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5000 TPD CEMENT PLANT PROJECT IN

CAMBODIA

PACKING DEPARTMENT

操作说明书
Operation Instruction

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
5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

目 录

Catalog
第一章 前 言............................................................................................................................... 1
Chapter 1 Preface ............................................................................................................................ 1
第二章 工艺流程及工艺设备介绍 ................................................................................................ 2
Chapter 2 Process Flow and Equipment Introduction....................................................................... 2
一、工艺流程简介 Process introduction ................................................................................. 2
二、工艺设备 Equipment ....................................................................................................... 4
第三章 启动前的准备工作 ........................................................................................................... 5
Chapter 3 Preparation Before Starting up ........................................................................................ 5
一、 现场设备的检查 Inspection and preparation for on-site equipment ............................ 5
二、电控室的准备工作 Preparation In CCR ......................................................................... 8
第四章 启动与停车操作 ............................................................................................................... 9
Chapter 4 Starting and Shutdown ................................................................................................. 9
一、 设备的启动操作顺序 Starting Sequence .................................................................... 9
二、 系统运转中的检查与调整 Check on and adjust in transferring .............................. 11
三、 系统的正常停车操作顺序 Normal Operational Sequence for Shutdown.................. 14
四、 设备故障停车及紧急停车的处理方法 Equipment failure and emergency shutdown
.............................................................................................................................................. 14
第五章 试生产阶段注意事项...................................................................................................... 18
Chapter 5. Notices in Commissioning ............................................................................................ 18
一、 概述 Overview ........................................................................................................ 18
二、 试生产的准备 Preparation for Commissioning ..................................................... 18
三、 试生产要领及注意事项 Notices in Commissioning ............................................. 18
四、 设备使用维护要领 Operation and Maintenance ..................................................... 19
5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

第一章 前 言
Chapter 1 Preface

本操作说明书仅供 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA 的 PACKING


PLANT 系统操作时使用。
This instruction manual is only used for operation of PACKING DEPARTMENT in 5000 TPD
CEMENT PLANT PROJECT IN CAMBODIA.
水泥包装的工艺流程范围:始自提升机进料开始至袋装水泥发运之间的设备。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,根据各单机设备的使
用说明书以及有关附图,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,以便及时解决生产过程中出现的各类问题。
Process flow range for packing plant: starting from elevator feeding to cement bagging and
delivery. This instruction manual is only limited to equipment normal running and basic process
operation. In order to make sure the smooth production and to improve the equipment operation rate,
the operators of this system must deeply know the structure, principle and performance of the
equipment according to the specification and attached drawings of each single equipment, skilfully
master the operation and maintenance of the single equipment and grasp the usage of instruments
and control devices on the basis of knowing the content of this manual, so that the various problems
occurring in the production process can be solved in time.
编制本操作说明书的基本依据是各类设计文件,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或与现场实际供货的设备使用说明书有偏差时,或
者对所述内容有疑问时,请与我院派往现场的调试技术人员进行协商解决,以现场实际供货
的设备使用说明书为准,根据实际情况进行修改。
This operating manual is made based on various kinds of design and technical documents and
in combination with the experience of producing and commissioning in the past. In the real
production, if there is deviation between the condition described in this manual and the actual
condition, or there is any doubt about the content of this manual, please negotiate with the technical
staff we send to the site and make modification. In order to know the equipment performance better,
please refer to the specification of relevant single equipment.

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

第二章 工艺流程及工艺设备介绍
Chapter 2 Process Flow and Equipment Introduction

一、工艺流程简介 Process introduction

水泥包装系统、码垛机系统的工艺流程图见附图。
Process for packing department refers to flowsheet.
包装系统采用三条八嘴回转式水泥包装机包装线,该系统由包装机、接包机、顺包机及
清包机、称重器、抛包机、破包机、分离机、自动插袋机组成,具有称量精度高、密封性能
好、扬尘小、自动化程度高及操作简便等优点。
Packing plant involves 3 lines of 8 nozzles rotary packer unit, consisting of bagging machine, bag
receiver, trimming machine, bag cleaner, weigher, bag thrower, bag breaker, separator, bag feeder,
features accuracy, excellent seal, dustless, high automation and easy operation.
由水泥储存系统来的水泥经斗提机(611-BE1、612-BE1、613-BE1)被送入振动筛
(611-VS1、612-VS1、613-VS1)筛除杂质,然后卸入带称重传感器的中间仓(611-3B1、
612-3B1、613-3B1)。中间仓下设气动蝶阀(661-SG1、662-SG1、663-SG1)、包装机喂料
阀(661-RF1、662-RF1、663-RF1)。包装机喂料阀通过包装机内的料位指示器控制,以确
保中间仓和包装机内的料位稳定。八嘴回转包装机(661-PM1、662-PM1、663-PM1)的能力
为 120t/h,由八台叶轮驱动电机驱动。水泥袋经自动插袋机(661-BA1、662-BA1、663-BA1)
插到包装机出料嘴上,包装机就开始自动灌装。装满水泥的水泥包被推到接包机(661-RD1、
662-RD1、663-RD1),顺包机及清包机(661-BN1、662-BN1、663-BN1)上,经设置的称重
器(661-BW1、662-BW1、663-BW1)的校验称重,合格的袋装水泥经抛包机(661-BT1、662-BT1、
663-BT1)通过带式输送机(661-BC1、662-BC1、663-BC1)及设置在带式输送机(661-BC1、
662-BC1、663-BC1)上的电动转弯溜子(661-BD1~BD4、662-BD1~BD4、663-BD1~BD4)
送至带式输送机(691-BC1、692-BC1、693-BC1、694-BC1),而后送至袋装水泥装车机
(691-LM1、692-LM1、693-LM1、694-LM1)直接汽车发运。称重不合格的袋装水泥经抛包
机(661-BT1、662-BT1、663-BT1)进入破包机(661-BT1-1、662-BT1-1、663-BT1-1)、分
离机(661-BT1-2、662-BT1-2、663-BT1-2)进行破包及分离,分离出来的水泥经螺旋输送机
(661-SC3、662-SC3、663-SC3)进入斗提机(611-BE1、612-BE1、613-BE1)返回至包装系
统,破纸袋经溜管送至地面由工人清理走。包装系统收尘点较多,本系统共设有三台收尘器
(661-BF1、662-BF1、663-BF1)、风机(661-FN1、662-FN1、663-FN1)分别对各收尘点进

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行收尘,收下的水泥粉尘汇同包装过程中泄漏并集于料斗的水泥经螺旋输送机(661-SC3、
662-SC3、663-SC3)返回到斗提机(611-BE1、612-BE1、613-BE1)返回至包装系统。
Cement coming from silo were conveyed by bucket elevator (611-BE1、612-BE1、613-BE1)into
vibration sieve (611-VS1、612-VS1、613-VS1) to remove the foreign matter and discharged to
surge bin(611-3B1、612-3B1、613-3B1) equipment with load cell. Under surge bin there set up
manual gate valve (661-SG1、662-SG1、663-SG1)and packing feeder(661-RF1、662-RF1、
663-RF1). Packing feeder was controlled by level indicator set up in bagging machine to ensure
that the stable material level in surge bin and bagging machine. The 8 nozzles rotary packer unit
(661-PM1、662-PM1、663-PM1)is capable of 120t/h and driven by 8 impeller motors. Cement bag
was put on nozzle by bag feeder (661-BA1、662-BA1、663-BA1)and bagging machine will start
to work. The cement bag filled up were push to bag receiver(661-RD1、662-RD1、663-RD1), bag
trimmer and bag cleaner(661-BN1、662-BN1、663-BN1), through weigher(661-BW1、662-BW1、
663-BW1)the qualified cement bag was conveyed by bag Trap / reject(661-BT1、662-BT1、
663-BT1), belt conveyor(661-BC1、662-BC1、663-BC1), and bag deflector (661-BD1~BD4、
662-BD1~BD4、663-BD1~BD4)which on belt conveyor (661-BC1、662-BC1、663-BC1)to bag
loader for truck to delivery(691-LM1、692-LM1、693-LM1、694-LM1). The unqualified cement
bag through bag thrower (661-BT1、662-BT1、663-BT1)get into bag breaker(661-BT1-1、
662-BT1-1、663-BT1-1) and separator (661-BT1-2、662-BT1-2、663-BT1-2)to be opened and
separated, the cement powder separated were conveyed by screw conveyor (661-SC3、662-SC3、
663-SC3)into bucket elevator(611-BE1、612-BE1、613-BE1) and further into packing machine,
the broken bag will be conveyed by chute onto ground for worker to clean. In packing plant there
are 3 bag filters (661-BF1、662-BF1、663-BF1)and fans (661-FN1、662-FN1、663-FN1)
to collect dust, the collected dust together with dust leaked and collected in packing line would be
conveyed by screw conveyor (661-SC3、662-SC3、663-SC3)into bucket elevator (611-BE1、
612-BE1、613-BE1)and back to packing machine.
码垛机系统采用一台自动码垛机,能力为:2400bags/h
由包装系统包装合格的水泥袋装成品经带式输送机(661-BC1、662-BC1、663-BC1)转
运至带式输送机(671-BC1、672BC2)送至自动码垛机(671PA1)进行码垛后存放于成品堆
棚,待装车发运。
Palletizing system uses an automatic palletizing machine, capacity is: 2400bags/h
The bagged cement transported by belt conveyor (661-BC1、662-BC1、663-BC1) and belt conveyor

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

(671-BC1、672BC2) sent to the automatic palletizing machine (671PA1) .

二、工艺设备 Equipment

本系统所有工艺设备主要技术参数见工艺设备表。
Equipment technical please see the equipment list.

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第三章 启动前的准备工作
Chapter 3 Preparation Before Starting up
本系统的全部设备,在启动前都应作认真的检查、调整工作。在试生产阶段和以后的正
常生产中作为制度都应严格执行。
All the equipments in this system must be inspected and regulated thoroughly before starting up,
and must as rules strictly be implemented in commissioning and later production.

一、现场设备的检查 Inspection and preparation for on-site equipment

1.润滑设备和润滑油量的检查调整

1.1 Inspection and adjustment for lubrication device and lubricating oil volume
设备的润滑对保证设备的长期稳定运转,起着关键性的作用,润滑油量应达到规定的油
标刻度范围,既不能过多,也不能过少。油量过多,会导致设备温度过高;油量过少,设备
会因缺油而损坏。另一方面,要定期检查、补充、更换润滑油。用油的品种、牌号不能错,
而且要保证油中无水无杂质。主要检查项目有以下几点:
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.Inspection mainly covers the fpllpwing
points:
1.1 所有设备的传动装置:包括电动机、减速机、联轴承等润滑点要加好油。
The transmission devices of all the equipment, including gearbox, motor, coupling and so on, need
lubrication at each lubricating point.
1.2 所有设备的各个轴承、活动部件及传动链条等部分加油。
Fill oil to every bearing, moving part and transmission link in all the equipment.
1.3 所有电动阀门的执行机构加油。
Fill oil to all the executor of electric valve.
1.4 检查油质是否变劣,确定换油与否。
Check if the oil quality turns bad and if the oil needs to be changed.
1.5 检查箱(机)底部所有放油(水)孔,拧紧堵孔螺栓。
Check all the oil drains at the bottom of tank(machine) and tighten the blockage bolts.

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

2. 设备内部人孔门、检查门的检查及密封
Check and seal equipment interior, manhole door and 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 starting the equipment, fully inspect the interior and remove the foreign matters left inside
during installation and maintenance to prevent the equipment from jamming during operation so as
to avoid the unnecessary losses.
在设备内部检查完后,将所有的人孔门、检查门严格密封,防止生产时漏风、漏料、漏
油等。
Seal all the manhole door and inspection door strictly after checking the equipment interior, in order
to prevent air leakage, material leakage and oil leakage during production.
3. 闸门 Gate
各闸门的进口闸板,要全部开到适当的位置,保证物料的畅通。
All the gate shall be open to proper position to ensure material free.
4. 所有阀门的开闭方向及开度的确认
Confirms all the gate openness direction and degree
4.1 所有的手动阀门,在设备启动前,都应打到适当的位置。
All the manual gate shall be open to proper position before starting up.
4.2 所有的电动阀门,首先在现场确认能否灵活开闭,阀轴与连杆是否松动,然后由电
控室遥控操作,确认控制室与现场的开关方向是否一致,开度与指示是否对应,如果阀门带
有上、下限位开关,要与控制室核对限位信号是否返回。
All the electric gate shall be confirmed at site for opening freely, gate shaft and tie rod to be
loosened or not, after that remotely operate in CCR, to confirm that openness direction is congruent
with operating at site, and openness degree is congruent with indicator, if gate configured with limit
switch, must verify the limit signals available in CCR.
5. 设备紧固检查 Check fastening of equipment
检查设备的紧固件(如设备部件的连接螺栓、基础地脚螺栓等),不允许出现松动。设
备的传动易松部位,都要进行严格的检查。
Check fasteners like connecting bolt and foundation bolt etc, loosening not allowed. Transmission
parts prone to loosening must be strictly inspected.
6. 斗提机、带式输送机、螺旋输送机的检查
Check on bucket elevator, belt conveyor and screw conveyor

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

6.1 检查运动部件是否完好;
Check on moving parts in good condition;
6.2 检查电机、减速机、滚筒、托辊、液压联轴节、传动链条处及各轴承部位润滑油量和
油质是否符合要求;
Check on motor, reducer, drum, roller, hydraulic coupling, transmission link and every bearing in
respect of oil level and quality conformed with requirements.
6.3 检查各紧固螺栓是否有松动、短缺;
Check on all the fastening bolt in terms of loosening or missing;
6.4 检查电机转向是否正确;
Check on motor in right rotating direct;
6.5 斗提机的各窥视门是否密闭,带式输送机的清扫装置、逆止装置及拉紧装置是否完好。
Check on elevator in respect of peek hole in closeness, and belt conveyor in respect of cleaner,
check unit and tension unit in good condition.
7. 振动筛的检查 Check on vibration sieve
确认筛孔无堵塞;确认各润滑点的润滑油脂充足;确认弹簧支座完好。
Confirms no stemming in sieve mesh; oil and grease are adequate; spring support in good condition.
8. 包装机的检查 Check on packing machine
检查包装机中电机运转是否符合要求;确认中间仓料位高度达到要求;确认包装机和叶
轮回转方向是否符合要求;确认包装机的称量系统处于静态。
Check on motor in packing machine confirmed with requirements; material in right level in surge
bin; bagging machine and impeller rotating in right direction; weighing system of bagging machine
stand still.
9. 收尘器的检查 Check on bag filter
手动操作清灰程序控制器,检查每个脉冲阀的操作是否正确;锁紧净风室的检修门,关
闭箱体、灰箱和灰斗上的检修门;检查电机、风机的转向是否正确。
Manually operate the controller of cleaning program and check on each pulse valve in right
operation; lock up the access door of clean air chamber, close the box body, dust box and access
door of dust hopper; check on motor and fan rotating in right direction.
10. 现场仪表检查 Check on instruments at site
现场设有多个温度、压力、料位等仪表,可帮助巡检人员及时了解设备的运行状态。在
开车前,都要进行系统的检查,并确认电源已供上,且有指示。如与中控有联系,还应与中
控人员联系,核实联系信号的准确性。

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

There are many thermometer, pressure gauge and level indicator on site which can help inspector to
get known to equipment running status, before starting up, check whole system and confirms power
is on and indicated, if connected with CCR, must contact with and verify the signal is right.
11. 压缩空气的检查 Check on compressed air
检查用气点的压缩空气压力是否符合供气要求,通知现场有关人员处理。
Check on air pressure in every user and informs to relevant person if any problem.

二、电控室的准备工作 Preparation In CCR

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


2. 检查设备的备妥情况,如果未备妥,应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,系统启动前的准备工作即完成,可根据实际情况,启动所有的设
备。
After completing all above work, the preparations before startup have been made, and then enable
all devices.

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

第四章 启动与停车操作
Chapter 4 Starting and Shutdown
本章叙述的内容,是正常生产时的启动与停车操作顺序,紧急停车操作及常见故障处理。
试生产时,根据机电设备的考核要求,有一些特殊的操作要求,望操作时注意。
This chapter describes the starting and shutdown sequence in normal running, and emergency
stopping as well as common troubleshooting. In commissioning, as electrical and mechanical
equipments required, some special demand must be noticed.

一、设备的启动操作顺序 Starting Sequence

PACKING PLANT 系统中设备的启动操作顺序见表 4-1。


Starting sequence in PACKING PLANT refer to table 4-1.
表 4-1 Table 4-1
序号 操 作 步 骤 检 查 与 调 整
No. Operating Steps Inspection and Adjustment
1 确认本系统运转前的准备工作已完成。
Confirms the preparations have been completed before
running.

2 包装收尘系统组启动 1.检查中间仓(611-3B1、612-3B1、
1.启动振动筛(611-VS1、612-VS1、613-VS1) 613-3B1)的料位
2.启动斗提(611-BE1、612-BE1、613-BE1) 2.注意斗提机电流
3.启动螺旋输送机(661-SC3、662-SC3、663-SC3) 1. Check on material level in surge
4.启动排风机(661-FN1、662-FN1、663-FN1 bin (611-3B1、612-3B1、613-3B1)
5.启动气箱脉冲收尘器(661-BF1、662-BF1、663-BF1 2. Notice the current of bucket
Starting up dedusting system in packing department elevator
1. Starting up vibration sieve (611-VS1、612-VS1、
613-VS1)
2. Starting bucket elevator (611-BE1、612-BE1、
613-BE1)
3. Starting screw conveyor (661-SC3、662-SC3、
663-SC3)
4. Starting fans (661-FN1、662-FN1、663-FN1)
5. Starting air-box pulse bag filter
(661-BF1、662-BF1、663-BF1)

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

3 袋装水泥输送组启动 根据水泥车就位的车道、开启包装
汽车直接发运: 机的编号有选择的开启相对应的水
1.启动移动式装车机(691-LM1、692-LM1、 泥输送组
693-LM1、694-LM1) Against the truck position, starts the
2.启动皮带机(691-BC1、692-BC1、693-BC1、 number of packing machine and
694-BC1)、皮带机(661-BC1、662-BC1、663-BC1)choose to start corresponding
3.启动气动转弯溜子(661-BD1~BD4、 transportation.
662-BD1~BD4、663-BD1~BD4)
Starting up cement bag transportation
Truck to delivery:
1. Starting movable loader (691-LM1、692-LM1、
693-LM1、694-LM1)
2. Starting belt conveyor (691-BC1、692-BC1、
(661-BC1、662-BC1、663-BC1)
693-BC1、694-BC1) &
3.Starting bag deflector (661-BD1~BD4、
662-BD1~BD4、663-BD1~BD4)

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

4 水泥包装组启动 确认自动插袋机上有纸袋
1.启动分离机 Confirms bags are available on bag
(661-BT1-2、662-BT1-2、663-BT1-2) feeder
2.启动破包机
(661-BT1-1、662-BT1-1、663-BT1-1)
3.启动抛包机
(661-BT1、662-BT1、663-BT1)
4.启动称重系统
(661-BW1、662-BW1、663-BW1)
5.启动清包机及顺包机 (661-BN1、662-BN1、
663-BN1)
6.启动接包机 (661-RD1、662-RD1、663-RD1)
7.启动八嘴回转式水泥包装机(661-PM1、662-PM1、
663-PM1)
8.启动自动插袋机(661-BA1、662-BA1、663-BA1)
9.启动包装机进料装置(661-RF1、662-RF1、
663-RF1)
Starting up packing machine
1. Start separator (661-BT1-2、662-BT1-2、663-BT1-2)
2. Start bag breaker (661-BT1-1、662-BT1-1、
663-BT1-1)
3. Start bag thrower (661-BT1、662-BT1、663-BT1)
4. Start weighing system (661-BW1、662-BW1、
663-BW1)
5. Start bag cleaner and trimmer (661-BN1、
662-BN1、663-BN1)
6. Start bag receiver (661-RD1、662-RD1、663-RD1)
7. Start 8 nozzles rotary packing machine (661-PM1、
662-PM1、663-PM1)
8. Start bag feeder (661-BA1、662-BA1、663-BA1)
Start feeding unit in packing machine (661-RF1、
662-RF1、663-RF1)

二、系统运转中的检查与调整 Check on and adjust in transferring

为了使系统安全、稳定地运转,必须经常观察各参数值的变化情况,及时判断系统的运

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

转状态,同时,采取适当的措施进行检查、调整。主要检查调整项目见表 4-2。
To ensure system running safely and stable, must regularly check on each data variation and get
known of running status immediately, while take proper action to inspect and adjust, main checking
items refer to table 4-2.
表 4-2 Table 4-2

序号 检查项目 检测、判断方法 调整、处理方法


NO. Check Item Testing and Concluding Adjusting and Deal
Method
1 收尘器出口 1.高高料位报警 1.检查滤袋是否破损
粉尘浓度大 High high material level 2.检查进口气体温度是否超
Dust density alarming 过滤袋材质允许的温度范围
more bigger 3.检查滤袋是否超过使用寿
at filter outlet

1. Check on filter bag for
damage
2. Check on inlet temperature
if it is overheat than bag
material allowed
3. Check on bag service life

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

2 收尘器汽缸 1.检查压缩空气是否正常
不动作 2.检查电磁阀是否正常
Bag filter 3.检查汽缸给油器的油量和
cylinder does 汽缸润滑情况
not work
4.检查油水过滤器,是否有水
进入汽缸
5.检查升阀阀杆是否变形
1. Check on compressed air in
good condition
2. Check solenoid valve in
good condition
3. Check on cylinder for oil
level and lubrication
4. Check on water oil filter, if
water permeate into
Check on lift valve stem for
deformation
3 均化仓卸料 1.包装系统斗提机电流大 减小出仓气动流量控制阀的
量过多 2.包装系统中间仓料位计高 开度
Blending bin 位报警 Down regulate the openness of
discharge 1. Bucket elevator over current flow valve in blending bin
much more 2. Material high level alarming
in surge bin
4 均化仓卸料 包装系统中间仓料位计低位 增大出仓气动流量控制阀的
量少 报警 开度
Blending bin Material low level alarming in Up regulate the openness of
discharge less surge bin flow valve in blending bin

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

5 水泥包重量 1.检查每嘴连续灌装 10 袋重 检查机械和电气设备


过多或过少 量的算术平均值 Check on mechanical and
Cement bag 2.抽查单袋重量 electric equipments
over or under 1. Check on each nozzle filling
weight up 10 bags continuously and
make out mean value of weight
2. Sample on single bag weight
6 包装中间仓 重量传感器高位或低位报警 调整水泥库底均化仓卸料气
料位过高或 Load cell higher or lower 动流量控制阀门开度
过低 alarming Regulate the openness of flow
Material level valve in blending bin under
in surge bin cement silo
higher or
lower

三、系统的正常停车操作顺序 Normal Operational Sequence for Shutdown

3.1 PACKING PLANT 装系统正常停车顺序与开车顺序相反。并注意确认停车范围及停


车时间,了解停车目的。
Normal operational sequence for shutdown of packing plant is reverse to starting up, notice to
confirm shutdown scope and time, get known the purpose of shutdown.

四、设备故障停车及紧急停车的处理方法 Equipment failure and emergency


shutdown

在设备运行过程中,由于设备突然发生故障,电动机过载跳闸,机电设备保护跳闸,现
场停车按钮按下时,系统的部分或全部设备会联锁停车。另外,在某种紧急情况下,为了保
证人身及设备安全,也会使用紧急停车按钮,使整个系统紧急停车。为了能顺利地再次启动,
必须进行如下处理、操作。
When equipments are running, due to sudden failures like motor overload tripping, protection
tripping, or button stop locally, the system would be interlocked to shut down partially or wholly,
additionally, in case of urgency to prevent personal injury and equipment damage also need button
the emergency stop for whole system to shut down, before next starting up, must take action as

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

following:
4.1 当设备突然停机时,基本的处理程序是:
After equipment stopped suddenly, actions shall be taken as:
(1)马上停止与之有关的部分设备;
Immediately stop relevant equipments;
(2)尽快查清原因,判断能否在短时间处理完,以定再次启动时间,并可进行相应的操作。
Make investigation of failure right after that and take stock of the time for troubleshooting, to
determine the next starting up and take some corresponding measurements.
4.2 常见故障及其处理见表 4-3
Common failure and troubleshooting thereof refer to table 4-3
表 4-3 Table 4-3

序号 故 障 设 备 现象及原因 处 理 方 法
No. Failed Equipment Symptom and Reason Troubleshooting
1 回转式包装机 包装机主动力开关发生 包装机停机(位于其流
Rotary packing machine 故障 程下游的输送设备待水
Main power switch 泥包送完后,按正常停
failure 车顺序停车)检查其机
械及电气部件
Stop the packing
machine (waiting for
downstream conveyor
empty the cement bag,
stop the conveyor in
sequence) and check
mechanical and electric
parts.

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

2 收尘器及其卸灰装置故 1.通风量减少 1.停机检查清理袋或检


障 a.糊袋;b.风机电机超 查风机电机。
Bag filter and dust 载;c.电源断电。
discharging unit 2.脉动阀工作失灵 2.检查压缩气源,清洗

a.空气压力降低;b.杂质 脉冲阀。
堵塞;c.定时器失灵。
3.排放浓度增大
3.滤袋修补或更换;重
a.滤袋破损;b.滤袋密封
新密封。
不严。
1. Stop the equipment
1. Airflow decrease
and check on bag and
a. Bag burned; b. Fan
fan motor.
motor overload; c. Power
2. Check on air source
off.
and clean the pulse
2. Pulse valve can’t work
valve.
a. Lower pressure; b.
3. Repair or replace the
Inclusion Stemming; c.
bag and rework the
Timer failed
sealing.
3. Emission density
increase
a. Bag damaged; b. Bag
seal failed.
3 系统排风机跳闸 1.排风机跳闸 1.现场检查处理
Fan Fan tripping Troubleshoot at site
4 斗式提升机故障 1.故障电机跳闸 1.将喂料量给定值调到
Bucket elevator 2.喂料组联锁停车 零位
1. Motor tripping 2.对故障设备进行检查
2. Feeding group 处理
interlock shutdown 1. Set zero the feeding
value
2. Check on failed
equipment

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

4.3 紧急停车操作 Operation for Emergency Stop


当出现紧急情况时,需要全部停车。设备紧急停车后,应对设定值、阀门等进行调整,
并及时处理紧急情况,尽快恢复系统运行。再次启动时必须注意:由于系统在紧急情况下停
车,各设备内均会有积料,因此不能象正常情况下那样启动后立即喂料,应待设备内部物料
输送之后,才开始喂新料。
In occurrence of urgent event, all equipments must be stopped. After urgency shutdown, reset the
set value and valve etc, immediately take action for troubleshoot, restart the system as soon as
possible. Notice to restarting: as under emergency stop, equipment should be left some residual
which must be cleaned out for next feeding.

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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

第五章 试生产阶段注意事项

Chapter 5. Notices in Commissioning

一、概述 Overview

当所有设备全部安装完毕,经过单机试车、联动无负荷试车和全面检查后,确认没有问
题后,就可以进入系统的试生产阶段。
If all the equipment installation completed, and conducted solo test running, interlock no-load
testing, and overall inspection, if without any problem, go to commissioning.

二、试生产的准备 Preparation for Commissioning

2.1 对各个带电机的设备逐个进行空载试运转,及时发现和排除故障,确认空载试运转合
格。
Conducts no-load test running for each motor equipped unit, immediately find fault and
troubleshoot it, confirms no load testing in certified condition.
2.2 按照电控程序启动空吹,检查能否满足工艺要求。
Starts air blowing pursuant to electric control program and check it if satisfied with process
requirements.
2.2 本子项的设备经单机试车和联动无负荷试车确认合格后,应在进行全面的检查;应该
润滑的部件必须按各自的要求注入相应进行空的润滑油,容易漏风的部件应该检查确认密封
良好。水泥库内有一定储量后,包装系统才可以进行装料试车。同时在投料运转之前,相关
生产系统如供电、供气、通讯、中控室、质量控制、化验、消防及医护等设施都必须备妥。
After solo test run and interlock no-load test are certified, must conduct overall inspection; check on
lubricant for no load testing, check leakage on seal parts prone to leaking. When cement silo were
filled up some material, packing system may go to load trial running. But before feeding to packing
system, must make sure the relevant facilities are ready for running, like power supply, air supply,
communication, CCR, quality control, chemical lab, firefighting and medical facility etc.

三、试生产要领及注意事项 Notices in Commissioning

斗提机开车时,喂料量应逐步增加,喂料要均匀。负荷试车后 2 个小时后开始检查轴承
温度,一般不超过 60℃。停车前必须将机内物料卸空,斗提机必须在空载状态下启动,启动
2~3 分钟后,再均匀的喂料。
When bucket elevator started, feeding must be increasing gradually and evenly. Check on bearing
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5000 TPD CEMENT PLANT PROJECT IN CAMBODIA PACKING PLANT

temperature after testing 2 hours, usually below 60℃. Material residual must be empty before
shutdown, bucket elevator must be started without material, after 2-3 minutes, go to feeding evenly.
包装机中间仓的料位达到指示器控制的高位置时才能开始插袋;定期抽查水泥的袋装重
量,看是否在允许的误差范围之内;每班工作结束后,应用压缩空气将包装机外部积灰吹扫
干净。生产中要注意观察中间仓的料位计是否准确。
Must make sure the material level in surge bin indicated in high level and then go further to start
bag feeder; regularly sample the cement bag to weigh it, make sure within the allowable weight;
after each shift shall clean the packing machine with air jet. In production must check on the
material level in surge bin for accuracy.

四、设备使用维护要领 Operation and Maintenance

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。
This part refers to each equipment for instruction manual. No redundant description here.

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