Air Compressor System Commissioning

Procedure

Compiled by:

Audited by:

Approved by:

Qingdao Huachen Weiye Electric Power Technology Engineering

Co., Ltd.

2014


Catalogue
1 ..........................................................................................................................

Introduction....................................................................................................................... 1
2 ...................................................................................................................

Equipments Introduction.................................................................................................. 1
3 ...................................................................................................................

Compile Basis....................................................................................................................... 3
4 ...................................................................................................................

Commissioning purpose..................................................................................................... 4
5 ..............................................................................................

Trial Run Conditions......................................................................................................... 4

6 ..................................................................................................

Commissioning Methods and Steps................................................................................ 5

7 ..............................................................................................

Commissioning Quality Check Standards...................................................................... 9

8 ................................................................................................................

10

Obligations and Divisions.............................................................................................. 10

9 ....................................................

12

HSE Control Measures.................................................................................................. 12

10 .......................................................................................................................

14

Appendix.......................................................................................................................... 14

1
Introduction
40m3/min 4 40m3/min
12 20m3/min 2

In this project, there are 4 40m3/min water-cooling no-oil instrument air compressors, 12
40m3/min water-cooling no-oil conveying air compressors and 2 20m3/min water-cooling
no-oil maintenance air compressors. Through compressor system commissioning, remove
system defects; blow pipes and the system to make equipments and system output and main
technology parameters as design required and provide stable and reliable compressed air
for all air equipments and confirm whether the whole system meets unit general
commissioning and trial run conditions.
2
Equipments Introduction
Zambia MCL 2150MW Coal Fired Power Plant( MCL 2150MW
) 2 510t/h
150MW

Zambia MCL 2150MW Coal Fired Power Plant is provided with two sets of 510t/h
super high pressure, natural circulating CFB steam drum boilers, which is single furnace,
single medium reheating, thermal isolation cyclone separator, tube-type air preheater,
balanced draft, end part double flue, suspension structure, half-unsheltered layout, solid
state deslagging, complete steel structure, matched with 150MW condense turbinegenerator.
2.1

Air compressor
.
instrument air
compressors
model
exhaust
pressure

manufacturer

SM250

exhaust flow

cooling mode

0.8 Mpa

Shanghai Ingersoll Ran

d
41.5 m3/min
water cooling

 cooling
water flow

19.6 m3/h

main
motor model
rated
power
Speed

Y2-400-4

.
Conveying air
compressor
model

12

0.6 Mpa
cooling water
pressure
2
exhaust
40

temperature
cooling water temperature
compress
stage
below 32
3
Q=90Nm
/min
,P=0.8MPa
Q=90Nm3/min ,P=0.8MPa

prefilters

air
dryers

Q=90Nm3/min ,P=0.8MPa
2
post
blas
filters
t type air
purify
device
(2)
air storage tank
4 V=25m3,P=1.0 MPa

exhaust
pressure
cooling
water flow

250 KW

rated Vol.

Rated cur.

manufacturer

1475 rpm

SM250
0.8 Mpa
19.6 m3/h

exhaust
temperature

40
cooling water temperature
below32
9 blast type air
purify device (9)
air storage tank

6.6 KV
16.73 A

Shanghai Ingersoll
Rand
41.5 m3/min

exhaust flow

water cooling
cooling mode

0.6 Mpa
cooling water
pressure
2

compress
stage
Q=60Nm3/min ,P=0.8MPa
12 V=30m3,P=1.0 MPa
2 V=20m3,P=1.0 MPa
2 V=10m3,P=1.0 MPa

main
motor model
rated
power

Y2-400-4
250 KW

rated Vol.

6.6 KV

 Speed

1475 rpm

.
maintenance air
compressor
model

Rated cur.

manufacturer

SM132

exhaust
pressure
cooling
water flow

0.8 Mpa

exhaust
temperature

40
cooling water temperature
below32
LS315

main
motor model
rated
power
Speed

9.6 t/h

132 KW

exhaust flow

cooling mode

cooling water
pressure

compress
stage

16.73 A

Shanghai Ingersoll
Rand
21.4 m3/min
water cooling
0.6 Mpa
2

400 V

main motor
model

rated power

2950 rpm

246 A

3
Compile Basis
2150MW
"Zambia Maamba 2150MW Coal-fired Power Plant Startup and Commissioning
Outlines"
DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to Completed
Acceptance DL/T5437-2009
[2000]589
Twenty-five Key Requirements to Prevent Serious
Electric Power Operation State Power [2000]589

Accident

and

Failure

in

Part

1:

DL5009.12002
Code of Safety Operation in Power Engineering
Steam Power Plants by Electric Power Industry Standard

Construction

1996
4

The Code of Erection and Acceptance of Electric Power Construction Section of Steam
Boiler Set (1996)
[1996]111
Standard for Quality Inspection and Evaluation on the Commissioning of Thermal Power
Plant (1996 version)
1996
Regulations on the Start-up Commissioning of Thermal Power Plant Projects (1996
version)

Equipments manufacturer materials, drawings and equipments manuals

Operation regulations compied by power plant

4
Commissioning purpose
4.1
Each air compressor system trial run
4.2
Each air purify system trial run.
4.3
Blow compressed air system pipes.
4.4

Air compressors group interlocks.

5
Trial Run Conditions
5.1.1

System equipments and pipes erections finished as required; base strength as design
required; electric CB cabinets wiring correct and firm.
5

5.1.2

Construction facilities removed; ditches and holes have complete covers onsite; ground
flat, ways free and lights sufficient.
5.1.3
Thermometers, pressure gauges calibrated and erected; cooling water system qualified after
flush and running conditions satisfied.
5.1.4
Air compressor proper system finished and startup requirements satisfied before trial run.
5.1.5
Before started, manufacturer must be on site and the compressor oil level as required.
5.1.6
Air compressors erection finished and the communicating equipments prepared as
manufacturer required.
5.1.7
Lub oil and cooling water system can be run normally.
5.1.8
Air compressor single motor trial run qualified; dry and regenerating filters qualified after
trial run.
5.1.9
Air compressor system pipes and relevant accessory equipments erected as design required
and the suspending and supports complete and reliable.
5.1.10

Dryers erection finished and pipes, electric circuits satisfy energizing requirements. Blow
and clean the pipes section by section before dryers. Air compressor supply conditions are
satisfied before dryers commissioning.
5.1.11

Control system erection and commissioning finished; relevant interlock and protections
reliable and correct by driving, which can be run normally.
5.1.12
Confirm compressors auto loading and unloading pressure settings as manufacturer
required.
5.1.13

Air compressor proper, oil filters, air purify devices, dust filters and air and water
separators commissioning finished.
6
Commissioning Methods and Steps
6.1
Air compressor trial run
6

6.1.1

Under manufacturer instruction, after conditions satisfied, trial run air compressors.
6.1.2

Before primary startup, manually run free wheel several circles to check whether there is
strike or other sounds and prevent compressor burnt caused by lack oil. Then start
compressor for trial run.
6.1.3

Check following data on air compressor panel: exhaust pressure and temperature, cooling
water pressure, inlet air temperature, back coolers exhaust temperature, air compressor
motor current.
6.1.4

During trial run, record above data as well as startup current and time; measure motors
temperature and vibration and record relevant parameters.
6.1.5

Pay attention whether compressor has loud noise and whether motor current is normal in
trial run.
6.1.6

Confirm oil filters, air purify device, dust filters and air and water separators work well.
6.1.7

Air compressor's exhaust temperature is normal.

6.1.8

20-30

Run compressor without load 20-3omin.

6.2
Trial run air purify device
6.2.1

Under manufacturer instruction, after conditions are satisfied, trial run dryers.

6.2.2

Before primary startup, blow compressed air pipes to prevent sundries into dryers and
filters.
6.2.3

0.7MP

Start air compressor, when system pressure is approaching to 0.7MPa and compressor
running normally, start dryers.
6.2.4
3

Close air switch and connect with power; at the time, power indicating light on panel is on
and control system is auto into 3min delay.
6.2.5
3

Set transferover switch on manual position and press startup button; after 3min delay,
dryers will be auto started and when running indicating light is on, it means dryers are
running.
6.2.6
5-10
0.3-0.5MP , 1.2-1.8MP
After observe 5-10min, air processed by dryers will satisfy use requirements and at the
time, cold medium LP gauge in 0.3-0.5MPa and cold medium HP gauge in 1.2-1.8MPa.
6.2.7

Slowly open brass valve on auto drainer to make condensate in air go into drainers and then
be drained out of compressors.
6.2.8

Interlock startup and stop mode: put transfer switch on interlock position. Dryers are
started by air compressors and controlled by stop signal, dryers can be auto run. When
dryers need manual stop, put switch on manual position to stop dryers.
6.2.9

Remote control mode: put transfer switch on remote position. Dryers are started by remote
and controlled by stop signal, dryers can be auto run. When dryers need manual stop, put
switch on manual position to stop dryers.
6.2.10

Dryers fault alarm functions: when the working dryers have fault alarms, equipments will
be auto stopped and controller will output fault alarm signals, the machine alarm indicating
light is on and the fault signals output to remote. Notice: after equipments stopped by
faults, users must press stop button to quit dryer fault alarm state.
6.2.11

If machines need be stopped, on local mode, press stop button to stop dryers and on remote
control mode, input remote stop signals to stop the dryers. Close inlet and vent valves.
6.2.12

Notice:
1
Avoid dryers running without load long time.
2 5
It is prohibited to start and stop dryers continuously in short time. At least 5min intervals
should be satisfied to prevent damaging refrigeration compressor.
3

When power lost suddenly, 2 inlet pneumatic valves of dryers will be auto opened and 2
regenerating VV will be auto closed. After power recovered, slowly increase 2 towers
pressure to normal working pressure, then press start button and controllers start working.
One of both towers goes into sucking state and another one will reduce pressure and be into
regenerating state.
6.3
Blow compressed air system pipes
6.3.1

Scope: All air header and branch pipes in boiler and ST house.
9

6.3.2

0.7MP

Steps: start 1 air compressor and close outlet valve of air storage tank. When tank outlet
pressure increased to 0.7MPa, open tank outlet valve to blow main pipes and then take
control through each branch pipes valves to blow each branch pipes till main pipe outlet air
clean.
6.4
Air compressor group interlock
6.4.1

After air compressors receive startup signals, interlock and remote control will be auto
realized. When one air compressor receives startup signal, auto operation will be realized.
6.4.2
0.6MP
0.8MP
When air supply header pipe pressure below 0.6MPa, the spare air compressor will be auto
started to remain header pipe pressure at 0.8MPa.
6.4.3

When instrument air header pipe pressure keeps down and the running air compressor on
fault, the air compressors in maintain spare state will be auto started to satisfy system
normal running requirements.
6.4.4

If the spare air compressor receives startup signals but refuse starting, alarm signals will be
sent out for fault disposal in time. At the same time, manually start other spare air
compressors.
7
Commissioning Quality Check Standards
7.1
Articles related to air compressors in "Commissioning and Trial Run Quality Check and
Assess Standards for Thermal Power Project"
7.2
10

Relevant regulations in manufacturer manuals.

7.3
Each system pipes have no leakage or jam.
7.4

No abnormal noise at bearing rotary parts and bearing temperature as manufacturer

technology standards required (if no manufacturer standards, state standards as basis)
7.5
Running parameters as design or manufacturer technology required.
7.6

Through observing storage tank charging time and actual air consumption, judge whether
flow satisfies parameters regulated in technology agreement by manufacturer; if the
deviation is obvious larger, require manufacturer to take flow measurement.
8
Obligations and Divisions
8.1
Produce Unit

Finish necessary produce preparation, i.e. compile operation regulations and system
drawings, operators training and relevant equipments nameplate hanging; participate in air
compressor system partial trial run and acceptance after the trial run; start and stop
equipments, make running adjustment, record running parameters and take routine checks
in trial run.
8.2
Construction unit

11

Finish single equipments trial run and acceptance related to air compressor system;
submit single equipment trial run records and relevant documents and materials; take
charge in safety, firefighting, defecting and maintenance on air compressor system trial run
site.
8.3
Owner

Organize and manage air compressor trial run, participate in checks and coordination
in equipments trial run preparation step, handover acceptance, erection and commissioning
acceptance.
8.4
Commissioning unit

Compile commissioning procedure; check air compressor system and the integrity and
rationality; participate in single equipment trial run related to air compressor system; play
technology responsible role in air compressor system trial run and finish compressor
system trial run; participate in acceptance after partial trial run and fill in the
commissioning and trial run assess table and bring out commissioning summarization.
8.5
Consultant unit

Take consultant in air compressor and the system commissioning steps, supervise
carrying out the procedure and participate in trial run and the acceptance.
9
HSE Control Measures
9.1

12

When air compressor and system started firstly, erection, commissioning, operation and
manufacturer people must be on site for supervision.
9.2

During trial run, stop equipments at once if some may risk human or equipments safety.
Carry out "3 No Startup" principles.
9.3
Stick warning signs around starting device.
9.4
Before changing pressure parts, isolate the unit and pressure resource reliably and release
system pressure.
9.5
While air compressor starting, pay attention to motors rotary direction. If it is run
conversely, equipments should be stopped at once.
9.6

Before unit running, check whether pressure, temperature and time setting is correct and
whether control and stop device functions normal.
9.7
Confirm whether the acoustic insulating materials on tank, compressor inlet and exhaust
systems good to guarantee noise is not increased.
9.8
Temporary system exhaust must avoid passerby and be fixed firmly, not face to other
buildings.
9.9
While blowing, around the exhaust, there should be people supervising, patrolling and
inspecting. Irrelevant people should not get close.
9.10

13

It is prohibited to run air compressor over exhaust pressure limited on nameplates.

9.11
Take intermittent water drain on dryers. Because water will reduce dryers efficiency even
make dryers invalid due to poison.
9.12
While blowing system, the exhaust should not face to equipments with reliable isolations.
9.13
During trial run, pay attention to control panel information and handle the found problems
in time.
9.14

In winter, the storage tank water discharge valve should be opened often to prevent the
condensate water freeze off valves.

14

10
Appendix

Air Compressor Trial Run Records

Time

:
Recorder:

Air
compre
ssor
exhaust
pressur
e
MPa

Air
compre
ssor
exhaust
Temp.

Air
compress
or current

cooling
water
Temp.

:
Date:

15

Vib.
motor
side

air
compressor
side