B0057电袋运行维护说明书.doc

电袋除尘器ESP+FF使用维护说明书Operating and Maintenance Manual浙江菲达环保科技股份有限公司Zhejiang Feida Environmental Science & Technology CO., LTD 目 录/Contents一、概述/Summary1.1 前言Introduction1.2 电袋复合式除尘器的工作原理及技术性能Working principle and technical performance of ESP+ FF combined dust collector1.3 电袋复合式除尘器基本配置及结构Basic configuration and structure of ESP+FF combined dust collector 1.4 控制、监测及报警的设备 Control, monitor and alarm equipment1.5 清灰系统 Ash removal system1.6 设备的启动与停机 Equipments start-up and shut-down 二、维修说明/Maintenance instruction2.1 概述 Summary2.2 维修的目的 Maintenance purpose 2.3 维修程序 Maintenance sequence2.4对维修人员的要求 Requirement of Maintenance personnel2.5日常维修 Ordinary maintenance2.6 故障维修 Breakdown maintenance2.7 滤袋的更换 Filter bag replacement三、操作说明/Operation instruction3.1概述Summary3.2启动前的措施 Measures before start-up3.3启动 Start-up3.4运行中的检查 Inspection during the operation3.5停机 Shut-down3.6特别措施 Special measures3.7故障报警 Breakdown alarm3.8历史曲线分析 History curve analysis四、安装规程/Erection specification4.1 一般规程 General specification4.2特殊规程 Special specification4.3在布袋除尘器内工作时 Working in the FF4.4 检修风门时 Overhauling the damper4.5 布袋除尘器发生火灾时的应对措施 Countermeasures when FF breaking out of fire一、概述/Summary1.1 前言Introduction本文件供所有有关人员、尤其是设备的运行及维修有关的人员阅读，这有助于他们了解该设备是如何工作的，如何发现并排除故障，以及如何进行维修。This manual is suitable for all relevant personnel to read, especially the relevant personnel of equipment running and maintenance, this is helpful for them to understand how this equipment works, how to discover and eliminate the breakdown and how to maintain.1.2电袋复合式除尘器的工作原理及技术性能Working principle and technical performance of ESP+ FF combined dust collector一、 电袋复合式除尘器定义/Definition of ESP+FF combined dust collector电袋复合式除尘器是综合利用和有机结合电除尘器与布袋除尘器的除尘优点，先由电场捕集烟气中大量的粉尘，再经过布袋收集剩余细微粉尘的一种组合式高效除尘器。具有除尘稳定（50mg/Nm3）、性能优异的特点。ESP+FF combined dust collector complexly utilizes and organic combines the dust removal advantage of ESP and FF. It is a combined high efficiency dust collector that most dust of the gas is collected in the electric fields, then the rest fineness dust is to be collected in the FF. It has the advantage of stable dust collecting and outstanding performance.二、工作原理/Principle of operation在电除尘器和布袋除尘器工作原理基础上,有机结合两者除尘优点：前级电场预收烟气中7090%以上的粉尘量；后级布袋除尘装置拦截收集烟气中剩余量的粉尘。其中，前级电场的预除尘作用和荷电作用为提高电袋除尘器的性能起到了重要作用。Based on the ESP+FF principle of operation, organic combines the advantage of the ESP and FF: the front electric fields pre-collect 70-90% dust; the rest dust is to be collected by the rear FF device. Meanwhile, the pre-dust collecting and charging function of the front electric fields plays an important part in increasing the ESP+FF performance.电场预除尘作用： Pre-dust collecting function of the electric field 预除尘降低滤袋的粉尘负荷量即降低了阻力上升率。 Pre-dust collecting reduces the dust load of the filter bag that is reducing the rising rate of the resistance. 预除尘延长滤袋的清灰周期、节省清灰能耗、延长滤袋使用寿命。 Pre-dust collecting prolongs the ash removal cycle of filter bag, saves the energy consumption and prolongs the service life of the filter bag.三、电袋复合式除尘器技术性能特点/Technical performance 1、适用高比阻粉尘收集，除尘效率具有高效性和稳定性。Its suitable for the high dust resistivity collecting; the collection efficiency is high and stable.电袋除尘器的效率不受高比阻细微粉尘影响，不受煤种、烟灰特性影响，排放浓度容易实现在50mg/Nm3以下，且长期稳定。Collection efficiency of ESP+FF will not be influenced by high resistivity of the fine dust, coal type and ash character, the emission concentration can easily reach 50mg/Nm3 and long-term stability.2、运行阻力比纯布袋除尘器低500Pa，可以减少引风机功率消耗。The operation resistance will be 500Pa less than pure FF; it can reduce the power consumption of the ID fan.3、清灰周期长、气源能耗小。Long ash removal cycle and small energy consumption of gas supply.由于滤袋收集的粉尘量少，阻力上升缓慢，其清灰周期时间是纯布袋除尘器的2倍以上，压缩空气消耗量不到纯布袋的1/3。Due to small dust collection of the filter bag, the resistance rise is slow, its ash removal cycle is 2 times more than pure FF, the compressed air consumption is not to be 1/3 of pure FF.4、延长滤袋使用寿命。Prolong the service life of the filter bag.（1） 运行阻力低、滤袋的负荷差压小延长了滤袋使用寿命。Low operation resistance and small pressure difference of the filter bag load prolong the service life of the filter bag.（2） 清灰周期长、清灰次数少延长了滤袋使用寿命。Long ash removal cycle and few times of ash removal prolong the service life of filter bag.（3） 在相同运行条件下电袋的使用寿命比纯布袋除尘器的寿命延长23年。 The ESP+FF service life is 23 longer than pure FF under the same operation condition.1.3 电袋复合式除尘器基本配置及结构Basic configuration and structure of ESP+FF combined dust collector1.3.1 电袋从功能上分为： From the function, the ESP+FF can be divided into:1、前级电场除尘 2、后级布袋除尘 3、检测功能 4、保护功能 5、电气控制1.The front ESP 2.The rear FF 3.Monitoring function 4.Protection function 5.Electrical controlA、前级电场除尘的组成与常规电除尘器一样。 The composition of the front ESP is same as the regular ESP.B、后级布袋除尘的组成有滤袋、袋笼、清灰系统、提升阀及分室壳体结构。The composition of the rear FF is filter bag, cage, ash removal system, lift valve and compartment casing. 1）滤袋结构：外滤式圆袋、弹性袋口与花板张紧固定密封。Structure of filter bag: Outside-filter type round bag, elastic bag mouth should be seal tightened with bag plate. 2）袋笼结构：上下分节式结构。Structure of bag cage: Up and down section structure. 3）清灰系统：脉冲喷吹结构。Ash removal system: Pulse injection structure. 4）提升阀：上下升降结构。 Lift valve: Up and down lifting structure.1.3.2电袋复合式除尘器结构特点 Structure characteristic of ESP+FF combined dust collector两级除尘方式之间采用了菲达专利技术的导流装置，具有技术成熟、容易维护等优点。Guiding device-the patented technology designed by FEIDA should be adopted between the two-part dust collections. It has the advantages of mature technology and easily maintenance.1.3.3 电除尘器部分： The part of ESP阳极系统/CE system阳极系统由阳极悬挂装置阳极板等零部件组成。阳极板为收尘极，它是由薄板在专用轧机上成型的。CE system is composed by CE suspension device, CE plate and other parts. CE plate is the collecting electrode; it is shaped by stressing the thin plate on the special stress. 阴极系统/DE system阴极系统是电除尘器的关键零部件之一，由阴极吊挂、框架、阴极线等零部件组成。阴极线为放电极。DE system is one of the ESP key parts; it is composed by DE suspension, frame, DE wire and other parts. DE wire is the discharging electrode.阴、阳极振打/DE & CE rapping振打装置是电除尘器的一个重要装置，通过振打使积附在极板、极线上的灰尘振落下来落入灰斗。Rapping device is an important device of ESP, the dust which accumulated on the plate and wire will be fallen into the dust hopper by rapping.进口封头/Inlet nozzle进口封头是进口烟道和电场外壳之间的连接过渡段。进口封头内部装有气流分布板，其目的是使烟道中来的含尘烟气经过时气流尽可能均匀进入全电场。因为封头内气流逐渐降速，一些较大的尘粒会产生自然沉降。Inlet nozzle is the connection and transition section between the inlet duct and ESP casing. Air flow distribution is installed in the inlet nozzle; the purpose is to let the passing dust-load gas which from the duct to get into the whole electric fields evenly. Because the speed of the air flow in the nozzle reduces gradually, some big dust particle will be naturally subsided 顶盖/Roof顶盖分为内顶盖和外顶盖，中间铺保温棉，防止烟气结露。The roof is divided into inner and outer roof; insulation is laid between the inner and outer roof to prevent the flue gas from condensation. 壳体/Casing壳体由立柱、侧封、端封、管撑等组成，是电除尘器钢壳受力支撑件，它与前后的进口封头和顶盖、灰斗、花板、净气室等组成一个密闭的容器。Casing is composed by the column, side panel, end panel and bracing, is the stress support of the ESP steel casing, it composes an airtight container with the front and rear inlet nozzle, roof, dust hopper, bag plate and nozzle house. 灰斗/Dust hopper灰斗是临时性的储灰空间。振打时，极板或极线上的积聚的灰落入灰斗，然后通过输灰系统外排。灰斗内装有料位计，当灰斗内积灰超过此高度时，报警系统将发出声光报警，此时必须加以迅速处理。灰斗内的积灰过多有可能严重损害极板等重要部件。一旦载荷超过除尘器的实际承载能力，还会酿成重大事故，必须严加小心。The dust hopper is the temporary dust holding space. The accumulated dust on the plate and wire drops into the dust hopper when rapping, and then discharged out by the ash removal system. The level indicator is installed in the dust hopper, the alarm system will send out the acousto-optic warning when the accumulated dust in the hopper passes this height, then it should be processed promptly. The excessive dust in the hopper may damage the important part seriously, such as the plate electrode. Once the load passes the actual bearing capacity of the dust collector, it will also cause the major accident, so it should be careful. 电气部分/Electrical part电除尘器电气部分由高压直流电源(包括其控制系统)和低压控制系统组成。The ESP electrical part is composed by the high voltage direct-current power supply (including the control system) and low voltage control system.a) 高压电源采用目前常规配用型号为GGAJ02型。该套装置一般包括高压整流变压器自动控制柜和电抗器，或高阻抗整流变压器和自动控制柜。High voltage power supply uses the present conventional type: GGAJ02 type. Generally this equipment includes the high voltage rectifier transformer, automatic control cabinet and reactor, or high resistance rectifier transformer and automatic control cabinet.该套装置能灵敏地随电场烟气条件的变化，自动调整电场电压；能根据电流反馈信号调整电场火花频率，使其工作在最佳状态下，达到最佳收尘效果。This equipment can rapidly change and adjust the voltage of the electric field according to the gas condition of the electric field; it can adjust the spark frequency of the electric field according to the current feedback signal, that cause it works in the optimum condition and reach the best collection effect. 该装置有比较完善的连锁保护系统。This equipment has the quite perfect interlock protection system.b) 低压控制系统及其功能可包括： Low voltage control system and its function:阴、阳极振打程序控制；DE and CE rapping program control;高压绝缘件的加热和加热温度控制；Heating and the temperature control of the high voltage insulation; 料位检测及报警控制；Level indicator detecting and alarm control;排灰及输灰控制；Ash discharge and ash transport control;门孔柜安全连锁控制；Safety interlocks control of door, hole and cabinet;灰斗电加热功能；Electrical heating function of the dust hopper;进、出口烟气温度检测及显示；Temperature detects and display of the inlet and outlet gas.综合信号显示和报警装置。Integrated signal display and alarm device. 注：根据需要选择设置上述功能。 Note: To choose the above function according to the need.1.3.4布袋部分/FF part结构特点/Structure characteristic1）成熟的低压长袋结构。Low voltage long-bag struction is mature.2）分室结构，可切换离线、在线清灰。Compartment structure, the off-line and online ash removal can be switched。3）采用OPTIPOW脉冲阀，保证清灰高效、稳定、可靠。OPTIPOW pulse valve is adopted to guarantee the high efficiency, stable and reliable of the ash removal.4）在烟气温度高和有油烟的情况下，能防止烧袋和糊袋。It can prevent the filter bag burning and sticking under the condition of high temperature gas and lampblack in it. 气流均布结构/Air flow equispaced structure1）作用：使气流经过电场和布袋时流速、气量分配均匀。Effect：It causes the even distribution of the flow speed and gas when it passes the electric fields and the filter bags.2）结构：独特的专利技术结构Structure: the special patented technical structure每台除尘器分4条线，每条线左右各6个气包，12只进出口风门，每条线配7只旁通风门，1台旁通风门密封风机。系统采用分室结构，关闭滤室可以直接更换滤袋、笼骨。在除尘器顶部设置100%烟气量的旁路烟道，烟气经过电除尘区后进入旁路烟道，布置零泄漏的密封阀旁路烟道，满足烟气工况异常时的袋区保护要求。Each dust collector separates into four lines, 6 air tanks and 12 inlet & outlet dampers for each line, each line equips with 7 bypass dampers and 1 seal fan of bypass damper. The system adopts compartment structure, you can exchange the filter bag and cage directly when compartment is closed. A 100% gas volume bypass duct is designed on the top of the dust collector, the gas gets into the bypass duct through the ESP area, and seal valve bypass duct with zero leakage is laid to satisfy the filter bag protection request when the gas condition is abnormal.气包上的脉冲阀与喷吹管相连，一根喷吹管对一排滤袋进行清灰。滤袋长8米，滤袋上部装有专门的不锈钢弹性圈，无需使用工具，就可以将滤袋牢固地固定在花板孔上。滤袋内装有由钢丝制作的笼骨，笼骨由上下两节组成。Pulse valves of the air tank are connected to the injection tubes, an injection tube does the ash removal for a row of filter bag. The length of the filter bag is 8 meters; the top of the filter bag is equipped with the special stainless elastic ring, so the filter bag can be reliably fixed on the bag plate hole without using the tool. The cage which is made by the steel wire is installed in the filter bag, the cage is composed by the up and down section.除尘器还配有PLC清灰系统用的电控设备，详见第三部分“操作说明”。The dust collector is also equipped with the electric control equipment for the PLC ash removal, please see part three “Operation Instruction” for details.1.4控制、监测及报警的设备 Control, monitor and alarm equipment除尘设备的运行主要由温度、压力、压差、电流、电压、行程反馈信号经过PLC来进行控制、通过上位机监测其运行。某些设备通过指示灯及音响设备来提示报警信息。The operation of the equipment is controlled by PLC through the temperature, pressure, differential pressure, current, voltage and the travel feedback signal, and monitored by the PC. Some equipment prompts the alarm message through the indicator light and acoustic equipment.1.5清灰系统 Ash removal system压差控制模式可以更好地使系统的阻力保持动态稳定，也有利于减少无谓的喷吹，有利于节能与保护滤袋，所以布袋除尘器一般采用压差控制模式清灰。Differential pressure control mode can well maintain the system resistance to be dynamic stable, it is propitious to reducing the senseless injection, it is also propitious to saving the energy and protecting the filter bag, so FF always adopts the differential pressure control mode to cleaning the ash.减压阀PLC喷吹管控制室图1 清灰系统示意图Reducing valve气包Air tank脉冲阀/Pulse valveInjection tube气包压力/Pressure of air tank除尘器压差/Differential pressure of dust collectorControl room在压差控制状态下，当除尘器的压差超过一个设定值时，PLC会向脉冲控制器发送一个信号，脉冲阀打开后，气包内的压缩空气瞬间释放抵达滤袋内。当滤袋扩张时，堆积在外侧的灰尘块就破碎松脱并落到底部灰斗内。Under differential pressure condition, when the differential pressure of the dust collector surpasses a setting value, PLC will transmit a signal to the pulse controller, then the pulse valve will open, the compressed air in the air tank will instantly release and enter into the filter bag. The dust cake accumulated on the outside will break and get loose and then drop into dust hopper when the filter bag expands.若一排滤袋被清灰后除尘器的压差仍然很大，则会最短会在间隔10秒后以同样的方式对另一排滤袋进行清灰。这一清灰顺序将持续进行下去，直到滤袋的压差降到预定值以下为止。但当滤袋阻力长时间维持设定的压差之下，只要距前一次喷吹的时间间隔达到225s以上 ，系统将自动触发一次新的喷吹，以避免粉尘长时间粘附在滤袋上。If the differential pressure was still very big after a row of filter bags was ash cleaned, then the same ash removal way will be done to another row of filter bag at the shortest interval of 10 seconds. The ash removal order will not stop until the differential pressure of the filter bag drops below the setting value. But when the resistance of the filter bag long-time maintains below the setting differential pressure, the system will automatically strike a new injection when the time interval from the preceding injection achieves above 225s to avoid the dust long-time sticking on the filter bag. 随着滤袋使用时间的延长，滤袋的残余阻力会逐渐增加，清灰周期则逐渐缩短。清灰用压缩空气的压力在设定后一般保持不变，但若清灰周期缩短到10min以内，可将清灰压力提高0.05MPa，但最高不得超过0.45MPa。With the extension of the filter bag service-time, the residual resistance of the filter bag will gradually increase and the ash removal cycle will gradually reduce. The compressed air pressure for ash removal will generally maintain after set, but if the ash removal cycle reduces to 10min, it may enhance the ash removal pressure 0.05MPa, but it should not surpass the highest pressure of 0.45MPa.若清灰后清灰用空气的压力达不到所需的压力，压力变送器启动报警。Pressure transformer will start the warning if the compressed air pressure for ash removal can not reach the required pressure after ash removal.1.6 电袋复合除尘器的启动/停机顺序 Equipments start-up and shut-down 详见（三、操作说明）Please see part three (Operation instruction) for details电袋复合除尘器是由程序来控制的，程序会应对发来的信号，如压差、温度等，对不同的目标进行启动及停机。ESP+FF combined dust collector is controlled by the program, the program will start or shut the different goal according to the sending signal, such as, differential pressure, temperature and so on.电袋复合除尘器的启动是从上位机上由操作人员用启动程序自动触发的。The start-up of the ESP+FF combined dust collector is automatically operated by the start-up program from the PC by the operator.电除尘器的电场投运可以各个电场分别投运,布除尘器当压差达到设定值后，PLC控制器根据预先设定的清灰间隔与清灰顺序发送指令给一组脉冲阀依次进行清灰。一组脉冲阀清灰完成后，PLC控制器比较布袋除尘器的阻力与设定值。若布袋除尘器的阻力低于设定值，就停止清灰，否则就继续清灰。这种控制模式可很好地适应锅炉负荷的变化，使除尘器的阻力维持在一个合适的范围，有利于减少喷吹的能量消耗，并延长滤布的使用寿命。 The ESP electric fields can operate separately, PLC controller will send an instruction to a group of pulse valves to carry on the ash removal in turn according to the preset ash removal interval and order when the differential pressure of the FF reaches a setting value. After the ash removal of a group of pulse valves, the PLC controller will compare the FF resistance with the setting value. If the FF resistance is lower than the setting value, the ash removal will stop, otherwise, the ash removal will continue. This kind of control mode can well adapt to the change of the boiler load, it can maintain the resistance of the dust collector in a proper scope, it is propitious to reduce the energy consumption of the injection and to prolong the service life of the filter bag.1.6.1 启动/Start-up投入电除尘低压系统，投入电场运行，再启动布袋程控，当程序的启动被触发时，进出口风门同时打开, 同时按比例关闭旁通风门。旁通风门全部关闭后，密封风机自动运行。完成布袋除尘器启动前的全部准备工作后，由操作人员确定清灰方式（压差清灰或时间清灰）并启动相应的清灰程序。Input the ESP low voltage system and ESP operation, then input the FF program control, when the program is started up, the inlet & outlet damper will open at the same time, and close the bypass damper in proportion at the same time. The seal fan will automatically run when all bypass dampers are closed. After the whole preparation work of the FF start-up is completed, the ash removal way should be determined and start the corresponding ash removal program by the operator (Differential pressure ash removal or time ash removal).若发现有的滤室未能给出“开到位”的信号，应立即查明原因并加以处理。If it is discovered that some compartments are not able to give the “REACHED” signal, the reason should be found out and to be processed immediately.具体步骤详见 （3.3启动）Please see (3.3 Start-up) for step details1.6.2停机/Shut-down正常停机程序是由操作人员手动触发的。The normal shut-down program is handed by the operator. 若进口温度达到高温保护设定值或满足其它除尘器保护条件时，系统自动执行紧急状态或保护停机程序。If the inlet temperature reaches the setting value of heat protection or satisfies the other protection conditions