ZGM123G-Ⅲ型中速辊式磨煤机使用和维护说明书.doc

印度GMR卡玛朗加能源有限公司4350MW电站工程文件编号: KTPP-0-BPEG-DOC-WI-0001 Rev.A ZGM123G-型中速辊式磨煤机使用和维护说明书OPERATION AND MAINTENANCE INSTRUCTIONSFOR ZGM123G- ROLLER MILL INDIA GMR 4350MW KAMALANGA THERMAL POWER PROJECT 北京电力设备总厂 BEIJING POWER EQUIPMENT GROUP2011年1月December 2010地址：北京市房山区良乡昊天大街12号 邮编：102401 Add：No.12, Haotian Street, Liangxiang, Fangshan District, Beijing, China Postcode: 102401目 录CONTENTS前言(1)Foreword(1)第一篇 磨煤机使用和操作说明(2)Chapter 1 Operation instructions(2)1.代号和技术数据.(3)1. Symbol and technical data.(3)2.工作原理.(4)2. Grinding principle of the ZGM123G- mill(4)3.部件介绍.(6)3. Function description of the subassemblies.(6)4.使用、操作要求.(15)4. Request of operation.(15)5.启、停说明.(21)5. Start-up and putting out operation.(21)6.启动前和运行检查.(27)6. Inspecting prior to start-up and preservice operation.(27)7.运行故障及处理.(30)7. Faults and remedy.(30)第二篇 磨煤机维护、检修说明.(35)Chapter 2 Maintenance and Repair Instructions(35)1.维护、检修注意事项 .(36)1. Maintenance, inspection and repair .(36)2.停机时的保养与维护内容(37)2. Maintenance and repair measures at coal mill standstills(37)3.维护、检修要求.(44)3. Requirement of maintenance and repair.(44)4.碾磨件及内部零部件拆卸与安装.(50)4. Dismantling and mounting of the mill internal elements and the grinding parts(50)5.内部部件的维修.(53)5. Repair of mill internal component.(53)第三篇 盘车装置使用和维护说明(63)Chapter 3 Operating and Maintenance Instructions for Turning Gear (63)1.技术要求(64)1. Technical data.(64)2.使用要求(64)2. Operation request(64)3.安装与调整(66)3. Assembly and adjust(66)4.维护保养(66)4. Maintenance(66)第四篇 磨煤机安装与调试导则(68)Chapter 4 Mounting and Trial Run Guide for ZGM Mill(68)1.安装事宜(69)1. General instructions(69)2.安装说明(70)2. Mounting instructions(70)3.启动前的调试(82)3. Trial running of mill(82)附录：Appendix：附表1: ZGM123G-型中速辊式磨煤机大件起吊单重重量表Appendix 1: Weight of main parts of ZGM123 mill附表2: ZGM123G-型中速辊式磨煤机润滑油脂一览表Appendix 2: Lubrication oil and greaseZGM123G-型中速辊式磨煤机使用和维护说明书 O&M INSTRUCTIONS FOR ZGM123G- ROLLER MILL前言Foreword感谢您选用了我厂的ZGM123G-型中速辊式磨煤机，为了使您更好地了解设备，使设备更好地为您的系统服务，我们编写了这本使用说明书，希望能给您以帮助，并真诚地希望您对其中的不足之处给予指出。Thank you for selecting our ZGM123G- mill. To be able to operate the mill properly and serve for your system successfully, this operation manual is necessary for you to read before operating the mill. In the meantime, your comments are of great value.本使用说明书是根据中速辊式磨煤机的特点和现场运行情况编写的，其中对磨煤机的运行、检查、维护、检修要求大部分是针对磨煤机易出问题的环节和总结现场出现的问题而提出的，所以下面提出的要求，用户在使用过程中请务必遵守：This manual has been revised project by project. If you have any comments or question, dont hesitate to contact our service engineer at site or service department. Generally speaking, the following regulations shall be observed during operation, inspection and maintenance.磨煤机运行应严格按照运行要求，不能违章操作。As for operation of the mill, the stipulation about installation, commissioning and maintenance shall be followed. 必须保证一次风量，一次风量的测量装置要定期标定，这对磨煤机运行极为重要。The sufficient primary air is essential to the steady operation. Therefore the measurement of the hot primary air shall be updated regularly.定期对磨煤机检查、维护，绝不允许连续数千小时不停磨、不检查、不间断地运行。As to the maintenance of the mill, the routine inspection shall be performed.一次风入口隔绝门至关重要，没有严密的隔绝门就无法进入磨内检查、维护和检修。It is important that isolating values will be installed at the inlet of hot primary air .出粉管上要有隔绝门。The isolating values shall be operation, which installed at the outlet of coal powder.必须为检查、维护、检修工作创造必要的条件。It is important that suppling condition to check, maintenance and repaire.应配置单独的密封风系统，不要直接采用冷一次风作为密封风。Regarding the sealing air system, the independent sealing air system shall be equipped. The hot primary air shall not be used as sealing air.- 1 -第一篇 磨煤机使用和操作说明Chapter 1 OPERATION INSTRUCTIONS - 2 -1. 代号和技术数据1. Symbol And Technical Data1.1 代号 Z G M 123 G - 高转速 分N、G两个型号， N为中型，G为大型。 磨环滚道工作半径（cm） 磨煤机 辊式 中速1.1 Symbol Z G M 123 G - High speed N、G type, N - Normal，G - Greatened。 Average radius of Grinding track （cm） Mill Grinding Roller typeMedium speed1.2 技术数据1.2.1 煤种范围 煤种 烟煤、贫煤、部分无烟煤和褐煤 发热量 1631MJ/kg 表面水份 18% 可磨性系数 HGI=4080(哈氏) 可燃质挥发份 1640% 原煤颗粒 040mm 煤粉细度 R90=1040%1.2 Technical Data1.2.1 Data about coal Coal type fat coal，poor coal，some anthracite and black lignite Calorific value 1631MJ/kg Moisture（exterior） 18% Grind ability HGI=4080 Volatile matter 1640% Grain size 040mm Coal powder fineness R90=1040%1.2.2 磨煤机技术数据 序号项目单位ZGM123G-1保证出力（铭牌出力）(R90=13.9%,HGI=45, W=11.9%)t/h73.532减速机额定功率kW7703电动机额定功率kW9004电动机电压kV6.65电动机转速r/min9906电动机旋转方向逆时针(正对电机输出轴)7磨煤机磨盘转速r/min30.98磨煤机旋转方向顺时针 （俯视）9通风阻力（保证出力）Pa73401.2.2 Technical data of millNo.ItemUnitZGM123G- 1Guaranteed output (R90=13.9%,HGI=45, W=11.9%)t/h73.532Rate power of gearboxkW7703Rate power of motorkW9004Voltage of motorkV6.65Rated speed of the motorr/min9906Direction of rotation of the motorCounter-clockwise(front view of output shaft)7Rated speed of the millr/min30.98Direction of rotation of the millClockwise (vertical view )9Windage （Guaranteed output）Pa73402. 工作原理2. Grinding principle of the ZGM123G- millZGM123G-型磨煤机是一种中速辊盘式磨煤机，其碾磨部分是由转动的磨环和三个沿磨环滚动的固定且可自转的磨辊组成。需粉磨的原煤从磨煤机的中央落煤管落到磨环上，旋转磨环借助于离心力将原煤运动至碾磨滚道上，通过磨辊进行碾磨。三个磨辊沿圆周方向均布于磨盘滚道上，碾磨力则由液压加载系统产生，通过静定的三点系统，碾磨力均匀作用至三个磨辊上，这个力经磨环、磨辊、压架、拉杆、传动盘、减速机、液压缸后通过底板传至基础（见图11）。原煤的碾磨和干燥同时进行，一次风通过喷嘴环均匀进入磨环周围，将经过碾磨从磨环上切向甩出的煤粉混合物烘干并输送至磨煤机上部的分离器，在分离器中进行分离，粗粉被分离出来返回磨环重磨，合格的细粉被热一次风带出分离器。ZGM123G- mill is a vertical mill with three grinding rollers and one grinding track. A grinding table rotates round a vertical axis in driven by a planetary gearbox. The three grinding rollers, mounted in fixed position, are passed down on the table under hydraulic loading. Raw coal enters through the center of the mill and is deposited on the grinding table. Centrifugal force feeds the coal radially outward where it is ground between the roller tyres and grinding track. The grinding force, is statically determined by three grinding rollers, which is generated by hydraulic loading. The transfer loop diagram of grinding force is shown in Fig1-1. It starts from loading, to grinding rollers, grinding track, towards the foundation. The pulverized coal is flowed by centrifuged force into the zone over the nozzle ring surrounding the table, where the coal particles are swept upwards by the stream of hot primary air into the classifier.The intimate contact with the hot primary air causes the moisture contaminated in the coal to evaporate spontaneously. The oversize particles rejected by the classifier fall back onto the grinding table for further grinding. The fine particles, i.e. finished product, are carried out of the classifier with the air. 图11 磨煤机加载传递系统“受力状态图”Fig1-1 The transfer loop of grinding force难以粉碎且一次风吹不起的较重石子煤、黄铁矿、铁块等通过喷嘴环落到一次风室，被刮板刮进排渣箱，由人工定期清理，清除渣料的过程在磨运行期间也能进行（见图12）。Pyrites and tramp iron that cannot be carried upward by the primary air drop down through the ring and into the primary air plenum chamber. Revolving scraper blades attached to the bottom of the grinding table push this foreign material outward to an external disposal system(Fig1-2). 图12 磨煤机“沸腾区”示意图 (Fig1-2)Fig1-2 Slagging discharge schematic ZGM123G-型磨煤机采用鼠笼型异步电动机驱动。通过立式伞齿轮行星齿轮减速机传递磨盘力矩。减速机还同时承受因上部重量和碾磨加载力所造成的水平与垂直负荷。 为减速机配套的润滑油站用来过滤、冷却减速机内的齿轮油，以确保减速机内部件的良好润滑状态。 配套的高压油泵站在运行时通过加载油缸对磨煤机进行加载和升降磨辊。通常一台磨配有一台密封风机，也可几台磨(一台炉)共用一台密封风机，密封风用于磨煤机传动盘处、机壳拉杆密封处和磨辊处的密封。维修磨煤机时，在电动机的尾部连接盘车装置。The ZGM123G- mill is to be driven by a squirrel-cage induction motor. The torque of grinding table is drived by the vertical bevel-planetary gearbox which also stands the horizontal and vertical load caused by upper parts weight and grinding load.The lubrications unit of the gearbox is used filtrating/cooling the oil inside the gearbox. In order to insure a good lubricant condition for the subassemblies inside gearbox.The hydraulic unit provide grinding load，lift or put down the rollers by three tensioning cylinders.Commonly one sealing fan is provided for one mill, optionally one sealing fan is available for several mills（for one boiler）. Sealing air was used for sealing at grinding table carrier/pivoting bearing of tie rod /rollers. When mill is needed for maintenance, the turning gear should be connected to mill motor tail.3. 部件介绍3. Functional description of the subassemblies3.1台板基础 台板基础主要包括齿轮箱基础台板、电动机基础台板、拉杆台板、盘车装置台板、地脚螺栓盒和地脚螺栓等。各台板调整固定后，二次灌浆时埋入基础。齿轮箱基础台板、电动机基础台板、拉杆台板，通过地脚螺栓固定在基础中，盘车装置台板通过地锚固定在基础中。稀油润滑站和高压油站通过膨胀螺栓固定在基础上。3.1 Foundation anchoring partsFoundation anchoring parts include the gearbox plate/the motor plate/the anchoring boxes/the tension rods seat/the turning gear. Anchoring boxes for fastening of gearbox plate, and motor frame have been aligned prior to concrete work and connected positively to the reinforcement resp. to the foundation plate. 3.2 主电动机 主电动机为高启动转矩异步电动机，转速为990转/分钟。磨煤机启动前，先要检查旋转方向。有关详细内容参见电动机制造厂家高启动转矩异步电动机使用说明书。3.2 Main motor The motor is an asynchronous one with high starting torque. The rated speed is 990r/min. Before the mill starting, the rotation direction should be checked. If more information required, please consult the instruction book of the High Start Torque Asynchronous Motor from the manufacturer.3.3联轴器电动机与减速机之间用联轴器传递功率，磨煤机启动前，首先要检查旋转方向。3.3 Coupling The power is transferred through Coupling from motor to gearbox, the direction of rotation must be inspected before mill operating.3.4减速机减速机为立式伞齿轮行星减速机，减速机既传递磨盘的转矩又承担磨辊加载力及磨煤机振动产生的冲击力。详细信息见减速机使用说明书。3.4 Gearbox The vertical mill drive is a bevel gear planetary gear unit with triple power transmission path for driving a vertical mill. The power is transferred through gearbox from motor to Grinding table carrier. High axial forces are generated during the milling process have to be lead into the foundation via the gear unit housing. If more information required, please consult the instruction book of gearbox.3.5机座机座主要承受磨煤机上部机壳和分离器等大型部件的重量和磨煤机工作中通过机壳导向装置传到机壳上的水平方向的扭转动载荷。机座下部容纳减速机，上部安装机座密封装置，侧面小口供安装排渣箱。3.5 Bottom housingThe bottom housing consists of the Base and the waste box, including the following main functions: accommodation of the ring fastening the base bottom seal and accommodation of the gearbox. It supports the great subassemblies for example the Casing and the Classifier etc. It still endures the torque of level direction acted on the Casing from the guiding element in mill operating. Rejected box will be installed on the side of the base. 3.6排渣箱排渣箱包括液压滑板落渣门和排渣箱体。液压滑板落渣门装在机座上，液压滑板落渣门用于控制一次风室与排渣箱之间石子煤排放口的隔绝。落渣门上的弹簧给门板施加压紧力，保持落渣门的密封性。液压滑板落渣门设有开、关位置指示。如果采用上下两道液压滑板落渣门，两道门应该互相联锁。3.6 Reject boxReject box includes hydraulic door and rejected box body.The hydraulic door can isolate hot air room and reject box. The pressure of springs inside the door can insure the sealing of the hydraulic door. The sealing between the hydraulic door and cylinders uses a filling graphite box. There are location indicators on the hydraulic door. If there are two hydraulic doors, they should be interlocking operated. 3.7机座密封装置正压运行磨煤机的机座密封装置由下连接环、上连接环、上密封环、下密封环、碳精密封环和弹簧等组成。整个装置通过过渡环安装在机座顶板上。密封壳体下部的两圈石墨密封环分为22个扇形段，靠弹簧箍紧在传动盘上形成浮动式密封，以防止安装和运行中轴的偏心所引起的损坏。采用石墨材料制成的密封环，具有密封效果好、耐磨损等优点。此外，采用石墨密封环有利于现场维修更换，在一定范围内有自动补偿磨损的作用。磨煤机正压运行时，为确保此处的密封作用，必须保证密封风室内密封风压高于一次风室内一次风压P2kPa，该压差值是受监控的。密封风绝大部分吹入一次风室，仅极少部分漏到大气中，这样就起到了防止一次风室中一次风和粉尘向外泄漏的作用，改善磨煤机周围环境。负压运行磨煤机的机座密封装置采用迷宫密封。3.7 Base sealing equipmentFor positive pressure running mill, Base sealing equipment includes up-connection flange, down-connection flange, up-sealing loop, down-sealing loop, graphite sealing loop and spring etc. The whole base sealing equipment will be installed on the top board of the bottom housing. The graphite ring consists of 22 segments, which are encircled with a spring, and form a floating seal. The life of the graphite seal ring is long and it has a good sealing effect. It can be compensated itself. And its replacement and maintenance is easy. Because the mill is running on the positive pressure, for the reliable sealing effect, the pressure of the sealing air must be higher than hot air, P2kPa, the value is under control. The most of the sealing air enter the hot air room, only little leak into the atmosphere. Sealing air prevents hot air and powder leaking, so that the surroundings of mills are improved. If the coal mill runs in negative pressure circumstance, the base sealing equipment uses labyrinth gland.3.8传动盘及刮板装置传动盘与减速机采用刚性连接，用来传递扭矩，它装在减速机的输出传动法兰上，通过24条M48的螺栓和输出传动法兰紧固，上部装有磨盘。磨运行时，减速机的输出力矩通过输出传动法兰和传动盘接触面间的摩擦力传递给传动盘，传动盘通过上部三个传动销带动磨盘转动。传动盘除了传递扭矩外，同时承受上部的加载力和部件重量，并通过减速机的推力瓦把力传递给减速机机体和磨煤机基础。传动盘上对称装有两个刮板装置，随传动盘转动。刮板和一次风室底部正常间隙是610毫米，当刮板磨损后，间隙变大，可通过刮板的紧固螺栓调整此间隙。3.8 Grinding table carrier and Scraper The grinding table carrier, for the torsion-proof and rigid connection to the output flange of the gearbox with 24 M48 bolts, transfers the torque. Grinding table turns driven by the grinding table carrier with 3 transmitted pins. At one time, the grinding table carrier must support the load force and the weight of parts inside the mill. Two scrapers for the waste are screwed to the Grinding table carrier, running with the grinding table carrier. The normal clearance between the scraper to the bottom of hot air house is 610 mm. When it became greater for wear, the clearance can be adjusted through bolt is tightened.3.9磨环及喷嘴环磨环及喷嘴环由旋转部分和静止部分组成，旋转部分包括磨环托盘、衬板（12件）、锥形罩等组成，这些部件在传动盘的带动下转动。喷嘴叶片与磨环托盘连成一体，跟随磨盘旋转。静止部分固定在机壳上。旋转部分与静止部分的间隙见安装图册。衬板嵌在磨环托盘内，通过楔形螺栓紧固。（注意！衬板与磨环托盘的接合面、全部螺栓的螺纹部分要涂MoS2脂。）锥形盖板的作用是把从落煤管落下的煤均匀布到磨盘上，并可防止水和煤漏到传动盘下面的空间内。3.9 Grinding table and nozzle ring The grinding table and nozzle ring is composed of rotary parts and static parts. The rotary parts consists of the supporting tray, segment (12 pieces), taper cover etc. running with the grinding table carrier. The nozzle lamina connect together with the supporting tray revolves with the grinding table. The static parts are fixed on the mill housing. The clearance between rotary parts and static parts refers to DIAGRAM FOR ZGM123G- COAL MILL.The inserted segments in the supporting tray are fixed with the cuniform bolt. (Note: MoS2 must be sprayed on the joint face between the segment to supporting tray and all of screw thread.)A taper cover on the supporting tray serves for distributing the raw material and prevents dust and water from penetrating into the space below.3.10磨辊装置磨辊装置由辊架、辊轴、辊套、辊芯、轴承、油封等组成。磨辊位于磨盘和压架之间，倾斜15，由压架定位。使用过程中辊套是单侧磨损，磨损达一定深度后可翻身使用，以合理利用材料。磨辊是在较高温度下运行，其内腔的油温较高（可达120），为保证轴承良好使用，润滑采用高粘度、高粘度指数、高温稳定性良好的合成烃SHC高温轴承齿轮油，每个磨辊注油36升，油密封由两道油封完成，第一道油封密封外部环境，第二道油封密封内部润滑油，两道油封之间填有耐温较高的润滑脂，用来润滑第一道油封的唇口。磨辊内有大小两种轴承，大轴承是圆柱滚子轴承，小轴承是双列向心球面滚子轴承，两个轴承分别承受磨辊的径向力和轴向力。辊架的作用是把通过铰轴的加载力传给磨辊，它通过磨辊密封风管与密封风系统连接，密封风通过辊架内腔流向磨辊的油封外部和辊架间的空气密封环，在此形成清洁的环形密封，防止煤粉进入而损坏油封，同时又有降低磨辊温度的作用。在辊架处的辊轴端部装有呼吸器，它使密封风和内部油腔相通，消除不同温度和不同压力下产生的不良影响，以保证油腔内的正常气压和良好环境。辊轴上设有测量油位探测孔，用后拧上丝堵。3.10 Grinding rollerThe grinding roller consists of the thrust piece, roller shaft, roller tyre, hub, bearing, and rotary shaft seal etc.The grinding roller is located between the grinding table and the frame fixed by the frame, the incline angle is 15. The tyre is shaped symmetrically in order that it can be rotated in a determined condition of wear for the purpose of an optimum utilization. Since the life of rolling bearing is decisively influenced by the lubricating condition, and operating in the area of high temperature (120), SHC gear oils of highly viscosity for highly temperature must be selected. The max. filling volume of each roller is 36 l. The oils is enclosed by two seals, the first seal encloses outside, the second seal encloses inside oils, the free space between two seal rings is filled with grease for lubricate the lip of first seal ring.The grinding roller accommodates two bearing, the bigger cylindrical roller bearing ensures radial load and the self-aligning rolle