空冷凝汽器运行维护手册.doc

Air Cooled Condenser Operation and Maintenance Manual 空冷凝汽器运行维护手册空冷凝汽器运行维护手册 Ref.-No.: D3461_MAN7901 Purchaser 采购方: ShanDong Electric Power Engineering 山东电力设计院 End User 最终用户: Shenhua Yili Power Plant神化亿利电厂 SPX - Contract - No. 合同号: 260-03461 SPX Cooling Technologies GmbH Ernst-Dietrich Platz 2 40882 Ratingen Phone 电话: +49 - 2102 - 1669-786 Fax 传真: +49 - 2102 - 1669-215 Project Manager 项目经理: Mrs. Hui Sun-Degenhard Phone 电话: +49 - 2102 - 1669-239 Final Issue 终版: 09.01.2007 Revision 版本: 0 Date 日期: 09.01.2007 Register 登记: d0025956_ Index 目录目录 1.GENERAL SAFETY CONCEPT 一般安全概念一般安全概念1 1.1GENERAL INSTRUCTIONS总说明1 1.2SAFETY INSTRUCTIONS FOR OPERATION, INSPECTION AND REPAIR3 运行,检查,修理安全指导3 1.3START-UP SAFETY安全启动6 1.4SAFETY DURING PERMANENT OPERATION持续运行时的安全措施8 1.5SHUT-DOWN SAFETY PROCEDURE停机安全步骤9 1.6 DANGER WHEN SAFETY INSTRUCTIONS ARE NOT FOLLOWED不遵守安全指导的危险10 1.7TRANSFORMER UNDERNEATH ACC 空冷下的变送器11 2.GENERAL 概要概要1 2.1GENERAL ARRANGEMENT总体布置图1 2.2DESCRIPTION OF DESIGN设计描述2 2.3TECHNICAL DATA AND DRAWINGS技术数据和图纸5 2.3.1Design Data 设计数据5 2.3.2 Minimum Steam Flow 最小蒸汽流量7 2.3.3ACC Characteristic Curves. 空冷特性曲线8 2.4DESCRIPTION OF PROCESS / MODE OF OPERATION工艺描述/运行方式9 2.5SAFETY AND MONITORING OF EQUIPMENT设备安全和监控11 2.5.1Outage Preservation 货物存储11 2.5.2 Long Term Preservation 长期保存11 2.5.3 Rotating Equipment 旋转设备11 3.CONTROL DESCRIPTION OF THE AIR COOLED CONDENSER 空冷控制描述空冷控制描述1 4.TROUBLE SHOOTING/故障处理故障处理1 5.INSPECTION AND REPAIR 检验和修理检验和修理1 5.1INSPECTIONS检验1 5.2 DISASSEMBLY AND REPLACEMENT OF FANS, FAN MOTORS AND GEARS风机组拆卸和更换9 5.3SERVICE FOR AIR COOLED CONDENSERS空冷维护10 6.COMPONENT DOCUMENTATION 部件文件部件文件1 6.1AXIAL COOLING FAN轴流风机2 6.2MOTOR 电机5 6.3GEAR BOX齿轮箱8 6.4FREQUENCY INVERTERS变频器10 6.5PUMPS泵12 6.5.1Drain pumps 疏水泵13 6.5.2Condensate pumps 凝结水泵15 6.5.3Water-ring pumps 水环泵17 6.6INSTRUMENTS AND CONTROL EQUIPMENT仪表和控制设备19 6.6.1Instrument List 仪表清单20 6.6.2Fan Vibration-Switches 风机振动开关21 6.6.3Remote instrumentation 远程仪表23 6.6.4Local instrumentation 就地仪表25 6.7VALVES AND FITTINGS阀门和配件27 6.7.1Valves 阀门28 6.7.2Steam traps 滤气阀30 6.7.3Rupture discs 爆破膜32 6.7.4Safety-Valve 安全阀34 6.7.5Butterfly valve 蝶阀36 6.8CONDENSATE TANK凝结水箱38 6.9EXPANSION JOINTS膨胀节40 6.10 HEAT EXCHANGER ELEMENTS换热器元件42 6.11 CLEANING DEVICE 清洗装置47 6.12 MONORAIL PUSH TRAVEL TROLLEY单轨手推车49 6.13 ELECTRIC电气51 6.14 DEAERATOR除氧器53 7.LISTS 清单清单1 7.1INSTRUMENT LIST仪表清单2 7.2ELECTRICAL CONSUMER LIST 电耗清单3 7.3I/O SIGNAL LIST I/O 信号清单4 7.4ALARM LIST报警清单5 7.5LUBRICATION INSTRUCTIONS 润滑说明6 7.6SPARE PARTS LIST备品备件清单7 8.GENERAL ARRANGEMENT DRAWINGS 总布置图总布置图1 1.General Safety Concept 一般安全概念一般安全概念 1.1General Instructions 总说明总说明 This operation and maintenance manual includes basic instructions for the operation, inspection and maintenance of the ACC. The operator must take these instructions into account. 该运行维护手册包含空冷运行、检验和维修的基本指导。有关操作员必须加以重视。 It is in the interest of the owner that the unit, in its function as a steam condenser, is only operated and inspected by qualified personnel. The operators must thoroughly study the operation and maintenance manual before taking any action. 该设备的功能为蒸汽的冷凝器, 必须由合格人员进行操作和检查. 操作员应在开始 使用前完整的学习本手册。 It is forbidden to employ unqualified and unauthorised personnel. It is of extreme importance that the operating personnel are aware of all safety instructions. 严禁雇用不合格的员工。操作员明白所有安全措施，这一点极其重要。 These operating instructions are intended for the specified operating conditions, however special consideration shall be given for extreme operating conditions. Specific operating conditions may require more frequent operator attention. Please contact SPX immediately for additional information regarding operating conditions or problems not contemplated herein. 本手册适用于指定的运行工况，极端运行工况应特殊考虑。特殊运行工况要求操作 员要更多的加以注意。对于本手册运行工况或问题未尽事宜请立即联系斯必克。 SPX shall not be responsible or liable under the contract or at law for any costs or damages of any nature resulting in whole or part from failure of the owner, its agents or employees to strictly comply in all respect with each and every procedure, instruction and caution contained in this instruction manual or from any modification or change not authorised by SPX. Any such non-compliance will also specifically void SPXs responsibility under any warrantee or guarantee provisions in connection with the portion of the work effected in whole or part by such non-compliance. 对于由于自然原因造成的业主的全部或部分损失, 由于业主的代理或雇员没有严格 遵守本手册的每一个过程, 指导和注意事项而造成的业主的全部或部分损失, 及擅自 改动本手册而造成的业主的全部或部分损失, 斯必克公司不承担责任。任何此类违 反操作规程的行为也将免去斯必克公司对受影响的工作部分的保障。 1.2Safety Instructions for Operation, Inspection and Repair 运行运行,检查检查,修理安全指导修理安全指导 Any work done on the unit must be carried out in accordance with the valid health and accident prevention procedures and safety instructions. 进行任何工作时都应遵守安全措施及事故预防措施。 Prior to any work being undertaken on the unit, all equipment must be electrically isolated and measures must be taken to prevent accidental re-energising of the equipment. Motors and fans / pumps / actuators must be motionless, de- energized and locked from the central control desk. 任何工作开始前, 所有设备应断电, 并采取措施防止重新加压的事故. 电机, 风机, 泵, 执行机构应静止, 断电, 并从中控台锁止。 Paying attention to the accident prevention procedures, the bearings of the fan gears and the fan-motors can be lubricated with the equipment in operation. This action is executed from the fan bridge walkway. To change the oil of the gearboxes is not possible during operation of the fans. 注意事故预防措施, 风机齿轮和电机的轴承可在设备运行时从风机梁步道润滑. 不 可在风机运行时给齿轮箱换油。 GENERAL WARNING 警告警告 PERSONNEL IN THE PLANT MUST WEAR HARD HATS AND PROTECTIVE SHOES. 电厂内人员应戴安全帽电厂内人员应戴安全帽, 穿防护鞋穿防护鞋. - During cleaning of the ACC heat exchanger elements the fan motor they are compressed in the evacuation system and discharged into the atmosphere. 不凝结气体通过分凝管束的上部抽出，经真空系统压缩后排入大气。 The produced condensate flows by gravity through the condensate drain line into the Turbine exhaust box. 凝结水通过重力流入排汽装置。 The cold air required for condensation is taken in from the ambient air by the axial-flow fans and is supplied to the cooling surfaces of the fin tube bundles. 冷凝所需冷空气由轴流风机从环境空气中获得，并供给到管束表面。 The cooling air flow rate can be altered by frequency of the driving motors. 冷凝空气流速可通过驱动电机频率来改变。 2.5Safety and Monitoring of Equipment 设备安全和监控设备安全和监控 2.5.1Outage Preservation 货物存储货物存储 The instructions of the individual component supplier must always be adhered too. 必须遵守每个设备供应商的指导。 For normal shutdown periods of up to 2 3 weeks, no special preservation procedure is required. The Air Cooled Condenser is best left undisturbed as much as possible. 正常停机 2-3 周时, 无需特别的保护措施. 最好不去碰 ACC。 Should there be a risk of freezing conditions, all components filled with condensate are to be drained or heat tracing to be applied. 当有冻结可能时,要把凝结水排掉或采取伴热措施。 2.5.2 Long Term Preservation 长期保存长期保存 If the duration of the shutdown is likely to be prolonged, then it is wise to drain all liquid from vessels and pumps. 如果停机时间延长, 最好把容器和泵内的水排出。 Furthermore the complete ACC is to be dried internally to prevent corrosion during the prolonged plant outage. 停机时间延长后, 应把整个 ACC 系统内部弄干以防腐蚀。 Before restarting the ACC back into operation each component has to be checked for failure free operation. 重新启动前应检查各部件并排除故障。 2.5.3 Rotating Equipment 旋转设备旋转设备 Quality and quantity of oil in the gearboxes and grease in the bearings have to be checked before start up. 启动前,应检查齿轮箱内润滑油和其它油脂的数量及质量。 All pumps should be turned at least one revolution each and every week of the shutdown period, no matter how long or short the period is. The same applies to fans, if they are not turning periodically, due to the wind action. The fans must be run at least once every month for 20 minutes to keep the motors and gearboxes operational. This is to protect against damage being done to bearings by static indentation, and to distribute oil inside the gearbox to cover the gears and protect against corrosion. 停机期间, 所有泵每周至少转动一圈, 无论停机时间多长. 如果没有风的作用使风机 周期性转动, 风机每月至少运行一次且持续 20 分钟, 以保持电机和齿轮箱可用. 保护 轴承不因静力而产生凹痕.且齿轮箱内部分配油保护齿轮并抗腐。 The suppliers O&M documentation in Chapter 6 should also be followed, along with any additional requirements referenced in this Chapter. 遵循供应商运行和维修文件第 6 章，连同本章所有附加需求参考。 3.Control Description of the Air Cooled Condenser 空冷控制描述空冷控制描述 4.Trouble Shooting/故障处理故障处理 See Chapter 3 见第三章。 5.Inspection and Repair 检验和修理检验和修理 5.1Inspections 检验检验 The listed inspections are standard for ACC-Systems. 下列检验为空冷系 统标准检验内容 The inspections are applicable, if the components are installed in this ACC. 本检验适用于本空冷安装部件。 During operation, regular inspection rounds and the following controls must be carried out: 运行期间, 必须进行如下常规检查和控制 Fittings 配件 - check gaskets and glands for leaks 检查密封垫和密封管有无泄漏 - check flanged connections for leaks and tighten, if necessary 如需要,检 查法兰的密闭性 - check thermal condensate traps acting as steam vents for proper functioning and clean, if necessary 如需要,检查蒸汽收集阀的功能并适时 清洁 fan, gear 风机, 齿轮箱 - Grease leakage at shaft openings (standstill required) 检查轴开口处油 脂的密封(需停机) - Oil levels 油位 - Vibrations at the unit and drive (during operation) 设备的振动(运行时) - Check bearing temperatures 检查轴承温度 - Check tightening torque of the fan blades (standstill required) 检查叶片 的上紧力矩(需停机) - Check blades for deposits (standstill required) 检查叶片有无沉淀物(需 停机) - pay attention to bearing noises 注意轴承噪音 - Check of Gearbox Pressure Switch and Heaters 检查齿轮箱压力开关和 加热器 Expansion joints 膨胀节 - check that the joints are corrosion-free 检查有无腐蚀 Inspection round in the area of the air-cooled condenser elements ACC 周边常规检查 - Pay attention to noises pointing to leaks in the area of the finned tubes 注意翅片管与泄漏相关的噪音 - Pay attention to a uniform temperature of the charged cooling surfaces 注意散热器表面的温度是否一致 - Compare the difference between condensate temperature and steam temperature, observed over a period of 24-h (DCS records). The difference should not exceed 4 - 6 C. If the difference is greater, the installation should be checked for leaks. 比较凝结水和蒸汽的温度差, 每 24 小时(PCS)观察一次, 差别不要超过 4-6OC. 如超过, 检查是否泄漏 - Check the element cooling surfaces (finned tubes within the air-cooled condenser) for contamination. 检查散热器表面是否结垢（ACC 上的翅片 管） Installation standstill 装置停止时 During longer standstills, the corresponding operating manuals of the components and units of the air-cooled condenser installation shall be observed. 长期停机时, 要遵守 ACC 各部件的相关操作规程 Maintenance and inspection plan 维护和检验计划维护和检验计划 Work to be carried out 工作内容工作内容Monthly 每月每月 6 months 每每 6 个月个月 12 months 每每 12 个月个月 FAN UNITS 风机机组 Check all tightening torque at the impeller, replace corroded bolts and nuts 检查叶片的上紧力矩,替换受腐蚀的螺栓/母 X Check the alignment of the impeller with respect to the fan ring (gap width) 叶片对中,(以和风筒间距为基准) X Check the fan blades for unbalance, check the blade angle, remove deposits on the blades 检查叶片是否平衡,检查叶片角度,去掉叶片上的污 垢 X Check gear noises for any changes / daily 检查齿轮噪音变化/每天 Check oil level at the gearbox 检查齿轮箱油位X Change gear oil 更换齿轮油X Change gear oil after commissioning 调试后换齿 轮油 Check gear for leaks 检查齿轮箱泄漏X Check operation of Gearbox Heater 检查齿轮箱加热器的运行 2 Months Check operation of Gearbox Pressure Switch 检查齿轮箱压力开关的运行 2 Months Check operation of the vibration switch 检查振动开关的运行 2 Months Check gear bearings for bearing noises 检查齿轮轴承噪音 X Re-grease the output bearings from the gear 给风机轴承加润滑油 X Check the electric motors for bearing noises 检查电机轴承噪音 X Re-grease the electric motors 给电机轴承加润滑油 X FIN TUBES 翅片管 Check the finned tube elements for: Contamination, corrosion, frost damages and leaks 检查翅片管:是否结垢,腐蚀,冻裂,泄漏 X Work to be carried out 工作内容工作内容Monthly 每月每月 6 months 每每 6 个月个月 12 months 每每 12 个月个月 CONDENSATE TANK and EXHAUST BOX 凝结水箱和排汽装置 Check the fastenings of the condensate tank at the erection points 检查凝结水箱安装点是否牢固 X Check the tanks slide bearing for contamination 检查凝结水箱的滑动轴承是否结垢 X Check the tank interior for contamination 检查凝结水箱的内部是否结垢 X Check the turbine exhaust box inner chamber for contamination 检查排汽装置的内部是否结垢 X Check the slide bearings and guides for contamination 检查滑动轴承和引导装置是否结垢 X Check the expansion joints for damages and corrosion 检查膨胀节是否损坏或腐蚀 X Check all flanged connections (leaks) 检查所有法兰是否有泄漏 X Check the debris separator 检查碎片分隔器X Check the flow meters 检查流量计X Check the condensate drains and automatic vents 检查凝结水疏水和自动导流 X Check the manual fittings for smooth operation and re-grease spindles 检查手工装配部件是否顺滑, 并给轴加润滑 X Re-grease the push rod, test the fastening and try out the control valves 润滑推(转)柄,检查紧固件和控制阀 X Check the float switch for damages and leaksX 检查浮球开关是否损坏或泄露 Check the level indicators for damages and leaks 检查液位计，看是否有损坏或泄漏 X Remove the steam nozzles and check for contamination and damages 移去蒸汽喷嘴,检查是否结垢和损坏 X Remove the condensate drains and check for contamination and damages 移去凝结水疏水管,检查是否结垢和损坏 X Work to be carried out 工作内容工作内容Monthly 每月每月 6 months 每每 6 个月个月 12 months 每每 12 个月个月 PUMPS AND MOTORS 泵和电机 Check the shaft gaskets of the pumps for leaks 检查泵的轴垫片密封 X Check the pumps and motors for running noises 检查泵和电机的噪音 X Check the oil level or the grease filling at the pumps 检查泵的油位或加油管 X GENERAL 概述 Vacuum holding test 真空测验X Besides the maintenance work and inspections to be carried out regularly, it is indispensable to perform a safety check of the installation at regular intervals, at least once a week. 除了常规的维护和检查外,定期的安全检查也是不可缺少的,至少每周一次, 5.2Disassembly and replacement of fans, fan motors and gears 风机组拆卸和风机组拆卸和 更换更换 5.3Service for Air Cooled Condensers 空冷维护空冷维护 For a reliable operation of the entire power plant it is important that the unit is performing correctly. Damage on the individual parts must be prevented. 为了整个电厂的可靠运行, 机组必须正确运行,避免对单个部件的损坏. For this reason preventive inspections are required. To support the owner in his maintenance activities SPX Cooling Technologies GmbH offers preventive inspections performed by our qualified personnel. 因此预防性的检查是必要的, 为支持业主的维护, SPX 提供合格人员进行预防性的 检查. In our inspection reports we will make recommendations for inspections, repairs, and further maintenance. This will enable the owner to plan the activities during planned outages to prevent breakdowns and accidental outages. 在我们的检查报告中,将推荐检查,修理和维护的方案. 使业主制定防止停机和事故 的计划. In summary, preventative inspections preserve the value and availability of your air cooled condenser. 综上所述, 我们的预防性的检查能使您的 ACC 发挥出它的价值. Your contact:联系人 Mr. Friedhelm Fischer Tel.: +49 (0)2102 / 1669-592 Fax.: +49 (0)2102 / 1669-215 Naturally, we are at your disposal should you have any queries or need advice. 我方乐意为您服务或提供建议. 6.Component Documentation 部件文件部件文件 6.1Axial Cooling Fan 轴流风机轴流风机 SPX Bejing 北京 Designation 名称 Axial Cooling Fan 轴流风机 意大利 Cofimco 公 司 Type 型号9144-8-33F/G2.0TR No.数量4 x 20 Diameter 直径9144 毫米 No. of blades 叶片数量 8 Material of blades 叶片材料FRP 玻璃钢 KKS-No.: 码10MAG30 AN00110MAG40 AN00110MAG50 AN001 10MAG30 AN00210MAG40 AN00210MAG50 AN002 10MAG30 AN00310MAG40 AN00310MAG50 AN003 10MAG30 AN00410MAG40 AN00410MAG50 AN004 10MAG60 AN00110MAG70 AN001 10MAG60 AN00210MAG70 AN002 10MAG60 AN00310MAG70 AN003 10MAG60 AN00410MAG70 AN004 20MAG30 AN00120MAG40 AN00120MAG50 AN001 20MAG30 AN00220MAG40 AN00220MAG50 AN002 20MAG30 AN00320MAG40 AN00320MAG50 AN003 20MAG30 AN00420MAG40 AN00420MAG50 AN004 20MAG60 AN00120MAG70 AN001 20MAG60 AN00220MAG70 AN002 20MAG60 AN00320MAG70 AN003 20MAG60 AN00420MAG70 AN004 KKS-No.:码 30MAG30 AN00130MAG40 AN00130MAG50 AN001 30MAG30 AN00230MAG40 AN00230MAG50 AN002 30MAG30 AN00330MAG40 AN00330MAG50 AN003 30MAG30 AN00430MAG40 AN00430MAG50 AN004 30MAG60 AN00130MAG70 AN001 30MAG60 AN00230MAG70 AN002 30MAG60 AN00330MAG70 AN003 30MAG60 AN00430MAG70 AN004 40MAG30 AN00140MAG40 AN00140MAG50 AN001 40MAG30 AN00240MAG40 AN00240MAG50 AN002 40MAG30 AN00340MAG40 AN00340MAG50 AN003 40MAG30 AN00440MAG40 AN00440MAG50 AN004 40MAG60 AN00140MAG70 AN001 40MAG60 AN00240MAG70 AN002 40MAG60 AN00340MAG70 AN003 40MAG60 AN00440MAG70 AN004 6.2Motor电机电机 Because of the low temperature during the winter period in Yili the supplier advises the following additional measures for winter storage 6 Months. 由于冬季期间亿利现场的低温工况，供应商建议参照冬季存储附加措施（大于 6 个月） Connect and turn on the heating elements.连接并开启发热元件。 Open condensation holes.打开凝结水孔 Protect unpainted areas.保护未上漆的区域 Cover with protective foil.覆盖保护膜 Before putting motors into operation check bearing noise.在运行电机之前检查轴承噪 音 SPX Bejing 北京 Designation: 名称 Motor 电机大连电机集团有限公 司 Type:类型MDSP315S-4 V1 No:数量4 x 20 KKS-No.:码 10MAG30 AN00110MAG40 AN00110MAG50 AN001 10MAG30 AN00210MAG40 AN00210MAG50 AN002 10MAG30 AN00310MAG40 AN00310MAG50 AN003 10MAG30 AN00410MAG40 AN00410MAG50 AN004 10MAG60 AN00110MAG70 AN001 10MAG60 AN00210MAG70 AN002 10MAG60 AN00310MAG70 AN003 10MAG60 AN00410MAG70 AN004 20MAG30 AN00120MAG40 AN00120MAG50 AN001 20MAG30 AN00220MAG40 AN00220MAG50 AN002 20MAG30 AN00320MAG40 AN00320MAG50 AN003 20MAG30 AN00420MAG40 AN00420MAG50 AN004 20MAG60 AN00120MAG70 AN001 20MAG60 AN00220MAG70 AN002 20MAG60 AN00320MAG70 AN003 20MAG60 AN00420MAG70 AN004 KKS-No.:码 30MAG30 AN00130MAG40 AN00130MAG50 AN001 30MAG30 AN00230MAG40 AN00230MAG50 AN002 30MAG30 AN00330MAG40 AN00330MAG50 AN003 30MAG30 AN00430MAG40 AN00430MAG50 AN004 30MAG60 AN00130MAG70 AN001 30MAG60 AN00230MAG70 AN002 30MAG60 AN00330MAG70 AN003 30MAG60 AN00430MAG70 AN004 40MAG30 AN00140MAG40 AN00140MAG50 AN001 40MAG30 AN00240MAG40 AN00240MAG50 AN002 40MAG30 AN00340MAG40 AN00340MAG50 AN003 40MAG30 AN00440MAG40 AN00440MAG50 AN004 40MAG60 AN00140MAG70 AN001 40MAG60 AN00240MAG70 AN002 40MAG60 AN00340MAG70 AN003 40MAG60 AN00440MAG70 AN004 6.3Gear Box 齿轮箱齿轮箱 SPX Bejing 北京 Designation:名称Gear box 齿轮箱佛兰德，西 门子公司 Type:类型H2NV 108 No.:数量4 x 20 6.4Frequency inverters 变频器变频器 Clients scope 业主供货 6.5Pumps 泵泵 6.5.1Drain pumps 疏水泵疏水泵 Clients scope 业主供货 6.5.2Condensate pumps 凝结水泵凝结水泵 Not applicable 不适用 6.5.3Water-ring pumps 水环泵水环泵 Clients scope 业主供货 6.6Instruments and Control Equipment 仪表和控制设备仪表和控制设备 6.6.1Instrument List 仪表清单仪表清单 6.6.2Fan Vibration-Switches 风机振动开关风机振动开关 SPX Bejing 北京 6.6.3Remote instrumentation 远程仪表远程仪表 SPX Bejing 北京 6.6.4Local instrumentation 就地仪表就地仪表 Clients scope 业主供货 6.7Valves and Fittings 阀门和配件阀门和配件 6.7.1Valves 阀门阀门 Clients scope 业主供货 6.7.2Steam traps 滤气阀滤气阀 Not applicable 不适用 6.7.3Rupture discs 爆破膜爆破膜 Clients scope 业主供货 6.7.4Safety-Valve 安全阀安全阀 Not applicable 不适用 6.7.5Butterfly valve 蝶阀蝶阀 Clients sc