The performance of oil and gas recovery equipment after its third commissioning largely depends on whether the daily maintenance is in place. These devices operate in an environment containing oil and gas for extended periods, leading to issues such as frosting on the condenser, dust accumulation on the filter, and gradual performance degradation of the membrane components over time. These are not sudden failures but rather normal issues that require periodic maintenance. By scheduling maintenance tasks on a daily, weekly, monthly, and yearly basis, most issues can be identified before they affect the recovery efficiency.
Several items to check every day
- Is the device operating status indication normal, and is there any abnormal alarm;
- Is the temperature of the condensation section within a stable range, or is it consistently too low or too high;
- Is the recovery liquid level and reflux normal, and is there any prolonged absence of liquid production;
- Whether the sound and vibration of rotating equipment such as vacuum pumps and compressors are stable.
Weekly and monthly inspection items
- Filter and filter element:Check the pressure difference between the intake air filter and the oil mist filter, and clean or replace them if the pressure difference increases significantly;
- Condenser heat exchange surface:Observe whether the frosting and defrosting processes are normal, and if the defrosting cycle has been prolonged;
- Piping and valves:Check whether there are any signs of leakage on the flange and flexible connection, and whether the valve switch is flexible;
- Electrical and Instrumentation:Check whether the displayed temperature, pressure, and concentration are consistent with the actual conditions on site;
- Recycled liquid quality:Observe whether there is any water or impurity mixed in, and perform stratification treatment by standing still if necessary.
Annual maintenance and performance review
The focus of annual maintenance is on performance review, not just on component replacement. It is necessary to record the inlet gas concentration, recovery liquid output, and exhaust gas status of the device under typical operating conditions, and compare them with the initial operation data to assess the degree of attenuation in condensation capacity and membrane module performance. Membrane modules are core components whose performance changes over time. Whether to replace them should be determined based on the review data, rather than a one-size-fits-all approach based on a fixed number of years.
Comparison of maintenance cycles and key points
| period | Main projects | focus |
|---|---|---|
| daily | Operating status, temperature, liquid level, sound | Is there any alarm or abnormal trend |
| weekly | Filter pressure difference, pipeline leakage | Pressure drop rise rate |
| monthly | Frosting on heat exchange surface, instrument calibration, quality of recovered liquid | Heat exchange efficiency and instrument deviation |
| every year | Performance review, membrane module evaluation, and replacement of vulnerable parts | Trend of recovery rate change |
How to judge common abnormalities
- The recovery liquid has significantly decreased:First, check whether the condensation temperature is appropriate, and then inspect the heat exchange surface for any abnormal scaling or frosting;
- Emission concentration increases:It may be due to performance degradation of the membrane module, or insufficient condensation at the front end, which needs to be verified separately;
- Frequent start-up and shutdown of the device:It is often due to fluctuations in intake air volume or concentration exceeding the adjustment range. It is necessary to verify the changes in operating conditions;
- Increased operating noise:Inspect the foundation, bearings, and couplings of the rotating equipment.
Frequently Asked Questions
Q: How often should the filter element be replaced?
Answer: Judging based on the actual pressure difference is more reliable than based on time. Replace the filter when the pressure difference reaches the replacement threshold, and the replacement cycle will be shorter in places with high dust levels.
Q: Do membrane components need to be replaced regularly?
Answer: Not necessarily. The replacement of membrane components depends on their performance degradation, with the data from annual performance reviews being the main basis.
Q: What maintenance should be carried out during the downtime?
Answer: Replace and protect the system according to the procedures, drain the accumulated fluid, perform routine maintenance on the rotating equipment, and recheck the instruments and interlocks before resuming operation.
Luoyang Wohong Petrochemical Equipment Co., Ltd. specializes in the manufacturing and servicing of tertiary oil and gas recovery equipment, and can offer maintenance guidance and performance verification support. We welcome inquiries and exchanges.