环缝洗涤塔说明书2801956-D050_TANGSHANBF2CHIN_ENG.doc

本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual项目 ： 唐钢GCS操作维护手册Project No: 2801956项目号 ： 2801956Prepared: ECN作者 ： ECNTANGSHAN IRON & STEEL COBlast Furnace No 2 RevampingGAS CLEANING SYSTEMSCRUBBER AND DEMISTEROPERATION & MAINTENANCE MANUAL0First bilingual version22.05.2005CLASSENWOLSFELDDAVIDI/EGNERRev. No.Description of RevisionDatePreparedCheckedApprovedTitle of Document / Designation:Drawing Number:2801956-D050_CHIN_ENGL.doc2801956-D050Order Number:Reference Documents:2801956 2801956-0001P&I diagram唐山钢铁有限公司2号高炉煤气净化系统洗涤器和脱水器操作、维护手册0双语第一版22.05.2005CLASSENWOLSFELDDAVIDI/EGNER版本号版本修改说明日期编写审核审批文件名称:图号:2801956-D050_CHINESE_xxx.doc2801956-D050订货号:参考文件:2801956 2801956-0001P&I 图1Preface42Functional Description and Process Data42.1Pre-Scrubber and Annular Gap Scrubber42.2The Demister72.3Plant Process Data73Inspection, Pressurizing and Adjustment94Safety Requirements105Re-Commissioning after Long Time Shut Down115.1Rotation Control115.2Filling of Media125.2.1Filling of Oil125.2.2Filling of Water135.2.3Filling of Grease155.3Pressurizing of Hydraulic System185.4Standard Setting on Eletronical Components195.5Water Control Valve Positioner Adjustment215.6AG-Element Adjustment225.6.1Execution of Positioner Adjustment245.6.2Interlockings255.7Water Run266Start Up Gas Cleaning Plant286.1Sequence of Start-Up286.2Blanketing of GCP296.3GCP Operation296.4Clarified Water Pumps306.5Field Monitoring316.5.1Local Pressure at Inlet of Spray Nozzles326.6Control Room Monitoring336.6.1Admissible Deviations:347Gas Cleaning Plant Safety347.1Water Supply Failure357.2Hydraulic Failure367.3Deviation of the position of AG-Elements367.4Deviation of Blast Furnace Gas Outlet Temperature377.5Deviation of the Clean Gas Dust Content387.6Deviation of Electric and Control388Shut Down399Maintenance Instructions399.1Raw Gas Pipe409.2Raw Gas Pressure Relief Valve429.3Spray Nozzles429.4Water Guiding Pipes439.5Pre Scrubber449.6Annular Gap Scrubber459.7Stuffing Box459.7.1Replacement of Stuffing Box Parts479.8Greasing System499.9Recirculation Pumps499.10Hydraulic Station509.11Level Tanks509.12Demister519.13Water valves519.14Condensation Traps5210Clarified Water Quality5210.1Clarified Water Requirements5310.1.1General5310.1.2Chemical Reactions in the Scrubber5310.2Clarified Water Outlet Conditions5410.3Clarified Water Inlet Conditions5511Turbine and None Turbine Operation5612Annex561前言42功能描述和工艺参数42.1预洗涤塔和环缝洗涤塔42.2脱水器72.3系统工艺参数73检查、加压和调整94安全要求105长时间停车后的再开车115.1转动控制115.2介质的充入125.2.1加油125.2.2加水135.2.3加润滑脂155.3液压系统的加压185.4电器部件的标准设置195.5水位调节阀位置调节215.6环缝元件调节225.6.1位置传感器的调节245.6.2联锁255.7试水266煤气净化系统的开车286.1开车顺序286.2煤气净化系统的密封296.3煤气净化系统操作296.4净化水水泵306.5现场监控316.5.1喷嘴入口就地压力显示326.6控制室监控336.6.1容许偏差347煤气净化系统安全347.1水供应故障357.2液压故障367.3环缝元件的位置偏差367.4高炉煤气出口温度的偏差377.5净煤气灰尘含量的偏差387.6电气和控制偏差388停车399维护说明399.1粗煤气管道409.2粗煤气放散阀429.3喷嘴429.4水导向管439.5预洗涤塔449.6环缝洗涤塔459.7密封箱459.7.1密封箱部件的更换479.8润滑系统499.9循环泵499.10液压系统509.11水位罐509.12脱水器519.13水阀519.14冷凝水收集器5210净化水质量5210.1净化水要求5310.1.1概述5310.1.2洗涤塔中的化学反应5310.2净化水出口条件5410.3净化水进口条件5511TRT工作和TRT不工作5612附件561 Preface When starting operation for Gas Cleaning Plants (GCP) the instructions of this operational Handbook shall be followed from the first day on in order to avoid unsafe operation, damages or unduly wear of components. Beside the normal operation two start-up situations will be explained:Re commissioning after long time shut downStart up after short outageFor efficient operation the instructions for start up situations as well as the maintenance obligations for all components must be followed.2 Functional Description and Process Data 2.1 Pre-Scrubber and Annular Gap ScrubberThe BF gas stream coming from the dry gas cleaning enters the scrubber from the top. The gas enters the spraying zone of the scrubber and passes through the water curtains emitted by the injecting nozzles. The coarse dust particles contained in the gas stream are embedded in the water droplets produced by the spray nozzles. The dust laden water droplets are collected in the sump of the spraying chamber and discharged to the water treatment plant.After having passed the water curtains, the gas is pre-cleaned. A certain amount of the pre-cleaned gas can be used for pressurizing of the hopper of the bell-less top. The key parts of the ANNULAR GAP SCRUBBER are the PAUL WURTH Annular Gap Elements.ATTENTION: In order to achieve an optimum cleaning efficiency and minimum of wear it is extremely important that the distribution of the gas flow through the annular gap element has to be exactly even and symmetric.Down stream the spraying chamber, the gas flows through the annular gap passage. Here, water is injected on top of the annular gap elements before the gas flows through the annular gap. When entering the annular gap the gas flow is accelerated. The high gas velocity produces strong turbulence, so that the gas is mixed with the injected water. During this mixing, even very small dust particles are embeded by the water droplets and removed from the gas. Please also refer to Fig 1 below.Figure 1:If e.g. the gas stream is interrupted due to clogging of dust, it is obvious that the water film on the cone is not evenly distributed on the circumference. The flow of the gas will therefore also not be distributed properly and high wear of the cone is unavoidable. This results in a changing L/G ratio (mass flow of water to mass flow of gas) over the circumference of the annular gap.The L/G ratio for the optimized cleaning efficiency is 1; i.e. 1 l of water has to be injected per 1 Nm3 of gas. In the case of misalignment between the cone and the venturi the L/G ratio will be lower than 1 at locations with higher gap width and higher than 1 at locations with lower gap width and the performance of the gas cleaning plant would get worseThe dust-laden water is collected in the annular gap zone sump and flows to the demister sump. From there it is recycled to the spray nozzles at the top of the scrubber via recirculation pumps. The clean gas that may still contain free water droplets leaves the scrubber in direction of the demister. 2.2 The DemisterThe gas enters the demister from top. The vertical demister ensures the optimized separation and droplets, which are separated at the demister shell, are not re-entering the gas stream. The gas passes through vanes that give the gas stream an angular momentum. Centrifugal forces move the water droplets contained in the gas stream to the wall. Here the water is collected at the end of the demister and flows down into the sump from where it is drained to the recirculation main. 2.3 Plant Process Data1BF dataUseful volume:2000m3Normal top pressure:2bar, gMax design pressure:2,2bar, gMin top gas flow rate:220000Nm3/hNormal top gas flow rate:330000 Nm3/hMax. top gas flow rate:350000Nm3/hNormal top gas temperature:250CMax top gas temperature400CAverage particle density1500Kg/m3Top gas dust content15g/Nm3Moisture content of BF gas: 30g/Nm3-Gas analysisCO22,5vol %CO219vol %H20,5vol %N256vol %Below figures are based on normal gas inlet temperature, pressure and flow rate2Annular Gap ScrubberWater flow rates and water conditionsTotal clarified water requirement500m3/h Recirculation flow rate330m3/hInlet conditions water Clarified water inlet temperature20CSuspended solids 100mg/lHardness (CaCO3) 1000mg/lChloride content 400mg/lInlet/ Outlet conditions cycloneDust content at cyclone inlet 15g/Nm3Dust content at cyclone outlet2,25g/Nm33Vertical DemisterDust content at normal operation pressure5mg/Nm3Demister outlet pressure with TRT in operation1,86bar, gClean gas pressure0,1bar, gCleaning efficiency85-90%Clean gas temperature40C4Gas Cleaning Plant General ConditionsNoise (TRT not in operation) of annular gap scrubber and vertical demister 1m outside gas cleaning plant.-dB (A)BF top pressure control accuracy if TRT is not in operation and annular gap elements controlling the top pressure.-kPa3 Inspection, Pressurizing and AdjustmentFor the start-up of gas cleaning plant the following points have to be checked and recorded: Foreign parts in the plant, for instance metal- wooden-, plastic material, glass parts as well as screws, wires, bottles, cans, insulating material, tools, scaffold etc. have to be removed The pipe work must be flushed and the cleaned from foreign parts Mud agglomeration or dust deposits have to be removed All manholes, openings and inspection holes must be closed and gas tight The greasing system must be ready for operation and the stuffing boxes of the rods must be checked for tightness The shut-off devices on the discharge side of the pump must be closed The hydraulic and electric actuated water valves must be checked and ready for operation All primary shut-off valves and other fittings to measurement and instrumentation must be opened All pumps must be ready for operation All measuring-, control- and regulation instruments must be checked and ready for operation All required utilities and consumables, like water, grease, lubricants, nitrogen, steam etc must be available for filling in The inert gas connection must be ready for operation4 Safety RequirementsFor safety reasons the site should be in clean condition. Stairways platforms and direct surrounding of the Gas Cleaning Plant shall be clear and scaffolding and hoisting equipment should be removed. The inside of the scrubber bottom as well as all stairways platforms and surrounding areas of the GCP need to be illuminated by sufficient lighting.5 Re-Commissioning after Long Time Shut DownAfter the measures required under chapter 5 have be carried out and the requirements for commissioning of all plant parts according to the instructions of the manufacturer are fulfilled, the entire plant can be putting into operation as described below.The safety technical regulation to the individual plant components have to be considered. To avoid explosive gas mixture the gas-bearing components are to be purged oxygen-free. As inert gas is nitrogen or steam required. The blanketing of the plant is required before first commissioning at least and always when the plant for walkways or inspection is made gas-free.The entire plant has to be put into operation as follows: Hydraulic system Measuring and control devices Water cycle system Gas cleaning system5.1 Rotation ControlIn case of replacement of rotating equipment a rotation test has to be done before re-commissioning.Pumps or other rotating equipment shall be checked for rotation direction of motor resp. impeller. This is to avoid damages and proper cooling is warranted. The hydraulic pumps shall be switched on only for a short time to prevent damages in case of wrong rotation.For water pumps the pump manual shall be checked to find out if it is required by the manufacturer to disconnect the coupling to separate motor from the impeller.The pump manual has to be checked in any case for additional advises and further manufacturer demands. For instance a few greasing pumps have optional rotation direction but with regard to the gear tooth system right rotation is recommended. 5.2 Filling of MediaAs far as piping or components has been renewed the piping system should be inspected for tightness of all flange connections. All pipes should have been cleaned from debris and flushed by water or chemicals in case of stainless steel material to be pickled. A pressure test with water (or oil in case of hydraulic pipes) for new pipe sections should have been done with all water as test medium drained. After these test procedures media can be filled to the system.5.2.1 Filling of OilIf the hydraulic system has been renewed or modified and a refill is required the following items should be checked before the specified oil is filled to the hydraulic oil tank: The hydraulic oil tank is cleaned The sealings and the paint is resistant to hydraulic oil Filters with specified mesh size are installed Filters are installed in flow direction Measuring devices have to be checked and ready for operation Electrical connections to MCC and from MCC to consumers have to be checked and ready for operation The accumulators are filled with nitrogen t the specified pressureAfter checking these items hydraulic oil can be filled up to the upper oil level mark.5.2.2 Filling of WaterAfter checking the cleanliness of all pipes, tanks and pumps water shall be filled into the systems installed on ground level up to the highest spray nozzle. The water will be fed by using the pressurized cold water supply system. The following safety measures have to be taken care of to protect the pump: Assure that sealing water lines are connected and the sealing system is in operation (mech. seal) or that the gland packing is properly packed and not tightened unevenly. Regulate flow rate with const. velocity to avoid water hammer and at discharge side only If no bypass line is integrated (minimal flow) pump shall not be operated longer than 2 min with discharge valve closed. The number of pump starts and stops per hour should not exceed the value given in the manufacturer manual Before re-starting make sure that the pump shaft is at rest and does not rotate in opposite direction.All valves should be in normal operation position during this procedure. Secondary water supply lines like i.e. flushing water to level tanks shall remain closed. Venting valves of pumps, tanks and pipes shall be watched carefully and if bubble free water escapes from them they should be closed.The demister overflow or an inspection hole at the demister can be opened during water filling for the use of over flow in order not to overfill the system.ATTENTION: The venting valves on top of the level tanks must be closed after water filling otherwise clean gas can be blown out during hot commissioning. Nevertheless the balance line between tank and scrubber must always be open.Conditions of shut off valves to start the water cycles:NoDescription GCP- CodeStatus1Nozzle water valves pre-sc.2GNU06AA103-105OPEN2Nozzles water valves pre-sc.2GNK02AA101-103OPEN3Nozzles water valves AG-sc.2GNK03AA101-103OPEN4Disch. level tank vent valve2GNS02AA 581CLOSE5Disch. level tank gas valves2GNS02-03AA 101OPEN6Reci level tank gas valves2GNU02-03AA 101OPEN7Reci level tank vent valve2GNU02AA 581CLOSE8Disch. level tank drain valves2GNS02,03AA 102OPEN9Reci level tank drain valves2GNU02,03AA 102OPEN10Reci station isolation valves2GNU06AA 101-112OPEN11Discharge station isol. valves2GNS01AA101-112OPEN12Reci pumps isolation valves2GNU04,05AA 101,102OPEN13Demister drain valve2GNG01AA 102CLOSE14Demister isolation valves2GNU01AA 101,102OPEN15Condensate traps isol. valve2GNU01AA 103OPEN16Water supply valve (nozzles)2GNK01AA 201OPEN17Reci station control valve2GNU06AA 221OPEN18Recirculation drain s/o valve2GNG01AA 021CLOSE19Recirculation drain isolation 2GNG01AA101OPEN20Level tank first filling valves2GNF02-06AA151CLOSE21Reci water by pass valve2GNU06AA 021CLOSE22Disch. water bypass valve2GNS01AA 031CLOSE23 Disch. water shut off valves2GNS01AA 021OPEN5.2.3 Filling of GreaseGrease need to be filled into two areas: Grease tank of the automatic greasing system Three containments above the stuffing boxesGrease TankIn case of a necessary refill of the grease tank it has to be assured that the tank is clean.In case of replacement of the level measurement (i.e. ultra sonic) it must be set up by simulating the different levels in the tank and set these values at the device by means of dip switches.In preparation to a trial run of the greasing pump the specified grease should be filled into the tank by preferably use the screw connection at the tank. It shall be avoided to fill from the top of the tank to prevent dirt from entering the system. A filling from the top also delays the grease flow for a while if not block the flow due to air inside the pump and air bubbles in grease itself. If a filling from the top is unavoidable and the pump can not convey air oil has to be filled in to the pump chamber in order to displace the air before filling in grease. During trial run this oil is collected in a container placed under the pressure outlet of the pump at disconnected pipes.Containment above Stuffing BoxTo prevent water and dust from entering the stuffing box the containment above the welded flange of the stuffing box should have been f