捞渣机说明书(英文)

1、棉兰电厂GL20型捞渣机说明书Indonesian medan plant（2×200MW）projectSubmerged Scraper Conveyor Operation manualShanxi electric power equipment factory MenuONE. Overview2TWO. Name、Type2THREE. Technical parameters3FOUR. Structure characteristics5FIVE.Install7SIX. Debug 13SEVEN. Use and maintenance15EIGHT. Packa

2、ging、 paint and transportation 17NINE. Failure analysis 18ONEoverview1. The system of bottom ash2 set 200MW construct in the project，removal system design to ash and slag respectively ，under each boiler have 1 Submerged Scraper Conveyor ，Submerged Scraper Conveyors head of ascension Angle 370，center

3、line of Submerged Scraper Conveyors drain slag mouth to boilers is 32.0m，centerline of roller in head of Submerged Scraper Conveyor standard height about 18.5m，slag ascend to the height of 14.8 by Submerged Scraper Conveyor ,crushed by crusher , feed in silo bin 。 wet slag dehydrate from silo bin tr

4、ansport to slag yard or comprehensive utilization of the user。We provide the system of bottom ash including slag wells、 hydraulic shutoff gate、Submerged Scraper Conveyor、silo bin、crusher。2. The use of bottom ashBottom ash conveying system equipment except the horizontal main body decorate in the boi

5、ler framework，the rest like head、silo bin、crusher all decorate in open-air。Under normal conditions of slag conveying system adopts continuous transmission mode。Water of seal water、cooling water adopts the water from the treatment cycle in the system of bottom ash。3. The scope of application of botto

6、m ash equipment As supporting the medan power plant （2×200MW）， boiler slag removal equipment's structure size and technical parameters of the main requirements, can satisfy the working principle and structure characteristics of large power plant boiler can suit the slag discharge。The equipm

7、ent cooperate with water board of couplet box under boiler，water seal grooves, maintain continuous flow of water absorbing the expansion of boiler。Slag Wells and shutoff gate for temporary short time don't stop cases of boiler slag reservoir，to create the conditions for the equipment maintenance

8、。Submerged Scraper Conveyor as the main equipment used in the slag removal system to cooling, conveying, dehydration, etc，convey slag to silo bin。Silo bin is store slag dewatering equipment，can be stored Submerged Scraper Conveyor exclusion of slag in a certain period，in the amount of deposit slag r

9、eaches a certain，transport out to process by car。4. bottom ash equipment applicable scope of operation manual This manual is only to Submerged Scraper Conveyor, slag wells, hydraulic shutoff gate of using and maintenance are explained, hydraulic motor equipment by professional manufacturers provide

10、a separate professional equipment manual。TWOName、type1. Submerged Scraper Conveyors name、typeMLGL - 20 MLGL-（Plant. Medan dedication）Submerged Scraper Conveyor20 - Supporting one tenth of the unit capacity2.with slag wells type MLZJ - 20 MLZJ-（Plant. Medan dedication）Submerged Scraper Conveyor20 - S

11、upporting one tenth of the unit capacity3. Shutoff gate type MLGDM -（Plant. Medan dedication）Shutoff gateTHREE. Technical parametersSubmerged Scraper ConveyorWet slag stacking density：1300kg/m3Serial numberprojectUnitsnumerical1Type of Submerged Scraper ConveyorMLGL-202typeImmersion, hydraulic drive

12、, portable type3Slag discharge volumepersist operationt/h515Accident slag discharget/h154chain driveNormal speedm/min0.5The maximum speed (0 maximum speed adopts stepless speed)m/min2.5Scraper widthmm1000Scraper heightmm180Scraper spacingmm10005Cooling waternormal conditiont/h22Maximum cooling water

13、t/h456The overflow of water temperaturenormal condition55Highest condition607ash content of overflow water ppm3008Bodys horizontal lengthm 18.59Bodys tilt length、Head up heightm30.019.010Body tilt Angle of section°3711 Top groove of bodydepth of waterm1.7Water Container VolumeM35012Hydraulic dr

14、iving devicestype wattageKW30VoltageV400rotate speedr/min1480overflow weirZigzag weirQ235-ATension deviceAutomatic tensionChain specifications30×108shifting rollerPair/set7Orbital typekg/m38Orbital lengthm5Wheel pressureT/轮20(horizontal section)、15（Inclined section）FOURStructure characteristics

15、1. summaryThis slag removal system including slag wells which connected couplet box of boiler，Hydraulic drive shutoff gate and Submerged Scraper Conveyor three parts。Slag well supported on the ground by six pillar，there are rectangle ring water seal trough in the above。Connected with the boiler wate

16、r tank under-link board into water trough seal boiler。Slag wells lower have 2 slag holes，under which is a Submerged Scraper Conveyor，slag come out to pass crusher into silo。Shutoff gate set on bottom slag hole of slag well，which bottom gate insert water trough，in the repair could close the shutoff g

17、ate，through the electric remove devices remove the Submerged Scraper Conveyor to Safety maintenance。2. Shutoff gate and hydraulic systemShutoff gate control by hydraulic system，each group shutoff gate form a circle by 8 side gate and 2 end gate，between the gate and gate with asbestos cloth seal，outs

18、ide the gate connect the oil cylinder by alien putter，when in need of repair，can drive oil cylinder，close the gate in order，seal the gate of slag well，Submerged Scraper Conveyor remove horizontal，to repair。3. Submerged Scraper Conveyor The Submerged Scraper Conveyor divided into body、hydraulic drive

19、、electric removed、tensioner、fluctuation guide wheel、Chain scraper、electric control eight sections。Top tank of body and inclined section lay down Wear-resistant plates，in order to reduce wear；bottom tank of body and inclined section lay down the basalt casting plates，in order to reduce resistance。Top

20、 tank of body have pull rod，to strengthen the rigid and prevent explosion caused by water body deformation。Main transmission part adopts hydraulic motor drive，and through hydraulic pump station realize stepless speed regulation。Hydraulic motor and the hydraulic station chose Germany rexroth imported

21、 products，Through hydraulic motor speed reducer realize low speed with Large torque output，and this device has overload ability strong characteristics，avoid hydraulic motor at extremely low rotation speed（0.8r/min） not smooth adverse interval，effectively improve the efficiency and service life of eq

22、uipment。Chain tensioner form for hydraulic tensioner automatically：When the chain worn without maintenance personnel after artificial tensioner，in the constant pressure hydraulic system can automatically under the effect of tension，and the constant tensioning status, and because of the chain is in p

23、roper working condition，Thus reduces wear and improve the using life of the equipment。Fluctuation guide wheel are equipped with rolling bearings，and a reliable seal measures，Ensure the normal operation of long-term。Under the guide wheel set drop chain, broken chain and stopping protection device。Sub

24、merged Scraper Conveyors chain adopt imported high quality high wear resistance ring chain（30×108），chain should not be less than HV800 surface hardness，connect firmly，disassembling convenience。Scraper connect chain adopt insert scraper grippers，Due to the plugin is adopted bolt connection，make

25、disassembling adjusting scraper spacing is extremely convenient，No bolt connection of loose connection antirust and rigidity connection of the harmful constraint，connection reliable, strong, and so on。Each Submerged Scraper Conveyor containing seven sets of electric machines remove device，each chief

26、 wheel was drove by a straight league rounds of cycloidal pinwheel reducer, strong power，simple structure，after a long time, still can move freely idle。When Submerged Scraper Conveyor maintenance ,start all move out，after repair reset。Submerged Scraper Conveyors tail is smooth transition arc，scraper

27、s return working in cast stone substrate，scrapers return slag can be gathered to tail ，Perpendicular to the level of hydraulic tensioner solutions with automatic device match with tail arc closed shells can realize the automatic scraper with slag，Thoroughly solved scraper no-load section with slag。S

28、ubmerged Scraper Conveyor adopts automatic filling water equipment, water can be regulated by automatic temperature valves,to ensure Submerged Scraper Conveyor in body temperature is not more than 60°。FIVE.install1. Foundation constructionSubmerged Scraper Conveyor including slag wells、silo bin

29、 according to the basic construction of electricity design institutes provide drawings and request。2. Submerged Scraper Conveyor install Installation of order：Walk wheelset - shell - Platform、fence - tensioner support and tensioner wheel group - Tensioner hydraulic system - hydraulic drive system -

30、Laying casting slab -chain-scraper-electrical system - cooling water pipes、Chain flush pipes。2.1 installation of move wheelsetMove wheelset uninstall before Submerged Scraper Conveyor delivery， In the construction site placed it paved orbit，then put Submerged Scraper Conveyor on its move wheelset，Ad

31、justed the pace of the track between the wheels，welding it to Submerged Scraper Conveyor（detailedSubmerged Scraper Conveyor moving organization chart）。Note：moving wheels motor- reducer not installed right now ，will Submerged Scraper Conveyor body adjustment after appropriate section ,install removed

32、 from motor - reducer，And adjust good gear lateral clearance。2.2 installation of shell2.2.1 Installing sequence and general requirementsThe body is divided into 8 from the head to tail。The shell installation from tail to head by order。Each manufacturing process has to mark，and each interface positio

33、n with character made markers。When will the docking site adjacent to the same symbol for two broken shells with together。Then thoroughly check chassis back plate、lateral plate adjacent parts etc，ensure all plane and joints are on the same level and pinzi after welding seam (seam is continuous angle

34、welding seam，detail in related drawings)。Each section of the body that are on the same plane longitudinal center within plane。And the attention in a shell before docking before a shell should be installed on the walk device。2.2.2 the positioning and installation of inclined section Before installati

35、on an welding inclined section，according to related drawings frame were assembled separately. frame welding:： posited framework according to general assembly drawings，then connect the framework by channel steel( so connection plate) and weld hard，。Then weld top framework。After inclined section of sh

36、ell be weld well，For ease of light cover installation should cut crane nose 2.2.3 Shell weld well，For all the weld do experiments check penetration by water or kerosene，Ensure shell filled with water no leakage。Use auxiliary support will fix the framework，bottoms joint of up channel wear plate shoul

37、d be catch up on（Play groove welding），And will mill seam smooth。note：In the installation of airframe should pay attention to the levelness of each shell after connection，and ensure the parallel between chain drive wheel of channel and the link line of each guide wheel。2.3 Installation of platform、fe

38、nce、slag funnel 2.3.1 Platform of head、fence、slag funnelIn the scene ,according to assembly drawing, weld the up plane of head platform with the up plane of shells first section steel after alignment，then weld ladder and fence。2.3.2 According to theSubmerged Scraper Conveyor platform ladder assembly

39、 drawing ，just to alignment the tail platform framework top plane and the top plane of tail shell steel then weld，after welding platform, ladders, fence welding-installation。2.3.3 Hydraulic tensioning devise the installationAccording toSubmerged Scraper Conveyor assembly drawingshow the position wel

40、d the Hydraulic station on the framework of tail shell，then install Hydraulic tank on sioner hydraulic station framework which on tail of shell.2.4 Tensioner system installationTo facilitate delivery and preservation，tensioner system has removed before equipment departure from factory，according to t

41、he following requirements on site。Assembly sequence：Tensioner wheel frame（Contain orbit）Tensioner wheelsethydrocylindertankhydraulic piping。2.4.1 Tensioner wheel frameAccording to the drawing will wheel frame position with tightening bolt connection，After other components installed adjustment stud b

42、olt，Ensure tensioner wheelset in orbit can slide freely，then weld raking shores。2.4.2 Tensioner wheelsetTtensioner wheelset include slider be installed in orbit，After installation lift the tensioner wheelset vertical with chain ，guarantee fluctuation slide freely。2.4.3 Cylinder installationThe oil c

43、ylinder sides will be installed in place，use pin shaft，note the mouth of oil cylinder clean（Before connecting pipe shall not remove oil mouths guards）。2.4.4 Tensioner hydraulic pipe systemThe tank fixed on frame before pipeline installation，according to the requirements of drawing hydraulic pipe con

44、nection。All piping installation should be cleaned before (such as internal corrosion, pickling), ensure the pipe cleaning。System startup before and during the start-up process should be checked all the pipe joints are all tightened, whether leakage。After the completion of the pipeline connection fil

45、ling the tank 60 litres of 46# hydraulic oil，But scraper unfinished before assembly shall start the hydraulic system。Specific details hydraulic tensioner agencies use manual。Note：(1) Connection of the connector protection device and the packing must be reserved to the final assembly before removed ;

46、(2) The connection body to be much more careful handling, such as immodesty drop on the ground, whether to check whether the seal, even the scratches；3) All the joints are likely due to thermal expansion or vibration and loose, start to normal after need to tighten.。2.5 Hydraulic drive system instal

47、lation2.5.1 The hydraulic motor installedHydraulic motor before installation, please read carefully the hydraulic drive system installation instructions，Installation procedures shall be in strict accordance with instructions on the part of motor on the hydraulic drive system installation。Before inst

48、allation, check for hydraulic motor with cleaning, need to drive axle shaft end cleaning。Then will be installed to drive motor assembly required position, according to the requirements of hydraulic pressure motor manual lock tight plate bolt screw。Remember: motor before installation must be within t

49、he coupler drive motor shaft axis holes and grease erased，Can't cheer lubrication！Locking plate bolt tightened rules（According to the instruction for hydraulic motor）：a. When tighten bolts，in order to avoid the two plunger collar is not parallel，in the whole process is needed in a few position m

50、easuring clearance between the two plunger collar。b. Tighten the bolt in designated torque values (50%) before 490KNm，The coupling bolts are tightened by diagonal pair，并严格监测压圈之间的间隙。c. Tighten the bolt in designated torque values (50%) after 490KNm，mark in the bolt with serial number，then set a speci

51、fied torque wrench maximum，Tighten bolts in sequence。Each bolts every tighten 1/4 turn，up to twist to the designated torque values（May need at least 15-20 times）。d. When the torque values further confirm all bolts have reached this value。Torque arm shall be installed according to the position on ins

52、tallation drawing。When the torque arm can not insert support saddle，shall to unscrew the nut of the fixed torque arm support saddle，adjusted the support saddle。For motor installed in place，According to the requirements of torque values should be lock nut。2.5.2The power station fixed and piping conne

53、ctions.First fixed the power station on the framework accord to layout drawing by nuts 、bolt，then accord to pipe requirment of Hydraulic drive system installation instructionsconnect power station and motor with hydraulic pipeline。If hose shuold cross zhe platform , cut hole on site 。System startup

54、before and during the start-up process should be checked all the joints, or whether all tightened leaks。After the completion of the pipeline connection accord to the requirmentHydraulic drive system installation instructionsfilled tank with 46# anti-wear hydraulic oil。Hydraulic pipeline installation

55、 of drive system shold pay attention to the clause of tense hydraulic pipeline installation 2.6 Installation of Casting slabs Site construction by electric power construction company，According to the relevant standards and requirements to lay。After installation shall be flat and no obstruction。2.7 C

56、hain scraper installationInstalled chain first then scraper。When the chain installation should be strictly in accordance with principle of scraper chain both side installation in pair . （marked before remove factory），to compensate chain manufacturing error。When the installation could drag the rotati

57、ng parts of mechanism lead in，before chain lead in sprocket shuold be note the chain ring must be vertical placement。After chain connection knock the size lock pin of chain ring into the pin endalignment with the side of chain。Note:After all chain installation ,the chain in a state of relaxation are normalstate，its be facilitate scraper installation，after scraper installation start the chain auto-tensioner sy