5,000 TPD CMIC CEMENT PLANT

PROJECT IN CAMBODIA

CLAY CRUSHER AND TRANSPORT

操作说明书

Operation Specification

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 CMIC CEMENT PLANT PROJECET IN CAMBODIA

目 录
Catalog
第一章 前 言 ........................................................................................................................... 1
Chapter 1 Preface ............................................................................................................................ 1
第二章 工艺流程和工艺设备........................................................................................................ 3
Chapter 2 Process Flow and Equipment ........................................................................................ 3
一、工艺流程简介 Introduction for process ............................................................................ 3
二、工艺设备 Equipment ........................................................................................................ 3
第三章 启动前的准备工作 ........................................................................................................... 4
Chapter 3 Preparation Before Starting .......................................................................................... 4
一、现场设备的检查和准备 Inspection and preparation for on-site equipment ....................... 4
二、电气设备的检查和准备 Examination and preparation for electrical devices .................... 8
.第四章 启动与停车操作 .............................................................................................................. 9
Chapter 4 Operations for start and stop ....................................................................................... 10
一、系统启动操作 Starting operations ................................................................................. 10
二、 系统运行过程中的检查与调整操作 Checking and regulating in system running ........ 12
三、系统正常停车操作 Stopping operations......................................................................... 14
四、设备故障停车和紧急停车的处理 Operations for fault shutdown and emergency stop . 15
第五章 设备单体试车 ................................................................................................................. 18
Chapter 5 Single-unit test run ..................................................................................................... 18
一、设备试车条件 Conditions for test run ........................................................................... 18
二、试车过程 The process of test run .................................................................................... 18
三、试车要求 Requirements for test run................................................................................ 18
四、单机试车后确认事项 Items to be confirmed after single-unit test run ........................... 20
第六章 试生产阶段注意事项...................................................................................................... 22
Chapter 6 Precautions at Trial Production...................................................................................... 22
一、概述 Generals ................................................................................................................. 22
二、试生产的准备 Preparation for trial production ............................................................ 24
三、试生产要领及注意事项 Trial production essentials and precautions .............................. 25
四、 设备使用维护要领 Utilization and maintenance essentials of equipment ................ 26
5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

第一章 前 言

Chapter 1 Preface
本操作说明书仅供 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA 的
CLAY CRUSHER AND TRANSPORT 系统在操作时使用。
This manual only apply to the operation for CLAY CRUSHER AND TRANSPORT of 5,000 TPD
CMIC CEMENT PLANT PROJECT IN CAMBODIA.
本系统是指从粘土受料斗开始到粘土被送到 291-BC3 皮带机为止的工艺生产线。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。
This system involves production line from clay hopper to belt conceyor(291-BC3). The instruction
manual only limited to ensure the normal operation for equipment and primary items in process
operation.
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，根据各单机设备的说明书及附图，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，掌握仪表及控制装置的使用要领，以便及时解决生
产过程中出现的各类问题。
This system means the limestone process production line from receiving hopper to the stacking belt
conveyor in pre-homogenizing yard. The content of this manual can only ensure the normal
operation of equipment and the basic matters of 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技术文件，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，并根据实际情况进行修改。为更好地了解设备性
能，请参阅有关的单机设备说明书。
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

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

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 CMIC CEMENT PLANT PROJECET IN CAMBODIA

第二章 工艺流程和工艺设备
Chapter 2 Process Flow and Equipment

一、工艺流程简介 Introduction for process

本系统的工艺流程见流程图。
Process for this department refers to flowsheet.
1.1 工艺流程叙述
粒度为 400mm 的粘土由汽车运至粘土堆棚，由铲车卸入粘土受料仓，经可调速板式喂料
机(221-AC1)将粘土喂入双辊破碎机(221-RC1)。
The 400mm clay transported to shed by truck. the stored clay feed into the hopper（221-HP1） by
forklift,then through the apron feeder (221-AC1) feed into double roll crusher(221-RC1).
破碎后的粘土(粒度<50mm)经胶带输送机(221-BC1)输送后，与来自石灰石破碎及输送系
统的石灰石进行混合，送至堆料皮带机(291-BC3)。由悬臂式堆料机(291-ST1)将混合料堆至
对棚内储存。
The clay crushed ( size <50mm) were conveyed by belt conveyor (221-BC1) to mix with limestone
coming from limestone crushing department, the mixture were transported by belt conveyor
(291-BC3) and cantilever stacker (291-ST1)into mixture storage.
本系统采用的双辊破碎机(221-RC1)最大入料粒度 400mm，生产能力 200t/h（DB）。
The double roller press (221-RC1) employed in the system features maximum feeding grain size of
500mm and capacity of 200t/h（DB).
本系统设有破碎机负荷自动调节回路，根据破碎机(221-RC1)的负荷自动控制板喂机
(221-AC1)的速度。当破碎机超负荷时，板喂机的速度会自动降低，喂料量减少，当破碎机负
荷低于额定值 80%时，板喂机会自动加速，以保证破碎机工作在最佳状态。
This system employs load self-regulation circuit for crusher which automatically control the speed
of apron feeder(221-AC1) pursuant to load of crusher(221-RC1). When crusher was overloading,
the apron feeder would automatically speed down to decrease the feeding, when load is below 80%
of rated value, the apron feeder would speed up, to ensure the best performance of crusher.

二、工艺设备 Equipment

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

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

第三章 启动前的准备工作

Chapter 3 Preparation Before Starting

粘土破碎及输送系统的全部设备，在启动前，都应做认真的检查调整工作，这不仅在试
生产时要做，还必须作为一条制度，在以后的生产中严格执行，保证设备的正常运转。
All the equipment including clay crusher and equipment in conveying system shall be thoroughly
inspected and regulated prior to starting up whatever in commissioning or later putting into
production and shall be strictly executed as rules to ensure best running of the equipment.
一、现场设备的检查和准备 Inspection and preparation for on-site equipment

1.1 润滑装置和润滑油量的检查和调整
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行，起着关键性的作用。润滑油量的多少直接影响
设备的运转，必须掌握恰当。油量过多，会引起设备发热，油量过少，设备将因缺油而损坏。
同时，要严格按照各单体设备制造厂说明书的要求，定期检查、更换润滑油。用油的品种、
标号不能错，油质应符合要求，应保证油中无水、无杂质。
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.
1.1.1 板喂机(221-AC1)润滑装置的油量应通过运转调试确定，达到能正常运转，各润滑
点能溢出油脂为止。
1.1.1 Apron feeder (221-AC1) lubricating oil should be determined through the commissioning
of the operation, to achieve normal operation, the lubricating point can spill oil1.
1.1.2 板喂机(221-AC1)减速器按油标位置注入润滑油。润滑油必须是过滤后的清洁油，
各润滑点注入适量的润滑脂。
1.1.2 The reducer of apron feeder (221-AC1)shall be filled with filtered oil to oil level. Grease
shall be applied to every points as case may be.
1.1.3 破碎机(221-RC1)轴承及传动装置的润滑油和润滑脂注入量要适当，油路要畅通。
1.1.3 The bearing and pinion shaft of crusher(221-RC1)shall be lubed by moderate lubricating
oil and grease. Keep the oil circuit smooth. The working pressure of hydraulic station and the

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

working speed of cover-opening oil cylinder shall achieve the value actually needed.
1.1.4 所有设备的传动装置，包括减速机、电机、联轴器等润滑点均要加好油。
1.1.4 The transmission devices of all the equipment, including gearbox, motor, coupling and so
on, need lubrication at each lubricating point.
1.1.5 所有设备轴承、活动部件等部分要加好油。
1.1.5 All the bearings and moving parts need lubrication.
1.1.6 检查油质是否变劣，确定换油与否。
1.1.6 Check all the oil drains at the bottom of tank(machine) and tighten the blockage bolts.
1.1.7 检查箱（机）底部所有放油孔，拧紧堵孔螺栓。
1.1.7 Check all the oil drains at the bottom of tank(machine) and tighten the blockage bolts.

1.2 设备内部、人孔门、检查门的检查和密封
1.2 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.
1.2.1 破碎机(221-RC1)腔内金属异物清除干净。
1.2.1 Clean up the metal foreign matters in the crusher(221-RC1) cavity.
1.2.2 破碎机(221-RC1)机体上所有的门必须牢固的关闭。
1.2.2 All the doors on the crusher body (221-RC1) must be closed firmly.
1.3 闸阀的检查和备妥
1.3 Inspect the gate valve to be ready
各处闸阀必须启闭灵活。系统启动前应开到适当开度。
All the gate valves shall be opened and closed flexibly. The opening shall be appropriate
before starting the system.
1.4 设备的紧固检查 Fastening inspection for the equipment
启动前，必须检查所有设备的紧固情况，将所有联接螺栓、地脚螺栓全部拧紧。连续运
转 4 小时后各部位连接螺栓要重新紧固一次，一周内再反复 2～3 次。

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

1.4 Before starting, all the fastenings of equipment shall be inspected. Tighten all the
connection bolts and anchor bolts. After the equipment operating for 4 hours, tighten all the
connection bolts again. In one week, repeat tightening 2 to 3 times.
1.4.1 板喂机(221-AC1)所有螺栓全部拧紧，确保机器各部联接可靠无误。
1.4.1 All the bolts of apron feeder(221-AC1)shall be fastened to ensure reliable and correct
connection.
1.4.2 破碎机(221-RC1)各部件螺栓及地脚螺栓应锁紧，转子卡箍应拧紧。
1.4.2 For the crusher(221-RC1) the bolts of all parts and the anchor bolts shall be fastened, and
the rotor clamp shall be tightened.
1.4.3 皮带机所有部件要联接牢固，地脚螺栓拧紧。
1.4.3 All the components of the belt conveyor shall be connected with each other firmly and
the anchor bolts shall be tightened.
1.4.4 确认系统全部设备易松动部位均已紧固无误。
1.4.4 Confirm the easy-to-loose parts of all the equipment have been fastened.
1.4.5 检查各溜管、收尘风管及棒阀等，确认其畅通，无堵塞，无破损和卡死现象。
1.4.5 Check all the chutes, the dust collecting duct and the three-way distributing valve to
confirm they are smooth. No blockage, damage or sticking is allowed.
1.5 现场仪表检查 Inspection for on-site instruments
现场设有许多温度表、压力表、油量表、跑偏开关等，可以帮助巡检人员及时了解设备
的运行状态。设备启动前要进行全面系统的检查，并确认各种仪表电源已供上，显示正常，
处于良好的工作状态。
There are so many instruments provided on site, including thermometer, pressure gauge, oil
scale, deviation switch and so on. They can help the inspectors know the operating state of the
equipment in time. The overall inspection shall be conducted for the system before starting to
confirm all instruments have powered on and work very well, and they display normally.
1.6 生产设备的调整和备妥 Adjust the production equipment to be ready
1.6.1 板喂机(221-AC1)的调整和备妥
1.6.1 Adjustment the apron feeder(221-AC1) to be ready
1.6.1.1 试车前必须检查减速器旋转方向，不允许逆工作旋转方向的反向旋转。
The rotating direction of the gearbox must be checked before the test run. Reversing rotation
that is opposite to the working rotating direction is not allowed.
1.6.1.2 进行润滑装置运转调试，达到正常运转，各润滑点能溢出油脂。减速器按油标位
置注入润滑油，润滑油必须是过滤后的清洁油，各润滑点注入适量的润滑油。

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

1.6.1.2 The operating commissioning shall be conducted for lubricating device until it can
operate normally and the oil and grease can overflow at each lubricating point. The lubricating oil
shall be added into the gearbox to the oil level mark. The lubricating oil must be clean oil which has
been filtered. Each lubricating point shall be lubed by appropriate amount of lubricating oil.
1.6.1.3 调节拉紧装置使链板具有足够的张力，得到较小的链板垂度，保证主从轮能很好
的啮合，并尽可能使两个拉紧丝杆的拉力近似相等。
1.6.1.3 Adjust the tensioning device to make the chain plate has enough tension and obtain
small sag. Ensure the driving and driven wheel mesh well with each other. And make the tensile
force of two tensioning screw rods as equal as possible.
1.6.1.4 检查链板装置螺栓是否拧紧，严禁松动。
1.6.1.4 Check if the bolts of chain plate device are tightened or not, never be loosened.
1.6.1.5 确认各部位无误后，低速启动空载运转，检查正常后，逐渐达到正常运转速度，
运转若干小时(时间长短根据情况而定)。
1.6.1.5After confirming all parts are correct, start no-load operation in low speed. After
inspection and making sure it operates normally, gradually accelerate it to achieve normal operating
speed, running for several hours(running time depends on the situation.).
1.6.1.6 空载运转检查完毕后，方可进行有载运转。有载运转之前，必须先在粘土受料仓
内装填一定量的碎石，作为设备缓冲层。
1.6.1.6After inspecting no-load operation, start on-load operation, before which, a certain
amount of gravels shall be filled into the limestone receiving bin as the buffer layer.
1.6.2 破碎机(221-RC1)的调整和备妥
1.6.2 Adjusting the crusher(221-RC1) to be ready
1.6.2.1 轴承、传动部位注入适量的润滑油和润滑脂。
1.6.2.1Bearing and drive unit shall be filled with proper oil and grease to certain quantity.
1.6.2.2 确认电动机方向正确无误。
1.6.2.2 Confirm the motor direction is correct.
1.6.2.3 确认破碎腔内无金属异物，转子盘车检查，消除一切不应有的金属碰撞声。
1.6.2.3 Confirm there is no metal foreign matters in the crusher cavity. Turning the rotor to
check and remove all undue metal clash.
1.6.2.4 确认各部件螺栓及地脚螺栓均已锁紧，机体上所有的门已牢固关闭。
1.6.2.4 Confirm the bolts of all the components and the anchor bolts have been tightened and
all the doors on crusher body have been closed firmly.
1.6.3 胶带输送机的调整和备妥

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

1.6.3 Adjusting belt conveyor to be ready

1.6.3.1 减速机、电机及各润滑系统的润滑点按规定加入足够的润滑油，联轴器、液力偶
合器按规定充入工作油。
1.6.3.1 Add enough lubricating oil into the lubricating points of gearbox, motor and each
lubricating system according to the regulation. Add working oil into the coupling and hydraulic
coupling in accordance with the regulation.
1.6.3.2 电气信号及控制装置的接线正确。
1.6.3.2 The wiring of electric signals and control device is correct.
1.6.3.3 点动电动机，确认滚筒转动方向正确。
1.6.3.3 Jog the motor to confirm the roller rotates in correct direction.
1.6.3.4 胶带打滑检测装置、双向拉绳开关、跑偏开关处于良好工作状态；调心装置效果
良好，清扫装置正常。
1.6.3.4 The belt slip detector, dual-direction stretching wire switch, deviation switch are in
good working condition. The aligning device works well and the cleaning device works normally.
1.6.3.5 滚筒及托辊转运灵活，输送带接头平直。
1.6.3.5 The roller and idler shall rotate flexibly and the belt joint shall be flat and straight.
1.6.4 系统所有设备的调整和备妥
1.6.4 Adjusting all the equipment of the system to be ready
对于收尘器、风机等其他设备均应详细检查设备及各个部件，确保能按要求可靠运行。
The detailed inspection shall be conducted to the dust filter, the centrifugal fan, the iron
separator and other equipment. All parts shall be inspected carefully to ensure the reliable operation
as required.
1.6.5 辅助材料预均化堆棚相关设备调整和备妥。
1.6.5 Relevant equipment in additive storage were regulated and ready.
二、电气设备的检查和准备 Examination and preparation for electrical devices

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

2.2 检查电源是否供上。Check whether it is energized.
2.3 电气开关柜推到工作位置上，注意是否有人维修，严防误送电发生事故。
2.3 Push the electrical cabinet to the working position and check if there are servicemen to
avoid electric shock.
2.4 确认控制室的阀门指示位置与现场是否一致。
2.4 Confirm whether the indicating position of the valve of control room is in line with that on

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

site.
2.5 确认高压设备送电条件并送电。
2.5 Confirm the MV devices is qualified for power transmission and then energize.
2.6 确认操作台以及各动力控制箱的按钮、选择开关、指示灯、报警器等均处于良好状
态。
2.6 Confirm the operation station and buttons, option switches, indicators and alarms of the
power control boxes are in good condition.
2.7 检查设备的备妥情况。如果有尚未备妥的，与电气及现场人员联系处理。
2.7 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，系统启动前的准备即已就绪，可根据实际情况，按起动顺序逐台
启动所有设备。
After completing all above work, the preparations before startup have been made, and then
enable all devices one by one in sequence.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

第四章 启动与停车操作
Chapter 4 Operations for start and stop

一、系统启动操作 Starting operations

本系统 PLC 启动，启动顺序及连锁关系见电气部分。有关 PLC 集中控制的具体操作见

电气说明。在正常启动前，必须做好系统启动前的所有准备工作，确认各主机系统及各辅机
系统能正常运行，确认供水系统工作正常，确认设备润滑正常。另外，在系统启动后，要勤
观察各设备、仪表及系统的运行状况，发现问题及时处理。
This system is started by PLC and the startup sequence and interlocks are shown in the
electrical part. See detailed operations for PLC centralized control in the electrical specification.
Before startup, all preparations must be made to confirm that the host system and the auxiliary
systems can be normally operated, the water supply system is in good condition and the lubrication
for devices is well done. In addition, after startup, the running condition for every device,
instrument and system should be frequently observed and problems (if any) must be solved
immediately.
表 4−1 粘土破碎及输送系统生产启动操作顺序表

Table 4-1 Starting Sequence for clay crusher and transportation system

1.1 粘土破碎受料地坑(221-HP1)至堆料胶带输送机机(291-BC3)
1.1 Clay crusher pit (C1L01) to belt conveyor(291-BC3)

序 号 操 作 步 骤 检 查 与 调 整

No. Operating Step Checking and Regulating

1 确认粘土受料仓装有物料，缓冲层已 通知有关系统，注意配合操作

准备完毕。确认粘土均化堆棚已作受 Informs to relevant system, pay attention

料准备并启动相应设备 to coordinate with other operation.

Confirms that material are ready in clay

hopper, surging layer are ready, clay

storage are also ready for material and

starting up relevant equipment.

启动堆料机(291-ST) (1)注意启动顺序。

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

Starting up reclaimer (C1H01) (2)注意轴承温度。

悬臂上的卸料皮带机启动。 (3)注意减速器温度。
2 Starting up cantilever belt conveyor 1. Notice starting sequence
液压系统启动。 2. Notice bearing temperature
Starting up hydraulic system 3. Notice reducer temperature
堆料皮带机启动。
Starting up stacking belt conveyor
电缆卷盘启动。
Cable spool starting up
(5)行走机构启动。
Travel unit starting up
3 启动跨皮带分析仪
Starting up on-line Analyser an quality
controlling device.
收尘系统启动 打开手动蝶阀（221-BV2、221-BV1）
starting dust collection system Open the manual butterfly valve
4 启动风机(221-FN2) (221-BV2、221-BV1)
Start fan (221-FN2)
启动卸灰阀(221-RC2)
Start rotary gate(221-RC2)
启动收尘器(221-FN2)。
Start bag filter(221-FN2)。
收尘系统启动 打开手动蝶阀（221-BV3、221-BV4）
starting dust collection system Open the manual butterfly valve
启动风机(221-FN1) (221-BV3、221-BV4)
4 Start fan (221-FN1)
启动卸灰阀(221-RC1)
Start rotary gate(221-RC1)
启动螺旋输送机(221-SC1)
Start screw conveyor(221-RC1)
启动收尘器(221-FN1)
Start bag filter(221-FN1)
5 启动除铁器(221-BW1)
Starting up metal remover(221-BW1)
滚筒托辊转动灵活，胶带运转平稳。
Ensure that the roller moves flexibly and
6 the belt runs steadily.
拉紧装置正常工作。
The tension device works normally.
空载运转一定时间(按实际情况确定)，检
查有无跑偏、打滑现象。
Run without load for certain time
胶带输送机(221-BC1)启动 (according to the actual conditions) to
Start belt conveyor(221-BC1) check whether it deflects or slips.
7 (1)检查驱动装置是否平稳。
破碎机(221-RC1)启动。 (2)注意启动电流。
Starting up crusher (221-RC1) (3)注意各点温度。
(4)达到正常转速后空载运转 5 分钟。

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

1. Check drive unit

2. Notice starting current
3. Notice every point temperature
4. Free running 5 minutes after reaching of
normal speed
板喂机(221-AC1)启动 (1) 检查喂料情况。Check the material
以低速喂料，逐渐提高至正常速度。
condition
Start the apron feeder(221-AC1)
(2)注意启动电流。Pay attention to the
8 gradually increases from low-speed
feeding up to normal speed. starting current
(3)注意轴承温度。Pay attention to the
bearing temperature
系统运行稳定后投入破碎机负荷自
9
动调节回路。
二、系统运行过程中的检查与调整操作 Checking and regulating in system running
破碎系统在生产中应严格按每台设备要求作好检查，主要检查项目见表 4-2。
Strictly check each equipment in crushing system in running according to requirement,
checking items refer to table 4-2.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

表 4-2 检 查 调 整 项 目 表

Table 4-2 Checking and Regulating Items

序 号 检 查 对 象 检 测 与 判 断 操 作 与 调 整

No. Checking Item Testing and Judgment Operating and Regulating

1 粘土受料 仓中物料 堆场长时间不运输粘土 (1)板喂机(221-AC1)停机。

Apron feeder
少 于 有 效 储 量 的 至受料仓。
(221-AC1)shutdown
1/3。 Long term stopping from

Material in clay storage to clay hopper

hopper below 1/3 of

effective level

2 板喂机(221-AC1)空 (1)料仓出料口堵死。 (1)板喂机(221-AC1)停机，清

运转。 (2)料仓已卸空。 理大块物料。
Apron feeder 1. Stemming on hopper (2)在空料仓铺设缓冲层后立
(221-AC1) running 即向料仓喂料
outlet
without material 1. Stop apron feeder (221-AC1)
2. Hopper empty
and clean the outlet.

2. Surge layer put in hopper and

fill into material
3 破碎机(221-RC1)不 (1) 主电机跳停或烧坏。 (1) 检查电机或供电系统，进
出料或出料很少。 Main motor tripped or 行处理。
Little output or not at burned Check motor or power supply
all from crusher and act on it as case maybe
(221-RC1)
4 破碎机(221-RC1)内 机器运转声音不正常。 板喂机(221-AC1)停止喂料，排
混入铁件。 Strange noise in machine 出破碎机内铁件。
Metal inclusion into running Stop feeding to apron feeder
crusher(K11-RC1) (221-AC1)and remove metal
inclusion

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

5 胶带跑偏 (1)安装中心线不直。 (1)校正安装中心线。

Belt run-out (2)胶带接头不整齐。 (2)重新粘接胶带头。

(3)滚筒托辊中心线与胶 (3)调整滚筒，清除滚筒上物

带机中心线不成直角。 料。

(4)滚筒不水平。 (4)调整下料点。

(5)滚筒表面粘结物料。 (5)启动跑偏开关。

(6)物料下料点不在胶带 1. Align the installation

中间。 centerline.

2. Rework the butt joint

(7)胶带初始张力太大。
3. Adjust drum and clean it.
1. Centerline misaligned
4. Adjust material falling point.
2. Belt butt joint not flush
5. Start off switch
3. Centerline of drum and

roller not perpendicular

with belt centerline

4. Drum not horizontal

5. Drum surface sticked

with material

6. Material falling not on

mid of belt

7. Belt starting tension too

large.

三、系统正常停车操作 Stopping operations

把决定要停止的设备所在组的启动开关按流程顺序逐一延时打到“停止”位置，此组内设
备再按停车顺序逐一延时停车。每次停车前，确保输送系统（如粘土输送系统等）设备正常
停车时应卸空设备上的物料，以便下次正常启动。另外，为了设备安全保护需要，注意各设

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

备的润滑、冷却按各设备要求进行操作，并勤于检查和维护。在正常情况下，停车顺序为启
动顺序的逆顺序。
According to the process sequence, push the start switches of the group including the devices
to be halted to “stop” position, and then the devices in the group is stopped by time-delaying
according to the stop sequence. Before stopping, it is confirmed that the materials on the
transporting systems (such as the limestone transporting system) are removed and cleared for the
next normal startup. In addition, operations for lubrication and cooling should be up to the
requirements, in order to protect the devices which must be checked frequently. In normal condition,
the stop sequence is opposite to the starting sequence.
四、设备故障停车和紧急停车的处理 Operations for fault shutdown and emergency stop

4.1 在系统运行过程中，由于设备发生故障、电机过载跳闸、机电保护跳闸及其事故，
现场的部分或全部设备会联锁停车。在某种紧急情况下，为了保证设备及人身安全，还会采
用紧急停车按钮使系统紧急停车，为了保证能够顺利地再次启动，故障停车或紧急停车后必
须进行处理操作。
During the system operation, because of the device faults, the trip by motor overload and
by local protection and the relevant accidents, some or all devices will be stopped by interlocking.
In certain emergency circumstances, the emergency button is applied to emergency stop for safety
of device ad personnel. To guarantee the successful restart, operations must be done after the fault
stop or the emergency stop.
4.1.1 本系统可能出现的需要进行人为紧急停车的情况有以下几种：
The following conditions need manual emergency stop:
（1）板喂机（221-AC1)突然卡死。The apron feeder (221-AC1) is suddenly jammed.
（2）破碎机腔内混入大块铁件。Large piece of iron enters the crusher .
（3）破碎机严重堵塞。The crusher is seriously jammed.
（4）胶带严重跑偏或打滑。The belt is in a severe deflection or slipping.
（5）胶带接头撕裂或脱开。The contact of the belt is torn or slipped off.
4.1.2 设备突然停车的基本处理方法 The basic methods to handle the hard shutdown
4.1.2.1 马上停止向已停车设备供料的相关设备。
Immediately stop the relevant equipment which provides materials to the halted device.
尽快查清原因，判断能否在短时间（30 分钟）内处理完，以决定再次启动时间，并进行
相应的操作。
Find out reason as soon as possible and judge if it is handled within a short time (in 30min),

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

and then determine the restart time and the follow-up procedures.
常见故障及其处理见下表:
The main checking and adjusting items can be referred to table
序 号 发 生 故 障 设 备 现 象 及 原 因 处 理 方 法

No. Device with faults Phenomenon and reason Solutions

1 板喂机卡死。 （1）电机电流增高，温度 (1)停机处理。

is 上升。
The apron feeder
blocked. The motor current and the Stop the machine.
temperature rise.
（2）矿石进入链板中卡死。(2)检查电机。
The chain conveyor is
blocked by limestones. Check the motor.
2 破碎机内混入大块铁件。 破碎机运转声音不正常。 板喂机停止喂料，及时排

There is large pieces of The running sound of the 出破碎机内铁件。

metal inside the crusher crusher is abnormal. Stop feeding materials to

the apron feeder and

remove the iron inside the

crusher.

3 胶带撕裂。 （1）胶带接头断裂。 （1）检查修复胶带。

The belt is torn. The contact of the belt is Check and repair the belt.

torn. （2）更换胶带。

(3)胶带带芯脱开。 Replace the belt.

The core of the belt slips off.

4 收尘器工作不正常，车间 1）糊带。The belt is burnt. （1）停机检查、清理、修

内冒灰或排尘浓度增大。 （2）滤带破损。The filter 补、更换滤带。

The dust collector fails to belt is worn. Stop for checking, cleaning,

work, resulting in the （3）电源发生故障。There is repairing and replacing the

discharged dust or ash some faults on the power filter belt.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

increases. supply. （2）检查供电系统，恢复

（4）收尘器控制装置失灵。正常。

The dust collector is out of Check the power supply

order. system.

(1) 停车检修控制装置和

工作机构。

Stop for checking the

control device and working

units.

5 堆、取料机 (1)皮带跑偏 (1)调节尾轮

Stacker and Reclaimer (2)下料口堵 (2)清堵

(3)滚筒轴承损坏 (3)更换

(4)皮带断裂 (4)重接皮带

1. Belt run out 1. Adjusting tail roller

2. Discharging stemmed 2. Cleaning

3. Drum bearing broken 3. Replacing

4. Belt severed 4. Rework butt joint

4.2 紧急停车操作 operations for emergency stop

当出现紧急情况时，需要全部停车，按紧急停车键，设备急停后，应对设定值、阀门等

进行调整。如润滑设备没有问题，立即启动，并尽快处理，恢复系统运行。

When the emergency happens, it must stop all devices. Press the emergency button to stop the

device, and adjust the set value and valves after the devices stops. If there is no fault on the

lubrication device, start the device immediately, solve problems and reoperate the system.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

第五章 设备单体试车

Chapter 5 Single-unit test run

一、设备试车条件 Conditions for test run

1.1 设备安装完成 Finish the installation of the devices

1.2 电器安装完成 Finish the installation of the electric appliance
1.3 减速机内按照设备要求加注润滑油 Add lubricating oil to the devices inside the reducer
in accordance with requirements
1.4 所有润滑点按照要求加注润滑油或润滑脂 Add lubricating oil or grease to the point
according to requirements
二、试车过程 The process of test run

2.1 首先把转换开关放在现场位置，点动开关，确认电机旋转方向。
Put the switch on site, open it and confirm the rotation direction.
2.2 确认电机旋转方向正确后，对设备带电进行试运转，观察设备的运行情况，并对电
机电流进行测量。如果电流正常，设备运行情况正常，在无负荷情况下运转 4 小时，在这个
过程中观察各润滑点，确认减速机、轴承不发热，即可以完成无负荷试车。
After confirming the right direction, have test run on the equipment with power on, observe the
equipment running condition and measure the motor current. If the current and the equipment is in
normal condition, run it without load for 4h and observe every lubricating point to confirm the
reducer and the bearing don’t generate heat before start the no-load test run.
无负荷试车结束后，在条件允许的情况下，进行负荷试车。
Start the loaded test run in a allowable condition after finishing the no-load test run.
三、试车要求 Requirements for test run

3.1 板式喂料机 The apron feeder：

3.1.1 低速启动空载运转，检查正常无误后，逐渐达到正常运转速度，运转若干小时（详
见单机操作说明书）。
Start the no-load test run in a low speed, check it and then gradually run it in a normal speed
for hours (see the single-unit operation specification for details).
3.1.2 所有紧固件应连接牢固，无松动现象。特别是注意检查链板的联接螺栓有无松动现
象。保持链条松紧适当，如发现跑偏应通过拉紧装置进行调整。
Make sure that all fasteners are tightened, especially the connecting bolts of the chain

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

conveyor. Keep the chains in a proper degree of tightness; if it deflects, adjust it by the tension
device.
3.1.3 检查是否有其它异常情况，如发现异常，应及时检查发生的原因，并排除故障。
Check whether there is other abnormal conditions; if some fault happens, check and find out
the reason and solve it.
3.2 破碎机 the crusher：
3.2.1 检查并确认破碎机机体内没有金属物品和任何其他异物。所有润滑点按照要求加注
润滑油或润滑脂。
Check and confirm that no metals and other foreign matters inside the crusher; add lubricating
oil or grease to the lubricating points according to requirements.
3.2.2 检查机器各门、视孔盖是否封闭。各门和视孔盖在关闭前应在其外沿四周抹一层较
厚的润滑油脂，以使其关闭后有较好的气密性。
Check whether each door and every inspection plate is closed or not. Apply thick lubricating
grease around every door and each inspection plate to make sure its good air impermeability.
3.2.3 空载连续运转试车时间不少于 4 小时。空载试车必须遵循先点动后连续的原则，待
确认情况正常后再连续运转（详见单机操作说明书）。
The time of the no-load test run should not be less than 4h. Following the principle of “first
start point and then the follow-up”, confirm it is in a normal operation before the continuous work
(see the single-unit specification for details).
3.2.4 各运动部位运转是否良好，不得有异常的振动和噪音，否则应停车检查。
Whether all moving parts run in good conditions, the abnormal vibration and noise are not
permitted, otherwise shut down the equipment to check.
3.2.5 检测轴承温升，不应超过规定值。
Check that the temperature rise of bearing should not be higher than the limited temperature.
3.2.6 所有紧固件应连接牢靠，无松动现象，如发现异常及时排除。
Make sure that all fasteners are tightened, check whether there is some other abnormal
conditions; if any, dispose it.
3.3 带式输送机：要求皮带运转平稳，无跑偏，拉线开关及跑偏开关动作灵活。
Belt conveyor: it’s required that the belt should be running smoothly and steadily without
deflection; the pull switch and the deflection switch are in good condition.
3.4 收尘器：要求各室能够按照程序进行喷吹清灰，阀门动作灵活。
Dust collector: it is required that every chamber can be cleaned according to the procedures
and the valves are in good condition.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

3.5 堆、取料机 Stacker and reclaimer

3.5.1 各传动部位应无异常振动、异常声音、温度应不大于 40℃；
No vibrations or abnormal sounds for all drive parts and the temperature is not over 40℃;
3.5.2 刮板装置中的刮板体表面的耐磨板磨损情况，当磨损到危及刮板体时，应予以及时
更换；
Inspect the wear on the wear-resistance plate of the solid blade face in the scraper assembly.
Replacement in time if the solid blade is endangered by a wear;
3.5.3 刮板装置中的中间导轮螺栓是否有松动现象，如有应及时紧固；
Inspect if the bolt on the intermediate guide wheel in the scraper assembly is loosening.
Please tighten if any;
3.5.4 检查导槽衬板磨损情况，当其磨损到危及导槽本体时应及时更换衬板；
Inspect the wear on the liner in the guide chute. And the liner is replaced in time if the solid
guide chute is endangered;
3.5.5 刮板运行中是否有偏斜现象，若偏斜可调整链轮尾部螺旋张紧装置中的螺杆、螺母，
以使支撑刮板的两链条张力一致；
nspect if the scraper is skewed in the operation. You can regulate the screw rod and the nut in
the screw tensioning device at the end of the sprocket wheel in order to make two chains supporting
scraper in the same tension if any;
3.5.6 料耙沿支撑轨道运行及换向是否平行，有无异常声音；如有应及时调整；
Inspect if the rake is moves parallelly when it is operated along the support rail or the direction
is changed and if there is an abnormal sound. Please adjust in time if any;
3.5.7 要求做到端梁行走机构运行平稳，调节换向可靠，开式齿轮啮合情况良好；
It is required that the walking mechanism of the end beam is operated stably and the can be
regulated and inversed reliably. The open gear engages well;
3.5.8 各部液压系统不得有漏油，油箱油温不得大于 40℃，泵站运行噪音不得大于 80 分
贝。
There is no oil leakage in the hydraulic system of all parts. The temperature of the oil in the
tank is not over 40℃ and the noise level is below 80dB in the operation of the pump station.
四、单机试车后确认事项 Items to be confirmed after single-unit test run

4.1 确认设备空载运转达到说明书要求，记录设备空载启动负荷变化特性及振动噪音、
轴承温升等技术参数。
Confirm the device idle motion is up to the requirements in the specification, record the load

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

change features of the device running without load, and write down technical parameters such as
vibration sound and bearing temperature rise.
4.2 确认设备旋转方向正确无误。
Confirm that the device is in a right rotating direction.
4.3 确认润滑系统工作正常，冷却水路通畅。各点油压、油温、水压正常。
Confirm that the lubrication system is in a normal operation and the cooling water pipe is not
jammed; the oil pressure, oil temperature and water pressure is normal.
4.4 机旁控制准确无误，阀门动作与仪表指示一致，且开启灵活。
Confirm that the control beside the machine is accurate, the valve motion is in line with that
indicated by the instrument, and it is easily opened.
4.5 检查、确认设备内外无损坏、异常部位。
Check and confirm that there is no damage inside and outside the devices and no abnormal
part.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

第六章 试生产阶段注意事项

Chapter 6 Precautions at Trial Production

一、概述 Generals

1.1 系统内所有设备安装完毕，各台单机均按产品说明书要求检查调整并确认合格后，
进行单机空载试运转。单机无故障、空载连续运转时间满足要求后，方可进行空载联动试运
转。联动试运转后应对所有设备再次进行全面检查，确认系统没有问题，再进行荷载联动试
运转。荷载联动试运转前，需检查粘土受仓中的物料备妥情况；荷载联动试运转中，要求注
意观察设备运行情况，控制和掌握进入破碎机物料的块度、水份等物理特性，记录破碎机、
板喂机、皮带机的基本考核指标。
All the equipment in the system has been installed, and each machine has been checked,
adjusted according to the product specification requirements and qualified, make single machine
no-load test run. Only after the fault-free, no-load continuous operation of single machine has
reached the required time, make no-load linkage test run. After that, fully recheck all the equipment
and confirm that there is no problem of the system, then make load linkage test run. Before the load
linkage test run, check if the material in the limestone receiving bin is ready; during the load
linkage test run, it is required to observe the operation of equipment, control and master the
physical properties such as the blockness size, moisture and others of the material into the crusher,
record the basic performance indicators of the crusher, apron feeder, belt conveyor.
1.2 本系统的荷载联动试运转分为半负荷小块料、半负荷正常料、满负荷正常料三个步
骤进行(见表 6−1)。
The load linkage test run of the system is divided into three steps: half-load small materials,
semi-load normal material, full load normal feed (see Table 6-1).

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

表 6−1 荷载联动试运转计划表

Load test run schedule

试车时间
进料粒度要求 喂料量 出料粒度 检查方式
试车步骤 Test time
Required feed size Feed rate Discharge size Check
Test steps (h,连续
(mm) (t/h) (mm) method
continuous）

<250 120 >2 <50 机外检查

半负荷小块料
粘土 占 90% Check
Half load,
Clay outside
small material
machine

<500 120 >2 <50 机内检查

半负荷正常料 占 90% 拧紧螺栓

粘土
Half load, Check in
Clay
normal material the machine,

tighten bolts

<500 200 >4 <50 机内检查

满负荷正常料 占 90% 拧紧螺栓

粘土
Full load, Check in
Clay
normal material the machine,

tighten bolts

1.3 满负荷试运转过程中，按各单机设备技术特性所规定的数据进行检验考核，经检验合格
后方可正式投产使用。
During the full load test run, test and examine the specified technical characteristic data of each
single machine, and put into use only after they are qualified.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

二、试生产的准备 Preparation for trial production

2.1 本系统必须在空载试运转合格后，方能投料进行荷载试运转和试生产。空载试车必
须达到下列要求：
It must be after the no-load test run and qualified, the system can be put into load test run and
trial production. No-load test must meet the following requirements:
(1)设备运转平稳正常，回转部位灵活，无卡死和擦碰现象。
The device is normally operated, rotating parts flexible, no stuck and collision.
(2)运转中无金属撞击声。
No metal crash in the operation.
(3)主电动机电流平稳。
Stable current of main motor.
(4)各润滑部位的密封处、结合面无渗油、漏油现象。
No oil leakage at the seal, joint surface of each lubricating part.
(5)轴承最高温度不超过规定值，温升满足要求。
The maximum temperature of bearing does not exceed the specified value, the temperature
rise meeting the requirement
(1) 停机后，应检查运转中各部分螺栓和联结销、紧固件有无松动现象，并拧紧松动的螺
栓和紧固件。
After shut-down, check if there is loosening of bolts, coupling pin, fasteners of any part in the
operation, and tighten loose bolts and fasteners.
(7)符合行业规范及设备说明书对空载试运转的各项要求。
Comply with the requirements for no-load test run in the industry standards and equipment
specification.

`2.2 系统首次投料之前，应对设备进行检查和调整，重点是：
Before the first feeding of the system, the equipment should be checked and adjusted, focusing on:
(1)检查和调整设备各运动部件。
Check and adjust the moving parts of equipment.
(2)确认电机、减速器及各润滑系统的润滑点加入足够的润滑油。
Make sure each lubrication point of the motor, reducer and lubrication system is filled with
enough oil.
(3)检查确认电气信号和仪表正常无误。
Check and confirm the electrical signal and instrument is correct.

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

(4)确认电动机转动方向正确。
Confirm the motor rotation direction is correct.
(5)检查各润滑部位密封处、结合面有无渗油、漏油现象。
Check if there is oil leakage at the seal, joint surface of each lubricating part.
2.3 原矿供应准备 Ore supply and preparation
本系统投入试生产前，矿山开采运输系统必须形成生产能力，保证原矿的连续稳定供应，
防止生产运行过程中断料。采场供应的原矿块度和数量必须满足表 6−1 所列要求。
Before the system is put into trial production, the mining transportation system must be
capable to ensure the continuous and stable supply of ore, and to prevent the material outages in the
process of production. The ore block size and quantity of stope supply must meet the requirements
listed in Table 6-1.
（1）在雨季来临之前选择晴天开采比较干燥的粘土预储于堆棚中风干，以备雨季试生产
阶段取用。试生产期间应尽量避免使用水分含量较大的冻土，确保粘土水分始终不超过合同
规定值。
Mining dry clay in sunny day before raining season and put in storage shed for later
commissioning in rainy season. In commissioning as much as possible avoid using of frozen clay to
ensure that moisture in clay below the value specified in contract.
（2）本系统自投产之日起，即应向厂区内供应能满足性能试验要求的合格原料。对于首
采矿段，应预先做好生产勘探和矿石取样化验工作，掌握所采矿石的化学成分和物理性质，
为本系统预配料和厂区的磨前配料作业提供必不可少的原始数据。在试生产阶段，应避免开
采含碎石、卵石和碱含量过高的矿石，目的是保证工厂的原料性质和成分满足水泥生产要求。
At beginning of production of the system, quality clay shall be supplied to plant area and meet
the requirements for performance testing. For the first mining of clay, shall conduct prospecting,
clay sampling and testing, to get clay chemical composition and physical properties, collecting the
necessary data thereof for previous material proportioning of this system and of pre mill. In
commissioning as much as possible avoid using of clay mixed with gravel, pebble and too much
alkali, to ensure that material properties and composition meet requirements for cement production.
三、试生产要领及注意事项 Trial production essentials and precautions
3.1 确认所有设备正常运行，供电系统、通讯设施备妥。
Make sure that all equipment are normally operated, power supply system, communication
facilities ready.
3.2 受料仓中必须先铺碎料缓冲层，保护给料机链板，然后方可卸入正常块度的粘土。
First place the gravel buffer layer in the receiving bin, to protect the feeder chain plate, and

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5000 TPD CMIC CEMENT PLANT PROJECET IN CAMBODIA

then feed the ore of normal block size.

3.3 各种粒度物料的连续破碎时间不能低于表 6−1 要求。
The continuous crushing time of various size materials can not be less than the requirements
in Table 6-1.
3.4 系统产量按额定产量 30%、60%、100%的比例逐步提高，直至正常产量。
The output of the system should be gradually increased to 30%, 60% and 100% of the rated
output until normal production.
3.5 在设备运行过程中重点检查下列部位：
Check the following during the equipment operation:
(1) 破碎机(221-RC1)电机、轴承温度，润滑油（脂）的温度、油量等。
Crusher (221-RC1) motor, bearing temperature, lubricant (grease) temperature, quantity and
so on.
(2) 板喂机(221-AC1)轴承温度，润滑油（脂）的温度、油量等。
Apron feeder (221-AC1)bearing temperature, lubricant (grease) temperature, quantity and so
on.
3.6 对设备进行检查、维修，必须在确认系统停车后进行，绝不允许设备运行时检修设
备。
The inspection, maintenance of the equipment must be carried out after confirming the system
is stopped, never allowed to maintain the equipment when it is running.
3.7 检修葫芦(221-EH1)起重量为 10t，不宜吊装过起重量的设备，起重设备应拆卸吊装。
Capacity of motor hoist (221-EH1) is 10t, overweight lifting is not allowed, crane equipment
shall be handled piece by piece.

四、设备使用维护要领 Utilization and maintenance essentials of equipment

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。
The utilization and maintenance essentials of equipment can be referred to the operating
manual of each equipment, it will not be elaborated repeatedly here.

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