第九章 PFG辊压机设备的正常操作与运转
Chapter 9 Normal Operation and Running of Equipment
一、系统工艺各设备的启动顺序
1. The startup sequence of each equipment of the system process
该工艺系统设备均由计算机程序控制其启闭关系，但在调试或计算机出现故障，需要手动时，必须按规定程序开启或关闭。
The process system equipment is controlled by computer program to control its opening and closing relations, but when debugging or computer failures require manual operation, they must be turned on or off according to the prescribed procedures.
1、启动出料系统各设备；由后往前至辊压机；
1. Start each equipment of the discharging system; from back to front to the roller press;
2、启动进料系统中的除铁器和金属探测器；
2. Start the iron separator and metal detector in the feed system;
3、打开主机电源及控制柜，检查确认各仪表正常工作；
3. Turn on the power supply of the main machine computer and the control cabinet, and check that the instruments are working normally;
4、开启集中润滑系统；
4. Turn on the centralized lubrication system;
5、启动主电机；
5. Start the main motor;
6、开启进料系统各设备；
6. Turn on the equipment of the feeding system;
7、开启液压油泵电机加压，使系统压力达到设定数值；
7. Turn on the hydraulic oil pump motor to pressurize to make the system pressure reach the set value;
8、观察称量仓的料位显示，调节进料插板使料饼达到适当的厚度。
8. Observe the material level display of the weighing bin, and adjust the feeding insert to make the cake reach the proper thickness.
二、系统工艺设备的停机顺序
2. The shutdown sequence of system process equipment
1、关闭进料系统各设备；
1. Turn off the equipment of the feeding system;
2、关闭除铁器及金属探测器；
2. Turn off the iron separator and metal detector;
3、将称量料仓中的物料挤压完毕，并关闭液压油泵电机；
3. After squeezing the materials in the weighing bin, turn off the hydraulic oil pump motor;
4、关闭主电机；
4. Turn off the main motor;
5、关闭集中润滑系统；
5. Close the centralized lubrication system;
6、关闭控制柜；
6. Close the control cabinet;
7、关闭所有出料系统设备。
7. Close all discharge system equipment.
三、辊压机长时间停车必须采取的措施
3. The measures that must be taken when the roller press is stopped for a long time
1.卸掉液压系统压力；
1. Remove the pressure of the hydraulic system;
2.将各润滑点加好充足的润滑油脂，防此设备零、部件生锈或有杂物进入设备密封腔内；
2. Add sufficient lubricating grease to each lubrication point to prevent rust or debris from entering the sealed cavity of the equipment;
3.将蓄能器的充气压力降至5×105 Pa;
3. Reduce the charging pressure of the accumulator to 5×105 Pa;
4.在设备重新启动之前,必须按第六章和第七章的程序进行检查、试车.
4. Before the equipment is restarted, it must be inspected and tested according to the procedures in Chapter 6 and Chapter 7.
四.设备运行的主要参数选择及其调整
4. Selection and adjustment of main parameters of equipment operation
辊压机在运行时，可供调节的参数主要有三个，即挤压粉碎、磨辊转速和被挤压出的料饼厚度。一般来说，调节挤压粉碎力，则可以改变被挤压后的物料性能；而改变磨辊转速（在本设备的范围内），仅改变设备自身处理物料的能力，对物料性能无影响；调节被挤压出的料饼厚度，可以改变设备自身的处理能力，同时对物料的性能稍有影响；
When the roller press is running, there are three main parameters that can be adjusted, namely, crushing, grinding roller speed and the thickness of the extruded cake. Generally speaking, adjusting the squeezing and crushing force can change the performance of the material after being squeezed; while changing the speed of the grinding roller (within the scope of this equipment) only changes the equipment's own ability to handle the material, and has no effect on the material performance; Adjusting the thickness of the extruded cake can change the processing capacity of the equipment itself, and at the same time have the slight impact on the performance of the material;
1、根据被挤压物料的性质，选择适当的粉碎力，以得到最佳的节能效果。本机的粉碎力与液压系统压力关系见下表：
1. According to the nature of the material to be extruded, select the appropriate crushing force to get the best energy saving effect. The relationship between the crushing force of this machine and the pressure of the hydraulic system is shown in the following table:
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液压系统压力×105Pa
Hydraulic system pressure ×105Pa
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总粉碎力kN
Hydraulic system pressure ×105Pa
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单位辊宽粉碎力kN/cm
Crushing force per unit roll width kN/cm
|
|
50
|
2512
|
38.6
|
|
60
|
3014
|
45.4
|
|
70
|
3516
|
54.1
|
|
75
|
3768
|
58.0
|
|
80
|
4019
|
61.8
|
|
90
|
4521
|
69.6
|
|
100
|
5024
|
77.3
|
在选择了适当的液压系统工作压力后，可调节液压系统阀台上的电接点压力表的上限与下限压力指针，使压力波动在一合适的范围内（如1.2～2.0Mpa），并将其余各压力控制阀表按“液压系统试车”中所述进行调节。
After selecting the appropriate hydraulic system working pressure, the upper and lower pressure pointers of the electric contact pressure gauge on the valve table of the hydraulic system can be adjusted. Make the pressure fluctuate within the suitable range (such as 1.2～2.0Mpa), and adjust the other pressure control valve meters as described in “Hydraulic System Trial Run”.
2、辊压机处理量可以通过设置在进料装置上的调节插板，改变被挤压出的料饼厚度加以调节。辊压机的工作辊缝原则是根据工艺要求的辊压机处理量来确定，但它的下限受到原始辊缝和设备运行状态的限制，当工作辊缝过小时，料饼太薄，缺乏弹性使设备震动加大，它的上限受到主电机额定负荷的限制；另外，如果新加入料的平均粒径较大（在25～30mm以上）物料较硬，除如前所述加大回料量外，还应适当加大工作辊缝，这样有利设备稳定运转，但料饼厚度调节范围一般不能过大，料饼厚度过厚或过薄，对挤压效果和设备本身都会产生不利的影响。一般调节范围为：25-40㎜ 水泥。
The processing capacity of the roller press can be adjusted by changing the thickness of the squeezed cake by adjusting the plate on the feeding device. The working roll gap principle of the roller press is determined according to the processing capacity of the roller press required by the process, but its lower limit is limited by the original roll gap and the operating state of the equipment. When the work roll gap is too small, the material cake is too thin and the lack of elasticity increases the vibration of the equipment, and its upper limit is limited by the rated load of the main motor; In addition, if the average particle size of the newly added material is larger (above 25-30mm) and the material is harder, in addition to increasing the amount of recycled material as mentioned above, the work roll gap should also be appropriately increased, which is beneficial to the stable operation of the equipment. However, the adjustment range of the cake thickness is generally not too large. If the cake thickness is too thick or too thin, it will have an adverse effect on the extrusion effect and the equipment itself. The general adjustment range is: 25-40mm cement.
这里指的厚度为料饼的平均厚度
The thickness here refers to the average thickness of the cake
3、辊压机系统工艺设备的连锁
3. Interlocking of process equipment of roller press system
除铁器、金属探测器Iron remover, metal detector 出料输送设备Discharge conveying equipment
集中润滑系统Centralized Lubrication System
主轴承温度检测Main bearing temperature detection
主机启动main machine start 称量料仓控制Weighing Silo Control
辊缝检测Roll gap inspection
液压系统压力检测Hydraulic system pressure detection
喂料系统设备Feeding system equipment
五、辊压机控制系统报警处理
5. Alarm processing of roller press control system
1、辊缝检测报警
1. Roll gap detection alarm
1）当移动辊一侧的轴承座或移动辊整体后退量过大，达到设定的最大辊缝时，系统控制柜报警，其特征是：报警铃响，同时闪光报警器发出闪光指示，从其上可以知道辊缝过大的情况；
1) When the bearing seat on one side of the moving roller or the overall retreat of the moving roller is too large and reaches the set maximum roller gap, the system control cabinet will give an alarm. The characteristic is: the alarm bell sounds and the flashing alarm will give out flashing instructions. It can know that the roll gap is too large;
2）发生此种情况一般是因为辊缝中有较大很硬的异物，也有可能是由于进料插板调得过大，系统操作失误也有可能造成报警；
2) This happens usually because there are large and hard foreign objects in the roll gap, or it may be because the feed plate is adjusted too large, and the system operation error may also cause an alarm;
3）当发生报警时，应及时处理。当查明因异物造成，则应立即停车，排除异物。若因操作失误，液压系统未加压力，则应检查、启动液压系统；若因辊缝过大，料饼过厚，则应将插板适当下调。
3) When an alarm occurs, it should be dealt with in time. When it is found that it is caused by the foreign body, the vehicle should be stopped immediately to remove the foreign body. If the hydraulic system is not pressurized due to operating errors, check and start the hydraulic system; if the roll gap is too large and the material cake is too thick, the insert plate should be appropriately lowered.
2、液压系统压力报警
2. Hydraulic system pressure alarm
1）当液压系统超过设定工作压力一定数值后，控制系统发出报警。特征是响铃、闪光。当压力达到规定的下限时，报警；当压力达到规定的上限时，则控制系统自动关闭主电动机。
1) When the hydraulic system exceeds a certain value of the set working pressure, the control system issues an alarm. The characteristics are bells and flashes. When the pressure reaches the prescribed lower limit, an alarm is issued; when the pressure reaches the prescribed upper limit, the control system automatically shuts down the main motor.
3、液压泵滤油器堵塞报警
3. Alarm for blockage of hydraulic pump oil filter
1）当液压泵站的滤油器因杂质堵塞过滤网，造成滤油器进、出油压差过大，控制系统发出报警。
1) When the oil filter of the hydraulic pump station blocks the filter screen due to impurities, causing the oil filter to enter and the oil outlet pressure difference is too large, the control system will issue an alarm.
2）当滤油器堵塞报警发生后，不必马上停车，可以让其继续工作一定时间，待主机停止工作时，拆卸滤油器，清洗滤网。但时间不可过长，否则将会损坏过滤网。
2) When the oil filter blockage alarm occurs, it is not necessary to stop the machine immediately, and it can continue to work for a certain period of time. When the main engine stops working, remove the oil filter and clean the filter screen. But the time should not be too long; otherwise the filter screen will be damaged.
4、润滑泵贮油筒空油报警
4. Alarm for empty oil in lubrication pump oil tank
1）当润滑泵贮油筒内油脂达到规定的下限位时，控制系统发出报警。特点是响铃、闪光；
1) When the grease in the oil tank of the lubrication pump reaches the specified lower limit, the control system will issue an alarm. The characteristic is ringing and flashing;
2）当发出贮油筒空油报警时，不必停主机，而应当立即取油，用充填泵向贮油筒内打油。一般加油应小于30L。
2) When the oil storage tank empty alarm is issued, it is not necessary to stop the main engine, but should immediately take oil, and use the filling pump to pump oil into the storage tank. Generally, the fuel should be less than 30L.
5.润滑油路阻塞报警
5. Alarm for blockage of lubricating oil circuit
1）当润滑油路中某一路或几路堵塞,控制系统均能发出报警信号。其特征是，当润滑油泵工作时，即控制柜模拟板上油泵电机工作指示灯亮时，分油器接近开关发出信号；
1) When one or several of the lubricating oil circuits are blocked, the control system can send out an alarm signal. Its characteristic is that when the lubricating oil pump is working, that is, when the oil pump motor working indicator on the analog board of the control cabinet is on, the oil separator proximity switch sends one signal;
2）当发现这一异常情况时，主机可不用停车，应仔细检查各分油器的出口，确定被堵塞油路的位置加以检修。若因检修时间较长，则应停机。
2) When this abnormal situation is found, the main engine does not need to be stopped, and the outlet of each oil separator should be carefully checked to determine the position of the blocked oil circuit for maintenance. If the maintenance time is long, the machine should be shut down.
六、设备正常检查表
6. Equipment normal checklist
为了保证设备能正常运转，提高运转率，及时发现设备故障及隐患，延长设备使用寿命，必须按下表对设备进行经常的检查；
In order to ensure the normal operation of the equipment, improve the operation rate, discover equipment failures and hidden dangers in time, and prolong the service life of the equipment, the equipment must be checked frequently according to the following table;
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序号项目No. Item
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检查系统Inspection system
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检查内容Inspection content
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检查周期Inspection cycle
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处理方法Processing method
|
|
1
|
电气控制系统Electrical control system
|
a.主电控柜各仪器仪表工作发热
a. Heating of the instruments and meters of the main electric control cabinet
b.主机控制柜各仪表工作状况
b. The working status of each instrument in the main machine control cabinet
|
每天
everyday
|
更换元器件或导线;重新拧紧接头
Replace components or wires; re-tighten the connectors
增加冷却设备
Increase cooling equipment
|
|
2
|
主电机及传动系统Main motor and driving system
|
a.主电机发热正常，工作电源正常
a. The main motor is heating normally and the working power supply is normal
b.万向节传动轴轴承座与底座的联接螺栓
b. Connecting bolts between bearing seat of universal joint drive shaft and base
c.行星减速器润滑油位
c. Lubricating oil level of planetary reducer
d.行星减速器法兰螺栓
d. Planetary reducer flange bolts
e.缩套联轴器缩紧螺栓
e. Shrink sleeve coupling shrink bolts
f.扭矩支承蝶形弹簧
f. Torque support butterfly spring
g.扭矩支承铰链座螺栓
g. Torque support hinge seat bolt
|
每天
everyday
每周
weekly
每周
weekly
每月
Every month
每半月
Every half month
每天
everyday
每周
weekly
|
检查电气控制；检查、更换主电动机
Check the electrical control; check and replace the main motor
按规定拧紧力矩重新拧紧
Re-tighten according to the specified tightening torque
补充润滑油
Replenish lubricating oil
重新拧紧Re-tighten
按规定力矩拧紧
Tighten according to the specified torque
更换碟形弹簧
Replace disc spring
重新拧紧Re-tighten
|
|
3
|
主轴轴系main shaft system
|
a.主轴承温度
a. Main bearing temperature
b.磨辊辊面耐磨堆焊层厚度
b. Thickness of wear-resistant surfacing layer on roller surface
c.磨辊辊面“菱”形花纹
c. “Diamond” pattern on the surface of the grinding roller
d.端盖密度圈
d. End cover density ring
|
每天
everyday
每半月
Every half month
每天
everyday
每天
everyday
|
若需要则更换轴承
Replace bearing if necessary
重新补焊修复
Re-welding repair
局部补焊
Partial repair welding
多加润滑脂,更换密度圈
Add more grease and replace the density ring
|
|
4
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液压系统
Hydraulic system
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a.所有管接头、法兰联接
a. All pipe joints and flange connections
b.系统保压性能
b. System pressure holding performance
c.各压力保护阀的功能
c. The function of each pressure protection valve
d.液压油油位高度
d. Hydraulic oil level
e.液压油质
e. Hydraulic oil quality
f.泵站滤油器滤网
f. Pump station oil filter screen
g.蓄能器充气压力
f. Pump station oil filter screen
|
每天
everyday
每周
weekly
每半月
Every half month
每周
Weekly
每半月
Every half month
每月
Every month
每月
Every month
|
重新拧紧, 更换密度圈
Retighten and replace the density ring
更换检修有关元器件
Replace and repair related components
重新调节或更换元件
Readjust or replace components
补充液压油(同型号)
Replenish hydraulic oil (same model)
更换新液压油
Replace with new hydraulic oil
更换滤网或滤油器
Replace the filter screen or oil filter
补充氮气
Nitrogen supplement
|
|
5
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润滑系统lubrication system
|
a.润滑脂油位高度
a. Grease oil level height
b.泵站安全片
b. Pump station safety piece
c.分油器工作状况
c. Working condition of oil separator
d.泵站出油口网
d. Pump station outlet network
|
每月
Every month
每天
everyday
每天
everyday
每月
Every month
|
检修、更换空油报警装置
Repair and replace the empty oil alarm device
更换安全片
Replace the safety piece
检修各润滑管路
Overhaul each lubrication pipeline
清洗滤网
Clean the filter
|
|
6
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进料装置feeding device
|
a.进料挡板、侧挡板
a. Feed baffle, side baffle
b.调节闸板的端部
b. Adjust the end of the gate
c.侧挡板下端衬板
c. Side baffle bottom liner
|
每二月
Every two month
每月
Every month
每周
Weekly
|
更换挡板、侧挡板
Replace baffle, side baffle
修复或更换闸板
Repair or replace the gate
修复、更换衬板
Repair and replace the liner
|
|
7
|
检测系统Detection Systems
|
a.各一次仪表工作状况
a. The working status of each instrument
b.标定检测仪表
b. Calibration detection instrument
|
每天
everyday
每半年
Every half year
|
更换一次仪表
Replace the meter once
重新调试
Re-debug
|
|
8
|
主机架main frame
|
a.上、下横梁与立柱的连接
a. Connection between upper and lower beams and columns
b.地脚螺栓
b. Anchor bolts
|
每天
everyday
每天
everyday
|
按规定拧紧机架联接螺栓
Tighten the frame connecting bolts as required
重新拧紧
Re-tighten
|
