赤泥转鼓过滤机.doc

CHEMICAL PLANT & ENGINEERING PTY. LTD.A.C.N. 006 967 988INSTALLATION, OPERATION & MAINTENANCE MANUAL 安装、运行、维护手册Type:Chemplant Rotary Drum Vacuum FilterSize:4267 mm Diameter x 9100 mm FaceTABLE OF CONTENTSINSTALLATION, OPERATION & MAINTENANCE MANUAL安装、运行、维护1EQUIPMENT SPECIFICATION 设备说明3GENERAL INFORMATION概述5MAJOR COMPONENTS SUB-ASSEMBLIES 主要部件及小部件8OPERATION 运行21MAINTENANCE & LUBRICATION 维护及润滑35LIST OF DRAWINGS 图纸清单42OTHER MANUFACTURERS MANUALS 其他手册43EQUIPMENT SPECIFICATION 设备说明GENERAL概述Filter Size过滤尺寸4.3 m Diameter x 9.1 m wide FaceFiltration Area过滤面积 120 m2Discharge Type卸料型号Roller Discharge卸料辊Submergence Level沉入液面37 %Hand of Filter过滤机方位1 x Left Hand左转鼓Total Weight Empty总净重approximately 50000 kg each StationMATERIAL OF CONSTRUCTION 材料Liquid Contact Parts与液体接触部分Mild Steel 碳钢Frame 框架 Mild Steel碳钢Electrical Supply供电380/3/50FILTER DRUM鼓组件Number of Compartments间隔数 28Drain line Size排水线路尺寸 65 NB Standard WeightDrain line Outlets per Compartment每个间隔的排水线出口1Drainage Grids排水格栅Injection moulded PP snap-in typeDivision and Edge Strips分隔316L S.S.Caulking嵌槽 10mm RopeFILTER DRUM DRIVE 转鼓驱动Drum Speed 转速2.7 rpm nominalGear Reducer减速机SEW PHF031KF97DV160L4/VS Ratio=543:1Motor电机SEW 15 kWIM:M1/0 380V/660V/50Hz Force Fan Cooled.Speed Control速度控制VFC 变频控制FILTER VALVE 阀Valve Size阀尺寸 800mm NominalValve Body阀体Mild SteelWear Plate耐磨板UHMWPEOutlets出口220 OD, 200 ID (2 off)Filtrate Connectors过滤连接By othersFILTER TANK 槽体Material材料Mild SteelLength长度9645 mmHeight 高度2525 mm (1655 mm above floor)Width宽度4600 mmFILTER TANK AGITATOR槽体搅拌Motor电机SEW 11kW 4pole DV160M4Gear Reducer Model减速机型号SEW FA107/G, Ratio = 67.62:1Oscillations/Minute振荡/每分21ROLLER DISCHARGE卸料辊Material (cake contact surfaces)材料（滤饼接触面）Mild Steel碳钢Discharge Roller卸料辊700 mm Diameter Motor电机 SEW 7.5kW 4pole DV132M4Gear Reducer Model减速机型号 SEW FA107/G, Ratio = 83.91:1Speed转速17 rpm Linked via VFC to main drive VFCCAKE WASH SPRAYS per HEADER TWO SUPPLIED 清洗滤饼喷淋Material材料Stainless SteelQuantity数量64 Model型号JBU 1980 B1 (1/4” BSPT) 20 PNTFlow Rate流量1320 litres / minute 5 bar Total CLOTH WASH SPRAYS清洗滤布喷淋Material材料Stainless SteelQuantity数量33 Model型号BETE NF 80 ” BSP 50 degree Fan NozzleFlow Rate流量1320 litres / minute 5 bar Total GENERAL INFORMATION概述 INTRODUCTION介绍Each filter has been completely assembled, tested and checked at the factory to assure an accurate and smooth running machine before the filter is shipped.过滤机在发货前必须在工厂完整地装配好，测试完毕，审核通过，以确保机器正常准确运转A complete record is kept of all equipment furnished by the company to facilitate the replacement of parts. In order to be able to correctly identify the parts, it is essential that the serial number appearing on the nameplate be accurately given to us when ordering or referring to the equipment.公司安装的设备应该有完整的记录有助于零部件的更换。当我们分类或谈及设备时，为了能够准确的辨认零部件，在标示牌上的序列号必须准确无误The purpose of this manual is to provide the necessary data for proper installation, operation and maintenance. Filtration data on particular products is not given herein because each product and each manufacturing facility produces different filtration characteristics. For assistance with your filtration variations, contact Chemical Plant and Engineering.此手册为正确的安装，操作及维修提供了必要的数据。特殊产品的过滤数据在此并未提供，因为每个产品及每个制造设备的过滤特征各不相同。为协助你方关于过滤方面的变化情况，可以联系CPEPlease read this manual carefully and follow the instructions given.请仔细阅读这本手册并遵照以下说明执行SAVE THIS MANUAL FOR FUTURE REFERENCE. 保存这本手册以供今后参考GENERALAll rotary drum filters consist mainly of a drum rotating within a tank with the filtering action taking place along the outer periphery of the drum. This outer surface is divided into a number of shallow compartments each covered with a suitable filtering media. Each compartment is framed with grooved members which are continuously attached to the drum shell to prevent air or liquid leakage between adjacent compartments. The circumferential grooved members are called division strips. The circumferential grooved rings at either end of the drum are called end seal strips. A plastic grid or a woven wire structure is fitted within the area of each compartment and acts as a support for the filtering media.所有的转鼓过滤机主要有带有槽罐的转鼓组成，而过滤工序主要在转鼓外围进行。外围被分成许多个浅的间隔，每个间隔上覆盖合适的过滤介质。每个间隔加带有凹槽的外框，可以持续依附在转鼓外壳，以防相邻间隔之间空气或液体的渗漏。整个凹槽单位我们称为分割条，转鼓每端的凹槽环称为终端密封条。在每个间隔内都装有塑料格栅和铁丝网，以支撑过滤介质。Each compartment is individually connected by means of a drain line to a common automatic valve. The valve controls the vacuum at each compartment.每个间隔由一个排水线连接到自动阀上。该阀控制着每个间隔的真空。The drum is suspended in a tank containing the slurry or liquid to be filtered. This slurry is maintained at a predetermined level in the tank. An agitator is normally supplied in the filter tank to keep the solids of the slurry in suspension during the filtering process. This agitator consists of two end members suspended from a point above the liquid level with plough and rakes extending longitudinally and parallel with the tank bottom.转鼓在槽罐内是悬浮的，包括需过滤的浆料或液体。浆料保持在槽内预先指定的水平线上。搅拌机在滤槽内正常工作，保证浆料在过滤过程中处于悬浮状态。搅拌机由两个端元组成，该端元从高于水平液面之上的某个点上悬挂下来，浆叶向水平及垂直方向延伸。Filtering or cake forming takes place while the compartment travels through the slurry. As the compartment emerges, dewatering or removal of the mother liquor begins. 间隔穿过浆料时则完成过滤或滤饼成形。间隔出料时，脱水开始。When the completion of the dewatering cycle is reached the cake is discharged from the drum. In this case a contact roller with scraper fingers is used to remove the cake from the drum. 脱水完成后，自动阀打开间隔，滤饼从转鼓上卸下。卸料使用各种方法，这种情况下，需要使用反吹/反洗刮刀。Refer to Section 3 for information regarding the roller discharge on your filter.关于特殊的卸料型号参考第三部分。START-UP起动When starting the filtering operation of the drum filter the following procedure should be used and is carried out in the order shown. The filter is always started with the drum stationary.转鼓运行后，按照下列程序进行操作，过滤机开始时是静止的1. Start agitator in filter tank 起动槽体内的搅拌机2. Put filtrate and feed pumps into automatic mode (all controls by others). 把滤液及进料泵调至自动模式（控制器其他人提供）3. Start vacuum pumps - make sure seal water is on first (suggest interlocking solenoid valve and flow switch).开始真空泵确保水密封首位（建议联锁螺线管阀及流量开关）4. Wait a short period of time to allow full cake formation before starting drum rotation.运转转鼓前停顿一段时间允许滤饼成形5. Start the drum rotation.运转转鼓SHUT-DOWN 关闭This procedure may vary with actual plant conditions but is usually carried out as follows: 程序可能根据实际车间条件有所不同，但大致如下：1. Stop the feed pump and withdrawal of slurry from filter tank. 停止进料泵，把浆料从槽体取出2. Run remaining cake off of drum.把剩余的滤饼从转鼓上刮下3. Stop vacuum pump.停止真空泵4. Stop filtrate pump.停止滤液泵5. Stop drum and agitator drive.停止转鼓及搅拌驱动OPERATION OF FILTRATE RECEIVER滤液接收器的运行 After the filtrate passes through the automatic filter valve, it flows into a sealed vessel called the filtrate receiver. The receiver is under a vacuum and hence must be a sealed unit. The inlet from the automatic valve is about two-thirds of the way up the receiver to allow plenty of room for collecting the filtrate. The line between the filter and filtrate receiver must be level or sloping down towards the filtrate receiver.滤液穿过自动过滤阀之后，进入滤液接收器的封闭容器。该容器处于真空状态下，因此是密封装置。自动阀进口大约位于高出接收器三分之二处，留有足够的空间收集滤液。过滤机与滤液接受器的位置应该保持水平或向下流向接收器。The outlet on the top of the receiver is connected to the vacuum pump. The height of the outlet is kept as high as possible to keep the amount of filtrate entering the vacuum pump to a minimum.接收器顶部的出口与真空管相连。出口的高度应尽可能的高使进入真空管的滤液保持最小。To remove the filtrate a pump is connected to the outlet on the bottom of the receiver. This pump can be controlled either manually by a switch or automatically. In automatic mode the pump is activated by the level of filtrate in the receiver接收器的底部连有一根管子去除滤液。该管子可以手动也可以自动。在自动模式下，管子由接收器内滤液的水平高度激活。A barometric leg can be used as an alternative to using a filtrate pump. The height needs to be adequate to overcome the vacuum in the filtrate receiver.也可以用气压计退代替过滤管。高度应该足够，克服滤液接受器中的真空。MAJOR COMPONENTS SUB-ASSEMBLIES主要小部件AUTOMATIC VACUUM VALVES 自动真空阀Your Chemplant Rotary Drum Vacuum Filter is equipped with a High Flow Type Valve with a bridge plate. 你方转鼓真空过滤机装有带桥板的高流量阀ASSEMBLY OF HIGH FLOW VALVE 高流量阀组件1. Assemble Valve Studs (4 off) to the Valve Hub Bearing. Secure Studs with Lock nut. 把阀门钉装到阀毂轴承上，用螺母保护钉2. Position the Wear Plate on the Terminal Plate using Set Screws. The Terminal Plate has been assembled to the valve hub at the factory. 用定位螺丝把耐磨板定位在尾板上， 尾板已经安装在阀鼓上。3. Assemble Valve Body with the Bridge Plate using the central Cap Screw. 用中心螺帽把阀体安装到桥板上4. Place and position the Valve Body / Bridge Plate Assembly over the Valve Studs. 安装并定位阀体/桥板到阀钉之上5. Place Spring, Washer and Nuts over Studs. 在钉上安装弹簧，垫圈及螺母6. Apply EQUAL tension to the springs with the hexagon nuts provided. Use enough tension to stop vacuum leakage. DO NOT OVER TENSION. 用提供的六角螺母给弹簧施加相同的张力，用足够的张力停止真空泄露。张力不可过大Refer to Figure Below ADJUSTING HIGH FLOW FILTER VALVE 调节高流量阀All filter valves have been assembled, tested and adjusted on the filter before leaving the factory. It is possible, however, that the readjustment may be necessary due to shipping vibration.所有的过滤机在出厂前都须装配好，测试完毕并进行了调试。但是由于运输中的颠簸，还有可能对机器进行重新的调试。After the filter is started, check to see if proper seal is being maintained between the stationary valve body and the wear plate. Should leakage occur, additional tension may be required on the springs.过滤器启动之后，须检查阀体与耐磨板之间的密封是否完好。如果发生泄漏则需对弹簧施加额外的张力。Occasionally valve leakage may persist even after additional tightening of the spring adjustment. This is due to the flow characteristics of some of the chemical resistant wear plate materials. It is then necessary to place excessive tension on the valve springs and continue operation until leakage stops. This procedure will accelerate wear on the wear plate and remove any high spots or irregularities from its surface. It is important to relieve this excess tension as soon as the two faces are seated.施加额外张力之后，偶尔还可能出现泄漏，这是因为某些化学耐磨板材不同的流量特征。有必要对阀门弹簧施加更多的张力，然后继续运行直到泄漏停止。该程序会加速耐磨板的磨损，需要去除表面的杂质污渍。一旦两面固定之后，有必要减轻这种张力。VALVE HUB BEARING ASSEMBLY 阀鼓轴承组件Valve Bearing Housing阀轴承座The valve hub bearing is a simple journal bearing requiring grease lubrication. It has a replaceable liner inside with lubrication grooves. It is split to allow easy replacement. Note it is possible to float the filter drum by filling the tank with water to access the bottom bearing half. Once adequate clearance to remove the liner is achieved the filter must be supported prior to placing hand or fingers between the liner and the hub. Remove liner and insert new piece.驱动及阀毂轴承是简单的滑动轴承，需要添加润滑，内部有可替换的轴瓦，带有油槽。可以进行简单的替换。在槽体内注入水，可以浮动转鼓使得底部轴承分为两半。一旦间隙够大可以移走轴瓦，在轴瓦与毂体之间应先放置支撑件，才可神手进去。 Replaceable LinerAGITATOR ASSEMBLY 搅拌组件The agitator is a simple oscillating rake arrangement. The agitator pivots around the centre bearing and is pushed by the rotating drive shaft connected to the agitator via crank arms. The cranks arms contain journal bearings that are grease lubricated.搅拌器是一个简单的振荡倾斜运动。中心轴承处的搅拌枢轴通过驱动轴的旋转而被推动，驱动轴由曲柄连接到搅拌器。曲柄包括滑动轴承，也带润滑系统。MAIN DRIVE ASSEMBLY 主驱动组件The main drive consists of a SEW Planetary Gear Reducer complete with a SEW force cooled electric motor. Both components are support by the representative in China who can offer service and technical assist if required. Refer to the Other Manufacturers section of this manual for additional information. 主驱动包括SEW减速电机及电机。两个部件都有SEW中国代表提供，有售后服务及技术支持。To replace the drive end bearing the main drive must be removed. Firstly support the weight of the drive so it doesnt drop and then using the jacking screws in the taper locked coupling the coupling can be loosened. Once the drive is remove float the drum and remove the bearing before replacing it.要拿下驱动端轴承，必须移走主驱动。首先撑起驱动，并用千斤顶，松开联结部位，驱动取下后，转动鼓体，取下轴承，然后再进行更换。Note that the torque arm has been modified to suit the installation.注意扭力臂的尺寸要与安装相配POLYPROPYLENE DRAINAGE GRIDS聚丙烯排水格栅The Chemplant Rotary Drum Vacuum Filter is provided with injection moulded polypropylene grids. These grids are designed to provide a smooth supporting surface for the filter cloth with maximum drainage area.转鼓真空过滤机配有注模聚丙烯格栅。这些格栅是为了给滤布提供一个平整的支撑表面，排泄面积达到最大。The grids are of the snap-in type and can be easily removed for cleaning or replacement. To remove an individual section, insert a screw driver under the grid mid-section and pry upward until an end comes out from under the division strip edge. The grid can then be further flexed until free.格栅是快速吸入型，易拆下清洗替换。如需拆除某一个部件，在格栅中部下嵌入一个螺丝驱动，向前嵌入直到末端出现在分隔密封条下方。格栅可以进一步弯曲直到自由可动。To reassemble a section, slip one end of the grid under the division strip. Bend the grid lengthwise to allow insertion of the free end. The grids will take considerable bending without fear of breakage. See following Figure.如重新装配某一部件，在密封条下滑动格栅的某一端。纵向弯曲格栅使得自由端能够嵌入。格栅可弯曲程度较大，不会出现断裂。ROLLER DISCHARGE ASSEMBLY 卸料辊组件 4 -._-Caulking atCake Build-upDrain LinesDivision Stripson Roll (1 thick)Knife Adjustment DischargeFilter ClothFilter Tank 2 1 3 6FILTER CLOTH INSTALLATION滤布的安装When the filter cloth has been removed for any reason, it should be re-installed as follows prior to any operation: 如果滤布需要更换，在运行之前要按下列步骤重新安装1. Spread the cloth out and roll it up on a pipe of sufficient length to span the top members of the filter tank. The cloth should be rolled in such a manner that when it is unrolled onto the drum, the finished sides of any seams in the cloth will be on the outside. It is important that the finished cloth has no slack in it. 在张紧棍内滚动滤布，把边缘拧紧到过滤机背后最近的分隔密封条上。压紧滤布时，如果没有卷到转鼓上，滤布的边缝露在外面。滤布在转鼓内不能有松动，这很重要2. Place the cloth pipe across the top members of the filter tank, centering the cloth with the drum.把滤布管子压到槽体上表面，使滤布固定在转鼓中心上3. Rotate the drum until a horizontal division strip is accessible. 旋转转鼓直到水平分割密封条条可以接触到4. Caulk the end of the cloth into the horizontal (longitudinal) division strip using the caulking material supplied with the filter. This should be driven in with a hammer and a wooden wedge. If the cloth is bruised a small patch can be attached to the cloth with a suitable adhesive for the cloth material. The caulking material need to be removed at a later stage hence there is no need to drive the material to the bottom of the groove. Start the filter drum rotating, and feed the cloth on to the drum, holding back slightly on the cloth pipe in order to keep the cloth tight. 用压条把滤布压进水平方向分割密封条，需要用榔头和木制锥形块 ，如果滤布被刮伤，可以用适用的胶水粘一小块补上去。压条的安装要能被取出，因此没必要把压条压到嵌槽底部，转动转鼓，把滤布压倒转鼓上，在滤布管子上稍微敲紧保证滤布压紧5. Stop the drum at 180 degrees and caulk the cloth into another longitudinal division strip. The caulking material should be driven in firmly in either case and it is best to use a wooden wedge for this purpose taking care not to damage the cloth.转鼓转到180度时停下，把滤布压进另一个水平方向分割密封条。压条必须压紧，小心不要对滤布造成损坏6. Start rotating the drum again. When the cloth has completely covered the filter drum, stop the drum, remove the caulking material from the cloth seal strip and caulk both ends of the cloth into the seal strip. The joints used here may be a simple lap joint or a rolled joint. In the latter case, it is necessary to trim off the excess cloth before making the joint. When overlapping filter cloth to complete the join always ensure that the overlap section is on the side away from the discharge roller.转动转鼓，如果滤布完全覆盖转鼓，停止转鼓，取出压条，把滤布的两端压进分割密封条，连接处可以是简单的接搭，接搭部分确保远离卸料辊方向7. Caulk the cloth in the end seal rings located on the drum ends and here again, the caulking material should be driven in with a wedge. 把滤布压进转鼓端面的密封条，用小锥块把滤布压进密封条内8. Trim off the excess cloth extending beyond the caulking grooves.修掉超出嵌槽的多余滤布9. It is important to check the level of the discharge roller before putting the filter into operation. Using the same independent reference level established for levelling the drum, during installation, check the discharge roller. 转鼓运行之前检查卸料辊的水平，安装时也需检查10. Carefully check the discharge roller to see that it is parallel to the drum surface. Adjust the discharge roller so that it is within 35mm.小心检查卸料辊是否与转鼓面平行，调整卸料辊在35mm内Note many filter cloths are fragile hence care should be taken not to bruise the filter cloth.小心不要刮伤滤布The two most important considerations for cloth installation are: 在安装滤布时必须考虑两个重要的因素1. Cloth must be stretched tightly and evenly滤布必须紧而均匀地展开2. All strips must be caulked securely in their entire length. 所有的嵌缝条在保证长度准确的情况下应该安全的完成TYPICAL CLOTH SEAL AT 90o OR 180o DIVISION STRIPS(4 OR 2 PLACES AND EDGE CAULKING)OPERATIONINTRODUCTION ROLLER DISCHARGE VACUUM FILTERS卸料辊真空过滤机OPERATING THE FILTER. 运行The speed of the filter drum is controlled by a Variable Speed Drive. 转鼓的转速由可调速驱动控制A GENERAL DESCRIPTION OF THE FILTER AND AUXILIARY EQU