Who has the operating procedures for various positions in dry quenching of coke?
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Who has the operating procedures for various positions in dry quenching of coke? Please share~ Quenching coke control operator, quenching coke boiler operator, quenching coke power plant operator, quenching coke inspection worker. Safety regulations, technical specifications, operating procedures, job responsibilities, tasks, work standards, etc. Thank you; seeking high scores for purchase~~~
Technical Operating Procedures for Various Positions in Dry Quenching of Coke A. Control Room Position I. Job Responsibilities 1. Complete all tasks assigned by superiors. 2. Strictly follow the safety operating procedures for this position ； Have a thorough understanding of the operating parameters of the dry quenching process. 3. Be familiar with the structure, performance, operating principles, and maintenance of the equipment, and ensure proper care of the equipment assigned to this position. 4. Responsible for monitoring and operating the CRT and control panel in the control room, and strictly filling out daily production reports. 5. Assist inspection workers and boiler operators with their tasks. 6. Maintain good communication with the coke screening building and the control room of the coke ovens to ensure the stable and smooth operation of production activities. 7. Carry out the operations related to startup, shutdown, and this position properly. 8. Cooperate with maintenance personnel to carry out maintenance work. 9. Strictly control all technical parameters in accordance with the job-specific technical operating procedures to ensure the normal and stable operation of the dry quenching system. 10. Strictly implement the shift handover system, ensure a proper handover from one shift to the next, and leave no issues unresolved. 11. Diligently carry out the management of order, cleanliness, and standardization for one’s own position. II. Process parameters for dry quenching of coke III. Operating procedures for the relevant positions Temperature: T2 (temperature at the inlet of the dry quenching furnace) ≤ 130°C; T6 (temperature at the boiler inlet) 910°C ≤ T6 ≤ 940°C. Boiler outlet temperature ≥ 160°C. Temperature at the inlet of the second stage of the boiler: 265°C ≤ temperature in this stage ≤ 300°C, with a normal value of 280°C. Main steam temperature: 450°C ± 10°C. T5: 800–1000°C. Coke discharge temperature: ≤ 150°C in winter, ≤ 180°C in summer. Pressure: Pressure in the pre-storage section –100 Pa ≤ pressure ≤ 0 Pa. Boiler inlet pressure: –1100 Pa ≤ pressure, with a maximum limit of –1300 Pa. Pressure behind the main steam valve: 3.82 MPa. Drum pressure: 4.14 ± 0.1 MPa. Circulating air volume: 170,000–180,000 m3/h. Air-to-coke ratio: around 1200. Coke discharge rate: approximately 140 t/h. Drum liquid level: 0 ± 10 mm. 1. Control and adjustment during production: (1) Adjust the circulating air volume as necessary based on the operating conditions, to ensure that the coke discharge temperature remains within normal limits and that the boiler operates properly. ⑵ Maintain stability in the temperature, pressure, and evaporation rate of the steam generated by the boiler. ⑶ Maintain stability in the temperature of the gas entering the boiler, ensuring that it does not exceed 960°C. ⑷ Control the pressure in the pre-storage section of the dry quenching furnace as well as the material level inside the furnace, to ensure that the coking discharge temperature meets the process requirements. ⑸ Strictly control the water temperature after deoxygenation, the inlet and outlet water temperatures of the economizer, the steam temperature at the exit of the superheater, as well as the temperature and pressure of the main steam, in order to produce steam that meets the required standards. ⑹ Adjust the liquid levels of the demineralized water tank, deaerator, and steam drum in a timely manner according to the equipment operation status. ⑺Adjust the contents of H2, CO, CO2, O2, and H2O in the circulating gas in a timely manner to meet the process requirements. ※Control of combustible gas components within the system: (1) When the temperature of the gas entering the boiler is greater than 600°C and less than 960°C, air should be introduced to ensure that all combustible components within the system are completely burned. ⑵ When the temperature of the gas entering the boiler is less than 600°C, nitrogen should be introduced to adjust the level of combustible components in the system. ⑶ When the combustible components in the system rise abnormally and cannot be reduced by introducing air, nitrogen should be introduced to adjust the level of combustible components in the system. 2. Boiler control during operation: ⑴ Maintain a stable evaporation rate for the boiler, within the rated value. ⑵ Maintain normal temperature and steam pressure. ⑶ Ensure balanced water supply and maintain normal water levels. ⑷ Ensure that the quality of the superheated steam is satisfactory. ⑸ Maintain stable circulating air volume to improve boiler efficiency. ⑹ Ensure the safe and stable operation of the boiler unit. ⑺ Adjustments should be intensified during operation to ensure the stable operation of the boiler. 3. Adjustment of the boiler drum water level: ⑴ The boiler feedwater should be supplied evenly, to maintain the boiler water level within the allowable range of variation. Under normal operation, it is strictly prohibited to interrupt the boiler feed water. ⑵ The boiler feed water should be adjusted based on the indications of the drum level gauge (taking into account the feed water flow rate, desuperheating water flow rate, drain water flow rate, and steam flow rate as well), and it is necessary to ensure that the automatic control device for maintaining the drum level is always in good working condition. ⑶ When the drum water level is under automatic control, it is still necessary to monitor changes in the drum water level, and regularly check whether the feedwater and steam flow rates are consistent. ⑷ During operation, at least two level gauges must remain intact and reliable (one on-site level gauge and one balance tank for remote level measurement); they should provide accurate, clear, and easily visible readings, with adequate lighting. The level gauges should be checked and flushed once during each shift. If abnormalities are detected during operation, it should be rinsed promptly. 4. Operation of the circulating fan (I) Checks before starting the fan: 1. All maintenance work on the fan’s motor and mechanical components has been completed ； The area around the fan should be clean and well-lit. 2. The cooling water for each bearing flows smoothly; the temperature and vibration meters are available, and their readings are within the normal range. 3. The oil level in each bearing should be at the middle oil level line. 4. Open the nitrogen valve for the fan shaft seal and adjust the pressure. 5. The fan inlet damper should be in the closed position. 6. Check that all foot screws are secure, the motor’s grounding wire is in good condition, the manual cranking operates smoothly, and the safety guards are properly installed. 7. Contact the control room to confirm that there are no alarms in the center. 8. If the downtime is long, the motor insulation should be tested. 9. After maintenance, it is necessary to ensure that there is no one inside the gas circulation system; the system can be started only after all manholes in the entire dry quenching system have been closed. 10. Start the circulating fan centralized lubrication system and adjust it to normal operating condition. 11. Verify that all interlocks of the circulating fan are functioning properly; in emergency situations, lifting these interlocks requires the approval of the area supervisor. (II) Startup: 1. Contact the electrical staff to supply power, and conduct on-site as well as centralized \"aerial drop\" tests. 2. During on-site startup, switch the toggle switch in the on-site control box to “On-site”” ； For central operation, switch the toggle switch in the on-site control box to “Central”, then press the start button to activate the circulation fan. 3. Observe the motor current indicator; once it is normal, fully open the inlet damper, and adjust the volume of circulating air using the frequency control device of the circulation fan to start the air volume adjustment process. 4. After starting, check whether all components are operating normally. (III) Stop: 1. Press the stop button to halt the operation of the circulating fan. 2. Close the inlet damper of the circulation fan. 3. Close the cooling water inlet valve and the nitrogen valve for the fan shaft seal according to the actual situation. (IV) Shutdown interlocks during the operation of the circulation fan: 1. Upper limit for fan bearing temperature: 80°C 2. Upper limit for motor bearing temperature: 80°C 3. All boiler feed pumps stop: after a 30-second delay 4. Lower limit for boiler circulation water volume: 260 t/h 5. Upper limit for fan bearing vibration: 49 µm 6. Upper limit for drum water level: 150 mm (with a 30-second delay) 7. Lower limit for drum water level: -250 mm (with a 30-second delay) 8. Upper limit for main steam temperature: 468 °C (with a 30-second delay) 9. Lower limit for deaerator water level: -650 mm (with a 30-second delay) 10. Pressure of compressed air for instruments: below 0.4 MPa (with a 30-second delay) 11. Upper limit for fan motor coil temperature. 12. Abnormal supply of cooling water or lubricating oil. 13. Inverter failure. 14. All boiler forced circulation pumps have stopped. 15. The CDQ central control stops completely. 5. Elevator Operation (I) Preparations before operation: 1. Ensure that all circuit breakers in the elevator control cabinet located in the electrical room on the ground are closed, and that the “Emergency Stop” button is turned up. 2. Verify that the “Emergency Stop” button in the control room has been activated. 3. Confirm that there are no fault alarms displayed on the central alarm panel. 4. Verify that the power indicator light on the elevator control panel is displaying normally. 5. Verify that all toggle switches on the console are set to the zero position. 6. Insert the elevator operation key into the “Ready to Operate” keyhole and turn the key to the “ON” position. 7. Turn the “Emergency Stop” button on the console clockwise. 8. Press the “Incoming Line Contactor On” button. 9. Verify that the “Incoming Contactor On” indicator light is lit. (II) Central automatic operation of the elevator (which should be synchronized with other equipment). Checks before switching to automatic mode: 1. Verify that there are no alarms on the central fault alarm panel. 2. Confirm that the lift, loading equipment, and auxiliary equipment on site are operating properly. 3. Confirm that the control mode of other devices has been switched to “Central Automatic”. 4. Confirm that the elevator is stopped in a position where it can be put into automatic mode. Operation 1: Switch the \"Elevator operation area\" to \"Central automatic\". 2. The “main trunk” indicator light turns on on the CRT operation screen in the control room. 3. Verify that the “can operate automatically on the vehicle” indicator light for the lift is on, and that the “operation available” indicator light for the lift on the central CRT screen is also on. 4. After confirming that there are no issues, press the “Automatic Operation Start” button on the elevator, or click “Start” in the center of the CRT operation screen in the control room; the elevator will then begin to operate automatically. 6. Discharge unit operation: 1. Switch the operation status toggle switch on the on-site control panel of the discharge unit to “Central”. 2. Contact the central control to switch the belt operation to “central”. 3. Verify that the “Interlocked Operation Available” indicator light on the central control panel is lit. 4. Press the “Run” (Stop) button, and the indicator light will turn on. 5. After confirming once again that the equipment is operating normally, the “OK” light on the CRT will turn on, initiating automatic operation of the system (it will stop). B. Inspection Worker Position I. Job Responsibilities: 1. Responsible for the on-site operation, maintenance, and adjustment of lifting equipment, furnace top traveling devices, charging devices, discharging devices, the main equipment of the dry quenching furnace, as well as boilers and their auxiliary equipment. 2. Keep proper records of equipment inspections. 3. Properly carry out chemical dosing for the boiler feed water. 4. Actively cooperate with the main controller and boiler operator in on-site operations. 5. Carry out the relevant operations for starting up and shutting down. 6. Cooperate with maintenance personnel to carry out maintenance work. 7. Strictly adhere to the operational procedures for the position, enhance inspections and maintenance, to ensure the safe and stable operation of on-site equipment. 8. Strictly implement the shift handover system, ensure proper handover from one shift to another and clear documentation, leaving no issues unresolved. 9. Diligently carry out the management of order, cleanliness, and hygiene in one’s own position. II. Operating Procedures for the Position 1. Boiler System (1) Deaeration Pump Room – Inspection Route and Key Inspection Items: Level of the desalination water tank → Deaerator feed pump (oil level, current, sound, inlet and outlet pressures) → Standby pump → Boiler feed pump (oil level, current, sound, cooling water, shaft temperature, inlet and outlet pressures) → Standby pump → Chemical dosing pump → Sampling device → Deaerator circulation pump → Comparison of deaerator level with that in the control room → Low-pressure steam pipeline (low-pressure steam pressure control valve, comparison with data in the control room). (2) Boiler – Inspection routes and items: Forced circulation pump (cooling water volume, inlet and outlet pressures) → standby pump (whether it is in hot standby mode) → three-way control valve, compared with data from the control room → opening status of steam traps in all areas → main steam pressure control valve, compared with data from the control room → drum pressure and level, compared with data from the control room. (3) Feedwater preheater 2. Dry quenching furnace – Inspection route and items to be checked: (1) 1DC, 2DC type ash discharge valves → chain scraper → bucket elevator → pressure control valve of the storage chamber (bypass) → air introduction valve (center plug) → circulating gas bypass valve → elevators (operation of each device) → loading device → roof water seal → roof vent valve water seal → operation of dust collection pipes → 1DC water seal. (2) Coke discharge system: Operation of the compressed air and nitrogen dual systems → Pressure at the inlet and outlet of the vibrating feeder → Nitrogen backpressure → Rotary seal valve → Testing and inspection of the CO alarm system. (3) Circulation fan: (oil pressure, nitrogen pressure, cooling water flow rate) → On/off status of nitrogen filling valves before and after the fan (bypass). (4) Ash discharge system: 1DC and 2DC level sensors and ash discharge valves → chain scraper → bucket elevator → double water-cooling jacket for water inlet and outlet. 3. Electrical control system: (1) Routine inspection and maintenance of system instruments are carried out on a daily basis during the day shift, as part of the regular checks for each shift ； (2) The limit switches and wiring should be checked twice per shift. 4. Dust removal system: (1) Primary dust removal, secondary dust removal, and ash discharge devices; (2) Environmental dust removal system. 5. Others: (1) Power distribution room: Inspection and recording once per shift; (2) Elevators: Inspection and recording once per week; (3) Platforms and passages: System inspection and recording daily during the working shift; (4) Auxiliary pipelines: System inspection and recording once per week. C. Boiler operator procedures: I. Job responsibilities: 1. Complete all tasks assigned by superiors. 2. Strictly follow the safety and technical procedures for this position. 3. Be familiar with the structure, performance, and operating principles of the equipment, and ensure proper maintenance of the equipment assigned to this position. 4. For each shift, carry out sewage discharge work according to the water quality conditions, as well as calibrate the water level gauge. At least 1 session is scheduled per shift. 5. Ensure the sensitivity and safety of safety accessories, and keep proper records. The safety valves should be manually checked once per month during the first shift; such operations must be carried out in an organized manner. 6. Record the operating status of the equipment under management every 2 hours, namely the boiler system and the deaeration pump room. 7. Work in conjunction with the control operator to ensure that all equipment is operating properly and that all parameters are displayed correctly. 8. All standby pumps are in good condition. 9. Maintain the cleanliness of the interior of the deaeration pump room, its floor, and the equipment. 10. Assist maintenance workers in maintaining the equipment, and be responsible for inspecting the equipment within this inspection system; for equipment that fails the inspection, promptly notify the maintenance staff to repair it. 11. The sewage discharge time at each point shall not exceed 10 seconds. 12. Carry out shift handover tasks carefully. II. Process Parameters and Specifications
| Item Name | Unit | Value |
|-------------|------|-------|
| Dry quenching capacity | tt/h | 140 |
| Circulating gas volume (standard condition) | max mNm3/h | 199,000; normal: 170,000 |
| Temperature of inlet circulating inert gas | °C | 900–980 (calculated as 960°C) |
| Evaporation rate | max tt/h | 76 |
| Rated steam pressure | MMPa | 4.14 |
| Rated steam temperature | °C | 450±10°C |
| Boiler feedwater temperature | °C | 104 |
| Resistance on the boiler’s circulating gas side | Ppa | ~750 |
| Temperature of outlet circulating inert gas | °C | 160–180 |
| Boiler type | Forced circulation + natural circulation |
| Outer surface temperature of the boiler | °C | ≯60 |
| Boiler thermal efficiency | % | ≮80% |
| Boiler air leakage coefficient | % | ≤1% |
| Total boiler blowdown | % | 2% |
III. Operating Procedures
Startup, operation, and maintenance of the equipment
1. Forced circulation water pump
(a) Checks before starting the forced circulation water pump:
(1) Ensure that all maintenance work on the forced circulation water pump and the boiler’s circulating water system pipelines has been completed. (2) Clean the area around the equipment. (3) Check whether all the meters in the water system of the forced circulation water pump are complete. (4) Check whether the positions of all valves in the boiler circulating water system are in a state ready for startup. (5) Check whether the positions of all valves in the circulating cooling water system are in a state ready for startup. (6) Contact electrical professionals to check the motor’s insulation; power can be supplied only after confirming that the insulation is in good condition. (II) Startup (1) Confirm that the preparatory work is complete and the drum liquid level is normal. (2) Open the valve at the inlet of the forced circulation water pump to ensure that the pump is filled with water, with no air trapped inside the pump or in the inlet piping. (3) Open the valve of the circulation cooling water pipeline for the forced circulation water pump; visually check that the water flow in the flow observer should be normal. (4) Connect the power supply; once the pump’s rotation speed reaches normal levels, gradually open the outlet valve until the pump is operating under its designed conditions. (5) Tighten the compression nuts on the packing gland evenly, while paying attention to the temperature rise in the packing chamber. (III) Shutdown: (1) Close the valve on the pump’s inlet pipeline, and gradually close the valve on the outlet pipeline. (2) Cut off the power supply to the motor. (3) Close the valve of the cooling water pipeline for the forced circulation water pump. (IV) Normal operation and maintenance of the forced circulation water pump: (1) Regularly monitor the outlet water pressure of the forced circulation water pump to keep it within normal levels. (2) Each bearing should be maintained with sufficient lubricating oil, and the quality of the oil should be good. (3) The vibration of the motor bearings should be normal, with no abnormal noises. 2. Continuous Drain Expansion Tank (I) Checks before starting the continuous drain expansion tank: (1) Confirm that all maintenance work on the continuous drain expansion tank and its associated piping systems has been completed. (2) Clean the area around the equipment. (3) Check whether the positions of all valves in the continuous wastewater discharge system are in the ready-to-start state. (4) Confirm that the drum liquid level is normal. (II) Startup: (1) Open the valve on the inlet pipeline of the continuous sewage expansion tank. (2) Once the liquid level in the continuous drainage expansion vessel reaches normal levels, open the valve on the outlet pipeline of the continuous drainage expansion vessel as well as its steam discharge valve. (III) Shutdown: (1) Close the valve on the inlet pipeline of the continuous blowdown expansion tank. (2) Close the valve on the outlet pipeline of the continuous drainage expansion tank and the exhaust valve of the continuous drainage expansion tank. (IV) Normal operation and maintenance of the continuous blowdown expansion tank: (1) When the continuous blowdown expansion tank is operating normally, its liquid level should be maintained within the normal range. 3. Periodic Drain Expansion Valve (I) Checks before starting the periodic drain expansion valve: (1) Confirm that all maintenance work on the periodic drain expansion valve and the associated piping system has been completed. (2) Clean the area around the equipment. (3) Check whether the valves on the pipelines related to the regular sewage discharge system are in a ready-to-start position. (II) Startup: (1) Open the valve on the inlet pipeline of the periodic blowdown expansion tank. (2) Once the liquid level in the periodic drain expansion vessel reaches normal levels, open the valve on the outlet pipeline of the periodic drain expansion vessel. (III) Shutdown: (1) Close the valve on the inlet pipeline of the periodic blowdown expansion tank. (2) Close the valve on the outlet pipeline of the periodic blowdown expansion tank. (IV) Normal operation and maintenance of the periodic drain expansion vessel: (1) When the periodic drain expansion vessel is operating normally, its liquid level should be kept within the normal range. 4. Flushing operation of the boiler glass tube water level gauge (I) Maintenance requirements: (1) Keep the water level gauge clean and bright, with clear water level indication. (2) The water level gauge must be flushed once per shift, and any abnormal conditions detected in the gauge must be addressed immediately. (3) Before flushing the water level gauge, it is necessary to contact the control room and obtain their permission before proceeding with the operation. 5. Maintenance operations for boiler safety valves and pressure gauges (I) Maintenance of safety valves (1) Keep the safety valves clean at all times to prevent the valve springs and other components from becoming covered with dirt or corroding, and to avoid blockages in the exhaust pipes of the safety valves caused by foreign objects. (2) Regularly check whether the lead seal of the safety valve is intact, and inspect whether the weight of the lever-type safety valve is loose, displaced, or used to suspend heavy objects. (3) When signs of leakage are detected in the safety valve, it should be replaced or repaired promptly. It is prohibited to use load to reduce or eliminate the leakage of safety valves. (4) To prevent the safety valve from being stuck or blocked by scale and dirt, it is required to perform a manual discharge test on the safety valve every Monday during the morning shift. (II) The operation method is as follows: (1) During the test, gently lift the lifting handle slowly; once steam is heard being released from the valve, slowly lower the handle. It is not allowed to lift the lifting hand quickly and then suddenly lower it. (2) After the emission test, if a leaking sound is heard inside the safety valve, it may be due to the valve disc being tilted; in this case, the lifting handle can be raised again to conduct another test. (III) Maintenance of pressure gauges (1) Pressure gauges should be kept clean; the glass on the dial should be clear and bright, and the pointer readings on the dial should be clearly visible. (2) The connection pipes of the pressure gauge should be blown out regularly to prevent blockages. During purging, the three-way valve should be rotated slowly to avoid damaging the pressure gauge. (3) Regularly check whether the fluctuations of the pressure gauge pointer are normal ； Check the pressure gauge connection tubes for any signs of leakage of liquid or steam. (4) The use of a pressure gauge should be stopped if any of the following conditions occur: (5) In a pressure gauge equipped with a stop pin, the pointer cannot return to that stop pin after moving when there is no pressure ； In a pressure gauge without a limiting pin, the pointer reading exceeds the specified allowable error when there is no pressure. (6) The glass on the surface of the pressure gauge is broken, or the scale on the dial is blurred. (7) The seal is damaged or has exceeded its verification validity period. (8) Internal leakage in the gauge or pointer oscillation. (9) Other defects that affect the accurate indication of the pressure gauge. 6. Boiler feedwater and steam sampling operations: (1) First, open the inlet and outlet valves for the cooling water of the feedwater, boiler water, and steam samplers to ensure smooth flow of the cooling water. (2) Open the secondary valves for boiler feedwater, furnace water, and steam sampling, and then open the sampling inlet valve of the sampler. (3) Sampling of feed water, boiler water, and steam should be maintained in a steady-flow state with a stable flow rate of the water samples. (4) The sampling tube should be rinsed first during the initial sampling. D. Operating Procedures for Dust Removal Workers in Dry Quenching of Coke I. Preparatory Work Before Operation 1. Before starting the machine, check the dust collector to ensure that all its safety devices are in good condition and functional. 2. Check whether the dust collection points, sealed doors, and covers at the workstations are properly and firmly in place. 3. Conduct a thorough inspection in accordance with the contents and requirements specified in the equipment inspection checklist. 4. Check that the accident switch is set to position “0”. 5. Check the fan and perform manual shaft rotation; the air intake control valve should be closed. 6. Confirm that power has been supplied, and proceed with an air-drop test run. II. Operations: 1. Upon receiving the instruction to start production, the dust removal equipment must be turned on first; once it is operating properly, the coking screening section should be notified to start the conveyor belt. 2. Upon receiving the stop command, first shut down the production equipment; only after the production equipment has come to a complete stop should the dust removal equipment be turned off. 3. The dust removal pipeline network controls the relevant production stations; in accordance with production requirements, the valves at various dust collection points and pipelines are adjusted as needed – the valves for the desired air intake points are opened, while the valves for the other points that do not require air intake are closed. 4. Provisions for preventing technical operation accidents: (1) Regularly inspect and replace damaged filter bags to avoid pollution incidents. (2) Check the ash level in the ash hopper as required to prevent pipe blockage. (3) If it is found that ash discharge from the ash bin is not smooth, the manual slide valve should first be closed to an appropriate position to prevent excessive movement of the ash discharge valve after processing from causing secondary dust generation. 5. Regulations and methods for starting and stopping the operation: (1) Upon receiving the command to start, turn on the dust removal fan; once the fan is operating properly, open the air intake valve of the fan. (2) Turn on the digital display of the back-blow dust cleaning controller, and adjust the blowing time and pulse interval according to the amount of dust. (3) Check whether the digital display and the pulse valve are working properly, as well as whether the spraying is forceful. If the pulse valve fails to operate or operates inadequately, there will be no sound or only a faint sound; if the filter bag is damaged or detached, there will be a loud sound. (4) Check whether the chimney is smoking. (5) When the amount of ash is low, the scraper conveyor should continue to operate to prevent dust accumulation; it is necessary to check that the amount of ash in the ash hopper does not block the air inlet ducts. (6) Upon receiving the shutdown command, first close the fan valve before stopping the fan. (7) Turn off the back-blow dust cleaning and dust discharge controllers. 6. Manual operation at the ash transfer site: (1) Switch the operation mode in the ash unloading motor control box to “Site”. (2) Start the bucket elevator and scrapers #1 and #3; stop scraper #2. (3) Select the chamber number to which the ash is to be conveyed, and activate the format valve and the screw ash conveyor. (4) Press the corresponding ash discharge start button; the green light will turn on. Once the ash transfer is complete, press the “Ash Transfer Stop” button and the red light will turn on. (5) Proceed sequentially with transporting the remaining ash; after the dust collector hoppers are empty, transport the ash from the cooler and the louver-type pre-dust collector. At this point, stop scraper No. 3 and start scraper No. 2. 7. Manual ash unloading operation at the powder coke silo site: (1) Switch the operation mode in the humidifier control box to “Site”. (2) After the ash transport vehicle arrives, record its arrival time, license plate number, and tonnage. (3) The truck bed is at the discharge port of the humidifier. (4) Power-on sequence: Turn on the humidifier first, then turn on the ash discharge valve. (5) Press the start button of the humidifier; the indicator light will turn on, and the time at which ash unloading begins is recorded. (6) After the humidifier is operating normally, press the button to start the motor of the ash discharge valve in the powder and coke bin. (7) Once the material flow in the ash bin enters the humidifier, open the water supply valve of the humidifier and adjust its opening to an appropriate level, so as to prevent secondary dust generation and the discharge of wet sludge. 8. Shutdown procedures for the powder coking bin: (1) Once the truck is full, first stop the motor of the discharge valve, then stop the water supply valve. When there is no material left in the humidifier, shut down the humidifier and inform the driver to drive away. (2) Record the ash unloading stop time. 9. Manual operation at the site for stoppage of air injection. (1) Switch the operation mode in the on-site control box of the wind-suction unit to “On-site”. (2) First, stop the air supply for a certain unit; once the red light comes on, press the corresponding blowing button and verify that the green light turns on. After 15 seconds, press the blowing button again; once the red light comes on, the air supply will be activated. (3) Operate the remaining stop-air injection in sequence. 10. Control room operations: (1) Contact the control room before starting up. (2) The machine may be tested only after confirming that the power, lubrication, water, and compressed air systems are functioning properly. (3) Start the dust removal fan; once everything is confirmed to be in order, open the fan’s air intake control valve. (4) Check the operation of the dust removal fan; if any abnormalities are detected, stop the machine for inspection and repair. (5) Activate the backflush cleaning mechanism. (6) When discharging ash, turn on the humidifying water first. (7) When discharging ash, first start the scraper conveyor, then open the ash discharge valve. E. Position at the circulating water and cooling tower treatment station – Operating procedures for the position I. Preparation work 1. Cooling water system: (1) Check whether the water volume stored and the water replenishment are normal ； (2) If there is a water quality stabilization system, ensure it is put into operation properly ； (3) Is the cooling tower fan turned on? Depends on water temperature and weather (cooling water temperature t
| Item Name | Unit | Value |
|-------------|------|-------|
| Dry quenching capacity | tt/h | 140 |
| Circulating gas volume (standard condition) | max mNm3/h | 199,000; normal: 170,000 |
| Temperature of inlet circulating inert gas | °C | 900–980 (calculated as 960°C) |
| Evaporation rate | max tt/h | 76 |
| Rated steam pressure | MMPa | 4.14 |
| Rated steam temperature | °C | 450±10°C |
| Boiler feedwater temperature | °C | 104 |
| Resistance on the boiler’s circulating gas side | Ppa | ~750 |
| Temperature of outlet circulating inert gas | °C | 160–180 |
| Boiler type | Forced circulation + natural circulation |
| Outer surface temperature of the boiler | °C | ≯60 |
| Boiler thermal efficiency | % | ≮80% |
| Boiler air leakage coefficient | % | ≤1% |
| Total boiler blowdown | % | 2% |
III. Operating Procedures
Startup, operation, and maintenance of the equipment
1. Forced circulation water pump
(a) Checks before starting the forced circulation water pump:
(1) Ensure that all maintenance work on the forced circulation water pump and the boiler’s circulating water system pipelines has been completed. (2) Clean the area around the equipment. (3) Check whether all the meters in the water system of the forced circulation water pump are complete. (4) Check whether the positions of all valves in the boiler circulating water system are in a state ready for startup. (5) Check whether the positions of all valves in the circulating cooling water system are in a state ready for startup. (6) Contact electrical professionals to check the motor’s insulation; power can be supplied only after confirming that the insulation is in good condition. (II) Startup (1) Confirm that the preparatory work is complete and the drum liquid level is normal. (2) Open the valve at the inlet of the forced circulation water pump to ensure that the pump is filled with water, with no air trapped inside the pump or in the inlet piping. (3) Open the valve of the circulation cooling water pipeline for the forced circulation water pump; visually check that the water flow in the flow observer should be normal. (4) Connect the power supply; once the pump’s rotation speed reaches normal levels, gradually open the outlet valve until the pump is operating under its designed conditions. (5) Tighten the compression nuts on the packing gland evenly, while paying attention to the temperature rise in the packing chamber. (III) Shutdown: (1) Close the valve on the pump’s inlet pipeline, and gradually close the valve on the outlet pipeline. (2) Cut off the power supply to the motor. (3) Close the valve of the cooling water pipeline for the forced circulation water pump. (IV) Normal operation and maintenance of the forced circulation water pump: (1) Regularly monitor the outlet water pressure of the forced circulation water pump to keep it within normal levels. (2) Each bearing should be maintained with sufficient lubricating oil, and the quality of the oil should be good. (3) The vibration of the motor bearings should be normal, with no abnormal noises. 2. Continuous Drain Expansion Tank (I) Checks before starting the continuous drain expansion tank: (1) Confirm that all maintenance work on the continuous drain expansion tank and its associated piping systems has been completed. (2) Clean the area around the equipment. (3) Check whether the positions of all valves in the continuous wastewater discharge system are in the ready-to-start state. (4) Confirm that the drum liquid level is normal. (II) Startup: (1) Open the valve on the inlet pipeline of the continuous sewage expansion tank. (2) Once the liquid level in the continuous drainage expansion vessel reaches normal levels, open the valve on the outlet pipeline of the continuous drainage expansion vessel as well as its steam discharge valve. (III) Shutdown: (1) Close the valve on the inlet pipeline of the continuous blowdown expansion tank. (2) Close the valve on the outlet pipeline of the continuous drainage expansion tank and the exhaust valve of the continuous drainage expansion tank. (IV) Normal operation and maintenance of the continuous blowdown expansion tank: (1) When the continuous blowdown expansion tank is operating normally, its liquid level should be maintained within the normal range. 3. Periodic Drain Expansion Valve (I) Checks before starting the periodic drain expansion valve: (1) Confirm that all maintenance work on the periodic drain expansion valve and the associated piping system has been completed. (2) Clean the area around the equipment. (3) Check whether the valves on the pipelines related to the regular sewage discharge system are in a ready-to-start position. (II) Startup: (1) Open the valve on the inlet pipeline of the periodic blowdown expansion tank. (2) Once the liquid level in the periodic drain expansion vessel reaches normal levels, open the valve on the outlet pipeline of the periodic drain expansion vessel. (III) Shutdown: (1) Close the valve on the inlet pipeline of the periodic blowdown expansion tank. (2) Close the valve on the outlet pipeline of the periodic blowdown expansion tank. (IV) Normal operation and maintenance of the periodic drain expansion vessel: (1) When the periodic drain expansion vessel is operating normally, its liquid level should be kept within the normal range. 4. Flushing operation of the boiler glass tube water level gauge (I) Maintenance requirements: (1) Keep the water level gauge clean and bright, with clear water level indication. (2) The water level gauge must be flushed once per shift, and any abnormal conditions detected in the gauge must be addressed immediately. (3) Before flushing the water level gauge, it is necessary to contact the control room and obtain their permission before proceeding with the operation. 5. Maintenance operations for boiler safety valves and pressure gauges (I) Maintenance of safety valves (1) Keep the safety valves clean at all times to prevent the valve springs and other components from becoming covered with dirt or corroding, and to avoid blockages in the exhaust pipes of the safety valves caused by foreign objects. (2) Regularly check whether the lead seal of the safety valve is intact, and inspect whether the weight of the lever-type safety valve is loose, displaced, or used to suspend heavy objects. (3) When signs of leakage are detected in the safety valve, it should be replaced or repaired promptly. It is prohibited to use load to reduce or eliminate the leakage of safety valves. (4) To prevent the safety valve from being stuck or blocked by scale and dirt, it is required to perform a manual discharge test on the safety valve every Monday during the morning shift. (II) The operation method is as follows: (1) During the test, gently lift the lifting handle slowly; once steam is heard being released from the valve, slowly lower the handle. It is not allowed to lift the lifting hand quickly and then suddenly lower it. (2) After the emission test, if a leaking sound is heard inside the safety valve, it may be due to the valve disc being tilted; in this case, the lifting handle can be raised again to conduct another test. (III) Maintenance of pressure gauges (1) Pressure gauges should be kept clean; the glass on the dial should be clear and bright, and the pointer readings on the dial should be clearly visible. (2) The connection pipes of the pressure gauge should be blown out regularly to prevent blockages. During purging, the three-way valve should be rotated slowly to avoid damaging the pressure gauge. (3) Regularly check whether the fluctuations of the pressure gauge pointer are normal ； Check the pressure gauge connection tubes for any signs of leakage of liquid or steam. (4) The use of a pressure gauge should be stopped if any of the following conditions occur: (5) In a pressure gauge equipped with a stop pin, the pointer cannot return to that stop pin after moving when there is no pressure ； In a pressure gauge without a limiting pin, the pointer reading exceeds the specified allowable error when there is no pressure. (6) The glass on the surface of the pressure gauge is broken, or the scale on the dial is blurred. (7) The seal is damaged or has exceeded its verification validity period. (8) Internal leakage in the gauge or pointer oscillation. (9) Other defects that affect the accurate indication of the pressure gauge. 6. Boiler feedwater and steam sampling operations: (1) First, open the inlet and outlet valves for the cooling water of the feedwater, boiler water, and steam samplers to ensure smooth flow of the cooling water. (2) Open the secondary valves for boiler feedwater, furnace water, and steam sampling, and then open the sampling inlet valve of the sampler. (3) Sampling of feed water, boiler water, and steam should be maintained in a steady-flow state with a stable flow rate of the water samples. (4) The sampling tube should be rinsed first during the initial sampling. D. Operating Procedures for Dust Removal Workers in Dry Quenching of Coke I. Preparatory Work Before Operation 1. Before starting the machine, check the dust collector to ensure that all its safety devices are in good condition and functional. 2. Check whether the dust collection points, sealed doors, and covers at the workstations are properly and firmly in place. 3. Conduct a thorough inspection in accordance with the contents and requirements specified in the equipment inspection checklist. 4. Check that the accident switch is set to position “0”. 5. Check the fan and perform manual shaft rotation; the air intake control valve should be closed. 6. Confirm that power has been supplied, and proceed with an air-drop test run. II. Operations: 1. Upon receiving the instruction to start production, the dust removal equipment must be turned on first; once it is operating properly, the coking screening section should be notified to start the conveyor belt. 2. Upon receiving the stop command, first shut down the production equipment; only after the production equipment has come to a complete stop should the dust removal equipment be turned off. 3. The dust removal pipeline network controls the relevant production stations; in accordance with production requirements, the valves at various dust collection points and pipelines are adjusted as needed – the valves for the desired air intake points are opened, while the valves for the other points that do not require air intake are closed. 4. Provisions for preventing technical operation accidents: (1) Regularly inspect and replace damaged filter bags to avoid pollution incidents. (2) Check the ash level in the ash hopper as required to prevent pipe blockage. (3) If it is found that ash discharge from the ash bin is not smooth, the manual slide valve should first be closed to an appropriate position to prevent excessive movement of the ash discharge valve after processing from causing secondary dust generation. 5. Regulations and methods for starting and stopping the operation: (1) Upon receiving the command to start, turn on the dust removal fan; once the fan is operating properly, open the air intake valve of the fan. (2) Turn on the digital display of the back-blow dust cleaning controller, and adjust the blowing time and pulse interval according to the amount of dust. (3) Check whether the digital display and the pulse valve are working properly, as well as whether the spraying is forceful. If the pulse valve fails to operate or operates inadequately, there will be no sound or only a faint sound; if the filter bag is damaged or detached, there will be a loud sound. (4) Check whether the chimney is smoking. (5) When the amount of ash is low, the scraper conveyor should continue to operate to prevent dust accumulation; it is necessary to check that the amount of ash in the ash hopper does not block the air inlet ducts. (6) Upon receiving the shutdown command, first close the fan valve before stopping the fan. (7) Turn off the back-blow dust cleaning and dust discharge controllers. 6. Manual operation at the ash transfer site: (1) Switch the operation mode in the ash unloading motor control box to “Site”. (2) Start the bucket elevator and scrapers #1 and #3; stop scraper #2. (3) Select the chamber number to which the ash is to be conveyed, and activate the format valve and the screw ash conveyor. (4) Press the corresponding ash discharge start button; the green light will turn on. Once the ash transfer is complete, press the “Ash Transfer Stop” button and the red light will turn on. (5) Proceed sequentially with transporting the remaining ash; after the dust collector hoppers are empty, transport the ash from the cooler and the louver-type pre-dust collector. At this point, stop scraper No. 3 and start scraper No. 2. 7. Manual ash unloading operation at the powder coke silo site: (1) Switch the operation mode in the humidifier control box to “Site”. (2) After the ash transport vehicle arrives, record its arrival time, license plate number, and tonnage. (3) The truck bed is at the discharge port of the humidifier. (4) Power-on sequence: Turn on the humidifier first, then turn on the ash discharge valve. (5) Press the start button of the humidifier; the indicator light will turn on, and the time at which ash unloading begins is recorded. (6) After the humidifier is operating normally, press the button to start the motor of the ash discharge valve in the powder and coke bin. (7) Once the material flow in the ash bin enters the humidifier, open the water supply valve of the humidifier and adjust its opening to an appropriate level, so as to prevent secondary dust generation and the discharge of wet sludge. 8. Shutdown procedures for the powder coking bin: (1) Once the truck is full, first stop the motor of the discharge valve, then stop the water supply valve. When there is no material left in the humidifier, shut down the humidifier and inform the driver to drive away. (2) Record the ash unloading stop time. 9. Manual operation at the site for stoppage of air injection. (1) Switch the operation mode in the on-site control box of the wind-suction unit to “On-site”. (2) First, stop the air supply for a certain unit; once the red light comes on, press the corresponding blowing button and verify that the green light turns on. After 15 seconds, press the blowing button again; once the red light comes on, the air supply will be activated. (3) Operate the remaining stop-air injection in sequence. 10. Control room operations: (1) Contact the control room before starting up. (2) The machine may be tested only after confirming that the power, lubrication, water, and compressed air systems are functioning properly. (3) Start the dust removal fan; once everything is confirmed to be in order, open the fan’s air intake control valve. (4) Check the operation of the dust removal fan; if any abnormalities are detected, stop the machine for inspection and repair. (5) Activate the backflush cleaning mechanism. (6) When discharging ash, turn on the humidifying water first. (7) When discharging ash, first start the scraper conveyor, then open the ash discharge valve. E. Position at the circulating water and cooling tower treatment station – Operating procedures for the position I. Preparation work 1. Cooling water system: (1) Check whether the water volume stored and the water replenishment are normal ； (2) If there is a water quality stabilization system, ensure it is put into operation properly ； (3) Is the cooling tower fan turned on? Depends on water temperature and weather (cooling water temperature t
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Operating and Maintenance Procedures for Environmental Dust Removal Fan Equipment – Equipment Operating Procedures
I. Main Technical Specifications and Allowable Limit Parameters of the Equipment
Fan Model: AH—R230DW
Rotation Speed: 970 r/min
Flow Rate: 327,000 m³/h
Medium Temperature: 110°C
Total Pressure: 6500 Pa
Medium Density: 0.879 Kg/m³
Date of Manufacture: July 2003
Manufacturer: Wuhan Blower Factory
Motor Model: YKKPT560-6
Current: 107 A
Power: 900 kW
Voltage: 6000 V
Rotation Speed: 1000 r/min
Manufacturer: Jiamusi Motor Factory
Important Accessories:
1. Fan shaft bearings
2. Fan inlet actuator
II. Provisions for the Handover and Use of the Equipment
1. During shift handover, a detailed description of the equipment’s operation during that shift must be provided, including the temperature of each bearing, the lubrication status, operating noises, as well as any signs of wear, detachment, or loosening of components. No information should be concealed. 2. Any abnormal conditions observed during equipment operation, the procedures for dealing with them, as well as the issues that need attention during operations, should be clearly explained to the successor. 3. It is necessary to explain to the successor whether the equipment operates properly after maintenance and component replacement, as well as any other operational requirements. 4. Any issues that arise during the inspection or operation of the equipment in this class must be carefully recorded in the equipment defect log. 5. The successor should listen carefully to the handover by the person handing over the duties and conduct a thorough inspection of the equipment. 6. Any issues identified upon taking over the shift should be addressed through consultation with the person handing over the shift, and reported to the shift supervisor or relevant personnel along with proper documentation. Issues that arise after taking over the shift are the responsibility of the person who has taken over. III. Steps for operating the mixer (I) Preparation before operation 1. The operator must understand the technical specifications of the equipment and hold an operation certificate in order to operate it. 2. Before operation, check that the mechanical and electrical equipment is complete and in good condition, that the connections are secure, that the lubrication is adequate, and that there are no damages to the structure; also open the valve for bearing cooling water. (II) Operating procedures for starting up and shutting down the equipment. IV. Safety precautions during equipment use: 1. It is not allowed to remove or modify the safety protection devices of the equipment arbitrarily. 2. Welding or cutting on the structure of the equipment is not permitted without approval. 3. In the event of a malfunction, the equipment must be stopped for repairs; it is strictly prohibited to address faults while the equipment is running. 4. It is prohibited to repair equipment faults while it is under power or under pressure. 5. Do not use the equipment under excessive pressure. 6. It is strictly prohibited to pull or close switches under load. 7. In the event of a fire involving electrical equipment, the power supply should be cut off immediately, and a dry powder fire extinguisher should be used to put out the fire. 8. When the equipment is operated despite being faulty, reliable protective measures must be in place; any new issues identified during use should be reported and addressed promptly. V. Troubleshooting of Malfunctions During Equipment Operation 1. If severe noise or intense vibration is detected during equipment operation, the machine should be stopped immediately for inspection. 2. If the temperature of the bearings in various parts of the equipment exceeds 65°C, and it continues to rise despite taking corrective measures, or if smoking or ignition occurs, the equipment must be shut down immediately as an emergency. 3. When there is severe axial movement of the blower or motor and the components are in a dangerous condition, the machine should be stopped promptly for repair. 4. If electrical equipment starts smoking or overheating, the power supply must be cut off immediately, and the issue should be inspected and addressed. 5. In the event of a sudden power outage, immediately turn off the power supply; once power is restored, start the equipment following the startup sequence. VI. A system of confirmation by two or more persons for key positions: The operations such as coke reception and transportation are carried out only after confirming, in accordance with the technical operating procedures and in coordination with the relevant personnel, that everything is in order.
I. Main Technical Specifications and Allowable Limit Parameters of the Equipment
Fan Model: AH—R230DW
Rotation Speed: 970 r/min
Flow Rate: 327,000 m³/h
Medium Temperature: 110°C
Total Pressure: 6500 Pa
Medium Density: 0.879 Kg/m³
Date of Manufacture: July 2003
Manufacturer: Wuhan Blower Factory
Motor Model: YKKPT560-6
Current: 107 A
Power: 900 kW
Voltage: 6000 V
Rotation Speed: 1000 r/min
Manufacturer: Jiamusi Motor Factory
Important Accessories:
1. Fan shaft bearings
2. Fan inlet actuator
II. Provisions for the Handover and Use of the Equipment
1. During shift handover, a detailed description of the equipment’s operation during that shift must be provided, including the temperature of each bearing, the lubrication status, operating noises, as well as any signs of wear, detachment, or loosening of components. No information should be concealed. 2. Any abnormal conditions observed during equipment operation, the procedures for dealing with them, as well as the issues that need attention during operations, should be clearly explained to the successor. 3. It is necessary to explain to the successor whether the equipment operates properly after maintenance and component replacement, as well as any other operational requirements. 4. Any issues that arise during the inspection or operation of the equipment in this class must be carefully recorded in the equipment defect log. 5. The successor should listen carefully to the handover by the person handing over the duties and conduct a thorough inspection of the equipment. 6. Any issues identified upon taking over the shift should be addressed through consultation with the person handing over the shift, and reported to the shift supervisor or relevant personnel along with proper documentation. Issues that arise after taking over the shift are the responsibility of the person who has taken over. III. Steps for operating the mixer (I) Preparation before operation 1. The operator must understand the technical specifications of the equipment and hold an operation certificate in order to operate it. 2. Before operation, check that the mechanical and electrical equipment is complete and in good condition, that the connections are secure, that the lubrication is adequate, and that there are no damages to the structure; also open the valve for bearing cooling water. (II) Operating procedures for starting up and shutting down the equipment. IV. Safety precautions during equipment use: 1. It is not allowed to remove or modify the safety protection devices of the equipment arbitrarily. 2. Welding or cutting on the structure of the equipment is not permitted without approval. 3. In the event of a malfunction, the equipment must be stopped for repairs; it is strictly prohibited to address faults while the equipment is running. 4. It is prohibited to repair equipment faults while it is under power or under pressure. 5. Do not use the equipment under excessive pressure. 6. It is strictly prohibited to pull or close switches under load. 7. In the event of a fire involving electrical equipment, the power supply should be cut off immediately, and a dry powder fire extinguisher should be used to put out the fire. 8. When the equipment is operated despite being faulty, reliable protective measures must be in place; any new issues identified during use should be reported and addressed promptly. V. Troubleshooting of Malfunctions During Equipment Operation 1. If severe noise or intense vibration is detected during equipment operation, the machine should be stopped immediately for inspection. 2. If the temperature of the bearings in various parts of the equipment exceeds 65°C, and it continues to rise despite taking corrective measures, or if smoking or ignition occurs, the equipment must be shut down immediately as an emergency. 3. When there is severe axial movement of the blower or motor and the components are in a dangerous condition, the machine should be stopped promptly for repair. 4. If electrical equipment starts smoking or overheating, the power supply must be cut off immediately, and the issue should be inspected and addressed. 5. In the event of a sudden power outage, immediately turn off the power supply; once power is restored, start the equipment following the startup sequence. VI. A system of confirmation by two or more persons for key positions: The operations such as coke reception and transportation are carried out only after confirming, in accordance with the technical operating procedures and in coordination with the relevant personnel, that everything is in order.
Operating and Maintenance Procedures for Dust Collector Scraper Equipment – Equipment Operating Procedures
I. Main Technical Specifications and Allowable Limit Parameters of the Equipment
Scraper: Model YD250; Length: 10m; Transport capacity: 20 m3/h; Date of manufacture: 2000.3; Manufacturer: Xishan Xuelang Machinery Factory.
Reducer: Model Bwy3322—187—4; Center height: 0.25m; Speed ratio: 187; Weight: 286 kg; Rotational speed: 1440 rpm; Manufacturer: Taixing, Jiangsu.
Motor: Model Y112M-4; Frequency: 50 Hz; Power: 4 kW; Weight: 34 kg; Rotational speed: 1440 rpm; Manufacturer: East China Electromechanical Manufacturing Factory.
Reducer: Model Bwy3322—187—5.5; Speed ratio: 187; Rotational speed: 1440 rpm; Center height: 0.25m; Weight: 302 kg; Manufacturer: Taixing, Jiangsu.
1. Number of sprockets (large and small): 3 pairs.
2. Chain.
3. Scrapers.
4. Rotating discharge valve, model YXD200; Capacity: 9 m3/min; Number: 12.
II. Provisions for the Handover and Use of the Equipment
1. During shift handover, it is necessary to provide a detailed account of the equipment’s operation during that shift, including the temperature of various bearings, lubrication status, operating noises, mechanical wear, as well as any signs of loosening or damage. Nothing should be concealed. 2. The abnormal situations that occur during equipment operation, the procedures for dealing with them, and the issues that need attention during operation must be clearly explained to the successor. 3. It is necessary to inform the successor whether the equipment operates normally after maintenance and part replacement, as well as any other operational requirements. 4. Any issues that arise during the inspection or operation of the equipment in this class must be recorded in the equipment defect log. 5. The successor should listen carefully to the handover by the person handing over the duties, conduct necessary testing, and carry out a thorough inspection of the equipment. 6. Any issues identified upon taking over the shift should be addressed through consultation with the person handing over the shift, and reported to the shift supervisor and relevant personnel, with proper records kept. III. Equipment Operation Steps (I) Preparation before operation 1. The operator must be familiar with the technical specifications of the equipment and must hold an operation permit to operate it. 2. The operator must check whether the electromechanical equipment is complete, whether the connections are firm and reliable, whether the lubrication is adequate, and whether there are any cracks or damages in the structure. It can be turned on only if there are no problems. 3. Before operating, check the chassis for any debris or other obstacles; operation can proceed only if there are no issues. (II) Operation sequence 1. Power-on operation a) Before turning on the machine, check whether the oil level and quality in the lubrication areas meet the requirements, and whether the foot bolts are tight. b) Operate in the sequence specified by the operating stacking rules. c) After starting up, check the material discharge situation; if the discharge is poor, the electric vibrator for discharge can be turned on ； If the scraper gets stuck, the machine should be stopped for handling. d) During operation, always pay attention to the sound of the machinery and the temperature of each bearing; if any abnormalities are detected, stop the machine immediately for inspection. 2. Shutdown procedure: a) Before shutting down, the discharge valve should be closed first; the machine should be shut down only after there is no material left inside the chassis. b) The power supply should be cut off after shutdown. IV. Safety precautions during equipment use 1. It is prohibited to remove or modify the safety protection devices of the equipment arbitrarily. 2. The structure of the equipment shall not be cut or welded without approval. 3. In the event of a malfunction, the equipment must be shut down for repairs; it is strictly prohibited to attempt to fix faults while the equipment is running. 4. It is strictly prohibited to pull or close switches under load; operation beyond capacity is not allowed, nor is it permissible to troubleshoot faults while the equipment is powered on. 5. When the thermal equivalent of overheating of electrical equipment is sufficient to cause a fire, the power supply must be cut off immediately, and a dry powder fire extinguisher should be used to put out the fire; water or foam fire extinguishers must not be used. V. Troubleshooting of Malfunctions During Equipment Operation 1. When the temperature of the bearings in various parts of the equipment exceeds 65°C, measures should be taken; if the temperature continues to rise or smoke appears in the electrical circuits, the equipment must be shut down immediately. 2. If the scraping plate causes severe scraping or jamming, or generates excessive noise, the machine should be stopped for inspection. 3. If the reducer experiences excessive vibration and high temperature, it should be stopped immediately. 4. If there is a blockage at the scraper machine’s outlet or if material gets stuck inside the casing, the machine should be stopped immediately for troubleshooting. 5. In the event of a sudden power outage, cut off the power supply immediately; restart the device only after power is restored.
I. Main Technical Specifications and Allowable Limit Parameters of the Equipment
Scraper: Model YD250; Length: 10m; Transport capacity: 20 m3/h; Date of manufacture: 2000.3; Manufacturer: Xishan Xuelang Machinery Factory.
Reducer: Model Bwy3322—187—4; Center height: 0.25m; Speed ratio: 187; Weight: 286 kg; Rotational speed: 1440 rpm; Manufacturer: Taixing, Jiangsu.
Motor: Model Y112M-4; Frequency: 50 Hz; Power: 4 kW; Weight: 34 kg; Rotational speed: 1440 rpm; Manufacturer: East China Electromechanical Manufacturing Factory.
Reducer: Model Bwy3322—187—5.5; Speed ratio: 187; Rotational speed: 1440 rpm; Center height: 0.25m; Weight: 302 kg; Manufacturer: Taixing, Jiangsu.
1. Number of sprockets (large and small): 3 pairs.
2. Chain.
3. Scrapers.
4. Rotating discharge valve, model YXD200; Capacity: 9 m3/min; Number: 12.
II. Provisions for the Handover and Use of the Equipment
1. During shift handover, it is necessary to provide a detailed account of the equipment’s operation during that shift, including the temperature of various bearings, lubrication status, operating noises, mechanical wear, as well as any signs of loosening or damage. Nothing should be concealed. 2. The abnormal situations that occur during equipment operation, the procedures for dealing with them, and the issues that need attention during operation must be clearly explained to the successor. 3. It is necessary to inform the successor whether the equipment operates normally after maintenance and part replacement, as well as any other operational requirements. 4. Any issues that arise during the inspection or operation of the equipment in this class must be recorded in the equipment defect log. 5. The successor should listen carefully to the handover by the person handing over the duties, conduct necessary testing, and carry out a thorough inspection of the equipment. 6. Any issues identified upon taking over the shift should be addressed through consultation with the person handing over the shift, and reported to the shift supervisor and relevant personnel, with proper records kept. III. Equipment Operation Steps (I) Preparation before operation 1. The operator must be familiar with the technical specifications of the equipment and must hold an operation permit to operate it. 2. The operator must check whether the electromechanical equipment is complete, whether the connections are firm and reliable, whether the lubrication is adequate, and whether there are any cracks or damages in the structure. It can be turned on only if there are no problems. 3. Before operating, check the chassis for any debris or other obstacles; operation can proceed only if there are no issues. (II) Operation sequence 1. Power-on operation a) Before turning on the machine, check whether the oil level and quality in the lubrication areas meet the requirements, and whether the foot bolts are tight. b) Operate in the sequence specified by the operating stacking rules. c) After starting up, check the material discharge situation; if the discharge is poor, the electric vibrator for discharge can be turned on ； If the scraper gets stuck, the machine should be stopped for handling. d) During operation, always pay attention to the sound of the machinery and the temperature of each bearing; if any abnormalities are detected, stop the machine immediately for inspection. 2. Shutdown procedure: a) Before shutting down, the discharge valve should be closed first; the machine should be shut down only after there is no material left inside the chassis. b) The power supply should be cut off after shutdown. IV. Safety precautions during equipment use 1. It is prohibited to remove or modify the safety protection devices of the equipment arbitrarily. 2. The structure of the equipment shall not be cut or welded without approval. 3. In the event of a malfunction, the equipment must be shut down for repairs; it is strictly prohibited to attempt to fix faults while the equipment is running. 4. It is strictly prohibited to pull or close switches under load; operation beyond capacity is not allowed, nor is it permissible to troubleshoot faults while the equipment is powered on. 5. When the thermal equivalent of overheating of electrical equipment is sufficient to cause a fire, the power supply must be cut off immediately, and a dry powder fire extinguisher should be used to put out the fire; water or foam fire extinguishers must not be used. V. Troubleshooting of Malfunctions During Equipment Operation 1. When the temperature of the bearings in various parts of the equipment exceeds 65°C, measures should be taken; if the temperature continues to rise or smoke appears in the electrical circuits, the equipment must be shut down immediately. 2. If the scraping plate causes severe scraping or jamming, or generates excessive noise, the machine should be stopped for inspection. 3. If the reducer experiences excessive vibration and high temperature, it should be stopped immediately. 4. If there is a blockage at the scraper machine’s outlet or if material gets stuck inside the casing, the machine should be stopped immediately for troubleshooting. 5. In the event of a sudden power outage, cut off the power supply immediately; restart the device only after power is restored.