HXTW-5測(cè)溫探針說明書(中英文)

目錄第一章前言.................................................11.1概述..............................................11.2工作過程..........................................11.3常規(guī)設(shè)計(jì)探針的主要技術(shù)參數(shù)........................1 第二章結(jié)構(gòu)................................................22.1傳動(dòng)支承系統(tǒng)......................................22.2測(cè)溫與控制系統(tǒng)....................................32.3位置顯示與信號(hào)輸出系統(tǒng)............................32.4探管冷卻系統(tǒng)......................................42.5操作與顯示儀表系統(tǒng)................................4 第三章安裝及調(diào)整..........................................43.1安裝就位..........................................43.2冷卻與密封管路....................................53.3電氣與儀表接線....................................53.4啟動(dòng)前的檢查......................................53.5手操運(yùn)行與試運(yùn)行..................................63.6位置顯示與信號(hào)輸出儀表及電位計(jì)的調(diào)整..............6 第四章運(yùn)行與維護(hù)..........................................64.1第一次投用........................................64.2日常運(yùn)行.........................................64.3使用前的檢查......................................74.4潤(rùn)滑..............................................74.5電位計(jì)的調(diào)整......................................74.6電位計(jì)彈簧的更換...................................74.7熱電偶的更換.......................................74.8動(dòng)力線、冷卻膠管的調(diào)整.............................84.9輔助托架的調(diào)整.....................................84.10探頭除垢...........................................8 第一章前言1.1概述HXTW-5型測(cè)溫探針（圖1）是一種將熱電偶送入爐膛，監(jiān)測(cè)爐膛煙氣溫度的機(jī)械裝置(圖1)。熱電偶固定在探槍頭部，在煙氣中作伸縮運(yùn)動(dòng)，移動(dòng)速度2.5米／分左右。測(cè)溫探針由一個(gè)1.1KW電機(jī)驅(qū)動(dòng)，可近操、遠(yuǎn)操和由DCS監(jiān)控。鍋爐啟動(dòng)期間，位于爐膛出口處的再熱器管束由于沒有循環(huán)蒸汽進(jìn)行冷卻，其溫度可能達(dá)到甚至超過材料耐溫極限值。測(cè)溫探針作為鍋爐啟動(dòng)時(shí)的煙溫監(jiān)測(cè)裝置，用來連續(xù)測(cè)量該區(qū)域的溫度，避免了再熱器被燒壞的危險(xiǎn)。測(cè)溫探針還可用來測(cè)量鍋爐低負(fù)荷運(yùn)行時(shí)的煙氣溫度，作為輔助控制手段。1.2工作過程探針啟動(dòng)后，跑車推動(dòng)探槍前進(jìn)，裝在探槍內(nèi)的熱電偶被送進(jìn)爐膛，將測(cè)得的溫度信號(hào)傳送到DCS，位置信號(hào)系統(tǒng)同時(shí)將熱電偶所在位置的信號(hào)也傳送到DCS。探針本體上的控制箱，可操作按鈕控制探針前進(jìn)、后退或停在任意位置，測(cè)量該點(diǎn)的溫度。探針啟動(dòng)后，當(dāng)探針前進(jìn)至觸及前端行程開關(guān)時(shí)，探槍會(huì)停在最前端，測(cè)量最前端的溫度。當(dāng)爐內(nèi)煙溫達(dá)到第一設(shè)定值(TS-1)時(shí)，冷卻系統(tǒng)會(huì)自動(dòng)開啟，對(duì)探槍進(jìn)行冷卻。當(dāng)煙溫升到第二設(shè)定值(TS-2)時(shí)，探針報(bào)警并自動(dòng)退回。當(dāng)觸及后端行程開關(guān)時(shí)，運(yùn)行停止，冷卻系統(tǒng)亦停止工作。以上是有冷卻系統(tǒng)的探針，沒有冷卻系統(tǒng)的探針則無開啟和關(guān)閉冷卻系統(tǒng)的過程。1.3電站鍋爐常規(guī)設(shè)計(jì)探針的主要技術(shù)參數(shù)行程按合同測(cè)溫范圍按合同熱電偶型號(hào)WRGKK2—131—HBS5001IELB(L一熱電偶長(zhǎng)度，㎜)探管材質(zhì)1Crl8Ni9Ti探管外徑￠89探管移動(dòng)速度~2.5m/min位置顯示與信號(hào)輸出儀表參數(shù)(推薦)4~20mA0~100％刻度溫度顯示輸出儀表參數(shù)(推薦)4~20mA0~800℃刻度或K分度電動(dòng)機(jī)Y90L--6B5型1.1KW~910r.p.m近似重量~300k+每米行程115kg第二章結(jié)構(gòu)測(cè)溫探針由傳動(dòng)支承系統(tǒng)、測(cè)溫與控制系統(tǒng)、位置顯示與信號(hào)輸出系統(tǒng)、探管冷卻系統(tǒng)、操作與顯示儀表系統(tǒng)等幾部分組成。2.1傳動(dòng)支承系統(tǒng)HXTW-5型測(cè)溫探針的傳動(dòng)支承系統(tǒng)連接并保護(hù)著探針的所有零部件，主要功能是將熱電偶送入和退出爐膛。探針的行程由安裝在梁兩端的行程開關(guān)控制。HXTW-5探針的傳動(dòng)支承系統(tǒng)與本公司的HXC-5系列吹灰器的外形結(jié)構(gòu)尺寸相近，部分零件通用。傳動(dòng)支承系統(tǒng)包括梁、跑車、探槍、分接箱、滑輪架、輔助托架、墻箱等部件。(1)梁梁是一個(gè)箱蓋式部件，對(duì)所有零部件提供支承和防護(hù)，跑車運(yùn)行的軌道和齒條就裝在梁的兩側(cè)。梁兩端有端板，前端板上裝有支承托架。梁由兩點(diǎn)支承，前端與固定在鍋爐上的墻箱栓接，后端支吊在鋼架上。(2)跑車電動(dòng)跑車與探槍連接，驅(qū)動(dòng)探槍前進(jìn)和后退。跑車包括一個(gè)1.1KW的大法蘭電機(jī)(Y90L-6-B5型)和一個(gè)由一級(jí)齒輪、一級(jí)蝸輪蝸桿減速的減速箱，減速箱輸出軸兩端的小齒輪與梁兩側(cè)的齒條嚙合，得以完成伸縮運(yùn)動(dòng)。(3)探槍探槍管由合金鋼管焊成，分不冷卻、空氣冷卻、水冷卻三種形式（圖3）。熱電偶裝在探管內(nèi)，其頭部固定在探槍的前端，前端有保護(hù)套——探頭。探頭前端密封，后端有螺紋與探管連接。探頭對(duì)熱電偶起保護(hù)作用，防止熱電偶損壞。探槍尾部為接口件，熱電偶引線通過與探管連接的接口件接到接線盒上。接口件上鉆孔攻絲，用以裝填料密封。設(shè)備運(yùn)行時(shí)，導(dǎo)線把熱電偶從爐內(nèi)發(fā)出的溫度信號(hào)傳送到位于梁中間的分接箱上。儀表導(dǎo)線也接在分接箱上。需用空氣或水冷卻的探管尾部有空氣（或水）的入口，探管前部有四個(gè)噴嘴，在管子上呈180。分布，軸向相距300毫米，呈45°后傾角，這樣使冷卻空氣（或水）避開探管前端，保證測(cè)溫的精確性。探管內(nèi)的冷卻空氣或水由分接箱提供。(4)分接箱分接箱位于梁的中部，電機(jī)電纜、熱電偶引出線、冷卻介質(zhì)的膠管從跑車通過滑輪架栓接到了分接箱上。(5)滑輪架滑輪架是一組動(dòng)滑輪，裝在梁內(nèi)，位于跑車的后面，由跑車牽引前進(jìn)和后退。它將動(dòng)力電纜、補(bǔ)償導(dǎo)線、冷卻介質(zhì)膠管等有序的排在滑輪架的滾輪上。其動(dòng)作原理如圖4所示。(6)墻箱墻箱是探針本體與鍋爐爐墻接口箱的連接件，也是探針的前支承點(diǎn)。墻箱分正壓墻箱和負(fù)壓墻箱。正壓墻箱裝在正壓鍋爐上，需要連接密封空氣對(duì)爐墻開孔進(jìn)行密封。負(fù)壓鍋爐上的負(fù)壓墻箱則不用密封空氣。2.2測(cè)溫與控制系統(tǒng)測(cè)溫與控制系統(tǒng)包括探槍內(nèi)的鎧裝熱電偶，連接熱電偶到分接箱的補(bǔ)償導(dǎo)線和電氣控制箱。鎧裝熱電偶為雙支式，外徑3毫米，隨測(cè)溫范圍要求的不同、熱電偶的材質(zhì)不同，電站鍋爐上用的多為鎳鉻—鎳硅熱電偶(K分度)。探針上裝的熱電偶上都帶有銘牌，購(gòu)置備品時(shí)，一定要按銘牌上的型號(hào)規(guī)格購(gòu)買。雙支熱電偶的一支直接送集控室，由用戶取信號(hào)進(jìn)行溫度顯示和作其它用。另一支接在位于探針本體報(bào)警繼電儀（或溫度變送器）上，根據(jù)要求，控制探針的運(yùn)行或在報(bào)警繼電儀上直接進(jìn)行溫度設(shè)置(TS－1和TS－2)。探針是否需要冷卻與測(cè)溫探針的測(cè)溫范圍與行程有關(guān)。我們將根據(jù)合同要求，確定探針是否需要冷卻和采用什么方式冷卻。電氣控制箱裝在梁的側(cè)面，左控探針位于梁的左側(cè)、右探探針位于梁的右側(cè)。該控制箱除具有伸入、返回、停止按鈕功能外，還留有和上位控制裝置及DCS聯(lián)絡(luò)接口：(1)至上位控制裝置、DCS開關(guān)量信號(hào):①探針返回到位②探針伸入到位③遠(yuǎn)操允許④近操允許(2)至上位控制裝置、DCS其它信號(hào):①溫度信號(hào)(K分度或4-20mA)②位置信號(hào)4-20mA(3)上位控制裝置、DCS至控制箱的開關(guān)量信號(hào)①探針伸入②探針返回③探針停止2.3位置顯示與信號(hào)輸出系統(tǒng)(參看圖5、圖8)該系統(tǒng)由一只10圈電位計(jì)和位置顯示與信號(hào)輸出儀表組成。10圈電位計(jì)鑲嵌在卷簧輪上，與卷簧輪同步。在卷簧輪旋轉(zhuǎn)的同時(shí)，10圈電位計(jì)也同步旋轉(zhuǎn)，改變了儀表輸入端阻值，使位置儀表顯示值和輸出值也相應(yīng)變化，從而使探針在原始位置時(shí)顯示0％零刻度---輸出4mA。在探針到達(dá)行程最終端后顯示100％刻度---輸出20mA。位置顯示與信號(hào)輸出儀表為智能數(shù)顯萬能信號(hào)輸入儀表。出廠時(shí)，已調(diào)整設(shè)定完畢。儀表（以上潤(rùn)儀表為例）的調(diào)整設(shè)定步驟如下(圖5):(1)探針在初始位置時(shí)，取下鑲嵌在卷簧輪上10圈電位計(jì)，將電位器調(diào)到16歐姆后，將其重新鑲嵌到卷簧輪上。合上控制電源、動(dòng)力電源、這時(shí)位置信號(hào)儀表的讀數(shù)應(yīng)為“0.0”，否則要進(jìn)行修改。按一下‘SET’，鍵顯示‘CLK’，再按一下‘SET’鍵，顯示數(shù)字。修改數(shù)字使CLK=132后同時(shí)按下‘SET’鍵、‘▲’鍵，5秒后儀表即進(jìn)入二級(jí)參數(shù)設(shè)定狀態(tài)，連續(xù)按‘SET’鍵，直至出現(xiàn)‘SLL’(測(cè)量量程下限)后的數(shù)字，修改數(shù)字。假如儀表顯示為‘10’時(shí)，則應(yīng)將SLL內(nèi)的數(shù)字減掉‘10’；如果為‘一10’則應(yīng)將SLL內(nèi)的數(shù)字加上‘10’，修改完后母按下‘SET’鍵保存，按下W標(biāo)志鍵(復(fù)位鍵)后觀察儀表顯示字，如果仍不為零，照前所敘繼續(xù)修改，直至儀表顯示數(shù)字為零。(2)按下“伸入”按鈕，將探針啟動(dòng)運(yùn)行直至探針碰撞前限開關(guān)后停止。觀察位置儀表顯示的數(shù)字應(yīng)為‘100’，如果不為‘100’則應(yīng)進(jìn)行修改。如前所述，讓儀表進(jìn)入二級(jí)參數(shù)設(shè)定狀態(tài)，連續(xù)按下‘SET’鍵直至出現(xiàn)‘SLH’測(cè)量量程上限，修改‘SLH’內(nèi)的數(shù)字。顯示的數(shù)字比100小多少，修改時(shí)就加多少；顯示的數(shù)字比100大多少，修改時(shí)就減多少。每次修改完后都應(yīng)按下‘SET’鍵保存，再按下W標(biāo)識(shí)鍵(復(fù)位鍵)，反復(fù)幾次直至出現(xiàn)‘100’。這樣前限位置設(shè)置就修改完畢。(3)當(dāng)儀表顯示值升降方向與電位計(jì)升降方向相反時(shí)，請(qǐng)將儀表上13、15兩個(gè)端子的線互換。2.4探管冷卻系統(tǒng)當(dāng)探針超過一定的行程和測(cè)溫范圍時(shí)，裝有冷卻系統(tǒng)。探管冷卻系統(tǒng)由電控閥門、膠管和壓力開關(guān)等組成，用以向探管內(nèi)送入空氣或水進(jìn)行冷卻，防止探管在高溫下彎曲或被燒壞。電控閥門控制冷卻介質(zhì)的通和斷，膠管輸送冷卻介質(zhì)到探管內(nèi)。壓力開關(guān)為保護(hù)探管有足夠冷卻流量而設(shè)置。當(dāng)冷卻介質(zhì)壓力過低，冷卻流量不能保證探管的安全時(shí)，則探針不能啟動(dòng)或伸出的探槍馬上退回。2.5操作與顯示儀表系統(tǒng)本系統(tǒng)指集控室內(nèi)控制盤上的控制開關(guān)(或按鈕)、溫度顯示儀表、位置顯示儀表和報(bào)警裝置等有關(guān)儀表，參數(shù)見第一章。本系統(tǒng)有關(guān)的電氣元件和儀表本公司不供。由用戶根據(jù)集控室的總體設(shè)計(jì)，選用合適的儀表和有關(guān)電氣元件，進(jìn)行控制盤面的設(shè)計(jì)。第三章安裝與調(diào)試3.1安裝就位：安裝探針，應(yīng)根據(jù)本公司提供的安裝圖(圖2)和鍋爐廠的有關(guān)圖紙，決定探針在鍋爐上的安裝部位。每一探針由梁上的兩點(diǎn)懸掛支吊。熱態(tài)時(shí)，探針應(yīng)處于水平狀態(tài)。注意：起吊探針時(shí)，一定要使用梁上的四個(gè)吊耳，不能用鏈條、鋼纜等纏在梁上起吊，以免損壞設(shè)備，引起故障。注意：探針安裝就位后，方能拆除包裝架，否則，容易對(duì)設(shè)備造成損壞。前支承：用兩個(gè)螺紋銷將探針梁前端耳板固定在墻箱的孔內(nèi)，組成探針的前支承。墻箱為鑄鋼件，通過鍋爐爐墻上的接口套管與鍋爐連接。在將探針裝到墻箱上之前，先把墻箱焊到套管上。后支吊：在梁的兩側(cè)焊上帶橢圓孔的支吊耳板，支承長(zhǎng)軸穿在兩耳板的長(zhǎng)孔內(nèi)，組成了探針的后端支承。圓鋼的外面套有鋼管，鋼管上焊有鋼板和2只M24螺柱用于支吊。支吊耳板根據(jù)平臺(tái)鋼架的位置，現(xiàn)場(chǎng)與梁焊接，距梁后端約1～1.4米。探針的前后支承組成一個(gè)萬向節(jié)型的機(jī)構(gòu)，使探針能承受鍋爐在所有三個(gè)方向的膨脹與收縮。注意：安裝探針的后支吊時(shí)，應(yīng)使支承長(zhǎng)軸位于橢圓長(zhǎng)孔的后端（遠(yuǎn)離爐墻端），使之能適應(yīng)鍋爐熱態(tài)時(shí)的膨脹注意：探針一定要支承或懸吊在鋼梁上，根據(jù)鋼梁位置，現(xiàn)場(chǎng)焊接后端支吊耳板。要采用適當(dāng)?shù)暮附臃椒ê拖鄳?yīng)的保護(hù)手段。保證梁內(nèi)的電纜不被烤壞。探針安裝前和安裝后，都應(yīng)進(jìn)行檢查，處理好在運(yùn)輸，裝卸和安裝過程中對(duì)設(shè)備可能造成的損壞。探針調(diào)試前，應(yīng)清除現(xiàn)場(chǎng)的雜物和包裝用品。3.2冷卻與密封管路有冷卻系統(tǒng)的探針，啟用前，將冷卻介質(zhì)的管道與探針連接。連接前，應(yīng)吹盡管內(nèi)所有雜物，防止臟物、鐵皮和焊渣等進(jìn)入探管。正壓鍋爐上安裝探針時(shí)，應(yīng)接有密封空氣和風(fēng)幕空氣的管路，并要有足夠的壓力和流量保證鍋爐在任何負(fù)荷下都能密封。3.3電氣與儀表接線探針的動(dòng)力電源，控制線路，位置顯示儀表，溫度顯示儀表分別接自探針的不同部位(圖6)。動(dòng)力電源、控制線路在控制箱上接線。位置顯示儀表安裝在控制箱內(nèi)。3.4啟動(dòng)前的檢查觀察梁的外觀直線度，檢查是否有彎曲、扭曲或其它變形；檢查探頭在運(yùn)輸和裝卸過程中是否造成損壞；在正壓鍋爐上安裝時(shí)，檢查密封空氣和風(fēng)幕空氣的管路是否接通；采用空氣或水冷卻的探針，檢查軟管接頭的密封性；檢查所有動(dòng)力、控制線路、熱電偶等所有終端接線是否牢固；檢查行程開關(guān)的拔叉是否在正確位置；參考圖9，保證所有的電纜、鋼絲蠅和膠管都在各自的滑輪上并至少有80毫米下垂，但不能垂到梁的底面以下；探針運(yùn)行前，參照第五章的潤(rùn)滑說明進(jìn)行潤(rùn)滑；取下位置轉(zhuǎn)換器內(nèi)的鎖定螺栓。注意：探針試運(yùn)行時(shí)，一定要按照位置信號(hào)轉(zhuǎn)換器內(nèi)警示牌上的說明操作，否則會(huì)損壞位置轉(zhuǎn)換器。警示牌如圖7所示：3.5手操運(yùn)行與試運(yùn)行警告：任何時(shí)候．手操運(yùn)行前務(wù)必切斷電源。探針進(jìn)行完啟動(dòng)前的所有檢查，并確信無問題后，方可進(jìn)行手操試運(yùn)行。手操運(yùn)行可用棘輪扳手轉(zhuǎn)動(dòng)跑車電動(dòng)機(jī)的方柄進(jìn)行。手操運(yùn)行主要檢查探針的各機(jī)構(gòu)（跑車、滑輪架、托輪、探槍等）的運(yùn)行是否正常，有無卡澀，滑輪架的電線，電纜，膠管等是否需要調(diào)整。手操運(yùn)行也常用于設(shè)備的維護(hù)、保養(yǎng)或故障時(shí)將探槍從爐內(nèi)退出。手操運(yùn)行一切正常后，檢查行程開關(guān)拔叉處在正確位置后，方可通電試運(yùn)行。試運(yùn)行時(shí)，先將跑車手操前進(jìn)一定距離后再通電，主要檢查所有電氣接線（行程開關(guān)、電動(dòng)機(jī)）是否正確。試運(yùn)行調(diào)試傳動(dòng)系統(tǒng)的機(jī)械、電氣一切正常后，再對(duì)冷卻系統(tǒng)、測(cè)溫系統(tǒng)、位置顯示與信號(hào)輸出系統(tǒng)進(jìn)行調(diào)整。3.6位置顯示與信號(hào)輸出儀表及電位計(jì)的調(diào)整位置顯示與信號(hào)輸出儀表和電位計(jì)在出廠前已調(diào)整設(shè)定完畢，無需再動(dòng)。但有時(shí)在運(yùn)輸和安裝過程中不慎將鋼絲繩弄松馳，這樣在調(diào)整和緊固鋼絲繩后，須將位置顯示與信號(hào)輸出儀表和電位計(jì)重新調(diào)整、設(shè)定。調(diào)整設(shè)定的步驟參看2.3的有關(guān)敘述。運(yùn)行與維護(hù)探針一般只在鍋爐點(diǎn)火啟動(dòng)時(shí)使用，每次使用時(shí)間不長(zhǎng)，但每次間隔往往很久。在使用中，要特別注意以下幾點(diǎn)：第一次投用第一次正式投用前務(wù)必進(jìn)行試運(yùn)行、調(diào)試。參照具體電路圖，確保所有電氣接線、熱電偶接線正確無誤。對(duì)用空氣或水冷卻的探針，保證有足夠的壓力和冷卻流量。對(duì)正壓鍋爐，保證爐墻接口處密封空氣的接通，并有足夠的壓力和流量。投用時(shí)，注意監(jiān)視行程和溫度的變化，發(fā)現(xiàn)異常，及時(shí)檢查并消除。特別當(dāng)溫度達(dá)到報(bào)警溫度和返回溫度時(shí)，觀察系統(tǒng)是否及時(shí)報(bào)警，探針是否返回。4.2日常運(yùn)行探針的電氣線路是按探槍行至最前端，行程開關(guān)動(dòng)作后探槍停止而不退回，達(dá)到溫度后探槍才退回而設(shè)計(jì)的。鍋爐啟動(dòng)期間，由于溫度分布的不均勻，探槍頭所處的位置不一定是溫度最高位置。因此有必要每隔一定時(shí)間，遠(yuǎn)操探針進(jìn)行伸縮運(yùn)動(dòng)，了解爐內(nèi)溫度分布的情況，最好將探頭停在溫度最高點(diǎn)，防止局部出現(xiàn)的超溫現(xiàn)象。在接近報(bào)警溫度時(shí)，更要注意這一點(diǎn)。注意：探針伸入爐內(nèi)后不得切斷控制箱及溫度測(cè)量、控制系統(tǒng)的電源，以免達(dá)到極限溫度后，探槍不能自動(dòng)退回而被燒壞。4.3使用前的檢查每次使用前，因間隔時(shí)間較長(zhǎng)，應(yīng)到現(xiàn)場(chǎng)對(duì)探針進(jìn)行檢查和必要的維護(hù)，及時(shí)消除存在的問題，清除探頭上可能存在的污垢（見4.10），并進(jìn)行試車。保證機(jī)械運(yùn)行系統(tǒng)和位置信號(hào)系統(tǒng)、冷卻系統(tǒng)的可靠性，絕對(duì)不能事前不進(jìn)行維護(hù)檢查就投用。否則，容易損壞設(shè)備，發(fā)現(xiàn)問題也來不及處理了。4.4潤(rùn)滑潤(rùn)滑部位潤(rùn)滑劑附注中國(guó)標(biāo)準(zhǔn)MObil跑車齒輪減速箱3～4kgN460GB3141N68GB3141MobilSHC634MobilSPC626溫度＞0℃溫度≤0℃前支承MoS2鋰基潤(rùn)滑脂MolilgreaseSpecial齒條的齒面緊固件螺紋等MoS2(0#)+2#防銹油GB4879刷涂或浸泡4.5電位計(jì)的調(diào)整位置轉(zhuǎn)換器內(nèi)電位計(jì)軸的最大轉(zhuǎn)數(shù)為十圈，而行程最大的探針僅需用8圈。探針彈簧纏繞如圖8所示，在卷簧輪的上部，則先將電位計(jì)逆時(shí)針轉(zhuǎn)到極限(從軸端看)，然后順時(shí)針倒轉(zhuǎn)半圈后安裝。注：調(diào)整電位計(jì)在探槍完全縮回時(shí)進(jìn)行。4.6電位計(jì)彈簧的更換電位計(jì)彈簧是一個(gè)恒轉(zhuǎn)矩動(dòng)力彈簧，在探槍縮回時(shí)，驅(qū)動(dòng)卷線輪卷緊鋼絲繩。當(dāng)它損壞時(shí)，按如下步驟更換：從位置轉(zhuǎn)換器盒內(nèi)取出彈簧和卷簧輪。如圖8所示，將新彈簧纏繞在張緊輪上。將彈簧固定在卷簧輪上并纏轉(zhuǎn)4—5圈，裝上鎖定螺栓，重新放入位置轉(zhuǎn)換器盒內(nèi)。注：彈簧按原卷曲方向纏繞在張緊輪上，與卷簧輪上的卷曲方向相反。固定卷線輪，將鋼絲繩盤到卷線輪上，探槍完全縮回時(shí)，鋼絲繩是收緊的，盤好鋼絲繩后，卸下鎖定螺栓，按2.3所述，調(diào)整電位計(jì)。4.7熱電偶的更換警告：操作前，切斷動(dòng)力，控制電源。警告：正壓鍋爐上抽出探槍前，開啟風(fēng)幕閥，對(duì)墻箱進(jìn)行風(fēng)幕密封。注意：更換的新熱電偶，應(yīng)和原熱電偶銘牌上所標(biāo)注的型號(hào)、規(guī)格一致。(1)更換熱電偶前，有必要進(jìn)行下列檢查，證明熱電偶確已損壞，必須更換：A、檢查所有導(dǎo)線是否有斷線，所有電線接頭是否有松動(dòng)。B、鍋爐運(yùn)行時(shí)，將探槍伸入爐內(nèi)約300毫米的高溫?zé)煔庵?，觀察溫度讀數(shù)是否升高。C、檢查溫度儀表是否完好，如溫度儀表也是好的，則熱電偶確實(shí)損壞。D、熱電偶為雙支式（四根熱電偶線前端焊在一起），更換其它線看是否全部損壞。（2）更換熱電偶時(shí)，首先卸開熱電偶后端導(dǎo)線；（3）空冷和水冷探針，卸下探槍尾部接口件上部的軟管接頭蓋板，使接口件能從跑車箱殼中抽出；（4）卸下探槍與跑車連接的螺栓，前移探槍將其全部從跑車前端抽出，然后下落探槍并將其前端從墻箱中抽出，在跑車附近和前支承附近托住探槍；注意：探槍從滾輪上落下時(shí)，保護(hù)探頭不受損壞；(5)卸下探槍前端的探頭，取出襯套和密封墊。將一根細(xì)鐵絲固定在舊熱電偶頭部。(6)旋下探槍后端蓋板（或接口件）并將其和舊熱電偶一起從探管后端拉出，同時(shí)鐵絲也被拉出；將舊熱電偶和填料螺母機(jī)構(gòu)從后蓋板（或接口件）上卸下；(7)將新熱電偶穿過后蓋板（或接口件），將其頭部與鐵絲粘在一起，將熱電偶從探管前端拉出（后端注意導(dǎo)向、推送）；裝好后部及熱電偶自帶的新填料螺母機(jī)構(gòu)；(8)在熱電偶頭部裝入新的密封墊和原襯套，調(diào)整熱電偶，使伸出部分長(zhǎng)度約40毫米。用“G”型二硫化鉬潤(rùn)滑脂潤(rùn)滑探頭的螺紋，上緊探頭；注：密封墊的錐形面朝向探管后端。(9)按與拆卸相反的順序重新裝上探槍。4.8動(dòng)力線、冷卻膠管的調(diào)整鋼絲繩、動(dòng)力電纜和冷卻膠管的安裝見圖9。電纜線、冷卻膠管至少下垂80毫米，但不能垂到梁的底平面以下。4.9輔助托架的調(diào)整定期檢查，保證探槍在前進(jìn)和后退時(shí)，輔助托架動(dòng)作靈活、準(zhǔn)確、可靠。必要時(shí)，重新調(diào)整輔助托架。4.10探頭除垢注意：正壓鍋爐運(yùn)行時(shí)，不能進(jìn)行探頭人工除垢。正壓鍋爐停爐或在負(fù)壓鍋爐上，除垢步驟如下：(1)切斷電源，卸下側(cè)板后部的兩個(gè)擋塊，搖動(dòng)跑車方柄，退出探槍，直到探頭露出；注意：不能讓探頭從前托輪處落下。(2)用小刀或其它利器刮凈探頭；(3)除垢后，將探槍對(duì)準(zhǔn)墻箱密封板，搖動(dòng)跑車上的方柄，使探頭送入墻箱；(4)重新裝上擋塊。CONTENTSSECTION1FOREWORDGeneralDescription…………PrinciplesofOperation…………………….MainTechnicalDataforNormalDesignedThermalProbe…………….SECTION2MAINCOMPENENTS2.1DriveandSupportingSystem………………2.2TemperatureMonitoringandControlSystem…………2.3PositionIndicatorandSignalOutput……….2.4ProbeTubeCoolingSystem………………….2.5OperationandInstrumentation……………….SECTION3INSTALLATIONANDCOMMISSIONING3.1InitialInstallation………………..3.2CoolingPipingandSealingAirLine…………3.3ElectricalandInstrumentWiring…………..…………………3.4InspectionbeforeStart-up…………………….3.5ManualRunandTestRun…………………….3.6PositionIndicatorandPotentiometerAlignment…………….SECTION4OPERATIONANDMAINTENANCE4.1InitialOperation…………………4.2DailyOperation…………………4.3InspectionbeforeStart-up………4.4Lubrication……………………….4.5PotentiometerAlignment………..4.6PotentiometerSpringReplacement…………….4.7ThermocoupleReplacement…………………….4.8PowerandCoolingsystem………4.9AuxiliarySupportAdjustment…………………….4.10ProbeTipCleaning………………SECTION1FOREWORDGeneralDescriptionTheHXTW-5thermalprobeisamechanicaldeviceforpositioningathermocoupleelementinthefurnacegasstreamfortemperaturemonitoring.RefertoFigure1foranoverallview.Thethermocoupleismountedintheendofaprobetubewhichtravelsforwardandbackwardinthegasstreamandtheprobetubemovesatanominalspeedof2.5mperminute.Thethermalprobeiselectricmotordrivenandcanbecontrolledbyalocalorremotepush-buttonstationoranautomaticpanel(DCS).Gastemperaturesintheareajustaheadofthesuperheatertubesattheexitofthefurnacemayreachorevengobeyondthecriticaltemperatureofmaterialduringboilerstart-upassteamcirculationisnotsufficientforcooling.Thethermalprobe,inpermittingcontinuousmonitoringofthesetemperatures,greatlyreducesthedangerofheatdamagetothetubes.Thethermalprobecanalsobeusedtoobtaingastemperatureswhichareusedasanaidincontrollinglowloadoperation.PrinciplesofOperationAfterthethermalprobestarted,theprobetubemovesforwardbythedrivecarriage,andthethermocoupleinsideoftheprobetubeisextendedintofurnace,whichsendstemperaturesignaltoDCS,meanwhile,thepositionindicatorsendsthepositionsignalofthethermocoupletoDCS.Pressingthepushbuttononthecontrolboxonthebodyofthermalprobecancontrolprobetubemovingforward,backwardorstoppingatanypointwithtemperaturemonitoring.Withprobebeingstarted,theprobetubemovesforwarduntilithitsthelimitswitchatthefrontend,thentheprobetubestopsatthespot,monitoringtemperature.Asthetemperatureinthefurnacereachesthefirstsetpoint(TS-1),thecoolingsystemoperatesautomaticallywhichsuppliescoolingforprobetube.Asthetemperaturereachesthesecondsetpoint(TS-2),thethermalprobeenablesanalarmwhileretracting,andwhenithitsthelimitswitchatthebackend,movementstops,sodoesthecoolingsystem.Aboveisthetypeofthermalprobewithcoolingsystem,forthethermalprobewithoutcoolingsystem,therearenotstartingorshutoffofcoolingsystem.MainTechnicalDataforNormalDesignedThermalProbeforPowerPlantTravelAsContractedTemperatureMonitoringRangeAsContractedThermocoupleModelWRGKK2-131-HBS5001IELB(where,Lmeansthelengthofthermocouple,mm)ProbeTubeMaterial1Cr18Ni9TiTubeOutsideDiameterΦ89TubeTravelSpeed~2.5m/minPositionIndicatorandSignaloutput4~20mA0~100%calibration(Recommended)TemperatureIndicatoroutput4~20mA0~800℃calibration,orKscale(Recommended)ElectricMotorModel:Y90L-6B5,1.1KW,~910r.p.mWeight(approx.)~300kg+115kgpermeteroftravelSECTION2MAINCOMPENENTSThethermalprobeconsistsofDriveandSupportingsystem,TemperatureMonitoringandControlSystem,PositionIndicatorandSignalOutputSystem,ProbeTubeCoolingSystemandOperationandInstrumentation.2.1DriveandSupportingSystemThedriveandsupportingsystemofHXTW-5thermalprobeconnectsandprotectsallpartsandcomponentsoftheprobe,whosemainfunctionisdrivingthethermocoupleintoandoutofthefurnace.Thetraveloftheprobeliesonbothlimitswitchesmountedateachendofthebeam.ThedriveandsupportingsystemofHXTW-5thermalprobeissimilartotheHXC-5sootblower,asregardsconfigurationanddimensionsandsomepartsareshared.Thedriveandsupportingsystemincludes:BeamAssembly,CarriageAssembly,ProbeTube,ManifoldBlock,RollerBracket,AuxiliarySupportandWallboxandsoon.BeamAssemblyTheBeamassemblyisacanopytypefabricationthatofferssupportandmaximumprotectionforallcomponentsoftheHXTW-5thermalprobe.Therailsandracksforcarriagetravelingaremountedatbothsidesofthebeam.Bulkheadsoneachendofthebeamstiffenthebeamattherearandprovideamountingatthefrontforthefrontsupportbracket.Thebeamissupportedbysuspensionattwopoints.Thefrontsupportisatthewallboxwhichisaffixedtotheboiler.Therearsupportislocatedneartherearofthebeamandisaffixedtothebuildingsteel.CarriageAssemblyTheprobetubeisdrivenforwardandbackwardbymeansofatravelingmotortypecarriage.Thecarriageconsistsofa1.1KWflangemountedelectricmotor(ModelY90L-6-B5)andagearreducerwithfirstgradegearandfirstgradewormandwormwheel.Drivepinionsoneachendofthegearreduceroutputshaftengagetheracksoneachsideofthebeam.ProbeTubeTheprobetubeassemblyisfabricatedfromalloytubing,dividedintothreetypes:Non-cooled,Air-cooledandwater-cooled.Thethermocoupleisanchoredinthefrontsectionoftheprobetube.Thefrontsectionisaprotectiveshieldwhichisclosedatthefrontandthreadedattherearforattachmenttotheprobetube.Thethermocoupleisthusprotectedfromphysicaldamage.Thethermocoupleleadwiresextendthroughtheprobetubetoajunctionboxlocatedonthemanifoldattherearoftheprobetube.Thebackoftheprobetubeisclosedoffwithamanifoldblockthathasbeendrilledandtappedtoacceptapackingglandforsealing.Duringthetravelmovement,theflexibleleadwireisprovidedtobringthesignalfromthethermocoupletoastationarymanifoldblocklocatedatthemiddleofthebeam.Instrumentleadwiresarealsoattachedtothestationarymanifoldblock.Probetubeassemblieswhichrequireaircoolingorwatercoolinghaveacoolinginletattherearandnozzleoutletsnearthefront.Thefournozzlesare180°apartpositioned300mmapartlengthwiseonthetube,andslanted45°totherear.Thiskeepsthecoolingairorwaterawayfromtheprobetip.Coolingairorwaterissuppliedtotheprobetubethroughthestationarymanifoldassembly.ManifoldBlockManifoldblockislocatedatthemiddleofthebeam,whichallowsmotorcable,thermocoupleleadwiresandcoolingtubingtogothroughthepulleyblockfromthecarriageandbeattachedtothemanifold.PulleyBlockPulleyblock,drivenbycarriage,includesacoupleoftravelingblocksinstalledinsidethebeam,locatedinbackofthecarriage.Itenablesthepowercable,compensatorywiresandcoolingtubingtoarrangeinorderontherollersofpulleyblock.TheoperationprincipleisillustratedonFigure4.WallboxCastingThewallboxcastingisaconnectionbetweenthermalprobebodyandboilerwallandisalsothefrontsupportpointofthethermalprobe.Wallboxisdividedintotwotypes:Positivepressurewallboxandnegativepressure(vacuum)wallbox.Positivepressurewallboxisinstalledatpositivepressureboilerandneedssealingandaspiratingairforsealingthefurnacewallholes,whileforvacuuminstallation,nosealingairneeded.2.2TemperatureMonitoringandControlSystemTemperaturemonitoringandcontrolsystemincludes“K”thermocoupleinsidetheprobetube,thecompensatoryleadwiresconnectingthermocoupletomanifoldblockandelectricalcontrolbox.The“K”thermocoupleisatwintype,3mmofoutsidediameter,anditsmaterialschangewiththechangeoftemperaturemonitoringrangerequirement.Normally,thematerialofthermocoupleusedinpowerplantboilerisNickelandchrome-Nickelandsilicon(KScale).Anameplateisalwaysattachedtothethermocouple,andsparepartsmustbepurchasedinaccordancewiththespecificationindicatedonit.OnethermocoupleofthetwinsendstemperaturesignalstoDCSfortemperatureindicationandotherfunctions.TheotherthermocoupleislocatedintheAlarmRelayorTemperatureTransmitteronthebodyofthermalprobeandcontroltheoperationofprobetubeorfortemperaturesetting(TS-1andTS-2)onthetemperaturetransmitter,asrequired.Thatthecoolingsystemisequippedornotisuptothetemperaturemonitoringrangeandtravel.Thethermalprobewillorwillnotbeequippedwithacoolingsystem,accordingtothecontract.Electricalcontrolboxismountedatsideofthebeam.Thecontrolboxlocatesatleftsideforlefthandtype,forrighthandtype,thecontrolboxisright.Thecontrolboxhaspush-buttonsformovingforward,movingbackwardandstop,aswellasconnectioninterfacewithuppercontroldeviceandDCS.On-offsignalstouppercontroldevice,DCS①Proberetract②Probeextend③Remotepermit④LocalpermitAnalogsignalstouppercontroldevice,DCSTemperaturesignal(Kscaleor4-20mA)②Positionsignal(4-20mA)On-offsignalsfromuppercontroldeviceandDCStocontrolbox①Probeextend②Proberetract③Probestop2.3PositionIndicatorandSignalOutput(RefertoFigure5andFigure8)Thesystemincludesaten-turnpotentiometerandpositionindicator.Theten-turnpotentiometerisinsertedintothebandspringandmoveinsynchronizationwithbandspring.Thetenturnpotentiometerrotateswiththebandspring,whichvariestheresistanceoftheinputendofthepositiontransducerwhichchangestheindicationandoutputaccordingly.Thetransducerproducesanoutputfrom4milliamperesandindicates0%scalewhentheprobeisfullyretracted,to20milliamperesand100%scalewhentheprobeisfullyextended.Thepositionindicatorisanintelligentdigitalinputinstrumentwithcalibrationandadjustmentcompletedbeforeleavingfactory.Thestepsofcalibrationandadjustmentforthepositionindicatorareasfollows:1)Theprobeshallbefullywithdrawn.Removethetenturnpotentiometer.Adjustitto16ohm.Thenre-insertitintothebandspring.Turnonthecontrolpowerandmotorpower.Thepositionindicatorreadingsshouldbe“0.0”,otherwise,adjustmentisnecessary.Pressthekey“SET”,theindicatorshallshow“CLK.”Press“SET”again.Theindicatorshowsnumbers.AdjustthenumberstomakesureCLK=132andpress“SET”and“▲”atthesametime.Fivesecondslaterthemeterwillgointothesecondlevelparametersettingstatus.Press“SET”continuouslytillnumbersappearafter“SLL”(bottompointofmeasuringrange).Changethenumbersbasedonthemeterreadings.Ifthemeterreadingis“10”,thenminusthenumberwith“10”.Ifitis“-10”,thenplus“10”.Savethesettingsbypressing“SET.”Pressthekey“W(reset)”andreadthenumberdisplayintheindicator.Repeattheabovestepstilltheindicatorshows“zero”.2)Pressthe“Forward”button,theprobeshallstartmovingforwarduntiltriggersthefrontlimitswitch.Thepositionindicatorshallshow“100”.Ifitisnot“100”,thenitneedstobeadjusted.Followthesamestepsabovetoenterthesecondlevelparametersettingstatus,press“SET”continuouslytilltheindicatorshows“SCH”(toppointofmeasuringrange).Changethenumberbasedonthemeterreadings.Ifthemeterreadingis“10”,thenminusthenumberwith“10”.Ifitis“-10”,thenplus“10”.Savethesettingsbypressing“SET.”Pressthekey“W(reset)”tilltheindicatorshows“100”.Nowthesettingiscompleted.c.Ifthenumbershowedontheindicatordecreaseswhileohmofthepotentiometerincreases,orviceversa,exchangethewiresmarkedas13and15.2.4ProbeTubeCoolingSystemWhenthetravelandtemperaturemonitoringrangeofthethermalprobeisbeyondcertainpoint,therewillbeacoolingsystem.Thecoolingsystemconsistsofelectricactuatedvalve,hoseandpressureswitch,whichallowscoolingairorwatertogothroughtheprobetubeandpreventthetubefrombeingdamagedbyhightemperature.TheelectricactuatedvalvecontrolOnandOffofthecoolingmediaandhoseisasapassage.Thepressureswitchmonitorsthepressureofthecoolingairorwaterandmakesurethereissufficientcoolingmedia.Ifthepressureistoolowtoguaranteethesafety,theprobetubewon’tstartorwithdrawimmediatelyifitisextended.2.5OperationandInstrumentationThisoperationandinstrumentsystemincludesthepushbuttonsoncontrolpanelatCentralControlRoom,temperatureindicator,positionindicatorandalarmdevicesandsoon,pleaserefertotheSection1forparameters.Electricalelementsandinstrumentationassociatedwiththesystemaresuppliedbyothers.CustomershallchooseappropriateinstrumentandelectricalelementanddesignthecontrolpanelinaccordancewiththegeneraldesignofCentralControlRoom.SECTION3INSTALLATIONANDCOMMISSIONING3.1InitialInstallationDeterminetheproperlocationofeachthermalprobeontheboilerasindicatedonthecompany’sdrawingorboilermanufacturer’sstandardsdrawingprovidedwitheachorder.Eachthermalprobeissupportedbysuspensionattwopointsonthebeamandtheprobeshouldbehorizontalwhentheboilerison.CAUTION:Whenhoistingthethermalprobeintoposition,besuretousethefourliftinglugsprovidedonthetopofthebeam.Avoidusingaslingaroundthebeamasthiscouldcausedamageandsubsequentmalfunction.``CAUTION:Thepackingbracketshallnotberemoveduntiltheprobeisinplace,otherwise,damagetotheequipmentmaytakeplace.Thefrontsupportbracketcontainsfrontendbulkheadandtwothreadedshoulderpinswhichareinsertedintotheholesonthehorizontalcenterofthewallboxcasting.Thewallboxcastingisattachedtotheboilerbyasleeveweldedtotheboilerwall.Fieldweldingofthewallboxcastingtothewallboxsleeveandthesleevetothewallmustbedonebeforeaffixingthethermalprobetothewallboxassembly.Therearsupportbracketconsistsoftwoslottedplateweldedtoeachsideofthebeam.Arod,passingthroughthehorizontalelongatedholesinthetwoplates,providesthesecondsupportingpointofthethermalprobe.ThesupportrodalsopassesthroughalengthofpipewhichhasaweldedplateandtwoM24nuts,andthesupportpipeisweldedtothebuildingsteel.Theslottedplatesareweldedtothebeamaccordingtoactualsituation,normally,1~1.4metersawayfromthebackendofthebeam.Combinationofthetwosupportbracketsformsauniversaljointtypesupporttopermitthethermalprobetotaketheexpansionandcontractionoftheboilerinallthreeplanes.CAUTION:Wheninstalltherearsupportbracket,putthesupportingrodatthebackoftheslot(farthestawayfromtheboilerwall),whichenabletheprobetoadapttheexpansionoftheboilerinhotstatus.CAUTION:Thethermalprobemustbesupportedorhungontothesupportsteelbeam,fieldweldingtherearsupportingslottedplatesaccordingtothesupportsteelbeam.Useproperweldingwayandprotectivemeasuresandmakesurethecablesandwiresinsidethebeamarenotdamaged.Afterinstallationandbeforestart-upofthethermalprobe,itissuggestedthattheprobebecarefullyinspectedforpossibledamagefromshipment,handlingorinstallationatjobsite.Removeallblockingandstrappingbeforestartingcommissioning.3.2CoolingPipingandSealingAirLineForthermalprobewithcoolingsystem,connectthecoolingpipetotheprobebeforestart-up.Alllinesortubingshallbeblownclearofanyforeignmatterbeforeconnectingtotheoperatingunits.Thisistoensurethatdirt,scaleorweldingbeadsfromthepipingsystemdonotentertheprobe.Onpositivepressureinstallations,ensurethatthesealingandaspiratingairlinesareconnectedandthatsufficientpressureandflowaresuppliedtoaccomplishsealingatallboilerloads.3.3ElectricalandInstrumentWiringThepowerandcontrolwiring,positionindicatorandtemperatureindicatorarelocatedatdifferentplacesofthethermalprobe.Thepowerandcontrolwiringisconnectedoncontrolpanel.Thepositionindicatorisinstalledinsidethecontrolbox.3.4InspectionbeforeStart-upObservealignmentofthebeamassembly.Checkforanybends,twists,orotherdistortions.Inspectthethermocoupletipassemblyforanydamagefromhandlingorshipment.Onpositivepressureinstallations,ensurethatthesealingandaspiratingairlinesareconnected.Iftheunitisairorwatercooled,checkthehoseconnectionsforpressuretightness.Checkallpowerandcontrolwiringforloosenedterminals,etc.Checkthelimitswitchactuatingarmstoseethattheyarethrowninthecorrectpositionforoperation.RefertoFigures9andensurethatallcablesand