Shenyang Xinyulin, as a professional petroleum machinery company, its pressure test pumps are mainly used for pressure resistance (strength) tests and sealing tests of equipment or pipelines in oil fields, pipelines, boilers, pressure vessels, etc. The commissioning of such equipment is a crucial step to ensure its performance, safety and reliability.
The core points of its debugging process are as follows:
Ⅰ. Preparations before debugging (foundation and safety)
This is the prerequisite for a successful debugging. Any negligence may lead to a failure in debugging or a safety accident.
1. On-site inspection:
Equipment positioning and fixation: Check whether the pump body is placed stably on a solid foundation and whether the anchor bolts are tightened to prevent vibration and displacement during operation.
Environmental cleanliness: Inspect the pump body and its surrounding area to ensure there are no debris or oil stains, especially near the inlet and outlet.
Electrical connection: Check whether the power voltage and frequency comply with the requirements specified on the motor's nameplate, and verify the firmness of the cable connections and the reliability of grounding.
2. Pipeline system connection and flushing:
Drainage pipe: Ensure the water source is clean (preferably using pure water), the drainage pipe is unobstructed, the filter is installed and clean. The drainage pipeline should be as short and straight as possible to reduce suction resistance.
Water outlet (high-pressure) pipeline: Check whether the connection with the pressure test system is firm. Use qualified high-pressure hoses or steel pipes, and ensure that all joints are well sealed. Key point: Before connecting the pressure test pump, the pressure test pipeline system must be thoroughly flushed to remove welding slag, iron filings and other impurities to prevent them from damaging the precision valves and plungers of the pump.
3. Preparation of the pump body itself:
Lubricating oil/lubricating grease: Check whether the oil level in the gearbox is within the standard range. Check if any lubrication points require the addition of lubricating grease.
Turning the shaft: Manually rotate the coupling several times to check if it is flexible and smooth, and if there is any sticking or abnormal noise. Ensure that there are no abnormalities inside the pump.
II. No-load Debugging (Preliminary Operation Inspection)
Start the pump without pressure to test its basic operating condition.
1. Point-to-point start: Start the motor for a moment and then stop immediately. Observe whether the motor rotation direction is correct (consistent with the direction indicated on the pump body). If it is reversed, the power phase sequence needs to be adjusted.
2. No-load operation: After the direction is correct, start the pump for no-load operation (it is preferable that the water outlet leads to the atmosphere or an open container). Run for 5 to 10 minutes and observe:
Is there any abnormal noise: Listen for any unusual banging or rubbing sounds coming from the motor, gearbox, pump head, etc.
Vibration condition: Check whether the vibration of the pump body is within a reasonable range.
Leakage inspection: Check for any water or oil leakage at all sealing points and joints.
Temperature rise situation: Touch the motor and the housing of the reduction gearbox, and check if the temperature rise is normal.
III. Load Testing (Core Performance Verification)
This is the key step in the debugging process. Gradually increase the load to verify the performance of the pump and the sealing of the system.
1. Low-pressure stage commissioning:
Close the pressure relief valve and start to fill the test system with water to evacuate the contents (open the vent valve at the highest point of the system until water flows continuously without bubbles and then close it).
Slowly increase the pressure to a lower level (such as 20%-30% of the rated pressure), and maintain the pressure for a certain period of time.
Check items: Conduct a thorough re-inspection of all connections and seals for any leaks. Observe whether the pressure gauge pointer is stable to determine the system's sealing performance.
2. Graded pressure increase debugging:
According to the procedure (or customer requirements), increase the pressure gradually in increments of 20% to 30% of the rated pressure. Do not allow the pressure to be raised suddenly or rapidly to the maximum value.
For each additional pressure level, the pressure should be maintained for 2 to 5 minutes before conducting a comprehensive inspection (for leaks, vibrations, abnormal noises, etc.).
Inspect the safety valve: When the pressure approaches the pump's rated pressure or the set safety pressure, observe whether the safety valve can activate normally under the specified pressure. This is a crucial safety test.
3. Rated pressure calibration:
Slowly increase the pressure to the rated working pressure of the pump and maintain the pressure for the specified period of time (as per the test requirements).
Performance verification: During this process, the pump should operate smoothly, with stable pressure, no abnormal vibration or noise, and the motor current should be within the rated range.
Testing for sealing performance: During the holding pressure period, the reading of the pressure gauge should not decrease beyond the allowable range specified by the standard.
IV. Post-Testing Work
1. Safety Pressure Relief: After the testing or pressure testing is completed, the system pressure must be gradually and smoothly reduced to zero through the relief valve. It is strictly prohibited to disassemble any components under pressure.
2. Shutdown: Cut off the power supply.
3. Drainage: In cold conditions, if the equipment is likely to freeze, the water in the pump and the piping must be drained to prevent cracking due to freezing.
4. Record: Carefully document all parameters encountered during the debugging process (such as pressure levels at various stages, holding pressure duration, leakage conditions, abnormal phenomena, etc.), which will serve as the basis for equipment acceptance and future maintenance.
Summary and Important Notes
Core Principle: Safety first, proceed slowly and steadily, and observe carefully.
Water quality is crucial: Untreated water sources are the primary cause of premature wear or damage to the plunger, seals, and valves.
Emptying must be thorough: Any remaining air in the system can cause unstable pressure, result in water hammer phenomena, affect the accuracy of the test and damage the equipment.
Prohibit overpressure: It is strictly forbidden to conduct tests beyond the rated pressure of the pump and the design pressure of the tested system.
Personnel safety: During the process of pressure increase and pressure maintenance, personnel should stay away from the pressure test area and the direction where a burst might occur.
Please strictly follow the technical documents provided by the manufacturer when operating. This is the best guarantee to ensure that the debugging work is completed safely and efficiently.