选粉机安装及操作说明书(Separator).doc

选粉机安装及操作说明书目录1 技术数据 2 主要性能及工作原理 3 部件 4 安装 5 试车 6 操作、养护及维修 7 油站控制 8 备注 9 易损件项目表 1 技术数据型号：XWX57用途：原料磨系统喂料：800-900t/hCapacity: 225t/h(Residue on 90 micron sieve: 10%)能力：225吨/小时（90微米筛余：10%）流量：350000立方米/小时转子速度：50-134转/分钟电机：西门子型号：1PQ8317-4PB90-Z（A61+A72+L1Y+Y53+K45）速度调节范围：Mounting arrangement 上提安装：Reducer 减速机（）型号：减速比：冷却：风机和水管冷却水流量：分钟油站：规格：油站流速：分钟Filter precision: 过滤器精度：0.12mm供油温度：403 Crated pressure额定压力：0.5MPa油罐容量：0.63立方米冷却区域：2.6平方米冷却水温度：28C冷却水流量：4.8立方米/小时冷却水压力：0.2-0.4MPaElectric parameter 电气参数电机： 型号：QA0.75-4B35/460V 60Hz 功率：0.75kW数量：2电热器：型号：SRY2 电压：220V 功率：2kW 数量：2switching value of temperature control 温度控制切换值：220V/5A（3个点）选粉机重量：81.5吨（不包括抗磨损混凝土重量23.7吨）2 主要性能及工作原理2.1 主要性能选粉机分三道工序：初次选粉、主选粉和三次选粉. 主选粉采用涡流室原理，所以效率较高The separator has great feed and the circulating feed of its system can reach 300%选粉机给料能力强大，系统的循环给料可达到300%The separator uses fan of system to lead exhaust air of mill for separating. The four cyclones can effectively collect fines, so it greatly simplifies process system.选粉机使用系统的风机引导磨的废气进行选粉。四个旋风筒可以高效率地收集细料，所以大大地简化了工艺2.1.4 The separators drive unit uses SIEMENS motor and FLENDER reducer. The separator is frequency control, so it can be adjusted conveniently by operator according to fineness of product and working condition.选粉机的驱动使用西门子电机和FLENDER减速机。选粉机是频率控制，可以由操作员根据物料的细度及工作情况进行调整2.1.5 Because of high efficiency separation and great circulating feed of system, milling condition of mill is greatly improved and the system works in optimal circulation, and this increases capacity and saves energy.由于选粉效率较高以及系统的大能量循环给料，磨的工作状况得到了大大的改进，系统运转达到最优化，这提高了系统的工作能力并节约了能耗。2.1.6 Anti-wear design is used in designing separator, so wearing parts have long service life and greatly save time and cost of maintenance选粉机的抗磨损设计使易磨损部件寿命延长，节省了时间和维修成本2.2 Working principle 工作原理See figure 1, air flows from mill directly into bottom of separator. Air rises up along the air duct and distributed by coarse collection cone, then air flows into inner cavity between coarse cone and the shell and go on rising. At the top of housing, air meets feed from upper part of separator and spread by spreading plate, and the feed are separated by air first time (primary separation) After primary separation, most of granule with air are led into whirling chamber by guide vanes and other coarse deposit to outlet by action of gravity. Granule in whirling chamber driven by rotary gas that created by high-speed rotation of turbine blades, and granule are further dispersed and gained circumferential speed (centrifugal force) At the same time granule also subjected drag of air. If centrifugal force of granule is less than drag of air, then granule is caught into inner whirling zone from turbine blades. Then the granule and air rise to air outlet part and cyclone. In cyclone, fines are collected and discharged from bottom of cyclone cone and air discharged from upper outlet. If centrifugal force of granule is more than drag of air, then granule deposit into coarse collection cone by gravity. When coarse deposit to the bottom of cone, they scoured by gas flow from bottom of collection cone and fines on coarse surface are separated again. Then air catching the fines flow into inner whirling zone and cyclone last. Coarse are discharged from lower of separator by three passes and conveyed to mill.见图1，空气从磨直接流向选粉机的底部。空气顺风管上升，由粗料锥体分流，进入粗料锥体与壳体之间的空洞，继续上升。在箱体顶部，空气遇到选粉机上部的给料，有散播盘铺展开，物料第一次被空气分离（首次选粉）。首次选粉之后，大多数颗粒随空气进入涡流室，其它粗物料受重力作用排出。在涡轮叶片高速旋转所产生的涡流的作用下，物料颗粒进一步分散并产生离心力,同时颗粒受到空气拉力。 如果离心力小于空气拉力，物料颗粒则从涡轮叶片进入内旋转区域。而后颗粒和空气上升到空气出口和旋风筒。在旋风筒内，细料被收集起来并从灰斗排出，空气从上部出口排出。如果离心力大于空气拉力，物料颗粒则在重力作用下进入粗料灰斗。当粗料在锥体底部堆积，在灰斗底部气流作用下，粗料表面的细料被再次分离。 空气带着细料进入旋转区和旋风筒。粗料从选粉机下部排出，进入磨。3 部件见图1 选粉机包括箱体、旋转部分、旋风筒、驱动、润滑系统等3.1 箱体箱体包括空气出口部分、箱体上部、箱体中部、箱体下部等等。导流叶片、缓冲板和上部密封圈在箱体的上半部分，空气出口和四个喂料进口在箱体上半部分的顶部。Collected coarse are discharged through three pipes at bottom of cone and each coarse discharge pipe equipped with one flap valve preventing air leakage. At the bottom of coarse collection cone, there is a guide cone. Fines on coarse surface can be separated once again by adjusting wind rate flow into coarse collection cone, it can be realized by adjusting space between guide cone and bottom of coarse collection cone. 收集的粗料从三个管子排出，每个泻料管有一个止回阀，避免空气泄漏。在粗料收集锥体底部，有一导锥。粗料表面的细料可以通过调整风速进行再次分离，可以通过调整导锥与粗料收集锥体底部的距离达到选粉的目的Upper of housing burdens the weight of rotation parts, motor, reducer and drive bracket.上部箱体承受旋转部件、电机、减速机和驱动支架的重量The maintenance and inspection holes are set on housing for convenience of maintenance and repair. 箱体上的维修和监视孔便于维修3.2 Rotation Part旋转部件Rotation part includes rotor, shaft sleeve, bearings an connection plate. Rotor is connected with shaft by key, and shaft driven by drive unit.旋转部件包括转子、轴套、轴承和连接板。转子与轴用轴键连接，轴由驱动装置驱动Rotor composes of spreading plate, dividing panel, turbine blades. Rotor is main portion of separator.转子包括散播盘、分配盘、涡轮叶片。转子是选粉机的主要部分Shaft and bearings are assembled in shaft sleeve. Shaft sleeve bears on air outlet part by upper flange and its lower part connects with housing by four connection plates for radial fixation. 轴和轴承安装在轴套里。轴套用上部法兰安装在空气出口部，它的下部用四个连接板与箱体连接。3.3 Cyclone旋风筒Four cyclones are divided into two groups and distributed at two sides of separator四个旋风筒分为两组，分装在选粉机的两侧3.4 Drive unit驱动装置Drive unit includes SIEMENS motor, FLENDER reducer and coupling驱动装置包括西门子电机，FLENDER减速机和联轴器3.5 Lubrication system润滑系统Lubrication system consists of NC-6.3S oil station and its pipeline润滑系统包括NC-6.3S油站及其管线4 Assembly安装The separator must be assembled completely by manufacturer in factory. Assembly of this separator should observe drawings and manual.选粉机必须由生产商在工厂安装。需遵照图纸和手册4.1 Preparation before assembly安装前的准备Erectors should familiarize with drawings, technical documents, structure of plant, and prepare assembly tools and equipments安装人员须熟悉图纸、技术资料、工厂的结构，以及准备好安装机具Assembly enterprise must check completeness and quality of parts of plant when the plant is handed over from manufacturer to Assembly enterprise. Everything must be checked according to the drawings.安装单位在生产商交付设备时须检查设备的完整性及质量4.2 Sequence of assembly安装程序Casting of wear resistant special concrete according to drawings(before assembly) 按照图纸浇注抗磨损混凝土-Determine assembly baseline确定安装基准线-Base plate底板-Middle section of housing箱体的中间段-Temporarily set rotor临时放置转子-Upper part of housing (guide vanes and buffer plate and other parts already been assembled), air outlet part箱体的上部（导叶片和缓冲板及其它部件已经装好），空气出口部分-Shaft, shaft sleeve and rotor轴、轴套及转子-Drive bracket驱动支撑-Motor, reducer and coupling电机、减速机和联轴器-Lower part of housing箱体的下部-Cyclone旋风筒-Lubrication system and pipeline.润滑系统及管线Sequence of assembly is only for reference, Assembly enterprise can adjust it according to specific condition.安装的顺序只是作为参考，安装单位可以根据具体情况进行调整4.2.1 Determine assembly datum line确定安装基准线Center line of separator and datum line of housing base plate and cyclone base plate should be marked according to processing set-up before assemble separator 安装前必须确定选粉机的中心线、箱体底板的基准线、旋风筒底板的基准线。4.2.2 Assembly of base frame基座的安装Assembly base frames of separator and cyclone according to datum line根据基准线安装选粉机及旋风筒的底座4.2.3 Assembly of middle section of housing箱体中间段的安装Assemble middle part of housing of separator. Adjust height and horizon of base plates by adjusting shims. Height permissible tolerance of highest face of shims on every base plate is 1mm安装选粉机的中间部分。调节垫片调整基座的高度及水平。4.2.4 Temporarily set rotor临时转子Put in the rotor after middle section of housing has been adjusted. Set up temporary support to support the rotor under the rotors assembly position (temporary support can be set in coarse collection cone). The center line of rotor should about coincide with center line of shaft and should pay attention to assembly azimuth of key groove of rotor调整箱体中段后，将转子放入。安装临时支撑（临时支撑可以安装在粗料锥体内）。转子的中心线应与轴的中心线相吻合，并注意转子键槽的安装位置Rotating part also can be assembled with upper part of housing before set on middle section of housing安装箱体的中段之间可以将旋转部分与箱体上部安装在一起4.2.5 Assembly of upper part of housing, air outlet part and feed inlet箱体上部、空气出口及喂料进口的安装The upper seal ring, guide vanes, buffer plate and liner should be assembled before assemble upper part of housing. 上部密封圈、导流叶片、缓冲板及衬板应在安装上部箱体之前安装Assemble guide vanes and buffer plate according to drawings and confirm direction and angle of guide vanes. 按照图纸安装导流叶片和缓冲板，并确认导流叶片的方向和角度。Upper part of housing and air outlet part are assembled and welded according to locating pin at site.上部箱体和空气出口的安装和焊接按照现场定位销进行Check seal of flanges and weld feed inlet with upper part of housing at site. 检查法兰的密封并把给料进口与箱体上部焊接起来4.2.6 Assembly of shaft, shaft sleeve and rotor轴、轴套和转子的安装Rotor must be taken balancing test according to drawings before export factory and supplied with test report. 转子在出厂前必须作平衡试验，并附试验报告。Shaft and rotor must be strictly checked and dissolve deformation created in transportation.轴和转子必须严格检查并解决运输当中出现的变形。Assemble shaft with shaft sleeve and adjust azimuth of oil hole and air seal hole of shaft sleeve, then inset bottom of shaft into axle hole of rotor and tighten nut. 将轴和轴套安装在一起， 调整轴套油孔和空气密封孔的方位角，然后将轴的底部装入转子的轴孔并拧紧螺母。When assemble double-lip seals, it must full of lithium grease. 当安装复唇密封时，必须注满锂基润滑脂After check, tighten bolts which connect shaft sleeve flange and housing top flange, weld adjusting shims with base palates, weld base plates with built-in plates, and weld air outlet part and upper part of housing. 检查后，将连接轴套法兰和箱体顶部法兰的螺栓拧紧，将调解垫片与底板焊接在一起，将底板与内置底板焊接起来，将空气出口部分与箱体上部焊接。Adjust space between lower seal ring of rotor and upper seal ring of upper part of housing (Adjust space by nut at lower end of shaft and tighten lock bolt at shaft end). 调整转子的下部密封圈与箱体的上部密封圈之间的缝隙Adjust space between exterior margin of spreading plate of rotor and inner margin of fixed ring of guide vanes.调整转子散播盘外缘与导流叶片固定圈内缘之间的距离4.2.7 Assembly of drive bracket驱动支架的安装Adjust height and degree of level of drive bracket by adjusting shims between drive bracket and top of air outlet. Degree of level of upper face of drive bracket should within 0.05mm. after adjustment, tighten bolts and weld adjusting shims通过调整驱动支架与空气出口顶部之间的垫片来调整驱动支架的高度和水平。经过调整、拧紧螺丝及焊接调整垫片，驱动支架上表面的水平度应在0.05mm以内。4.2.8 Assembly of motor and reducer电机和减速机的安装Assembly of motor and reducer should observe instruction of its manufacturer电机和减速机的安装应该遵守生产商的作业指导书4.2.9 Drill locating hole at stand bar of drive bracket and flange of shaft sleeve, then fit into locating pins or bolt. Tighten all bolts and the rotor should be easily rotated by hand在驱动支架的支撑杆和轴套法兰上钻定位孔，然后将定位销子或螺栓固定。拧紧所有螺栓，转子可用手很容易的旋转4.2.10 Assembly of lower part of housing 箱体下部的安装Guide cone should be assembled between middle section of housing and lower part of housing before assembly of lower part of housing. Annular space between guide cone and bottom of coarse collection cone must be equal. 箱体下部安装之前，应先安装导锥。导锥应安装在箱体中段与箱体下部之间.导锥与粗料锥体底部的环隙应该相等Assemble lower part of housing and flap valve according to drawings and check seal of all flanges.箱体下部和瓣阀的安装要按照图纸。检查所有法兰德密封4.2.11 Assembly of cyclone 旋风筒的安装Set cyclone and its base plates according to datum line and flange interface of separator shell. Adjust height of base plates of cyclone by adjusting shims. And height permissible tolerance of upper face of shim on each base plate is 1mm. Check seal of all flanges. Weld adjusting shims, shims and base plates, base plates and built-in plates after adjustment. 根据基准线及选粉机壳体的法兰界面放置旋风筒和底板。 通过调整垫片调整旋风筒底板的高度。每个底板垫片的上表面的允许高差为1mm.检查所有法兰的密封。调整后焊接调整垫片、垫片与底板、底板与嵌入板。4.2.12 Tighten bolts of separator base plates and cyclone base plates拧紧选粉机底板及旋风筒底板的螺栓4.2.13 Assembly of lubrication system and pipeline润滑系统及管线的安装Assembly of lubrication system and pipeline should strictly observe drawings and documents. Pay attention to cleaning pipes before assembly and seal of pipe junctions.润滑系统及管线的安装应严格遵照图纸和资料。安装及密封管接头之前应注意保持管子的清洁。5. Run test试车After termination of all setting work and checked acceptably, a run test can be made所有部件安装好并经过检查后，可以试车5.1 Check before run test试车前的检查5.1.1. The rotor must run smoothly转子必须旋转平滑5.1.2 The direction of rotation of motor is correct. 电机的转动方向必须正确5.1.3 All the equipment of lubrication system is complete and act accurately. Lubrication pipes are unimpeded. 润滑系统所有的设备应完整并运转精确。润滑管道应畅通5.1.4 Shaft sleeve is filled with enough oil轴套应灌满油5.1.5 Check and tighten all connection bolts检查并拧紧所有连接螺栓5.2 No-load run test无物料试车The no-load test shall have a duration of 2 to 4 hours at maximum speed of rotor. The no-load test should make sure:无物料试车应在转子最高转速上连续运转2到4个小时。无物料试车应保证：Run smoothly, no abnormal vibrations and noises运转平稳，没有异常震动及噪音Temperature rise of all bearings must below 30C所有轴承的温度升高必须在30度以下The lubricant should clean and should not have any dirty when checking with the filter paper. Lubrication pipes should flow well and the joint does not leak and lubricate well.润滑油应清洁，用滤纸检查应没有污物。润滑管线应通畅，管接头处没有渗漏。All the monitor meters, detection meters and control system should intelligent and accurate. 所有检测器、控制系统都应精确灵敏Observe, detect and record the fluctuation of the current. If there is abnormality, should find out the reason immediately and take into the exclusion. 检测电流波动。如发现异常，立即检查并排除5.2.6 Check and tighten all connection bolts检查并拧紧所有连接螺栓5.3 Load run test 带料试车After the no-load test is accepted, then can proceed to load test. Load test can accord to the operation plan of mill不带料试车通过后，进行带料试车。带料试车可以根据磨的情况决定Load test should satisfy not only requirements of no-load test but also the following requirements:带料试车除了应满足无料试车的要求以外，还要满足以下要求：Each connection and seal place must seal well, cannot leak air, ash and oil各个连接处应密封完好，不得渗漏空气、粉尘或油Temperature rise of all bearing must below 40所有轴承的温度升高不得超过40度The motors current is normal电机的电流应正常During the run test, the plant must be switched off following the shutdown sequence once abnormal conditions occur在试车期间，如果发生异常情况，停机必须按照停机顺序操作6. Operation, maintenance and repair操作、养护及维修6.1 operation 操作After the run test is accepted, then can operate the separator. The separator must be operated by specialist operator. Also the operator must master the structure, performance and operation gist试车通过后，就可以开始操作了。选粉机必须由专业操作员操作。操作员必须掌握选粉机的结构、性能及操作要领6.1.1start开机The start sequence of separator and related equipment is following:选粉机及相关设备的开机顺序如下：Start motor and its cooling system of oil station of separator启动电机和选粉机油站的冷却系统Start discharge conveying system of dust collector启动粉尘集尘器的卸料输送系统Start dust collector and its system fan (Note: the adjusting plate of fan should gradually open)启动粉尘集尘器和风机系统（注意：风机调节板应逐渐打开）Start conveying system of product from separator启动选粉机产品的输送系统Start coarse conveying equipment from mill to separator启动从磨到选粉机的粗料输送设备Start motor of separator启动选粉机的电机Start feed equipment of separator启动选粉机的给料设备Start main motor of mill (Lubrication and cooling system of mill bearing should be previously started)启动磨的主电机 （磨轴承的润滑系统和冷却系统应该先行启动）Start feed equipment of mill启动磨的给料设备6.1.2 Shut down sequence of separator选粉机停机顺序Shutdown sequence of separator is contrary to start sequence停机顺序与开机顺序相反6.1.3 operation 操作Speed setting速度设定Adjust the rotor speed should within range of speeds that the separator specifies. The fineness can be regulated by change the rotor speed可以在选粉机规定的范围内调整转子的速度。物料细度可以通过转子的转速调节In addition, regulate the products fineness by changing air flow is not promoted, because that will influence separate efficiency and graduation of the fines.另外，不能通过改变风速调整产品的细度，因为那样会影响选粉的效率和细粉的分级Guide cones usage导锥的用途By means of adjusting the space between guide cone and bottom of coarse collection cone, fines can be separated from coarse surface once again. 通过调整导锥与粗料斗底部的距离， 可以再次把细粉从粗粉表面分离Space adjustment implemented by adjusting the guide screws out of housing. The rule of space adjustment is gradually enlarged space and set space according to site conditions. 通过调节箱体导螺杆来调整距离。调节的原则是根据现场情况逐渐增大距离While regulating, the length of three guide screws out of housing should equal, that can make annular space about equal调节距离时，箱体外的三个导螺杆的长度应该相等，这样环隙才能一样Lubrication oil of bearing轴承的润滑油Oil outlet of oil station equipped with oil flow signal implement. The minimum oil flow is 3.5-4 l/min. while oil flow in lubrication pipes is low or electricity failure, the implement send out sign, then should find out the reason immediately and take into the exclusion油的最小流速为3.5-4 l/分钟。当油的流速慢或是断电时，仪表发出信号。应找出原因并立即解决。6.2 Maintenance养护选粉机应如出现异常震动或噪音，应停机检查。原因可能是旋转部件磨损不均匀、散播盘不平或轴承润滑不正常所有轴承的温度应低于65度检查油的流量、油压、轴承冷却水及润滑系统的温度，及过滤器入口和出口的压力，及时消除异常检查轴、轴承及所有连接部分的油密封。 如磨损应立即更换所有管子、风管应该定期清洗，避免粉尘堆积每个风管连接处不得接触雨水，避免形成灰饼第一次注入润滑油以后，一周后应更换润滑油。如果设备较长时间不用，或环境温度低于10度，应将润滑油放出6.2.8 润滑油表润滑点润滑名称润滑种类温度名称 标准代号间隔轴的轴承连续润滑65L-CKC-68 齿轮油GB5903-1995一年lip-type packing 安装时注油锂基润滑油 No 4SH/T0380-1992减速机遵照FLENDER减速机说明书电机遵照SIEMENS 电机说明书6.3 Repair维修Before performing any repair work, make sure that all electrical components are de-energized and materials in it are deposited. When repairing, the visible plate for safety must be set at electric switch. After repair, the plate must be taken away by the man who set it. No one is permitted to start separator without permit. 维修之前，确定所有电器部件必须断电，物料应沉积下来。