Compressor Operation Guide: 6 Steps to Ensure Safety and Avoid 99% of Industrial Risks
Step 1: Pre-Startup Inspection (6 Key Checks)
Introduction
In industrial applications, compressors are the “heart” of the system. They are widely used in industries such as oil & gas, laser cutting, food processing, and medical systems.
However, improper operation can lead to:
- Gas leakage
- Equipment damage
- Explosion risks (especially in hydrogen or oxygen systems)
👉 Standard operating procedures are essential, especially when working with gas compressors, nitrogen generators, and oxygen systems.
1. Gas System Check
- Ensure gas purging is completed and qualified
- Nitrogen sealing pressure ≥ 0.1 MPa
- Instrument air pressure: 0.5–0.8 MPa
- All valves are in correct position
👉 Recommendation:
Use a PSA nitrogen generator for stable and safe nitrogen supply.
2. Cooling System Check
- Open all cooling water valves
- Close bypass valves
- Ensure proper circulation
3. Motor Purging
- Complete purging process
- Maintain pressure at 1–3 KPa
- Power on only after confirmation
4. Electrical System
- No loose wiring
- Stable power supply
5. Lubrication System
- Oil level normal
- Oil temperature ≥ 25°C
- Stable oil pressure
6. Manual Rotation
- Rotate ≥ 3 turns
- No abnormal resistance
Step 2: Gas Purging Process (Nitrogen → Hydrogen)
⚠️ Rule: Never introduce hydrogen unless nitrogen purging is qualified.
Process:
- Continuous purging (10 mins)
- Pressure cycle (>50 KPa → 5–10 KPa, repeat 10 times)
- Final purging (10 mins)
Step 3: Startup Procedure
- Final inspection
- Start oil pump
- Activate unload system
- Start compressor
- Adjust pressure gradually
- Routine inspection every 30 minutes
Step 4: Normal Shutdown
- Gradually unload system
- Stop compressor
- Allow pressure to drop
- Stop auxiliary systems
Step 5: Long-Term Shutdown
- Drain system
- Close cooling water
- Use nitrogen protection
Step 6: Common Mistakes to Avoid
❌ Skipping gas analysis
❌ Running at low oil temperature
❌ Improper cooling
❌ Lack of monitoring
Conclusion
For optimal performance and safety, it is recommended to integrate: