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1、OPERATING MANUAL操作手册ATOMIZING SYSTEM喷雾系统FOR供HEFEI WTE PROJECTCHINA中国合肥垃圾焚烧发电项目CLIENT: 用户FISIA BABCOCK ENVIRONMENT GmbH德国费塞亚巴高克环境工程公司D0430 TABLE OF CONTENTS 目录Section章节1.0.RECEIVING, STORAGE AND INSTALLATION收货、储存和安装1.1.Receiving and Storage收货和储存1.2.Installation安装1.2.0General Description概述1.2.1Atomize
2、r System Control (ASC) 喷雾器控制系统（ASC）1.2.2Atomizer (Motor) 喷雾器（电机）1.2.3.Variable Frequency Drive (VFD) 变频驱动器（VFD）1.2.4Permanent Installation设备永久固定2.0.SYSTEM DESCRIPTION 系统说明2.1.Atomizer Design Concept General喷雾器设计理念 概述2.2.Atomizer (Motor) Mechanical喷雾器（电机）- 机械方面2.3.Atomizer (Motor) Electrical 喷雾器（电机）-
3、 电气方面2.4.Variable Frequency Drive (VFD) 变频驱动器（VFD）2.5.Atomizer System Control (ASC) 喷雾器控制系统（ASC）2.5.0General Description, Procedure and Sequencing概述、流程和顺序：2.5.1Oil Lubrication System润滑系统2.5.2Oil Return System油回流系统2.5.3Atomizer Cooling System喷雾器冷却系统2.5.4Purge Air and Wheel & Shaft Cooling/Wash Water吹
4、扫空气和转盘/轴冷却/清洗水2.6.Theory of Operation of the Atomizer System Control (ASC) 喷雾器控制系统（ASC）的操作原理2.6.0References参考2.6.1VFD Fault 变频驱动器故障2.6.2Cooling Water Flow Switch 冷却水流量开关TABLE OF CONTENTS (contd) 目录（续）Section (contd)章节（续）2.6.3Lube Oil Level Switches润滑油油位开关2.6.4Lube Oil Mist Pressure Sensor润滑油雾压力传感器2.
5、6.5Vibration Element / Transmitter振动元件 / 变送器2.6.6Upper Bearing RTD Element / Temperature Transmitter顶部轴承热电阻元件/温度变送器2.6.7Alarm Summary报警概述2.6.8Alarm Bypass 报警跨接2.7.Summary of the Atomizers Utility Services喷雾器的公用设施概述2.7.0General 概述2.7.1Instrument Air 仪用空气2.7.2Lubrication 润滑系统2.7.3Cooling Water 冷却水2.7.
6、4Wheel & Shaft Cooling/Wash Water转盘和轴冲洗水3.0.START UP AND OPERATION启动和运行3.1.Commissioning the Atomizer System 喷雾系统调试3.1.0General / Start-up Engineer 概述/启动工程师3.1.1Priming the Lubrication System 润滑系统加注3.1.2Atomizer Preparation and Run-In 喷雾器的准备和试车3.2.Normal Start Up 正常启动3.3.Normal Operation 正常运行3.4.Nor
7、mal Shutdown 正常停止3.5.Emergency Shutdown of the Atomizer喷雾器的紧急停止TABLE OF CONTENTS (contd) 目录（续）Section (contd) 章节（续）4.0ROUTINE MAINTENANCE例行维护4.1.Lubrication 润滑系统4.2.Preventative and Periodic Maintenance of the ASC ASC防护保养和定期维护4.3.Preventative and Periodic Maintenance of the Atomizer and Wheel喷雾器和转盘的
8、防护保养和定期维护4.4. Long Term Storage of the Atomizer 长期存储喷雾器4.5.Instrument Calibration仪表校准5.0ATOMIZER DISASSEMBLY AND ASSEMBLY INSTRUCTIONS喷雾器拆卸和装配指南5.1General Recommendations一般建议5.2Disassembly Instructions 拆卸指南5.3Re-Assembly Instructions 重新装配指南5.4Atomizer Wheel Balancing Guidelines 喷雾器转盘平衡调校指南6.0SPARE P
9、ARTS LIST备品备件清单6.1Recommended Spare Parts - Model 900 Atomizer型号900 旋转喷雾器，建议的备品备件6.2 Recommended Spare Parts - Model EI-804 Wheel 型号EI-804喷雾器转盘，建议的备品备件6.3 Recommended Spare Parts ASCASC面板，建议的备品备件6.4 Recommended Spare Parts VFD型号A1000，Yaskawa（日本安川电气）喷雾器变频驱动器，建议的备品备件7.0TROUBLE SHOOTING GUIDE 故障排除指南7.1
10、.General 概述7.2.Operating Log 运行日志7.3.Problem Symptoms and Probable Cause Outline故障症状和可能的原因概述7.4.Specific Atomizer Wheel Troubleshooting Guide喷雾器转盘特殊故障排除指南TABLE OF CONTENTS (contd) 目录（续）Section (contd) 章节（续）7.5.Other General Inspection and Trouble Shooting Issues其它总体检查和故障排除事项7.6.Freezing Weather Prec
11、autions寒冷天气应对措施8.0REFERENCE DRAWINGS 参考图纸(Please see drawing list at start of section)（请参阅章节前述的图纸清单）9.0VENDOR DATA 供货商数据(Please see catalogue list at start of section)（请参阅章节前述的目录清单）SAFETY SUMMARY: 安全概述The general information in this part of the summary is for both operating and maintenance personnel
12、. Specific cautions and warnings will be found throughout the manual where they apply, but may not appear in this summary.此部分概述包含的总体信息供操作和维护人员所用。具体注意事项和警告可以在整个手册中的相关章节中找到，但在本概述中不做说明。TERMS：术语In Manual: 在手册中CAUTION statements identify conditions or practices that could result in damages to the equipme
13、nt or other property.注意指的是可能会导致设备或其他财产损害的状况或行为。WARNING statements identify conditions or practices that could result in personal injury or loss of life.警告指的是可能会导致人员受伤或死亡的状况或行为。On Equipment: 在设备上“CAUTION” indicates a personal injury hazard not immediately accessible as one reads the marking, or a haz
14、ard to property including the equipment.“注意”指的是当阅览该标记时，不会立即产生人员伤害，或者指的是对包括设备在内的财产产生损失。“DANGER” indicates a personal injury hazard immediately accessible as one reads the marking.“危险”指的是当阅览该标记时，就立即产生人员伤害的后果。WARNING:This atomizing system operates at high voltage and at high speed. It is provided with
15、a number of interlocks, safety devices, and specific operating procedures to prevent serious injury to personnel and to prevent damage to equipment. Do not attempt to defeat any interlocks, or operate in any way not consistent with the instructions!警告：该喷雾系统处于高电压和高速下运行。配备了多组联锁装置、安全防护装置、以及特定的操作程序，以防止严
16、重的人员伤害和设备损坏。不得试图停用任何联锁设置，或以任何方式违规操作！1.0 RECEIVING, STORAGE AND INSTALLATION收货、储存和安装1.1Receiving and Storage 收货和储存Inspect all shipments of material and equipment for weather or shipping damage. Immediately report any observed damage or discrepancy to the carrier or to Komline-Sanderson, as appropriat
17、e.检查所有运到的材料和设备是否因天气原因或在运输过程中发生损坏。立即向承运人或Komline-Sanderson公司报告任何发现的损坏或缺货现象。Upon receipt, the equipment is in the customers custody and requires precautions in handling and storage. Unless specifically provided for otherwise, the atomizer and its associated equipment are prepared for only brief exposu
18、re to weather, and must therefore be stored in a clean, dry and heated indoor location. In particular, the atomizer itself should remain in its shipping crate and must be kept in an upright position.收到货物后，由客户负责保管设备，并应按规定处理和储存设备。除非另有规定，喷雾器及其相关设备只能短时暴露在露天，因此必须存放在一个清洁、干燥、常温的室内。特别是，应将喷雾器保存在其装运箱中，并保持直立状态
19、。For information concerning Long Term Storage refer to Section 4.4详情请参阅第4.4章节“长时间储存”1.2Installation安装1.2.0General Description: 概述For convenient operation and maintenance of the atomizer, it is necessary to provide a hoist and monorail centered over the spray dryer atomizers operating position. The m
20、onorail should extend to a point that will permit lowering the machine to an elevation (e.g. grade) from where it can be transported by other means for offsite maintenance or storage.为了方便喷雾器的操作和维护，有必要在旋转干燥喷雾器操作位置上方设置吊机和单轨。单轨应该延伸至一个可以将机器下放到提升平台（如：地平面）的操作点，自此可以以其他方式将其运输至厂外进行维修或储存。The atomizer operatin
21、g site requires adequate platforming and lighting for safe and careful operation. The atomizer should, once outside its shipping crate, only be stored or transported in its maintenance stand or suspended from a hoist.喷雾器操作现场需要有足够的平台和照明，便于安全和细致操作。一旦将喷雾器从其装运箱取出后，其储存或运输只能通过维护支座或吊机进行。The atomizers contr
22、ol / lubrication panel, in the following referred to as the Atomizer System Control (ASC), is a NEMA-4 design for location adjacent to the atomizers operating position (the “support tube”). It connects to the atomizer via the so-called “umbilical cord”. The atomizers power supply enclosure, the Vari
23、able Frequency Drive (VFD) is a NEMA-1 design for location in a remote, electrical equipment room area. 喷雾器的控制/润滑面板以下简称为喷雾器控制系统（ASC），采用NEMA- 4标准设计，其位置与喷雾器的操作位置（“支撑管”）相邻。它通过所谓的“母管”连接到喷雾器。喷雾器的电源供应装置：变频驱动器（VFD）采用NEMA- 1标准设计，位于远程电气设备间内。Refer to later sections of these instructions for further informatio
24、n and drawings. General reference drawings for the installation procedure are as follows:在以后章节中可参阅相关资料和图纸。安装过程中的总体参考图如下：Electrical power connections between the Atomizer System Control (ASC), the Variable Frequency Drive (VFD), and the Atomizer are shown on the dwgs. D0430-90000D, D0430-92000D, and
25、D0430-90006D. Oil lubrication, cooling water, purge air, wash water, and electrical signal connections between the ASC Panel and the Atomizer are made via an umbilical hose assembly, shown on dwg. D0430-91061D. This assembly contains lubrication lines (air/oil mist supply and return lines); cooling
26、water supply and return lines; purge air line, wheel wash and shaft wash lines; and vibration, and temperature signal wiring (the umbilical cords electrical signal schematics are shown on dwg. D0430-91091D). Power to the atomizer is supplied by a cable, which plugs into a receptacle to be mounted ne
27、ar the atomizer operating position.喷雾器控制系统（ASC）、变频率驱动（VFD）以及喷雾器之间的电源连接见图纸D0430-90000D、D0430-92000D和 D0430-90006D所示。ASC面板和喷雾器之间的油润滑、冷却水、吹扫空气、冲洗水、以及电气信号通过母管组件连接，如图纸D0430-91061D所示。 该组件包括润滑管路（空气/油雾气供应和回流管路）、冷却水供应和回流管路、吹扫空气管路、喷雾转盘清洗和轴清洗管路、以及振动和温度信号电缆（母管的电气信号原理图见图纸D0430-91091D）。喷雾器的电源电缆插在一个安置在喷雾器操作位置附近的插座
28、上。1.2.1.Atomizer System Control (ASC): 喷雾器控制系统（ASC）In the following, please reference in particular dwgs. D0430-90001D, D0430-90006D, and D0430-91061D)关于如下要点，请特别参阅图纸D0430-90001D, D0430-90006D和 D0430-91061Da.Set the Atomizer System Control (ASC) near the atomizers operating position (support tube), o
29、riented for the most convenient observation and access to the front.将喷雾器控制系统（ASC）安置在喷雾器的操作位置（支撑管）附近，调整角度至最方便观察及接触前面板的位置。b.Avoid placing the ASC unit on top of removable floor plates (when furnished). It is suggested that permanent fastening down of the ASC should be postponed until the remaining wor
30、k in this section is complete.避免将ASC装置放置在可移动的底板上（如果有的话）。建议在本章节所述剩余工作未完之前，先不要永久固定ASC。c.Measure the distance from the umbilical connection panel on the ASC to the bottom of the atomizer support tube (the atomizers operating position). This should be 18 ft (5.5 m) or less.测量从ASC上的母管连接面板至喷雾器支撑管（喷雾器的操作位置
31、）底部的距离。应该是18英尺（5.5米）或更少。d.Pipe the instrument air supply to connect to the fitting “N1” on the left side of the ASC enclosure.将仪用空气管与ASC机柜左侧上的接头“N1”相连。e.Mount the provided water softener assembly (dwg. D0430-80007C) at a suitable connection near the ASC enclosure. Pipe potable (clean) water supply t
32、o its inlet fitting and pipe from its discharge to the fitting “N4” on the left side of the ASC enclosure. 将供水软化装置（图纸 D0430-80007C）安装在ASC机柜附近适当的连接位置上。饮用（清洁）水接至其入口接头，并从出口接头接出管线与ASC机柜左侧上的接头“N4”相连。 f.Install the vacuum tank assembly (dwg. D0430-90001D, item 04, and dwg. D0430-91086D) behind the ASC enc
33、losure. Connect the tank inlet and outlet hoses to the proper connections on the right side of the ASC panel (the hose attached to the vacuum tank assembly filter is to be connected to the ASC port that is labeled TO VACUUM FILTER ON 5 GAL TANK and the hose that is attached directly to the tank is t
34、o be connected to the ASC port that is labeled RETURN FROM 5 GAL TANK.将真空罐组件（图纸 D0430-90001D，部件04，和图纸D0430-91086D）安装在ASC机柜后面。将真空罐入口和出口软管连接到ASC面板右侧的接头上（与真空罐过滤器相连的软管应连接到ASC上标有“至5加仑罐真空过滤器”的端口上，直接与真空罐连接的软管应接到ASC上标有“从5加仑罐回流”的端口上）。g.Connect cooling water supply and return (or drain) piping to the fittings
35、 “N2” and “N3”, respectively, on the left side of the ASC enclosure.将冷却水供应和回流（或排水）管道分别与ASC机柜左侧接头“N2”和“N3”相连。h.Connect the umbilical hose fittings to the connection panel in the right side of the ASC enclosure. Note the identification of the individual hoses on the attached tags and cross-reference w
36、ith dwg. D0430-91061D. Also connect the electrical signal (Amphenol) connector with the panels mating receptacle. Secure the umbilical assembly to the enclosure by the use of the provided strain relief chain.将母管组件与ASC机柜右侧面板相连接。注意识别各个软管附带的标签并相互参照图纸D0430-91061D。然后将电气信号（安费诺）连接器与面板的适配插座相连。使用所提供的应力释放链将母管
37、固定到壳体上。i. Mount the feed strainer (provided by others) at a suitable location in the vicinity of the atomizers operating position. The 1-1/2” (40 mm) and 20-ft (6 m) long feed hose (dwg. D0430-91070C), which should be mounted directly to the strainer via the Camlok connector, must be within reach of
38、 the atomizer in its operating position. Run feed piping to the strainer inlet.将进料过滤器（由其它公司提供）安装在喷雾器操作位置附近的一个合适的位置上。1-1/2英寸（40毫米）和20英尺（6米）长的给料软管（图纸 D0430-91070C）（该软管应通过Camlok连接器直接安装到过滤器上）必须处在能够达到喷雾器的操作位置范围之内。将给料管道布置到过滤器入口。j.Install electrical power and signal wiring to the terminals located in the u
39、pper enclosure of the ASC unit. Use the connection schematic dwg. D0430-90006D for proper identification of the terminals. 将电源线和信号线接到位于ASC单元外壳顶部的端子上。按照图纸D0430-90006D区分各个端子。1.2.2.Atomizer (Motor):喷雾器（电机）In the following, please reference in particular dwgs. D0430-01102D and D0430-01100D.关于如下要点，请特别参阅图
40、纸D0430-01102D 和D0430-01100D.a. Uncrate the atomizer and transport it to the operating site. The machine should be kept erect at all times. Save the crate for later use! Refer to the Atomizer Shipping Box Drawing CSM80-00017D in Section 8.拆封喷雾器，并运送到作业现场。应使机器始终保持直立状态。保存拆卸的箱子，为日后所用！参阅在第8章的喷雾器装运箱图纸 CSM8
41、0-00017Db. Set the atomizer into its maintenance stand (dwg. D0430-01046D) or suspend it from the hoist within reach of the ASC panels attached umbilical hose.将喷雾器放置在检修支架上（图纸 D0430-01046D）或在可以触及ASC面板的母管长度范围内把它挂在起吊器上。CAUTION:Never allow the atomizer shaft or wheel to support the weight of the unit!注意
42、：禁止让喷雾器轴或转盘承载装置的重量！Connect the umbilical cords cooling water fittings (3/4”) (20 mm), the color-coded (Swagelok) quick connectors (3/8” and ”) (10 mm and 6 mm), and the (Amphenol) signal connector of the umbilical hose with the mating connectors mounted on the atomizer. Cross-reference with the umbi
43、lical hose drawing (dwg. D0430-91061D) if necessary. Avoid any lines crossing or excessive strain imposed on any hoses or connectors. Finally secure the umbilical hose to the atomizer by the use of the strain relief chain provided.将母管的冷却水接头（3 / 4英寸）（20毫米）、标有颜色的（世伟洛克）快接（3 / 8英寸和1/4英寸）（10毫米和6毫米）、以及母管的
44、信号连接器（安费诺）与安装在喷雾器上的匹配连接器相连接。如有需要，参阅母管图纸（图纸 D0430-91061D）。避免任何管线交叉，以及任何软管或连接器的过度受载。最后，使用所提供的应力消除链紧固母管与喷雾头的连接。1.2.3Variable Frequency Drive (VFD): 变频驱动器（VFD）In the following, please reference in particular dwg. D0430-92000D, as well as the VFD information provided in the Vendor Data Section 9 of this
45、manual. 关于如下要点，请特别参阅图纸D0430-92000D，关于VFD的信息请参阅本手册的第9章节供货商数据。a.It is assumed that the VFD is properly installed in an electrical equipment room area, its input terminals have been wired to the facilitys power supply, the unit has been adequately grounded, etc. Also, it is assumed that the power wirin
46、g between the VFD and the atomizer receptacle, incl. the interlock wiring, is in place 假定，VFD被正确地安装在电气设备室内，其输入端已与设备电源相连接，装置已充分接地等，此外，假定，VFD和喷雾器插座之间的电源接线，包括联锁装置接线均已就位。b.Complete the interconnect wiring at the ASCs upper enclosure, as also referenced on Dwg. D0430-90006D完成在ASC机柜上部的互连布线，请参阅图纸 D0430-90006D。1.2.4.Permanent Installation: 最终固定If no adjustment of the ASC location appears necessary, complete permanent installation by bolting
