南京凱盛國(guó)際工程有限公司NKRL-YY-10NanjingKisenInternationalEngineeringCo.,LtdNKRL-YY-10南京凱盛國(guó)際工程有限公司NanjingKisenInternationalEngineeringCo.,Ltd液壓系統(tǒng)說(shuō)明書(shū)HydraulicSystemManualKC4型推動(dòng)篦式冷卻機(jī)KC4ReciprocatingGrateCoolerNKRL-YY-10編制/COMPILED：校對(duì)/CHECKED：審核/APPROVED：2012-12-01目錄TOC\o"1-5"\h\z\o"CurrentDocument"1.概述及用途 1\o"CurrentDocument"SummaryandPurposes 1\o"CurrentDocument"2.技術(shù)參數(shù) 1\o"CurrentDocument"Technicalparameter 1\o"CurrentDocument"設(shè)備組成及工作原理 2\o"CurrentDocument"Compositionofequipmentandworkingprinciple 2\o"CurrentDocument"系統(tǒng)原理圖和外形圖 74.Skeletondrawingsandoutsidedrawingsofsystem 7\o"CurrentDocument"系統(tǒng)控制功能 8\o"CurrentDocument"Controlfunctionofsystem 8\o"CurrentDocument"設(shè)備安裝 8\o"CurrentDocument"Controlfunctionofsystem 8\o"CurrentDocument"設(shè)備的調(diào)試 11\o"CurrentDocument"Testofequipments 11\o"CurrentDocument"操作規(guī)范 18\o"CurrentDocument"8.Operatingregulation 18\o"CurrentDocument"維護(hù)與保養(yǎng) 19\o"CurrentDocument"9.Maintenance 19\o"CurrentDocument"10.故障及應(yīng)采取的措施 22\o"CurrentDocument"10.Malfuctionandsolution 22以5000t/d生產(chǎn)線用以5000t/d生產(chǎn)線用KC4型篦冷機(jī)為例）TakeKC4gratecoolerfor5000t/dproductionforexample.型號(hào)Type公稱流量NominalFlow(L/min)公稱壓力NominalPressure(MPa)油箱容積FuelTankCapacity(m3)過(guò)濾精度FilterAccuracy(mm)冷卻器Cooler(m2)5000t/d200X4203.50.01/0.00515循環(huán)流量RecycleFlow(L/min)循環(huán)壓力RecyclePressure(MPa)工作溫度WorkingPressure°C加熱器功率HeaterPowerKw1600.430?502X3南京凱盛國(guó)際工程有限公司必NanjingRisenInternationalEngineeringCo.,Ltd1?概述及用途此液壓系統(tǒng)是配套用于南京凱盛KC4型推動(dòng)篦式篦冷機(jī)（以下簡(jiǎn)稱KC4型篦冷機(jī)）的傳動(dòng)。以5000t/d生產(chǎn)線用KC4型篦冷機(jī)為例，簡(jiǎn)單介紹其工作原理：通過(guò)每?jī)蓚€(gè)液壓缸帶動(dòng)一列運(yùn)動(dòng)通道單元。該篦冷機(jī)共有10列運(yùn)動(dòng)通道單元，依次編號(hào)為：①②③④⑤⑥⑦⑧⑨⑩，往前推料時(shí)，10列通道一起同步向前運(yùn)動(dòng)；回退時(shí)，分3個(gè)步驟依次完成，首先①④⑦⑩同步回退，其次②⑤⑧同步回退，最后③⑥⑨同步回退，至此一個(gè)循環(huán)（即一沖程）結(jié)束。然后進(jìn)入下一個(gè)循環(huán)進(jìn)行熟料輸送，從而保證整條生產(chǎn)線的順利運(yùn)行。2.技術(shù)參數(shù)NKRL-YY-10SummaryandPurposesThishydraulicsystemisusedforKC4reciprocatinggratecooler(KC4gratecoolerforshort).TakeKC4gratecoolerfor5000t/dproductionforexampletointroducetheprinciple.Everygrateinarrayisdrivedby2hydrauliccylinders.KC4gratecoolerhas10queueworkingunits,whichisnumbered①②③④⑤⑥⑦⑧⑨⑩inturn.All10unitsmoveforwardtogether.Theyfallbackinthreesteps,whichformintoacycle.①④⑦⑩unitsmovebackatfirst.Then②⑤⑧unitsmovebackimmediately.③⑥⑨unitsmovebackatlast.Aterthis,thegratecoolerentersintonextcycle.Technicalparameter南京凱盛國(guó)際工程有限公司必NanjingRisenInternationalEngineeringCo.,Ltd3?設(shè)備組成及工作原理3.1設(shè)備組成（以5000t/d生產(chǎn)線用KC4型篦冷機(jī)為例）液壓站由油箱、五臺(tái)高壓變量泵裝置（四用一備）、一臺(tái)葉片泵裝置、過(guò)濾器、冷卻器、功能性閥門（插裝式單向閥、插裝式溢流閥、螺紋式插裝單向閥、板式溢流閥、梭閥、節(jié)流閥、比例換向閥、安全閥、開(kāi)關(guān)閥門等）及管道、油缸、控制元件（液位控制器、壓差控制器、壓力變送器）、顯示儀表（壓力表、液位液溫計(jì)）及電控柜等組成。3.2工作原理（以5000t/d生產(chǎn)線用KC4型篦冷機(jī)為例）篦冷機(jī)液壓站總體分為兩個(gè)系統(tǒng)，即主工作系統(tǒng)和自循環(huán)過(guò)濾冷卻系統(tǒng)。主工作系統(tǒng)共十一條回路，十條為工作回路連接相對(duì)應(yīng)的執(zhí)行油缸；另一條為備用回路。主工作回路工作時(shí)：油泵從油箱中吸油，經(jīng)過(guò)插裝單向閥、比例換向閥連接到油缸，通過(guò)比例換向閥的換向來(lái)改變油路的方向，從而通過(guò)執(zhí)行油缸帶動(dòng)對(duì)應(yīng)列運(yùn)動(dòng)通道單元的前進(jìn)后退。在泵出口設(shè)有板式溢流閥作為安全閥。在泵的出口、連接油缸的有桿腔和無(wú)桿腔的回路中、負(fù)載傳感回路中都設(shè)有壓NKRL-YY-10CompositionofequipmentandworkingprincipleCompositionofequipment(TakeKC4gratecoolerfor5000t/dproductionforexample.)Thehydraulicstationismadeupofoiltank,fivehigh-pressurevariabledisplacementpumps(foursetsworkingcontinuously,anotherbackup),onebladepump,filter,cooler,fuctionalvalve(plug-inone-wayvalve,plug-inoverflowvalve,screwplug-inone-wayvalve,plateoverflowvalve,shuttlevalve,throttlevalve,proportionalreversingvalve,saftyvalve,switchvalve,andsoon),pipelines,hydrauliccylinder,controllingunits(liquidlevelcontroller,pressuredifferencecontroller,pressuretransmitter),displayinstruments(manometer,liquidlevelandliquidtemperature),electriccontrolcabinet,andsoon.Workingprinciple(TakeKC4gratecoolerfor5000t/dproductionforexample.)Thehydraulicstationhastwosystems,mainworkingsystemandself-circulationfilteringcoolingsystem.Mainworkingsystemhas11circuits,11circuitsconntingwithcorrespondinghydrauliccylinders.Theprincipleofmainworkingcircuits:Oilpumpsabsorboilfromtank.Connectwithhydrauliccylindersbyplug-inone-wayvalveandproportionalreversingvalve.Oilstrikeiscontrolledbyproportionalreversingvalve,anddrivesqueueworkingunitstomoveforwardorfallback.Plateoverflowvalvelocatesattheoutletofpumptobesafe.Manometerisinstalledat

南京凱盛國(guó)際工程有限公司NanjingRisenInternationalEngineeringCo.,Ltd力表顯示壓力。備用回路工作時(shí)：當(dāng)工作系統(tǒng)的泵因故障需要檢修時(shí)，則需要將需檢修的工作回路對(duì)應(yīng)連接備用回路的高壓球閥打開(kāi)，同時(shí)將負(fù)載傳感回路的三通閥門轉(zhuǎn)換至與備用回路相通。確認(rèn)以上步驟完成后，備用泵方可投入使用。自循環(huán)過(guò)濾冷卻系統(tǒng)工作時(shí)：葉片泵從油箱中吸取油液經(jīng)單向閥、冷卻器冷卻、過(guò)濾器過(guò)濾后回到油箱。泵的出口裝有安全閥，用來(lái)保證系統(tǒng)安全工作?；芈分醒b有壓力表用來(lái)顯示壓力。自循環(huán)回路主要是用來(lái)冷卻和過(guò)濾油液，使油箱中的油液清潔，保證主工作系統(tǒng)正常工作。3.3元件功能3.3.1油箱油箱主要功能是蓄油，還兼作散熱和沉淀油液中的雜質(zhì)。3.3.2排污閥該閥是油箱放油閥，在正常情況下，該閥關(guān)閉，以防油箱油液外泄，只有在需要排掉油箱內(nèi)的油液時(shí)才打開(kāi)該閥。3.3.3空氣濾清器空氣濾清器安裝在油箱的蓋板上，是油箱的呼吸口也是加油口。3.3.4液位控制器YKJD型液位控制繼電器是一種新型液

NKRL-YY-10theoutletofpump,circuitsofcylinder'sucker-rodcavityandrodlesscavity,andloadedsensorcircuit.Theprincipleofbackupworkingcircuits:whilepumpneedsrepairowingtomalfunction,connectthiscircuitwithbackupcircuitsbyopeningupthehigh-pressureballvalveandswitchthetriplevalveattheloadedsensorcircuittobackupcircuits.Afteralltheuppersteps,backuppumpcanbeoperated.Theprincipleofself-circulationfilteringcoolingsystem:Thebladepumpabsorbsoilfromtank.Oilgoesbyone-wayvalve,cooler,filterbacktooiltank.Thereissaftyvalveattheoutletofpumptoensuresafe.Thereismanometertoshowthepressure.Self-circulationcircuitisusedforcoolingandfilteringtheoil,makesuretheoilinthetankclean,andensurethehydraulicsystemworkingnormally.FunctionofpartsOiltankThemainfunctionisstoringoil,andeliminationofheat,depositionofimpurityatthesametime.BlowdownvalveThevalveisusedfordrainingtheoil.Normally,thevalveisclosedtopreventoilleakage.Justwhiledrainingtheoil,openthisvalve.AircleanerAircleanerisinstalledatthecoverplateofoiltank.Itisforbreathingandoilfilling.LiquidlevelcontrollerYKJDliquidlevelcontrollerisanew

南京凱盛國(guó)際工程有限公司NanjingRisenInternationalEngineeringCo.,Ltd面高度電發(fā)訊控制裝置，主要用于箱內(nèi)液體位置與液體源電機(jī)的自動(dòng)控制或報(bào)警。當(dāng)液位低于液位下限時(shí)發(fā)出報(bào)警信號(hào)，此時(shí)應(yīng)向油箱補(bǔ)充油液；當(dāng)?shù)陀谝何幌聵O限時(shí)則停主機(jī)；當(dāng)高于最高液位發(fā)出報(bào)警信號(hào)，此時(shí)應(yīng)停止加油。液位液溫計(jì)液位液溫計(jì)可指示液位及液溫的高低。數(shù)顯溫控儀數(shù)顯溫控儀是通過(guò)鉑熱電阻檢測(cè)油箱內(nèi)油液的溫度，在現(xiàn)場(chǎng)顯示。并且控制電加熱器的啟停。電加熱器電加熱器的功能是對(duì)油箱中的油液進(jìn)行加熱，當(dāng)油箱中油液的溫度低于下限設(shè)定值時(shí)，電加熱器自動(dòng)進(jìn)行加熱，當(dāng)油箱中油液的溫度達(dá)到正常設(shè)定值時(shí)，電加熱器自動(dòng)停止。高壓泵裝置篦冷機(jī)液壓站共有五臺(tái)高壓油泵裝置，四臺(tái)工作、一臺(tái)備用，當(dāng)一臺(tái)泵因故障需要檢修時(shí)，可啟動(dòng)備用泵，以保證系統(tǒng)正常運(yùn)行。3.3.9單向閥單向閥的作用是使油液只能向一個(gè)方向流動(dòng)，反向截止。前者為插裝式單向閥，由插件和蓋板組成，主要是防止油泵停止時(shí)油

NKRL-YY-10equipmentforliquidheightsignal.ltisusedforthecontrollingandalarmingofliquidlevelandliquidsourceelectricmotor.Whenliquidlevelisbelowthelowliquidlimit,itraisethealarm,andoilshouldbefilledup.Whenliquidlevelisbelowtheultimatelowliquidlimit,thehydraulicstationstops.Whenliquidlevelisabovethehighliquidlimit,itraisethealarm,andoilfillingshouldbestopped.Liquidlevelandtemperaturegageltisusedfordisplayingtheliquidlevelandtemperature.DigimatictemperaturecontrollerltdetectstheoiltemperatureinthetankbyPtthermalresistance,anddisplayinfield.ltalsocontrolsthestart-stopofelectricheater.Electricheaterltisusedforheatingoilinthetank.Whenliquidtemperatureisbelowthelowliquidtemperaturelimit,theelectricheaterworks.Whenliquidtemperatureisabovethenormalvalue,itstopsautomatically.HighpressurepumpsThehydraulicstationofgratecoolerhas5highpressurepumps.4setsworkscontinuously,anotherbackup.While1pumpneedsrepairowingtomalfunction,startthebackuppumptoensurethehydraulicsystemworkingnormally.One-wayvalveOne-wayvalveisusedforoilflowingalongonedirection,andstoppinginversely.Theformerisplug-inone-wayvalve,whichismadeupofplug-inmoduleandcover.ltis液倒流。后者為板式單向閥，用于過(guò)載保護(hù)中單向從油箱中補(bǔ)油，反向截止。3.3.10溢流閥溢流閥用來(lái)控制進(jìn)口壓力。前者為板式溢流閥，作為安全閥。3.3.11比例換向閥比例換向閥能按輸入電信號(hào)的正負(fù)及幅值大小，同時(shí)實(shí)現(xiàn)流動(dòng)方向的控制及流量的比例控制。3.3.12過(guò)濾器過(guò)濾器安裝在油箱的蓋板上，用于除去系統(tǒng)中件磨損產(chǎn)生的金屬顆粒以及其它污染物，使油箱中的油液保持清潔，以利于系統(tǒng)中油液循環(huán)使用。當(dāng)過(guò)濾器的濾芯堵塞致使進(jìn)出口壓差為0.35MPa時(shí)，發(fā)訊器發(fā)訊，此時(shí)應(yīng)更換濾芯。在因故不能及時(shí)更換使壓差上升到0.4MPa時(shí)，旁通閥自動(dòng)打開(kāi)，從而保證系統(tǒng)正常工作，但必須盡快更換濾芯。前者為單筒，需停機(jī)才能更換濾芯；后者也為單筒，可以通過(guò)手動(dòng)切換使一個(gè)備用過(guò)濾器工作，再更換濾芯。3.3.13節(jié)流閥節(jié)流閥是用于調(diào)節(jié)流量。該閥為管式閥安裝在負(fù)載傳感回路中，用于調(diào)節(jié)負(fù)載反饋信號(hào)。NKRL-YY-10usedforpreventingoilbackwardswhenpumpstops.Thelatterisplateone-wayvalve,whichisusedforabsorbingoiluniaxiallyfromtankinoverpowerprotection,andstoppinginversely.OverflowvalveOverflowvalveisusedforcontrollingtheinletpressure.Theformerisplateoverflowvalve,assaftyvalve.ProportionalreversingvalveProportionalreversingvalvecancontroltheflowdirectionandproportionalflowatthesametimebyidentifyingtheelectricsignalplus-minusandvalue.FilterThefilterismountedonthecoverplate,usedforremovingmetalparticleandotherpollutantinthehydraulicsystem,keeptheoilinthetankclean,andisbeneficialforoilcirculating.Whilethefiltercoresareblocked,andthepressuredifferencebetweeninletandoutletachieves0.35MPa.Signalisemitted,andthefiltercoresneedtobereplaced.Forsomereasons,thefiltercorecan'tbereplacedimmediately.Whilethepressuredifferenceachieves0.4MPa,by-passvalveopensuptomakesurethesystemoperatesnormally,butthefiltercoreshouldbereplacedatonce.Theformerismonocular,whichisreplacedwhenthesystemstops.Thelatterisalsomonocular,whichisreplacedbyswitchingtobackupfiltercoremanually.ThrottlevalveThrottlevalveisusedforregulatingflow,whichistubevalve.Itismountedattheloadedsensorcircuittoadjustloadfeedbacksignal.3.3.14壓力表壓力表安裝在儀表盤上，用于測(cè)量測(cè)壓接頭處的壓力。3.3.15測(cè)壓接頭安裝在閥塊上，用于連接測(cè)壓軟管接頭測(cè)量壓力。3.3.16測(cè)壓軟管測(cè)壓軟管用于連接測(cè)壓接頭和壓力表。3.3.17三通球閥三通球閥用于連接負(fù)載至泵負(fù)載傳感接口的管路中，能實(shí)現(xiàn)共用接口與另外兩個(gè)接口中的任一接口相通。在啟動(dòng)備用回路時(shí)應(yīng)切換至相應(yīng)位置。3.3.18葉片泵裝置葉片泵具有良好的自吸能力、振動(dòng)小、效率高、壽命長(zhǎng)等特點(diǎn)。在油站中主要用于自循環(huán)系統(tǒng)，使油箱中的油液冷卻過(guò)濾，以便達(dá)到理想的工作油液。3.3.19安全閥安全閥安裝在自循環(huán)系統(tǒng)的管路上，用于設(shè)定系統(tǒng)溢流壓力，從而保證系統(tǒng)安全運(yùn)行。3.3.20壓力表壓力表用于顯示自循環(huán)系統(tǒng)的壓力，壓力表開(kāi)關(guān)用于連接壓力表，安裝在管路上。NKRL-YY-10ManometerManometersismountedatthegaugeboard.Theyareusedtomeasurethepressureatthejoints.Pressure-measuredjointItismountedatvalveblock,andusedtojoinuppressure-measuredflexiblepipes.Pressure-measuredflexiblepipesItisusedtoconnectpressure-measuredjointwithmanometer.TeebendballvalveItisusedtoconnectpipeofpumploadsensorinterfacewithload.Itcanjoincommoninterfacewitheitherofthetwointerface.Whilebackupcircuitisstarted,itshouldbeswitchedtocorrespondingposition.BladepumpBladepumphasthefeaturesofgoodself-sucking,lowvibration,highefficiency,longlife,andsoon.Itisusedforself-circulationsystem,filteringandcoolingtheoil,andmakingidealworkingoil.SaftyvalveSaftyvalveismountedatthetubeofself-circulationsystem.Itisusedforsettingoverflowingpressureofsystem.Itmakessurethesystemoperatessafely.ManometerManometerisusedtoshowpressureoftheself-circulationsystem.Manometerswitchisusedtoconnectthemanometer梭閥梭閥能將系統(tǒng)中的兩個(gè)油路交替地直接引到同一公共油路上，壓力高的一路優(yōu)先接入。具有尺寸小、安裝方便、切換動(dòng)作迅速等優(yōu)點(diǎn)。油缸油缸即系統(tǒng)的執(zhí)行元件，連接在篦床上帶動(dòng)篦床前進(jìn)或后退。3.3.23位移傳感器位移傳感器時(shí)時(shí)檢測(cè)油缸運(yùn)行行程位移并發(fā)出信號(hào)，用于控制液壓缸。3.3.24控制元件和電控柜控制元件的作用是檢測(cè)系統(tǒng)中的溫度、壓力、壓差等參數(shù)，當(dāng)達(dá)到設(shè)定值時(shí)，向電控柜發(fā)出信號(hào)，由電控柜控制系統(tǒng)某主元件工作或發(fā)出聲光報(bào)警信號(hào)；電控柜的功能是對(duì)系統(tǒng)用電元件的操作及同主機(jī)電控系統(tǒng)的通訊。系統(tǒng)原理圖和外形圖系統(tǒng)原理圖（見(jiàn)液壓系統(tǒng)圖紙）液壓站外形圖（見(jiàn)液壓系統(tǒng)圖紙）NKRL-YY-10withtube.ShuttlevalveShuttlevalvecanleadtwooiltubesalternatelytoonecommonoiltube.Thehigherpressuretubeisattachedfirst.Ithastheadvantageofsmallsize,easyinstallation,high-speedswitch,andsoon.HydrauliccylinderHydrauliccylindersaretheactionelementofthesystem.Theyareconnectedwithgrate,anddrivethegrateforwardandbackward.DisplacementsensorDisplacementsensorsdetectthestrokeofhydrauliccylinders,emitdiscretesampling,andcontrolhydrauliccylinder.ControlingelementandelectriccontrolledcabinetControlingelementisusedtodetectthetemperature,pressure,differentialpressure,andsoon.Whileachievingsettingvalue,itemitsignaltoelectriccontrolledcabinet.Andtheelectriccontrolledcabinetcontrolstheopreratingoftheelements.Theelectriccontrolledcabinetisusedfortheoperatingoftheelectricelementsandthecommunicationwithmainelectriccontrolsystem.4.SkeletondrawingsandoutsidedrawingsofsystemSkeletondrawingsofsystem(refertodrawingsofhydraulicsystem)Outsidedrawingsofsystem(refertodrawingsofhydraulicsystem)系統(tǒng)控制功能系統(tǒng)控制功能詳細(xì)參見(jiàn)電氣控制說(shuō)明書(shū)。設(shè)備安裝6.1安裝執(zhí)行標(biāo)準(zhǔn)YBJ207-85《液壓、氣動(dòng)、潤(rùn)滑系統(tǒng)施工及驗(yàn)收規(guī)范》中相關(guān)條款和圖紙技術(shù)要求及說(shuō)明書(shū)內(nèi)容。整體式液壓設(shè)備安裝整體式液壓設(shè)備所有元件構(gòu)成一個(gè)剛性體，安裝在緊靠主機(jī)旁的單獨(dú)房間里，液壓設(shè)備內(nèi)部安放完畢后，方可進(jìn)行現(xiàn)場(chǎng)管道的安裝，液壓站的電控箱放在油站附近。管道安裝6.3.1切割?液壓的管子一般應(yīng)用機(jī)械方法切割；?管子切割表面必須平整，不得有裂紋、重皮。管端的切削粉、毛刺、熔渣、氧化皮等必須清除干凈；?切口平面與管子軸線垂直度公差為管子外徑的1/100。6.3.2彎管NKRL-YY-10ControlfunctionofsystemControlfunctionofsystemreferstoelectriccontrollingdirections.ControlfunctionofsystemStandardsofinstallationIntheYBJ207-85<Constructionstandardsforhydraulic,pneumatic,andlubircation>,coheretitems,drawingtechnicalrequirements,andinstructionsaredeclared.IntegralerectionofhydraulicstationIntheintegralhydraulicstation,allelementsformastiffequipment.Itisplacedattheseparateroomnearthegratecooler.Whileitisinstalled,thepipelinesbegintotube.Theelectriccabinetisplacednearthehydraulicstation.TheinstallationofpipelinesCutting?Pipesaregenerallycutbymechanicalway.?Thecuttingsurfaceofpipesshouldbesmooth,havenocrack,andnocold-lap.Thecuttingpowder,burr,slag,oxideskinatthethecuttingendshouldbeclearedup.?Theverticalityofcuttingsurfaceandaxisofpipesisbelowthe1/100oftheouterdiameterofpipe.Windingpipe.?液壓、潤(rùn)滑系統(tǒng)的管子一般采用冷彎。?Thewayofwindingpipeinhydraulicandlubricationsystemisusuallycold?彎道的最小彎曲半徑應(yīng)采用外徑的3倍,管子工作壓力高，彎曲半徑宜大。管子彎曲處應(yīng)圓滑,不應(yīng)有明顯的凹痕、波紋及壓扁現(xiàn)象。6.3.3管道焊接※管道焊接采用氬弧焊接打底、電弧焊填充。焊縫質(zhì)量要求工作壓力等于或高于6.3MPa(63Bar)的管道，其對(duì)口焊縫質(zhì)量應(yīng)不低于I級(jí)焊縫標(biāo)準(zhǔn)；工作壓力低于6.3MPa的管道,其對(duì)口焊縫質(zhì)量應(yīng)不低于II級(jí)焊縫標(biāo)準(zhǔn)。坡口加工及接頭組對(duì)?焊縫的坡口應(yīng)用機(jī)械方法加工，其加工形式、加工方法和尺寸標(biāo)準(zhǔn)等均應(yīng)符合GB/T985、GB/T986的有關(guān)規(guī)定。可用砂輪打磨坡口，但決不允許用乙炔焰加工，加工后不允許有影響焊接質(zhì)量的凹凸不平處。?管子、管件的對(duì)口應(yīng)做到內(nèi)壁平齊：I、II級(jí)焊縫的對(duì)口，內(nèi)壁錯(cuò)邊量應(yīng)不超過(guò)管壁厚度的10％，且不大于14mm。管道焊接?管道焊接應(yīng)用氬弧焊接或用氬弧焊打底、

NKRL-YY-10bending.Theminimumbendingradiusisthreetimesoftheouterdiameterofpipe.Thehighertheworkingpressureis,andthebiggerthebendingradiusis.Thebendingareashouldbesmooth,andhavenovisiblecave,nocrack,andnoflaser.Theweldingofthepipes※Theweldingofpipesshouldbethatargonarcweldingisusedtorenderandthenweldinelectric-arcwelding.QualityrequirementsofweldedseamIftheworkingpressureisnotlowerthan6.3MPa,qualityrequirementsofweldedseamshouldnotlowerthanclassI.Iftheworkingpressureislowerthan6.3MPa,qualityrequirementsofweldedseamshouldnotlowerthanclassII.BevelingoftheedgeandassemblyofthejointsThebeveloftheweldingshouldbefinishedinmechanicalway.Theformofprocess,jobstep,andthestandardsofsizeshouldmeetthecriterionGB/T985、GB/T986.Sandercanbeused,butacetylenecuttingisforbidden.Afterprocessing,thereshouldnothaveroughness.Thejointsofpipesandaccessoriesshouldbeflatinside,andachievethebuttweldofclassI,II.Theunfitnessofbuttweldshouldnotbelowerthanthe10%ofthepipewallthickness,andnotmorethan14mm.TheweldingofthepipesTheweldingofpipesshouldbethat電弧焊填充。電弧焊填充。NKRL-YY-10argonarcweldingisusedtorenderandthenweldinelectric-arcwelding.?焊工應(yīng)按有關(guān)規(guī)定進(jìn)行考試，取得所施焊范圍的合格證書(shū)后方能參加本施焊范圍的焊接工作。

?Theweldershouldhavecertificateofqualificationintherangebycoherentexams.Andthenhecangoonthisjob.?焊接材料應(yīng)具有制造廠的合格證明書(shū)。?焊條、焊劑在使用前應(yīng)按產(chǎn)品說(shuō)明書(shū)的規(guī)定烘干，并在使用過(guò)程中保持干燥，焊條藥皮應(yīng)無(wú)脫落和顯著裂紋。

?Weldingelectrodeshouldhavecertificateofqualification.?Weldingelectrodeandfluxmaterialshouldbedriedaccordingtocoherentinstruction.Itshouldkeepdryduringworking.Weldingelectrodeoatingdon'tsloughandcrackobviously.?焊絲在使用前應(yīng)清除表面的油污、銹蝕等。?施焊前應(yīng)對(duì)坡口及附近寬20mm范圍的內(nèi)外管壁進(jìn)行清理，除凈其上的油、水、漆、銹及毛刺等。

?Greasedirtandrust-eatenontheweldingwireshouldbeclearedup.?Beforewelding,theoil,water,paint,rusty,burr,etc,shouldbeclearupatthebevel,rangeof20mm.?管道點(diǎn)固焊時(shí)，點(diǎn)固的工藝措施及焊接材料應(yīng)與正式焊接一致。點(diǎn)固焊后應(yīng)認(rèn)真檢查焊肉，如發(fā)現(xiàn)有裂紋等缺陷，應(yīng)及時(shí)處理。?在管道焊接全過(guò)程中，應(yīng)防止風(fēng)、雨、雪的侵襲。

?Duringdotweldingtofastenthepipe,theprocessandweldingelectrodeshouldbecorrespondingtoformalweldingelectrode.Afterdotwelding,checkifthereiscrack,etc.Andhandleitimmediately.?Duringwelding,preventwind,rain,snowfromthepipe.?焊接完畢，應(yīng)將焊縫表面熔渣及其兩側(cè)的飛濺清理干凈，并作好記錄。

?Afterbilateralwelding,clearupthesurfaceslagandsplash.Andmakeoutmarks.?焊縫的返修應(yīng)有工藝措施；同一焊縫的返修次數(shù)不得超過(guò)3次。

?Repairofweldedseamhastheprocesssteps:repairtimesofoneweldedseamisnotmorethan.4焊接檢驗(yàn)Checkofweldedseam?管道對(duì)口焊接后必須進(jìn)行外觀檢查，且應(yīng)在無(wú)損探傷和壓力試驗(yàn)前進(jìn)行；

?Weldingshouldbecheckedinappearance,beforenondestructiveevaluationandpressuretest.NKRL-YY-10檢查前應(yīng)將妨礙檢查的渣皮和飛濺清理干凈。按規(guī)定比例探傷不合格者，應(yīng)加倍抽查該焊工的焊縫，如仍有不合格者，則應(yīng)對(duì)該焊工的全部焊縫進(jìn)行無(wú)損探傷。?角焊縫的焊腳高度應(yīng)符合設(shè)計(jì)規(guī)定，其外形應(yīng)平緩過(guò)渡，表面不得有裂紋，氣孔，夾渣等缺陷，咬肉深度不得大于0.5mm。6.4管道酸洗、沖洗6.4.1管道酸洗管道的酸洗和沖洗是保證液壓系統(tǒng)工作可靠性和元件使用壽命的關(guān)鍵環(huán)節(jié)之一，必須給予足夠重視。應(yīng)按《機(jī)械設(shè)備安裝工程及驗(yàn)收通用規(guī)范》（GB50231）、《重型機(jī)械液壓系統(tǒng)通用技術(shù)條件》（JB/T6996）等有關(guān)規(guī)范進(jìn)行。建議將焊好的管道拆下后送到有專業(yè)酸洗槽的專業(yè)公司進(jìn)行酸洗！如確需在現(xiàn)場(chǎng)酸洗，應(yīng)向供貨方咨詢。設(shè)備的調(diào)試（參見(jiàn)系統(tǒng)原理圖）調(diào)試的一般規(guī)定調(diào)試應(yīng)在循環(huán)沖洗合格后進(jìn)行，并且系統(tǒng)閥門的開(kāi)關(guān)狀態(tài)應(yīng)符合原理圖的規(guī)定。7.1.2出廠調(diào)試用介質(zhì)為N46抗磨液壓油,安裝后調(diào)試介質(zhì)應(yīng)為規(guī)定的工作介質(zhì)。Clearuptheweldingslagandsplashbeforechecking.Ifthereareoff-gradeweldingseamsduringdetecting,checkthiswelder'stwotimesweldingseams.Iftherearestilloff-gradeones,checkalltheweldingseams.?Theheightoflegshouldagreetodesign.Theoutlineshouldbeflat.Thereisnotcrack,pore,slag,etc.Unfitnesssizeshouldnotbemorethan0.5mm.PicklingandflushingofpipesPicklingofpipesPicklingandflushingofpipesisakeysteptoensurethereliabilityofthehydraulicsystemandthelifeoftheunits,whichshouldbeattachedimportance.Thestandardsare“Generalstandardformachineryandequipmentconstructionandcheck”(GB50231),“GeneralHydraulictechnicforheavymachineryconditionsassembly”(GB50231),andsoon.Wesuggestthatweldedpipescouldbesenttoprofessionalpicklingfactoriestobepickled.Ifneededtobepickledinfileld,askadvicefromsupplier.Testofequipments(Refertoskeletondrawingsofsystem)RequirementsoftestTestisdoneaftercircularflushing.Theswitchstatusofvalvesshouldmatchskeletondrawings.Factory-testedoilisN46wear-resistantoil.Afterinstallation,thetestoilisspecified.7.1.3調(diào)試用油液必須用過(guò)濾精度W20pm的過(guò)濾機(jī)過(guò)濾加油，油箱液位應(yīng)在最高液位與最低液位之間。7.1.4耐壓試驗(yàn)和循環(huán)沖洗時(shí)，管道上的壓力變送器、比例換向閥不宜參與。7.1.5壓力逐級(jí)升高規(guī)定：每級(jí)2?3MPa,保壓1?3分鐘后方可再次升高。7.1.6各類控制元件的調(diào)整方法參見(jiàn)其說(shuō)明書(shū)。液壓設(shè)備安裝后的調(diào)試7.2.1液壓站安裝完畢后,確認(rèn)放油閥關(guān)閉后，用過(guò)濾精度W20pm的過(guò)濾機(jī)過(guò)濾加油,油位至油箱蓋板面200mm。油從空氣濾清器口加入。起泵：先點(diǎn)動(dòng)一次看泵轉(zhuǎn)向是否正確，再連續(xù)點(diǎn)動(dòng)三次，排除泵中空氣，使泵中充滿油液后啟動(dòng)油泵。7.2.3泵試運(yùn)轉(zhuǎn)：調(diào)節(jié)溢流閥閥口調(diào)至最大，相應(yīng)的閥門按原理圖開(kāi)閉，起動(dòng)泵裝置，使其在無(wú)負(fù)荷條件下運(yùn)轉(zhuǎn)10分鐘，應(yīng)無(wú)異常噪聲，否則應(yīng)停泵檢查。7.2.4循環(huán)沖洗在液壓站自循環(huán)泵附近放置一桶沖洗液（液壓系統(tǒng)準(zhǔn)備使用的工作介質(zhì)或與它相容的低粘度用工作介質(zhì)），用配套外發(fā)的50-1S-2500（—端M64X2;—端焊接管屮60）高壓軟管總成的螺紋端與葉片泵配制吸油口法蘭接頭M64X2連接，膠管另一端插放入準(zhǔn)備的沖洗液油桶中，如果長(zhǎng)度限制可以用NKRL-YY-10Theoilshouldbefilterdwith<20pmfilter.Theoillevelshouldbewithinmaximumandminimum.Duringpressureprooftestandflushing,thepressuretransmitterandproportionalreversingvalvedon'tjoinin.Therequirementofpressurerising:everytime2~3MPa,keepingfor1~3min.Theadjustingmethodsofunitsreferstocoherentinstruction.7.2TestafterinstallationAfterinstallinghydraulicstation,andconfirmingtheoildrainvalve,theoilshouldbefilterdwith<20pmfilter.Theoillevelisbelowthecoverplate200mm.Oilisfilledbythewayofaircleaner.Startpump:crawlthepumponetimetocheckiftherollingdirectionisright.Andthencrawlthepumpthreetimestoclearuptheairinthepump.Fillthepumpwithoil,andstartpump.Testrunning:Adjusttheoverflowvalvetomaximum,andswitchcorrespondingvalvesaccordingtoskeletondrawingsofsystem.Thenstartthepumps,andoperatewithoutloadfor10min.Duringthis,theyshouldnothaveanynoise.Otherwisestopit.CircularflushingLayonebarrelofflushfluidnearthecircularpump(workingoilorlowerviscosityoil).Usingtheextra50-1S-500(oneendM64x2,another^60)high-pressureflexiblepipeunittoconnectitsscrewdendwithinletM64X2flangeofbladepump.Anotherendofflexiblepipeisinsertedintotheflushfluidbarrel.Iflimitede)注視油箱上的油位，當(dāng)油位到達(dá)指定Observetheliquidlevel.Stopthefilterpressifthelevelarrivedatdesignatede)注視油箱上的油位，當(dāng)油位到達(dá)指定Observetheliquidlevel.Stopthefilterpressifthelevelarrivedatdesignated南京凱盛國(guó)際工程有限公司NanjingRisenInternationalEngineeringCo.,Ltd焊接管360加焊一端硬管；循環(huán)泵供油口管路上焊接管接頭擰開(kāi)，用外發(fā)的25-1S-4000(M42X2)軟管總成連接到其中一臺(tái)泵對(duì)應(yīng)的壓力管路上，另一管路也用外發(fā)的25-1S-4500(M42X2)軟管總成連接到油桶上安置的回油過(guò)濾器上；將連接兩管路構(gòu)成短路連接。至此自循環(huán)泵與系統(tǒng)外部管路構(gòu)成沖洗回路，便可進(jìn)行管路的循環(huán)沖洗。沖洗應(yīng)連續(xù)進(jìn)行，沖洗時(shí)間一般在72h以上。沖洗過(guò)程宜采用改變方向或?qū)附犹幍墓茏臃磸?fù)敲打、振動(dòng)等方法加強(qiáng)沖洗效果。沖洗至連續(xù)過(guò)濾1h在過(guò)濾器上無(wú)肉眼可見(jiàn)的固體污染物時(shí)為沖洗合格。同理可對(duì)其他外部管路進(jìn)行循環(huán)沖洗。沖洗完畢后應(yīng)放掉沖洗液，加入工作介質(zhì)，更換過(guò)濾器濾芯，將相關(guān)閥門恢復(fù)。7.2.5向油箱內(nèi)加油注意事項(xiàng)：油箱內(nèi)注油之前必須確保油箱外表和內(nèi)部干燥、清潔，沒(méi)有灰塵和水。油箱用濾油車進(jìn)行注油，注油時(shí)應(yīng)確保所使用的是指定牌號(hào)的液壓油。加油操作步驟:打開(kāi)油桶蓋前先將油桶蓋清理干凈，不得有任何污物。打開(kāi)油桶蓋，將濾油車的吸油管插入油桶。打開(kāi)油桶上的通氣螺塞(若有螺塞)。把濾油車上的出油管連接到油箱的注油口(空氣濾清器的法蘭口)加油。給濾油車通電，注油工作即已開(kāi)始。

NKRL-YY-10bylength,use屮60weldedpipe.Twistoffjointintheoutletofrecyclepump.Usingtheextra25-1S-4000(M42X2)flexiblepipeunittoconnecttoanyplungerpump'spipeline,anotherpipelineisconnectedwithoilfeed-backfilter.Makethetwopipelinesintoshortcircuit.Self-circulationpumpandexteriorpipelinesformintoflushingcircuit,anditcanflush.Flushthepipelinescontinuouslyformorethan72h.Duringflushing,achievebetterflushingeffectbychangingthedirection,beatingandvibratingtheweldingarea.Whilethereisnovisiblepowderinthefilter,theflushingcanbestopped.Theextracanalsobeflushedinthisway.Afterflushing,dischargetheflushingoil,replacethefiltercore,andresetthevalves.FeedoilintotankAttentionmatters：Beforefilling,thetankshouldbedryandclean,withoutdustandwaterinsideandoutside.Feedoilbyfilterpress.Theoilshouldbehomologousbarandhydraulicoil.Operatingprocedure：Clearupthecoverofbarrelandensurenopollutionbeforeopening.Openthecover,andinsertthesuctiontubeintobarrel.Opentheairingplugscrew(ifthereis).Connecttheoutletoffilterpresswithoilfillerofthetank(flangeofaircleaner).Stratthefilterpress.油位7.2.6向油管內(nèi)充油及液壓管網(wǎng)的排氣操作步驟：目的：清除系統(tǒng)中的空氣、污物。先從第一組開(kāi)始,其工作順序如下：將連接液壓缸有桿腔、無(wú)桿腔油管上的高壓膠管短接，保證同一模塊篦床兩液壓缸管路上同時(shí)執(zhí)行這一操作。檢查管線系統(tǒng)，確保正確連接；確保安裝在泵吸油管道上的蝶閥打開(kāi)；逐個(gè)檢查泵的注油孔，確保泵內(nèi)已充滿液壓油，并確保電機(jī)的旋向正確；為了能使管路充滿油，逐個(gè)地在比例換向閥完全打開(kāi)的條件下讓泵工作5~10分鐘。檢查回油過(guò)濾器的堵塞情況（如有必要，更換濾芯），重復(fù)此次操作2~3次。注意：油管中充完油后檢查油箱油位，如油位較低，則還應(yīng)向油箱中加油。對(duì)篦冷機(jī)的其它組油路段重復(fù)以上操作。7.2.7檢查系統(tǒng)的泄漏為了檢查系統(tǒng)的泄漏情況，關(guān)閉液壓缸進(jìn)、回油管上的所有高壓球閥，啟動(dòng)主泵電機(jī)，在控制柜的觸摸屏上設(shè)置推程回程時(shí)比例閥的一定開(kāi)度并啟動(dòng)，這時(shí)管道內(nèi)的壓力將達(dá)到系統(tǒng)的額定壓力，即使是連接處最

NKRL-YY-10value.FeedoilintopipelinesanddischargeairinthepipelinesProcedure:Purpose:Clearupairandpollutionfromthesystem.Beginwiththefirstgroup.Thesequenceis:Jointheflexiblepipesofcylinder'ssucker-rodcavityandrodlesscavity.Makesuretwohydrauliccylindersinonegratetodothisatthemeantime.Checkthepipelinetoberight.Checkthebutterflybamperattheinletofpumptobeopen.Checkeveryoilfillerholetomakesurethatoilisfilledintopump,andtherollingdirectionofpumpisright.Forthepipescanbefilledwithoil,opentheproportionalreversingvalve,andoperatethepumpfor5~10minonebyone.Checkiftheoilreturnfilterisplugged(replaceitifneeded).Repeatallthesefor2~3times.Notice:Afterthepipesarefilledwithoil,checkifitisneedtofillupoil.⑤Repeatallstepsaboveatotherspipes.ChecksystemleakageForcheckingleakage,closehigh-pressureballvalvesattheinletandoutletofhydrauliccylinders.Startthemotorofworkingpumps.Settheturnaroundjawopeningofproportionalreversingvalveonthetouchscreenofcontrolcabinet.Then南京凱盛國(guó)際工程有限公司NanjingRisenInternationalEngineeringCo.,Ltd輕微的泄漏也會(huì)被發(fā)現(xiàn)。在觸摸屏上設(shè)定停止模塊篦床運(yùn)行，打開(kāi)連接液壓缸有桿腔、無(wú)桿腔油管上的高壓球閥。在篦冷機(jī)的其他組油路段重復(fù)以上操作。7.2.8液壓缸的排氣排氣前必須確保如下先決條件：觸摸屏面板上已設(shè)定篦床處于停止運(yùn)行狀態(tài)或泵處于關(guān)閉狀態(tài)打開(kāi)連接液壓缸有桿腔、無(wú)桿腔油管上的高壓球閥閥。對(duì)于每模塊篦床，重復(fù)如下操作5~10分鐘：①起動(dòng)泵；在觸摸屏上調(diào)試狀態(tài)下設(shè)定將液壓缸活塞移動(dòng)到前端的限位位置；擰松缸尾的排氣，在觸摸屏上設(shè)定液壓缸活塞回退，使液壓缸無(wú)桿腔排氣；當(dāng)液壓缸活塞移動(dòng)到后端的限位位置時(shí)，擰緊缸尾的排氣螺栓，同時(shí)擰松缸頭的排氣螺栓，在觸摸屏上設(shè)定液壓缸活塞前推，使左、右液壓缸的有桿腔同時(shí)排氣。重復(fù)上述操作步驟幾次，直到從液壓缸中出來(lái)的油不含氣泡，重新擰緊排氣螺栓。

NKRL-YY-10thetubepressureachievesratedpressure.AndItwillbedetectedevenslightleakageatjoints.Stopoperatingthegrateonthetouchscreen.Openballvalvesatthecylinder'ssucker-rodcavityandrodlesscavity.Repeatallstepsaboveatotherspipes.ExhaustofcylindersEnsureitemsbeforeexhaustasfollow:Stopgratesandpumpsonthetouchscreen.Openballvalveswhichconnectscylinder'ssucker-rodcavitywithrodlesscavity.Operateeverygratefor5~10minutesasfollows.Startpumps.Operatethehydrauliccylindertofrontutmostpositiononthetouchscreen.Loosentheairevacuationattheendofcylinder.Andreturnthepistonofcylinder.Thismaketherodlesscavityoutgassing.Whenthepistonofcylindermovestorearend,screwuptheairevacuationattheendofcylinderandloosentheairevacuationatthefrontofcylinder.Operatethehydrauliccylinderforwardonthetouchscreen.Repeattheupperstepsseveraltimesuntilthereisnobubbleintheoilfromthe對(duì)篦冷機(jī)的每列篦床重復(fù)以上操作。當(dāng)對(duì)所有的缸全都完成排氣后，即可停機(jī)。注意：一定不要將液壓缸排氣時(shí)所接的液壓油（已污染）用于液壓系統(tǒng)中（如倒回油箱中）。排氣后，檢查油箱中的油位，如油位較低，應(yīng)向油箱中補(bǔ)油。檢查回油過(guò)濾器堵塞情況，以決定是否更換濾芯。7.2.9備用泵功能的測(cè)試調(diào)試期間，為了檢驗(yàn)電氣和液壓的連接以及備用泵的功能，所有的主泵都應(yīng)由備用泵替換來(lái)測(cè)試一遍。備用泵的切換應(yīng)按下面步驟進(jìn)行：切斷故障泵電機(jī)的電源，關(guān)閉故障泵所在回路的進(jìn)油蝶閥并將三通高壓球閥切換至備用泵油路導(dǎo)通。再打開(kāi)備用泵進(jìn)油蝶閥和高壓球閥。最后合上備用泵電機(jī)的電源，進(jìn)行開(kāi)車操作。對(duì)每一段操作后，如果運(yùn)行均無(wú)異常，停機(jī)后將管路上的所有閥門切換至主泵工作所需狀態(tài)。7.2.10耐壓試驗(yàn)溢流閥閥口調(diào)至最大；換向閥（手動(dòng)換向閥）在工作位。啟動(dòng)油泵，逐漸關(guān)閉溢流閥開(kāi)口度，直至關(guān)死。壓力試驗(yàn)應(yīng)逐步升高，每升高一級(jí)穩(wěn)壓1—3分鐘，達(dá)到試驗(yàn)壓力至22.5MPa后持壓10分鐘然后降至工作壓力18MPa進(jìn)行全面檢查，以系統(tǒng)所有焊縫和連接處無(wú)漏油為合格。電磁換向閥（手動(dòng)換向閥）

NKRL-YY-10cylinder.Thenscrewupairevacuationvalve.⑤Repeattheupperstepsateverygrate.Whileeverycylinderexhaustsair,stophydraulicsystem.Notice:donotdraintheoilintooiltankduringairexhaust.Afterairexhaust,checkiftheoillevelislow.Supplyoilifneeded.Checktheoilreturnfilter.Changeifneeded.TestofbackuppumpDuringtest,everymainpumpshouldbereplacedbybackuppump,fortestingelectricandhydraulicconnectandbackuppump.Swicththebackuppumpasfollows:Turnoffaccidentpumpmotoranditscircuitbutterflybamper.Switchtriplevalvetobackuptube.Openinletbutterflybamperandhigh-pressureballvalveofbackuppump.Startthemotorofbackuppump.Operateeverycircuit.Ifthereisnodisorder,switchallvalvestomainpumpstatusafterstopping.PressureprooftestAdjustoverflowvalvetomaximum.Ensurethechangevalveatworkingstatus.Startpump,andclosetheoverflowvalvegradually.Thepressurerisesstepbystep.Stabilizeeverypressureclassfor1~3minutes.Whenachieving22.5MPa,stabilizefor10minutes.Thenreduceto18MPa,andcheckthatall換至左位、右位分別在試驗(yàn)壓力下保壓10分鐘。耐壓實(shí)驗(yàn)完成后換上比