磨煤機(jī)油站說明書

1、GYZ型高壓站說明書 Operation & Maintenance Manual for Hydraulic Unit Type GYZ北 京 電 力 設(shè) 備 總 廠BEIJING POWER EQUIPMENT GROUPGYZ型高壓油泵站使用和維護(hù)說明書 Operation & Maintenance Manual for Hydraulic Unit Type GYZ2008年6月 Jun. 2008Catalogue目錄一 、General2概述12 二、Main Components of the Hydraculic Unit2主要元件說明12三、Operatio

2、n Procedure8 系統(tǒng)操作步驟161、Commissioning8系統(tǒng)的調(diào)試162、 Operation9系統(tǒng)的運(yùn)行17 3、Operating Procedure After Maintenance9檢修后的操作步驟174、Working State of the Main Components10主要元件的工作狀態(tài)17四、 Operation & Maintenance of the Hydraculic Unit10系統(tǒng)的使用與維護(hù)171、Installation10 系統(tǒng)的安裝172、 Oil Charging10油液的加注183、 Circulation10系統(tǒng)的循環(huán)

3、184、 Maintenance10系統(tǒng)的維護(hù)18附注1 管路的沖洗.19 Flushing manual.19 原理圖 . .A3 Illustrative diagram.A3 The operation & maintenance manual is for the installation, operation, and maintenance of the GYZ series Hydraulic unit.一、GeneralHydraulic unit，consisting of high-pressure oil pump unit , oil pipeline , hy

4、draulic reversing valve ,loading cylinder, and accumulator etc, is an important part of mill. Its functions are as follows: Hydraulic unit provides the grinding roller with dynamic loading efforts which is controlled by solenoid controlled relief vavle according to the coal quality to lift and drop

5、the rollers simultaneously. The loading system contains three loading cylinders and three accumulators. The oil filled side of the accumulator, assembled with rubber gas bag filled with nitrogen inside, connects with the piston rod of the oil cylinder. The three oil cylinders connect with the public

6、 oil supply pipeline. The high-pressure oil pump unit, installed on the base next to mill, provides the motive effort to the loading cylinder and accumulator that are mounted on the mill. High-pressure oil pump unit and loading cylinder are connected with 0Cr18Ni9 cold-drawn seamless steel pipelines

7、 with welded fitting. The oil tank volume is 680L, with 600L as the first oil charge L-HM46 anti-friction hydraulic oil shall be adopted. The oil is charged through the air filter and the filter accuracy is 10m. The oil shall be circulated until the oil cleanliness up to NAS1638 grade 8 after the sy

8、stem and the pipelines are completed installed. Then, the hydraulic unit can be operated. Details see schematic diagram 02MG00.20.00.二、Main Components of the Hydraulic Unit1、 No.1 and No.2, Loading Oil Pump Group Oil pump group is made up of motor and gear pump. Pump shaft is directly inserted into

9、the keyway of the motor to ensure the axiality between gear pump and motor. The pump is constant external gear rotary pump. Oil pump group is mounted on the upper cover of the oil tank to provide motive effort to the loading system.Parameters:Type of gear pump: K1P10L11A-HTType of motor: .CT-08(PA)-

10、HSW-HTPressure class: 20.6MPaPower: 7.5kWVoltage: .415V/50HzRotation speed: .1440r/minMax. flow: .15L/minRated working pressure of oil pump: 18MPa, shown at measuring point on pressure gauge 11.1Rotation direction: .counterclockwise, view from pump shaft end2、 No.3, 4 and 32.1 High Pressure Filter G

11、roupHigh pressure filter group is made up of two filters, two check valves and one three-way glove valve. High pressure filters working drum and standby drum can be switched over. When the filter core is replaced, the system oil shall not be interrupted by switching three-way glove valve. High press

12、ure filter is used of filtering solid impurity of oil in oil tank to avoid the impurity into loading system. The difference is the differential pressure of inlet and outlet. When it reaches 0.5MPa, it means that the working filter core is restricted and shall be replaced. If the filter core is not r

13、eplaced in time and when the differential pressure reaches 0.6MPa, bypass valve will be opened automatically to protect the filter core from broken by the higher differential pressure. The filter core is one-off type which can not be repetitively used.Parameters:Type of filter: .FMM0502BACA06NP03/N7

14、-HTType of check valve: .ADR-15-HTType of three-way ball valve: .KHB3K-G1/2-L-1112-O2X-HTConnection type: .pipe-type, interface dimension is G1/2”Pressure class: .28MPaNominal flow: .55L/minFiltering accuracy: .6mType of filter core: HP0502A06ANP03-HT.3、 No.5 Relief Valve Relief valve is a modular v

15、alve. It is to set the safe pressure of loading system. Set value is 14MPa . Parameters:Type: . . MRV-03-P-3-B-HTPressure class: .21MPaPressure adjustment range: .721MPaMax. flow: 35L/min4、 No.6 Plate Glove ValvePressure oil is straight-through to the system while running normally. When commissionin

16、g, oil flows to oil tank through return filter by switching the handle.Parameters:Type: KHP-06-1114-14X-HTInside nominal diameter: .06mmPressure class: .50MPa5 、No.7 Relief ValveRelief valve is a modular valve. Relief valve 7.1 is to set the pressure of pilot oil system. Set value is 8MPa shown at p

17、ressure gauge 11.3. Relief valve 7.2 is to set the pressure of lifting grinding roller and set value is 7MPa.shown at pressure gauge 11.2. Parameters:Type: . MRV-03-B-3-B-HTPressure class: 21MPaPressure adjustment range: .721MPaMax. flow: .35L/min6、 No.12 Flow Control ValveLoading cylinder lifts syn

18、chronously by adjusting flow control valve 12.1, 12.2, 12.3 of return line. The loading cylinder drops synchronously by adjusting flow control valve 12.4, 12.5, 12.6.When adjusting, turning the hand wheel adjusting screw clockwise, flow will decrease, contrarily increase.Parameters:Type: .QV-06/16-H

19、TMax. pressure: .25MPaMax. adjusted flow: .16L/min7、 No.13 Solenoid Directional ValveSolenoid directional valve is two-position four-way diverter valve. Steel ball is adopted for locating the position. So the electromagnet doesnt need to be electrified often. Solenoid directional valve 13.1 is loadi

20、ng system diverter valve. When lifting grinding roller and before roller drops, diverter valve locates at the right-hand position. Solenoid directional valve 13.2 is control system diverter valve .when ready to lift and drop grinding roller and in the lifting and dropping state, diverter valve locat

21、es at left-hand position. Parameters:Type: .4WE10-D/OF-E-W240-20-HT Pressure class: 31.5MPaAdmissible backpressure: .16MPaAC power: .W240VMax. flow: .120L/min 8 、No.14 Inlet Filter Inlet filter 14 is be used in the inlet of pump to filter solid impurity in oil tank for protecting pump. The filter is

22、 equipped with bypass valve which opens automatically when the differential pressure between inlet and outlet of filter reaches 0.03Mpa. The filter core can be used again after cleaning. We suggest cleaning once before 168 trial-run and once after 168 trial-run. During three months after putting int

23、o operation, it shall be cleaned every one month and after that it shall be cleaned every three months. Filter core will be replaced after cleaning 3 to 5 times according to running state of the unit.Parameters:Type: . .STR070-3BG1M60-HT Connection type: .mesh structure, pipe-type, interface dimensi

24、on is G3/4”Nominal flow: .60L/minFiltering accuracy: .60m9、 No.15 Solenoid Controlled Relief Valve Solenoid controlled relief valve adopts sub-base mounting. It has pilot control cone valve to control the loading pressure. Set value is 16MPa.shown at pressure gauge 11.4.After working; the pressure c

25、ould be adjusted during 9-12 Mpa according to the actuarial condition.Parameters：Type: . SBSG-03-1NP-3-R-A240-20-HTNominal diameter: .10mmPressure class: .35MPaPressure adjustment range: .321MPaMax. flow: .200L/minDC power: 240V。10 、No.16 Water CoolerThe water cooler is to cool the return oil of loa

26、ding system. The system circulates cooling water to cool the oil when oil temperature of tank is up to 55, and cuts off cooling water when the oil temperature of tank is lower than 45.Parameters：Type: GLC3-4/1.0-HTCooling area: 4m2Pressure class: .1.0MPaHeating exchange factor: .350W/m2. kCooling wa

27、ter volume: 7.2T/hCooling water pressure: .0.6MPaHeat exchange tube: finned red copper tube11、 No.18 AccumulatorAccumulator and loading cylinder are together mounted on the mill base to store excessive oil of loading system or provide make-up oil when operation. It can absorb pressure pulse.Paramete

28、rs:Type: NXQ1-F16/20-H-HTNominal volume: 16L Pressure class: .20MPaNitrogen charged pressure: .4MPa12、 No.19 Loading CylinderLoading cylinder is for loading or lifting the roller. Only during maintenance, the roller can be lifted. Mechanical caging device shall be used to prevent roller dropping and

29、 avoid injuries. The bleeder valve on the upper chamber of cylinder can eliminate the air from cylinder and system.Parameters:Type: 26MG40.11.14Cylinder diameter: .200mm Piston rod diameter: 125mmCylinder stroke: .300mmPressure class: .20MPa13 、No.20 Stop ValveThis valve is mounted on the return oil

30、 tube. Before operation of loading system, Stop valve shall be opened. When the system starts the maintenance procedure, this valve can be closed to avoid oil drainage from the tank.Parameters:Type: KHNV-S-G1 1/2-2233-HTInterface dimension: G1 1/2”Nominal diameter: .40mm Pressure class: .2.5MPa14 、N

31、o.31 and 32.2 Return Filter GroupReturn filter group is made up of two filters and one threeway glove valve. Return filters working drum and standby drum can be switched over. When the filter core is replaced, the system oil shall not be interrupted by switching three-way glove valve. Return filter

32、is used of filtering solid impurity produced in running or from environment to avoid the impurity into loading system. The filter is equipped with bypass valve. Return pressure of filter is shown at the pressure gauge 22. When it reaches 0.15MPa, it means that the working filter core is restricted a

33、nd shall be replaced. If the filter core is not replaced in time and when the pressure reaches 0.175MPa, bypass valve will be opened automatically to protect the filter core from broken by the higher pressure. In order to find whether filter core is restricted or not in time, pressure gauge 22 shall

34、 be checked every two hours. The filter core is one-time type which can not be repetitively used.Parameters:Type of filter: MPT0213SAG2A10HBB/35-HT Type of three-way ball valve: KHB3K-G1/2-1112-02X-HTType of filter core: .MF0203A10HB-HTPressure class: 0.7MPaInterface dimension: .G1/2”Nominal flow: .

35、50L/min Filtering accuracy: .10m15 、No.8 Temperature Gauge Temperature gauge is used to measure oil temperature of the oil tank.Parameters:Type: .WSS-4-8-1-HTNominal diameter: .100 mm Pressure class: 20MPaDepth of penetration: .500mmMeasuring range: .0100Range of oil temperature: .106516 、No.9 Press

36、ure TransmitterIt sends output signal 4-20mA to secondary instrument .it can also indicate the total pressure of the system. The pressure range of the pressure transmitter is 0-21MPa.Parameters:Type:. 3051TG4AHTWorking voltage: DC 24V17 、No.11 Pressure GaugesThey are anti-vibration pressure gauges.

37、Pressure gauge 11.1 is to measure the safe pressure of loading system. Pressure gauge 11.2 is to measure the lifting pressure of loading cylinder. Pressure gauge 11.3 is to measure the control pressure of hydraulic reversing valve. Pressure gauge 11.4 is to measure the loading pressure. Parameters:T

38、ype: .YN100-IV25-HTInterface: . M20×1.5Pressure measurement range: 0-25MPa18 、No.22 Pressure GaugeThey are anti-vibration pressure gauges. The pressure gauge is to measure the return oil pressure of system. When the pressure reaches 0.15Mpa, return filter is restricted and filter core need to b

39、e replaced. It shall be checked every two hours at least to find whether the filter is restricted or not.Parameters:Type: . YN100-IV0.6-HT Interface: . M20×1.5Pressure measurement range: 00.6MPa 19 、No.23 Liquid Lever MeterLiquid lever meter is mounted on the sideboard of oil tank to indicate t

40、he oil level of tank. When the liquid level rises to 70mm above surface of the oil tank plate, it is the highest point of liquid level. When the liquid level drops to 220mm above surface of the oil tank plate, it is the lowest point of liquid level and the machine will stop running when the liquid l

41、evel drops to 270mm above surface of the oil tank plate. The normal liquid level is 70220mm above surface of the oil tank plate. First oiling level is about 100mm above surface of the oil tank plate.Parameters:Type: . YWZ-250-HT 20 、 No.24 Oil TankThe tank reserves oil for the hydraulic unit. Its vo

42、lume is 680L. The hydraulic elements are mounted on the tank. The manhole cover is mounted on the sideboard of the tank, through which the tank can be cleaned. The tank has a fully enclosed structure. There is baffle in tank, which divides the tank into two parts-oil absorbing part and oil returning

43、 part. This structure is favorable to deposit impurity.21 、No.25 Electric HeaterElectric heater is mounted on the sideboard of the tank to heat the oil. It is started to heat the oil when the oil temperature falls to 10 and stopped heating when the oil temperature rises to 20.Parameters:Type: GYY2-4

44、15/1-HTPower: 1KWAC voltage: .400V /50Hz22 、No.26 Hot ResistancesThree-wire double thermal resistance (Pt 100) is used to indicate the oil temperature of oil tank. The depth of penetration is 500mm and measuring range is 0100. When the oil temperature rises up to 55, it will give a signal and charge

45、 the cooling water. When the oil temperature falls to 45, it will give a signal and close the cooling water. When the oil temperature falls to 10, it will give a signal and start the electric heater. When the oil temperature rises up to 20, it will give a signal and stop the heater.23 、No.27 Air Cle

46、anerThe type of Air Cleaner is QUQ2-20×2.5-HT mounted on the cover of oil tank, is for air venting and oil charging. The air filtering accuracy is 20 m. Airflow is 2.5m3/min. Mesh size of oil filtering is 0.5mm.24 、No.28 Glove ValveThis valve is used for tank oil drainage. On the normal conditi

47、on, the valve is closed to prevent oil leakage. The valve will be opened for the tank oil drainage when necessary.Parameters:Type: KHNVN-G1/2-2233-HTInterface dimension: G1/2Nominal diameter: .16 mm Pressure class: .3MPa25 、No.30 Hydraulic Reversing ValveThe type of hydraulic reversing valve is MG00

48、.11.19.01 manipulated by controlling oil and mounted vertically on the coal mill. Solenoid directional valve 13.2 locates at right-hand position for original and working state. Hydraulic reversing valve control oil reservoir and the valve core locate on the highest position. Return oil reservoir of

49、three loading oil cylinder is connected with oil tank. The oil of return reservoir can flow into tank directly and oil in tank also can be freely supplemented into the return reservoir. When preparing to lift and drop the grinding roller, solenoid directional valve 13.2 located at left-hand position

50、. Control oil flows into controlling reservoir of the hydraulic reversing valve and valve core located at the lowest position. Return reservoirs of three loading oil cylinder separate each other and oil in loading cylinder return to tank by flow control valve and magnetic diverter valve 13.1. Three

51、loading cylinder lift and drop synchronously by adjusting flow control valve 12. There are two stroke switches in the hydraulic reversing valve to send position signal.三、Operation Procedure1、 Commissioning(1) By-pass is connected to the interface of hose for each cylinders oil inlet and oil return p

52、ipes after the whole system is installed.(2) To ensure that the stop valve 28 is closed. The oil is filled into the filter with accuracy 10. The oil level shall be 100mm to the flange of tank cover. The oil volume shall be 600L. The oil is filtered to cleanliness NAS1638 grade 8.(3) To charge the Ni

53、trogen to the accumulator. The charge pressure is 4MPa.(4) Each flow control valve should be set at the Max. Flow state.(5) Loosen all the adjusting screws on the relief valve to make it off-load.(6) To ensure that the solenoid directional valve without electricity. (7) Start up the oil pump group a

54、nd make sure they rotate counterclockwise.(8) Switch over the handle of the glove valve 6 to make the oil of the system directly go back into the tank. After 1 hour run, switch over the handle of the glove valve again to make the oil flow into the system. At the same time, the oil is filtered by the

55、 filter to cleanliness NAS1638 grade 8.(9) To recover hoses of oil inlet and oil return tubes of each cylinder to the normal state.(10) Adjust relief valve 5, the system shall respectively run for 10 minutes with pressure 5MPa, 10MPa, 14MPa ,18MPa and 19MPa Then the system shall run for half an hour when the pressure drops to 18MPa.(11) Make the solenoid directional valve 13.2 at the left position when the lef