旋轉(zhuǎn)霧化器說明書

OPERATINGMANUAL 操作手冊ATOMIZINGSYSTEM噴霧系統(tǒng)FOR供HEFEIWTEPROJECTCHINA中國合肥垃圾焚燒發(fā)電項(xiàng)目CLIENT:顧客FISIABABCOCKENVIRONMENTGmbH德國費(fèi)塞亞巴高克環(huán)境工程公司D0430TABLEOFCONTENTS目錄 Section章節(jié) 1.0. RECEIVING,STORAGEANDINSTALLATION收貨、儲存和安裝 1.1. ReceivingandStorage收貨和儲存 1.2. Installation安裝1.2.0 GeneralDescription概述1.2.1 AtomizerSystemControl(ASC)噴霧器控制系統(tǒng)（ASC）1.2.2 Atomizer(Motor)噴霧器（電機(jī)）1.2.3. VariableFrequencyDrive(VFD)變頻驅(qū)動器（VFD）1.2.4 PermanentInstallation設(shè)備永久固定 2.0. SYSTEMDESCRIPTION系統(tǒng)闡明 2.1. AtomizerDesignConceptGeneral噴霧器設(shè)計理念–概述 2.2. Atomizer(Motor)Mechanical噴霧器（電機(jī)）-機(jī)械方面 2.3. Atomizer(Motor)Electrical噴霧器（電機(jī)）-電氣方面 2.4. VariableFrequencyDrive(VFD)變頻驅(qū)動器（VFD） 2.5. AtomizerSystemControl(ASC)噴霧器控制系統(tǒng)（ASC） 2.5.0 GeneralDescription,ProcedureandSequencing概述、流程和次序：2.5.1 OilLubricationSystem潤滑系統(tǒng)2.5.2 OilReturnSystem油回流系統(tǒng)2.5.3 AtomizerCoolingSystem噴霧器冷卻系統(tǒng) 2.5.4 PurgeAirandWheel&ShaftCooling/WashWater吹掃空氣和轉(zhuǎn)盤/軸冷卻/清洗水 2.6. TheoryofOperationoftheAtomizerSystemControl(ASC)噴霧器控制系統(tǒng)（ASC）的操作原理2.6.0 References參考2.6.1 VFDFault變頻驅(qū)動器故障2.6.2 CoolingWaterFlowSwitch冷卻水流量開關(guān)

TABLEOFCONTENTS(cont’d)目錄（續(xù)） Section(cont’d)章節(jié)（續(xù)） 2.6.3 LubeOilLevelSwitches潤滑油油位開關(guān)2.6.4 LubeOilMistPressureSensor潤滑油霧壓力傳感器2.6.5 VibrationElement/Transmitter振動元件/變送器2.6.6 UpperBearingRTDElement/TemperatureTransmitter頂部軸承熱電阻元件/溫度變送器2.6.7 AlarmSummary報警概述2.6.8 AlarmBypass報警跨接 2.7. SummaryoftheAtomizer’sUtilityServices噴霧器的公用設(shè)施概述2.7.0 General概述2.7.1 InstrumentAir儀用空氣2.7.2 Lubrication潤滑系統(tǒng)2.7.3 CoolingWater冷卻水2.7.4 Wheel&ShaftCooling/WashWater轉(zhuǎn)盤和軸沖洗水 3.0. STARTUPANDOPERATION啟動和運(yùn)行 3.1. CommissioningtheAtomizerSystem噴霧系統(tǒng)調(diào)試 3.1.0 General/Start-upEngineer概述/啟開工程師3.1.1 PrimingtheLubricationSystem潤滑系統(tǒng)加注3.1.2 AtomizerPreparationandRun-In噴霧器的準(zhǔn)備和試車 3.2. NormalStartUp正常啟動 3.3. NormalOperation正常運(yùn)行 3.4. NormalShutdown正常停止 3.5. EmergencyShutdownoftheAtomizer噴霧器的緊急停止TABLEOFCONTENTS(cont’d)目錄（續(xù)） Section(cont’d)章節(jié)（續(xù)） 4.0 ROUTINEMAINTENANCE例行維護(hù) 4.1. Lubrication潤滑系統(tǒng) 4.2. PreventativeandPeriodicMaintenanceoftheASCASC防護(hù)保養(yǎng)和定時維護(hù) 4.3. PreventativeandPeriodicMaintenanceoftheAtomizerandWheel噴霧器和轉(zhuǎn)盤的防護(hù)保養(yǎng)和定時維護(hù) 4.4. LongTermStorageoftheAtomizer長久存儲噴霧器 4.5. InstrumentCalibration儀表校準(zhǔn) 5.0 ATOMIZERDISASSEMBLYANDASSEMBLYINSTRUCTIONS噴霧器拆卸和裝配指南 5.1 GeneralRecommendations普通建議 5.2 DisassemblyInstructions拆卸指南 5.3 Re-AssemblyInstructions重新裝配指南 5.4 AtomizerWheelBalancingGuidelines噴霧器轉(zhuǎn)盤平衡調(diào)校指南 6.0 SPAREPARTSLIST備品備件清單 6.1 RecommendedSpareParts-Model900Atomizer型號900旋轉(zhuǎn)噴霧器，建議的備品備件RecommendedSpareParts-ModelEI-804Wheel型號EI-804噴霧器轉(zhuǎn)盤，建議的備品備件RecommendedSpareParts–ASC ASC面板，建議的備品備件RecommendedSpareParts–VFD型號A1000，Yaskawa（日本安川電氣）噴霧器變頻驅(qū)動器，建議的備品備件 7.0 TROUBLESHOOTINGGUIDE故障排除指南 7.1. General概述 7.2. OperatingLog運(yùn)行日志 7.3. ProblemSymptomsandProbableCauseOutline故障癥狀和可能的因素概述 7.4. SpecificAtomizerWheelTroubleshootingGuide噴霧器轉(zhuǎn)盤特殊故障排除指南

TABLEOFCONTENTS(cont’d)目錄（續(xù)）Section(cont’d)章節(jié)（續(xù)） 7.5. OtherGeneralInspectionandTroubleShootingIssues其它總體檢查和故障排除事項(xiàng)7.6. FreezingWeatherPrecautions嚴(yán)寒天氣應(yīng)對方法8.0 REFERENCEDRAWINGS參考圖紙(Pleaseseedrawinglistatstartofsection)（請參閱章節(jié)前述的圖紙清單） 9.0 VENDORDATA供貨商數(shù)據(jù)(Pleaseseecataloguelistatstartofsection)（請參閱章節(jié)前述的目錄清單）SAFETYSUMMARY:安全概述Thegeneralinformationinthispartofthesummaryisforbothoperatingandmaintenancepersonnel.Specificcautionsandwarningswillbefoundthroughoutthemanualwheretheyapply,butmaynotappearinthissummary.此部分概述包含的總體信息供操作和維護(hù)人員所用。具體注意事項(xiàng)和警告能夠在整個手冊中的有關(guān)章節(jié)中找到，但在本概述中不做闡明。TERMS：術(shù)語 InManual:在手冊中CAUTIONstatementsidentifyconditionsorpracticesthatcouldresultindamagestotheequipmentorotherproperty.注意指的是可能會造成設(shè)備或其它財產(chǎn)損害的狀況或行為。WARNINGstatementsidentifyconditionsorpracticesthatcouldresultinpersonalinjuryorlossoflife.警告指的是可能會造成人員受傷或死亡的狀況或行為。 OnEquipment:在設(shè)備上“CAUTION”indicatesapersonalinjuryhazardnotimmediatelyaccessibleasonereadsthemarking,orahazardtopropertyincludingtheequipment.“注意”指的是當(dāng)閱覽該標(biāo)記時，不會立刻產(chǎn)生人員傷害，或者指的是對涉及設(shè)備在內(nèi)的財產(chǎn)產(chǎn)生損失。“DANGER”indicatesapersonalinjuryhazardimmediatelyaccessibleasonereadsthemarking.“危險”指的是當(dāng)閱覽該標(biāo)記時，就立刻產(chǎn)生人員傷害的后果。WARNING: Thisatomizingsystemoperatesathighvoltageandathighspeed.Itisprovidedwithanumberofinterlocks,safetydevices,andspecificoperatingprocedurestopreventseriousinjurytopersonnelandtopreventdamagetoequipment.Donotattempttodefeatanyinterlocks,oroperateinanywaynotconsistentwiththeinstructions!警告： 該噴霧系統(tǒng)處在高電壓和高速下運(yùn)行。配備了多組聯(lián)鎖裝置、安全防護(hù)裝置、以及特定的操作程序，以避免嚴(yán)重的人員傷害和設(shè)備損壞。不得試圖停用任何聯(lián)鎖設(shè)立，或以任何方式違規(guī)操作！1.0 RECEIVING,STORAGEANDINSTALLATION收貨、儲存和安裝1.1 ReceivingandStorage收貨和儲存Inspectallshipmentsofmaterialandequipmentforweatherorshippingdamage.ImmediatelyreportanyobserveddamageordiscrepancytothecarrierortoKomline-Sanderson,asappropriate.檢查全部運(yùn)到的材料和設(shè)備與否因天氣因素或在運(yùn)輸過程中發(fā)生損壞。立刻向承運(yùn)人或Komline-Sanderson公司報告任何發(fā)現(xiàn)的損壞或缺貨現(xiàn)象。Uponreceipt,theequipmentisinthecustomer'scustodyandrequiresprecautionsinhandlingandstorage.Unlessspecificallyprovidedforotherwise,theatomizeranditsassociatedequipmentarepreparedforonlybriefexposuretoweather,andmustthereforebestoredinaclean,dryandheatedindoorlocation.Inparticular,theatomizeritselfshouldremaininitsshippingcrateandmustbekeptinanuprightposition.收到貨品后，由客戶負(fù)責(zé)保管設(shè)備，并應(yīng)按規(guī)定解決和儲存設(shè)備。除非另有規(guī)定，噴霧器及其有關(guān)設(shè)備只能短時暴露在露天，因此必須寄存在一種清潔、干燥、常溫的室內(nèi)。特別是，應(yīng)將噴霧器保存在其裝運(yùn)箱中，并保持直立狀態(tài)。Forinformationconcerning"LongTermStorage"refertoSection4.4 詳情請參閱第4.4章節(jié)“長時間儲存”1.2 Installation安裝1.2.0 GeneralDescription:概述Forconvenientoperationandmaintenanceoftheatomizer,itisnecessarytoprovideahoistandmonorailcenteredoverthespraydryeratomizer’soperatingposition.Themonorailshouldextendtoapointthatwillpermitloweringthemachinetoanelevation(e.g.grade)fromwhereitcanbetransportedbyothermeansforoffsitemaintenanceorstorage.為了方便噴霧器的操作和維護(hù)，有必要在旋轉(zhuǎn)干燥噴霧器操作位置上方設(shè)立吊機(jī)和單軌。單軌應(yīng)當(dāng)延伸至一種能夠?qū)C(jī)器下放到提高平臺（如：地平面）的操作點(diǎn)，自此能夠以其它方式將其運(yùn)輸至廠外進(jìn)行維修或儲存。Theatomizeroperatingsiterequiresadequateplatformingandlightingforsafeandcarefuloperation.Theatomizershould,onceoutsideitsshippingcrate,onlybestoredortransportedinitsmaintenancestandorsuspendedfromahoist. 噴霧器操作現(xiàn)場需要有足夠的平臺和照明，便于安全和細(xì)致操作。一旦將噴霧器 從其裝運(yùn)箱取出后，其儲存或運(yùn)輸只能通過維護(hù)支座或吊機(jī)進(jìn)行。Theatomizer’scontrol/lubricationpanel,inthefollowingreferredtoastheAtomizerSystemControl(ASC),isaNEMA-4designforlocationadjacenttotheatomizer’soperatingposition(the“supporttube”).Itconnectstotheatomizerviatheso-called“umbilicalcord”.Theatomizer’spowersupplyenclosure,theVariableFrequencyDrive(VFD)isaNEMA-1designforlocationinaremote,electricalequipmentroomarea.噴霧器的控制/潤滑面板下列簡稱為噴霧器控制系統(tǒng)（ASC），采用NEMA-4原則設(shè)計，其位置與噴霧器的操作位置（“支撐管”）相鄰。它通過所謂的“母管”連接到噴霧器。噴霧器的電源供應(yīng)裝置：變頻驅(qū)動器（VFD）采用NEMA-1原則設(shè)計，位于遠(yuǎn)程電氣設(shè)備間內(nèi)。Refertolatersectionsoftheseinstructionsforfurtherinformationanddrawings.Generalreferencedrawingsfortheinstallationprocedureareasfollows: 在后來章節(jié)中可參閱有關(guān)資料和圖紙。安裝過程中的總體參考圖以下：ElectricalpowerconnectionsbetweentheAtomizerSystemControl(ASC),theVariableFrequencyDrive(VFD),andtheAtomizerareshownonthedwgs.D0430-90000D,D0430-9D,andD0430-90006D.Oillubrication,coolingwater,purgeair,washwater,andelectricalsignalconnectionsbetweentheASCPanelandtheAtomizeraremadeviaanumbilicalhoseassembly,shownondwg.D0430-91061D.Thisassemblycontainslubricationlines(air/oilmistsupplyandreturnlines);coolingwatersupplyandreturnlines;purgeairline,wheelwashandshaftwashlines;andvibration,andtemperaturesignalwiring(theumbilicalcord’selectricalsignalschematicsareshownondwg.D0430-91091D).Powertotheatomizerissuppliedbyacable,whichplugsintoareceptacletobemountedneartheatomizeroperatingposition.噴霧器控制系統(tǒng)（ASC）、變頻率驅(qū)動（VFD）以及噴霧器之間的電源連接見圖紙D0430-90000D、D0430-9D和D0430-90006D所示。ASC面板和噴霧器之間的油潤滑、冷卻水、吹掃空氣、沖洗水、以及電氣信號通過母管組件連接，如圖紙D0430-91061D所示。該組件涉及潤滑管路（空氣/油霧氣供應(yīng)和回流管路）、冷卻水供應(yīng)和回流管路、吹掃空氣管路、噴霧轉(zhuǎn)盤清洗和軸清洗管路、以及振動和溫度信號電纜（母管的?電氣信號原理圖見圖紙D0430-91091D）。噴霧器的電源電纜插在一種安置在噴霧器操作位置附近的插座上。1.2.1. AtomizerSystemControl(ASC):噴霧器控制系統(tǒng)（ASC）Inthefollowing,pleasereferenceinparticulardwgs.D0430-90001D,D0430-90006D,andD0430-91061D)有關(guān)以下要點(diǎn)，請?zhí)貏e參閱圖紙D0430-90001D,D0430-90006D和D0430-91061Da. SettheAtomizerSystemControl(ASC)neartheatomizer’soperatingposition(supporttube),orientedforthemostconvenientobservationandaccesstothefront.將噴霧器控制系統(tǒng)（ASC）安置在噴霧器的操作位置（支撐管）附近，調(diào)節(jié)角度至最方便觀察及接觸前面板的位置。b. AvoidplacingtheASCunitontopofremovablefloorplates(whenfurnished).ItissuggestedthatpermanentfasteningdownoftheASCshouldbepostponeduntiltheremainingworkinthissectioniscomplete.避免將ASC裝置放置在可移動的底板上（如果有的話）。建議在本章節(jié)所述剩余工作未完之前，先不要永久固定ASC。c. MeasurethedistancefromtheumbilicalconnectionpanelontheASCtothebottomoftheatomizersupporttube(theatomizer’soperatingposition).Thisshouldbe18ft(5.5m)orless.測量從ASC上的母管連接面板至噴霧器支撐管（噴霧器的操作位置）底部的距離。應(yīng)當(dāng)是18英尺（5.5米）或更少。d. Pipetheinstrumentairsupplytoconnecttothefitting“N1”ontheleftsideoftheASCenclosure.將儀用空氣管與ASC機(jī)柜左側(cè)上的接頭“N1”相連。e. Mounttheprovidedwatersoftenerassembly(dwg.D0430-80007C)atasuitableconnectionneartheASCenclosure.Pipepotable(clean)watersupplytoitsinletfittingandpipefromitsdischargetothefitting“N4”ontheleftsideoftheASCenclosure.將供水軟化妝置（圖紙D0430-80007C）安裝在ASC機(jī)柜附近適宜的連接位置上。飲用（清潔）水接至其入口接頭，并從出口接頭接出管線與ASC機(jī)柜左側(cè)上的接頭“N4”相連。f. Installthevacuumtankassembly(dwg.D0430-90001D,item04,anddwg.D0430-91086D)behindtheASCenclosure.ConnectthetankinletandoutlethosestotheproperconnectionsontherightsideoftheASCpanel(thehoseattachedtothevacuumtankassemblyfilteristobeconnectedtotheASCportthatislabeled"TOVACUUMFILTERON5GALTANK"andthehosethatisattacheddirectlytothetankistobeconnectedtotheASCportthatislabeled"RETURNFROM5GALTANK".將真空罐組件（圖紙D0430-90001D，部件04，和圖紙D0430-91086D）安裝在ASC機(jī)柜背面。將真空罐入口和出口軟管連接到ASC面板右側(cè)的接頭上（與真空罐過濾器相連的軟管應(yīng)連接到ASC上標(biāo)有“至5加侖罐真空過濾器”的端口上，直接與真空罐連接的軟管應(yīng)接到ASC上標(biāo)有“從5加侖罐回流”的端口上）。g. Connectcoolingwatersupplyandreturn(ordrain)pipingtothefittings“N2”and“N3”,respectively,ontheleftsideoftheASCenclosure.將冷卻水供應(yīng)和回流（或排水）管道分別與ASC機(jī)柜左側(cè)接頭“N2”和“N3”相連。h. ConnecttheumbilicalhosefittingstotheconnectionpanelintherightsideoftheASCenclosure.Notetheidentificationoftheindividualhosesontheattachedtagsandcross-referencewithdwg.D0430-91061D.Alsoconnecttheelectricalsignal(Amphenol)connectorwiththepanel’smatingreceptacle.Securetheumbilicalassemblytotheenclosurebytheuseoftheprovidedstrainreliefchain.將母管組件與ASC機(jī)柜右側(cè)面板相連接。注意識別各個軟管附帶的標(biāo)簽并互相參考圖紙D0430-91061D。然后將電氣信號（安費(fèi)諾）連接器與面板的適配插座相連。使用所提供的應(yīng)力釋放鏈將母管固定到殼體上。Mountthefeedstrainer(providedbyothers)atasuitablelocationinthevicinityoftheatomizer’soperatingposition.The1-1/2”(40mm)and20-ft(6m)longfeedhose(dwg.D0430-91070C),whichshouldbemounteddirectlytothestrainerviatheCamlokconnector,mustbewithinreachoftheatomizerinitsoperatingposition.Runfeedpipingtothestrainerinlet.將進(jìn)料過濾器（由其它公司提供）安裝在噴霧器操作位置附近的一種適宜的位置上。1-1/2英寸（40毫米）和20英尺（6米）長的給料軟管（圖紙D0430-91070C）（該軟管應(yīng)通過Camlok連接器直接安裝到過濾器上）必須處在能夠達(dá)成噴霧器的操作位置范疇之內(nèi)。將給料管道布置到過濾器入口。j. InstallelectricalpowerandsignalwiringtotheterminalslocatedintheupperenclosureoftheASCunit.Usetheconnectionschematicdwg.D0430-90006Dforproperidentificationoftheterminals.將電源線和信號線接到位于ASC單元外殼頂部的端子上。按照圖紙D0430-90006D辨別各個端子。1.2.2. Atomizer(Motor):噴霧器（電機(jī)）Inthefollowing,pleasereferenceinparticulardwgs.D0430-01102DandD0430-01100D.有關(guān)以下要點(diǎn)，請?zhí)貏e參閱圖紙D0430-01102D和D0430-01100D. Uncratetheatomizerandtransportittotheoperatingsite.Themachineshould bekepterectatalltimes.Savethecrateforlateruse! RefertotheAtomizerShippingBoxDrawingCSM80-00017DinSection8. 拆封噴霧器，并運(yùn)輸?shù)阶鳂I(yè)現(xiàn)場。應(yīng)使機(jī)器始終保持直立狀態(tài)。保存拆 卸的箱子，為后來所用！ 參閱在第8章的噴霧器裝運(yùn)箱圖紙CSM80-00017Db. Settheatomizerintoitsmaintenancestand(dwg.D0430-01046D)orsuspendit fromthehoistwithinreachoftheASCpanel’sattachedumbilicalhose.將噴霧器放置在檢修支架上（圖紙D0430-01046D）或在能夠觸及ASC面板的母管長度范疇內(nèi)把它掛在起吊器上。CAUTION: Neverallowtheatomizershaftorwheeltosupporttheweightoftheunit!注意： 嚴(yán)禁讓噴霧器軸或轉(zhuǎn)盤承載裝置的重量！Connecttheumbilicalcord’scoolingwaterfittings(3/4”)(20mm),thecolor-coded(Swagelok)quickconnectors(3/8”and?”)(10mmand6mm),andthe(Amphenol)signalconnectoroftheumbilicalhosewiththematingconnectorsmountedontheatomizer.Cross-referencewiththeumbilicalhosedrawing(dwg.D0430-91061D)ifnecessary.Avoidanylinescrossingorexcessivestrainimposedonanyhosesorconnectors.Finallysecuretheumbilicalhosetotheatomizerbytheuseofthestrainreliefchainprovided.將母管的冷卻水接頭（3/4英寸）（20毫米）、標(biāo)有顏色的（世偉洛克）快接（3/8英寸和1/4英寸）（10毫米和6毫米）、以及母管的信號連接器（安費(fèi)諾）與安裝在噴霧器上的匹配連接器相連接。如有需要，參閱母管圖紙（圖紙D0430-91061D）。避免任何管線交叉，以及任何軟管或連接器的過分受載。最后，使用所提供的應(yīng)力消除鏈緊固母管與噴霧頭的連接。1.2.3 VariableFrequencyDrive(VFD):變頻驅(qū)動器（VFD）Inthefollowing,pleasereferenceinparticulardwg.D0430-9D,aswellastheVFDinformationprovidedintheVendorDataSection9ofthismanual.有關(guān)以下要點(diǎn)，請?zhí)貏e參閱圖紙D0430-9D，有關(guān)VFD的信息請參閱本手冊的第9章節(jié)供貨商數(shù)據(jù)。a. ItisassumedthattheVFDisproperlyinstalledinanelectricalequipmentroomarea,itsinputterminalshavebeenwiredtothefacility’spowersupply,theunithasbeenadequatelygrounded,etc.Also,itisassumedthatthepowerwiringbetweentheVFDandtheatomizerreceptacle,incl.theinterlockwiring,isinplace假定，VFD被對的地安裝在電氣設(shè)備室內(nèi)，其輸入端已與設(shè)備電源相連接，裝置已充足接地等，另外，假定，VFD和噴霧器插座之間的電源接線，涉及聯(lián)鎖裝置接線均已就位。b. CompletetheinterconnectwiringattheASC’supperenclosure,asalsoreferencedonDwg.D0430-90006D 完畢在ASC機(jī)柜上部的互連布線，請參閱圖紙D0430-90006D。1.2.4. PermanentInstallation:最后固定IfnoadjustmentoftheASClocationappearsnecessary,completepermanentinstallationbyboltingtheentireunittothefloor,followingtheanchorboltpatternondrawingD0430-90001DSheet2.Also,anchorthevacuumtankassemblytothefloorasdescribedondrawingD0430-90001D.如果無需調(diào)節(jié)ASC位置，則通過螺栓將整個裝置固定在底板上，進(jìn)行最后固定。參閱圖紙D0430-90001D2第2頁所示地腳螺栓布置。同時也要將真空罐錨定在底板上，請參閱圖紙D0430-90001D。2.0. SYSTEMDESCRIPTION系統(tǒng)闡明2.1. AtomizerDesignConcept–General噴霧器設(shè)計理念–概述TheKomlineSandersonatomizerhigh-speedinductionmotorisaruggedlybuiltprecisionmachine,designedtooperatereliablyunderthedifficultdemandsofhigh-speedoperationintheenvironmentofhotdryinggasesandabrasiveslurryatomization.Thecompactdesignofthismachinelimitstheriskforexcessivevibrationduringoperation,andalsoallowsforeasyhandlingduringremoval,maintenance/inspectionservice,andreinstallation.帶有高速異步電機(jī)的KomlineSanderson噴霧器的是一種結(jié)實(shí)的精密機(jī)器，該設(shè)計滿足在火熱干燥煙氣和研磨性漿液噴霧的環(huán)境中高速可靠運(yùn)行的高規(guī)定。本機(jī)構(gòu)造的緊湊設(shè)計減低了運(yùn)行過程中過分振動的風(fēng)險，并且易于拆卸、維護(hù)/檢查、及重新安裝。Thisrotaryatomizerachievesthehighspeed(rpm)requiredbytheprocess(generationoffinedroplets[30-40micron])bytheuseofahigh-frequencypowersupplyfurnishedbyafrequencyinverter,orVariableFrequencyDrive(VFD).Efficientlubricationoftheatomizerbearingsandadequatecoolingoftheatomizermotorisprovidedbyacustomizedserviceterminal,incorporatedwiththeatomizer’scontrolpanel,generallyreferredtoastheAtomizerSystemControl(ASC).Thecontrolpanelincludesstart/stopfunctionsaswellascertainmonitoringcapabilitiesandsafetyinterlocks.Provisionsforinterfacewiththecustomer’scontrolsystemareincluded.通過使用由變頻器或者變頻驅(qū)動器（VFD）產(chǎn)生的高頻電源達(dá)成工藝（霧滴[30-40微米]）所需的高轉(zhuǎn)速（rpm）。由集成于噴霧器控制面板（普通稱為噴霧器控制系統(tǒng)（ASC））上的專用服務(wù)終端提供噴霧器軸承的有效潤滑和噴霧器電機(jī)的有效冷卻?？刂泼姘迳婕皢?停止功效，以及某些監(jiān)測能力和安全聯(lián)鎖功效。還預(yù)留了與顧客控制系統(tǒng)的接口。Withpropercareandattentiontheatomizerandassociatedequipmentwillgiveyearsofsatisfactoryservice.Theatomizerwheelhasbeenequippedwithabrasionresistantinserts,whichwillrequiresomeroutinereplacementdependingoftheabrasivenessofthefeedslurry.Also,itisrecommendedthatthehigh-speedbearingsbereplacedonaregularbasis.通過對的的使用并予以足夠的重視，噴霧器及其有關(guān)設(shè)備可覺得客戶提供數(shù)年令人滿意的服務(wù)。噴霧器轉(zhuǎn)盤已經(jīng)配備了耐磨鑲件，該耐磨鑲件視進(jìn)料石灰漿的磨蝕性狀況需要定時進(jìn)行更換。同樣建議定時更換高速軸承。2.2. Atomizer(Motor)–Mechanical噴霧器（電機(jī)）-機(jī)械方面Thedrawingentitled"Series900AtomizerDriveAssembly,CustomerDrawing“,dwg.D0430-01100D,sht.1&2,isreferencedextensivelyinthefollowingdescription.Eachspecificpartdescribedinthetextisidentifiedbyanitemnumberinparenthesis,whichcanbefoundonthematerialslistofthisdrawing.在下面的描述中廣泛引用了名為“系列900噴霧器驅(qū)動器組裝，顧客圖紙”的圖紙，圖紙編號為D0430-01100D，圖1＆2。文中所述的每一種特定部件通過括號中的部件編號識別，對于該編號請參閱在該圖紙上的材料清單。TheatomizerisanACsquirrel-cageinductionmotor,specificallydesignedforhigh-speedoperationofupto16,200rpm.Themotor’srotor/shaftassembly(item04)revolveswithinandisdrivenbythestator(item05)andoperatesonthesamebasicprinciplesasanythreephaseinductionmotor.噴霧器采用交流鼠籠式異步電機(jī)，專為可達(dá)16200rpm高速運(yùn)行工況而設(shè)計。電機(jī)的轉(zhuǎn)子/轉(zhuǎn)軸組件（部件04）在定子內(nèi)部轉(zhuǎn)動，并由定子（部件05）驅(qū)動，其工作原理與任何三相異步電機(jī)的基本原理相似。Therotorismountedonarigidshaft(partofitem04),andcarriedbetweentwoprecisionangularcontactbearings(items20).Thesebearingssupporttheweightoftherotatingparts,andprovidetherequiredrigidsupportagainstlateralforces.Theentirerotatingassemblyhasbeendesignedtooperatewellbelowanyharmfulcriticalspeeds,andithasbeencarefullyconstructedandbalancedtominimizevibration.轉(zhuǎn)子安裝在一種剛性軸（部件04的一部分）上，并且被承載于兩個精密的角面接觸剛性軸承（部件20）之間。這些軸承支撐轉(zhuǎn)動部件的重量，并提供應(yīng)對側(cè)向力所需的剛性支撐。整個旋轉(zhuǎn)組件的設(shè)計能夠滿足在任何危害性臨界速度下正常運(yùn)行，并且它已被精心構(gòu)造并通過平衡校準(zhǔn)，以將振動減小至最低。Theupperbearingcarriestheentireweightoftherotatingassemblyandisalsothefixedbearingthatlocatestheassembly'saxialposition.Thisbearingispositionedinsideasleeve,partoftheupperbearinghousing.Thelowerbearingismountedinthelowerbearingsleeve,incorporatedintothemainhousing.Theouterraceofthelowerbearingisfreetomoveaxiallyinthehousing.Asetofpreloadsprings(item21)exertathrustloadonthelowerbearingtotakeupanyslackandmaintainaconstantloadonthebearings,regardlessofvariationscausedbynormalmanufacturingtolerancesorbycyclingthermalexpansion.上部軸承承載旋轉(zhuǎn)裝置的整個重量，并且也是位于該裝置軸向位置的固定軸承。該軸承被定位在屬于上部軸承殼體部分的軸套內(nèi)。下部軸承被安裝在下部軸套中，并集成在主殼體中。下部軸承的外環(huán)能夠在軸承殼內(nèi)軸向自由移動。一組預(yù)加載彈簧（部件21）對下部軸承施加推力載荷，從而賠償任何疏松狀況，并維持在軸承上的一種恒定負(fù)荷，以應(yīng)對任何正常制造公差或熱膨脹引發(fā)的變化。Theatomizermotorisencasedinaheavyrigidenclosureconsistingofthemainhousing/upperbearinghousingassembly(item01).Themotorstatorisheldfixedinthemainhousing.Heatgeneratedduringnormaloperationistransferredfromthestatortoawaterjacketbuiltintegralwiththemainhousing.噴霧器電機(jī)被裝在一種重型結(jié)實(shí)的殼體內(nèi)，它涉及主殼體/上部軸承座組件（部件01）。電機(jī)定子固定在主殼體內(nèi)。在正常運(yùn)行過程中產(chǎn)生的熱量從定子轉(zhuǎn)移到集成于主殼體內(nèi)的水夾套中。Itisvitallyimportanttothismachinethatproperlubricationisfurnishedtothebearingsatalltimes.Ahighlyspecializedlubricationsystemisprovided,anditsoperationandmaintenancemustbeunderstoodbytheusertoinsurepropercareandoperation.始終對軸承進(jìn)行對的的潤滑是及其重要的。本機(jī)提供了一種高度專業(yè)化的潤滑系統(tǒng)，顧客必須熟悉其運(yùn)行和維護(hù)要點(diǎn)，從而確保能夠?qū)Φ倪M(jìn)行維護(hù)和操作。LubricationRequirements:潤滑規(guī)定a. Lubricantmustbeintroducedataconstantrate,justenoughtoinsurethebearingsarealwayswettedbyoilfilm,butnotsomuchaswouldresultinchurningthelubricantandoverheatingthebearings. 潤滑油必須以一種恒定的速率被加入，這樣能夠確保軸承總是被油膜潤滑，但是不能過 多，否則會造成潤滑油的攪拌，以及軸承過熱。b. Oilwhichhaspassedthroughthebearingmustbecollectedandextractedfromthemachine,andpreventedfromre-enteringthemachinehousing.已通過軸承的潤滑油必須集中收集起來，并從機(jī)器中抽取出去，并避免它們重新進(jìn)入機(jī)體內(nèi)。c. Bearingsmustbeprotectedfromcontamination.必須保護(hù)軸承免受污染。Tomeettheserequirements,aspeciallydesignedlubricationsystemhasbeenprovided.Oilisconveyedbyastreamofairandisdirectedateachbearingthroughasmallnozzle.Theupperbearingreceivesoilthroughanozzle(item16),whichismountedintheupperbearingcap(item06).Asecondbranchofoilisconductedthroughpassagesintothelowerbearingcap(item09)andisdirectedontothelowerbearingthroughanintegralnozzle.為了滿足這些規(guī)定，本機(jī)提供了一種特殊設(shè)計的潤滑系統(tǒng)。潤滑油通過壓縮空氣流輸送，并通過一種小噴嘴進(jìn)入各個軸承。潤滑油通過安裝在上部軸承蓋（部件06）上的噴嘴（部件16）流入上部軸承，潤滑油的第二個支流通過管道和下部軸承蓋（部件09），然后通過集成噴嘴流入下部軸承。Theoilandconveyingairpassthroughthebearingsand,bymeansofslingersandbaffling,aredirectedtosmallsumps(item07anditem08)beneatheachbearing.AvacuumejectorlocatedintheASCenclosuredrawstheairandspentoilfromthesesumpsandtransportsitthroughawasteoiltankwheretheoiliscollected.潤滑油和輸送空氣通過軸承，借助檔油環(huán)被導(dǎo)入至各個軸承下方的小油槽內(nèi)（部件07和08）。位于ASC機(jī)柜內(nèi)的真空噴射器從這些油槽中抽吸空氣和廢油，并輸送到收集廢油的廢油罐中。Sincethelowerendoftheshaftextendsthroughthehousing,thelowerbearingsumpisexposedtothesurroundings.Thelowerslinger/spacer(item12)andlowerbearingretainer(item11)actasbarriersagainstenteringcontaminants.由于軸下端延伸穿過軸承座，下部軸承油槽暴露在周邊環(huán)境中。底部檔油環(huán)/墊片（部件12）和底部軸承托（部件11）可制止污染物的侵入。Theatomizingwheel(dwg.D0430-03018D)ismountedonthelowershaft,andthefeedmaterialtobeatomizedisintroducedintothewheelaroundthehubbymeansofafeedpipeanddistributorassembly(items17and18).Thisassemblyensuresthatthefeedisdistributedevenlyintheatomizerwheelviaanannularopeninginthedistributor.Also,asecondary,smallerfeedlineisprovided,foroptionaluseasdictatedbyspecificprocessrequirements(see“feedflush”cutoutdetailondwg.D0430-01100D).噴霧器轉(zhuǎn)盤（圖紙D0430-03018D）被安裝在底軸上，需要霧化的進(jìn)料通過進(jìn)料管和分派器裝置（部件17和18）導(dǎo)入轉(zhuǎn)盤。通過一種在分派器上的環(huán)形開口，使得進(jìn)料均勻分布在噴霧器轉(zhuǎn)盤上。本機(jī)也提供了較小的進(jìn)料管線，作為備選，由特殊工藝規(guī)定決定（參閱“進(jìn)料沖洗”局部詳圖，圖紙D0430-01100D）。 Theatomizerdesignalsoincludesprovisionsforpurgeairintroductionintotheatomizer(connectordetail“F”onabovedwg.),inordertominimizetheriskthathumidandcorrosiveprocessgasesenterintothemotorcavityarea.Finally,thedesignincorporatesprovisionsforintroducingsmallamountsofcleanrinsewater(seecutoutsentitled“wheelwash”and“shaftwash”ontheabovedwg.),whichservesthepurposeofcleaningcertainareasandpreventsolidsbuildupbetweenrotatingandnon-rotatingparts).為了減低潮濕和腐蝕性氣體進(jìn)入到電機(jī)腔室的風(fēng)險，噴霧器還配備了將吹掃空氣引入噴霧器的預(yù)留接口（見上述圖紙中連接器局部詳圖“F”），最后，設(shè)計還采用少量的清潔用水沖洗裝置（見上述圖紙中“轉(zhuǎn)盤沖洗”和“軸沖洗”），用于達(dá)成清潔某些區(qū)域的目的，并避免旋轉(zhuǎn)部件和非旋轉(zhuǎn)部件之間形成固體顆粒的堆積）。Astheatomizercannotbeinspectedorservicedinitsoperatingposition,itisnecessarytoprovideameansforextractingitperiodically.Also,thedesignisbasedontheprinciplethattheentireatomizerassemblypicksupthesmallvibrationsgeneratedbytherotatingparts,ratherthanbepickedupbythebearings.Theoperatingatomizerisaccordinglynotbolteddowninitsoperatingposition,butmountedbyitsownweightonthe“Resilientsupportassembly”(item46).Also,thesupportequipment(umbilicalhose,powercordandfeedhose)isconnectedviaflexiblehoses.Pleasereferencedwg.D0430-01036D,showingtheatomizermountedinthesupporttubeviathisresilientsupportassembly.Thesupporttubealsoservesthepurposeofprovidingprotectionoftheatomizerhousingfromthedirectexposuretothespraydryer’sprocessgases,whileallowingasmallamountofambientairinleakagetoventthroughtherotatingatomizerwheel.Ahoist,whichduringoperationshouldremainattachedtothesling(item43),allowsforeasyremovalandreinstallationoftheatomizer.由于不能檢查和維護(hù)在操作位置上的噴霧器，因此有必要提供一種方法方便定時將其取出。另外，本機(jī)設(shè)計原理基于由整個噴霧器裝置吸取轉(zhuǎn)動部件產(chǎn)生的微小振動，而不是通過軸承來吸取。因此，正在運(yùn)行的噴霧器沒有被螺栓固定在其操作位置上，而是通過其本身的重量被放置在“彈性支座組件”上（部件46）。另外，公用工程設(shè)備（母管、電源線和給料軟管）通過軟管連接。請參閱圖紙D0430-01036D，可見噴霧器通過彈性支座組件被安裝在支撐管上。支撐管也用于保護(hù)噴霧干燥器外殼，避免直接受工藝煙氣的直接影響，同時允許少量環(huán)境空氣滲入并通過旋轉(zhuǎn)噴霧器轉(zhuǎn)輪。在噴霧器運(yùn)行過程中，起吊裝置應(yīng)保持與吊索（部件43）相連，便于拆卸和重新安裝噴霧器。2.3. Atomizer(Motor)–Electrical噴霧器（電機(jī)）-電氣方面TheACinductionmotor,whichistheessentialpartofthehigh-speedatomizer,isa2-polesquirrelcagetypewithspeciallymodifiedconstructiontowithstandhighspeedandtoaccepthighfrequencyelectricalpower.Asinanyinductionmotor,thenominalspeed(N,rpm)issetbythefrequency(F,Hz)andcanbecalculatedasfollows:交流異步電機(jī)是高速噴霧器的重要構(gòu)成部分，它采用一種2極鼠籠式特別改裝構(gòu)造，能承受高速度和高頻率電源。對于任何異步電機(jī)，其額定轉(zhuǎn)速（N，RPM）由頻率（F，赫茲）決定，能夠按以下計算：N=[F(cyc/sec)x60(sec/min)]/[1(pairofpoles)]=F*60N=[F(周期/秒)x60(秒/分鐘)]/[1(對極)]=F*60At250Hzforexample,thenominalspeedis250x60=15,000RPM.Theactualmotorspeedisslightlylessbecauseofslipinherentinasquirrelcagemotor,typicallybyabout1%,dependingontheload.例如在250赫茲時，額定轉(zhuǎn)速為250×60=15000RPM。由于鼠籠式電機(jī)存在固有轉(zhuǎn)差率，實(shí)際電機(jī)轉(zhuǎn)速稍偏低，普通在1％左右，這取決于電機(jī)的負(fù)載。Itisabasiccharacteristicofasquirrelcagemotorthatthemaximumcurrentratingofthemotor(fullloadamps)willproduceacertainmaximumamountoftorqueregardlessofthemotorspeed.Exceedingthistorquecausesexcessivemotorcurrent,whichinturncausesoverheatingofthewindingsandprematurefailureoftheelectricalinsulation.Themotoristhereforeaconstantmaximumtorquemachine.鼠籠電機(jī)的基本特性是，無論電機(jī)的轉(zhuǎn)速是多少，最大的電機(jī)額定電流（滿載安培）會產(chǎn)生某一最大扭矩值。超出此扭矩會造成電機(jī)電流過大，從而造成繞組過熱和電氣絕緣過早失效。因此，該電機(jī)為恒定最大扭矩機(jī)器。Thehorsepowerdevelopedbyamotoristheproductofthetorquetimestherotationalspeed.Sincethismachineisvariablespeed,constantmaximumtorque,itfollowsthatthemaximumhorsepower,P,isinproportiontothespeed.Toillustrate,thestandardK-SModel900machineisratedatapoweroutputof75HPatanominalspeedof16,200RPM,andwilldrawabout96Ampsattheseconditions.Thismaximumloadcorrespondstoabout32gpmoffeedslurry.電機(jī)功率是轉(zhuǎn)矩乘以轉(zhuǎn)速的乘積。由于該機(jī)器的速度是可變的，為恒定最大扭矩，就可得出，最大功率P與速度正成比，為了闡明這一點(diǎn)，原則K-S型號900機(jī)器的額定輸出功率為75馬力，額定轉(zhuǎn)速為16200RPM, 在這些條件下產(chǎn)生安培值約為96。這個最大負(fù)載對應(yīng)約32GPM（加侖每分鐘）給料石灰漿。At12,000RPM,thestandardmaximumpoweroutputis:在12,000RPM轉(zhuǎn)速下，原則最大功率輸出為：P=75HPx(12,000/16,200)=55HPNotethatatthisstandardmaximumhorsepowercondition,themotorwillstilldraw96Amps,whichisitsstandardfullloadcurrentrating.Thecorrespondingmaximumloadatthisreduced-speedconditioncorrespondstoabout38gpmoffeedslurry.請注意，在這個原則最大功率條件下，電機(jī)仍然產(chǎn)生96安培，這是其原則的滿負(fù)荷額定電流。在此減速條件下對應(yīng)最大載荷約為38GPM（加侖每分鐘）給料石灰漿。Animportantfacttobeconcludedfromtheaboveisthatunderalloperatingconditionsthemotorcurrentistheonlymeasuretoinsurethemotorisbeingkeptwithinitsrating,andrequiresmonitoringanddevicestoprotectthemachinefromovercurrent.CurrentmonitoringisaccomplishedinternaltotheVFD.ShouldthecurrentexceedthelimitssetintheVFDsetup,aVFDfaultwilloccur.從以上可得出一種重要事實(shí)結(jié)論是，在全部工況條件下，為確保電機(jī)保持在其額定值范疇內(nèi)，電機(jī)的電流是唯一的衡量原則，并規(guī)定設(shè)立監(jiān)測裝置并配備過流保護(hù)裝置。在VFD內(nèi)部可實(shí)現(xiàn)電流監(jiān)控。如果電流超出了變頻器設(shè)定的極限值，就會產(chǎn)生VFD故障。Anothercharacteristicofthismotoristhatinoperatingwithvaryingfrequenciesandspeeds,theappliedvoltagemustalsovaryinproport