1 problems in the design 1. 1 electric control cabinet and chlorine gas turbine compressor unit are set in the same operation workshop on June 30, 2009 23: 30, 1 The turbo compressor group has multiple alarms of shaft vibration over-limit failure, and the vibration value is rapidly expanded (after-the-fact analysis is considered to be the corrosion of the contact vibration of the on-site unit shaft vibration protection transmitter, and the false signal transmitted to the DCS control system). In order to avoid damage to the equipment, the on-duty operator will stop the flat compressor unit after the dispatch. Stop 1 After the compressor gives 2 Compressor power transmission, found 2 The compressor is faulty, the PLC cannot be displayed, and it cannot be started. Then start 1 Compressor, 1 The PLC also has a PLC failure and cannot be started. After the inspection, it was found that the electrical components such as soft start and PLC in the two electric control cabinets were corroded and damaged. After the failure occurred, the workshop actively contacted the compressor manufacturer to solve the problems of the two turbine compressor units as soon as possible, in order to resume production as soon as possible; while actively searching for and analyzing the cause of the failure. After confirmation by the manufacturer, the cause of the compressor failure is as follows. The new chlorine-hydrogen treatment process 2 sets of chlorine gas turbine compressor electric control cabinets are installed in the turbine compressor operating room according to the design requirements of the design institute (the equipment manufacturer does not explicitly require the electric control cabinet to be separated from the unit), and in subsequent use, Due to the leakage of chlorine gas in the factory, the site was seriously corroded, and it was rainy in the middle and late June of 2009. The humidity on the site was large, which caused corrosion and damage to the electrical components such as soft start and PLC in the electric control cabinet. Corrective measures: In order to avoid the corrosion of the electrical instruments in the electric control cabinet, the workshop quickly arranged the installation company to shift the electric control cabinet. Now the two turbine compressor electric control cabinets have been smoothly moved to the ion. Membrane master control room. 1. 2 Turbine Compressor Intercooler Cooling System with Closed Circulating Water Cooling According to the design drawings of the design institute, the turbine compressor intercooler is cooled by a closed circulating water process. The problem with this closed cycle water cooling process is that the circulating water system pressure is greater than the intercooler chlorine system pressure. If the intercooler tube path has a leak point, the cooling water may enter the intercooler chlorine system, thereby allowing the chlorine gas to enter the turbine. The water content of the chlorine gas in the compressor exceeds the standard (in order to ensure that the moisture content of the chlorine gas before entering the chlorine gas turbine compressor is not higher than the control index requirement of 0.01%, the company selects the American Mengmoike filter in the water mist separation and acid mist separator. ), damage to the chlorine gas turbine compressor unit, severe cases may lead to the entire unit scrapped. Due to the accident caused by the leakage of the cooler, the manufacturers of turbine compressors in China have also reported frequently. In addition, the oil temperature of the turbine compressor tank is cooled by circulating water. When the ambient temperature is high, the oil temperature cannot be cooled to the specified value. Rectification measures: returning water to non-pressure return water process, and requiring operators to regularly sample and analyze the return water pH value of the cooler; the oil tank oil temperature is cooled to add a chilled water line to switch in time when the ambient temperature is high. 2 problems in construction Construction is not strictly in accordance with technical requirements, and more welding slag remains in the chlorine gas pipeline. In order to avoid damage to foreign objects such as welding slag during high-speed operation of the turbo compressor impeller, turbine compressor manufacturers require that all pipes from the outlet of the acid mist trap to the outlet valve of the turbo compressor be sandblasted or pickled. The instrument port and nozzle cut with oxygen on the pipeline must be polished with a polishing machine before welding. The welding must be done with argon arc welding, and then welded with electric welding. After the welding of the pipeline, it must be removed for sandblasting. Treatment or pickling. Due to the good market sales situation, the company required the ion-exchange membrane caustic soda plant to be put into operation after the Spring Festival. In order to complete the construction task as soon as possible, the installation company failed to strictly follow the technical requirements during the rectification of some of the later pipelines, resulting in more weld slag left in the pipeline. Due to the advance of the test run time, the pipeline was not sandblasted or pickled as planned. When the chlorine gas turbine compressor pipe was purged after the holiday, it was found that there were impurities such as welding slag in the inlet pipe. The factory test crew saw this situation and insisted that the pipeline be removed for sandblasting or pickling. Corrective measures: A flat-bottom cone filter is designed and installed in the two-stage inlet pipe of the chlorine turbine compressor, and a stainless steel mesh with a mesh of 0.42 mm is wrapped on the surface (note the change of the turbine compressor current when using it). The normal running current drops below 40 A, so as to avoid too much impurities in the inlet to stop the turbo compressor, or remove the filter during the maintenance process, and remove the foreign matter in time to ensure that no foreign matter such as welding slag enters the chlorine gas. Turbine compressors also ensure the company's commissioning schedule requirements. 3 problems in the operation 3. 1 Turbine compressor corrosion of stainless steel expansion joints of primary and secondary air inlets In order to prevent the thermal expansion of the pipeline and the external force applied to the turbine compressor unit, the inlet and outlet of the unit are fitted with stainless steel expansion joints provided by the turbine compressor manufacturer. Shortly after the use of the turbine compressor, chlorine leakage occurred in the first-stage inlet expansion joints of the two units. After dismantling, it was found that the stainless steel expansion joint was made coarser and the leaking points were point-like corrosion. Corrective measures: After the repair treatment of the stainless steel expansion joint leakage point, the outer wall was made of oil and corrosion protection; and a set of stainless steel expansion joints of various specifications used by the unit was purchased as a spare. 3. 2 When the turbine compressor starts, the motor wiring is burned and burnt. On the afternoon of August 20, 2009, after the ion membrane system was shut down for maintenance, the turbine compressor unit was switched to 1 compressor operation as planned. After the operator starts the button on the field for about 2 s, a short circuit and a fire occurs at the motor junction box. After the inspection, it was found that the motor coil was burnt and there was a breakdown mark at the motor terminal. After on-site analysis by electrical personnel, it is believed that the power line at the motor terminal is loose, which is the main cause of the accident. Rectification measures: Require workshop electrical maintenance personnel to regularly check the power supply wiring of important equipment, and find problems in a timely manner. 3. 3 oil cooler pipe leakage, the tank is slightly corroded On October 10, 2009, the ion membrane system was shut down for maintenance. 1 When the turbine compressor was changed according to the plan, it was found that there was water in the shell of the oil cooler, which proved that the tube was leaking (1 October 1st) One oil filter of the compressor had a large difference in oil pressure difference. At that time, it was thought that the filter element was dirty, and two oil filter elements were replaced. The result of the post-mortem analysis is: If it is not because of the system shutdown and maintenance on the second day, the unit will continue to be used, and the oil contains too much water, which is likely to cause greater damage to the turbine compressor. After replacing the oil cooler tube and running the unit, it was found that the oil filter element of the unit was very dirty. After the unit was inspected, it was found that the oil tank had been slightly corroded due to water leakage from the previous oil cooler. fast. Corrective measures: clean the fuel tank dirt and change the oil, and require the operator to carefully observe the changes in oil level and oil quality, and find problems in a timely manner. By summarizing the above problems, we have further understanding of the chlorine gas turbine compressor, and remind us that we should carefully observe the operating status of the unit, and timely discover the abnormal state that occurs during the operation and operation of the unit, and improve the abnormal state of the unit. The processing capacity ensures the safe and stable operation of the chlorine turbine compressor. 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