基于工业以太网的火电厂电气自动化系统应用研究.doc

自补偿式落料阀使用说明书陕西骏马环保工程有限公司1.0用途： 我公司研制生产的PZLF型系列带排气自补偿式落料阀，主要用于火力发电厂的气力除灰系统（正压密相、低正压、负压等系统）中；也可用作水泥、冶金和化工等行业粉状物料输送系统中。2.0技术参数：2.1型号的意义：（P） Z L F X X 落料阀通径(cm) 自补偿式落料阀 带排气2.2进口法兰： DN150DN3002.3工作压力： 1.0MPa2.4工作温度： 200(最高400)2.5工作气源压力： 0.51.0MPa3.0主要结构： 1、壳体上法兰 2、阀 座 3、阀 板 4、调整螺钉 5、托 架6、轴 座 7、转 轴 8、转 柄4.0结构特点：4.1采用我公司的专利技术，阀门结构新颖、独特。使阀板与阀座在弹力作用下始终处于良好的密封状态。该阀门的使用寿命高于国内外的同类产品。阀门专利号为ZL 002268450。4.2阀板开启时进料和排气同时进行。替代传统的落料和排气分离系统，使系统简化，控制点减少。4.3阀门采用金属硬面密封，气动操作，动作迅速。4.4阀板、阀座采用金属材料，无需冷却水，工作温度可达到400。4.5关键部件（阀板、阀座）采用硬质合金工具钢经淬火处理，工作硬度HRC55，耐磨性好，使用寿命长。4.6阀门的阀板、阀座与阀体为独立结构，采用螺栓连接，便于维修和更换，减少运行维护费用。5.0安装尺寸： 型号PZLF15PZLF20PZLF25PZLF30ZLF15ZLF20ZLF25ZLF30进口法兰DNXX PNXXDN150 PN1.0DN200 PN1.0DN250 PN1.0DN300 PN1.0DN150 PN1.0DN200 PN1.0DN250 PN1.0DN300 PN1.0A(mm)150200250300150200250300B(mm)170205240276.23C(mm)105125130128165175190150D(mm)3535505035355050E(mm)38.5455041.28F(mm)97133.5132.5133.597133.5132.5133.5G(mm)134145165175134145165175H(mm)7381107.513885100140165I(mm)6512295.5482069.5390J(mm)143175180180143175180180K(mm)400350465348400350465348L(mm)460600710806.45460600710806.45M(mm)50064076087050064076087015203030n-XX(mm)14-2220-2220-2624-3314-2220-2220-2624-336.0安装及运行注意事项：6.1该阀门与压力输送罐安装时，垫圈上、下密封面均涂耐高温硅密封胶。6.2该阀门在长期不安装时，应采取防雨、防潮、防腐措施。6.3气源母管距离阀门在2m之内，气源管道选用121以上；在2m之外选用141以上。6.4系统的出力需通过调整落料阀的动作周期来实现。6.5系统投运前应确认阀门中无焊条头、焊渣、铁丝、棉纱等杂物，防止夹杂在阀板与阀座之间，影响阀门密封。6.6气动阀门安装时，应对气源管道进行吹扫，确认气源无杂质后才能连接电磁阀及气缸接头，确保电磁阀阀芯、气缸密封圈不受损伤。6.7系统控制程序应在收到落料阀关闭信号5秒后，再进行系统输送。6.8当气源压力达到0.5MPa以上时，气缸动作，带动转柄、转轴、托架、阀板6.9每半个月应向转轴上部及气缸与转柄连接头处油杯中添加润滑油或按现场运行情况确定加油周期，以防转轴与铜套出现抱死现象。6.10安装阀板与阀座时，其两者间隙不大于1m，阀座与壳体上法兰接触面涂耐高温硅密封胶。6.11阀门长期停止运行时，应进行防腐保护，防止密封面锈蚀。7.0故障分析与处理：故障现象故障分析处理措施阀门无法开关1、电磁阀无电或故障a)检查电源线路，排除故障b)检修或更换电磁阀2、气源压力不足检查气源压力，排除故障阀门开关不到位1、阀门长期放置，生锈，摩擦力增大a)清除铁锈，注意保养2、气源压力不足a)检测并调整气源压力3、气缸工作不正常a)调整气缸节流孔b)检查气缸密封圈，并及时更换破损的密封圈c)更换工作不正常气缸4、有硬物卡住阀门a)检查阀门，清除硬物阀门转轴冒灰1、转轴密封磨损a)检查密封，更换已磨损的盘根阀门漏灰1、阀门开关不到位a)检查阀门，排除故障2、阀板磨损a)更换阀板8.0检修工艺8.1该阀门与压力输送罐安装时，垫圈上、下均涂耐高温704硅密封胶。8.2当转轴与轴座出现转动不灵活时，首先应用M5内六方扳手拆开轴盖，然后取出盘根和密封圈，抽出转轴，再清除轴座内的杂物，用细砂纸把转轴砂光，然后把转轴放在轴座里来回转动，灵活时加上密封圈即更换新的盘根，注耐高温润滑油之后方可固定轴盖，耐高温润滑油规格为3#通用锂基脂。8.3更换阀座 先用钳子剪断锁紧调整螺钉的铁丝，松开调整螺钉取下阀板。 用M6内六方扳手拆下阀座上所有的内六角螺栓，卸下阀座，清除壳体内及阀座上粘的杂物。 安装阀座时应往阀座与壳体上法兰接触面处涂耐高温704硅密封胶，然后对准螺丝孔，均匀拧紧阀座上的内六角螺栓。8.4调整阀座与阀板之间的力度和间隙 当阀座在壳体上安装好时，往阀座下表面涂点干净的普通机油。将阀板贴于阀座上来回动作几次之后，阀板上的孔应对准托架上的孔，先拧紧阀板中间的调整螺钉，再放入周围孔中的弹簧，拧紧调整螺栓，调整螺栓的力度，要用力矩扳手达到1012NM（即弹簧的间隙达到12mm之间）即可。 拧紧防止阀板转动的内六角螺栓，其作用是防止阀板转动拧断弹簧。 调整螺栓调整好后，再用铁丝锁紧调整螺栓，防止阀门工作时，调整螺栓松动，导致弹簧松动，弹力不足。8.5更换气缸 先去掉旧气缸。 安装新气缸，对准转轴上法兰与轴座之间的钢印，将连接头与气缸连接，再调整连接头上的孔与转柄上的孔同心，且安装销轴，拧紧气缸上的锁紧螺母。将气缸通入气源，观察阀门开、关转轴上法兰与轴座之间的钢印对准即可。8.6阀门的正常工作从外界观察，当气源压力达到0.5MPa以上时，阀门的全开、全关时间不大于6秒。9.0易损件清单：序号名 称代号单位数量备注1弹簧PZLF-07套1此数量为单台阀门配套零部件2石棉盘根JC222-79套110.0订货须知：10.1订货时应注明：阀门型号、公称通径、工作压力、工作温度、工作介质等。10.2根据用户要求配带电磁阀及附件（电磁阀支架、接头、消音器、连接软管）；行程开关及附件；配对法兰及附件（垫片、螺栓、螺母），订货时应注明。10.3该阀要在其它系统使用时，应提前与我公司技术人员商讨，以确保阀门的使用寿命及可靠性。10.5阀门技术参数如有变动，恕不另行通知。OPERATING INSTRUCTIONSFORSELF-COMPENSATORY FEEDING VALVESHAANXI GRANDHORSE ENVIRONMNTIAL PROJECT CO., LTD1.0 Function： PZLF vented self-compensatory feeding valve which is excogitated by our company are mainly used in ash handling system (press and vacuum) of thermal power plant, which also find wide use in the conveying system of cement production, metallurgy and chemical plants. 2.0 Technical parameter：2.1 Meaning of model：（P） Z L F X X Dia. (cm) Self-compensatory Venting 2.2import flange： DN150DN3002.3 work tension： 1.0MPa2.4 work temperature： 200( highest 400 )2.5 work air pressure： 0.51.0MPa3.0 Main structure： 1、flange 2、valves seat 3、valve disc 4、adjusting bolts 5、supports 6、shaft seat 7、shaft 8、handle4.0 Structural traits：4.1 The valve is one of our companys patent, which is unique and of novel structure. Under the elasticity, valves seat and valve disc is well-sealed and its life-span is longer than the congener products. Its patent NO. is ZL 002268450. 4.2 when is valve disc is on, feeding and venting goes simultaneously instead of working separately so as to simplify the system and reduce the control points4.3 The valve is mental-sealed and pneumatically operated. It responses quickly.4.42 Valve seat and valve disc is made of metal. there is on need in using cooling water with a work temperature up to 400. 4.5 Key parts (valve seat and valve disc), which is made of hard alloy steel and get quenched, is wearable and last longer. 4.6 Connected with bolts, valve seat and valve disc are separate parts. This design makes it easy to maintain and replace, as a result, the cost spent in maintain is reduced. 5.0 Installment dimensions： Model PZLF15PZLF20PZLF25PZLF30ZLF15ZLF20ZLF25ZLF30Import flange DNXX PNXXDN150 PN1.0DN200 PN1.0DN250 PN1.0DN300 PN1.0DN150 PN1.0DN200 PN1.0DN250 PN1.0DN300 PN1.0A(mm)150200250300150200250300B(mm)170205240276.23C(mm)105125130128165175190150D(mm)3535505035355050E(mm)38.5455041.28F(mm)97133.5132.5133.597133.5132.5133.5G(mm)134145165175134145165175H(mm)7381107.513885100140165I(mm)6512295.5482069.5390J(mm)143175180180143175180180K(mm)400350465348400350465348L(mm)460600710806.45460600710806.45M(mm)50064076087050064076087015203030n-XX(mm)14-2220-2220-2624-3314-2220-2220-2624-336.0 Notice in installation and operation：6.1 When installed with pressure vessel conveyor, its up cover and down cover should be smeared with heat-resistant silicon seal glue. 6.2 When valves are not been installed, measures should be taken to protect it from injury by dampness, heavy rains, and corrosion. 6.3 When the distance between air header and valve is within 2m, 121 or larger air pipes should be used; when the distance is beyond 2m, 141 or larger pipes should be used. 6.4 Output of the system should be achieved though adjusting the work period of feeding valve。 6.5 Before it is put into use , make sure there is no welded head, welded dross、iron wire、cotton yarn etc in the valves, in case valves can not be well-sealed. 6.6 when installing pneumatic operated valves, air pipes should be blowed first to make sure that there is no impurity in the air before connecting solenoid valve with the cylinder. Ensure solenoid valve core and gasket are not damaged. 6.7 system conveying should be started after the control program receive shut-off signal from feeding valve for 5 seconds. 6.8 when air pressure reach 0.5MPa,clinder moves and bring along handle ,shaft，supports and valve disc. 6.9 add lubricating oil periodically to the upper part of shaft and the joint between cylinders and handle, in case handle hold tightly with the copper sleeve. 6.10 when installing valve disc and valve seat, keep the distance within 1m. Put heat-resistant silicon glue on the surface between valve seat and valve shell.6.11 when placed unworking for a long time, the valve should be protected from corrosion and rust. 7.0 Malfunction analysis and treatment：PhenomenonMalfunction analysisTreatmentValve can not been opened1、no current in solenoid valve or functional failurea)check the circuitryb)check and change the solenoid valve2、air pressure is not enough Check the air pressure and，remove malfunction.Valve switch can not reach the proper place 1、placed for a long time, valves are rusted and its friction rise. a) Remove rust and take care of maintain. 2、air pressure is not sufficient.a) Check and adjust the air pressure. 3、cylinder can not work normally. a)adjust cylinder reduce holeb) Check cylinder seal gasket and change the broken gasket. c) Change the cylinder that does not work normally. 4、valves are stuck by hard things. a) Check valves and remove the hard thing.Ash come from Valve shaft 1、shaft seal wears. a)check seal and change attrited stuffing Ash come out of valves1、valve switch is not in proper position. a) Check valve and eliminate malfunction. 2、valve discs are worn.a) Change the valve disc.8.0 Examine and repair 8.1 When installed with pressure vessel conveyor, its up cover and down cover should be smeared with heat-resistant 704 silicon seal glue. 8.2 If the shaft and valve seat can not running smoothly, first disconnect the shaft cover with M5 inner hexagon spanner; then take out stuffing and gasket and draw off shaft. Clean out the dusty from shaft seat and then grind the shaft smooth. Turn the shaft round in the shaft seat. When it moves change the new stuffing. Infuse heat-resistant lubricating oil (l3#common lithium-based grease) and fix the shaft cover. 8.3 Change the valve seat Snip the iron wire of lockbolt and release the bolt. Take off valve disc. Remove all the inner hexagon bolts in the valve seat with M6 inner hexagon spanner. Unload valve seat and clean the smudge on the shell and valve seat. smear heat-resistant silicon seal glue when install valve seat. Then aiming at bolt hole tighten the inner hexagon bolt. 8.4 Adjusting the degree of tightness and distance between valve seat and valve discs. when the valve seat is fixed on shell, smear some oil on the valve seat. Keep valve discs close to valve seat and move it back and forth for several times. Put the hole of valve disc concentric with that of the supports. Fasten the adjusting bolts of valve disc and put the springs into the holes around. Adjust the pressure of adjusting bolts. Enable the moment spanner to 1012NM( maintain the distance between springs 1-2 mm). Tighten the inner hexagon bolt whose function is to prevent valve disc from rotating and breaking the springs. After adjusting the bolt fix the adjusting bolt in case adjusting bolt loose which result in loose spring when valves works. 8.5 Change cylinder remove the old cylinder first. install the new cylinder. Aiming at the steel seal between the flange and valve seat of the shaft, connect the tie-in and cylinder. Then make the hole of the coupling concentric with the hole of the handling. Install bolt sleeve. Tighten the screws of the cylinder. Put air though cylinder and make the flange concentric with