钢灰仓说明书.doc

GHC-8型（8m）钢灰仓。2三八国际妇女节装 安装、运行、和维护使用说明书印度尼西亚拉布湾2300MW燃煤电厂专用四川战旗机械制造有限公司二00八年四月目 录一、用途1二、设计说明及设备规范1三、工作原理1四、安装方法2五、控制系统和操作要求5六、操作步骤6七、可能出现的故障及排除方法6八、售后服务及技术支持7一、用途 钢灰仓是一种贮灰和待运装置，适用于燃煤电厂锅炉动力除灰系统，利用运灰车或皮带机等运输工具或输送设备将飞灰渣外运，并加以综合利用。 钢灰仓设备结构简单，操作方便。钢灰仓下部采用双轴搅拌机和汽车散装机,配有密封装置，启闭灵活，密封性能好，保证了工作环境的清洁，减轻了工人的劳动强度。二、设计说明及设备规范 1灰仓依据技术协议书进行设计及制作，其有效容积不小于2500m3；仓体采用10钢板制作；支架有足够的强度及刚度，满足现场工况要求；灰仓配有空气炮防堵装置和料位计等装置。 2灰仓设备规范2.1型号：GHC-82.2直径：80002.3容积：2500m3/台2.4空气炮型号：CMP-150型2.5气化箱型号：QHX200型三、工作原理 1灰仓是飞灰贮存装置。灰仓内灰渣经过一定时间后（可根据贮存情况而定）即可卸灰外运。卸完灰后及时清理卸料装置及装车散落灰渣，进入下一循环。 2灰仓仓体上部为圆柱形筒体，下部为圆锥形。仓体底端设有双轴搅拌机和汽车散装机；灰仓顶部设置平台，用以支撑进料装置、料位计压力真空释放阀、布袋除尘器及其它附件，并兼做巡视检查维护用平台；仓体装有防拱空气炮，在卸灰不畅时，协助卸灰。四、安装方法安装总则 灰仓为一套功能完整的设备，其主体结构为钢结构件，其中含电气控制装置及设备，卸灰及卸料辅助设备等。 1钢结构安装技术要求 1.1一般规定 1.1.1钢结构安装应按施工组织设计进行。安装程序必须保证结构的稳定性和不导致永久性变形。 1.1.2安装前，应按构件明细表核对进场的构件，查验工地施工图册。 1.1.3钢结构安装过程中，组装、焊接和涂装等工序的施工均应符合有关规定。 1.1.4钢结构在运输、存放和安装过程中损坏的涂层以及安装连接部位应补涂。结构面层涂装应在安装完成后进行。 1.1.5设计要求对钢机构进行结构试验时，试验应符合相应的设计文件要求。 1.1.6钢结构吊装前应清除其表面上的油污、冰雪、泥沙和灰尘等杂物。 1.1.7吊车架的受拉翼缘或吊车衔架的受拉弦杆上不得焊接悬挂物和卡具等。 1.2基础和支承面 1.2.1钢结构位于安装前应对灰仓的定位轴线、基础轴线和标高等进行检查。并应符合下列规定。 1.2.1.1基础混凝土强度达到设计要求； 1.2.1.2基础周围回填完毕； 1.2.1.3基础的轴线标志和标高基准点准确、齐全。 1.2.2基础顶面直接作为柱地支承面和基础顶面预埋钢板或支座作为柱地支承面时，其支承面、地脚螺栓（锚栓）地允许偏差应符合下表地规定。支承面、地脚螺栓（锚栓）地允许偏差（）项目允许偏差支承面标高3.0水平度1/10001.3钢结构运输和存放1.3.1钢结构应根据钢结构的安装顺序，分单元成套供应。1.3.2运输钢构件时，应根据钢构件的长度、重量选用车辆，钢构件再运输车辆上地支点、两端伸出的长度及绑扎方法均应保证钢构件不产生变形、不损伤涂层。1.3.3钢构件存放场地应平整坚实、无积水。钢构件应按种类、型号、安装顺序分区存放；钢构件底层垫枕应有足够的支承面，并应防止支点下沉。相同型号的钢构件叠放时，各层钢构件地支点应在同一垂直线，并应防止钢构件被压坏和变形。 1.4安装和校正 1.4.1钢结构安装前，应对钢构件的质量进行检查。钢构件的变形、缺陷超出允许偏差时，应进行处理。 1.4.2钢结构安装的测量和校正，应根据工程特点编制相应地工艺。厚钢板和异种钢板的焊接、高强度螺栓安装、栓钉焊和负温度下施工等主要工艺，应在安装前进行工艺试验，编制相应的施工工艺。 1.4.3钢结构采用扩大拼装单元进行安装时，对容易变形的钢构件应进行强度和稳定型验算，必要时应采取加固措施。钢构件采用综合安装时，应划分成若干独立单元。每一单元的全部钢构件安装完毕后，应形成空间刚度单元。 1.4.4灰仓钢结构的柱、梁、平台、支撑等主要构件安装就位后，应立即进行校正、固定。当天安装的钢构件应形成稳定的空间体系。 1.4.5钢结构安装、校正时，应根据风力、温差、日照等外界环境和焊接变形等因素的影响，采取相应的调整措施。 1.4.6利用安装好的钢结构吊装其它构件和设备时，应征得我公司技术部门同意，并进行验算，采取相应措施。 1.4.7设计要求顶紧的节点，接触面应 70%的面紧贴。用0.3厚塞尺检查，可插入的面积之和不得大于接触顶紧总面积的30%。 1.5连接和固定 1.5.1钢构件的连接接头，应经检查合格后方可紧固或焊接。 1.5.2钢构件拼装前，应清除飞边、毛刺、焊接飞溅物。摩擦面应保持干燥、清洁，不得在雨中作业。 1.6安装偏差检测 1.6.1钢结构安装偏差的检测，应在结构形成空间刚度单元并连接固定后进行。 1.6.2构件安装的允许偏差应符合下表的规定。钢柱安装的允许偏差（）项 目允许偏差柱脚底座中心线对定位轴线的偏移5.0挠曲矢高H 100015.0柱轴线垂直度H10m10.0H10mH/100025钢平台、钢梯和防护栏杆安装的允许偏差（mm）项 目允许偏差平台标高10.0平台梁水平度1/100020.0平台支柱垂直度H/100015.0承重平台梁侧向弯曲1/100010.0承重平台梁垂直度h/100015.0栏杆高度10.0栏杆立柱间距10.0直梯垂直度1/100015.02电气设备安装技术要求 见随机提供的电控箱使用说明书3设备安装 设备安装前，应仔细阅读有关材料，其中包括工地施工图册和安装使用说明书。一般情况下，按如下次序安装：立柱拉撑仓体上下平台围栏扶梯卸料装置管路系统附件（主要包括：料位计、空气炮等）整体修整（含补涂油漆）充水试漏及基础沉降检验最后修整调试待运。 特别注意：在安装仓体时，首先应在地面倒锥预组装，在保证错变量和对接焊缝错开符合安装技术要求的情况下，对纵向焊缝按工地施工图册要求焊接。而环向焊缝则根据现场启吊设备的启吊能力确定一层或几层焊接在一起，同时吊装。吊装时，要对筒体适当加强以保证起吊时不致于出现有害变形，在一般情况下，需首先安装与立柱对接的仓体段。五、控制系统和操作要求 灰仓在进料以前，操作者应先启动双轴搅拌机系统，操作面板上指示灯将提示操作者。此时即可进料。出现卸渣困难时，可启动一台或全部空气炮，迫使结渣脱落。六、操作步骤 1运行前的准备工作（1）通电前必须仔细检查各元件是否安装牢固，接线是否正确，端子是否松动，外部连线是否正确可靠；（2）合上电源开关，电源指示灯亮；（3）启动下部双轴搅拌机（同时调节进水量到适当流量）或者汽车散装机；（4）调整气控箱内减压阀，使进入气化系统的空气压力为0.50.8Mpa。 2操作步骤（1）进料前先启动双轴双轴搅拌机；（2）排灰卸料中，如有困难，可启动一只或全部空气炮系统，防止起拱堵塞，迫使灰渣脱落；（3）排灰完毕，停机待用时，打开水阀将双轴搅拌机内叶片及内壁的残留灰渣冲洗干净后，即可进入运行状态。3运行注意事项 卸灰出力大小应视运输工具或输送设备的能力而定。七、可能出现的故障及排除方法出现的故障排除故障方法1灰料起拱2排料不畅1空气炮破拱是否正常，检修。2双轴搅拌机运转是否正常，检修。八、售后服务及技术支持 公司通过ISO9001全面质量体系认证并严格按其运作。公司信守承诺，对售后产品进行跟踪服务，除此之外，公司对用户还进行不定期走访，解决用户实际中的问题。公司专设售后服务处，负责公司产品售后服务。 如果用户遇到与公司产品有关的重大技术问题或疑难问题，也可直接与公司技术处联系。公司将给予技术支持。附：公司售后服务电话：公司技术处电话：公司技术处传真： 028-870736859GHC-8 Model (8 m) Steel Gray Warehouse Installation and Operation InstructionLabuan 2x300MW Thermal Plant in IndonesiaSICHUAN ZHANQI INDUSTRIAL CO., LTDCHINA April, 2008 Contents1. Appliance Scope-12. Design Instruction and Equipment Specifications-13. Operation Principle-14. Installation Instruction-25. Control System and Operation Standard-56. Operation Procedure-67. Maintenance-68. After-Sale Service and Technical Support-71. Appliance ScopeSteel Gray Warehouse, a ash storage device and part of conveyor system, is apt to ash-clearing system in the thermal power plant and is applied to clear and convey pulverizing fuel dust with the assistance of ash cart or conveyor system for the sake of comprehensively recycling the dust.The Steel Gray Warehouse with the simple structure and easily-operating system, equipped with two-shaft mixer and sealed bulk loading device under the bottom of it, can offer the clean working environment and relieve the work load of staff. 2. Design Instruction and Equipment SpecificationsThe Steel Gray Warehouse with effective capacity, no less than 2x500m3, is designed and manufactured in accordance with the Technical Agreement; the bin of it , manufactured with 10mm steel plate and equipped with air cannon and point level probe as well as firm prop , can meet the demand of the plant. Equipment specificationsModel: GHC-8Diameter: 8000mmCapacity: 2x500m3/setAir cannon model: GMP-III-150Model of Compressed Air Cabinet: QHX2003. Operation Principle3.1 Steel Gray Warehouse in the dust bin which is the storage device of the Gray, can be discharged, and conveyed, cleared after unloading during a period of time.3.2 Upper part of the Steel Gray Warehouse is the cylinder and the lower part of it is the cone;there are a double-shafted mixer and a unloader at the bottom and , at the top of it, a platform supporting loading device, point level probe ,air compressor unloader valve, Gray cleaner bag and other accessories as well as maintenance; in the bin of it, the air cannon equipped helps unload dust. 4. Installation InstructionGeneral Rule of InstallationSteel Gray Warehouse, a complete unloading system, consists of steel bin, electrical control equipment and auxiliary equipment etc,. Installation Requirement of the Steel StructureGeneral Requirement Installation of the steel structure must be carried out in accordance with engineering design, and procedure of the installation must safeguard the stability and firmness of the structure. All parts of the equipment must be checked in accordance with the equipment part list and construction blueprint before installation. All procedures of the installation of the steel structure, including assembly, welding and painting, must be in accordance with relevant regulations. Coat of the steel structure damaged in the process of transport, storage and installation, and assembly joint must be re-painted after the installation. Steel structure test must be in accordance with relevant design regulations. Greasy dirt, snow and ice, sand and dust etc, must be cleared before the lift installation. Edge and prop of arms of the crane must be kept clear.Basement and Supporting Platform4.1.2.1 Steel Gray Warehouse location axis, basic axis and standard altitude etc, must be inspected before the installation so that they must be in accordance with regulations as follows. 4.1.2.1.1 Intensity of the basement of concrete building must be in accordance with design. 4.1.2.1.2 Area around the basement must be refilled. 4.1.2.1.3 Sign of the basement axis and point of the standard altitude must be accurate, precise and complete. 4.1.2.2 Tolerance of the installation of the supporting platform and foot bolt must in accordance with figures listed in the form as follows on the condition that the supporting platform of the equipment is the top of the basement, or the steel plate or pedestal built at the top of the basement. Tolerance of the installation of the supporting platform and foot bolt(mm)ProjectTolerance Supporting PlatformStandard Altitude+_3.0Levelness1/1000Transport and Storage of Steel PartsSteel parts must be supplied in set in accordance with the sequence of the installation In the way of transport, steel parts must be conveyed in accordance with length and weight of parts, supporting points of parts on the vehicle, length of parts protruding outside of the vehicle and appropriate packing approaches so that parts can be prevented from being transformed and damaged. Site for storing the steel parts must be flat and solid without water. Parts must be stored in different sections in accordance with type, model and installation sequence, and parts of the same model must be piled up vertically to prevent them from being damaged. In addition, enough surface of the wood cushion supporting the parts in storage and the stability of the supporting pivot must be ensured4.1.4 Installation and Adjustment4.1.4.1 Quality of the steel parts must be inspected before installation; any transformed and damaged parts must be repaired. 4.1.4.2 Appropriate craftsmanship of installation must be designed in the survey and correction period; the main craftsmanship, including weld of thick and special steel plate, enforcing bolt fixing, bolt welding and construction at degrees below , must be designed and tested before installation. 4.1.4.3 The intensity and stability of the weak steel parts must be calculated, and weak parts must be fixed if necessary in the expanded steel structure assembly; the solid steel structure of each independent unit installed in the system must be ensured in the separated assembly. 4.1.4.4 Correction and fixing work must be done immediately to ensure a firm and stable steel structure after main parts of the equipment , including pillar, beam, platform and support etc, are installed. 4.1.4.5 The relevant installation and correction approaches must be adopted in accordance with influence of wind force, temperature gap, sunlight etc, and welding technique. 4.1.4.6 Permitted by the manufacturer, calculation of installation and relevant approaches must be taken before the installed steel structure is applied to lift other parts and equipment. 4.1.4.7 Area of the attached joint point between two parts, according to requirements of the design, must be no less than 70% of the total area in the inspection with the 0.3mm thick ruler. 4.1.5 Joint and Fixing 4.1.5.1 Adapter of the steel parts must be fixed and welded after inspection 4.1.5.2 Coat of the parts must keep clear and dry before assembly, and assembly work can not be conducted in the rain. 4.1.6. Installation Tolerance Inspection 4.1.6.1 Installation tolerance inspection must be carried out after the equipment is completely installed. 4.1.6.2 Installation tolerance inspection of the equipment must be in accordance with figures listed as follows Installation Tolerance of the Steel Pillar (mm)ProjectToleranceTolerance between Axis of the Installed Pedestal of the Pillar and Location Axis5.0Flexure RiseH 100015.0Vertical Degree of the Pillar AxisH10mH/100025 Installation Tolerance of Steel Platform, Ladder and Railing (mm)ProjectTolerance Standard Altitude of the Platform+_ 10.0Levelness of the Girder of the Platform1/100020.0Vertical Degree of the Pillar of thePlatformH/100015.0Lateral Bending Degree of the Pillar of Load-Bearing Platform1/100010.0Vertical Degree of the Load-Bearing Platformh/100015.0Height of the Railing+_10.0Spacing between Railings+_10.0Vertical Degree of the Ladder1/100015.0Technical Rule in Electric Equipment InstallationSee “Electric Control Box Instruction” along with the equipment.Equipment InstallationBefore the equipment installation, relevant information, including “Construction Blueprint” and “Operation and Installation Instruction”, must be scrutinized. Generally, the procedure of the installation is as follows:PillarSupportBinUpper and Lower PlatformRailingUnloading DevicePipe SystemAccessories including Point Level Probe and Air Cannon etc,-Installation Correction including Re-PaintingWaterproof TestBasement Stability TestLast CorrectionTest and Shipment. Notes: Before the bin installation, the test installation must be carried out on the ground with the upside-down cone bin, and vertical welding must be conducted in accordance with “Construction Blueprint” on the condition that assembly and welding tolerance must meet installation requirements. Circular welding connecting two parts or several parts can be conducted in accordance with the capacity of the crane equipment on the scene. Generally, part of bin joining the pillars must be installed at first and body of bin must be reinforced in the lift installation. 5. Control System and Operation Standard The double-shaft mixer system must be launched before feeding the Steel Gray Warehouse and fuel dust can feed when indicator light on the panel of the equipment turns on. Any problem on unloading can be solved by operating one cannon or all cannons. 6. Operation Procedure 6.1 Preparation before Operation 6.1.1 All electrical apparatus, cables terminals and cables outside of the equipment must be inspected before powering. 6.1.2 Power indicator light turns on after power switching on 6.1.3 Operate double-shaft mixer while adjusting water feeding volum