kkkap风机的运行维护手册(中英文对照).doc

专业 专心 专注 专业资料 参考首选 operating and maintenance manual for fans type kk a locking piece prevents twisting. between the two oil seals is an opening linked to the atmosphere by holes and lines. this provides the seals with the pressure equalisation they require. the shaft is fitted with bushes in the area of the seals. laminar rings engage with rotating grooves. the rings are held by their external diameter and are axially movable. they provided protection from oil spray (from within) and dirt (from without). 密封轴孔需要合适的密封。轴承盖水平剖分。每侧轴套上装有一对可径向移动 的人造石墨密封圈，该圈由三段组成，用一管状弹簧围箍，有一定位块防 止转动。两密封圈之间有一个通道与大气相通，使内外压力平衡防止泄漏。 轴套上环槽内装有叠层密封环，靠外径定位，隔离内部的溅油和外部的灰 尘。 专业 专心 专注 专业资料 参考首选 2.3.20.accessories 附件附件 couplingthe fan is driven by the motor by means of a steel multi-plate coupling. the coupling is flexible to bending but stiff against torsion. the motor shaft and fan rotor each have a coupling hub. both hubs are connected to an intermediate shaft. 联轴器联轴器为膜片联轴器。刚挠性膜片联轴器具有误差补偿、吸振且不需维 护等优点，电机轴和风机转子各装配一个半联轴器，安装在中间传扭轴 两端，将电动机功率传递给风机。 oil-supply unitthe oil-supply unit supplies the main bearing and servomotor with oil. see accessories see also the paragraph “lubrication”. you can see the oil circuit from the oil pipe scheme and circuit diagram. 油站油站提供主轴承和伺服马达用油。详见“附件”，也可参见“润滑油”章节 的润滑油路图。 cooling/ sealing- the main bearing and the servomotor inside are air- cooled. air (id/fgd fans)in the flow chamber of the fan the pressure is higher than the surrounding pressure. the internal spaces are blocked by higher pressure in order to prevent penetration and corrosion by flue gases. 冷却密封风机（引风机和增压风机专用） 主轴承和伺服马达均为空气冷却。风机流道内的压力比环境压力高。内 部的空间被高压气体密封，可以防止烟气流入和腐蚀。 locking braketo prevent the rotor during standstills from idling it is equipped with a locking brake which acts on the brake disc at the fan-side coupling half. this is a manually activated shoe brake which may only be closed when the fan speed has dropped below 50 rpm or when the fan has stopped completely. 锁刹装置为防止转子惰走，在风机联轴器侧装有锁刹装置。当风机转速低于 50rmp，或者完全停止后才可以关下锁刹装置。 important!重要重要 this brake is not suited to brake the fan at a speed above 50 rpm. therefore the speed must be checked without fail before closing the brake. the brake must be secured against inadvertent activation. 锁刹装置不能在风机转速大于 50rpm 时工作。所以在关下锁刹装置时， 转速需要准确无误的确认。需确认锁刹装置不要无意被启动。 the motor is interlocked by a limit switch when the brake is closed. therefore, it must be ensured before each starting that the brake is open. 当锁刹装置锁定后，电机通过一个限位开关内锁。因此，启动时需要确 定是否每个锁刹装置都已经打开了。 3. operation/运行运行 3.1. technical plant requirements 设备技术要求设备技术要求 in order to operate safely and economically the fan must be matched to suit the plant. this includes for example: 为了使系统更经济更安全的运行，风机配置必须适合于系统，这就包含了如下： the planning of its operating characteristics/运行参数的确定 专业 专心 专注 专业资料 参考首选 the arrangement of valves and by-pass lines 隔绝门及管路系统的布置 piping flow control/各管道中流量的调配 important重点重点： corrosion (e.g. due to cooling flue gas) can cause important components to fail. make sure that no flue gas is allowed to remain in the fan during stoppages. 腐蚀介质（例如冷却后的烟气）会导致一些重要元件在运行中出现故障，因此，一定要保证在停机 时风机中没有遗留烟气。 3.1.1. operating range 工作运行区域工作运行区域 operating range is the range which allows for continuous operation of the fan without the risk of damage. 工作运行区域是在风机没有损坏危险的情况下，能持续工作运转的区域。 axial fans of the ap series can operate in a wide range, in which their power can be matched to suit the plant requirements by means of rotor blade adjustment. operating the fan outside of this range, especially for a longer period of time may lead to damage: ap 系列轴流风机能在一个大的区域内运行，依靠叶片调节，能满足系统工况的需求。在不允许区 域内，尤其是长时间运行，会导致风机损坏。 when the volume flowrate is too small the flow gets unstable, it stalls“. operation with unstable flow results in higher loads and stress on some components, especially of the rotor blades. 当流道中流量过小时，气流会变得不稳定，这种不稳定的气流会导致某些元件的 负载与压力过大，尤其是叶片。 when the volume flowrates are very small the fan may heat up inadmissibly. 当流道中流量非常小时，风机温度会过高致风机无法承受。 the sketch below shows the operating ranges prohibited for continuous operation. for your unit the admissible operating range in the section operating data“ is plotted in the performance graph. 下简图显示了风机连续运行的禁止运行区域和可运行的范围区域。 reverse conveyance/反转运行： 专业 专心 专注 专业资料 参考首选 with our twisted blades there is a reverse conveyance with the blade angle closed“ (min. rated blade angle). 在叶片关闭时，扭转叶片有一个反转运行的过程。 this means that near the impeller hub the blades continue to convey in flow direction, however, in the outer area the blades are already overtwisted?“, resulting in a conveyance against the normal flow direction, i.e. reverse conveyance. this is an undesired process, especially for forced draft fans and induced draft fans. 这说明叶片接近轮毂的地方，若持续顺着气流方向转动，超过允许区域，叶片就会出现“过度扭 转”，这时就会导致气流倒流，这是非正常运转，尤其对送、引风机。 especially the range where there is zero conveyance of the fan is critical, as axial hunting may occur here. the permissible min. angle of the blades is accounted for by the indication prohibited range“ in the performance graph. 尤其警示当风机在 0 开度运转时，会发生轴向气流紊乱，叶片允许的最小开度范围在性能曲线上 已经表示出来了。 it is advisable to check the flow during trial operation. if the machine is started with closed shut-off dampers on the discharge side the min. pressure at the diffuser end should be 2 mbar. if the machine is started with closed suction-side shut-off dampers the min. pressure should be 2 mbar at the suction bend inlet. 在试运转期间可检查气流，若风机在关闭出口挡板门的情况下开始运转，那么在扩压器出口处的 最小压力会达到 2mbar，若风机在关掉进口挡板门的情况下开始运转，那么在进气箱入口处的最 小压力会达到 2mbar。 3.1.2. security 安全安全 in many cases the arrangement of the plant is such that the fan can only be operated within it is permitted performance characteristics. 在各种情况下，系统的布置必须保证风机在其性能曲线允许的范围内运行。 however, if the plant conditions change or the plant control system does not prevent the fan from being operated in a prohibited range, it is highly recommended to secure it against being operated in a prohibited range. 无论如何，如果系统设备改变或控制系统不能阻止风机进入禁止区域运行，就必须使用安保系统 阻止风机进入禁止区域运行。 there are various procedures to achieve this: 现有很多设备都能达到安全保护要求： stall control/失速控制 the stall point of the characteristic diagram is simulated in the computer. the computer determines the current position of the operating point, measuring 风机失速的特性要素在电脑中能被模拟出来，电脑能测定出运行点的位置，并进行监测。 the ambient pressure/外界大气压 the static pressure at various points/不同点的静压 the gas temperature/流体温度 专业 专心 专注 专业资料 参考首选 the operating point is compared with the stall limit of the performance graph. if it is exceeded the rotor blade angle is e.g. altered by a few degrees. 把运行点与性能曲线中失速区域进行比较，如果进入失速区，动叶片要作适当调节，以进入安全 区域运行。 stall display/失速显示 the differential pressure of the flow is measured upstream of the impeller in circumferential direction. in the stable region of the performance graph the differential pressure fluctuation is small. if the stall limit is exceeded it rises by a multiple. then a pressure switch alters e.g. the rotor blade angle by a few degrees. 在叶轮前部圆周方向上，能测量出流体压差，当运行点在性能曲线中的稳定区域，压差波动较小， 一旦超过失速线，压差波动会增加数倍，这时压力转换开关与控制系统动作，调节动叶角度，达 到安全运行。 low volume flow/低流量情况 as safety device against too low volume flow rates we recommend the installation of a time relay which stops the machine again after starting if the discharge-side and/or suction-side damper does not open timely when the operating speed is reached (limit switch at the damper). see the following paragraph shut-off dampers“. 由于安保装置不允许气流流量过低，我们建议使用时间继电器装置，这种装置（挡板门处有限位 开关）在运转速度已达到，但进口侧或出口侧挡板门没有打开的时候，便会使风机停转。详见 “挡板门”。 important重点：重点： the planning and installation of the monitoring devices described should be carried out only by specialist personnel. 检测设备的设计与组装应该由专业人员进行。 shut-off dampers/挡板门 some fans can be separated from the plant by means of dampers. the dampers can be provided for the following reasons: 一些风机可以依靠挡板门从系统中分隔开，配置挡板门有以下几个原因： the motor shaft input power must be limited during starting. 电机轴输入轴功率在开始运转时必须被限制 the plant can be started up only when the fan runs. 只有在风机运行时，系统才能启用 several fans belong to a plant. fans which are not operating are disconnected from the plant to avoid any disturbing gas influences, return flows, idling or reverse running of fans. 一套系统一般都有多个风机，那些没有使用的风机都应该从系统中分隔出去， 以避免气流回流，使其惰走或反转。 with closed dampers the volume flowrate equals zero. continuous operation with closed dampers is not allowed, see section 2. it must be agreed upon from case to case between the operator and ckpf whether starting with closed dampers is permitted. 在挡板门关闭时气流流量为 0，挡板门关闭时的连续运转是不允许的，在第二部分有说明，挡 板门在风机启动时是否允许开闭，操作人员与 ckpf 之间也应该取得一致意见。 专业 专心 专注 专业资料 参考首选 the damper opening must then be controlled such that same are fully opened at the latest 1 minute after the fan has reached operating speed. this should preferably be made automatically. only then may the requested rotor blade angle be adjusted. 风机达到额定转速之后，最多一分钟之内挡板门就应该完全打开，这个过程应该是自动控制完 成的，此后只需调整叶片角度。 3.1.3. adjustment 调节调节 the values set during assembly must not be changed without good cause. 在安装时没有正当理由是不允许改变设定值的 important/重点：重点： altering the set values for no reason may seriously damage the fan. be extremely careful when adjusting screens, chokes and stopcocks).do not operate the hand wheel of the actuator unless the oil supply unit is switched on. 无故改变设定值会对风机造成严重损害。当调节挡板门、隔绝门、油缸时应非常小心。除非已经 启动供油，否则不要操作执行器的手轮。 the following settings of the fan and its components must be checked: 以下设置和风机元件都应该认真检查： actual values to be inserted/实际指标有待实际指标有待加加入入 rotor-blade angle/叶片角度叶片角度 position closed 全关位置 positionopen 全开位置 control-panel display（dcs）控制面板显示0%100% local degree indicator 现场刻度指示- + impeller gap/叶轮间隙叶轮间隙 min/最小max/最大 rotor blades/housing 动叶片/机壳0%100% rotor blades/impeller hub 动叶片/轮毂 torque settings/扭扭矩设定矩设定 for further torque settings see sectional drawing其它扭矩设定详见组装图 rotor blade/blade shaft 叶片/叶片轴ma = nm main bearing/fan housing 主轴承/机壳ma = nm coupling hub/drive wheel 联轴器/驱动轮ma = nm instructions on tightening screws:螺栓拧紧指示螺栓拧紧指示: apply mos2paste/涂 mos2润滑剂在 - to the thread/螺纹上 -beneath the head/螺栓头接触面 专业 专心 专注 专业资料 参考首选 tighten with/拧紧用 - a calibrated torque wrench/校准扭矩扳手 - to the specified torque setting 扭矩设定的指定 hydraulic assembly, shaft/impeller 液压组装，轴液压组装，轴/叶轮叶轮 stip-on dimension 轴头尺寸a = mm required oil pressure in hydraulic nut 液压螺母需要的油压bar permissible oil pressure in hydraulic nut 液压螺母许用油压bar permissible oil pressure in fitting gap 组装间隙许用油压bar fits / bearing seating 轴承座轴承座配合配合 shaft 轴housing 孔 cylindrical-roller bearing,fixed-bearing side 圆柱滚子轴承，固定端 angular-contact ball race 角接触球轴承 cylindrical-roller bearing, movable- bearing side 圆柱滚子轴承，浮动端 bearing descriptions 轴承种类轴承种类 these vary from one manufacturer to another 供货商不同种类名称也不同 cylindrical-roller bearing (movable bearing)圆柱滚子轴承（浮动支撑） cylindrical-roller bearing (fixed bearing) 圆柱滚子轴承（固定轴承） torsionally-twisted piston ring 角环 angular-contact ball race角接触球轴承 3.2. prior to test run/ commissioning/ overhauls 试运转前期试运转前期/试运转试运转/检查检查 danger/危险：危险： when operating the fan or carrying out any work on the fan, comply with safety instructions as specified by din en iso 12100 and local accident-prevention regulations. 在运行风机或对风机进行任何操作时，须遵照din en iso12100的安全条款及所在地的事故预防 规章。 danger危险：危险： 专业 专心 专注 专业资料 参考首选 touching rotating or hot fan components can cause serious injury. do not operate the fan unless the following essential protective devices are in place: 接触正在运转或高温下工作的风机设备会造成重大伤害。在没有下列保护设备的情况下，禁止运 行风机： shaft protection/护轴管 coupling guard/联轴器护罩 thermal and acoustic insulation/隔热和消音层 close the access and inspection openings. 关闭用于检查和验收的人孔门。 important/重点：重点： the following work must be carried out before commissioning and inspections: 下列工作在运转和检查之前必须实施： remove all preservatives/移走所有防腐剂 gap measurement according to the sectional drawing and the values given on the “installation data” sheet 根据组装图和组装数据清单的设定值进行间隙测量 - external gap (gap between rotor blades and outer housing of the rotor blade which produces the smallest gap when the impeller is turned) 外部间隙（叶轮旋转时，机壳和叶片之间的最小间隙） - hub gap (gap between rotor blades and impeller hub) 轮毂的间隙（叶片与轮毂之间的间隙） important/重点：重点： if an impeller blade touches the housing it can cause serious damage. a too small gap between rotor blades and impeller can lead to problems of adjustment. after replacing the rotor or blades please measure necessarily all a.m. gaps and compare them with the values on the “installation data” sheet 若有动叶片与机壳有接触干涉，会造成严重损坏。动叶片与轮毂之间的间隙太小会导致调节故障， 更换动叶片之后，要测量所有必要间隙，满足装配数据清单的设定值之要求。 make sure that all screws/bolts are tightened and secured. check all pipes, flanges and screw connections for leakages 确认所有螺栓都拧紧可靠，检查所有油管、法兰的螺栓连接是否存在泄漏 fill the oil reservoir with the specified oil and flush the oil system. check the function of the oil supply unit. see “lubrication” 按规定冲洗油管路系统，并给油箱注满油，测试油站功能，详见“润滑部分” test the rotor blade adjustment function 测试动叶调节功能 with the control-oil pump switched on move the rotor blades to their limit positions 开启控制油泵，调节动叶到极限位置 test the emergency-off switch/测试紧急断电开关 check that no tools or foreign parts have been left in the fan or in the suction or discharge pipes 专业 专心 专注 专业资料 参考首选 检查确认没有工具或其它异物遗留在风机内及进出口管道中。 important/重点：重点： objects sucked into the fan can cause serious damage. remove all tools and foreign parts from the fan flow chamber and from the suction and discharge pipes 风机若吸入异物会造成严重损坏，确认清除所有遗留在风机内及进出口管道中的工具和异物 if the drive motor has been disconnected from the power supply, check the direction of rotation before coupling it with the fan 若驱动电机还未连接电源，连接风机与电机之前检查电机旋转方向是否正确 check coupling and drive motor as per the instructions of the manufacturer 按照制造厂商的每一条说明检查联轴器和驱动电机及其联接要求 test the interlock system and display instruments when they are in position to make sure they are functioning properly. see interlock diagram 系统联锁控制和显示仪器就位后，进行检查测试，确保功能正常，详见“联锁 控制图表” 3.3. test run 试运行试运行 after assembly a test run is carried out. in test runs it is common for not all the interlock points to have been correctly switched. it is therefore important to pay close attention to the readings 组装之后，应开始试运行，试运行中，并非所有的联锁控制点都能正确切换，因此要高度重视显 示数据。 important/重点：重点： in test runs it must be possible to shut down the drive motor very quickly. make sure the emergency-off switch is working properly 试运行中能迅速关掉驱动电机是相当重要的。 确保紧急断电开关工作正常。 danger/危险：危险： the possibility of some residual danger when the fan is first started up cannot be ruled out. ensure that the necessary personnel are available in the vicinity of the fan 风机第一次运转时，不能排除有一些故障发生，确保风机附近有必要的相关人员。 the following has to be observed during the test run 在试运行中应密切警示下列事项： while the fan accelerates check that it is running smoothly 风机加速时确认它运行平稳 record bearing temperatures and vibration readings at 5-minute intervals 每 5 分钟记录一次轴承温度与振动数据 when the bearing temperatures have reached a constant value, slowly open the rotor blades until the motor current consumption reaches 100%. once the bearing temperatures have reached a constant value it is sufficient to record the readings at 15-minute intervals. 当轴承温度达到稳定值，再缓缓打开动叶片直至电流功率到 100%额定值，之 后当轴承温度再次达到稳定值时，每间隔 15 分钟记录一次显示数据 专业 专心 专注 专业资料 参考首选 after a 3-hour test run switch off the drive motor with the rotor blades closed and secure it against being inadvertently switched on again 试运转 3 小时之后，切断电机的电源，同时关闭动叶，并防止无意间开启 examine the fan and rectify any irregularities detected 检查并纠正所发现的任何非正常情况 3.4. starting up 启动启动 starting up the oil-supply unit. see accessories开启油站，详见“附件” switch on cooling and sealing-air fan(s) (if present)开启密封冷却风机（如有） switch on the oil pump/打开油泵 admit cooling water to the oil cooler/让冷却水进入油冷装置 move rotor blades to closed position/将动叶片调到“关闭”(0%)位 make sure the interlock conditions are met/确认联锁控制正常 close shut-off valve on the discharge side/关闭压力侧流道挡板门 release safety brake (if present)/放开安全锁刹装置（如有） switch on main motor/启动主电机 after 1 minute open shut-off valves in pipelines (if present) 1 分钟内打开风道系统各挡板门（如有） move the rotor blades to the desired position/将动叶片调到所需位置 important/重点：重点： operating the fan for an extended period with no volume flow can lead to unacceptable overheating. the shut-off valves must therefore be opened in good time 风机长期在过低流量运行会导致无法承受的过高温度，因此，挡板门要在适当的时候打开。 3.5. shutting down 关机关机 move rotor blades to closed (0%) position 将动叶片平稳调到“关闭”(0%)位 switch off main motor/关闭主电机 apply safety brake (if present)/启动锁刹装置（如有） switch off oil-supply unit/关闭油站 stop cooling water supply to the oil cooler 停止冷却水进入冷却器 close the shut-off valves/关掉跳机闸 专业 专心 专注 专业资料 参考首选 switch off cooling and sealing-air fan(s) (if present) 关闭密封冷却风机（如有） important/重点：重点： corrosion (e.g. due to cooling flue gas) can cause important components to fail. when shutting down make sure no flue gas remains in the fan. 腐蚀介质（例如冷却后的烟气）会导致一些重要元件在运行中出现故障，停机时要确认没有废气 留在风机内。 3.6. monitoring during operation 运行监控运行监控 the fan is monitored automatically in daily intervals via the interlock diagram readings 风机每隔一段时间就需通过联锁控制图表中的要求进行自动化监控。 additional monitoring shall be done in weekly intervals for 其余下列监控应该每周做一次： noise, vibration/噪音、振动 condition of instruments and sensors/设备及传感器工作情况 oil level/油站 degree of oil filter clogging/油过滤器堵塞情况 tightness of fan and expansion joints/风机和膨胀节紧密程度 tightness of components in contact with oil 接触油的零部件的密封情况 degree of contamination of gratings of sealing and cooling-air fans (if present) and relief lines 密封冷却风机入口栅栏和主要管路的污染程度 the implementation and documentation of condition checks lead to the following advantages 适时检查风机有如下好处： malfunctions can be detected in good time/能及时发现故障 the causes of malfunctions are easier to ascertain 更加容易确定故障的原因 effective measures to be taken during stoppages can be determined 停机时更准确更有效率的测量检查 the reliability and durability of the fan are increased 增强风机的可靠性和耐久性