5,000 TPD CMIC CEMENT PLANT

PROJECT IN CAMBODIA

COAL CRUSHING
AND STORAGE HALL
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 ......................................................................................................... 4
Chapter 1 Introduction ................................................................................................................. 4
第二章 工艺流程及工艺设备介绍 ........................................................................................ 6
Chapter 2 Introduction for process and quipment .................................................................. 6
一、工艺流程简介 Introduction for process ....................................................... 6
二、工艺设备 Equipment ................................................................................... 7
第三章 启动前的准备工作 ...................................................................................................... 8
Chapter 3 Preparation Work prior to Startup .......................................................................... 8
一、现场设备的检查和准备 Inspection for equipment ...................................... 8
二、电气设备的检查和准备 Examination and preparation for electrical devices
.......................................................................................................................... 14
第四章 启动与停车操作......................................................................................................... 16
Chapter 4 Operations for start and stop.................................................................................. 16
一、系统启动操作 Starting operations ............................................................ 16
二、系统正常停车操作 The normal stop operation of the system .................... 21
三、设备故障停车和紧急停车的处理 Operations for fault shutdown and
emergency stop ................................................................................................. 22
第五章 设备单体试车 ............................................................................................................. 25
Chapter 5 Single-unit test run ............................................................................................... 25
一、设备试车条件 Conditions for test run ....................................................... 25
二、试车过程 The process of the trial run. ...................................................... 25
三、试车要求 Requirements for test run .......................................................... 26
四、单机试车后确认事项 Items to be confirmed after single-unit test run ...... 29
第六章 试生产阶段注意事项 ............................................................................................... 30
Chapter 6 Precautions at Trial Production............................................................................. 30

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

一、概述 The overview .................................................................................... 30

二、试生产的准备 The preparation for the trial run ......................................... 31
三、试生产要领及注意事项 The main points and items needing attention in the
trial run ............................................................................................................. 32
四、 设备使用维护要领 Utilization and maintenance essentials of
equipment ........................................................................................................ 34

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第一章 前 言

Chapter 1 Introduction
本 操 作 说 明 书 仅 供 5,000 TPD CMIC CEMENT PLANT PROJECT IN
CAMBODIA 的 COAL CRUSHING AND STORAGE 在操作时使用。
This operating manual shall be only applied to the COAL CRUSHING AND
STORAGE for 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
本系统是指从原煤卸车开始到原煤被送到 COAL MILL 原煤仓为止的工艺
生产线。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及附图，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，掌握仪表及控制装置
的使用要领，以便及时解决生产过程中出现的各类问题。
The system refers to the processing production line from raw coal unloading to
raw coal bin of COAL MILL . The manual is only limited to ensure the normal
running of equipment and the basic matter for the processing operation. In order to
make sure that production goes smoothly, and the running rate of equipment is
improved, firstly, the operator of the system must master the content of the manual,
and know further about the configuration, principle and performance of the equipment
according to the specification and attached drawing of single equipment. In this way,
master skillfully the operation, maintenance, and overhaul technology of the single
equipment, know the using points of instrument and its control device, to eliminate
the various problems appeared in the production immediately.
编制本操作说明书的基本依据是各类设计技术文件，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有偏差时，或者对所述
内容有疑问时，请与我公司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。为更好地了解设备性能，请参阅有关的单机设备说明书。
The establishment of the operation manual is on the base of the various design
technique documents, moreover, combining with the antecedent experience of the

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

production debugging. In the actual production, if you find that there is any deviation
between the operation manual and the actual condition, or you have any doubt about
the stated content, please get in touch with the debugging technician sent to the work
field by our company to negotiate and solve, and correct it according to the actual
condition. Please read the relevant single equipment's operation manual for knowing
the performance of equipment well.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第二章 工艺流程及工艺设备介绍

Chapter 2 Introduction for process and quipment

一、工艺流程简介 Introduction for process

水泥储存及输送系统的工艺流程图见附图。
Process for this department refers to flowsheet.
外来原煤由汽车运输进厂，经汽车翻车机（L11-T11）卸入受料斗（L11-HP1），
然后经板式喂料机（L11-AC1）、胶带输送机（L11-BC1）经三通阀门（L11-MW1）
输送至破碎机（L11-RC1）进行破碎，破碎之后的原煤经皮带机（L11-BC2）送
至悬臂式侧堆料机（L11-ST1）在预均化堆场内往返布料，堆场内共设有两个料
堆，储存能力 2×10760 吨。原煤由桥式刮板取料机（L21-RE1）从端面取料并
送入胶带机（L21-BC1）,一路经胶带机（L21-BC2）、三通阀（L21MW1）、胶
带机（L21-BC3）输送至原煤仓（L21-3B1）。
Raw coal transported to the plant by the truck and unloaded by automobile tripper
（L11-T11）to receiving hopper（L11-HP1）， then conveyed by apron feeder
（L11-AC1）,belt conveyor（L11-BC1）,two-way gate（L11-MW1） to coal crusher
（L11-RC1）the crushed coal transported to pre-homogenization yard, return
distributed by cantilever side stacker（L11-ST1）on pre-homogenization yard.There
are two stock piles with stock capacity of 2×10760 tons on the yard. Raw coal is
reclaimed by bridge scraper reclaimer （L21-RE1）from end surface and conveyed to
belt conveyor （L21-BC1）. Raw coals are conveyed to raw coal bin （L21-3B1）
through belt conveyor（L21-BC2）,two-way gate（L21MW1）,belt conveyor
（L21-BC3）.
外来原煤也可以不经过破碎机（L11-RC1），直接由三通阀门（L11-MW1）
排出。
The coal also can be dischange by bypass through the two-way gate（L11-MW1）
before coal crusher（L11-RC1）.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

在胶带机（L21-BC2）上设有除铁器(L11-MS1)，以去除原料中可能的铁件。在
各转运站设置有袋式除尘器处理粉尘。
There is magnetic separator(L11-MS1) on the belt conveyor（L21-BC2）to remove
metal from the coal.There is bag filter on all the transport stations to handle the
powder and dust.

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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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第三章 启动前的准备工作

Chapter 3 Preparation Work prior to Startup

本车间全部设备，在启动前都应做认真的检查调整工作，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，保证设备的正常运转。
Before the starting, all the equipments of this system should be seriously checked
and adjusted, which not only should be done in the trial production, but also must be
carried out in the hereafter production as a system, to ensure the normal running of the
equipment.

一、现场设备的检查和准备 Inspection for equipment

1.1 润滑装置和润滑油量的检查和调整
设备的润滑对保证设备的长期稳定运行，起着关键性的作用。润滑油量的多
少直接影响设备的运转，必须掌握恰当。油量过多，会引起设备发热，油量过少，
设备将因缺油而损坏。同时，要严格按照各单体设备制造厂说明书的要求，定期
检查、更换润滑油。用油的品种、标号不能错，油质应符合要求，应保证油中无
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. The lubricating oil shall be inspected and exchanged regularly
in strict accordance with the specification of each single equipment. The kind and
grade of oil shall not be wrong and the oil quality shall meet the requirements. No
water or impurity is allowed in the oil. The main chek project has the following points:
1.1.1 汽车翻车机 (L11- TI1)、板式输送机 (L11-AC1)、堆料机 (L11-ST1)、
取料机 (L21-RE1)、辊式破碎机（L11-RC1）。各润滑点润滑油和润滑脂注入量
要适当，油路要畅通。润滑油必须是过滤后的清洁油。
1.1.1Each lubricating point of Side tipper (L11- TI1) 机 Apron

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

conveyor(L11-AC1),Stacker(L11-ST1), Reclaimer（L21-RE1）and crusher(L11-RC1)

must be injected proper lubricating oil and grease, and the oil line must go smoothly.
The lubricating oil must be filtered cleansing oil.
1.1.2 所有设备的传动装置，包括减速机、电机、联轴器等润滑点均要加好
油。
1.1.2 Inject adequate oil to each lubricating point at the gearings of all the equipments,
including the speed reducer, motor, coupling and so on.
1.1.3 所有设备轴承、活动部件等部位要加好油。
1.1.2 Inject adequate oil to each lubricating point at the gearings of all the equipments,
including the speed reducer, motor, coupling and so on.
1.1.4 检查油质是否变劣，确定换油与否。
1.1.4 Check whether the oil becomes bad and decide whether the oil is needed to be
replaced.
1.1.5 检查箱（机）底部所有放油孔，拧紧堵孔螺栓。
1.1.5 Check all the drainage holes for the oil at the bottom of the examination box,
and tighten the plugging hole bolt.
1.2 设备内部、人孔门、检查门的检查和密封。
1.2 Check and seal the inside of equipment, manhole door, and the inspection door.
在设备启动前，要对设备内部进行全面的检查，清除安装或检修时掉在设备
内部的杂物，以防止设备运行时，卡死或打死设备，造成不必要的损失。
Before the startup of equipment, take an overall check for the interior of
equipment. Eliminate the sundries left inside the equipment when installation or
maintenance to prevent the equipment from being locked or stopping abnormally and
resulting in the unnecessary loss.
After the check for the interior of equipment, seal all the manhole door,
inspection door strictly to prevent the leakage of air, material, oil and so on.
1.3 闸阀的检查和备妥。Inspection and preparation of the shut off gate
各处闸阀必须启闭灵活。系统启动前应开到适当开度。
Each shut off gate must be able to be opened and closed freely. Before the

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

startup of the system, the brake valve must be kept a certain opening.
1.4 设备的紧固检查 Check for the fastening of equipment
启动前，必须检查所有设备的紧固情况，将所有联接螺栓、地脚螺栓全部拧
紧。连续运转 4 小时后各部位连接螺栓要重新紧固一次，一周内再反复 2～3 次。
Before the startup, the fastening condition of all the equipments must be checked.
Tighten all the connecting bolts and foundation bolts firmly. Each connecting bolt
must be tightened one time again after continuously running for 4 hours, and repeat it
for two or three times during one week.
1.4.1 汽车翻车机 (L11- TI1)、辊式破碎（L11-RC1）、板式输送机(L11-AC1)、
堆料机 (L11-ST1)、取料机 (L21-RE1)所有螺栓全部拧紧，确保机器各部联接可
靠无误。
All the bolts of automobile tipper (L11- TI1), Apron conveyor (L11-AC1),
crusher（L11-RC1）Stacker(L11-ST1)and Reclaimer (L21-RE1)should be tightened
firmly to ensure the connecting of each part for the machine must be reliable and
correct.
1.4.2 确认系统全部设备易松动部位均已紧固无误。
1.4.2 Confirm the easy-to-loose parts of all the equipment have been fastened.
1.4.3 检查各溜管、收尘风管及棒阀等，确认其畅通，无堵塞，无破损和卡
死现象。
1.4.3 Check all the chutes, the dust collecting duct and the rod valve to confirm
they are smooth. No blockage, damage or sticking is allowed.
1.5 现场仪表检查 Inspection for on-site instruments
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

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

well, and they display normally.

1.6 生产设备的调整和备妥
1.6 Adjust the production equipment to be ready
1.6.1 板喂机(L11-AC1)的调整和备妥
1.6.1 Adjustment the apron feeder(L11-AC1) to be ready
1.6.1.1 试车前必须检查减速器旋转方向，不允许逆工作旋转方向的反向旋转。
1.6.1.1 The rotating direction of the gearbox must be checked before the test run.
Reversing rotation that is opposite to the working rotating direction is not allowed.
1.6.1.2 进行润滑装置运转调试，达到正常运转，各润滑点能溢出油脂。减速
器按油标位置注入润滑油，润滑油必须是过滤后的清洁油，各润滑点注入适量的
润滑油。
1.6.1.2 The operating commissioning shall be conducted for lubricating device
until it can operate normally and the oil and grease can overflow at each lubricating
point. The lubricating oil shall be added into the gearbox to the oil level mark. The
lubricating oil must be clean oil which has been filtered. Each lubricating point shall
be lubed by appropriate amount of lubricating oil.
1.6.1.3 调节拉紧装置使链板具有足够的张力，得到较小的链板垂度，保证主
从轮能很好的啮合，并尽可能使两个拉紧丝杆的拉力近似相等。
1.6.1.3 Adjust the tensioning device to make the chain plate has enough tension
and obtain small sag. Ensure the driving and driven wheel mesh well with each other.
And make the tensile force of two tensioning screw rods as equal as possible.
1.6.1.4 检查链板装置螺栓是否拧紧，严禁松动。
1.6.1.4 Check if the bolts of chain plate device are tightened or not, never be
loosened.
1.6.1.5 确认各部位无误后，低速启动空载运转，检查正常后，逐渐达到正常
运转速度，运转若干小时(时间长短根据情况而定)。
1.6.1.5 After confirming all parts are correct, start no-load operation in low speed.
After inspection and making sure it operates normally, gradually accelerate it to
achieve normal operating speed, running for several hours(running time depends on

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

the situation).
1.6.1.6 空载运转检查完毕后，方可进行有载运转。
1.6.1.6 After inspecting no-load operation, start on-load operation,
1.6.2 胶带输送机(L11-BC1、L11-BC2、L11-BC3、L21-BC1、L21-BC2、
L21-BC3)的调整和备妥.
1.6.2 Adjusting belt conveyor (L11-BC1、L11-BC2、L11-BC3、L21-BC1、
L21-BC2、L21-BC3)to be ready
1.6.2.1 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，联
轴器、液力偶合器按规定充入工作油。
1.6.2.1 Add enough lubricating oil into the lubricating points of gearbox, motor
and each lubricating system according to the regulation. Add working oil into the
coupling and hydraulic coupling in accordance with the regulation.
1.6.2.2 电气信号及控制装置的接线正确。
1.6.2.2 The wiring of electric signals and control device is correct.
1.6.2.3 点动电动机，确认滚筒转动方向正确。
1.6.2.3 Jog the motor to confirm the roller rotates in correct direction.
1.6.2.4 胶带打滑检测装置、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。
1.6.2.4 The belt slip detector, dual-direction stretching wire switch, deviation
switch are in good working condition. The aligning device works well and the
cleaning device works normally.
1.6.2.5 滚筒及托辊转运灵活，输送带接头平直。
1.6.2.5 The roller and idler shall rotate flexibly and the belt joint shall be flat and
straight.
1.6.3 破碎机(L11-RC1)的调整和备妥
1.6.3 Adjusting the crusher(K11-RC1) to be ready
1.6.3.1 轴承、传动部位注入适量的润滑油和润滑脂。
1.6.3.1 Add appropriate amount of lubricating oil and grease to the bearing and
pinion shaft.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

1.6.3.2 确认电动机方向正确无误。
1.6.3.2 Confirm the motor direction is correct.
1.6.3.3 确认破碎腔内无金属异物，转子盘车检查，消除一切不应有的金属碰
撞声。
1.6.3.3 Confirm there is no metal foreign matters in the crusher cavity. Turning
the rotor to check and remove all undue metal clash.
1.6.3.4 确认各部件螺栓及地脚螺栓均已锁紧，机体上所有的门已牢固关闭。
1.6.3.4 Confirm the bolts of all the components and the anchor bolts have been
tightened and all the doors on crusher body have been closed firmly.
1.6.4 堆料机(L11-ST1)、取料机(L21-RE1)的调整和备妥。
1.6.4 Adjustment the Stacker(L11-ST1)、Reclaimer(L21-RE1) to be ready
1.6.4.1 检查传动机构及零部件，保证其装配正确，铰接点转动灵活；链条张
紧程度合适。
1.6.4.1 Check the drive mechanism and its part, ensure that they assemble
properly, the pin-connected point rotates flexibly, and tension degree of the chain is
proper.
1.6.4.2 检查各部分润滑是否正常，油位是否符合要求。
1.6.4.2 Check whether the lubrication of each part is normal, and the oil level
meets the requirement or not.
1.6.4.3 检查制动器、行程开关、总开关等，保证其处于正常状态，动作灵活、
准确安全、间隙合适。
1.6.4.3 Check the arrester, excursion switch and the master switch, ensure that
they are in normal condition, and they rotate flexibly, accurately and safely, with
proper clearance.
1.6.4.4 检查电缆卷盘及电缆，确定电缆卷绕正确、电缆不得有损坏、烧焦现
象。
1.6.4.4 Check the cable coiling and the cable, ensure that the cable coils correctly,
and the cable should not have damage and scorch condition.
1.6.4.5 检查料耙钢丝绳，确定其在卷筒中和滑轮中卷绕正确。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

1.6.4.5 Check the steel rope of the material harrow, ensure it coils correctly in
the roll and in the pulley.
1.6.4.6 检查各种保护装置是否齐全。
1.6.4.6 Check whether all kinds of the protecting devices are enough.
1.6.4.7 检查刮板输送链的润滑是否良好，滴油嘴磨损是否严重，是否对准内
外链板的缝隙；
1.6.4.7 Check whether the scraper conveyor chain works well, whether the oil
nozzle is damaged severely, and whether the gap for inside and outside of the chain
plate is zeroed.
1.6.4.8 确认各部位无误后，低速启动空载运转，检查正常后，逐渐达到正常
运转速度，运转若干小时(详见各单机操作使用说明书)。
1.6.4.8 Make sure each part has no mistake, and start up in low speed for
unloading run. After checking and ensuring all is right, speed up to the normal
operating speed for several hours (details can be seen in the operation manual of each
single equipment).
1.6.4.9 空载运转检查完毕后，方可进行有载运转。
1.6.4.9 After checking the unloading run, the loading run can start.

二、电气设备的检查和准备 Examination and preparation for

electrical devices

2.1 选择要启动的设备。Choose the device to be started.

2.2 检查电源是否供上。Check whether it is energized.
2.3 电气开关柜推到工作位置上，注意是否有人维修，严防误送电发生事故。
Push the electrical cabinet to the working position and check if there are
servicemen to avoid electric shock.
2.4 确认控制室的阀门指示位置与现场是否一致。
Confirm whether the indicating position of the valve of control room is in line
with that on site.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

2.5 确认高压设备送电条件并送电。
Confirm the MV devices is qualified for power transmission and then energize.
2.6 确认操作台以及各动力控制箱的按钮、选择开关、指示灯、报警器等均
处于良好状态。
Confirm the operation station and buttons, option switches, indicators and alarms
of the power control boxes are in good condition.
2.7 检查设备的备妥情况。如果有尚未备妥的，与电气及现场人员联系处理。
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，系统启动前的准备即已就绪，可根据实际情况，按起
动顺序逐台启动所有设备。
After completing all above work, the preparations before startup have been made,
and then enable all devices one by one in sequence.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第四章 启动与停车操作

Chapter 4 Operations for start and stop

一、系统启动操作 Starting operations

本系统 PLC 启动，启动顺序及连锁关系见电气部分。有关 PLC 集中控制的

具体操作见电气说明。在正常启动前，必须做好系统启动前的所有准备工作，确
认各主机系统及各辅机系统能正常运行，确认供水系统工作正常，确认设备润滑
正常。另外，在系统启动后，要勤观察各设备、仪表及系统的运行状况，发现问
题及时处理。
This system is started by PLC and the startup sequence and interlocks are shown
in the electrical part. See detailed operations for PLC centralized control in the
electrical specification. Before startup, all preparations must be made to confirm that
the host system and the auxiliary systems can be normally operated, the water supply
system is in good condition and the lubrication for devices is well done. In addition,
after startup, the running condition for every device, instrument and system should be
frequently observed and problems (if any) must be solved immediately.
表 4−1 卸料系统至散装系统启动操作顺序表
Table 4-1The Startup Operation Sequence List from automobile tripper to coal
bulk loading

序 号 操 作 步 骤 检 查 与 调 整

No. Operating Step Checking and Regulating

1 散装机(L11-TC1)启动。
Start up Telescopic Chute
(L11-TC1)

2 风机（L11-FN2）启动。
Start up fan（L11-FN2）

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3 收尘器（L11-BF2）启动。
Start up bag filter（L11-BF2）
4 胶带输送机(L11-BC3)启动。 检查各部件运行情况。
Start up belt conveyoy(L11-BC3) Check the running condition of each
part.

5 风机（L11-FN1）启动。
Start up fan（L11-FN1）

6 收尘器(L11-BF1) 启动。
Start up bag filter (L11-BF1)

7 切换三通阀(L11-MW1)。 检查三通阀转向是否在正确的位置。
Start up two-way gate(L11-MW1) Check the damper position.

8 除铁器(L11-MS1)。
Start up Magnetic Separator
(L11-MS1)

9 胶带输送机(L11-BC1)启动。 检查各部件运行情况。
Start up belt conveyoy (L11-BC1) Check the running condition of each
part.

10 风机（L11-FN3）启动。
Start up fan（L11-FN3）

11 收尘器 (L11-BF3) 启动。

Start up bag filter (L11-BF3)

12 板喂机(L11-AC1)启动。 检查各部件运行情况。
Start up apron conveyor Check the running condition of each
(L11-AC1) part.

13 汽车翻车机现场启动。 检查各部件运行情况。
Start up automobile tripper Check the running condition of each
part.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

表 4−2 卸料系统至原煤堆料机启动操作顺序表
Table 4−2The Startup Operation Sequence List from automobile tripper to stacker
序 号 操 作 步 骤 检 查 与 调 整
1 堆料机(L11-ST1)启动。 (1)注意启动顺序。
(1)悬臂上的卸料皮带机启动。 (2)注意轴承温度。
(2)液压系统启动。 (3)注意减速器温度。
(3)堆料皮带机启动。 (1)Pay attention to the startup
(4)电缆卷盘启动。 sequence.
(5)行走机构启动。 (2)Pay attention to the temperature of
Start up stacker (L11-ST1) the bearing.
(1)Start up the discharging belt (3)Pay attention to the temperature of
conveyor on the cantilever. the reducer.
(2)Start up the hydraulic system.
(3)Start up the stacking belt
conveyor.
(4)Start up the cable coiling.
(5)Start up the running mechanism.
2 胶带输送机(L11-BC2)启动。 检查各部件运行情况。
Start up the belt conveyor(L11-BC2) Check the running condition of each
part.
3 破碎机(L11-RC1) 启动。 (1)检查驱动装置是否平稳。Check
Start up the crusher(L11-RC1) whether the drive device is smooth
and steady.
(2)注意启动电流。Pay attention to
the starting current
(3)注意各点温度。Pay attention to
every point temperature.
(4)达到正常转速后空载运转 5 分
钟。Run without load for 5min after it

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

reaches the normal speed.

4 风机（L11-FN1）启动。
Start up fan（L11-FN1）

5 收尘器(L11-BF1) 启动。
Start up bag filter (L11-BF1)

6 切换三通阀(L11-MW1)。 检查三 通 阀转 向是否 在正确 的 位

Start up two-way gate(L11-MW1) 置。
Check the damper position.

7 除铁器(L11-MS1)。
Start up Magnetic Separator
(L11-MS1)

8 胶带输送机(L11-BC1)启动。 检查各部件运行情况。
Start up belt conveyoy (L11-BC1) Check the running condition of each
part.

9 风机（L11-FN3）启动。
Start up fan（L11-FN3）

10 收尘器 (L11-BF3) 启动。

Start up bag filter (L11-BF3)
11 板喂机(L11-AC1)启动。 检查各部件运行情况。
Start up apron conveyor (L11-AC1) Check the running condition of each
part.

12 汽车翻车机现场启动。 检查各部件运行情况。
Start up automobile tripper Check the running condition of each
part.

表 4−3 取料系统至原煤仓(L21-3B1)启动操作顺序表
Table 4-3 The Startup Operation Sequence List from reclaimer to raw coal bin
序 号 操 作 步 骤 检 查 与 调 整
1 确认原煤仓(L21-3B1)已作受料准 通知有关系统，注意配合操作

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

备并启动相应设备。 Inform the relative system of paying

Ensure that the raw coal attention to compounding practice.
bin(L21-3B1)is ready for receiving
the material and start up the relative
equipment.

2 胶带输送机(L21-BC3)启动。 检查各部件运行情况。
Start up belt conveyoy(L21-BC3) Check the running condition of each
part.

3 离心风机(L21-FN2)启动。
Start up fan(L21-FN2)

4 收尘器(L21-BF2)启动。
Start up bag filter(L21-BF2)

5 除铁器(L21-MS2)启动。
Start up Magnetic Separator
(L11-MS2)

6 胶带输送机(L21-BC2)启动。 检查各部件运行情况。
Start up belt conveyoy(L21-BC2) Check the running condition of each
part.

7 离心风机(L21-FN1)启动。
Start up fan(L21-FN1)

8 收尘器(L21-BF1) 启动。
Start up bag filter(L21-BF1)

9 胶带输送机(L21-BC1)启动。 检查各部件运行情况。
Start up belt conveyoy(L21-BC1) Check the running condition of each
part.

10 取料机(L21-RE1)启动 (1)注意启动顺序。
(1)取料皮带机启动。 (2)注意轴承温度。
(2)电缆卷盘启动。 (3)注意减速器温度。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

(3)刮板输送系统启动。 (1)Pay attention to the startup sequence.

(4)耙车启动。 (2)Pay attention to the temperature of
(5)行走端梁启动。 the bearing.
Start up the fork lift feed or (3)Pay attention to the temperature of
reclaimer the reducer.
(L21-RE1)
(1)Start up the reclaiming belt
conveyor
(2)Start up the cable coiling plate。
(3)Start up the scraper conveying
system
(4)Start up the harrow car。
(5)Start up the travelling end beam

二、系统正常停车操作 The normal stop operation of the system

把决定要停止的设备所在组的启动开关按流程顺序逐一延时打到“停止”位
置，此组内设备再按停车顺序逐一延时停车。每次停车前，确保输送系统设备正
常停车时应卸空设备上的物料，以便下次正常启动。另外，为了设备安全保护需
要，注意各设备的润滑、冷却按各设备要求进行操作，并勤于检查和维护。在正
常情况下，停车顺序为启动顺序的逆顺序。
The starting switch of the group which includes the relative equipments need to
stop shall be put into the "off" position with some time delay sequentially one by one.
Then the equipment in the group shall stop with delay sequentially one by one. Before
each stop, confirm that when the equipment of conveying system stops normally, all
the material in the equipment must be discharged completely for a normal next start.
Moreover, in order to guarantee the equipment safety, pay more attention to the
lubrication and cooling of each equipment, operate according to the relative
requirement, and check and maintain regularly. In normal condition, the stop

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

sequence is the backwardness of the starting sequence.

设备故障停车和紧急停车的处理 Operations for fault shutdown

三、

and emergency stop

3.1 在系统运行过程中，由于设备发生故障、电机过载跳闸、机电保护跳闸
及其事故，现场的部分或全部设备会联锁停车。在某种紧急情况下，为了保证设
备及人身安全，还会采用紧急停车按钮使系统紧急停车，为了保证能够顺利地再
次启动，故障停车或紧急停车后必须进行处理操作。
During the system operation, because of the device faults, the trip by motor
overload and by local protection and the relevant accidents, some or all devices will
be stopped by interlocking. In certain emergency circumstances, the emergency
button is applied to emergency stop for safety of device ad personnel. To guarantee
the successful restart, operations must be done after the fault stop or the emergency
stop.
3.1.1 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） 板喂机（L11-AC1）突然卡死。
The apron feeder (L11-AC1) is suddenly jammed.
（2） 破碎机腔内混入大块铁件。
Large piece of metal enters the crusher
（3） 破碎机严重堵塞。
The crusher is seriously jammed.
（4） 胶带严重跑偏或打滑。
The belt is in a severe deflection or slipping.
（5） 胶带接头撕裂或脱开。
The contact of the belt is torn or slipped off.
3.1.2 设备突然停车的基本处理方法
The basic methods to handle the hard shutdown

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.1.2.1 马上停止向已停车设备供料的相关设备。
Immediately stop the relevant equipment which provides materials to the halted
device.
3.1.2.2 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.
3.2.2 本系统设备常见故障及处理方法如下：
3.2.2The main checking and adjusting items can be referred to table
（1）皮带机

故 障 可能的原因 处 理
皮带跑偏 头、尾滚筒不平行 调整头尾轮
皮带打滑 进料口物料卡死 清除进料口的物料
皮带未张紧 调正皮带张紧力
皮带撕裂或折断 有钢件卡在皮带上 更换新皮带
皮带张得过紧，或胶接不好 用皮带扣连接
油冷式电动滚筒烧坏 缺油 更换油冷式滚筒电机
进料口物料堆积而过载
（1）belt conveyor

Possible cause Treatment

The belt is off tracking Both ends of the roller are not Adjust the head and tail
The belt slips. parallel. wheels.
The material in feeding inlet is Clear out the material in
locked feeding inlet.
Belt is not tensioned Adjust the tension of the belt.

The belt is tore or broken. Steel pieces are locked on the belt. Replace with a new belt.
The belt is over tense, or is not Connect with a belt buckle.
glued well.

Oil cooling motorized Lack of oil. Replace the oil cooling roller
roller is burnt out. The material in feeding inlet is motor.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

accumulated to result in overload.

（2）堆、取料机

故 障 可能的原因 处 理
a. 皮带跑偏 张紧不够 调节尾轮
b. 下料口堵 下料过大，原料夹土过多 清堵
或含水偏高
c. 滚筒轴承坏 轴承缺润滑油，进灰尘 更换
d. 皮带断裂 张紧过大，磨损 重接皮带
（2）stacker and reclaimer

Malfunction Possible cause Treatment

a. The belt is off tracking. Tension is not enough. Adjust the tail wheel.

b. Discharging outlet is The discharging is too large, clay Clear the block.
blocked. or water content mixed in the raw
material is over high.

c. The bearing of the roller The bearing lacks in lubricating Replace it.
is broken. oil, and dust enter the bearing.
d. Belt is broken. The belt is over tense, and is Reconnect the belt.
damaged.

3.3 紧急停车操作 operations for emergency stop

当出现紧急情况时，需要全部停车，按紧急停车键，设备急停后，应对设定
值、阀门等进行调整。如润滑设备没有问题，立即启动，并尽快处理，恢复系统
运行。
When the emergency happens, it must stop all devices. Press the emergency
button to stop the device, and adjust the set value and valves after the devices stops. If
there is no fault on the lubrication device, start the device immediately, solve
problems and reoperate the system.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第五章 设备单体试车

Chapter 5 Single-unit test run

一、设备试车条件 Conditions for test run

1.1 设备安装完成
Finish the installation of the devices
1.2 电器安装完成
Finish the installation of the electric appliance
1.3 减速机内按照设备要求加注润滑油
Add lubricating oil to the devices inside the reducer in accordance with
requirements
1.4 所有润滑点按照要求加注润滑油或润滑脂

Add lubricating oil or grease to the point according to requirements

1.5 本系统每台设备应逐个进行单机试运转，并根据相应设备的说明书及验
收标准进行。
Every equipment of this system should make trail run one by one, according to
the corresponding instruction and checking and acceptance standard for the
equipment.

二、试车过程 The process of the trial run.

2.1 首先把转换开关放在现场位置，点动开关，确认电机旋转方向。
Put the switch on site, open it and confirm the rotation direction.
2.2 确认电机旋转方向正确后，对设备带电进行试运转，观察设备的运行情
况，并对电机电流进行测量。如果电流正常，设备运行情况正常，在无负荷情况
下运转 4 小时，在这个过程中观察各润滑点，确认减速机、轴承不发热，即可以
完成无负荷试车。
After confirming the right direction, have test run on the equipment with power

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

on, observe the equipment running condition and measure the motor current. If
the current and the equipment is in normal condition, run it without load for 4h
and observe every lubricating point to confirm the reducer and the bearing don’t
generate heat before start the no-load test run.

无负荷试车结束后，在条件允许的情况下，进行负荷试车。
Start the loaded test run in a allowable condition after finishing the no-load test
run.

三、试车要求 Requirements for test run

3.1 板式喂料机 The apron feeder：

3.1.1 低速启动空载运转，检查正常无误后，逐渐达到正常运转速度，运转若干
小时（详见单机操作说明书）。
Start the no-load test run in a low speed, check it and then gradually run it in a
normal speed for hours (see the single-unit operation specification for details).
3.1.2 所有紧固件应连接牢固，无松动现象。特别是注意检查链板的联接螺
栓有无松动现象。保持链条松紧适当，如发现跑偏应通过拉紧装置进行调整。
Make sure that all fasteners are tightened, especially the connecting bolts of the
chain conveyor. Keep the chains in a proper degree of tightness; if it deflects, adjust it
by the tension device.
3.1.3 检查是否有其它异常情况，如发现异常，应及时检查发生的原因，并
排除故障。
Check whether there is other abnormal conditions; if some fault happens, check
and find out the reason and solve it.
3.2 破碎机 the crusher：
3.2.1 检查并确认破碎机机体内没有金属物品和任何其他异物。所有润滑点按照
要求加注润滑油或润滑脂。
Check and confirm that no metals and other foreign matters inside the crusher;
add lubricating oil or grease to the lubricating points according to requirements.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.2.2 检查机器各门、视孔盖是否封闭。各门和视孔盖在关闭前应在其外沿四周
抹一层较厚的润滑油脂，以使其关闭后有较好的气密性。
Check whether each door and every inspection plate is closed or not. Apply thick
lubricating grease around every door and each inspection plate to make sure its good
air impermeability.
3.2.3 空载连续运转试车时间不少于 4 小时。空载试车必须遵循先点动后连
续的原则，待确认情况正常后再连续运转（详见单机操作说明书）。
The time of the no-load test run should not be less than 4h. Following the
principle of “first start point and then the follow-up”, confirm it is in a normal
operation before the continuous work (see the single-unit specification for details).
3.2.4 各运动部位运转是否良好，不得有异常的振动和噪音，否则应停车检
查。
Whether all moving parts run in good conditions, the abnormal vibration and
noise are not permitted, otherwise shut down the equipment to check.
3.2.5 检测轴承温升，不应超过规定值。
Check that the temperature rise of bearing should not be higher than the limited
temperature.
3.2.6 所有紧固件应连接牢靠，无松动现象，如发现异常及时排除。
Make sure that all fasteners are tightened, check whether there is some other
abnormal conditions; if any, dispose it.
3.3 带式输送机：要求皮带运转平稳，无跑偏，拉线开关及跑偏开关动作灵
活。
Belt conveyor: it’s required that the belt should be running smoothly and steadily
without deflection; the pull switch and the deflection switch are in good condition.
3.4 收尘器：要求各室能够按照程序进行喷吹清灰，阀门动作灵活。
Dust collector: it is required that every chamber can be cleaned according to the
procedures and the valves are in good condition.
3.5 堆、取料机 Stacker and reclaimer

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.5.1 各传动部位应无异常振动、异常声音、温度应不大于 40℃；

3.5.1 No vibrations or abnormal sounds for all drive parts and the temperature is
not over 40℃;
3.5.2 刮板装置中的刮板体表面的耐磨板磨损情况，当磨损到危及刮板体时，
应予以及时更换；
3.5.2 Inspect the wear on the wear-resistance plate of the solid blade face in the
scraper assembly. Replacement in time if the solid blade is endangered by a wear;
3.5.3 刮板装置中的中间导轮螺栓是否有松动现象，如有应及时紧固；
3.5.3 Inspect if the bolt on the intermediate guide wheel in the scraper assembly
is loosening. Please tighten if any;
3.5.4 检查导槽衬板磨损情况，当其磨损到危及导槽本体时应及时更换衬板；
3.5.4 Inspect the wear on the liner in the guide chute. And the liner is replaced in
time if the solid guide chute is endangered;
3.5.5 刮板运行中是否有偏斜现象，若偏斜可调整链轮尾部螺旋张紧装置中
的螺杆、螺母，以使支撑刮板的两链条张力一致；
3.5.5 Inspect if the scraper is skewed in the operation. You can regulate the
screw rod and the nut in the screw tensioning device at the end of the sprocket wheel
in order to make two chains supporting scraper in the same tension if any;
3.5.6 料耙沿支撑轨道运行及换向是否平行，有无异常声音；如有应及时调
整；
3.5.6 Inspect if the rake is moves parallelly when it is operated along the support
rail or the direction is changed and if there is an abnormal sound. Please adjust in time
if any;
3.5.7 要求做到端梁行走机构运行平稳，调节换向可靠，开式齿轮啮合情况
良好；
3.5.7 It is required that the walking mechanism of the end beam is operated
stably and the can be regulated and inversed reliably. The open gear engages well;
3.5.8 各部液压系统不得有漏油，油箱油温不得大于 40℃，泵站运行噪音不
得大于 80 分贝。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.5.8 There is no oil leakage in the hydraulic system of all parts. The temperature
of the oil in the tank is not over 40℃ and the noise level is below 80dB in the
operation of the pump station.

四、单机试车后确认事项 Items to be confirmed after single-unit

test run

4.1 确认设备空载运转达到说明书要求，记录设备空载启动负荷变化特性及
振动噪音、轴承温升等技术参数。
Confirm the device idle motion is up to the requirements in the specification,

record the load change features of the device running without load, and write down
technical parameters such as vibration sound and bearing temperature rise.
4.2 确认设备旋转方向正确无误。
Confirm that the device is in a right rotating direction.
4.3 确认润滑系统工作正常，冷却水路通畅。各点油压、油温、水压正常。
Confirm that the lubrication system is in a normal operation and the cooling
water pipe is not jammed; the oil pressure, oil temperature and water pressure is
normal.
4.4 机旁控制准确无误，阀门动作与仪表指示一致，且开启灵活。
Confirm that the control beside the machine is accurate, the valve motion is in
line with that indicated by the instrument, and it is easily opened.
4.5 检查、确认设备内外无损坏、异常部位。
Check and confirm that there is no damage inside and outside the devices and
no abnormal part.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第六章 试生产阶段注意事项

Chapter 6 Precautions at Trial Production

一、概述 The overview

1.1 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。堆料机必须在破碎系统启动前率先开启。
根据设备厂家提供的操作的具体要求和说明进行合理堆料，以确保预均化效果。
取料机将根据各配料库的料位开启或停止。
All the equipments in the system have been installed, check and adjust each
single equipment according to the product specification. After everything is
confirmed to be qualified, take the unloading trial run of single equipment. Only after
the single equipment has no malfunction and the time of continuous unloading run
meets the requirement, the unloading linkage trial run can start. After the linkage trial
run, recheck all the equipments, and confirm that the system works well, then take the
loading linkage trial run. The stacker should start before the crushing system. Stack
the material properly according to the detailed requirements and instructions supplied
by the equipment factory, to ensure the effect of pre-homogenization. The stacker can
start or stop according to material level of the batch bin.
1.2 本系统的荷载试运转分为部分负荷试车与满负荷试车两种工况进行。应
先进行不少于 12h 的部分负荷试车。部分负荷试车时应逐步增加负荷，最终达到
满负荷程度，部分负荷试车没有问题后才可进行满负荷试车。
The loading trial run of the system is divided into two working conditions:
partial loading trail run and full loading trail run. Partial loading trail run which can be
finished in not less than 12 hours should be done first, then increase the loading
gradually until it finally reaches the degree of full loading, the full loading trail run

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

can be done if there is no wrong with the partial loading trail run.
1.3 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考
核，经检验合格后方可正式投产使用。
During the process of the full loading trial run, inspect and assess according to
the technological characteristic of each single equipment. Only after the qualified
evaluation, it can be put into the formal production.

二、试生产的准备 The preparation for the trial run

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和试生产。
空载试车必须达到下列要求：
The loading trial run and the trial production can not be taken until the unloading
trial run is qualified for the evaluation in the system. The unloading trial run must
meet the following requirements:
(1) 设备运转平稳正常，回转部位灵活，无卡死和擦碰现象。
The equipment runs stably and normally, the rotating part works flexibly, and
there is not the condition of locking and friction or touch.
(2) 运转中无金属撞击声。
No any metal impact sound in the run.
(3) 主电动机电流平稳。
The current of main motor is steady
(4) 各润滑部位的密封处、结合面无渗油、漏油现象。
No any condition of oil seeping and leakage in the sealed place and
connecting surface of each lubricating part.
(5) 轴承最高温度不超过规定值，温升满足要求。
The maximum temperature of bearing can not beyond the limited value and
the temperature rise must meet the requirement.
(6) 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。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

After the stop of equipment, check whether the bolts, coupling pins, and the
fastening pieces at each running part are loose or not. Then tighten all the
loose bolts and fastening pieces.
(7) 符合行业规范及设备说明书对空载试运转的各项要求。
Accord with each requirement of the unloading trial run in the equipment
manual and the professional specification.
2.2 系统首次投料之前，应对设备进行检查和调整，重点是：
Check and adjust the equipment before the first feeding to the system. The main
points are as follows:
(1) 检查和调整设备各运动部件。
Check and adjust each moving part of the equipment.
(2) 检查电机、减速器及各润滑系统的润滑点，确认已加入足够的润滑油。
Check the lubricating points of the motor、speed reducer and each lubricating
system, confirm that adequate lubricating oil has been injected into them.
(3) 检查确认电气信号和仪表正常无误。
Check and confirm that the electrical signal and the instrument are normal
and correct.
(4) 确认电动机转动方向正确。
Confirm that the rotating direction of motor is correct.
(5) 检查各润滑部位密封处、结合面有无渗油、漏油现象。
Check whether there is any oil leakage in the sealed place and connecting
surface of each lubricating part.

三、试生产要领及注意事项 The main points and items needing

attention in the trial run

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 the equipments run normally, the power supply system and the
communication facility are prepared well.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.2 确认所有设备所需供水、供气的管路通畅，压力满足设计和运行要求。
Confirm that the water and gas supply pipes which are needed by all the
equipments are smooth, the pressure meets the needing of design and run.
3.3 确认本系统中每台设备完好无损，旋转方向正确无误，无异常故障；各
种阀门动作灵活准确，调节控制量与实际操作要求相符，各种仪器仪表指示和信
号联络有效无误。
Confirm that each equipment of this system is in good order and condition, the
rotating direction is right, no abnormal malfunction; every kind of valves work freely
and accurately, adjust control variable to make it accord with the actual operation
requirement, the indication and signal communication of each instrument are effective
and correct.
3.4 确认集中控制完全满足工艺开停与联锁要求，各操作岗位和生产车间通
讯联络畅通。
Confirm that the centralized control completely meets the needing of start and
stop for the processing and interlocking, every operation post and production
workshop communicates freely.
3.5 与中控室、相关电气室联系，确认所有设备已经做好供电的准备，随时
可以按操作要求投入运行。
Contact the centralized control room and related electrical room, confirm that all
the equipments are ready for power supply, and they can be put into operation
according to the requirements at any time.
3.6 系统产量按额定产量 30%、60%、100%的比例逐步提高，直至正常产量。
The output of the system should be gradually increased to 30%, 60% and 100%
of the rated output until normal production.
3.4 在设备运行过程中重点检查下列部位：
(1)破碎机(L11-RC1)电机、轴承温度，润滑油（脂）的温度、油量等。
Crusher (L11-RC1) motor, bearing temperature, lubricant (grease) temperature,
quantity and so on.
(2)板喂机(L11-AC1)轴承温度，润滑油（脂）的温度、油量等。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

Apron feeder (L11-AC1) bearing temperature, lubricant (grease) temperature,

quantity and so on.

3.6 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。

The inspection, maintenance of the equipment must be carried out after

confirming the system is stopped, never allowed to maintain the equipment when it is

running.

3.7 检修葫芦(L11-EH1)起重量为 10t，不宜吊装过起重量的设备，起重设

备应拆卸吊装。

Capacity of motor hoist (L11-EH1) is 16t, overweight lifting is not allowed, crane

equipment shall be handled piece by piece.

四、设备使用维护要领 Utilization and maintenance

essentials of equipment

设备的使用维护要领参见各设备的使用说明书，在此不再赘述。
The utilization and maintenance essentials of equipment can be referred to the
operating manual of each equipment, it will not be elaborated repeatedly here.

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