m008启动和服务压缩空气系统start and service air system rev0-issue official

1、TABLE OF CONTENT目录1GENERAL 概述错误！未定义书签。1.11.21.3Pure 目的3Responsibility 义务3References and Drawings 参阅的文件和图纸32345SYSTEM DESCRIPTION 系统概述6SCOPE 范围6PRE-REQUISITES 前提条件6EXECUTION 执行75.15.25.35.4System Checklist 系统检查. 8Safety Precautions 安保措施8Fieldnel Deployment 现场调度9Inspection by Vendors Service Represeni

2、ve 供应商检查9678COMMISING PROCEDURES 调试程序10TABLES 表格12TEST ACCEPTANCE测试验收222 of 221General 概述1.1 Pure 目的The pure of this procedure is to give clear instructions for the activities to be carried out tocomplete the commising of the described system.To ensure proper installation of the compressed air syste

3、mTo demonstrate the operational capabilities of the air compressors, air dryer, air receivers and control and safety devi这个程序的目的是为了给予工作明确的指示，实行完整的调试系统描述。确定起动及工作压缩空气系统的安装正确确定起动及工作压缩空气系统操作功能的可行性.1.2 Responsibility 义务Any updates/revis of thiswill be the responsibility of the Commising Team. Anydeviatio

4、ns from this procedure will have to beed. In case of major changeshe workdescribedhis procedure (e.g. reduced scope of operating tests to be performed), a reviof theprocedure is required.任何更新/文件的修改都是调试团队的义务程序任何的偏差都需将化，这个程序的工作必须修改程序版本（例如：减少操作测试）下来假如发生变1.3 References and Drawings 参阅的文件和图纸1.3.1Operatio

5、n and Maenance Manuals 操作手册Service Air Compressor operation and maenance manuals of Ingersoll-rand.Service Air Dryer operation and maenance manuals of Ingersoll-rand.3 of 221.3.2Engineering Drawings 工程图纸1.3.3Mechanical and Electrical Completion Inspection Test Record 机电完工4 of 22Item项目Description描述In

6、itial初始NameDate日期MCReview Mechanical Inspection Test Reports for:机械检查测试Service Air Compressor #1Service Air Compressor #2Service Air Compressor #3Service Air DryerStart Air Reservoir #1Start Air Reservoir #2Service Air Reservoir #1Service Air Reservoir #2Drilling Air ReservoirAuxiliary Equipment Coo

7、ling SystemH6001-SW463.03-003H6001-SW463.03-005No.序号Drawing No.图号Description描述Remarks备注1HP6001-M430-05Air Compressor Room Layout2HP6001-P463-03Auxiliary Equipment Cooling System3HP6001-P465-01Start and Service Air System4HP6001-E612-01480V Main Switchboard 1 & MaCC 1 Single Line Diagram5HP6001-E612-

8、02480V Main Switchboard 2 & MaCC 2 Single Line Diagram6HP6001-E612-03480V Emergency Switchboard & E-MCC Single Line Diagram5 of 22Start and Service Air SystemH6001-CA465.01-001H6001-CA465.01-002H6001-CA465.01-003H6001-CA465.01-004H6001-CA465.01-005H6001-CA465.01-006H6001-CA465.01-007H6001-CA465.01-0

9、08H6001-CA465.01-009H6001-CA465.01-010H6001-CA465.01-011H6001-CA465.01-012H6001-CA465.01-013H6001-CA465.01-014H6001-CA465.01-015H6001-CA465.01-016H6001-CA465.01-017H6001-CA465.01-018H6001-CA465.01-019H6001-CA465.01-020H6001-CA465.01-021H6001-CA465.01-022H6001-CA465.01-023H6001-CA465.01-024H6001-CA46

10、5.01-025H6001-CA465.01-026H6001-CA465.01-027H6001-CA465.01-028ECReview Electrical Inspection Test Reports for:电气检查测试2SYSTEM DESCRIPTION 系统概述The pure of the compressed air system is to provide air for rig patic equipment. The systemconsists of three service air compressors, orvice air dryer and five

11、air receivers which arelocated throughout the vefor storage of compressed air. Two service air receivers are in aircompressor room, two start air receivers are in engine room and one drill floor air receiver islocated on the drill floor. Compressed air piis run from the service air compressors to se

12、rviceair dryer and then to air receivers. The service air compressors are controlled by an automaticsequencer. After the sequencing priority iected, the compressors will automatically cut-in andcut-out as required to achieve the desired outlet pre compressor #1 and #2 is obtained through breakersre.

13、 Theer supply to service airhe 480VAC main switchboard, while theer supply to service air compressor #3 and service air dryer is obtained though a breaker 480VAC emergency switchboard .he3SCOPE 范围This procedure will cover the following items:Service air compressors Service air dryer Sequence control

14、 panelUtility sions4PRE-REQUISITES 前提条件All the equipment shall be properly installed.All thpe lines shall be properly installed and hydro tested.All the electrical control panel and cables shall be properly installed and connected.All the instruments and calibrated.hpe lines and equipment skid shall

15、 be properly installedThe following is required for sucsful commising of the system:Two-way radio setsClammeterVoltmeter Megger testerNote: All test instruments shall bear evidence of calibration within 12 months of test.所有设备应正确安装。6 of 22Service Air Compressor #1Service Air Compressor #2Service Air

16、Compressor #3Service Air Dryer所有的管道应正确安装,水电测试所有电气控制面板和电缆应正确安装和连接。橇装管道和设备的所有仪器应正确安装和校准。下面是为了调试成功所需的系统:对讲机钳形表电压表绝缘表注意:所有测试仪器应当有表明在 12 个月内校准测试的。5EXECUTION 执行5.1System Checklist 系统检查7 of 22Item项目Description描述Initial施工人Name确认人Date日期5.1.1Service Air CompressorsaEnsure all air pisystems have already been c

17、ompleted.bCheckt all AC motors have been bumped for correct roion. This is to be done together with vendors service represenive.cCheck and verify ref valve setting.dEnsure the auxiliary equipment cooling system is operational.eOpen the drain and vent valves of the air compressors during start up. (T

18、his removes condensed water thus preventing water hammering)fEnsure t the pre re transducers are properly installed and signal cables are properly connected to the individual control panels.gEnsure the control panels are properlyerconnected.hEnsure the airake is free of obstruction.iEnsure the venti

19、lation cooling fan is free of obstruction.5.1.2Service Air DryeraCheck and verifyt ves (towers) are filled with desiccant.bCheck the pre-filter and after-filter are properly installed.5.2Safety Precautions安保措施8 of 22Item项目Description描述Initial施工人Name确认人Date日期5.2.1All commising activities must be in a

20、ccordance with the HPWS permit-to-work system.所有的调试工作必须依照黄埔厂工作制度。5.2.2The permit-to-work system shall specify the conditions of work and precautions to be taken during the execution of the commising work to protectnel, plant and the environment.工作制度将会具体说明工作的情况同时在调试执行的过程中采取预防措施以保护个人，工厂和环境。5.2.3All co

21、mmisingnel shall receive training to the level of their individual responsibilities on thePermit-to-Work System prior to its commencement.所有调试应在调试工作开始之前接受个人责任培训。5.2.4All activities shall be carried out in accordance with the shipyard safety procedures, project standards andcLine up the discharge fro

22、m starting / utility and utility air receivers to air headassing through the pre-filter, the air dryer and the after-filter.dEnsure the auto-drain valve is properly installed and water is drained from the system prior to air dryer start-up.5.1.3Sequence Control PanelsaCheck all theer cables are prop

23、erly connectedbCheck the signal cable from prere transducer is connectedcCheck the three control panels areerconnected properly5.1.4Utility Sions (Service Outlets)aEnsure all air pisystems are completed and tested.bEnsure there are no blockages on thpelines.5.3Fieldnel Deployment 现场调度5.4Inspection b

24、y Vendors Service Represenive 供应商检查9 of 22Item项目Description描述Initial施工人Name确认人Date日期5.4.1All the mechanical components of the system are installed to vendors specification系统所有的机械按照规格安装5.4.2All the electrical components of the system are installed to vendors specification系统所有的电气按照规格安装5.4.3Vendors ser

25、vice engineer to verifyt the system is ready and safe to be start up and commised供应商工程师确保系统可以安全的开始调试内容Item项目Description描述Initial施工人Name确认人Date日期5.3.1Ensure requirednel are sioned at the Air Compressor Room确保相关在空压机室5.3.2Ensure requirednel are sioned at Switch Board Room确保相关在开关间5.3.3Ensure there are s

26、afetyon site.确保安全员在场sutory regulations.所有调试行为需要按照黄埔厂安全程序，项目基准，法定规则实施。5.2.5HPWS commising engineers and supervisors will ensuret allnel involvedhe activity / work scope assisthe completion of hazard identification as per shipyard procedure.黄埔厂调试工程师和监督 必须确保所有调试行为或者工作范围按照每一个调试程序都做好 安全确认之后实行。6COMMISING

27、PROCEDURES调试程序6.1Service Air Compressors10 of 22No.序号Description描述HPWS船厂AOD船东ABS船检6.1.1Perform step 6.1.2 to 6.1.9 for compressor 1 to 3 and recordable 2.0&2.1&2.26.1.2Start air compressor and stop it immediay. Check roion direction of the compressor drive motor.6.1.3Start air compressor as per make

28、rs instruction and bring the compressor to rated capacity and allow it to run for sufficient time to check items 6.1.4 to 6.1.9.6.1.4Simulate compressor motor thermal overload trip by opening contact. Verifyt the starter conductor trips, the flushing LED indicator on the module iivated andt depressi

29、ng the STutton will clear the LED indicator.6.1.5Simulate high air discharge prere. Verifyt the starter conductor trips, the flushing LED indicator on the module iivated andt depressing the STutton will clear the LED indicator.6.1.6Simulate high air discharge temperature. Verifyt the starter conduct

30、or trips, the flushing LED indicator on the module iivated andt depressing the STutton will clear the LED indicator.6.1.7Simulaow cooling watrere. Verifyt the starter conductor trips, the flushing LED indicator on the module iivated andt depressing the STutton will clear the LED indicator.6.1.8Crack

31、 open the shut off valve to the discharge line. Check manual start function. Verifyt the air compressor starts up as normal and no air leakage is detected. Close the discharge valve and verifyt the compressor runs to the rated prere and unloads. Manually stop the air compressor.6.2 Service Air Dryer

32、11 of 22No.序号Description描述HPWS船厂AOD船东ABS船检6.2.1With switch in “off”ition, energize the dryer. Leave the dryer energized foreast 24 hours before operating.6.2.2Open refrigerant service valves using the wrench6.1.9Check the functionality of emergency stop.6.1.10Set lead compressor #1 as per the settin

33、g below: Cut in:0.9 MpaCut out:1.0 Mpa6.1.11Set second lead compressor #2 as per the setting below: Cut in:0.9 MpaCut out:1.0Mpa6.1.12Set lag compressor #3 as per the setting below: Cut in:0.9MpaCut out:1.0Mpa6.1.13Start the air compressor with shut off valve cracked open, then open until the discha

34、rge valve is fully open. Run the air compressors for not lessn one hour in conjunction with service air dryer test.6.1.14Inspect compressor and attached auxiliaries thoroughly to detect any sign of inadequacy such as ex sive vibration in foundation/pi and noise.6.1.15Check the oil level during loade

35、d operation. The level should be betn the bottom and mid poof the sight glass.6.1.16Switch on the sequence control panel. Demonstrate the functionality of the automatic sequence control. Select a sequence priority. Start the lead compressor and bring it to its rated capacity. Bleed air from the air

36、receiver until service air compressor no. 2 starts. Continue to bleed air from air receiver until service air compressor no. 3 starts. Let the system prere increase and verify all compressors unload after the system reached the setprere and stops after a time delay. Record result.7TABLESTables 1.0Eq

37、uipment Data 设备数据12 of 22No.序号Item项目Design设计值Name Plate铭牌内容Commising Supervisor调试责任人1Service Air Compressor 11.1Location 位置Air Compressor Room1.2Maker 制造商Ingersoll-rand1.3M型号R90I_W101.4Tag ID 设备1.5Capacity 容量8411.6Dry Weight 浄重2617provided.6.2.3Check the refrigerant leaks and proper electrical volta

38、ge.6.2.4Set the main disconnect switch to “ON” and verify t the yellow LED on the control panel illuminates. Allow dryer to run for about 5 mins.6.2.5Slowly prerize the unit by operating air inlet valve. Check for air leaks.6.2.6After 15 mins, slowly open outlet isolation valve.6.2.7Check compressor

39、 roion direction. Verifyt the prere reading on the low prere gauge decreases.6.2.8Close air bypass valve.6.2.9Run the unit for one hour in conjunction wiir compressor test.6.2.10Check prere and temperature gauges and alarms for abnormal indication.6.2.11Check automatic draime setting ofum 3 mins bet

40、n operations and 5 seconds valve open time andt condensate is discharging from the drain.6.2.12Demonstrate the supply of compressed air to various outlets as per table 4.013 of 222Service Air Compressor 22.1Location 位置Air Compressor Room2.2Maker 制造商Ingersoll-rand2.3M型号R90I_W102.4Tag ID 设备2.5Capacity

41、 容量8412.6Dry Weight 浄重26173Service Air Compressor 33.1Location 位置Air Compressor Room3.2Maker 制造商Ingersoll-rand3.3M型号R90I_W103.4Tag ID 设备3.5Capacity 容量8413.6Dry Weight 浄重26174Service Air Dryer4.1Location 位置Air Compressor Room4.2Maker 制造商Ingersoll-rand4.3M型号D3090INR-W4.4Tag ID 设备4.5Capacity 容量30904.6D

42、ry Weight 浄重7555Start Air Reservoir #15.1Location 位置Engine Room5.2Maker 制造商Jingsu Jinhai5.3M型号5.4Tag ID 设备5.5Capacity 容量1000L5.6Dry Weight 浄重6Start Air Reservoir #26.1Location 位置Engine Room6.2Maker 制造商Jingsu Jinhai6.3M型号6.4Tag ID 设备6.5Capacity 容量1000L6.6Dry Weight 浄重Table 2.0Test Results of Service

43、Air Compressors #1 1 号空压机14 of 22No.DescriptionDesignActual valueHPWSAODABS1Voltage460V2Starting current3Full load current4Running current5Test run time6Discharge air prere7Service Air Reservoir #17.1Location 位置Air Compressor Room7.2Maker 制造商Jingsu Jinhai7.3M型号7.4Tag ID 设备7.5Capacity 容量2500L7.6Dry W

44、eight 浄重8Service Air Reservoir #28.1Location 位置Air Compressor Room8.2Maker 制造商Jingsu Jinhai8.3M型号8.4Tag ID 设备8.5Capacity 容量2500L8.6Dry Weight 浄重9Drilling Air Reservoir9.1Location 位置Drill Floor9.2Maker 制造商9.3M型号9.4Tag ID 设备9.5Capacity 容量3m39.6Dry Weight 浄重145015 of 22No.DescriptionDesignActual valueH

45、PWSAODABS7Discharge air temperature8Prere SwitchCut in (bar)0.9MpaCut-out (bar)1.0Mpa9Ref valve opening1.1Mpa10Loading/Unloading11Motor overload (M1)12Sump low prere (DP3)165psi13Cooling water low prere14Discharge air high Temperature (T1)15Sump discharge temperature (T2)16Sump high prere (P1)17Line

46、 prere (P2)10bar18Separator diff. Prere (DP1)19Oil Filter diff. Prere (DP2)20Automatic shutdown21Emergency stuttonTable 2.1Test Results of Service Air Compressors #2 2 号空压机16 of 22No.DescriptionDesignActual valueHPWSAODABS1Voltage460V2Starting current3Full load current4Running current5Test run time6

47、Discharge air prere7Discharge air temperature8Prere SwitchCut in (bar)0.9MpaCut-out (bar)1.0Mpa9Ref valve opening1.1Mpa10Loading/Unloading11Motor overload (M1)12Sump low prere (DP3)165psi13Cooling water low prere14Discharge air high Temperature (T1)15Sump discharge temperature (T2)16Sump high prere

48、(P1)17Line prere (P2)10bar18Separator diff. Prere (DP1)19Oil Filter diff. Prere (DP2)Table 2.2Test Results of Service Air Compressors #2 2 号空压机17 of 22No.DescriptionDesignActual valueHPWSAODABS1Voltage460V2Starting current3Full load current4Running current5Test run time6Discharge air prere7Discharge

49、 air temperature8Prere SwitchCut in (bar)0.9MpaCut-out (bar)1.0Mpa9Ref valve opening1.1Mpa10Loading/Unloading11Motor overload (M1)12Sump low prere (DP3)165psi13Cooling water low prere14Discharge air high Temperature (T1)15Sump discharge temperature (T2)No.DescriptionDesignActual valueHPWSAODABS20Aut

50、omatic shutdown21Emergency stuttonTable3.0Compressor Sequence Test Data (using three compressors)Table 4.0Service Outlets18 of 22No.序号Location位置Valve No.HPWS船厂AOD船东ABS船检1Start Main Engine#1CAV0192Start Main Engine#2CAV0203Start Main Engine#3CAV0214Start Main Engine#4CAV0225Start Main Engine#5CAV0236

51、Service E-gen room serviceCAV0457Service LIFEBOAT PORTCAV086ItemPreset cut-in pre reActual cut-in pre rePreset cut-out pre reActual cut-out pre reRemarksLead compressor9bar10barSecondary compressor9bar10barThird compressor9bar10barNo.DescriptionDesignActual valueHPWSAODABS16Sump high prere (P1)17Lin

52、e prere (P2)10bar18Separator diff. Prere (DP1)19Oil Filter diff. Prere (DP2)20Automatic shutdown21Emergency stutton19 of 228Service LIFEBOAT STBDCAV0879Service TO CANTILEVER & DRILLFLOORCAV01810 HYPERLINK mailto:ServiceAUX.MACH.ROOM ServiceAUX.MACH.ROOM PORT SERVICECAV04611Service SACK STORAGE ROOM

53、UPPER SEVICECAV04712Service TO SACK CUTTING UNIT AND CHEMICAL MIXINGCAV040/CAV04113Service TO P/P ASPIRATORSCAV094/CAV09514Service WELL TEST AREACAV08515Service COMPRESSOR RM LCAV084/CAF00216Service TO GULPUMPCAV03917Service BULK AIR COMP.ROOM SERVICECAV04918Service SACK STORAGE ROOM SERVICECAV04819

54、Service LOADING SION SCAV07320Service SEA CHEST PORTCAV02521Service PUMP ROOM P SERVICECAV05122Service TO P/P ASPIRATORSCAV03723Service MUD PUMP ROOM SERVICE(P)CAV05024 HYPERLINK mailto:ServiceMECH.WORKSHOP ServiceMECH.WORKSHOP SERVICECAV05225Service ENGING ROOM SERVICE(P)CAV05326Service TO BILGE GU

55、LPUMPCAV02627Service TO MDO PURIFIERS AND TO P/P ASPIRATORSCAV043/CAV04428Service TO BILGE GULPUMPCAV02729Service TO AIR GULPUMPCAV02830Service PUMP ROOM S SERVICECAV05731Service SEA CHEST STBDCAV02432Service HVY TOOL STORE SERVICECAV05933Service WATER MAKER ROOM SERVICECAV06034Service TO POTABLE WA

56、TER T MKCAV029/CAV03135Service NEAR BOOBY HATCH SCAV07836Service MUD LABCAV08320 of 2237Service TRANSFORMER ROOM SERVICECAV05438Service ENGINE ROOM SERVI)CAV05539Service MUD PUMP ROOM SERVI)CAV05640Service ELEC.WORKSHOP SERVICECAV05841Service TO P/P ASPIRATORSCAV092/CAV09342Service MUD PIT ROOM SERV

57、ICECAV062/CAV06343 HYPERLINK mailto:ServiceAUX.MACH.ROOM ServiceAUX.MACH.ROOM S SERVICECAV06144Service AIR WINCHCAV03645Service TO P-CAV06446Service TO P-CAV07047ServiceCO2 ROOM SERVICECAV06548Service TO CRANE STBDCAV06649Service TO SPUDCAN EDUCTOR(FWD)CAV09050Service NEAR LEG WELL FWDCAV08151Servic

58、e NEAR LEG WELL FWDCAV08252Service LOADING SIOAV07253Service TO CRANE PORTCAV06754Service TO CRANE FWDCAV06855Service NEAR LEG WELL PORTCAV07956Service TO SPUDCAN EDUCTOR(PORT)CAV08957Service NEAR BOOBY HATCH PORTCAV07758Service WELDING SHOP AREACAV07659Service WELDING SHOP AREACAV07560Service RADIATOR PLATFORMCAV07461Service LQ TOP - LOGGING