491 511 6K1 Clinker Silo - Transport2

5,000 TPD CMIC CEMENT PLANT
PROJECT IN CAMBODIA
CLINKER STORAGE AND TRANSPORT
操作说明书
Operation Specification
中信重工工程技术有限责任公司
CITIC HIC Engineering&Technology Co.,Ltd
二零一七年三月
March 2017
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
目录
Catalog
第一章前言 ............................................................................................................................. 1
Chapter 1 Foreword......................................................................................................................... 1
第二章工艺流程及工艺设备介绍 ................................................................................................ 2
Chapter 2 Introduction for technical process and equipment ............................................................ 2
一、工艺流程简介 Introduction for process ............................................................................ 2
二、工艺设备 Equipment ........................................................................................................ 2
第三章启动前的准备工作 ........................................................................................................... 3
Chapter 3 The preparation before startup ......................................................................................... 3
第四章启动与停车操作 ............................................................................................................... 7
Chapter 4 Starting and Shutdown .................................................................................................... 7
一、设备的启动操作顺序 Starting Sequence .......................................................................... 7
系统运转中的检查与调整 The inspection and adjustment during operation .......................... 12
三、系统的正常停车操作顺序 Normal Operational Sequence for Shutdown ....................... 13
四、设备故障停车及紧急停车的处理方法 Operations for fault shutdown and emergency stop
............................................................................................................................................... 14
第五章试生产阶段注意事项...................................................................................................... 17
Chapter 5 Matters need attention during the pilot production ......................................................... 17
一、概述 The general introduction ........................................................................................ 17
二、试生产的准备 Preparation for pilot production .............................................................. 17
三、试生产要领及注意事项 Main points and matters need attention during the pilot
production .............................................................................................................................. 18
四、主要设备使用维护要领 Matters for maintenance of the main device ............................. 18
第一章前言
Chapter 1 Foreword
本操作说明书仅供 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA 的熟料
储存与输送系统操作时使用。
This operation specification is only applied for operations of clinker silo and transport system
for 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA.
熟料储存与输送系统的工艺流程范围：自熟料库顶开始至配料储存库顶为止。本说明书
的内容，仅限于保证设备的正常运转及工艺操作的基本事项。为了保证顺利生产，提高设备
的运转率，本系统的操作人员必须在掌握本操作说明书内容的基础上，根据各单机设备的说
明书以及有关附图，深入了解该设备的构造、原理和性能，熟练掌握单机设备的操作、维护、
检修技术，以便及时解决生产过程中出现的各类问题。
The technical process of clinker silo and clinker transport system is from the top of clinker silo
to the top of batching storage. The specification only refers to the basic items to guarantee the
normal operation and technological operation.In order to make sure the smooth production and to
improve the equipment operation rate, the operators of this system must deeply know the structure,
principle and performance of the equipment according to the specification and attached drawings of
each single equipment, skilfully master the operation and maintenance of the single equipment and
grasp the usage of instruments and control devices on the basis of knowing the content of this
manual, so that the various problems occurring in the production process can be solved in time.
编制本操作说明书的基本依据是各类设计文件，同时结合以往生产调试的经验。在实际
生产中，如本操作说明书所述与实际情况、现场到货的设备使用说明书有偏差时，或者对所
述内容有疑问时，请与我院派往现场的调试技术人员进行协商解决，并根据实际情况进行修
改。
This operating manual is made based on various kinds of design and technical documents and
in combination with the experience of producing and commissioning in the past. In the real
production, if there is deviation between the condition described in this manual and the actual
condition, or there is any doubt about the content of this manual, please negotiate with the technical
staff we send to the site and make modification. In order to know the equipment performance better,
please refer to the specification of relevant single equipment.
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第二章工艺流程及工艺设备介绍
Chapter 2 Introduction for technical process and equipment
一、工艺流程简介 Introduction for process
本系统的工艺流程见流程图。
Process for this department refers to flowsheet.
该系统设有 1－Φ40×47.9 m 熟料库(491-3S1)和 1－Φ10×25.1m 黄料库(491-3B1)，储量分
别为 50000 吨和 1000 吨。出篦式冷却机的熟料由链斗输送机(491-AC1)送入熟料储库中，黄
料库库底开孔，接熟料散装机，由汽车运走。从熟料储库(491-3S1)库底出来的熟料经棒阀
(511-NGA~511-NGW) 、电液动扇形闸门 (511-DFA~511-DFW) 、胶带输送机 (511-BCA) 、
(511-BCB)、(511-BCC)、(511-BC1)、(511-BC2)等设备转运到水泥配料系统。
In this system there are 1－Φ40×47.9 m m clinker silo(491-3S1) and 1－Φ10×25.1m unburnt
clinker silo (491-3B1), the reserve capacity of which are respectively 50,000t and 1,000t. The
clinker from the grate cooler is transported into the silo(491-3S1or491-3B1) by pan conveyor
(491-AC1); under the unburnt silo there is connected with the clinker bulk loader, by which the
materials can be delivered by truck. The clinker from the bottom of the clinker silo is transported to
the cement batching system through rod gate(511-NGA~511-NGW), clamshell gate gate
(511-DFA~511-DFW), belt conveyor(511-BCA)、(511-BCB)、(511-BCC)、(511-BC1)、(511-BC2).
从黄料库(491-3B1)库底出来的熟料经棒阀(511-NG1)、胶带输送机(511-BCB)、(511-BC1)、
(511-BC2)等设备转运到水泥配料系统。
The clinker from the bottom of the unburnt clinker silo (491-3B1)aslo can be transported to the
cement batching system through rod gate (511-NG1), belt conveyor (511-BCB)、(511-BC1)、
(511-BC2).
二、工艺设备 Equipment
本系统所有工艺设备主要技术参数见设备表。
Equipment technical please see the equipment list.
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第三章启动前的准备工作
Chapter 3 The preparation before startup
该系统的全部设备，在启动前，都应做认真地检查、调整工作，这不仅在试生产时要做，
还必须作为一条制度，在以后的生产中，严格执行。The inspection and commissioning for the
equipment in this system must be carefully made before the startup, which should be done and
executed not only in test run but also in production.
一. 现场设备的检查 Inspection for on-site equipment
1. 润滑设备和润滑油(脂)量的检查调整
Inspection and adjustment for lubrication device and lubricating oil volume
设备的润滑对保证设备的长期稳定运转，起着关键性的作用，润滑油(脂)量应达到规定
的油标刻度范围，既不能过多，也不能过少。油(脂)量过多，会导致设备温度过高；油(脂)
量过少，设备会因缺油而损坏。另一方面，要定期检查、补充、更换润滑油(脂)。用油(脂)
的品种、牌号不能错，而且要保证油(脂)中无水无杂质。
The lubrication for the equipment plays a key role on the long-term stable operation, and the
volume of the lubricating oil directly influence the operation of equipment. Overmuch oil will lead
to equipment heating, while too little oil will result in equipment damage. On the other hand,
regularly check, add and replace the lubrication oil (grease). The type and brand of the oil (grease)
cannot be mistaken and it is guaranteed that no impurity is in it.主要检查项目有以下几点：The
main items to be checked are as follow:
1.1 所有设备的传动装置：包括电动机、减速机、联轴承等润滑点要加好油(脂)。
The transmission devices of all the equipment, including gearbox, motor, coupling and so on,
need lubrication at each lubricating point.
1.2 所有设备的各个轴承、活动部件等部分加油(脂)。
All the bearings and moving parts need lubrication.
1.3 检查油(脂)质是否变劣，确定换油(脂)与否。
Check if the oil quality turns bad and if the oil needs to be changed.
1.4 检查箱(机)底部所有放油(水)孔，拧紧堵孔螺栓。
Check all the oil (water)drains at the bottom of tank(machine) and tighten the blockage bolts.
2. 设备相关人孔门、检查门的检查及密封
Check and seal equipment interior, manhole door and inspection door.
在设备启动前，要对与设备相关设施进行全面的检查，清除由于安装或检修时掉在设备
内部的杂物，以防止设备运行时，卡死或堵死设备，造成不必要的损失。
3
Before starting the equipment, fully inspect the interior and remove the foreign matters left
inside during installation and maintenance to prevent the equipment from jamming during operation
so as to avoid the unnecessary losses.
在设备内部或相关设施检查完后，将所有的人孔门、检查门严格密封，防止生产时漏风、
漏料、漏油等。
Seal all the manhole door and inspection door strictly after checking the equipment interior, in
order to prevent air leakage, material leakage and oil leakage during production.
3. 闸门 Gate
闸门的进口闸板，要全部开到适当的位置，保证物料的畅通。
All the gate shall be open to proper position to ensure material free.
4. 所有阀门的开闭方向及开度的确认
Confirms all the gate openness direction and degree
4.1 所有的手动阀门，在设备启动前，都应打到适当的位置。
All the manual gate shall be open to proper position before starting up.
4.2 所有的电动阀门，首先在现场确认能否灵活开闭，阀轴与连杆是否松动，然后由电
控室遥控操作，确认控制室与现场的开关方向是否一致，开度与指示是否对应，如果阀门带
有上、下限位开关，要与控制室核对限位信号是否返回。
All the electric gate shall be confirmed at site for opening freely, gate shaft and tie rod to be
loosened or not, after that remotely operate in CCR, to confirm that openness direction is congruent
with operating at site, and openness degree is congruent with indicator, if gate configured with limit
switch, must verify the limit signals available in CCR.
5. 各溜管、收尘风管及输送设备的检查 The inspection for every chute, dust collection duct and
conveyor equipment
检查各溜管、收尘风管及输送设备等，确认其畅通，无堵塞，无破损和卡死现象。Check
every chute, dust collection duct and conveyor equipment to guarantee it is smooth and unblocked
without jam, damage and lock.
6. 设备紧固检查 The fastening inspection
检查设备的紧固情况，如设备的基础地脚螺栓等，不能出现松动，有的设备的传动的连
杆等易松动部件，都要进行严格的检查。Strictly check the fastening condition of equipment, such
as the foundation bolt without loosening and the driving rod without becoming flexible.
6.1 所有袋除尘器的所有螺栓全部拧紧，确保机器各部联接可靠无误。Tighten the bolts of
all bag filters to guarantee all connections are correct and stable without mistakes.
6.2 皮带机所有部件要连接牢固，地脚螺栓应拧紧。Fasten all parts of belt conveyor and
4
tighten the foundation bolts.

7. 现场仪表检查 Check on instruments at site
现场设有许多温度表、压力表、油量表、跑偏开关等，可以帮助巡检人员及时了解设备
的运行状态。设备启动前要进行全面系统的检查，并确认各种仪表电源已供上，显示正常，
处于良好的工作状态。
There are so many instruments provided on site, including thermometer, pressure gauge, oil
scale, deviation switch and so on. They can help the inspectors know the operating state of the
equipment in time. The overall inspection shall be conducted for the system before starting to
confirm all instruments have powered on and work very well, and they display normally.
8. 压缩空气的检查 Check on compressed air
检查用气点的压缩空气压力是否符合供气要求，通知现场有关人员处理。
Check on air pressure in every user and informs to relevant person if any problem.
9. 胶带输送机的调整和备妥 The adjustment and ready for the belt conveyor
9.1 减速机、电机及各润滑系统的润滑点按规定加入足够的润滑油(脂)。Add enough
lubricating oil (grease) for the reducer, motor and the lubricating point for every lubrication system
according to the regulation.
9.2 电气信号及控制装置的接线正确。Make sure that the wiring for the electrical signal and
controlling device is correct.
9.3 点动电动机，确认转动方向正确。Enable the motor to confirm that the direction is
correct.
9.4 打滑检测装置、双向拉绳开关、跑偏开关处于良好工作状态；调心装置效果良好，
清扫装置正常。Make sure that the slip detector , the double-direction stretching wire and the
deviation switch are in good condition; the centering device and the cleaning device work well.
9.5 滚筒及托辊转运灵活，输送带接头平直。Confirm that the drum and the roller move
flexibly and the contact of conveyor belt is straight.
10. 系统所有设备的调整和备妥 The adjustment and ready for all equipment
对于胶带输送机、收尘器、离心式风机等其他设备均应详细检查设备及各个部件，确保
能按要求可靠运行。Carefully check the equipment such as the belt conveyor, the dust collector
and the centrifugal fan to confirm that all can work well.
二．中控室、电控室的准备工作 Preparations in central control room & electrical control
room
1. 选择要启动的设备。Choose the device to be started.
2. 检查设备的备妥情况，如果未备妥，应与电气及现场人员联系处理。
5
Check if the devices are ready or not. If it is not ready, please contact with the electrical staff
on site for solutions.
以上各项工作完成后，系统启动前的准备工作即完成，可根据实际情况，按照启动顺序
的要求依次启动相应的设备。
After completing all above work, the preparations before startup have been made, and then
enable all devices.
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第四章启动与停车操作
Chapter 4 Starting and Shutdown
本章叙述的内容，是正常生产时的启动与停车操作顺序，紧急停车操作及常见故障处理。
试生产时，根据机电设备的考核要求，有一些特殊的操作要求，望操作时注意。
This chapter describes the starting and shutdown sequence in normal running, and emergency
stopping as well as common troubleshooting. In commissioning, as electrical and mechanical
equipments required, some special demand must be noticed.
一、设备的启动操作顺序 Starting Sequence
在设备、系统启动前，要确认系统内各设备及相关设施启动前的各项准备工作已经完成。
Before starting the equipment and the system, confirm that
序号操作步骤检查与调整
No. Operation steps Maintenance and adjustment
I 熟料库顶进料系统 he feeding system at the top of clinker silo

1 1.确认系统内各设备启动前的准备工作 1．通知有关系统，注意配合操作 inform
已经完成。Confirm that the preparation for the related departments to cooperate
starting the equipment has been done. 2．检查库内料位 check the material level
2.确认料位在低料位，允许进料 confirm
that the material is in low level for feeding
materials
2 确认各阀门的位置 confirm every valve 确认各阀门已调整到正确位置 confirm
position every valve is adjusted to the proper
position
3 启动 CLINKER SILO(491-3S1)库顶收尘
器组：风机 (491-FN2)→ 下料阀
(491-FV2)→螺旋输送机(491-SC1)→收尘
器(491-BF2)Start the dust collection group
at the top of clinker silo (491-3S1):the
fan(491-FN2)→the discharging
valve(491-FV2)→the screw
conveyor(491-SC1)→the dust
collector(491-BF2)
4 启动 CLINKER BIN(491-3B1)仓顶收尘
7
器组：风机 (491-FN3)→ 下料阀
(491-FV3)→ 收尘器 (491-BF3)Start the
dust collection group at the top of clinker
silo (491-3B1):the fan(491-FN3)→the
discharging valve(491-FV3)→he dust
collector(491-BF3)
5 启动侧三通(491-MW1)tart the side tee
(491-MW1)
6 启动窑头熟料输送组 start the clinker
transport group at the kiln head
II CLINKER BIN(491-3B1)库侧散装系统 the bulk system at the side of the clinker bin
(491-3B1)
1 确认汽车就位。Confirm the truck is in 1．通知有关系统，注意配合操作 inform
place the related departments to cooperate
2．检查库内料位 check the material level
2 确认各阀门的位置 onfirm every valve 确认各阀门已调整到正确位置 confirm
position every valve is adjusted to the proper
position
3 启动收尘组：风机 (491-FN3)→ 下料阀
(491-FV3)→ 收尘器 (491-BF3)start the
dust collection group ： the
fan(491-FN3)→the discharging
valve(491-FV3)→he dust
collector(491-BF3)
4 启动库侧卸料组：散装机(6K1-TC1) →棒
阀 (6K1-NG1)→ 电动弧形阀
(6K1-DF1)start the side unloading group：
bulk machin(6K1-TC1) →the rod
bar(6K1-NG1)→the electric arc
valve(6K1-DF1)
III 库底熟料输送系统：此系统分为以下各启动组，可根据需要进行选择。
The bottom clinker transport system: it is divided into the following startup group,
which can be chose as required.
1 风机(511-BF6) →卸灰阀(511-FV6) →收
尘器(511-BF6)→皮带机(511-BC2) →风
机(511-FN5) →卸灰阀(511-FV5) →收尘
8
器 (511-BF5)→ 皮带机 (511-BC1)→ 风机
(511-FN2) →卸灰阀(511-FV2) →收尘器
(511-BF2)→皮带机(511-BCA)→收尘器/
棒阀/电动扇形阀(511BFA~D 中任意 1 个
或 2 个 3 个开启，其余关闭;与其对应的
511-NGA~G 中任意 1 个或 2 个 3 个开启，
其余关闭;与其对应的 511-DFA~G 中任
意 1 个或 2 个 3 个开启，其余关闭)
The fan(511-BF6) →the cinder
valve(511-FV6) →the dust
collector(511-BF6)→the belt
conveyor(511-BC2) →fan(511-FN5) →the
cinder valve(511-FV5) →the dust
conveyor(511-BC1)→the fan(511-FN2)
→the cinder valve(511-FV2) →the dust
conveyor(511-BCA)→the dust
collector/the rod bar/the electric quadrant
valve(start one, two or three of511BFA~D，
and close the rest;start the corresponding
one, two or three of511-NGA~G，and close
the rest；start the corresponding one, two or
three of511-DFA~G，and close the rest)
2 风机(511-BF6) →卸灰阀(511-FV6) →收
尘器 (511-BF6)→ 皮带机 (511-BC2)
→fan(511-FN5) →卸灰阀(511-FV5) →收
尘器(511-BF5)→皮带机(511-BC1)→风机
(511-FN3) →卸灰阀(511-FV3) →收尘器
(511-BF3)→皮带机(511-BCB)→收尘器/
棒阀/电动扇形阀(511BFE~I 中任意 1 个
511-NGH~P 中任意 1 个或 2 个 3 个开启，
其余关闭;与其对应的 511-DFH~P 中任意
1 个或 2 个 3 个开启，其余关闭)
9

conveyor(511-BC2) →The fan(511-FN5)
conveyor(511-BC1)→The fan(511-FN3)
conveyor(511-BCB)→the dust
valve(start one, two or three of511BFE~I，
one, two or three of511-NGH~P，and close
the rest；start the corresponding one, two or
three of511-DFH~P，and close the rest)
3 风机(511-BF6) →卸灰阀(511-FV6) →收
尘器(511-BF6)→皮带机(511-BC2) →风
机(511-FN5) →卸灰阀(511-FV5) →收尘
器 (511-BF5)→ 皮带机 (511-BC1)→ 风机
(511-FN4) →卸灰阀(511-FV4) →收尘器
(511-BF4)→皮带机(511-BCC)→收尘器/
棒阀/电动扇形阀(511BFJ~M 中任意 1 个
511-NGQ~W 中任意 1 个或 2 个 3 个开启，
其余关闭;与其对应的 511-DFQ~W 中任
意 1 个或 2 个 3 个开启，其余关闭)
conveyor(511-BCC)→the dust
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valve(start one, two or three of511BFJ~M，
one, two or three of511-NGQ~W ， and
close the rest；start the corresponding one,
two or three of511-DFQ~W，and close the
rest)
4 风机(511-BF6) →卸灰阀(511-FV6) →收
尘器(511-BF6)→皮带机(511-BC2) →风
机(511-FN5) →卸灰阀(511-FV5) →收尘
器 (511-BF5)→ 皮带机 (511-BC1)→ 风机
(511-FN3) →卸灰阀(511-FV3) →收尘器
(511-BF3)→ 皮带机 (511-BCB)→ 收尘器
(511-BFI)→ 棒阀 (511-NG1)→ 扇形阀
(511-DF1)
conveyor(511-BCB)→the dust
collector(511-BFI)→the rod
bar(511-NG1)→the electric quadrant
valve(511-DF1)
5 风机(511-BF6) →卸灰阀(511-FV6) →收
尘器(511-BF6)→皮带机(511-BC2) →风
机(511-FN5) →卸灰阀(511-FV5) →收尘
器 (511-BF5)→ 皮带机 (511-BC1)→ 风机
(511-FN1) →卸灰阀(511-FV1) →收尘器
(511-BF1)→棒阀(511-NG2)
11
collector(511-BF1)→the rod bar(511-NG2)
系统运转中的检查与调整 The inspection and adjustment during operation
为了使系统安全、稳定地运转，必须经常观察各参数值的变化情况，及时判断系统的运
转状态，同时，采取适当的措施进行检查、调整。主要检查调整项目见表 4-1。In order to
guarantee the system is running safely and stably, the changes of parameters must be observed to
make judgment for the system operation, and proper measures and actions must be taken to inspect
and adjust. See Table 4-1 for main items to be checked.
表 4-1
Table 4-1
序号检查项目检测、判断方法调整、处理方法
No. Items to be Inspection and judgment method Adjustment and disposal method
checked
1 收尘器工作不 1.糊袋。The bag is burnt. 1.停机检查、清理、修补、更换
正常，车间内冒 2. 滤袋破损。The filter bag is 滤袋。Stop to check, clean, repair
灰或排尘浓度 worn. and replace the bag.
增大。 3.电源发生故障。There is some 2.检查供电系统，恢复正常。
The bag filter fault on the power supply. Check the power supply and
cannot work 4. 收尘器控制装置失灵。 The return it to normal.
well and the ash controller of the bag filter fails to 3.停车检修控制装置和工作机
and discharged work. 构。Stop to check the controlling
dust consistence device and structure.
in the
department
increases.
2 胶带跑偏 (1) 安装中心线不直。 The (1)校正安装中心线。Adjust the
12
The belt installation centerline is not installation centerline.

deviates. straight (2)重新粘接胶带头。Reconnect
(2)胶带接头不整齐。The contact the belt contact.
of the belt is uneven (3)调整滚筒，清除滚筒上物料。
(3)滚筒托辊中心线与胶带机中 Adjust the drum and remove the
心线不成直角。The centerline of materials on the drum.
the roller and that of the belt (4)调整下料点。Adjust the point
conveyor is not in a right angle. of discharging point.
(4)滚筒不水平。The drum is out (5) 启动跑偏开关。 Start the
of level. deflection switch.
(5) 滚筒表面粘结物料。 The
materials are stuck on the drum
surface.
(6)物料下料点不在胶带中间。
The point of discharging point is
not in the center of the belt.
(7)胶带初始张力太大。
The initial tension of belt is very
large.
三、系统的正常停车操作顺序 Normal Operational Sequence for Shutdown
把决定要停止的设备所在组的启动开关按顺序逐一延时打到“停止”位置，此组内设备再
按停车顺序逐一延时(延时时间可根据实际情况进行设定)停车。每次停车前注意尽量确保输
送系统设备正常停车时卸空设备上的物料，以便下次正常启动。在正常情况下，停车顺序为
启动顺序的逆顺序。
According to the process sequence, push the start switches of the group including the devices
to be halted to “stop” position, and then the devices in the group is stopped by time-delaying
according to the stop sequence. Before stopping, it is confirmed that the materials on the
transporting systems (such as the limestone transporting system) are removed and cleared for the
next normal startup. In addition, operations for lubrication and cooling should be up to the
requirements, in order to protect the devices which must be checked frequently. In normal condition,
the stop sequence is opposite to the starting sequence.
13
四、设备故障停车及紧急停车的处理方法 Operations for fault shutdown and emergency stop
在设备运行过程中，由于设备突然发生故障，电动机过载跳闸，机电设备保护跳闸，现场停车按纽按下时，
系统的部分或全部设备会联锁停车。另外，在某种紧急情况下，为了保证人身及设备安全，也会使用紧急
停车按纽，使整个系统紧急停车。为了能顺利地再次启动，必须进行如下处理、操作。
When equipments are running, due to sudden failures like motor overload tripping, protection
tripping, or button stop locally, the system would be interlocked to shut down partially or wholly,
additionally, in case of urgency to prevent personal injury and equipment damage also need button
the emergency stop for whole system to shut down, before next starting up, must take action as
following:
4.1.1 本系统可能出现的需要进行人为紧急停车的情况有以下几种：
The following conditions need manual emergency stop:
1). 胶带严重跑偏或打滑。The belt seriously deviates and slips.
2). 胶带接头撕裂或脱开。The belt contact is torn or dropped.
3). 袋收尘器掉袋或袋破损。The filter-bag is fallen or worn.
4.1.2 设备突然停车的基本处理方法
After equipment stopped suddenly, actions shall be taken as:
1). 马上停止相关设备。
Immediately stop the relevant equipment which provides materials to the halted device.
2). 尽快查清原因，判断能否在短时间(30 分钟)内处理完，以决定再次启动时间，并进行
相应的操作。
Find out reason as soon as possible and judge if it is handled within a short time (in 30min),
and then determine the restart time and the follow-up procedures.
常见故障及其处理见下表 Common faults and processing methods:
4.2 常见故障及其处理见表 4-2。 Common faults and processing methods4-2
14
表 4-2
Table 4-2
序号发生故障设备现象及原因处理方法
No. Device with faults Phenomenon and Solution
reason
1 胶带撕裂。 1.胶带接头断裂。 1.检查修复胶带。
The belt is torn. The contact of the belt Check and repair the
is torn. belt.
2.胶带带芯脱开。 2.更换胶带。
The core of the belt
slips off.
2 收尘器工作不正常， 1.糊袋。 1.停机检查、清理、修
车间内冒灰或排尘 The belt is burnt. 补、更换滤袋。
浓度增大。 2.滤袋破损。 Stop for checking,
The dust collector The filter belt is worn. cleaning, repairing and
fails to work, 3.电源发生故障。 replacing the filter belt.
resulting in the There is some faults on 2.检查供电系统，恢复
discharged dust or the power supply. 正常。
ash increases. 4.收尘器控制装置失 Check the power supply
灵。 system.
The dust collector is out 3.停车检修控制装置和
of order 工作机构。
Stop for checking the
control device and
working units.
4.3 紧急停车操作 Operation for Emergency Stop

当出现紧急情况时，需要全部停车。设备紧急停车后，应对设定值、阀门等进行调整，
15
并及时处理紧急情况，尽快恢复系统运行。再次启动时必须注意：由于系统在紧急情况下停
车，各设备内均会有积料，因此不能象正常情况下那样启动后立即喂料，应待设备内部物料
输送之后，才开始喂新料。
In occurrence of urgent event, all equipments must be stopped. After urgency shutdown, reset
the set value and valve etc, immediately take action for troubleshoot, restart the system as soon as
possible. Notice to restarting: as under emergency stop, equipment should be left some residual
which must be cleaned out for next feeding.
16
第五章试生产阶段注意事项
Chapter 5 Matters need attention during the pilot production
一、概述 The general introduction
系统内所有设备安装完毕，各台单机均按产品说明书要求检查调整并确认合格后，进行
单机空载试运转。单机无故障、空载连续运转时间满足要求后，方可进行空载联动试运转。
联动试运转后应对所有设备再次进行全面检查，确认系统没有问题，再进行荷载联动试运转。
荷载联动试运转前，需检查前面烧成系统及后面的水泥配料站备妥情况；荷载联动试运转中，
要求注意观察设备运行情况，记录设备的基本考核指标。Install all equipment in this system,
check and confirm every single unit according to the specifications, and then start the test run for
the single unit with dead load. Make sure that the single unit works without fault and it runs for
certain time before the linkage trial run with dead load. After the linkage trial run, recheck all
equipment without fault and then start the linkage trial run with load. Before the trial run, it is
necessary to check if the firing system and the cement batching station are ready or not; during the
trial run, it must observe the running condition of equipment and record the basic indicators for
performance appraisal.
该系统的荷载联动试运转分为空负荷、满负荷两个步骤进行。满负荷试运转过程中，按
各单机设备技术特性所规定的数据进行检验。There are two steps for the linkage trial run: dead
load and full load. When it runs with full load, inspect and check the specified data according to the
technical feature of every single unit.
二、试生产的准备 Preparation for pilot production
2.1 本系统必须在空载试运转合格后，方能投料进行荷载试运转。The system must meet the

requirements of trial run without load before feeding materials for the trial run with load.
空载试车必须达到下列要求：
The no-load trial run must meet the following requirements:
1) 运转平稳正常，无擦碰现象。The running is normal and stable without any friction.
2) 主电动机电流平稳。The main motor electricity current is smooth and stable.
3) 各润滑部位的密封处、结合面无渗油、漏油现象。The sealing points and interfaces of the
lubrication parts is free of oil leakage.
17
4) 轴承最高温度不超过规定值，温升满足要求。The maximum bearing temperature should

not be higher han the specified value and the temperature rise should meet requirements.
5) 停机后，应检查运转中各部分螺栓和联结销、紧固件有无松动现象，并拧紧松动的螺
栓和紧固件。After the machine stops, check whether the bolts, coupling pins and fasteners become
flexible; if any, tighten them.
6) 符合行业规范及设备说明书对空载试运转的各项要求。Follow the industry standards and
the requirements specified in the specifications.
2.2 系统首次投料之前，应对设备进行检查和调整，重点是：
Before the first material feeding, check and adjust the equipment, and the key points are:
1) 检查和调整设备各运动部件。Check and adjust each moving part.
2) 检查电机、减速器及各润滑系统的润滑点加入足够的润滑油。Check the lubrication points
of motor, reducer and every lubrication system, and add enough lubrication oil.
3) 检查确认电气信号和仪表正常无误。Check and confirm the electrical signal and
instrument are in good condition.
4) 确认电动机转动方向正确。Confirm the rotation direction of motor is right.
5) 检查各润滑部位密封处、结合面有无渗油、漏油现象。Check if there is oil leakage on
sealing points and interfaces of the lubrication parts.
三、试生产要领及注意事项 Main points and matters need attention during the pilot
production
3.1 确认所有设备正常运行，供电系统、通讯设施备妥。Confirm that all equipment are in

normal running, the power supply system and the communication facilities are ready.
3.2 对设备进行检查、维修，必须在确认系统停车后进行，绝不允许设备运行时检修设
备。Check and maintain the equipment after the system stops; forbid the maintenance when the
equipment is running.
四、主要设备使用维护要领 Matters for maintenance of the main device
设备的使用维护要领参见各设备的使用说明书。
See the relevant operation specification of each device for information about usage and
maintenance.
1. 胶带输送机 the belt conveyor
1.1 机器润滑 the lubrication
18
机器润滑详见单机操作说明书。See the operation specification for details about the

equipment lubrication.
1.2 使用和维护要领 main points for operation and maintenance
机器试运转前要做到以下几点：
The following points must be done before trial run:
1) 检查地脚是否牢固。Check if the foundation bolts are tightened.
2) 检查机器各部联接是否无误。 Check whether the connections for each part are correct.
3) 检查拉紧情况。Check the tensioning conditions.
4) 检查各润滑点的润滑情况。Check the lubrication condition of each lubricating point.
5) 空载运转检验合格后，方可进行荷载运转。The no-load trial run must be qualified before
starting the trial run with load.
1.3 保持胶带松紧适当。如发现跑偏应及时进行调整。Keep the belt in a proper tension;
adjust it immediately if it deviates.
1.4 运转过程中发生不正常声响和故障，应立即停止运转，认真检查发生的原因，并排
除故障。Stop the machine if there is abnormal sound and fault during the running, and then
carefully check to find out the reasons and remove the fault.
1.5 使用中除注意日常维修保养外，还要定期检查、维护驱动装置、拉紧装置，及时更
换已磨损或失效零件。Besides the daily maintenance for the parts, it is necessary to regularly
check and maintain the driving device and tension device, and timely replace the worn or invalid
parts.
2. 袋收尘器 Bag filter
2.1 试运转 Trial run
1). 开车前，严格检查机内是否有杂物，如有应在试运转之前清理干净。Check if there are
impurities inside the machine and clean it (if any) before trial run.
2). 检查滤袋是否悬挂牢固。如太松，应重新扎紧。Check if the filter-bag is firmly hung;
retighten it if it is loose.
3). 检查各检查门是否密封，关严。Check if the inspection door is sealed and closed.
2.2 操作维护和检修 operation and maintenance
2.2.1. 维护 Maintenance
1). 各传动部件如轴承、齿轮、蜗轮蜗杆，都要定期注润滑油。Regularly add lubrication oil
to each driving parts such as bearing, gear, worm and gear.
2). 定期打开顶盖上的人孔门，检查清洁室内悬臂和悬臂上的切换阀门，撞头机构的运转
19
情况，发现问题，及时处理。Regularly open the manhole door to check the cantilever, the switch
valve on it, and the condition of rams in the cleaning room; timely handle it if there is any fault.
3). 经常检查各人孔门的密封性能，发现问题应及时处理，以避免漏风。Regularly check the
sealing condition of the manhole door and timely handle the problems to avoid air leakage.
4). 灰斗积存的粉尘，应定时清卸。Clean and discharge the dust in the dust hopper at
intervals.
2.2.2. 收尘器运行半年后应中修一次。中修包括下列内容：
The bag filter should have a medium maintenance after running for half a year, and it
includes the following items:
1). 检查滤袋有无破损，如有则应及时更换。Check if the bag is worn and replace it (if any).
2). 检查滤袋是否过松，如过松则应重新扎紧。Check if the bag becomes flexible and tighten
it if it is loose.
3). 检查各处仪表工作是否正常；如不正常应更换元件。Check if every instrument works
well and replace it (if any).
4). 收尘器运行一年后应进行大修。大修内容除中修内容外，还应检查有无损坏和锈蚀的
部件。若有应进行处理或更换。Have a turnover job after the bag filter runs for a year. Besides the
items in the medium maintenance, it is necessary to check if there is any damaged and corrosive
part; if any, dispose or replace it.
2.3 日常维修 ordinary maintenance
2.3.1 排灰装置 dust-removal device
1). 检查重锤是否灵活；check if the hammer is flexible;
2). 加油点要定期加油；regularly add lubrication oil;
3). 不要使螺栓之类的硬质杂物进入排灰装置；make sure that no stiff impurities such as
bolts in the dust discharging device;
4). 定期清除由于粉尘潮湿引起的结块和起拱的故障。Regularly clean and remove the
blocks and arch camber caused by moisture dust.
20

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5,000 TPD CMIC CEMENT PLANT

CLINKER STORAGE AND TRANSPORT

CITIC HIC Engineering&Technology Co.,Ltd

Chapter 2 Introduction for technical process and equipment

一、工艺流程简介 Introduction for process

tighten the foundation bolts.

一、设备的启动操作顺序 Starting Sequence

I 熟料库顶进料系统 he feeding system at the top of clinker silo

valve(511-FV6) →the dust

collector/the rod bar/the electric quadrant

系统运转中的检查与调整 The inspection and adjustment during operation

增大。 3.电源发生故障。There is some 2.检查供电系统，恢复正常。

The belt installation centerline is not installation centerline.

三、系统的正常停车操作顺序 Normal Operational Sequence for Shutdown

四、设备故障停车及紧急停车的处理方法 Operations for fault shutdown and emergency stop

4.3 紧急停车操作 Operation for Emergency Stop

Chapter 5 Matters need attention during the pilot production

一、概述 The general introduction

二、试生产的准备 Preparation for pilot production

2.1 本系统必须在空载试运转合格后，方能投料进行荷载试运转。The system must meet the

4) 轴承最高温度不超过规定值，温升满足要求。The maximum bearing temperature should

3.1 确认所有设备正常运行，供电系统、通讯设施备妥。Confirm that all equipment are in

四、主要设备使用维护要领 Matters for maintenance of the main device

机器润滑详见单机操作说明书。See the operation specification for details about the

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