Examination tickets are compiled according to the requirements of the professional standard upon request qualification requirements to professions and professional training standards
Order of the Ministry of Labor and social protection RF dated September 9, 2015 N 619n “On approval professional standard"Operation worker for compressor units at a thermal power plant"
Order of the Ministry of Labor of Russia dated December 21, 2015 N 1070n (as amended on March 17, 2016) “On approval of the professional standard “Worker for the maintenance of pumping or compressor installations of the engineering infrastructure of housing and communal services (in water and heat supply systems)”
Order of the Ministry of Education and Science of Russia dated 08/02/2013 N 917 (as amended on 03/25/2015) “On approval of the federal state educational standard average vocational education by profession 240101.02 Machinist process pumps and compressors"
Professional standard requirement (Order of the Ministry of Education and Science of Russia dated August 2, 2013 N 917)
PM.01 Maintenance and repair of process compressors, pumps, compressor and pumping units, gas drying equipment
have practical experience:
maintenance and repair;
performing plumbing work;
ensuring safe working conditions;
be able to:
follow the rules for the maintenance of pumps, compressors, and gas drying equipment;
prepare equipment for repair;
carry out repairs of equipment and installations;
comply with fire and electrical safety rules;
prevent and eliminate malfunctions in the operation of pumps, compressors, gas drying equipment;
exercise control over waste generated during production of products, wastewater, atmospheric emissions, disposal and recycling methods;
implement the requirements for labor protection, industrial and fire safety when repairing equipment and installations;
assess the state of safety and environmental regulations at gas drying plants, pumping and compressor installations;
prepare technical documentation;
know:
design and principle of operation of equipment and communications;
maintenance rules;
layout diagrams of workshop pipelines and inter-shop communications;
rules and instructions for performing fire and gas hazardous work;
rules for maintaining technical documentation;
technology for draining and pumping liquids, gas drying;
rules for preparation for repair and repair of equipment and installations;
pipelines and pipeline fittings;
methods for preventing and eliminating malfunctions in the operation of pumps, compressors, gas dryers;
labor safety rules during repairs
PM.02 Operation of process compressors, pumps, compressor and pumping units, gas drying equipment
As a result of studying professional module the student must:
have practical experience:
conducting the process of transporting liquids and gases in accordance with the established regime;
regulating the parameters of the process of transporting liquids and gases in the serviced area;
conducting the gas drying process; regulation technological mode gas drying;
operation of electrical equipment;
ensuring safe operation of production;
be able to:
ensure compliance with parameters technological process;
operate equipment for transporting liquids, gas and gas drying;
monitor the consumption of transported products according to instrumentation readings;
take samples for analysis; carry out bottling, packaging and transportation of products to the warehouse;
keep records of consumption of products, operating and fuel lubricants, energy resources;
maintain reporting and technical documentation;
comply with labor protection, industrial and fire safety requirements;
comply with environmental safety rules;
know:
basic principles of liquid and gas transportation technology;
basic principles of gas drying technology;
technological parameters of processes, rules for their measurement;
purpose, design and principle of operation of automation equipment;
diagrams of pumping and compressor units, rules for their use;
diagrams of gas drying installations;
industrial ecology;
basics of industrial and fire safety;
labor protection;
metrological control;
rules and methods of sampling;
possible violations of the regime, causes and solutions, warning;
maintaining reporting and technical documentation on the operation of equipment and installationsMDK.02.01. Operation of equipment for transporting gas, liquids and gas dryingOK 1
Topics:
Topic 1. General requirements to compressor units and pipelines
Topic 2. System of monitoring, control and emergency automatic protection of compressor units
Topic 3. Operation of electrical equipment of thermal power plants
Topic 4. Maintenance and repair of compressor units
Regulatory and technical literature:
Order of the Ministry of Labor and Social Protection of the Russian Federation dated September 9, 2015 N 619n “On approval of the professional standard “Worker for the operation of compressor units of a thermal power plant”
Order of the Ministry of Labor of Russia dated December 21, 2015 N 1070n (as amended on March 17, 2016) “On approval of the professional standard “Worker for the maintenance of pumping or compressor installations of the engineering infrastructure of housing and communal services (in water and heat supply systems)”
Order of the Ministry of Education and Science of Russia dated 08/02/2013 N 917 (as amended on 03/25/2015) “On approval of the federal state educational standard for secondary vocational education in the profession 240101.02 Technological pump and compressor operator”
PB 03-581-03 “Rules for the design and safe operation of stationary compressor units, air and gas pipelines”
PB 03-582-03 “Rules for the design and safe operation of compressor units with piston compressors operating on explosive and harmful gases”
Answers
For question 5 of the exam papers
Technological compressor operators
Ticket No. 1
The procedure for training workers in safety measures and labor protection (instructions and knowledge testing, admission to independent work), industrial safety and fire safety. (Clause 4.2. ESUOT in OJSC Gazprom VRD 39-1.14-021-2001).
4.2.1. Training of employees (workers, other employees) safe methods and labor practices should be carried out in all branches of the organization, regardless of the nature, complexity and degree of danger of production.
At facilities controlled by state supervision and control bodies (Gosgortekhnadzor of Russia, Gosenergonadzor of Russia and other bodies), only persons who have a document confirming completion of the appropriate special training are allowed to work.
4.2.2. Training workers and other employees in safe labor methods and techniques includes:
induction training;
initial training at the workplace;
industrial (theoretical and practical) training on safe methods and techniques of work in the amount of at least 10 hours, and when training workers in professions that are subject to additional (increased) labor safety requirements, as well as in professions and work related to servicing objects under control state supervisory authorities in industry, construction, transport, etc. at least 20 hours during on-the-job training under the guidance of a teacher, industrial training master (instructor) or highly qualified worker;
internship of at least 2 - 14 work shifts;
primary test of knowledge - admission to independent work;
repeated training in the workplace;
unscheduled on-the-job training;
targeted training in the workplace;
another knowledge test;
extraordinary knowledge test.
4.2.3. Admission to independent work of persons who have not undergone appropriate training and the necessary internship is prohibited. Training, internship and admission to independent work are formalized by order of the head of the branch (group, section, workshop, service, department) with an entry in the order log and personal instruction registration card.
Introductory briefing
4.2.4. Introductory training on occupational safety is carried out with all newly hired workers, regardless of their education, work experience in a given profession or position, with temporary workers, business travelers, students arriving for internships, and excursionists.
4.2.6. Introductory briefing involves familiarizing those being instructed with the rules of the internal labor regulations, specific features of this production, basic labor protection requirements, hazards and hazards, technical, fire, blowout, gas safety and industrial sanitation at the facility.
4.2.7. Introductory training is carried out by employees of the labor protection service or persons who are assigned these responsibilities by order (instruction) of the organization (branch).
Specialists from relevant services may be involved to conduct introductory training on special issues.
Initial training at the workplace
4.2.18. Target initial briefing in the workplace - training each worker or employee in correct and safe work techniques and methods. During the briefing, the person being instructed should be familiarized with the equipment, devices, their characteristics and design features, possible hazards, safe work practices, the procedure for preparing the workplace, the use of protective equipment and the rules for providing first-aid care.
4.2.19. Initial training at the workplace is carried out before the start of production activities:
With all those newly hired into the organization (branch), transferred from one unit to another or in the unit where they were transferred to work in another profession;
with employees performing new work for them, business travelers, temporary workers;
with builders performing construction and installation work on the territory of an operating organization;
with students and students who arrived for industrial training or practice before performing any type of work, as well as before studying each new topic when conducting practical classes in educational laboratories, classes, workshops, areas, during extracurricular activities in clubs and sections.
4.2.20. Initial instruction at the workplace is carried out according to programs developed by the head of the branch (shop, service, etc.) and approved by the heads of organizations or branches. The programs are coordinated with the labor protection department (engineer) and the trade union committee of the organization or branch.
Industrial training on safe work methods and techniques
4.2.24. All newly hired workers and other employees, after initial training at the workplace, undergo industrial training on safe methods and techniques of work for at least 10 hours, and when training workers in professions for which additional (increased) labor safety requirements are imposed , as well as in professions and work related to the maintenance of objects controlled by state supervisory authorities in industry, construction, transport, etc. at least 20 hours during on-the-job training;
Training is carried out according to programs approved by the chief engineer of the organization or branch and compiled on the basis standard programs on occupational safety approved by OJSC Gazprom.
Internship
4.2.28. Workers and other employees, after undergoing initial on-the-job instruction and industrial training, must, during the first 2-14 work shifts or days (depending on the nature of the work, qualifications), undergo an internship under the supervision of persons appointed by order for the service (shop, section, group , department, etc.).
Note: The management of the service (shop, site, group, department, etc.), in agreement with the production service (department) for labor protection and the trade union committee, may exempt from internship an employee who has at least 3 years of experience in the specialty, transferring from one workshop to another, if the nature of his work and the type of equipment on which he previously worked does not change.
Testing knowledge - admission to independent work
4.2.29. Before admission to independent work, after introductory briefing, initial briefing at the workplace, on-the-job training and internship, a knowledge test is carried out.
4.2.30. Testing the knowledge of workers and other employees is carried out by an examination committee (EC), created by order (instruction) for a branch of the organization. The head of the workshop (service, section, etc.) is appointed as the Chairman of the EC.
The number of members of the commission must be at least three people.
4.2.31. Knowledge testing should be carried out individually:
from managers and specialists on approved programs, in accordance with clause 4.1.11;
for workers and other employees according to the approved List of Labor Safety Instructions, production instructions. For workers in professions that are subject to additional (increased) labor safety requirements, as well as in professions and work related to the maintenance of facilities controlled by the Gosgortekhnadzor of Russia, in addition to the List of instructions, references to necessary items current rules and other regulations on labor protection and industrial safety.
4.2.33. The next test of knowledge of workers and other employees is carried out at least once a year from the moment of passing the exam according to the schedule (Appendix 4.7.) developed by the foremen and approved by the head of the workshop, service, etc. indicating the calendar date of the next knowledge test.
4.2.34. Knowledge test schedules are brought to the attention of workers and other employees by immediate supervisors no later than 15 days before the day of the knowledge test.
4.2.36. If, during a knowledge test, an employee shows unsatisfactory knowledge of labor protection, then he is not allowed to work independently; he must pass additional training and no later than one month, take the knowledge test again.
4.2.37. Failure to appear for the next knowledge test without objective reasons or the employee’s unpreparedness for the knowledge test is considered a violation of labor discipline.
4.2.38. An extraordinary test of workers’ knowledge is carried out:
when changing the production (technological) process, replacing or upgrading equipment and mechanisms;
upon the introduction of new safety rules and standards, instructions on labor protection and safe work;
in case of violations by employees of safety rules and labor protection instructions;
by order or direction of a higher organization, a branch of the organization;
at the request of state supervision and control authorities, in case of detection of insufficient knowledge by employees of labor protection instructions;
The list of questions for an extraordinary knowledge test is established in each specific case by the branch management, incl. taking into account the instructions of state supervision and control bodies.
Persons who, for any reason objective reasons(vacation, illness, business trip, etc.) were absent during the next knowledge test, are required to pass the knowledge test within 15 days from the date of return to work. In this case, the period for the next inspection is extended by the specified period.
Re-briefing
4.2.40. All workers, regardless of qualifications and work experience, must undergo repeated training at least once every six months according to the initial training program at the workplace in full, and persons employed in work with increased danger workers, the list of which is determined by the management of the organization (branch), undergo repeated instruction at least once every three months, with the exception of workers who, due to the specific features of the work performed, are given other deadlines by special rules.
Unscheduled on-the-job training
4.2.43. In special cases caused by production needs, workers and other employees should be given unscheduled instruction on the safe conduct of work.
4.2.44. Unscheduled briefing is carried out earlier deadline in cases:
changes in the technological process, modernization or replacement of equipment, devices and tools, changes in raw materials, materials and other changes;
violation by workers of instructions, rules, regulations, as well as the use of incorrect techniques and methods of work, which could lead to an accident or accident;
when introducing new rules and instructions for the safe conduct of work, safety standards, information letters and accident reports and orders on labor protection issues;
at the request of state supervisory and control authorities or the administration of the organization (branch);
during breaks in work - for work for which additional (increased) labor safety requirements are imposed for more than 30 calendar days, and for other work - 60 days.
4.2.48. Persons who, for any reason (vacation, illness, business trip, etc.) were absent during unscheduled instruction, receive instruction on the day they return to work.
Targeted training in the workplace
4.2.49. Targeted instruction is carried out when performing one-time work that is not related to the direct performance of work in the specialty, i.e. not included in the list of instructions for a given profession of a worker or other employee (loading, unloading, cleaning the territory, one-time work outside the organization’s workshop, etc.), as well as in eliminating the consequences of accidents, natural disasters and catastrophes; production of work for which a permit, permit and other documents are issued. If the work is not formalized with an approval order, a permit, where a record of the briefing is made, then this type of briefing is formalized by an entry in the briefing log at the workplace of the workshop where the work is performed.
Ticket No. 2
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Compressor unit operator" 4th category
1. Classification of compressors.
Purpose. A compressor is used to compress, increase pressure and move (transport) air or gas. The compressor is the basis of the compressor unit, which in addition to it includes auxiliary interstage devices, a drive, gas pipelines and various systems(lubrication, cooling and regulation).
Compressors are used in the chemical, metallurgical and mining industry, energy, mechanical engineering, construction, transport and other industries national economy to ensure the technological production process and for auxiliary purposes.
Classification. Compressors are classified by purpose, principle of operation, final pressure, supply, method of heat removal, type of drive, type of installation.
By purpose Compressors are classified depending on the type of production in which they are used (chemical, gas pumping, general purpose, etc.), as well as by their intended purpose (starting air, brake air, pumping, etc.).
By operating principle Compressors are divided into volumetric and dynamic. The first include piston compressors with reciprocating piston movement, rotary (plate) ) with rotational movement of displacer pistons, screw ones with variable pitch rotors and membrane ones, in which the membrane plays the role of a piston. Dynamic compressors (turbocompressors) are divided into centrifugal with a gas flow directed radially from the center to the periphery, and axial with a gas flow moving in the axial direction when the wheel with blades rotates.
By final pressure There are low pressure compressors that create a gas pressure of 0.2...1.0 MPa (2...10 kgf/cm2), medium -1...10 MPa (10...100 kgf/cm2), high -10... 100 MPa (100... 1000 kgf/cm 2) and ultra-high pressure - over 100 MPa (1000 kgf/cm 2).
By submission compressors are divided into machines with small (up to 0.015 m: 7s), medium (0.015...1,500 m 3 / s) and large (over 1,500 m 3 / s) flow, different for each type of compressor (volumetric or dynamic).
By heat removal method compressors are divided into machines with cooling (air or water) of the compressor and the discharge gas;
By drive type- for compressors with an electric motor, steam or gas turbine oh, internal combustion engine;
By type of installation- stationary (on a foundation or special supports) and mobile (on a chassis or frame). 2. Design and purpose of separators and filters included in compressor units and requirements for them.
Separators (Oil and moisture separators) are used to purify gas from oil and moisture (in turbochargers - from moisture). Separation occurs when there is a sudden change in the direction of gas flow due to different densities of the gas and the oil and moisture droplets it contains. The direction of gas flow is changed by installing additional partitions in the cylindrical body, placing the gas inlet and outlet pipes at an angle, or making the inlet pipe in the form of a branch that changes the direction of flow (Fig.
2.45. Air intake (suction) by an air compressor should be done outside the compressor station at a height of at least 3 m from the ground level.
For air compressors with a capacity of up to 10 m 3 /min, which have air filters on the machine, it is allowed to take air from the compressor station premises.
2.46. To clean the intake air from dust, the suction air duct of the compressor is equipped with a filter protected from the ingress of atmospheric precipitation.
The design of the filter device must provide safe and convenient access to the filter for cleaning and disassembly.
The filter device should not deform or vibrate as air is sucked in by the compressor.
2.47. Filtering devices can be individual or common to several compressors. In the latter case, for each compressor it should be possible to disconnect it (in case of repair) from the common suction pipeline.
2.48. For enterprises where there may be a high level of dust in the intake air, compressor units should be equipped with filters and other special equipment in accordance with the design documentation.
2.49. In compressors equipped with end coolers, moisture-oil separators should be provided in the pipelines between the cooler and the air collector. It is allowed to combine an end cooler and a moisture-oil separator in one apparatus.
2.50. If it is necessary to have deeply dried air, in addition to end refrigerators, compressors are equipped with special drying units. Drying units operating using the method of freezing moisture using refrigeration units must be located in rooms isolated from the compressor unit.
Drying units operating using the method of moisture absorption by solid sorbents and using non-toxic and non-explosive refrigerants can be located in the machine room of the compressor unit.
3. Preparation for start-up, starting and stopping the piston compressor.
Preparing the compressor for start-up
To prepare the compressor for start-up, the following steps must be taken:
– carry out an external inspection of the equipment, make sure that there are no foreign objects in the compressor service area, that the compressor is equipped with thermometers and pressure gauges;
– check the reliability of tightening the fastening of moving parts of coupling halves and anchor bolts;
– check the level and quality of oil in the circulating lubrication oil tank and lubricators for lubrication of cylinders and oil seals; The oil level should not be below the middle of the indicator glass; if necessary, add oil;
– check the cleanliness of the oil tank filter mesh and the circulating lubrication system;
– clean the filter of the circulating lubrication unit with scrapers;
– check the closure of the shut-off valve on the bypass pipes of the oil cooler;
– check the position of the three-way valve on the circulation lubrication pipeline - the valve must connect the pressure fitting of the pump to the coarse filter;
– turn on the electric motors of the pumps for circulating lubrication and lubrication of cylinders and seals;
– check the oil supply to all lubrication supply points for cylinders and oil seals, using oil check valves;
– check the opening of shut-off valves at all lubricant supply points, check the oil pressure to lubricate the movement mechanism;
– using a turning mechanism, rotate the compressor shaft 3–4 turns to better distribute the oil over the rubbing surfaces and check for the absence of foreign objects in the compressor
– turn off the turning mechanism by placing the handle in the “off” position and turn on the electric motor of the turning mechanism;
– include instrumentation and automation systems into operation;
– open the valves on the water inlet and outlet to the compressor;
– check the flow of water to the compressor cooling points using test taps;
– open the shut-off valves installed on the return water pipelines at the bypass refrigerator;
– check the opening of valves on pressure gauges;
– close the shut-off valves, the electric valve on the gas discharge line to the spark plug, the purge valves on the purge manifold (the valves on the low-pressure nitrogen purge pipeline must be closed and sealed with nameplate plugs);
– open the shut-off valves on the central heating and water supply pipelines at the bypass refrigerator; the shut-off valves on the discharge and receiving manifolds must be closed;
– turn on the blower system for the compressor electric motor.
If it is necessary to purge the compressor system after any type of repair, perform the following measures:
– open the shut-off valves, the electric valve on the gas discharge line to the spark plug;
– remove the plugs and open the valves on the low-pressure nitrogen supply line for purge;
– close the shut-off valves on the bypass pipeline between the receiving and discharge manifolds;
– blow out the compressor intake and discharge buffer tanks;
– close the shut-off valves, the electric valve on the gas discharge line to the spark plug, and the purge valves on the purge manifold;
– open the shut-off valves on the bypass pipeline between the receiving and discharge manifolds;
– close the valves and install plugs on the low-pressure nitrogen supply line for purge.
The compressor is started in the following sequence:
– open the shut-off valves and the electric valve on the receiving manifold;
– displace nitrogen from the compressor installation system with the working medium into the atmosphere through a spark plug, purge the intake and discharge manifolds, and compressor discharge buffer tanks;
– close the shut-off valve, the electric valve on the gas discharge line to the spark plug;
– if there is permission to start, turn on the main electric motor of the compressor; circulate the working medium through the bypass line for 5...10 minutes, check the flow of oil to all points of the compressor lubrication system, the serviceability of the movement mechanism and intake and discharge valves.
– open the shut-off valves located on the compressor discharge manifold, smoothly reducing the flow area of the shut-off valves on the compressor bypass line, supply the working medium for circulation through the bypass refrigerator, close the shut-off valves on the compressor bypass line;
– gradually install required consumption working medium into the reactor block system, smoothly reducing the flow area of the shut-off valves on the working medium supply line to the bypass refrigerator;
– inspect the operating compressor, discharge and intake manifolds;
– after starting the compressor, make an entry in the logbook about the start time and technical condition of the compressor.
Compressor stop
The compressor is stopped in the following sequence:
Smoothly open the shut-off valves on the compressor bypass line, while simultaneously closing the shut-off valves located on the compressor discharge manifold.
Close the shut-off valve located on the compressor intake manifold.
Stop the main compressor motor. After the compressor has completely stopped, it is necessary to stop the blower fan of the main electric motor, the cylinder and oil seal lubrication unit, and the circulating lubrication unit.
Open the shut-off valve, electric valve on the gas discharge line to the spark plug.
5...10 minutes after stopping the compressor, it is necessary to stop the supply of circulating water to the oil cooler of the compressor. Make a note in the logbook about the time and reason for the compressor shutdown. After stopping the compressor, make a record of the time and reason for stopping the compressor, and its technical condition.
4.System planned – preventive maintenance equipment, its essence and goals.
The PPR system is a set of organizational and technical measures for the supervision, maintenance and repair of equipment carried out according to a pre-drawn up plan and helping to increase its durability at optimal operating parameters, prevent accidents, improve the culture of operation and the level of organization of repairs.
The PPR regulations provide for the following types of repairs and overhaul maintenance:
overhaul service
maintenance
current repairs
average renovation
major repairs.
Maintenance is a set of works to monitor the technical condition of equipment, timely warning, malfunction, replacement of quickly wearing parts, which entails minor disassembly of the equipment. At the same time, the volume is specified
preparatory work to carry out current, average, and major repairs. For the period of maintenance, the equipment is switched off from the technological cycle (stopped). In this case, only such equipment malfunctions are identified and immediately eliminated, in the presence of which it is impossible to operate it normally until the next repair. Maintenance is carried out by repair personnel under the supervision of a repair service mechanic.
5. Causes of fires during operation of compressor units and fire prevention measures.
At oil and gas refineries where they process and store large quantities flammable gases and liquids, fire prevention measures are organically related to the technological process itself. In factories, fires can occur as a result of various organizational and technical shortcomings, for example:
deviations from the established operating mode of the installation (temperature, pressure) and irregular preventive inspection of equipment;
failure to comply with fire safety requirements when placing and installing installation equipment;
non-compliance fire regulations set for this installation.
All fire safety measures can be divided into two groups - prevention (prevention) of fires and elimination of an existing fire.
Fire prevention is a set of measures aimed at preventing fires and limiting their size.
Elimination of the causes of fires is achieved by the correct selection and arrangement of technological and auxiliary equipment. Limiting the spread of fire is carried out by: design and construction measures, including proper planning and placement of buildings and equipment; the use of structures and materials that meet the requirements of fire standards; installation of fire protection zones and embankments.
Measures are provided to ensure the evacuation of people and property in case of fire. This includes: arrangement of the required number of stairs, doors, passages both on the territory of the installations and in the premises; placement of devices in compliance with the required width of the passage or passage between them; emergency lighting device and others.
Preventive measures also include those that ensure successful extinguishing of a fire if it occurs.
For example, the construction of roads for free access by frying machines to buildings; communication with the fire brigade; providing the enterprise with sufficient quantities of necessary fire extinguishing means (fire extinguishers, water, sand, etc.).
An important role in ensuring fire safety is given to the managers of workshops, installations, and foremen. Being responsible for fire safety in their area, they are obliged to develop, together with the fire protection authorities, fire safety instructions, train their subordinate personnel in the measures that must be taken in the event of a fire, as well as the rules for using fire extinguishing agents.
EXAMINATION TICKETSFOR CERTIFICATION OF WORKERS BY PROFESSION
"COMPRESSOR UNIT MACHINE"
Ticket No. 1
1. Compressors, classification.
2. The concept of bypass lines.
3. Fuel economy of compressors operating with drives.
4. Types of plumbing work and their purpose.
5. General safety requirements when placing compressor units in premises.
Ticket number 2
l. Classification of piston compressor units.
2. Pipeline insulation, its purpose, types of insulation.
3. Water management of compressors. Cooling towers and pools for cooling water, their design and principle of operation. Filters for water purification.
4. Compressor unit operator’s working tools, purpose and care for them.
5. Basic safety requirements when installing compressors.
Ticket number 3
1. Operating principle of piston compressor units.
2. The concept of pipeline corrosion, measures to combat corrosion.
3. Steam compressor facilities. Schematic diagram of steam supply for turbine-driven compressors.
4. Control and measuring instruments for compressor unit operators, their purpose and care.
5. Basic requirements for the safe operation of instrumentation and equipment.
Ticket number 4
1. Schematic diagram of the compressor.
2. Pipeline equipment, its purpose and marking.
3. Lifting and transport devices for compressor units.
4. The concept of the technological process.
5. Basic safety requirements for cooling compressor units.
Ticket number 5
1. Theoretical compression process of a single-stage compressor.
2. Rules and locations for installing fittings.
3. Basic rules for operating a running compressor.
4. Technology of metalworking of parts.
5. Basic safety requirements for compressor lubrication.
Ticket number 6
1. Multi-stage compression.
2. Design and principle of operation of taps, valves, valves, check valves and safety valves.
3. The main possible malfunctions during the start-up and operation of the compressor, their causes and methods of elimination.
4. Basic operations of the technological process of metalworking of parts.
5. Basic safety requirements for air intake and purification by compressor.
Ticket number 7
1. Compressor performance. Compressor efficiency
2. The concept of valves having electric, hydraulic and pneumatic drives.
3. The concept of diagnostics and maintainability of a compressor unit.
4. The concept of dimensional deviations and tolerances of parts
5. Basic safety requirements for moisture separators and air collectors.
Ticket number 8
1. Methods for regulating the performance of piston compressors.
2. Testing of installed pipelines for strength and density.
3. The procedure for assigning maintenance and repairs to the compressor unit.
4. Types of measuring and testing instruments, design and rules of use.
5. Basic requirements of the instructions for the safe maintenance of compressor units.
Ticket number 9
1. Automatic regulation compressor performance.
2. Types of compressor unit drives. Selection of drives.
3. Scheduled preventive maintenance, their characteristics and timing.
4. Preparing the compressor for work.
5. List the cases that require immediate stop of the compressor.
Ticket number 10
1. Lubrication systems for piston compressors.
2. Electric drive of compressors. Types of electric motors.
3. Methods for detecting faults and defects in machines and devices.
4. Sequence, methods of disassembling compressors.
5. Causes of fire in a compressor unit.
Ticket number 11
1. The use of oil for lubrication of compressors, their main characteristics.
2. Engines internal combustion, used for compressor drives.
3. Sequence, methods of disassembling compressors.
4. Bending, purpose. Cold and hot bending. Calculation of the workpiece for bending.
5. Occupational diseases and their main reasons. Prevention of occupational diseases.
Ticket number 12
1. Oil pumps, their structure.
2. Compressor drive from steam and gas turbines.
3. Methods for washing and cleaning parts. Branding of parts.
4. Felling, purpose and use of manual cutting. The sharpening angle of the working part of the chisel on the bottom of steel, cast iron and non-ferrous metals.
5. Medical and sanitary services for workers at the enterprise.
Before testing begins, the cavities, as well as the pipelines through which air enters the cylinders, must be purged.
Air compressor units (compressors) are tested under load at operating pressure. Exceeding the operating pressure during testing is not allowed. Compressors must be loaded in several stages, gradually increasing the pressure. The degree of pressure increase and the operating time of the compressor at this pressure are indicated in the manufacturer's instructions. In all modes, it is necessary to carefully monitor the operation of valves, seals, and rods. During testing, one should continuously check the air pressure and temperature in stages, the pressure and water supply to all places provided for by the design of the compressor installation equipment, check the operation of the circulation lubrication system, the temperature of the main bearings and other rubbing surfaces of the crank mechanism, the temperature in the electric motor windings, tightness of pipelines.
The duration of continuous testing under load of compressor units with horizontal compressors is 48 hours, with vertical compressors – 24 hours. During testing, the running-in of rubbing joints is checked:
1) in horizontal compressors:
Opening main and connecting rod bearings for inspection and running-in of liners;
Checking the running-in of pistons on cylinders;
2) in piston, angular, V-shaped compressors:
Removing cylinder valves to clean and check the running-in of the plates;
Checking the running-in of pistons on cylinders.
The final control test of compressor units under load is carried out at the operating discharge pressure. The duration of the load test for compressor units with horizontal piston compressors is 8 hours, with vertical and angular compressors - 8 hours.
After the test is completed, a report is drawn up.
4. For which compressor units is it allowed to take air from the premises?
For air compressors with a capacity of up to 10 m 3 /min that have air filters on the machine, it is allowed to take air from the compressor station premises.
See answer ticket No. 2, question. 5.
Ticket number 10
1. Compressors, their types, purposes.
Compressor is a machine for increasing pressure and moving gas. Compressor unit is a set of compressor, drive, apparatus, pipelines and equipment necessary to increase pressure and move gas.
Compressors are used in the energy sector, mechanical engineering, construction, chemical, metallurgical and mining industries, on ships, in pneumatic transport, in aviation, etc.
Variety of compressor applications by pressure, performance, compressed medium, conditions environment, in which the compressor operates has led to the creation of a wide variety of designs and types of these machines.
General purpose stationary air piston compressors must be manufactured of the following types:
VU – crossheadless with a V-shaped arrangement of cylinders;
VP – crosshead with a rectangular arrangement of cylinders (types P and PB);
VM – crosshead with horizontally opposed cylinders
Compressors with a rectangular cylinder arrangement of the VP type are manufactured with water cooling. The symbol of the compressor characterizes its main parameters. So, for example,
302VP-10/8 means that this is a compressor of the third modification (3) with lubrication of cylinders and oil seals (0), with a base piston force of 19.6 kN (2 tf), type VP - crosshead with a rectangular arrangement of cylinders. Numbers in the form of a fraction mean: numerator – compressor capacity 10 m 3 /min, denominator – final excess compression pressure 0.8 MPa (8 kgf/cm 2).
The piston compressor type 302VP-10/8 is equipped with automatic protection and has two-position supply control.
2. Pipeline diagrams of the compressor station.
In addition to air ducts, the compressor station has
pipelines necessary for the operation of the compressor unit, through which water is transported, intended for cooling the cylinder jackets, as well as for cooling the compressed air in auxiliary equipment(refrigerators, moisture-oil separators), as well as pipelines (oil pipelines) through which oil is transported to lubricate the equipment of the compressor unit.
3. Compressor performance.
There are volumetric productivity V - volumetric gas flow rate at the outlet of the compressor unit (m 3 / s, m 3 / min, m 3 / h) and M - mass productivity (kg / s, kg / s, kg / min, kg / h ) – gas mass flow rate at the outlet of the compressor unit. Volumetric and mass productivity are related by the relation M = Vhr, where
р – gas density at temperature and pressure at the performance measurement points.
The capacity measured at the outlet of the compressor unit is a variable quantity, since it depends on the temperature and pressure of the discharge gas, which in turn, due to fluctuations, for example, the temperature of the cooling water and the variable discharge pressure, are also variable. Therefore, the volumetric capacity compressor can serve as a characteristic of the compressor only for the given parameters of the measured gas (temperature, pressure).
A characteristic of a compressor unit is the performance (supply) of the compressor, measured at the outlet of the compressor unit and recalculated to suction conditions V vs. This performance is called the actual volumetric performance, and it is a value that is practically constant under all suction conditions. Suction conditions are characterized by temperature, pressure, gas humidity...
Volumetric productivity and actual volumetric productivity are related by the relation V sun = RT sun / P sun ТхV
where P sun and T sun are the pressure and temperature of the suction gas; P and T are the pressure and temperature of the gas at the outlet of the compressor unit at the measurement point.
Due to gas leaks through leaks in the piston rings and the 1st stage suction valve, the influence of the dead volume in which the compressed gas remains and which, when expanded, reduces the suction volume, heating of the suction gas and the pressure drop in the cylinder as a result of throttle losses in the suction valves, the volume issued by the cylinder gas is less than the volume of its working cavity. The ratio of actual productivity
V sun to the volume described by the 1st stage piston per unit time V p is called the performance coefficient.
4. At what height is air taken from the air compressor from outside the room?
Air intake (suction) by an air compressor should be done outside the compressor station room at a height of at least 3 m from the ground level.
See answer ticket No. 3, question. 5.
Ticket number 11
Cylinders. Cylinder designs depend on pressure, performance, design and purpose of the compressor, cooling method and cylinder material.
Gray cast iron is used as a material, since it has sufficient strength and high anti-friction properties. In most cases, gray cast iron of the SCh21 grade is used. For machines operating at high pressures, more durable gray cast irons are used SCh24, SCh28, SCh32, as well as alloyed ones cast iron; cylinders are also filled with forged carbon or alloy steel.
The cylinders are made with air or water wall cooling. Air-cooled cylinders have annular or longitudinal ribs on the outer surface. These cylinders are easy to manufacture and operate; they are used mainly in low-performance machines.
The cylinders of medium and high capacity compressors, which in addition to the working cavity have a water jacket, valve boxes and channels connecting them with the suction and discharge pipes, are complex multi-layer castings. The front (facing the frame) end wall of the valve box of double-acting cylinders is sometimes cast integrally with body, but it is advisable to make it in the form of a volumetric cover.
Cylinders must be rigid. Their deformation increases wear work surface mirrors of the cylinder, piston and piston rings and causes the need to increase the gap between the piston and cylinder.
Piston- a moving part of the machine that tightly covers the cross section of the cylinder and moves in the direction of its axis. Compressors use trunk, disc and differential pistons.
The purpose of the piston is to suction, compress and expel gas from the cylinder. The developed cylindrical surface of the piston consists of two parts: the upper belt with compression rings located on it and the lower belt with oil scraper rings.
The piston is connected to the connecting rod via a piston pin.
Trunked pistons are used in crossheadless compressors; they are pivotally connected to the connecting rod using a piston pin. Aluminum pistons are used in the first stages of the compressor, and cast iron pistons are used in the second stages to balance the reciprocating moving parts.
To reduce their mass, piston pins are made tubular in shape with straight cylindrical or conical internal surfaces. The ends of the pin are installed in the boss of the trunk piston, the middle part of the pin covers the bearing of the upper head of the connecting rod.
Disc pistons are used in crosshead-type compressors. In order to balance the inertial forces of the reciprocating moving parts, the pistons of low pressure stages are often made of welded steel or cast from aluminum alloys, and of higher stages they are made of cast iron and solid. To increase rigidity and strength disc pistons are equipped with radial ribs.
Differential pistons are used when cylinders of different pressures are located in the same row, for example, a higher pressure cylinder is located on a low pressure cylinder.
Piston rings are designed to seal the gap between the surfaces of the cylinder and the piston, as well as to remove heat from the piston into the cylinder walls. To ensure the tightness of the piston, the ring, so that it is pressed tightly against the inner surface of the cylinder, is made split, and its diameter in the free state is slightly larger than the diameter of the cylinder. The working ring is pressed by the outer sealing surface to the cylinder mirror by gas pressure and ring elastic forces.
Rings are usually made of rectangular cross-section. The cut of the ring, the so-called lock, can be straight, oblique, or stepped (overlapping).
The most widely used are piston rings made of cast iron. At high pressures in the cylinder, steel and bronze rings are used, combined from cast iron and bronze, cast iron with antifriction packings in the grooves on the rings, textolite rings, nylon rings, chrome-plated steel and cast iron, etc.
To remove excess oil from the cylinder wall, oil scraper rings of various designs are used in crosshead compressors. As the piston moves towards the shaft, the sharp lower edge of the rings removes oil from the wall and drains oil into the crankcase through holes in the piston.
Oil seal (stuffing box seal) – a machine part that seals the gap between the moving and stationary parts of the machine (for example, between the rod and the cylinder cover). There are seals with forced sealing and self-sealing ones. The former are made with soft or semi-soft packing.
The material for the manufacture of soft packings is a mixture of equal parts of finely crushed babbitt shavings and sawdust boiled in oil. The mixture is placed in fabric covers and pressed into round packing rings of square cross-section. Soft semi-metallic packings do not require a lubricant supply and are characterized by high anti-friction properties. In addition, they are compact and easy to manufacture. Their disadvantage is the need for constant monitoring of the omentum and periodic tightening.
Semi-soft packing consists of solid metal sealing rings made of plastic anti-friction material and steel rings placed between the sealing rings. The sealing rings are triangular in shape, steel rings are triangular or diamond-shaped for better compression of the rod.
Valve– gas flow control mechanism. Reciprocating compressors use various types and designs of self-acting valves: ring, strip, direct-flow, etc. The valves are called self-acting because they open and close automatically: they open from the pressure difference before and after the valve, and close under the action of springs (in strip and direct-flow valves the role of springs is played by the plate itself Suction and discharge valves are installed on each compressor cylinder, the fundamental design of which is the same.
The ring valve consists of a seat, a socket, between which ring plates are placed, pressed against the seat with springs. To reduce the impact of the plate on the socket (when
when the valve opens), a damper plate is installed. The seat and socket are assembled using a stud and nut.
Strip valves are made with self-springing plates, which have the shape of rectangular strips. In a free state, they are adjacent to the seat, but under gas pressure they bend along the arc of recesses in the lift limiter. As soon as the pressure before and behind the plate is equalized, the plate straightens and closes the hole in the seat valve. Rectangular cuts in the guides form sockets for the plates.
Band valves consist of a set of cells arranged in one or more rows.
Direct-flow valves, like strip valves, are self-springing. They are assembled from elements: a seat and an elastic plate adjacent to it. The seat has cells on the working surface that are separated by jumpers and serve as flow channels. On the back side of the seat there is a wide recess - a niche with a wedge-shaped bevel into which the plate bends when the valve opens. The profile of the bevel is close to the profile of a plate bent by the pressure of the gas flow.
Thanks to the direct gas flow and the rational shape of the flow channels, the cross-sectional area of direct-flow valves is 2 - 2.5 times larger than that of annular valves of the same size, which gives a 4 - 6-fold reduction in energy losses.
Frame, crankcase and crankcase These are the main load-bearing parts of the compressor; they contain a connecting rod and crank mechanism, the forces from which they perceive.
A frame with one bearing is called a bayonet one; with two, it is called a fork frame. The frames of opposed compressors are made in the form of a box-shaped cast iron with stocks for the main bearings.
The crankcases of crosshead compressors operate under pressure. The tightness of the crankcase improves with a decrease in the number of connectors, so the cylinders began to be manufactured in the same casting with the crankcase - the crankcase.
The frame, crankcase and crankcase are cast, they must be rigid, durable and convenient for attaching cylinders and auxiliary components of the compressor.
connecting rod The crosshead compressor connects the crankshaft to the slider (crosshead), while the crosshead compressor connects it directly to the piston (via the piston pin). It is forged from steel.
The crank head of the connecting rod is detachable. The bearing of the crank head is called a crank bearing.
The crank bearing has cast iron liners filled with B-83 babbitt. The detachable connecting rod head is tightened with connecting rod bolts.
Gaskets are placed in the parting plane of the crank bearing shells; by adjusting their thickness, you can change the size of the harmful space.
Bronze bushings are pressed into the upper heads of the connecting rods, to which forced lubrication is supplied.
Crankshaft (or main shaft).One of the most critical and labor-intensive parts of the compressor to manufacture. The crankshaft, through the main bearings, transmits forces from the moving parts of the compressor to the frame. Connecting rods are attached to the crankpins of the crankshaft. Using the crankshaft, the cranks of which, together with the connecting rods, form a connecting rod-crank mechanism, The rotational motion of the engine is converted into reciprocating motion of the pistons.
Crankshafts are forged or stamped from KSK metal, then turned and ground on machines.
The inertial forces of the moving masses of the compressor are partially balanced by the counterweights mounted on the cheeks of the crankshaft.
Flywheel.Regulates the operation of the engine, storing energy when the piston is in the middle position and releasing it when the piston approaches the extreme positions (dead centers). The flywheels of large horizontal compressors are made as one piece with the rotor of a synchronous electric motor.
Flywheels of vertical compressors with V-belt transmission from the engine to the compressor simultaneously serve as drive pulleys. When used V-belts The corresponding grooves are machined in the flywheels.
Crosshead or slider.Connects a rectilinearly moving rod with a connecting rod that performs a complex movement.
The piston rod is attached through a steel pin to the slider. To regulate the harmful space, there are special nuts on the rod.
2. Purpose of pipelines of compressor units.
See answer ticket No. 10, question 2.
3. Design and purpose of heat exchangers.
Collapsible plate heat exchangers are designed for heat exchange between various liquids, as well as between liquid and steam. They are used as refrigerators, heaters, condensers in various industries.
They are designed to operate at excess pressures up to 10 kgf/cm 2 (1,0 MPa) and working environment temperature from -30 to +180°.
Heat exchangers are assembled from standardized prefabricated units and parts and can have a heat exchange surface from 3 to 800 m 2.
The device consists of thin stamped stainless steel plates with a corrugated surface mounted on a cantilever-type frame.
The frame consists of a fixed plate with fixed pressure plate rods and tie bolts.
The plates are assembled onto the frame so that one relative to the other is rotated 180°, with the rubber gaskets facing the pressure plate.
The void between adjacent plates is a channel for the passage of coolant; a group of plates forming a system of channels in which the working medium moves only in one direction makes up a package.
One or more packages sandwiched between a stationary plate and a pressure plate are called a section. There are holes in the corners of the plates that form distribution manifolds for the coolant in the assembled section. The plates are sealed together using a rubber gasket along the sealing groove.
Hot coolant moves through slotted channels from the corresponding collectors on one side of each plate, and cold coolant on the other. Coolants move countercurrently.
Due to the corrugated surface of the plates, the liquid flow swirls intensely. Increased turbulization and a thin layer of liquid make it possible to obtain a high heat transfer coefficient with relatively low hydraulic resistance.
If various contaminants appear on the surface of the plates, the device can be easily and quickly disassembled, cleaned and put back into operation.
Intermediate and final coolers.In refrigerators, compressed air is cooled and heated when it is compressed in the compressor cylinders. Depending on the performance of the compressor, shell-and-tube and “pipe-in-pipe” type refrigerators are used.
Shell and tube refrigerator with floating head consists of a bundle of tubes, flared in tube sheets, one of which is rigidly fixed in a common body, the other, equipped with a head, is movable, floating.
Compressed air flows from the compressor into the inter-tube space of the refrigerator, where it is cooled by water passing through the tubes.
Water and compressed air in the refrigerator move according to the countercurrent principle. At the bottom of the refrigerator there is a fitting for purging accumulated oil and condensate.
Fridge the “pipe in pipe” type is used for pressures above 35 kgf/cm 2. Compressed air passes through the internal pipes; cooling water flows through the annular channel formed by the pipes towards the compressed air.
In compressor installations, PRT type refrigerators are used, which during their operation provide better cooling of compressed air, they are convenient for their maintenance
4. Timing for checking safety valves at pressures above 12 kgf/cm 2.
The timing of inspection of safety valves operating at pressures above 12 kgf/cm 2 is established by technological regulations and operational documentation. After closing, the valves must maintain tightness.
See answer ticket No. 1, question 5.
Ticket number 12
1. Design of internal combustion engines used to drive the compressor.
Piston internal combustion engines have the following main components and systems:
- engine frame, which absorbs all dynamic forces during engine operation. It includes fixed parts: a base frame with frame bearings, a frame, a parallel, cylinders, cylinder covers;
- crank mechanism, converting the reciprocating motion of the piston into the rotational motion of the crankshaft. The main parts are the piston, rod, cross member (crosshead), connecting rod and crankshaft.
- timing mechanism(gas distribution elements and drive), which releases combustion products from the cylinder and admits a fresh charge of air (in diesel engines) or a combustible mixture (in carburetor engines);
- fuel supply system, designed for preparing and supplying fuel to the engine cylinders. The system consists of fuel storage tanks, devices for cleaning it and fuel equipment - pumps, injectors (diesels), carburetor (carburetor engines);
- ignition system, ensuring forced ignition of the combustible mixture in the engine cylinders in carburetor internal combustion engines;
- cooling system to remove heat from engine parts. It consists of water pumps, filters, refrigerators and pipelines;
- lubrication system, providing the supply of lubricants to rubbing parts. It includes containers and devices for storage, cleaning, cooling and lubricant supply;
- control system, designed to start, stop, change the crankshaft speed. The system includes special mechanisms and instrumentation.
Depending on the main characteristics, internal combustion engines are distinguished:
According to the method of implementing the working cycle - four-stroke and two-stroke;
According to the method of action - simple action, in which the working cycle is performed only in the upper cavity of the cylinder (Fig. 7, a), double action, when the working cycle is performed alternately in two cavities of the cylinder - the upper (above the piston) and the lower (under the piston)
(Fig. 7, b), and two-stroke with oppositely moving pistons (essentially two single-acting engines with a common combustion chamber) (Fig. 7, c);
According to the method of filling the working cylinder - without supercharging (Fig. 8, a), when the combustible mixture or air is sucked in by a piston (four-stroke), or when the cylinder is filled with low-pressure purge air (two-stroke), and with supercharging (Fig. 8, b) , when air is supplied to the cylinder under excess pressure p k by an air compressor k;
According to the method of mixture formation - with internal mixture formation, i.e. air and fuel enter the engine cylinder separately and the process of formation of the working mixture occurs inside the cylinder (all diesel engines include; and with external mixture formation, when air and fuel are pre-mixed in the carburetor, and then the working mixture enters the cylinder. This group includes carburetor and gas engines.;
According to the method of ignition of the working mixture - with self-ignition of the fuel (due to the high temperature obtained at the end of the air charge compression process) and with forced ignition, when the ignition of the working mixture occurs from an electric spark (carburetor and gas engines));
According to the method of carrying out the combustion process - with combustion at a constant volume (all carburetor and gas engines) and at constant pressure (compressor diesel engines with air atomization of fuel), and with mixed combustion, when part of the fuel burns along an isochore, and part through an isobar (non-compressor diesels);
By design - trunk, in which the lateral force from the connecting rod is perceived by the piston (Fig. 7, a); crosshead, when the piston and connecting rod are connected through a rod and a cross member (crosshead), and the lateral forces are perceived by the sliders and transmitted to the parallels (Fig. 7 ,b);
According to the arrangement of the cylinders - single-row, double-row, vertical, horizontal, V-shaped, W-shaped, X-shaped, star-shaped;
2.Emergency stop of the compressor.
See answer ticket No. 5, question 4.
3. Basic safety requirements when operating a compressor unit.
See answer ticket No. 7, question 4.
4. Measures to be taken before starting work inside the vessel.
Before starting work inside a vessel connected to other operating vessels by a common pipeline, the vessel must be separated from them by plugs or disconnected. Disconnected pipelines must be plugged.
The plugs installed between the flanges must be of adequate strength and have a protruding part (shank), by which the presence of the plug is determined.
Oil should be delivered to the machine room in special containers for each type of oil (buckets and cans with lids, etc.).
Vessels intended for transportation and storage of compressor oil must not be used for other purposes. Vessels should be kept clean and periodically cleared of sediment.
Used oil should be drained into a container located outside the compressor unit.
Oil should be poured into lubricating devices through funnels with
filters.
Ticket number 13
1. Oil pumps and their design.
The Sh-40 type gear pump is designed for pumping liquids with lubricity, without abrasive impurities, with a kinematic viscosity from 0.2 to 15 cm2/s at temperatures up to 80 degrees C.
According to the principle of operation, the gear pump is positive displacement.
The pump consists of: a working mechanism, a housing with covers, a mechanical seal and a safety valve.
The working mechanism consists of two rotors: driving and driven.
The drive rotor consists of a shaft on which two gears with oblique teeth are mounted in an interference fit.
One gear is left-handed and the other is right-handed. The gears are installed so that they form one gear with a chevron tooth.
The driven rotor has the same gears on its shaft as the drive rotor, but one gear is fixed rigidly, the other loosely. This installation of the gear allows it to self-align relative to the teeth of the drive gear during pump operation to compensate for the inaccuracy of the gears on the drive rotor shaft. Driven rotation the rotor receives through a gear from the drive rotor. The rotors are installed in special bores in the housing.
The ends of the housing are closed with rear and front covers.
The pump drive shaft seal is a single end seal, located in the front cover. It consists of a thrust bearing, a heel, an oil seal spring, a ring, a thrust ring and a ring. When turning, the thrust bearing is locked with a pin.
The safety valve protects the pump from overpressure.
When the rotor rotates, a vacuum is created on the suction side, as a result of which liquid under atmospheric pressure fills the inter-tooth cavities and moves into them from the suction cavity to the discharge cavity.
2. Methods of washing and cleaning parts. Branding, marking during disassembly.
See answer ticket No. 8, question 3.
3. Reception of the compressor from repair. Run-in, testing.
See answer ticket No. 9, question 3
4. Occupational diseases and their main causes. Prevention of occupational diseases.
Loss of hearing and performance by compressor unit maintenance personnel is an occupational disease.
5. Responsibilities of a compressor unit operator before starting work.
See answer ticket No. 1, question 5.
Ticket number 14
1. Design and purpose of the main parts and components of the compressor.
See answer ticket No. 11, question. 1
2. Measures to ensure trouble-free operation of compressor equipment.
To ensure trouble-free, safe operation of compressor units, proper organization of maintenance and routine repairs of equipment, the most appropriate system is a system of scheduled preventive maintenance (PPR). This system provides for a set of measures to ensure the operability of all units during operation (daily maintenance, inspection, lubrication, cleaning, elimination of defects), as well as timely scheduled shutdown for maintenance in order to maintain the technical and economic indicators of the compressor unit within acceptable limits.
Based on this, a schedule of inspections and repairs is drawn up. Compressor repair data is entered into the compressor log and into the compressor operation log.
For each type of compressor, the frequency of inspections and repairs is indicated in the Installation and Operation Instructions for the compressor by the manufacturer.
3. In what cases are pressure gauges not allowed for use?
Pressure gauges are not allowed for use in cases where:
a) there is no seal or mark;
b) the pressure gauge check period has expired;
c) the pressure gauge needle, when it is turned off, does not return to the zero scale reading by an amount exceeding half the permissible error for a given pressure gauge;
d) the glass is broken or there is other damage to the pressure gauge, which may affect the accuracy of its readings.
4. Training and testing the knowledge of personnel servicing the vessels.
Training and testing of the knowledge of personnel servicing vessels should be carried out in accordance with educational institutions, and also on courses specially created by organizations.
Periodic testing of the knowledge of personnel servicing vessels should be carried out at least once every 12 months.
An extraordinary knowledge test is carried out:
When moving to another organization;
If changes are made to the instructions for the operating mode and safe maintenance of the vessel;
At the request of the Rostechnadzor inspector.
If there is a break in work in their specialty for more than 12 months, after testing their knowledge, personnel must undergo an internship to restore practical skills before being allowed to work independently.
The results of testing the knowledge of service personnel are documented in a protocol signed by the chairman and members of the commission with a mark on the certificate.
Personnel access to self-service vessels is formalized by an order for the organization or an order for the workshop.
5. Responsibilities of the operator of compressor units during operation.
See answer ticket No. 2, question. 5.
Ticket number 15
1. Compressor station equipment.
The compressor station includes: a compressor, its drive (electric motor), auxiliary equipment (filters, intermediate and final coolers, moisture-oil separator, air collector), as well as pipelines necessary for supplying compressed air through them to consumers, water for cooling the jackets of compressor cylinders, cooling compressed air in refrigerators.
2.What is the purpose and principle of operation of a piston compressor?
The compressor is designed to increase pressure and move gas.
The compressor consists of a cylinder 4 in which a piston 5 moves. With the help of a rod 6, a slider 7, a connecting rod 8 and a crank 9, the rotational movement created by the engine is converted into a reciprocating movement of the piston in the cylinder. The cylinder and piston form a working cavity in which the working process is carried out. The working cavity has 3 suction and 2 discharge valves installed in the corresponding cavities of the cover of 1 cylinder 4. The discharge cavity is hermetically separated from the suction cavity. When the piston moves from top to bottom, a vacuum is created in the cylinder, as a result of which, under the influence of pressure in the suction cavity, they open suction valves 3 and the working cavity are filled with gas. The cylinder is filled until the piston reaches its lowest position, i.e. while the suction valves are open due to the existing pressure difference in the suction pipe and the cylinder cavity. The discharge valves remain closed.
During the reverse stroke of the piston, the suction and discharge valves are closed, the volume of the cylinder cavity decreases, and the pressure in it increases - gas compression occurs. The pressure in the cylinder increases until it exceeds the pressure in the network. Under its action, the discharge valves and gas open is pushed out of the cylinder by a piston into the discharge line. At the same time, the suction valves remain closed. The working process occurs during full turn compressor crankshaft, which corresponds to a double stroke of the piston.
The extreme positions of the piston are called dead centers. At such positions of the piston, the axes of the rod, connecting rod and crank lie on the same straight line. The space between the piston located at the top dead center (TDC) and the cylinder cover is called
harmful (dead) space. Its value is expressed in fractions of the volume described by the piston in one stroke, and depends not only on the distance between the piston at the dead center and the cylinder cover, but also on the volume of the channels supplying and discharging gas, and on the design of the suction and discharge valves.
3. Who and when checks the operation of safety valves at pressures above 12 kgf/cm 2?
The compressor unit operator checks the operation of safety valves operating at pressures above 12 kgf/cm 2 within the time limits established by the technological regulations and operational documentation.
4.What pressure gauges should be used on air collectors and gas collectors?
On air collectors or gas collectors, pressure gauges with a diameter of at least 150 mm and an accuracy class of at least 2.5 should be used.
It is necessary to use pressure gauges with such a scale that, at operating pressure, the insole is in the middle of the scale. A red line must be marked on the dial of the pressure gauge at the division corresponding to the highest permissible operating pressure.
Pressure gauges should be equipped with a three-way valve. At pressures above 25 kgf/cm2, instead of a three-way valve, it is allowed to install a separate fitting with a shut-off device for connecting a second pressure gauge.
5. Responsibilities of a compressor unit driver after work.
See answer ticket No. 3, question. 5.
Ticket number 16
1.Equipment of compressor units.
See answer ticket No. 15, question 1.
2. Compressor malfunctions, causes, solutions.
See answer ticket number 3, question 3
3.What should be monitored during operation of the compressor unit?
See answer ticket No. 2, question 5
4.Measures to reduce noise and vibration.
When a compressor unit operates, noise is generated by check valves, suction line filters, rotating parts, equipment gears, air flowing through pipelines, as well as faulty and worn parts. Noise also occurs during the production of vessels and pipelines.
Noise has a detrimental effect on the health of operating personnel of compressor units. Working in a noisy environment, these personnel often gradually lose their hearing and ability to work. If operating personnel stop hearing signals from control and measuring instruments, as well as automation equipment, this can lead to injuries and a failure of the compressor unit .
Reducing noise and vibration can be achieved by:
Placement of compressors in a soundproof chamber;
The use of vibration-isolating foundations for building structures of the compressor station building;
The use of soundproofing gaskets at the junction of the compressor with air ducts and other parts, as well as special mufflers on air ducts for purging vessels and exhausting air into the atmosphere;
Installation of metal shields at air suction filters;
Covering mufflers, walls and roofs in the compressor station premises with sound-absorbing materials; drivers are recommended to use special helmets.
5. Responsibilities of a compressor unit operator before starting work.
See answer ticket No. 1, question 5.
Ticket number 17
1.Auxiliary equipment for compressor units.
The equipment of each compressor unit, in addition to the compressor and its drive motor, also includes auxiliary equipment: suction filter chambers (filters), intermediate and end coolers, moisture-oil separators, oil purge tank, pipelines and fittings.
2. Frequency of cleaning the oil pump and lubricator of the compressor unit.
The oil pump and lubricator should be cleaned at least once every month and a half.
3. Places for installing pressure gauges on compressor units.
Pressure gauges are installed after each compression stage and on the discharge line after the compressor, as well as on air collectors or gas collectors; at a pressure at the last compression stage of 300 kgf/cm 2 and above, two pressure gauges must be installed; on the pipeline supplying oil to lubricate the movement mechanism; on the supply pipeline water for cooling compressor jackets and refrigerators.
4. Main responsibilities of maintenance personnel.
1. Maintain and ensure trouble-free operation of compressors and auxiliary equipment of the compressor station and air ducts.
2. Switch over and put compressor station equipment and air ducts into reserve or repair.
3.Prepare defective lists for equipment repairs.
4.Participate in the repair of compressor station equipment.
5.Keep records in work logs in accordance with the requirements of the Rules.
6. Comply with the internal labor regulations of the enterprise and maintain labor discipline.
7.Fulfill established labor standards.
8.Comply with the requirements of the Labor Protection, Safety and Fire Safety Rules.
9. Treat the property of the enterprise with care.
10. Immediately inform the enterprise administration or immediate supervisor about the occurrence of situations that pose a threat to the life and health of people, or the safety of the enterprise’s property.
11.Constantly improve your vocational training through advanced training in various educational centers, self-training, etc.
5.Safety requirements for compressor lubrication.
See answer ticket No. 1, question 4
Ticket number 18
1. Main indicators characterizing the operation of the compressor.
The main indicators characterizing the operation of the compressor are: the temperature of the compressed air at the compression stages; the pressure of the compressed air at the compression stages; oil pressure in the oil line; the presence of a cooling water flow; discharge pressure and supply regulation.
2.What devices should be equipped with air compressors with a capacity of more than 10 m 3 /min?
Air compressors with a capacity of more than 10 m 3 /min should be equipped with end coolers and moisture-oil separators.
3.Where should safety valves be installed in compressor installations?
Safety valves should be installed after each compression stage of the compressor in the cooled air or gas section. If there is one air collector for each compressor and there is no shut-off valve on the discharge pipeline, the safety valve after the compressor can only be installed on the air or gas collector.
Size and throughput safety valves are selected so that a pressure cannot be formed that exceeds the working pressure by more than 0.5 kgf/cm 2 at a working pressure up to 3 kgf/cm 2 inclusive, by 15% at a working pressure from 3 to 60 kgf/cm 2 and at 10% at operating pressure over 60 kgf/cm 2.
The installation of safety valves must meet the requirements of regulatory and technical documents on industrial safety.
Adjustment of safety valves should be carried out on special stands by persons authorized to independently service compressor units, with a record of the adjustment carried out in the operational documentation.
4. Responsibility for violation of labor protection rules during the operation of compressor units.
Persons who violate the requirements of the Labor Protection and Safety Rules are liable in accordance with the current legislation of the Russian Federation.
(Disciplinary, material, administrative and criminal liability).
5. Responsibilities of the operator of compressor units during operation.
See answer ticket No. 2, question. 5.
Ticket number 19
1. Air ducts, pipelines, fittings.
At compressor stations, pipelines are laid to supply compressor units with air, water, and oil. Depending on the transported medium and purpose, pipelines are classified according to the scheme.
Air ducts are pipelines designed to transport air through them. Air ducts are divided into suction, discharge and main. The suction air duct is the section of the pipeline from the filter (filter chamber) to the suction pipe of the compressor, the discharge pipe is from the discharge pipe to the flange of the auxiliary equipment, the main – from the air collector to the compressed air consumer. The purpose of the air ducts is to transport air in the compressor unit from the moment it is sucked from the atmosphere until the air line exits the air collector to the consumer.
In addition to air ducts, the compressor station contains pipelines necessary for the operation of the compressor unit, through which water is transported, intended for cooling the cylinder jackets, as well as for cooling compressed air in auxiliary equipment (refrigerators, moisture-oil separators), as well as pipelines (oil lines) through which oil is transported to lubricate the equipment of the compressor unit.
Pipeline fittings.The fittings installed on the pipelines of the compressor station are designed to control the flow of the working medium.
According to their purpose, fittings are divided into: shut-off valves - gate valves, taps and valves; safety - check and safety valves; control - control, mixing and distribution valves, regulators; condensate traps.
The design and material of the fittings used must correspond to the conditions of its operation and are determined depending on the operating pressure, temperature and nominal diameter of the pipe on which the fittings are installed. For air pipelines in which the pressure reaches 2.5 MPa
Bronze shut-off valves (valves, gate valves, taps) are allowed on pipelines provided that the pressure in the pipeline is no more than 1.3 MPa (13 kgf/cm2), and its diameter does not exceed 200 mm, or no more than 0.8 MPa ( 8 kgf/cm 2) with a diameter of up to 500 mm. The most common shut-off valves are valves, which is explained by their fairly high tightness, ease of control, more long term service, the possibility of wider regulation, relative safety during operation.
2.What fire protection system should each compressor unit be equipped with?
Production premises and structures must be provided with primary fire extinguishing means (manual and mobile): fire extinguishers, boxes of sand (if necessary), asbestos or felt blankets, etc.
To place primary fire extinguishing means in production and other premises, special fire shields must be installed.
Single placement of fire extinguishers, taking into account their design features allowed in small rooms.
On fire shields only those primary fire extinguishing means that can be used in a given room or installation should be placed. Fire extinguishing means and fire shields must be painted in the appropriate colors according to the current State Standard.
3.What documentation is supplied with the compressor unit?
Each compressor unit or group of similar compressor units is equipped with the following technical documentation:
Passport (form) for the compressor unit;
A diagram of pipelines (compressed air or gas, water, oil) indicating the installation locations of valves, valves, moisture-oil separators, intermediate and end coolers, air collectors, instrumentation, as well as diagrams of electrical cables, automation, etc.; the diagrams are posted in a visible place;
Instructions (guidelines) for safe maintenance of the compressor unit;
Compressor operation log;
A journal (form) for recording repairs of the compressor unit, in which the results of checking welded seams should also be entered;
Passports-certificates of compressor oil and the results of its laboratory analysis;
Passports of all pressure vessels;
Compressor unit repair schedule;
A logbook for testing the knowledge of service personnel.
4. Occupational safety requirements when performing repair work.
When repairing compressor units, repair personnel must comply with established safety rules when carrying out repair work.
Disassembly of compressor units should be carried out only after disconnecting the electric motor and control equipment from power sources. On the electrical panel and on starting device it is necessary to display a poster “Do not turn on. People are working”, which is removed only with the permission of the shift supervisor after completion of equipment repairs and completion of the relevant work to prepare the compressor unit equipment for start-up.
Conduct renovation work on existing compressor installation equipment prohibited.
When repairing compressor units, the following safety requirements must be met:
Use proper plumbing and measuring tools of appropriate sizes;
Use only serviceable lifting equipment, lifting attachments and slings, and strictly adhere to the terms of their testing;
When washing the water jackets of cylinders with liquid caustic, you should use rubber gloves, an oilcloth apron and safety glasses;
Check the height of the linear dead space of the compressor using a lead wire; this operation is not allowed to be performed by touch;
The crankshaft of the assembled compressor should be turned using a shaft turning device only after removing foreign objects from the cavities of the cylinders, crankcase and crosshead;
Do not unscrew bolts or nuts using chisels, hammers, or sledgehammers;
It is not allowed to use impact instruments with peeling, knocked-down strikers, or split handles;
When scraping, filing and stripping, sawdust should be removed with rags or brushes; do not throw them off with your hands or blow them away;
Wear safety glasses when working with a chisel or grinder.
5. Responsibilities of a compressor unit driver after work.
See answer ticket No. 3, question. 5.
Ticket number 20
1.Operation and control of the compressor unit.
The task of monitoring the operation of a compressor unit is to ensure its trouble-free, safe, reliable and correct operation
Supervision of the operation of equipment and the process of producing compressed air is carried out using instrumentation. Monitoring is carried out not only during operation of the compressor unit, but when testing them in order to determine the main parameters characterizing the technical condition of the compressors.
When operating a compressor unit, the following parameters and characteristics are subject to control:
Temperatures of air, cooling water, oil of the circulating lubrication system, rubbing parts of the compressor and the stator winding of the drive motor;
Pressure of intake and discharge air, cooling water and oil;
Consumption of compressed air, oil, cooling water and electricity;
Condition of the grounding network of the compressor unit;
Condition of filters for cleaning air sucked from the atmosphere.
Air, water and oil temperature measurements must be taken every hour while the compressor unit is operating.
2. Technical inspection of the compressor unit.
When carrying out a scheduled technical inspection, faults are eliminated that do not require disassembly and a long shutdown of the compressor unit. The list of technical inspection work includes:
Replacement of all working valves with spare ones, cleaning of removed valves from carbon deposits and dirt;
Cleaning valve boxes from soot and dirt; eliminating the causes of soot formation;
Checking the pin fastening and the condition of the crosshead;
Checking the fastening of the piston to the rod and the rod in the crosshead body;
Checking the tightness of anchor bolts and other threaded connections;
Cleaning the piston pump; washing the fine oil filter;
Checking the condition and cotter pins of connecting rod bolts and counterweight bolts, taking into account the serious consequences of accidents due to accidental defects of connecting rod bolts, it is necessary to monitor their condition, using possible compressor stops for this purpose;
Checking the gaps between the crosshead shoes and the bed parallels;
Checking the condition of support rings and clearances between pistons and cylinders for compressors without a lubrication system;
Removing and washing the air filter filter elements;
Changing the oil in the lubrication system of the crank mechanism and cleaning the coarse oil filter and oil line (only after the first technical inspection).
In the future, this operation is performed after 1500–3000 hours
compressor operation;
Checking the condition of the cylinder mirrors through the valve windows; if there is carbon deposits, marks or scuffing, it is necessary to remove the piston, remove the deposits and clean the cylinder mirror; lubricate the working surface of the compressor cylinder with oil;
Checking the condition of the piston and piston rings.
Every 1200 - 1500 hours of operation of the compressor during inspection, the following operations are additionally performed:
Checking the condition of the bearings of the lower head of the connecting rod, adjusting the gap between the liners and the crankshaft crankpin; risks and other defects on the crankshaft crankpin and liners are not allowed;
Checking the condition of the connecting rod upper head bushing and crosshead pin, checking the gap between them;
Adjusting the gap between the crosshead shoes and the parallels of the bed; to adjust the gap, use special gaskets that are placed on each shoe;
Checking and adjusting the linear dead spaces, which must correspond to those specified in the form, using lead wire with a diameter of 2.5-3 mm; when checking the linear space, the lead wire must be laid at two diametrically opposite points;
Inspection and, if necessary, adjustment of safety valves in the working air to the opening pressure according to the passport data.
Every 4000 – 6000 hours of compressor operation it is necessary to carry out following works:
Clean the water cavities of the cylinders and intermediate and end coolers from scale.
3. What is the frequency of manual purging of moisture-oil separators, air collectors, and gas collectors?
In the absence of automatic purge, manual purge of moisture-oil separators should be carried out twice per shift, unless the factory instructions provide for a shorter purge period; air collectors or gas collectors included in the compressor unit should be purged at least once per shift if there is an end cooler and a moisture-oil separator, and at least twice once per shift in their absence.
4. In what cases does the compressor need to be stopped?
See answer ticket No. 12, question 2.
5. Responsibilities of a compressor unit operator before starting work.
See answer ticket No. 1, question 5.
Answers to tickets for social studies 11th grade.
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