Safe operation of high-pressure air pumps in high-pressure environments

Operating high-pressure air pumps in high-pressure environments must strictly follow safety regulations. A closed-loop management should be formed from equipment inspection, operation procedures, protective measures to emergency response. The following are the specific operation points:

First, preparations before operation

Equipment integrity inspection

Structural inspection: Check the appearance of the air pump for any cracks or deformations, with particular attention paid to the welds and sealing surfaces of the pressure vessel section. Conduct flaw detection on high-pressure pipelines to ensure there are no sand holes or corrosion.

Connection verification: Check the connection between the air pump and high-pressure pipelines and valves. Use double clamps or flanges for connection and apply torque marks to prevent loosening under high pressure.

Instrument calibration: Use a standard pressure gauge to compare and verify the pressure gauge to ensure that the error is within ±1%. The safety valve needs to be sent to a professional institution for setting pressure testing.

Electrical insulation: Measure the insulation resistance of the motor with a 500V megohmmeter to ensure that its value is ≥1MΩ. Check that the grounding resistance is ≤4Ω to avoid the risk of high-voltage electric shock.

Environmental assessment

Space cleaning: Within a 5-meter radius of the operation area, remove flammable and corrosive substances, and set up high-pressure warning signs and cordon lines.

Ventilation confirmation: Activate the forced ventilation device to ensure that the oxygen concentration in the space is ≥19.5% and the concentration of toxic gases is lower than the TLV (threshold value).

Temperature monitoring: Install an infrared thermometer to monitor the ambient temperature. If it exceeds the upper limit of the allowable operating temperature of the air pump, start the cooling system or suspend the operation.

Personnel protection and training

Protective equipment: Operators should wear arc-resistant suits, impact-resistant goggles, high-voltage protective gloves, and portable gas detectors.

Qualification review: Operators must hold a special equipment operation certificate, be familiar with the P&ID diagram (pipeline and instrument flow chart) of the high-pressure air pump and the emergency plan.

Safety briefing: Hold a pre-shift meeting to clarify the operation steps, risk points and escape routes, and conduct a simulated emergency drill.

Second, the operation process is standardized

Start-up stage

Pre-pressurization: Slowly open the intake valve to increase the system pressure at a rate of ≤0.1MPa/s, and observe the readings on the pressure gauge and leakage detector.

No-load test: Run the air pump under low pressure for 5 minutes, and check that the vibration value is ≤4.5mm/s and the bearing temperature is ≤70℃.

Gradually increase the pressure: Run stably for 2 minutes every 0.5MPa increase to check if there is any leakage in the safety valve and if the signal of the pressure sensor is normal.

Operation monitoring

Pressure control: The pressure fluctuation range is controlled within ±2% of the set value through the PID control system to avoid sudden pressure changes.

Leakage detection: Use an ultrasonic leakage detector to scan the pipelines and joints every 30 minutes and record the changes in decibel values.

Lubrication management: For air pumps lubricated with oil, check the oil level and quality every two hours to prevent lubrication failure and bearing burning.

Shutdown and pressure relief

Pressure reduction procedure: First, close the intake valve and open the bypass valve to reduce the pressure at a rate of ≤0.05MPa/s to avoid the water hammer effect.

Residual pressure treatment: When the pressure drops below 0.1MPa, open the manual vent valve to ensure that there is no residual pressure in the system.

Equipment isolation: Cut off the power supply, hang a "Do Not Close" sign, and install blind plates at the inlet and outlet to prevent accidental start-up.

Third, safety protection measures

Physical protection

Protective barrier: Install explosion-proof walls or metal mesh covers around the air pump to prevent components from flying out and injuring people.

Interlock protection: Install a pressure switch interlock device with the solenoid valve. When the pressure exceeds the limit, the gas source will be automatically cut off and an alarm will be triggered.

Explosion-proof design: Use explosion-proof motors (Ex dⅡCT4) and static grounding devices in flammable and explosive environments.

Emergency preparedness

Fire-fighting equipment: Equip ABC dry powder fire extinguishers and carbon dioxide fire extinguishers, and regularly check the pressure and validity period.

First aid kit: Equipped with emergency supplies such as burn ointment, tourniquet, and goggles cleaning solution.

Emergency passage: Ensure that the width of the escape passage is no less than 1.2 meters, there are no obstacles, and the evacuation signs are clearly visible.

Fourth, handling of abnormal situations

Abnormal pressure

Overpressure: Immediately press the emergency stop button, open the bypass of the safety valve, and evacuate personnel to a safe area.

Pressure loss: Shut off the gas source, inspect the leakage points and carry out leak sealing, and conduct non-destructive testing on the damaged components.

Leakage treatment

Gas leakage: Start the axial flow fan to dilute the leaked gas. Use a copper wrench to tighten the joint. Do not operate under pressure.

Lubricating oil leakage: After the machine stops, clean the oil stains, replace the seals, and carry out decontamination treatment on the contaminated area.

Personal injury

High-pressure injury: Rinse and disinfect the wound, bandage it with sterile gauze, and seek medical attention promptly.

Electric shock injury: After cutting off the power supply, perform cardiopulmonary resuscitation, use an AED defibrillator, and call the 120 emergency number.

Fifth, maintenance and upkeep

Regular inspection

Pressure vessels: Conduct an internal and external inspection once a year, with a focus on checking for thinning of the wall thickness and corrosion.

Safety accessories: Calibrate the safety valve and pressure gauge once every six months, and replace the failed rupture discs.

Preventive maintenance

Replacement of vulnerable parts: Regularly replace vulnerable parts such as sealing rings and piston rings according to the operating hours.

Performance testing: Conduct a load test once every quarter to verify the performance indicators of the air pump under high pressure.

Record Management

Establish archives: Record the operating parameters, maintenance records, and inspection reports of the equipment to achieve traceable management.

Data analysis: Utilize vibration analysis, oil monitoring and other means to predict equipment failures and formulate preventive maintenance plans.