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1、Operating and Maintenance Manualfor Fans Type KK&KKK&K风机的运行和维护手册Type:类型：CKPF-Job-No.:工作号：Machine-No.:设备号：Application:应用：Year of design:设计年份：Client No.: 客户号Plant:厂家：Plant Location:厂家地址：Chengdu KK&K Power Fan Co. Ltd. 成都KK&K电站风机有限公司610041 Changyi Road 12 610041 长益路 12Wuhou District Chengdu City 成都市武侯区
2、Sichuan Province 四川省Tel. +86 Fax +86 This instruction is exclusive property of Chengdu KK&K Power Fan Co. Ltd.Availability is limited to supervisors or service personnel. Surrender to or access by third persons, as well as duplication of the plant in its entirety or in parts is prohibited. We reserv
3、e the right to claim for full reimbursement of all damages resulting form non-compliance.We must point out that these operating instructions cannot always cover every eventuality completely. Accordingly they do not free the operator from the usual responsibility when operating technical equipment al
4、so in respects of health, safety and environmental protection. It is assumed that the operation personnel has been instructed and knows how to run the plant.No claims of any kind may be derived from these operating & maintenance instructions.该说明书版权为成都KK&K所有。仅限管理和服务人员使用。不允许第三方使用、完全或部分拷贝该说明书。我方保留索赔权。我
5、们需要指出这些运行操作说明书不能包括所有的不可预测的情况。因此在操作时，还应警示个人健康，安全，以及对环境的保护等。本说明书供组装、运行、维护人员认真阅读，严格遵循，风机的组装和维护工作必须由专业人员承担。操作人员需要掌握如何操作这些设备。目 录1.OPERATING DATA运行参数61.1.PRESSURE INDICATIONS压力指示61.2.OPERATING CONDITIONS 运行条件61.3.LIMITATIONS TO OPERATING DATA 运行参数限制61.4.PERFORMANCE GRAPH 性能曲线71.5.STARTING TORQUES AND MASS
6、 MOMENT OF INERTIA 启动力矩和转动惯量81.6.ACOUSTICS声学82.DESCRIPTIONS简介92.1.FLUIDIC EFFECT (1-STAGE)工作原理（单级）92.2.FLUIDIC EFFECT (2-STAGE)工作原理（双级）92.3.DESCRIPTION OF THE FAN风机（部件）简介92.3.1.STATOR COMPONENTS静止件102.3.2.ROTOR (1-STAGE) 转子（单级）112.3.3.ROTOR (2-STAGE) 转子（双级）112.3.4.IMPELLER (1-STAGE, WITH COUNTERWEIG
7、HTS) 叶轮（单级，带平衡锤）112.3.5.IMPELLER (2-STAGE, WITH COUNTERWEIGHTS) 叶轮（双级，带平衡锤）112.3.6.IMPELLER (1-STAGE, WITHOUT COUNTERWEIGHTS)叶轮（单级，不带平衡锤）112.3.7.IMPELLER (2-STAGE, WITHOUT COUNTERWEIGHTS)叶轮（双级，不带平衡锤）122.3.8.BLADE ADJUSTMENT叶片调节122.3.9.BLADE BEARINGS 叶片轴承132.3.10.SHAFT (1-STAGE) 主轴（单级）132.3.11.SHAFT
8、(2-STAGE) 主轴（双级）132.3.12.SERVOMOTOR (1-STAGE)伺服马达（单级）132.3.13.SERVOMOTOR (2-STAGE)伺服马达（双级）132.3.14.CONTROL HEAD控制头132.3.15.ADJUSTING PISTON油缸132.3.16.ADJUSTING DISC (1-STAGE) 调节盘（单级）142.3.17.ADJUSTING DISC (2-STAGE)调节盘（双级）142.3.18.ROTOR BEARINGS (ANTIFRICTION BEARING) 主轴承（滚动轴承）142.3.19.ROTOR BEARING
9、S (SLEEVE BEARING) 主轴承（滑动轴承）142.3.20.ACCESSORIES附件153.OPERATION/运行163.1.TECHNICAL PLANT REQUIREMENTS技术设备要求163.1.1.OPERATING RANGE工作运行区域163.1.2.SECURITY安全173.1.3.ADJUSTMENT调节193.2.PRIOR TO TEST RUN/ COMMISSIONING/ OVERHAULS试运转前期/试运转/检查213.3.TEST RUN试运行223.4.STARTING UP启动233.5.SHUTTING DOWN关机243.6.MON
10、ITORING DURING OPERATION运行监控244.MAINTENANCE 维护264.1.DURING OPERATION风机运行期间264.2.OIL MAINTENANCE油系统维护264.3.MAINTENANCE INTERVALS & SCOPE计划停机（检修）维护274.3.1.FAN壳体274.3.2.IMPELLER 叶轮284.3.3.SERVOMOTOR伺服马达294.3.4.MAIN BEARINGS主轴承294.3.5.ADJUSTMENT DEVICE调节装置304.4.UNSCHEDULED STOPPAGE 非计划停机维护304.5.WEAR DAT
11、A (ID/ FGD FAN ONLY)磨损数据（仅适用于引风机/增压风机）315.ASSEMBLY组装325.1.FAN风机345.1.1.PREPARATION 准备345.1.2.CHECKS 检查345.1.3.ASSEMBLY 组装345.1.4.CONNECTIONS 连接355.1.5.FUNCTION TESTS 功能测试355.2.SEALS, PARTS SUBJECT TO WEAR密封件和易损件的拆装365.3.ROTOR转子365.3.1.LIFTING OFF THE HOUSING COMPONENTS 机壳部分的起吊365.3.2.DISCONNECTION 拆
12、卸375.3.3.REMOVING ROTOR BLADES 拆卸动叶片385.3.4.ROTOR REMOVAL 转子的拆卸385.3.5.FITTING THE ROTOR 组装转子385.3.6.FITTING ROTOR BLADES动叶片组装385.3.7.SECURING THE CONNECTIONS 连接保护385.3.8.FITTING THE HOUSING COMPONENTS 壳体部件的组装395.4.IMPELLER叶轮405.4.1.REMOVAL OF ROTOR 转子拆卸405.4.2.BLADE-BEARING REMOVAL 叶片轴承的拆卸405.4.3.D
13、ISASSEMBLY OF THE ADJUSTING LEVER 曲柄的拆卸415.4.4.ASSEMBLY OF ADJUSTING LEVER 曲柄的组装415.4.5.ASSEMBLY OF BLADE BEARING 叶片轴承的组装425.5.ROTOR BLADES动叶片455.5.1.REMOVAL 拆卸455.5.2.FITTING 组装455.6.SERVOMOTOR伺服马达485.6.1.REMOVAL FROM THE IMPELLER 从叶轮上拆卸485.6.2.FITTING TO THE IMPELLER 组装到叶轮上495.7.ADJUSTING DISC (1-
14、STAGE) 调节盘（单级）495.7.1.DISASSEMBLY 拆卸495.7.2.ASSEMBLY 组装495.8.ADJUSTING DISC (2-STAGE) 调节盘（双级）495.8.1.DISASSEMBLY拆卸495.8.2.ASSEMBLY组装515.9.MAIN BEARINGS (ANTIFRICTION BEARING) 主轴承（滚动轴承）515.9.1.DISASSEMBLY拆卸515.9.2.ASSEMBLY组装525.10.MAIN BEARING (SLEEVE BEARING) 主轴承（滑动轴承）555.10.1.DISASSEMBLY拆卸555.10.2.
15、ASSEMBLY组装565.11.SHAFT SEALS轴封：575.11.1.DISASSEMBLY拆卸575.11.2.ASSEMBLY组装575.12.NOTES ON THE COUPLING联轴器提示595.13.HYDRAULIC ASSEMBLY SHAFT/ IMPELLER液压组装主轴与叶轮595.13.1.METHOD OF OPERATION操作方法595.13.2.INSTALLATION DEVICES组装设备595.13.3.DISASSEMBLY拆卸605.13.4.ASSEMBLY组装615.14.COOLING/SEALING AIR SYSTEM (ID F
16、AN ONLY) 冷却/密封空气系统（仅用于引风机）645.14.1.SEALING AIR密封空气645.14.2.COOLING AIR冷却空气655.15.CONNECTION OF THE PIPES管道连接656.TRANSPORTATION运输677.LUBRICATION润滑687.1.GENERAL概述687.2.MAIN BEARING AND SERVOMOTOR主轴承和伺服马达用油687.2.1.REQUIRED PROPERTIES要求特性687.2.2.OIL CARE润滑油警示事项697.2.3.OIL SYSTEM油系统707.2.4.OIL FILLING注油7
17、07.2.5.CHANGING THE OIL换油717.2.6.DOCUMENTATION OF LUBRICATION润滑油记录文档727.3.BLADE BEARINGS叶片轴承用油727.3.1.REQUIRED PROPERTIES要求特性728.SPARE PARTS备件748.1.STOCKS库存748.1.1.AVAILABILITY建议存储的备件748.1.2.WEAR, MALFUNCTIONS磨损、故障748.2.ORDERING订货768.3.STORAGE贮存769.PRESERVATION保存789.1.NOTE说明789.2.INTERRUPTION OF INS
18、TALLATION组装间歇期的防护789.3.STANDSTILL停机时的防护799.4.PRIOR TO COMMISSIONING试运行之前8110.MALFUNCTION ANALYSIS故障分析8210.1.VIBRATION振动8210.2.BEARING TEMPERATURE轴承温度8210.3.OIL TEMPERATURE油温8310.4.OIL PRESSURE油压8310.5.OIL CONDITION油况8410.6.OIL LEVEL油位8410.7.BEARING LEAKING轴承泄漏8410.8.BEARING CONDITION轴承状态8510.9.WEAR磨
19、损8510.10.POWER CONTROL动力控制8610.11.BLADE BEARING BLOCKED叶片轴承卡滞861. Operating data运行参数1.1. Pressure indications 单位说明Pressures indicated in bar and/or mbar are gauge pressures. Pressures indicated in “abs” are absolute pressures.单位为bar或mbar的压力为表压力，单位为abs的压力值为绝对压力。1.2. Operating conditions运行条件Descriptio
20、n描述Customers machine no.用户设备编号CKPF machine no. CKPF设备编号Fan type风机型号Axial fan with adjustable blades动叶可调轴流风机Fan Size风机尺寸Dimension尺寸Fluid介质Ambient air当地大气压Load负荷Design设计Volume at 0C and 1,013 bar标态流量Nm3/minVolume at fan inlet实际入口流量m3/sTemperature at inlet fan入口温度CStructural design temperature设计温度CPres
21、sure at fan inlet入口压力mbar absDensity at fan inlet入口密度kg/m3Total pressure rise风机全压mbarFan speed风机转速1/minMotor speed电机转速1/minAbsorbed power at motor coupling电机输出功率kWInstalled nominal motor power电机额定功率kWPerformance graph性能曲线no.PG Acoustic data声学数据no.AC Starting torques启动扭矩no.ST Mass moment of inertia转动
22、惯量Kgm21.3. Limitations to operating data运行参数限制DANGER !警示The fan or parts and all parts of the fan are specifically designed based on information supplied by the customer.If in the course of time any changes to this information take place or are planned, these should be checked with CKPF to ensure th
23、at they are permissible.风机及配件是按用户提供的参数资料进行专门选型设计的，若参数改变，应由CKPF检验校核以确认其可行性。Motor speed Fluctuations in the power-supply frequency must not cause the speed of the drive motor to exceed the rpm figure specified in the operating data by more than 2%.电机转速 电源频率的波动导致转速的波动不能超过运行数据规定的2%。Motor power The permi
24、ssible motor power may exceed the power required at the fan shaft indicated in the operating data by max. 15%.电机功率 电动机安全的功率余量应至少大于风机运行工况下轴功率的15%。Gas temperature The admissible gas temperature measured at the fan intake气流温度 风机入口气流温度must not exceed a maximum of C permanently 最大不能长时间超过（ ）may be at a ma
25、ximum of . C for a short time for max. . minutes.或（ ）时最长不得超过（ ）分钟。IMPORTANT !重要In case of exceeding these limits please若超过上述限制要求check the fan for damage检查风机的损害and contact CKPF并联系CKPFOperating points The fan may only be operated for brief periods with an insufficient volume flow. The limit is mention
26、ed in the attached performance graph.运行点 风机尽量避免在不稳定区运行。此区域在特性曲线图上可以查到。IMPORTANT !重要Low volume operation over a longer period can cause overheat of the fan. This should be avoided.风机若长时间在低流量运行会导致过热，应避免。IMPORTANT !重要The fan must not be operated above the surge limit. The limit is mentioned in the atta
27、ched performance graph.不允许风机在失速喘振区域运行，此区域在特性曲线图上可以查到。IMPORTANT !重要The operation of the fan above the surge limit strains blades, other fan parts, plant components extremely. Impacts and vibration can cause heavy damage to all parts of the fan and the plant. This should be avoided.若风机在失速喘振区域运行会导致动叶和其
28、它机件重大损坏、撞击和振动导致更大的系统设备事故，应避免。1.4. Performance graph 性能曲线(to be inserted here)（由此插入） 1.5. Starting torques and mass moment of inertia 启动扭矩和转动惯量 (to be inserted here)（此处插入） 1.6. Acoustics声学特性 (to be inserted here)（此处插入）2. Descriptions简介2.1. Fluidic effect (1-stage)工作原理（单级）On entering the direction of
29、the flow is altered in the suction bend, accelerated by a nozzle and directed into the impeller.气流由系统管道流入风机进气箱后改变方向，经集流器收敛加速后流向叶轮。In the impeller the axially-directed flow becomes circumferential and is accelerated. The pitch angle of the rotor blades is infinitely variable during operation. The adj
30、ustment has the effect of changing the volume flow.电动机带动叶轮对气流作功，动叶的工作角度与叶栅距可无级调节，由此改变风量、风压满足工况变化需求。After the impeller the guide vanes (outlet guide-vane unit) redirect the flow in an axial direction, thus increasing the pressure (reaction-type fan). 气流由轴向运动经叶轮作功后变为螺旋运动，流出的气流经后导叶导向转为轴向流动。In the diffu
31、sor the kinetic energy is then converted into static pressure.再经扩压器，将部分动能转换成静压能，流至系统满足运行要求。2.2. Fluidic effect (2-stage)工作原理（双级）On entering the direction of the flow is altered in the suction bend, accelerated by a nozzle and directed into the impeller.气流由系统管道流入风机进气箱后改变方向，经集流器收敛加速后流向叶轮。In the impell
32、er the axially-directed flow becomes circumferential and is accelerated. The pitch angle of the rotor blades is infinitely variable during operation. The adjustment has the effect of changing the volume flow.电动机带动叶轮对气流作功，动叶的工作角度与叶栅距可无级调节，由此可改变风量、风压满足工况变化需求。After the impeller the guide vanes (outlet
33、guide-vane unit) redirect the flow in an axial direction, thus increasing the pressure (reaction-type fan).气流由轴向运动经叶轮作功后变为螺旋运动，流出的气流经后导叶转为轴向流动。In the second stage pressure is further increased.在第二级叶轮处压力进一步增加。The pitch angle of the rotor blades in both stages is adjusted synchronously.两级叶轮的叶片角度同时调整。I
34、n the diffusor the kinetic energy is then converted into static pressure.再经扩压器，将部分动能转换成静压能，流至系统满足运行要求。2.3. Description of the fan风机（部件）简介Seen in the direction of the flow the 1-stage fan consists of the following components Suction bend with shaft protection tube Fan housing with flow hub Guide vane
35、 housing Rotor with bearing (in the flow hub) Diffuser从气流方向看，单级风机由以下部件组成带护轴管的进气箱带整流罩的机壳装配后导叶装配主轴承装配（在整流罩中）扩压器Seen in the direction of the flow the 2-stage fan consists of the following components Suction bend with shaft protection tube and flow hub Fan housing Rotor with bearing (in core of fan hous
36、ing) Guide vane housing Diffuser从气流方向看，双级风机由以下部件组成带护轴管和整流罩的进气箱机壳装配主轴承装配（在整流罩中）后导叶装配扩压器The structure is made clear by the accompanying sectional drawing.结构详见附图。2.3.1. Stator components定子部件Stator components are suction bend, fan housing, guide vane housing and diffusor. 定子部件分为进气箱，机壳装配，后导叶装配和扩压器。Genera
37、lThe stator components are welded structures made of even rolled sheeting reinforced with ribs and flanges. The process of welding them together is not completed until the stage of on-site assembly.概述定子部件由焊接了加强筋板和法兰的壳体铆焊件构成，到组装时再将其焊接或组合在一起。Suction bend The suction bend has a rectangular inlet cross-
38、section. It has an access door on the front. The base fastenings are sliding supports, when the fan expands on heating they can move on the foundation.进气箱进气箱入口截面为矩形，在前端面带人孔门，当风机热胀冷缩时，基础可适量滑动，抵消热膨胀量。Fan housing 1-stage: The fan housing is horizontally split.机壳装配 单级：中分剖分。 2-stage: The fan housing is h
39、orizontally split. The guide vanes of the first impeller stage are welded in. 双级：中分剖分。第一级叶轮的后导叶焊接。Guide vane housing1-stage: The guide vane housing is horizontally split. The guide 后导叶装配 vanes are welded in place. 单级：中分剖分，后导叶焊接。 2-stage: The stator housing is horizontally split. The guide vanes of t
40、he second impeller stage are welded in. 双级：定子壳体中分剖分，2级后导叶焊接。Diffuser There is a door in the diffusor core permitting access from the discharge pipe.扩压器 芯筒带人孔门，允许人从出口管路进入其中。2.3.2. Rotor (1-stage)转子（单级）The rotor consists of the impeller, the shaft and the servomotor. The shaft has a pin to engage with
41、 the coupling hub. 单级风机的转子包括叶轮、主轴、伺服马达。主轴通过键与联轴器轮毂联接。2.3.3. Rotor (2-stage) 转子（双级）The rotor consists of the impeller, the shaft, the servomotor and the adjusting rod with adjusting disc. The first-stage impeller has a drive disc for the coupling hub. 双级风机的转子包括叶轮、主轴、伺服马达、带调节盘的芯轴。第一级叶轮由驱动盘（中介环）和联轴器连接。
42、2.3.4. Impeller (1-stage, with counterweights) 叶轮（单级，带平衡锤）The impeller is overhung. The impeller hub is a welded structure. The forged body accommodates the blade bearings. It is connected to the shaft with a hub disc. The hub disc is attached to the shaft with a taper press fit.叶轮为悬臂式、焊接件。叶片轴承组装在叶轮
43、毂体内，叶轮毂通过毂盘与主轴联接，毂盘由圆锥面过盈配合联接固定到主轴上。The restoring moments of the blades are generated by the rotating mass of the blading and the air forces. For a partial compensation of the restoring moments compensating weights are attached to the blade shaft which generates a moment reacting to the restoring moment of the blades. 叶片回复力矩由叶片的旋转质量和气体压力产生。作为回复力矩的部分补偿，组装在叶片轴上的平衡锤能产生一个力矩来抵消叶片产生的回复力矩。2.3.5. Impeller (2-stage, with counterweights) 叶轮（双级，带平衡锤）The impeller is overhung. The impeller hubs are welded structures. The blade bearings fit into the forged carriers. They are con
