulation resistance of the motor. The insulation resistance of a 380V motor should be greater than 0.5 megohms, a 6000V motor should be greater than 6 megohms, and a 10000V motor should be greater than 10 megohms. At the same time, check whether the wiring of the motor is secure and whether the grounding is good.
5. Other inspections:
Turn the wheel 2-3 times, check if the compressor rotates flexibly, if there is any heaviness, jamming, or abnormal sound, and let the crosshead stop in the middle of the slide.
Check if the foundation bolts and coupling bolts of the compressor are tightened.
Maintenance during operation
1. Parameter monitoring and recording:
At regular intervals (such as 1-2 hours), record parameters such as intake pressure, exhaust pressure, intake temperature, exhaust temperature, oil pressure, oil temperature, etc., to ensure that these parameters operate within the specified range. Generally speaking, the oil pressure should be maintained between 0.15-0.3MPa, and the oil temperature should be between 40-60 ℃.
Observe the operating current of the compressor, which should not exceed the rated current.
Pay attention to the vibration situation of each part, and the vibration value should be within the allowable range. Vibration measuring instruments can be used for regular testing. If abnormal increase in vibration is found, the cause should be promptly identified and dealt with.
2. Equipment inspection:
Use the method of "listening, touching, seeing, smelling" to check the operation status of the equipment. Listen to whether the operating sound of the compressor is normal, and whether there are any abnormal impact sounds, friction sounds, or other noises; Check if the temperature of bearings, cylinders, motors, and other parts is normal and if there is any overheating phenomenon; Check if there are any leaks in the connecting and sealing parts, and if the oil level, water level, and instrument indicators are normal; Smell for any abnormal odors, such as burning smell, oil and gas leakage smell, etc.
Check the working condition of the air valve, which can be judged by the temperature, sound, etc. of the air valve cover to determine whether the air valve is normal. If the temperature of the valve cover is too high or there is abnormal noise, it may be due to valve leakage or valve plate damage, and the machine should be stopped for inspection and maintenance in a timely manner.
Check the working condition of the piston, piston ring, and piston rod, and judge by observing the operating sound of the cylinder and the leakage of the piston rod. If there is any abnormality, it may be due to worn piston rings, worn piston rods, or damaged seals, which require further inspection and handling.
Check the operation of the crankshaft and connecting rod, observe the oil temperature and pressure in the crankcase, listen for any abnormal sounds, and determine if there are any issues such as wear, deformation, or looseness in the crankshaft and connecting rod.
3. Maintenance of lubrication system:
Regularly check the quality of lubricating oil. If the oil quality deteriorates (such as blackening, odor, impurities, etc.), the lubricating oil should be replaced in a timely manner.
Check the working status of the oil pump to ensure that it runs smoothly without any abnormal sounds or vibrations.
Observe the pressure difference of the lubricating oil filter. When the pressure difference exceeds the specified value (such as 0.1MPa), the filter element should be cleaned or replaced in a timely manner.
4. Maintenance of cooling water system:
Check the flow rate and pressure of the cooling water to ensure sufficient supply. If abnormal flow or pressure is found, the water pump, pipeline, valve, etc. should be checked for faults and dealt with in a timely manner.
Regularly clean the dirt and scale on the surface of the cooler, using chemical or mechanical cleaning methods to improve the heat transfer efficiency of the cooler.
Check the quality of the cooling water to prevent impurities, microorganisms, and other contaminants from corroding and blocking the cooling system. Regular water quality testing can be conducted, and corresponding water treatment agents can be added based on the test results.
5. Safety check:
Check whether safety devices such as safety valves and pressure gauges are working properly. The pressure gauge should indicate accurately, and the safety valve should be in good standby condition without leakage or blockage.
Ensure the safety of the surrounding environment of the compressor, with no flammable, explosive materials or debris piled up, and good ventilation.
Maintenance after parking
1. Normal parking steps:
First, close the intake valve, then gradually open the air valve or bypass valve to unload the compressor and reduce the system pressure.
Press the stop button to stop the motor from running.
Close the cooling water valve, drain the accumulated water in the cooling system, and prevent equipment from freezing and cracking in winter.
Turn off the lubricating oil pump and wait for the oil temperature to decrease before closing the valves of the lubricating oil system.
2. Equipment inspection and maintenance:
Check the wear of components such as air valves, pistons, piston rings, piston rods, crankshafts, connecting rods, etc. If there is wear or damage, it should be repaired or replaced in a timely manner.
Clean the dust, oil stains, and debris inside and outside the compressor to keep the equipment clean.
Conduct a comprehensive inspection of the equipment, tighten the bolts and nuts in all parts to prevent loosening.
Check electrical equipment and wiring to ensure they are in good condition.
3. Anti corrosion treatment: For compressors that have been parked for a long time, anti-corrosion measures should be taken, such as applying anti rust oil to the cylinders, pistons, and other parts to prevent equipment from rusting.
