液壓破碎關斷門

液壓破碎關斷門為乾式除渣系統的主要產品之一。

基本介紹

• 中文名：液壓破碎關斷門
• 電機功率：2×5.5Kw
• 油泵流量：14.3 ml/rev
• 油箱容積：400L

基本信息

1.液壓破碎關斷門

2.液壓破碎關斷門與濕式除渣系統的液壓關斷門類似，系統位置基本相同。

3.主要工作原理，是依靠液壓油缸，實現水平擠壓破碎的設備

4.詳細介紹

4.1概述Summarization

液壓破碎關斷門又叫大渣破碎裝置或液壓擠渣關斷門。主要作用有兩個：一是對大渣進行預冷卻後破碎的作用；二是在設備檢修時起關斷門的作用。

The Hydraulic Cut-off Gate is also known as large slag crushing machine or hydraulic slag crushing gate. There are two main functions of it: first, large slag can be pre-cooled and crushed; second, the gate will be closed during equipment maintenance, so slag can not be directly into the following equipment.

產品優點：①設定在渣井下面，冷空氣進入爐膛時可以充分預熱，有利於熱量回收。②設定在乾渣機上級，有利於冷卻。乾式除渣冷卻的困難就是大渣塊，渣塊內外溫差梯度大，需要較長的冷卻時間。而限於空間布置和鍋爐進風量要求限制，很難保證此時間。在乾渣機上部預破碎後，渣塊變小，內部高溫可直接與冷空氣換熱，有利於冷卻，同時增加了設備使用壽命。③擠渣門體多，無堵塞問題。對應不同的機組，渣井採用1～4口布置；對應破碎關斷門也有1～4口，每口由2～3對門。在任何一對門進行擠壓破碎時，另外的擠渣門處於打開狀態，可以繼續排渣，不影響系統的正常運行。

The Hydraulic Cut-off Gate has many advantages, for example, first heat can be effectively reclaimed. Because it is under the Bottom Slag Hopper, cold air can be effectively preheated when it into the furnace. Second, it is installed before the Air-cooled DSC, good for cooling. In Bottom Ash/Slag Dry Handing System, big slag as large temperature difference between its inside and outside is need a longer cooling time. However, it is difficult to ensure this time because the space layout and wind-inlet flow requirement. But when the slag is pre-crushing by the Hydraulic Cut-off Gate, high temperature can directly change with the cold air, not only conducive to cooling but also extend the equipment life. Third, the Hydraulic Cut-off Gate has many doors, without blocking problems. For different units/funnels, the Bottom Slag Hopper has 1 to 4 parts, so the corresponding Hydraulic Cut-off Gate also has 1 to 4 parts, and every part with 2 to 3 pairs of doors. When one of the doors operates, the others will be opened to discharge, not effect the normal operation of whole system.

液壓破碎關斷門安裝於渣井的下面，採用自支撐式結構，與渣井間採用金屬膨脹節連線，與乾式排渣機間採用高強度螺栓連線。

Hydraulic Cut-off Gate installs blow the Bottom Slag Hopper, adopt self-supporting structure, connect Slag Hopper with metal expansion joint, and connect DSC with high strength bolt.

每台爐的渣井布置有1～4個落渣口，每個落渣口配有高溫攝像頭，用於觀察落渣情況；設有觀察孔和捅焦孔。每個擠渣門由2個油缸驅動，在液壓缸的驅動下，擠渣門沿著其下部的耐熱鋼蓖管導軌做往復直線運動。每扇擠渣門都可根據實際情況單獨進行操作。全部擠渣門使用一個液壓站控制。每個液壓站配套2台油泵，一備一用，可以相互切換。

Bottom Slag Hopper for each of boiler furnished 1 ~ 4 slag-falling units, each slag-falling unit is equipped with high-temperature camera used to observe the slag-falling situation; with observation holes and slag-poked holes. Every Gate/Door driven by two cylinders, it does reciprocating linear motion along the heat-resisting steel tube guide at the bottom of it. Every Slag Cut-off Gate may operate separately according to the actual situation. All Slag Cut-off Gates are control by one hydraulic station. Every hydraulic station sets 2 oil pumps, one use and the other stand by. They can switched with each other.

在鍋爐正常運行時，擠渣門全部處於開啟位置，小於200×200mm的底渣通過擠渣門下部的蓖板落至乾式排渣機的輸送帶上；大於200mm的渣快被密集格柵攔截。此格柵具有兩個作用：阻擋>200mm的渣塊和承受大渣塊衝擊。密集格柵下面設定有大型鋼結構，可承受巨大渣塊從爐膛高處下落的衝擊。保證除渣系統的正常運行。參見圖4-2。

During normal operation of boilers, Hydraulic Cut-off Gate is in open position, all slag less than 200 × 200mm fall into the conveyor belt of DSC through the gate grid; slag more than 200mm are intercepted by the dense grid. There has been large steel structure below the dense grid. This grid also can withstand impact of large slag, to ensure the normal operation of the Bottom Ash Dry Handing System. Show in Fig.4-2.

當通過攝像頭觀察到有大於200×200mm的底渣落至蓖管上時，延遲一段時間（5～10分鐘左右），待落下的大渣初步得到冷卻後，在控制系統點擊相應的擠渣門關閉按鈕，擠渣門對大渣進行預破碎，破碎後的渣落至乾式排渣機的輸送帶上。若遇到內部高溫大渣快，則需要多次擠壓破碎。任何一扇擠渣門可獨立運動，且有3個位置回響監測點。

Observe through the camera, more than 200 × 200mm bottom slag fall on the grid, delay some times (about 5~10 minutes), after large falling slag are initially cooled, control the corresponding Slag Cut-off Gate closed button in the control system, the large slag pre-broken by Slag Cut-off Gate and then fall into the conveyor belt of DSC. Because hot sticky, it need several times to cooling & broken the big slag which high temperature inside. Any Slag Cut-off Gate can be independence movement, and three locations respond to the monitoring point.

當後續除渣系統遇到故障，故障設備發出報警信號，需要臨時停機進行檢修時，在控制系統將擠渣門全部關閉。使渣斗形成一封閉容器。檢修完畢後，按下面步驟開啟擠渣門。

When the follow-up device failures, faulty equipment sends a warning signal, when need to temporarily shut down for maintenance, control Slag Cut-off Gates to closed. Slag Hopper forms a closed container. After maintenance, open the Slag Cut-off Gate according to the following steps.

開啟擠渣門步驟：

① 首先將乾式排渣機輸送帶的變頻器調到額定頻率，即運行速度調至最快速度；

② 點動接近乾式排渣機頭部（弧段）的第一對擠渣門，置於較小的開口位置，大量存渣落到乾渣機上被冷卻並輸送，此時大渣檢測裝置可能報警，可以忽略報警，乾渣機運行一段時間，待大渣檢測裝置處於正常位置，說明渣量減少；

③ 將此擠渣門慢慢打開，直到完全打開；

④ 同理，將所有擠渣門依次全部打開；

Steps of open the Slag Cut-off Gate:

① First, the transducer of DSC(Dry Slag Conveyor) belt adjust to rated（60Hz）, the fastest operation speed;

② Jog control, make the first pair of Slag Cut-off Gate which is close to the arc/head of DSC on smaller opening position, many slag will fall on DSC and be cooled and conveyed, this time large slag detection device may alarm, alarms can be ignored, when DSC runs for some times, with big slag detection device in the normal position, slag quantity reduced.

③ Open the Slag Cut-off Gate slowly, until to open fully.

④、Similarly, open all doors in turn.

在打開每對擠渣門過程中，如發現有大渣，視其渣塊的大小，適時進行擠壓。

When opening the Slag Cut-off Gate, if there are large slag, timely extrusion depending on the size.

特別注意：

①. 正常運行時每對擠渣門每月要進行一次全開、半開、全關操作。

②. 事故關斷後處理後，慢慢開啟每對擠渣門，待渣量減小大渣檢測回復正常後再進行操作。否則可能會引起乾渣機過載。

③. 如果開啟擠渣門時，大量灰渣排泄到乾渣機上，可能引起過載；此時允許乾渣機倒轉，將渣從其尾部排出。如圖4-3。

Special Note:

①. during normal operation, every Slag Cut-off Gate should do a whole-open, half-open and whole-closed operation once a month.

②. Be carefull, when open all closed gates after maintenance, must care & jog control, allowed & smaller Slag fall on DSC. After DSC runs for some times, with big slag detection device in the normal position, allowed another operation.

③. There are too much slag to DSC may over loading, when you open the gate quickly. At this point, DSC is allowed to reverse. Slag discharged from the end of DSC. Show in Fig.4-3.

4.2安裝Installation

4.2.1概述Summarization

請參考國家相關規定和7.3.1鋼結構安裝技術要求，嚴格按照隨機圖紙要求進行安裝。

Please refer to relevant national regulations and 7.3.1 steel structure installation technique requirements, strictly in accordance with the drawings for installation.

設備本體重量>10噸，應特別注意安全；在起吊時，設備下面禁止站人；因為每扇門重達1噸多，僅靠下方導軌支撐，所以起吊之前應確保所有擠渣門已捆綁固定牢固，起吊過程中不得出現滑動；起吊時不得傾斜，嚴禁直立和倒置。

The weight of equipment body more than 10 tons, you should special pay attention to safety; in lifting, prohibits anybody standing under the equipment; Because every door weighed more than 1 ton, only support by the bottom guide, so it should ensure that all Slag Cut-off Gates have been fixed firmly before lifting, and must not appear sliding during lifting process; when lifting it shall not be titled, strictly prohibited erection and inversion.

安裝時應保證油缸與其接管的同軸性，從而保證兩根油缸平行推動一扇擠渣門體。任何的偏差將影響擠渣門的推動，從而增大磨損，減小設備的使用壽命。

When installation should ensure that the oil cylinder and its connecting tube is in the same axis, thereby ensuring two oil cylinder parallel to promote a Slag Cut-off Gate. Any deviation will affect the door pushing, increased the wear and tear, reduce equipment life.

安裝完畢後，應對液壓管路進行排氣，煤油清洗；然後按照4.1中擠渣門開啟步驟進行試車。若發現任何問題，請諮詢現場服務人員。

After installation, should exhaust and kerosene wash the hydraulic pipe; then commissioning the Slag Cut-off Gate according to the 4.1 steps. If you have any questions, please contact the on-site service personnel.

4.2.2安裝順序Installation Sequence

檢查基礎→立柱→本體、膨脹節→油缸支架→平台圍欄→油缸、液壓管路→電控系統→清洗管路、檢查→試車。

Check foundation →pillar→ body, expansion joints→oil cylinder support→platform fence→oil cylinder, hydraulic pipe→electric control system→cleaning pipe, inspection→ commissioning.

4.3液壓系統 Hydraulic System

4.3.1技術參數Technical Parameters

Motor Power：2×5.5Kw；

系統流量：21L/min

Oil Pump: flow 14.3 ml/rev; system flow: 21L/min

工作介質：N46號普通液壓油或同等級抗磨液壓油；

Working Medium: common hydraulic oil for N46 type or the same level anti-wear hydraulic oil;

系統清潔度：NAS9級

System Cleanliness: NAS9 class

系統額定工作壓力：10Mpa；最大≤16MPa

System Rated Working Pressure: 10Mpa；Max ≤16MPa

正常工作油溫：25-55℃

Working oil temperature: 25-55℃

加油量：6～8L×油缸數量。

Fill oil ：6～8L×the number of Hydraulic cylinder

4.3.2注意事項Notes

設備安裝、使用前，請詳細閱讀說明書。

Read the instructions carefully before equipment installation and using.

設備在使用前，必須對所有緊固件進行檢查、緊固。

All fasteners must be checked and fasted before equipment using.

設備在使用前清洗，注油；不得在載油情況下吊裝。

The equipment must be filled with oil and cleaned before use, and it is not lifting contain oil.

電氣接入前，請檢查供電電源和地線是否符合要求。

Check whether the power source and ground line meet requirements before electrical access.

供電電源接入後，請立即檢查設備是否有漏電。

Please check whether the equipments have electricity leakage after power supply access.

設備調試、使用期間，請遠離可能由壓力作用造成元件脫離飛出的位置。

Please stay away from the position where the components fly out caused by pressure during the equipment debugging and use time.

設備使用壓力不得超過要求。

The use pressure shall not exceed the manual instructions.

設備檢修時、必須對設備壓力泄載。

The equipment pressure must be let out during equipment maintenance.

按中華人民共和國和企業的電氣和液壓安全標準，檢查和操作。

Inspect and operate according to the China electrical and hydraulic safety standards.

設備應在安全的情況下，安裝、使用、操作、維護。

Installation, use, operation and maintenance of equipment should be in safe conditions.

對不按說明和安全要求產生的事故，本公司不負任何責任。

Our company is not responsible to the accidents those resulting from fail to note and security requirements.4.3.2試運行前準備Preparing before Commissioning　①.清潔油箱管路；檢查管接頭和法蘭是否擰緊（必須在無壓的狀態下擰緊接頭）；檢查電機轉向。

Cleaning the oil tank pipeline; check if the pipe joint and flange are tighten (the joint must be tighten without pressure); check motor rotation direction.

②.檢查液壓站與各個管路、油缸連線。

Check the connections of hydraulic station with pipeline and oil tank.

③.檢查各閥門的接口是否正確。

Check if every valve interface is right.

④給油箱加油，單油缸需要約4L；為了降低油溫，建議加入兩倍以上。

Fill oil in oil tank, and single cylinder need 4L. Please twice the oil for get a lower oil temperature.

4.3.4空載試運行No-load Commissioning

①.注意安全，非專業人員須遠離現場。

To ensure safety, no-professional staff must be也需擰緊。

Stop motor, re-tighten all joints even if the joints without leaking;

4.3.5保養及維護Maintenance

①.正常運行後每周至少檢查一次油箱液位的高度。

After normal operation, the height of oil tank level must be checked at least once a week.

②.液壓油的保養周期和程度與下列因素有關：油液的老化程度、含水量、溫度、充液量等。油液應在冷卻狀態排放更換。老化非常的嚴重或污染非常嚴重的油不能通過注入新油來改善其狀況；給系統加油一定要經過過濾，且過濾精度不低於系統的要求；在加油時必須使用同一廠家同一品牌及型號的液壓油；並定期從油液中取樣，檢驗其含有顆粒、雜質的狀況，對油液的成分進行分析，並記錄在案。

Maintenance period and extend of hydraulic oil are relate with the oil aging, water content of oil, oil temperature, oil amount and etc. Oil should be replaced in the cooling status. The serious aging or pollution oil should not change its situation from filling new oil; oil must be filter, and its filtering accuracy can not be less than the system requirement; when oil filling, the hydraulic oil must be the same manufacturer, brand and mode; periodically sampling from the oil, test its situation with particles and impurities, analyze its composition and record.

③.工作溫度隨時測量，油溫的升高意味著，內部的磨損及泄漏的增加。

Measure the working temperature at any moment, oil temperature rise means the internal wear and leakage increase.

④.管路系統應無泄漏，若存在泄流，尤其是地下管路的泄漏，意味著油料的損失，同時也對地面及元器件造成損壞及環境的污染。

Pipeline system should not leak. If there is any leakage, especially for the underground pipeline leak, which not only means oil loss but also can cause ground and components damage or environmental pollution.

⑤.檢測主迴路壓力:設備正常運行後，定期檢測系統壓力，並記錄；壓力的頻繁調整意味著溢流閥的磨損加劇。

Check main circuit pressure. After normal operation, check system pressure regularly and record; frequent adjustment of pressure means the wear of relief valve increased.

⑥.蓄能器的充氣（若有）：正常運行後，一周檢查一次充氣壓力，並做好記錄；若壓力不斷的下降意味著氣體的泄漏，必須及時的更換維修；只允許用氮氣作為使用氣體，且氮氣為4.0級，最純的。

Accumulator charging (if has): after normal operation, check the charging pressure once a week and record; if pressure decline means gas leak, accumulator must be replaced and maintenance in time; only nitrogen as the use gas, and it is for 4.0 class, the most pure.

⑦. 油液的污染是導致系統元件損壞一個重要因素，過濾器是清潔度的一個重要保障，若濾芯已經污染時，要及時的更換濾芯，更換濾芯時必須保持周圍環境的清潔，避免更換過程中的二次污染；纖維或紙制濾芯不能清洗再次使用。

The oil pollution is an important factor of system components damage, the filter is an important guarantee for cleanliness. If filter core has been polluted, the core must be replaced in time. In the replacement, we must keep the surrounding environment clean to avoid secondary pollution; fiber or paper filters can not be washed and use again.

4.4電控系統Electronic Control System

4.4.1概述Summarization

中國大陸使用電源：

Power source used in China:

動力電源：380V/220V AC 50Hz；

Power supply: 380V/220V AC 50Hz；

接觸器、繼電器、指示燈：220V AC / 24V DC；

Contactor, relays, indicator light: 220V AC / 24V DC；

電磁閥：24VDC；

Electromagnetic valve：24VDC；

按鈕──220VAC/24VDC。

Button－220VAC/24VDC。

國外請參照技術協定要求。

In abroad please refer to the technology agreement.

4.4.2控制功能Control Function

4.4.2.1 就地、遠程控制轉換Local, Remote Control Conversion

通過"就地V集控"轉換開關實現液壓擠渣門就地與遠程控制的轉換。

Switch the local and center control of Slag Cut-off Gate through “local V center control” button.

4.4.2.2油泵電機過載保護

當油泵電機長時間過載時，空氣開關動作，系統將立即停車，同時發出報警信號。

When the pump motor overload a long time, the air button moving, the system will immediately stop, while give an alarm signal.

4.4.2.3 安裝Installation

將控制櫃落地安裝在基礎上，安裝基礎應在液壓站的旁邊，便於調試及檢修維護，參照互連圖要求提供電源，油路上接有各擠渣門動作控制的電磁閥，其支撐框架上有擠渣門開度檢測用限位開關，對照互連圖從控制櫃端子排引線至上面的各個控制部件，完成設備接線。

Control cabinet is installed on the foundation which is installed near the hydraulic station, easy debugging and maintenance, the power is provided according to the requirement of wiring diagram. There are several electromagnetic valves which control action of every Slag Cut-off Gate in the oil pipeline, and detection limit switches for Slag Cut-off Gate opening is on the supporting frame of oil pipeline. Wiring from the cabinet terminal to all control components according to the wiring diagram, equipment wiring is completed.

4.4.2.4 調試Debugging

送電前，檢查控制盤面，將選擇開關打到就地位置，操作方式選擇開關打到中間位置，其餘選擇開關全部打到左側停止位；然後逐個合上動力電源開關觀察有無異常，直流電源的冷卻風扇是否工作正常，測量確定直流電源輸出電壓為24V，消除盤面異常報警。

Before switching on the current, check the control panel, turn select switch to local position, turn operation select switch to middle position, and turn all the other select switches to the left stopping position; then close the power supply switches one by one and observe if it is any abnormal, check if DC power cooling-fan normally work and make sure its DC power output voltage is 24V, remove abnormal alarm of control panel.

檢查液壓動力站油箱是否加滿液壓油，確定油泵吸油球閥打開，泄壓球閥關閉；擠渣門油站有兩套動力系統，可分別控制打壓，調試時先起動油泵電機打壓，觀察壓力表油壓，減壓閥出廠設定工作壓力為10MPa，幾乎沒有壓力則電機反轉，調整電機電纜相序。

Check if oil tank of hydraulic station fill with hydraulic oil, make sure the oil-pumpingoil pumping ball valve open andosition in time after every action in place, and then re-select the Slag Cut-off Gate and select the operation mode, repeat in this manner; after the operation, first turn the operation select switch to intermediate position, then turn the operation select switch of Slag Cut-off Gate to the left stopping position, now a whole process is completed.

遠程操作時，只要接線正確，只需將選擇開關打到遠程位置，就能在上位機操作。

In remote operation, if the wiring is correct, turn the select switch to a remote position, you can operate in the PC machine.

4.4.2.6 注意事項Notes

每次操作完成離開前應立即停止油泵，檢查確認盤面各個選擇開關都在停止位，以免下次油泵啟動時液壓缸直接動作；

After each operation, the oil pump should be stopped immediately before leaving. Check if all select switches on the control panel is on the stop position, avoid the oil cylinder direct acting when oil pump start for the next time.

操作的擠渣門到位後，先將“操作選擇”開關打到中間的停止位，再將擠渣門運行選擇開關打到左邊停止位，防止擠渣門誤動作；

When the Slag Cut-off Gate is in the specified location, turn “select switch” to the middle stop position, then turn operation select switch to the left stop position, avoid the gate wrong action.

油泵電機未啟動時，操作電磁閥，電磁閥不能得電。

When oil pump motor doesn’t start, electromagnetic valve can be operated without current.