Circulation Systems Commissioning procedure

1 Flush system. Mote: circulation systems must be thoroughly flushed through to remove foreign solids.

2 Check main items of equipment.

3 Test-run and adjust.

No special equipment is required to carry out the above but spare pressure gauges for checking system pressures, etc., and flexible hoses for bypassing items of equipment, should be available.

POINTS OF

APPLICATION

PUMP(S)

INTERMEDIATE EQUIPMENT

Figure 19.2 Schematic diagram of typical oil-circulation system. Oil is discharged to points of application, returned and re-circulated

PUMP(S)

INTERMEDIATE EQUIPMENT

POINTS OF

APPLICATION

Figure 19.2 Schematic diagram of typical oil-circulation system. Oil is discharged to points of application, returned and re-circulated

Flushing

1 Use the same type of oil as for the final fill or flushing oil as recommended by the lubricant supplier.

2 Before commencing flushing, bypass or isolate bearings or equipment which could be damaged by loosened abrasive matter.

3 Heat oil to 60-70°C and continue to circulate until the minimum specified design pressure drop across the filter is achieved over an eight-hour period.

4 During flushing, tap pipes and flanges and alternate oil on an eight-hour heating and cooling cycle.

5 After flushing drain oil, clean reservoir, filters, etc.

6 Re-connect bearings and equipment previously isolated and refill system with running charge of oil.

Main items of equipment

RESERVOIR

(a) Check reservoir is at least two-thirds full.

(b) Check oil is the type and grade specified.

(c) Where heating is incorporated, set temperature-regulating instruments as specified and bring heating into operation at least four hours prior to commencement of commissioning.

ISOLATING AND CONTROL VALVES

(a) Where fitted, the following valves must initially be left open: main suction; pump(s) isolation; filter isolation; cooler isolation; pressure-regulator bypass.

(b) Where fitted, the following valves must initially be closed: low suction; filter bypass; cooler bypass; pressure-regulator isolation; pressure-vessel isolation.

(c) For initial test of items of equipment, isolate as required.

MOTOR-DRIVEN PUMP(S)

(a) Where fitted, check coupling alignment.

(ib) Check for correct current characteristics.

(c) Check electrical circuits.

(d) Check for correct direction of rotation.

PUMP RELIEF VALVE

Note setting of pump relief valve, then release spring to its fullest extent, run pump motor in short bursts and check system for leaks.

Reset relief valve to original position.

CENTRIFUGE

Where a centrifuge is incoporated in the system, this is normally commissioned by the manufacturer's engineer, but it should be checked that it is set for 'clarification' or 'purification' as specified.

FILTER

^a) Basket and cartridge type—check for cleanliness.

(A) Edge type (manually operated)—rotate several times to check operation.

(c) Edge type (motorised)—check rotation and verify correct operation.

(d) Where differential pressure gauges or switches are fitted, simulate blocked filter condition and set accordingly.

PRESSURE VESSEL

(a) Check to ensure safety relief valve functions correctly.

(b) Make sure there are no leaks in air piping.

PRESSURE-REGULATING VALVE \a) Diaphragm-operated type — with pump motor switched on, set pressure-regulating valve by opening isolation valves and diaphragm control valve and slowly closing bypass valve.

Adjust initially to system-pressure requirements as specified.

(i) Spring-pattern type—set valve initially to system-pressure requirements as specified.

COOLER Check water supply is available as specified.

Running tests and adjustments

(1) Run pump(s) check output at points of application, and finally adjust pressure-regulating valve to suit operating requirements.

(2) Where fitted, set pressure and flow switches as specified in conjunction with operating requirements.

(3) Items incorporating an alarm failure warning should be tested separately by simulating the appropriate alarm condition.

Fault finding

Action in the event of trouble is best determined by reference to a simple fault finding chart illustrated in Table 19.1

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