Translated from Chinese (Simplified) to English - www.onlinedoctranslator.

com

Shenhua Shendong Power Co., Ltd. shop towerBpower plant SDDL-12-02/DT(B)/DQ

Inspection and maintenance procedures for thermal control equipment

(first draft)

approve:

Audit:

First trial:

Compiled by: Yan Xiangyong

Published on February 30, 2012 October 15, 2012

apply
 Shenhua Shendong Power Co., Ltd. Dianta B Power Plant release

Procedure control table

Version issued next time Whether

editor Trial examiner Reviewer approver
Numbering date nuclear date revise

1.0

The main contents of this revision are as follows:

1
 Controlled deduction office

foreword

1. General principles

The repair and maintenance procedures for thermal control equipment are based on the power industry, Shendong Electric Power Company, equipment manufacturers, equipment

The standards, systems, guidelines, and technical materials provided by the Institute of Design and Design were compiled in combination with the author's on-site maintenance experience. this regulation

It stipulates the content, method and maintenance of the thermal automation control system of Shenhua Shendong Electric Power Company B Plant.

The standards that technical management should meet are the basis for the maintenance of thermal control equipment. As an overhaul process requirement and quality

The criteria for acceptance criteria are equivalent to the 'maintenance technical standards' in the equipment point inspection and maintenance management system.

2
 This regulation applies to DCS, DEH, TSI, PLC, FSSS, image flame detection, thermal control instrument transmitter, implementation

Devices, MCS control, SCS control, DAS acquisition and chemical instruments and other equipment, from specifications, technical characteristics,

The maintenance cycle, maintenance items, maintenance steps, quality standards, etc. are described in detail; the equipment

A, B, and C-level maintenance items, process flow, quality standards, etc. have been specified in detail, and are applicable to Shenhua Shendong Branch

Overhaul and daily operation and maintenance of the thermal automation system of the 660MW generating unit in Plant B of Tower Power Company.

Since the new unit in our factory is still in the process of installation and commissioning, there may be differences between this regulation and the on-site design

If there are discrepancies or even errors, everyone is welcome to make suggestions for improvement of this procedure.

If there is any content in this regulation that is in conflict with the superior regulation, it shall be approved by the deputy director of production or the chief engineer according to the superior

level procedures, and amend this procedure.

2. Reference standards

1. "Guidelines for Operation and Maintenance of Distributed Control System in Thermal Power Plants" (DLT774-2004)

2. "Operation Regulations for Overhaul of Thermal Control Instruments and Control Devices"

3. "Guidelines for Operation, Maintenance and Overhaul of Thermal Control Devices in Thermal Power Plants"

4. "Regulations for Overhaul, Operation and Maintenance of Thermal Automation System in Thermal Power Plants" (DLT774-2004)

5. "Technical Regulations for Thermal Control System Design of Thermal Power Plants" (DLT5175-2003)

6. Acceptance test procedures for boiler furnace safety monitoring system in thermal power plants (DL/T/655-2006)

7. Technical Regulations on Thermal Automation Design of Auxiliary Systems in Thermal Power Plants (DL/T5227-2005)

8. DL/T 656-2006 On-line Acceptance Test Regulations for Steam Turbine Control System in Thermal Power Plants

9. DL/T 657 -2006 On-line Acceptance Test Procedures for Analog Control Systems in Thermal Power Plants

10. DL/T 658 -2006 On-line Acceptance Test Regulations for Digital Control System in Thermal Power Plants

11. Acceptance test procedures for decentralized control systems in thermal power plants (DL/T/659-2006)

12. "Technical Regulations on On-site Equipment Installation, Piping and Cable Design of Thermal Automation in Thermal Power Plants"

(DLT5182-2004)

13. Design standard DL/T5004/2004 for thermal automation laboratory of thermal power plant

14. Shendong Electric Power Company management and control system thermal control technical supervision implementation rules

3. The following personnel should be familiar with and understand this regulation

1. Factory Director of Factory B Chief Engineer of Factory B

2. Manager of Biotechnology Department and Thermal Control Supervisor of Plant B

3. Manager and professional supervisor of the Operation Department of Plant B

3
4. Manager of Maintenance Department and Thermal Control Supervisor of Dianta Power Generation Company

5. Technical personnel of thermal control outsourcing management unit

4. Writing and Approval

This regulation is written by the Thermal Control Department of the Production Preparation Department of Shenhua Shendongdianta Power Generation Company B Plant.

The main editor of this regulation: Yan Xiangyong Yao Zheng Lu Yongxing Min He

Initial review of this regulation:

Review of this procedure:

This regulation approves:

5. Execution

This regulation has been approval, since start execution.

4
 Table of contents

Chapter One Terminology for Thermal Control .............................................. ...................................................10

Chapter two Distributed Control System (DCS) ................................................ ...................................13

1 Equipment overview and parameters................................... ................................................... ...13

2 Maintenance category and cycle .............................................. ................................................... ...29
3 Maintenance items................................................... ................................................... .........30
4 Maintenance steps, process methods and quality standards................................... ................................................31

5 Analysis and pre-control of dangerous points................................... ................................................... .38

6 Safety, health and environmental protection requirements................................... ...................................................39

Chapter 3 Digital Electro-hydraulic Control System (DEH) ................................................ ...................................41

1 Equipment overview and parameters................................... ................................................... ...41

2 Maintenance category and cycle .............................................. ................................................... ...41
3 Maintenance items................................................... ................................................... .........41
4 Maintenance steps, process methods and quality standards................................... ................................................42

5 Analysis and pre-control of dangerous points................................... ................................................... .47

6 Safety, health and environmental protection requirements................................... ...................................................48

Chapter 4 Turbine Testing and Instrumentation System (TSI) ................................................ ................................................49

1 Equipment overview and parameters................................... ................................................... ...49

2 Maintenance category and cycle .............................................. ................................................... ...54
3 Maintenance items................................................... ................................................... .........54
4 Maintenance steps, process methods and quality standards................................... ................................................55

5 Analysis and pre-control of dangerous points................................... ................................................... .60

6 Safety, health and environmental protection requirements................................... ...................................................61

Chapter 5 Thermal Control Protection System (ETS/ FSSS) ................................... ...................................63

1 Steam turbine emergency trip system (ETS) inspection and maintenance process regulations........................... .........63

1.1 Equipment overview and parameters................................... ...................................................63

1.2 Maintenance category and cycle..................................................... ...................................................63
1.3 Maintenance items................................................... ................................................... …63
1.4 Maintenance steps, process methods and quality standards................................... ................................64

1.5 Analysis and pre-control of dangerous points................................... ...................................................67

1.6. Safety, health and environmental protection requirements................................... ................................................67

2 Overhaul process regulations for boiler furnace safety monitoring system (FSSS).......................... .........68
2.1 Equipment overview and parameters................................... ...................................................68
2.2 Maintenance category and cycle................................... ...................................................69
2.3 Maintenance items................................................... ................................................... …69
2.4 Maintenance steps, process methods and quality standards................................... ................................69

2.5 Analysis and pre-control of dangerous points................................... ...................................................77

Chapter 6 Analog Control System (MCS) ................................................ ...................................................83

1 Technical specification for maintenance of water supply control system................................... ...................................83

5
 1.1 Equipment overview and parameters................................... ...................................................83
1.2 Maintenance category and cycle..................................................... ...................................................83
1.3 Maintenance items................................................... ................................................... …83
1.4 Maintenance steps, process methods and quality standards................................... ................................84

1.5 Analysis and Pre-control of Dangerous Points................................................... ...................................................85

2 Overhaul process regulations for steam temperature control system................................... ................................................90

2.1 Equipment overview and parameters................................... ...................................................90

2.2 Maintenance category and cycle................................... ...................................................91
2.3 Maintenance items................................................... ................................................... …91
2.4 Maintenance steps, process methods and quality standards................................... ................................91

2.5 Risk analysis and pre-control................................................... ...................................................93

2.6. Safety, health and environmental protection requirements................................... ................................................98

3 Overhaul process regulations for combustion control system................................... ...................................99

3.1 Equipment overview and parameters................................... ...................................................99

3.2 Maintenance category and cycle..................................................... ...................................................99
3.3 Maintenance items................................................... ................................................... …99
3.4 Repair steps, process methods and quality standards................................... ...................................101
3.5 Risk analysis and pre-control................................................... ...................................................107
4 Auxiliary equipment control system maintenance process regulations................................... ...................................112

4.1 Equipment overview and parameters................................... ...................................................112

4.2 Maintenance category and cycle................................... ...................................................112
4.3 Maintenance items................................................... ................................................... ....113
4.4 Maintenance steps, process methods and quality standards................................... ...................................113

4.5 Risk analysis and pre-control................................................... ...................................................115

5 Overhaul process regulations for machine-furnace coordinated control system................................... ...................................122

5.1 Equipment overview and parameters................................... ...................................................122

5.2 Maintenance category and cycle..................................................... ...................................................125
5.3 Maintenance items................................................... ................................................... .....125
5.4 Maintenance steps, process methods and quality standards................................... ...................................125

5.5 Risk analysis and pre-control................................................... ...................................................127

6 Data Acquisition System Overhaul Process Regulations..................................................... ...................................133

6.1 Equipment overview and parameters................................... ...................................................133

6.2 Maintenance category and cycle .............................................. ...................................................133
6.3 Maintenance items................................................... ................................................... .....133
6.4 Maintenance steps, process methods and quality standards................................... ...................................133

6.5 Analysis and pre-control of dangerous points................................... ...................................................136

Chapter 7 Sequential Control System (SCS) ................................... ................................................143

1 Sequential control system maintenance process regulations................................... ...................................143

1.1 Equipment overview and parameters................................... ...................................................143

1.2 Maintenance category and cycle..................................................... ...................................................143
1.3 Maintenance items................................................... ................................................... ....143
1.4 Maintenance steps, process methods and quality standards................................... ...................................143

1.5 Risk analysis and pre-control................................................... ...................................................160

6
Chapter VIII Auxiliary Network and PLC Control System................................... ...................................................166

1 Water network control system................................... ................................................... .....166

1.1 Equipment overview and parameters................................... ...................................................166
1.2 Maintenance category and cycle..................................................... ...................................................166
1.3 Maintenance items................................................... ................................................... ....166
1.4 Maintenance steps, process methods and quality standards................................... ...................................167

1.5 Analysis and pre-control of dangerous points................................... ...................................................170

2 Gray net control system................................... ................................................... .....171

3 Coal handling control system................................... ................................................... .....171
4 Air conditioning control system................................... ................................................... ....171

Chapter 9 Other Thermal Control Systems ................................................ ...................................................172

1 Overhaul process regulations for boiler flame monitoring system................................... ...................................172

1.1 Equipment overview and parameters................................... ...................................................172

1.2 Maintenance category and cycle..................................................... ...................................................172
1.3 Maintenance items................................................... ................................................... .....172
1.4 Maintenance steps, process methods and quality standards................................... ...................................172

1.5 Analysis and Pre-control of Dangerous Points................................................... ...................................................173

2 Technological regulations for furnace tube leak inspection................................... ...................................................179

2.1 Equipment overview and parameters................................... ...................................................179

2.2 Maintenance category and cycle................................... ...................................................179
2.3 Maintenance items................................................... ................................................... .....179
2.4 Maintenance steps, process methods and quality standards................................... ...................................179

2.5 Analysis and pre-control of dangerous points................................... ...................................................181

4 TDM overhaul process specification................................... ...................................................186

5 Boiler soot blowing maintenance process regulations................................... ...................................................186

5.1 Equipment overview and parameters................................... ...................................................186

5.2 Maintenance category and cycle..................................................... ...................................................186
5.3 Maintenance items................................................... ................................................... ....186
5.4 Maintenance steps, process methods and quality standards................................... ...................................186

5.5 Risk analysis and pre-control................................................... ...................................................188

6 Air preheater gap adjustment and maintenance process regulations................................... ...................................194

6.1 Equipment overview and parameters................................... ...................................................194

6.2 Maintenance category and cycle .............................................. ...................................................194
6.3 Maintenance items................................................... ................................................... .....194
6.4 Maintenance steps, process methods and quality standards................................... ...................................194

6.5 Analysis and pre-control of dangerous points................................... ...................................................194

Chapter Ten Valve Actuator ................................................ ...................................................201

1 SIPOS 5 Electric Actuator Overhaul Regulations................................... ...................................201

1.1 Equipment overview and parameters................................... ...................................................201
1.2 Maintenance category and cycle..................................................... ...................................................203
1.3 Maintenance items, steps, process methods and quality requirements................................... .........204
1.4 Commissioning and trial operation................................... ................................................... ..205

7
 1.5 Safety, health and environmental protection requirements................................... ...................................210

1.6 Dangerous point analysis and pre-control................................................... ...................................................210

2 Pneumatic Actuator Overhaul Regulations................................................... ...................................................212

2.1 Equipment overview and parameters................................... ...................................................212

2.2 Maintenance category and cycle................................... ...................................................212
2.3 Maintenance items and their quality requirements................................... ...................................213
2.4 Debugging and trial operation of ABB pneumatically adjustable positioner................................... ................................216

2.5 Safety, health and environmental protection requirements................................... ...................................222

2.6 Analysis and pre-control of dangerous points................................... ...................................................223

Chapter 11 Measuring Instruments................................... ................................................... ...225

1 Thermocouple maintenance procedures..................................................... ................................................... .225

1.1 Equipment overview and parameters................................... ...................................................225

1.2 Maintenance category and cycle..................................................... ...................................................226
1.3 Maintenance items................................................... ................................................... ....226
1.4 Maintenance steps, process methods and quality standards................................... ...................................226

1.5 Analysis and pre-control of dangerous points................................... ...................................................227

2 Maintenance procedures for thermal resistance..................................... ................................................... .228

2.1 Equipment overview and parameters................................... ...................................................228

2.2 Maintenance category and cycle................................... ...................................................228
2.3 Maintenance items................................................... ................................................... ....228
2.4 Maintenance steps, process methods and quality standards................................... ...................................229

2.5 Analysis and pre-control of dangerous points................................... ...................................................231

3 Overhaul procedures for pressure (differential pressure) transmitters................................... ...................................231

3.1 Equipment overview and parameters................................... ...................................................231

3.2 Maintenance category and cycle..................................................... ...................................................232
3.3 Maintenance items................................................... ................................................... ....232
3.4 Maintenance steps, process methods and quality standards................................... ...................................232

3.5 Analysis and pre-control of dangerous points................................................... ...................................................233

4 Overhaul procedures for pressure switches..................................... ...................................................234

4.1 Equipment overview and parameters................................... ...................................................234
4.2 Maintenance category and cycle................................... ...................................................234
4.3 Maintenance items................................................... ................................................... ....234
4.4 Maintenance steps, process methods and quality standards................................... ...................................235

4.5 Analysis and pre-control of dangerous points................................... ...................................................236

5 Zirconia Oxygen Analysis Maintenance Regulations................................... ................................................236

5.1 Equipment overview and parameters................................... ...................................................236
5.2 Maintenance category and cycle..................................................... ...................................................237
5.3 Maintenance items................................................... ................................................... ....237
5.4 Maintenance steps, process methods and quality standards................................... ...................................237

5.5 Analysis and pre-control of dangerous points................................... ...................................................239

6 Overhaul procedures for tachometer................................... ................................................... .239

6.1 Equipment overview and parameters................................... ...................................................239
6.2 Maintenance category and cycle .............................................. ...................................................240

8
 6.3 Maintenance items................................................... ................................................... ....240
6.4 Maintenance steps, process methods and quality standards................................... ...................................240

6.5 Analysis and pre-control of dangerous points................................... ...................................................241

7. Conductivity meter maintenance procedures................................... ...................................................242

7.1 Equipment overview and parameters................................... ...................................................242
7.2 Maintenance category and cycle .............................................. ...................................................242
7.3 Maintenance items................................................... ................................................... ....242
7.4 Maintenance steps, process methods and quality standards................................... ...................................242

7.5 Analysis and pre-control of dangerous points................................... ...................................................243

8 Maintenance procedures for acidity meter................................... ................................................... .244

8.1 Equipment overview and parameters................................... ...................................................244
8.2 Maintenance category and cycle................................... ...................................................244
8.3 Maintenance items................................................... ................................................... ....245
8.4 Maintenance steps, process methods and quality standards................................... ...................................245

8.5 Analysis and pre-control of dangerous points................................... ...................................................247

9 Maintenance procedures for dissolved oxygen analyzers in water................................... ................................................248

9.1 Equipment overview and parameters................................... ...................................................248

9.2 Maintenance category and cycle................................... ...................................................249
9.3 Maintenance items................................................... ................................................... ....249
9.4 Maintenance steps, process methods and quality standards................................... ...................................249

9.5 Analysis and pre-control of dangerous points................................... ...................................................250

10 Maintenance procedures for silicate analyzer................................... ...................................................251

10.1 Equipment overview and parameters................................... ...................................................251
10.2 Maintenance category and cycle .............................................. ...................................................251
10.3 Maintenance items................................................... ................................................... ..251
10.4 Maintenance steps, process methods and quality standards................................... ...................................251

10.5 Hazardous point analysis and pre-control................................................... ...................................................252

11 Maintenance procedures for micro-sodium monitor................................................... ...................................................253

11.1 Equipment overview and parameters................................... ...................................................253

11.2 Maintenance category and cycle..................................................... ...................................................253
11.3 Maintenance items................................................... ................................................... ..253
11.4 Maintenance steps, process methods and quality standards................................... ...................................253

11.5 Hazardous point analysis and pre-control................................................... ...................................................254

12 Belt scale and cyclic chain code verification device................................... ...................................254

12.1 Equipment overview and parameters................................... ...................................................254
12.2 Maintenance category and cycle................................... ...................................................260
12.3 Maintenance items................................................... ................................................... ..260
12.4 Maintenance steps, process methods and quality standards................................... ...................................260

12.5 Analysis and Pre-control of Dangerous Points................................................... ...................................................261

12.6 Safety, health and environmental protection requirements................................... ...................................261

9
 Chapter 1 Special Terminology for Thermal Control

The following terms, definitions and abbreviations apply to this standard.

1 Distributed Control System, DCS for short

Using computer, communication and CRT display technology to realize the functions of data acquisition, control and protection of the production process,

The multi-computer monitoring system that uses communication technology to realize data sharing is characterized by decentralized functions and centralized operation and display.

Data sharing, high reliability.

2 Data Acquisition System Date Acquisition System, referred to as DAS

The digital computer system is used to detect the operating parameters and status of the process system and equipment, and the detection results are analyzed.

Process, record, display and alarm, calculate and analyze the operation of the unit, and propose a monitoring system for operation guidance.

3 Analog control system Modulation Control System, referred to as MCS

A general term for automatic control of parameters of boilers, steam turbines and auxiliary systems. In such systems, parameters are often included to automatically

For control and deviation alarm functions, for the former, the output is a continuous function of the input.

4 Coordinated Control system, referred to as CCS

Control the boiler-steam turbine unit as a whole, and coordinate the boiler and steam turbine unit in automatic control through the control loop.

work in dynamic state, and send instructions to the automatic control system of boilers and steam turbines to meet the needs of load changes and maximize

It may give full play to the unit's ability of frequency regulation and peak regulation. Its direct action level is the boiler combustion control system and the steam turbine control system.

system.

5 Automatic Generation Control, referred to as AGC

Automatic control of generating power according to grid load command.

6 Sequence Control System, referred to as SCS

According to a certain rule (input signal condition sequence, action sequence or time sequence) for a certain process system or main auxiliary machine of the unit

sequence) to control the control system.

7 Furnace Safeguard Supervisory System, referred to as FSSS

Automatic program control of boiler ignition, burner and oil gun to prevent boiler furnace from flameout due to combustion, overpressure, etc.

An automatic system for the monitoring and control measures taken to cause a furnace explosion (exterior or implosion). FSSS includes burner

Control system (Burner Control System, referred to as BCS) and furnace safety system (Furnace Safety System,

Abbreviated as FSS).

8 Master Fuel Trip, MFT for short

The control measures taken by manual operation or automatic action of protection signal to quickly cut off all fuel entering the boiler furnace

apply.

9 Digital Electro-Hydraulic Control of Steam Turbine, referred to as DEH

Sensitive components designed according to electrical principles, digital circuits (computers), amplifying components designed according to hydraulic principles and

A steam turbine control system composed of a hydraulic servo mechanism.

10
10 Automatic turbine startup or shutdown control system, referred to as

ATC
According to the thermal stress of the steam turbine or other set parameters, command the steam turbine control system to complete the start-up of the steam turbine, grid-connected belt

Automatic control system for load or shutdown.

11 Over-speed Protection Control Over-speed Protection Control, referred to as OPC

A control function that suppresses overspeed. It is realized by using the acceleration limiting method, and some are realized by the double-position control method.

In the former, when the speed of the steam turbine accelerates, an overriding command is issued to close the high and medium pressure regulating valves; when the acceleration is zero,

The normal speed is maintained by the normal speed control loop. The latter will automatically shut down when the steam turbine speed reaches 103% of the rated speed

High and medium pressure regulating valves; when the speed returns to normal, open these regulating valves, and so on until the normal speed control

The loop can maintain rated speed; or both methods can be used simultaneously.

12 Turbine supervisory instrument, referred to as TSI.

Instruments for monitoring the operating status of steam turbines (mechanical parameters such as speed, vibration, expansion, displacement, etc.).

13 Maintenance Grades

The maintenance level is based on the maintenance scale and shutdown time of the unit, and the maintenance of the unit is divided into four levels: A, B, C, and D.

13.1 A Class Maintenance

A-level maintenance refers to a comprehensive dismantling inspection and repair of the generator set to maintain, restore or improve equipment performance.

13.2 B Class Maintenance

B-level maintenance refers to the dismantling inspection and repair of some equipment of the unit in view of the problems with some equipment of the unit. Class B inspection

Some A-level maintenance items or periodic rolling maintenance items can be implemented in a targeted manner according to the assessment results of unit equipment status.

13.3 C Class Maintenance

C-level maintenance refers to inspecting, evaluating, repairing,

clean up. C-level maintenance can carry out operations such as replacement of a small number of parts, elimination of equipment defects, adjustments, preventive tests, and implementation of

Some A-level maintenance items or regular rolling maintenance items.

13.4 D Class Maintenance D Class Maintenance

D-level maintenance means that when the overall operation of the unit is in good condition, the ancillary systems and equipment of the main equipment are eliminated. D.

In addition to the elimination of auxiliary systems and equipment for C-level maintenance, some C-level maintenance can also be arranged according to the evaluation results of equipment status

project.

14 Proactive Maintenance (PAM)

Improved maintenance refers to the congenital defects or frequent failures of equipment, according to the current technical level and development trend of equipment

Transformation, fundamentally eliminate equipment defects, in order to improve the technical performance and availability of equipment, combined with the overhaul process implemented

Way.
15 Troubleshooting Run Till Failure (RTF)

Troubleshooting refers to the unplanned maintenance of equipment when it breaks down or other failures.

11
16 Primary Equipment and Ancillary Equipment

Main equipment refers to boilers, steam turbines, generators, main transformers, unit control devices and other equipment and their auxiliary equipment;

Auxiliary equipment refers to production equipment other than main equipment.

12
 Chapter 2 Distributed Control System (DCS)

1 Equipment overview and parameters

1.1. Equipment overview

The 2×660MW project DCS of Shenhua Shendong Dianta Power Generation Company B Plant adopts the DCS of Hangzhou Hollysys Automation Co., Ltd.

HOLLiAS-MACS6.5.0 system, the functional scope of the entire DCS system covers data acquisition (DAS) , Analog control

(MCS) , sequence control (SCS), boiler furnace safety monitoring (FSSS) , Turbine Bypass Control (BPC), air cooling system (ACC),

Boiler flue gas denitrification SCR area control, boiler soot blowing control, boiler slag removal control, auxiliary cooling water pump room control, etc.

It is a complete control system that integrates software and hardware to complete various control functions of the entire unit.

The DCS of this project is designed according to the principle of combining functional dispersion and physical dispersion. The monitoring of the public system is included in the DCS public

system, the DCS of unit #1 and #2 can monitor the common system of the two units, and at the same time, only one unit can

The DCS of the group realizes the control of the common part of the equipment; the control function of the other unit is blocked and only has the monitoring function.

The DCS network of this project is divided into three levels from top to bottom: monitoring network, system network and control network.

The communication between engineer station, operator station, advanced computing station and system server is 100Mb/s Ethernet; system network

The network realizes the communication between the field control station and the system server, which is 100Mb/s Ethernet; the control network adopts Profibus-DP

The field bus realizes the connection between the field control station and the process I/O unit.

The DCS system of this project is divided into 3 domains, among which the #1 unit DCS is the #1 domain, the #2 unit DCS is the #2 domain, and the public DCS

It is domain #0, and each domain realizes communication through the monitoring network, and the inter-domain is 1000Mb/s Ethernet.

The DCS of this project adopts the MACS series distributed system designed and developed by Hollysys as the general system configuration and

The software version of the operation control platform is MACS 6.5.0 (thermal power version), and the hardware adopts SM series hardware.

The main nodes of MACS6.5.0 include:

a Operator station, the human-machine interface equipment used by the operator when the system is running. The human-machine interface provided by the operator through it

Monitor and control the operating status of the system. This type of computer can also be configured as a communication station, some communication software (such as

Such as OPC, ModBus) run on it to exchange data with other systems or devices.

b Engineer station,The computer used for system configuration, through which the system administrator can download the compiled project to each

operator station, server and field control station.

c On-site control station,Including various main control units, other hardware modules, cages and cabinets.

d History Station,Computer used to provide historical database, real-time database, report printing, alarm and IO services. General redundancy

For other configurations, use KVM to switch between the two machines.

13
e Main control unit,Is the control module, also known as the lower computer. It processes the collected data according to the algorithm pre-loaded into its memory.

field data and pass the result to the server or the corresponding command to the actuator to control the actual process.

fI/OA module is a hardware module used to convert and transmit data/commands between the controller and field instruments/actuators.

g other,Switches, routers, Ethernet cards and network cables, etc.

The unit units of this project are equipped with a total of 6 operator stations (including the duty chief station), 1 engineer station, 1 historian station,

2 servers, the numbering principle of the on-site control station is (unit unit) boiler controller number #10-#23, steam turbine controller number

No. #24-#31, air-cooling controller #32-#35, electrical controller No. #36-#39, public system controller No. #41-#44.

1.2. Hollysys DCS proper name abbreviation

name abbreviation

distributed control system DCS

engineer station ES

operator station OPS

field control station FCS

real-time database RTDB

historical database HDB

system network SNET

control network CNET

Multi-domain management MDM

Manufacturing Execution System MES

Client/Historical Station CS

communication station CMS

main control unit MCU

history station HIS

1.3. DCS Field Control Station Control Equipment Allocation Table

serial number Control station number Control equipment and systems

Fuel oil leak, furnace purge, total fuel loss, boiler flame loss, main fuel trip MFT and

1 Station 10 First out memory, oil fuel trip OFT and first out memory, fuel oil inlet fast closing valve, fuel oil return fast

Close valve, RB skip fuel, boiler side SOE.

2 Station 11 A coal seam, including all equipment and program control of A grinding group, A coal micro-oil.

14
 3 Station 12 B coal seam: including all equipment and program control of B grinding group, A sealing fan, A fire detection cooling fan.

4 Station 13 C coal seam, including all equipment and program control of C grinding group, A side primary fan.

5 Station 14 D coal seam; including all equipment and program control of D grinding group, B sealing fan, B fire detection cooling fan.

6 Station 15 E coal seam, including all equipment and program control of E mill group, B side primary fan.

7 Station 16 F coal seam; including all equipment and program control of F mill group, auxiliary oil of F seam.

A side smoke air system; including air preheater A, induced draft fan A, blower A, and other related systems and corresponding

8 Station 17
Program-controlled, air-supply system adjustment.

B side flue air system; including air preheater B, induced draft fan B, blower B, and other related systems and corresponding

9 Station 18
Program-controlled, air-induced adjustment.

10 Station 19 Superheated steam temperature adjustment, reheat steam temperature adjustment.

11 Station 20 Machine furnace coordinated control, fuel control, water supply (including 22 points on the machine side).

12 Station 21 Soot blowing and slag removal.

13 Station 22 Boiler starting system, boiler side drainage.

14 Station 23 Denitrification, pebble coal, boiler DAS data collection.

15 Station 24 High side, low side, main steam reheat, drain.

16 Station 25 A feed water, A condensate, A closed pump, condensate system.

17 Station 26 B Feed water, B Condensate water, B Closed pump, SOE point on machine side, deaeration system.

18 Station 27 C Feed water, condensate make-up pump, condensate transfer pump, shaft seal system, condenser exhaust device.

19 Station 28 High, low plus, extraction.

Auxiliary steam, condenser vacuum pump A, condenser centrifugal pump A, turbine lubricating oil, DC oil pump, hydrogen-tight

20 Station 29
seal oil pump, airside seal oil AC pump, #1 stator cooling water pump.

ETS, turbine TSI, condenser vacuum pump B, condenser centrifugal pump B, jacking shaft oil pump A, #2 stator
twenty one Station 30
Cooling water pump, #1EH oil pump, AC oil pump.

Condenser vacuum pump C, condenser centrifugal pump C, jacking shaft oil pump B, #2EH oil pump, EH oil system,
twenty two Station 31
open water.

twenty three Station 32 Air cooling fan: row 4-5.

twenty four Station 33 Air-cooling fans: rows 3-6.

25 Station 34 Air-cooling fans: rows 2-7.

26 Station 35 Air-cooling fans: rows 1-8.

15
 27 Station 36 Generator-transformer unit, synchronous device and AVR adjustment, electrical degree.

28 Station 37 DC system, diesel engine, UPS, peripheral circuit breaker, etc.

29 Station 38 Electrical section A circuit breaker, etc.

30 Station 39 Electrical B-section circuit breaker, etc.

31 Station 41 Auxiliary cooling water, heating and heating.

32 Station 42 Public substation A, lighting substation A, desulfurization substation A, coal handling substation A, ash removal substation A, and air cooling substation A.

33 Station 43 Public substation B, lighting substation B, desulfurization substation B, coal handling substation B, ash removal substation B, and air-cooling substation B.

34 Station 44 Start-up transformer, UPS, DC system, electrical #1, common part of unit 2 and common SOE point, PI.

1.4. List of DCS system equipment specifications

sequence one unit public Production

device name Specification/Model

No bit unit system factory

one monitor control level network

1 Operator Station/Foreman Station

DELL, T3500 W3503 Xeon Dual Core 2.4G/4G

DDR3/250G SATA(7200rm)/DVD-RW/256M
a the host tower 6 0 Dell
NVS295 (with VGA interface, support dual display

device)/USB keyboard/mouse/winxp Chinese version

b monitor 24″ widescreen LCD tower 6 0 Dell

c Ethernet card PILA8460M piece 6 0 Intel

2 big screen

AKAOLA

a LCD Monitor 82″LCD model: AL82S-3600C tower 1 0 (Australia

Leah)

DELL, T3500 W3503 Xeon Dual Core 2.4G/4G

DDR3/250G SATA(7200rm)/DVD-RW/256M
b the host tower 2 0 Dell
NVS295 (with VGA interface, support dual display

device)/USB keyboard/mouse/winxp Chinese version

auspicious

c led display 4000X260X110mm tower 1 1

(Xi'an)

16
sequence one unit public Production

device name Specification/Model

No bit unit system factory

3 History Station/Server

DELL, T410 E5606 2.13G (dual)/4G

DDR3/500G*2 SAS Raid1/DVD-RW/integrated dual

a History station host tower 1 1 Dell
Network port/redundant power supply/USB keyboard and mouse/2003server

operating system

DELL, T410 E5606 2.13G (dual)/4G

b server host DDR3/500G/DVD-RW/integrated dual network ports/redundant power tower 2 2 Dell

Source/USB mouse/keyboard/2003server operating system

c monitor 24" widescreen LCD tower 1 1 Dell

d switcher CS62U-A tower 1 1 ATEN

4 engineer station

DELL, T3500 W3503 Xeon Dual Core 2.4G/4G

DDR3/250G SATA(7200rm)/DVD-RW/256M
a the host tower 1 0 Dell
NVS295 (with VGA interface, support dual display

device)/USB keyboard and mouse/winxp Chinese version (win7 downgrade)

b monitor 24" widescreen LCD tower 1 0 Dell

c Ethernet card PILA8460M piece 3 0 Intel

5 printer

black and white laser U.S.

a LJ5200Lx, A3, 600*600dpi/25ppm tower 3 0
A3/A4 printer hp

color laser
U.S.
b A3/A4 graphic printing CP5225n A3, 600*600dpi, 20PPM tower 1 0
hp
printer

c printer cable 15 meters root 4 0 Hollysys

6 Communication Interface Workstation

SIS interface calculation E5800 3.2G/2G DDR3/250G SATA/integrated network

a piece 1 0 Dell
Host Card/DVD-RW/USB mouse/keyboard/Win XP Chinese Professional Edition

17
sequence one unit public Production

device name Specification/Model

No bit unit system factory

SP3

b monitor 24" widescreen LCD tower 1 0 Dell

E5800 3.2G/2G DDR3/250G SATA/integrated network

communication interface station

c Card/DVD-RW/USB mouse/keyboard/Win XP Chinese Professional Edition piece 2 0 Dell

the host

SP3

d monitor 24″ widescreen LCD tower 1 0 Dell

e Ethernet card PILA8460M piece 4 0 Intel

f switcher CS62U-A tower 1 0 ATEN

Multi-port communication Taiwan

g MOXA, CP-118U, multi-serial communication card piece 2 0
Card MOXA

7 network communication system

Hirschman network Germany

a RS20 (2 optical ports, 24 electrical ports) tower 8 0

switch Hersman

Hirschman network Germany

b RS20 (2 optical ports, 16 electrical ports) tower 2 2

switch Hersman

DP fiber optic transceiver

c FM1202 tower 0 2 Hollysys

device

metal-sheathed4-wire

d GYXTW-4b1 Meter 2000 1600 synthesis

multimode fiber optic cable

e cable Prefab on demand Meter 4000 500 amp

f hardware firewall DFL-800 set 1 1 D-LINK

DCS power supply

g ZR-KVV Meter 2500 1000 Hollysys
cable

two Process Control Level Network

main control unit

1 SM203 indivual 60 8 Hollysys

(DPU)

18
sequence one unit public Production

device name Specification/Model

No bit unit system factory

2 Main Control Cage SM130 indivual 30 4 Hollysys

3 I/O cage SM131 indivual 66 9 Hollysys

24V DC power distribution

4 SM940 piece 33 5 Hollysys

plate

5 5V power supply SM902 piece 192 26 Hollysys

6 24V power supply SM911 piece 66 10 Hollysys

7 48V power supply SM920 piece 60 8 Hollysys

8-channel RTD
8 SM432 piece 123 7 Hollysys
Input module RTD

8-channel RTD
9 SM3432 piece 123 7 Hollysys
Terminals

8-channel thermocouple

10 SM472 piece 43 0 Hollysys

Input module TC

8-channel thermocouple

11 SM3470/SM3471 piece 43 0 Hollysys

Terminals

8 channel current input

12 SM481 piece 168 20 Hollysys

Import module AI

8-channel current interface

13 SM3480 piece 168 20 Hollysys

wire terminal

8 channel analog
14 SM510 piece 39 2 Hollysys
Output module AO

8-channel mold output

15 SM3510 piece 39 2 Hollysys

Terminals

16 channels input

16 Quantity input module SM618 piece 374 52 Hollysys

DI

17 16 channels input SM619 piece 28 10 Hollysys

19
sequence one unit public Production

device name Specification/Model

No bit unit system factory

Quantity input module

SOE

16 channels input
18 SM3610 piece 402 62 Hollysys
measuring terminal

16-channel power supply

19 SM3612 piece 33 5 Hollysys

distribution terminal

8 channel pulse quantity

20 SM620 piece 6 1 Hollysys

Input module PI

8 channel pulse quantity

twenty one input terminal SM3310 piece 6 1 Hollysys

son

16 channels out

twenty two volume output module SM711 piece 155 16 Hollysys

do

16 channels of communication

twenty three Relay output SM3710 piece 103 6 Hollysys

terminal

16 channels DC

twenty four Relay output SM3711 piece 52 10 Hollysys

terminal

In-cabinet system
25 SX001 2.6 m/piece root 936 108 Hollysys
connecting cables

In-cabinet system
26 SX009 1.1 m/piece root 126 16 Hollysys
connecting cables

In-cabinet system
27 SX010 2.8 m/piece root 10 2 Hollysys
connecting cables

28 timing hub FM197 piece 1 1 Hollysys

20
sequence one unit public Production

device name Specification/Model

No bit unit system factory

29 Time distribution board SM3613 piece 3 2 Hollysys

hard button Switzerland

30 DPDT set 20 0
(with hood) EAO

31 alarm speaker set 4 0 constant wave

three Remote temperature collection

DP fiber optic transceiver

1 FM1202 tower 4 Hollysys

device

2 I/O cage SM131 indivual 6 Hollysys

3 24V power supply SM911 piece 12 Hollysys

8-channel RTD
4 SM432 piece 12 Hollysys
Input module RTD

8-channel RTD
5 SM3432 piece 12 Hollysys
Terminals

8-channel thermocouple

6 SM472 piece 44 Hollysys

Input module TC

8-channel thermocouple

7 SM3470/SM3471 piece 44 Hollysys

Terminals

In-cabinet system
8 SX001 2.6 m/piece root 56 Hollysys
connecting cables

In-cabinet system
9 SX009 1.1 m/piece root 8 Hollysys
connecting cables

In-cabinet system
10 SX010 2.8 m/piece root 4 Hollysys
connecting cables

Foursoftware

History station operation

1 Windows XP set 1 1 Hollysys

system software

2 Operation Station/Engineering Windows XP set 1 0 Hollysys

twenty one
sequence one unit public Production

device name Specification/Model

No bit unit system factory

Division Station Operations Department

system software

operator station soft

3 HOLLiAS-MACS set 8 0 Hollysys

bag

Engineer stands soft

4 HOLLiAS-MACS set 1 1 Hollysys

bag

historical data station

5 HOLLiAS-MACS set 1 1 Hollysys

package

6 DPU monitoring software HOLLiAS-MACS set 28 4 Hollysys

communication station software

7 HOLLiAS-MACS set 1 1 Hollysys

Bag

SIS Gateway Station Driver

8 HOLLiAS-MACS set 1 1 Hollysys

moving software

Norton Antivirus
9 Norton12.0,1+25 English version set 0 1 Hollysys
pieces

1.5. Main technical parameters (technical indicators) of DCS system

1.5.1. Main control cage

A.HOLLiAS SM130 type

serial number Indicator name Up to standard

1 electrical characteristics

a Power lead voltage drop < 0.1V

b Master control station address setting 6-position DIP switch

c Terminal matching resistance One end is fixed, and the other end is set by a 4-bit DIP switch

d power input 24V±10%

2 physical properties

A total of 14 slots, including 2 slots for power supply;

a Number of slots

Slot 2 slot; IO slot 10 slot.

twenty two
b Power input socket 5-pin Phoenix terminal, mounted behind the base plate

c Power status detection socket 4-pin Phoenix terminal, mounted behind the base plate

d Ethernet RJ45 connector 4-joint inverted RJ45 connector, mounted on the front of the chassis

e DP net connector 9-pin D-type header, mounted on the front of the chassis

f IO cable connector outlet 25-pin D-type header, installed behind the cage

3 Environmental indicators

a Operating temperature 0~50℃

b Working humidity 5〜95%, non-condensing

B.HOLLiAS SM131 type

serial number Indicator name Up to standard

1 electrical characteristics

a Power lead voltage drop < 0.1V

b Master control station address setting The upper 5 bits are set by the 5-bit DIP switch, and the lower 2 bits are set by the bottom

plate curing

c Terminal matching resistance One end is fixed, and the other end is set by a 4-bit DIP switch

d power input 24V±10%

2 physical properties

There are 14 slots in total, including 2 slots for power supply;

a Number of slots

Slot 12 slots.

b Power input socket 5-pin Phoenix terminal, mounted behind the base plate

c Power status detection socket 4-pin Phoenix terminal, mounted behind the base plate

d DP net connector 9-pin D-type header, mounted on the front of the chassis

e IO cable connector outlet 25-pin D-type header, installed behind the cage

3 Environmental indicators

a Operating temperature 0~50℃

b Working humidity 5〜95%, non-condensing

1.5.2. Main controller SM203

serial number Indicator name Up to standard

1 Voltage 5.1VDC±3%

twenty three
2 power consumption 10W Max

3 control network 2-way, redundant, ProfiBus-DP protocol

4 system network 2-way, redundant, 10base-T Ethernet

5 CPU . Embedded 32-bit processor, main frequency 400MHZ

6 DRAM 128MB DDR

7 SRAM 1MB

8 SSD (DiskOnChip) 16MB

9 Operating temperature .0~50℃

10 Working humidity 5%~95%, no condensation

1.5.3 8-channel thermal resistance input module RTD SM432 type

serial number Indicator name Up to standard

1 Voltage 5.1VDC±3%; 24.5VDC±5%

2 power consumption 300mA [email protected] ; 100mA [email protected]

3 Protocol ProfiBus-DP

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps optional

5 Communication port isolation voltage 500Vrms

6 number of channels 8

7 signal type RTD signal

8 gain 8421

9 Resistance range (Ω) 0 ~ 85, 0 ~ 170 ,0 ~ 340 ,0 ~ 400

10 Cu50 measurable temperature range (°C) - 50~150

11 Pt100 measurable temperature range (°C) - 200~ -39, -200~ 184, -200~ 683,

- 200~850

12 stability 0.1%FS

13 Conversion accuracy (25°C) 0.2%FS

14 Common Mode Rejection Ratio (50Hz) 120dB

15 temperature drift ±50ppm/℃

16 Operating temperature. 0~50℃

twenty four
17 Working humidity 5%~95%, no condensation

1.5.48Channel current analog input module SM481

serial number Indicator name Up to standard

1 number of channels 8

4 input resistance 246.3Ω

5 ADC bits 16 bits

6 channel maximum input current 30mA

7 Do not filter 0x00 250ms/8ch

8 filter 0x01 500ms/8ch

9 filter 0x02 750ms/8ch

10 filter 0x03 1S/8ch

11 filter 0x04 1.5S/8ch

12 filter 0x05 2S/8ch

13 Accuracy (25°C) 0.1% FS

14 stability 0.05% FS

15 Filtering 500ms/8ch The time to reach 90% of the target value is better than 3 seconds

16 No filter 250ms/8ch Time to reach 90% of target value is better than 1 second

17 time drift 1000ppm/year

18 temperature drift ±100ppm/℃

19 hot swap support

20 Isolated voltage-resistant channel-pair system ≥ 500VAC@1min @5mA

21 Input voltage 5VDC±3%; 24VDC±10%

22 power consumption (max) [email protected] ; [email protected]

23 Protocol Profibus-DP

24 communication rate 500kbps, 93.75kbps, 45.45kbps,

31.25kbps, 19.2kbps, 9.6kbps

25 Dual network redundancy support

26 Working temperature 0℃~55℃

27 Working environment relative humidity 5%~95%, no condensation

25
1.5.5 8-channel 4〜20mA current output module SM510

serial number Indicator name Up to standard

1 supply voltage 5.1VDC±3%/24.5VDC±5%

2 Power consumption 7W@Max

3 Protocol ProfiBus-DP protocol

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps optional

5 signal type 4〜20mA current signal

6 Output accuracy 0.2% FS

7 Update Speed 10 times/sec

8 stability 0.1%

9 Step response time ≤1S

10 load capacity Maximum 750Ω

11 temperature drift ±100ppm/℃

12 Operating temperature 0℃~50℃

13 Working humidity 5~95%, non-condensing

1.5.6 16-channel 48VDC contact type digital input module SM618

serial number Indicator name Up to standard

1 supply voltage 5.1VDC±3%

2 Power consumption 150mA/5.1V; 100mA/48V

3 Protocol Profibus-DP protocol

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps

5 signal type Contact type digital input signal

6 input threshold < 24V = OFF, > 36V = ON

7 debounce time 10mS (software mode)

8 Scan time of all input channels 1m S

26
 9 Query voltage 48V

10 query current 4mA〜5mA

11 Operating temperature 0℃~50℃

12 Working humidity 5~95% relative humidity, non-condensing

1.5.7 16-channel 48VDC contact type SOE input module SM619

serial number Indicator name Up to standard

1 supply voltage 5.1VDC±3%/24.5VDC±5%

2 Power consumption 240mA/5.1V, 100mA/48V

3 Protocol ProfiBus-DP protocol

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps optional

5 signal type Contact type digital input signal

6 input threshold < 24V = OFF, > 36V = ON

7 debounce time 10mS (software mode)

8 Scan time of all input channels 1mS

9 Query voltage 48V

10 query current 4mA〜5mA

11 Operating temperature 0℃~50℃

12 Working humidity 5~95% relative humidity, non-condensing

1.5.8 16-channel common-negative terminal transistor-type switching output module SM711

serial number Indicator name Up to standard

1 supply voltage 5.1VDC±3%/24.5VDC±5%

2 Power consumption 350mA/5.1V, 350mA/24.5V

3 Protocol ProfiBus-DP protocol

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps optional

5 signal type DARLINGTON optocoupler output

6 Output current 50mA/channel

7 Operating temperature 0℃~50℃

27
8 Working humidity 5~95% relative humidity, non-condensing

1.5.98Channel (isolation between channels) thermocouple input module SM472

serial number Indicator name Up to standard

1 Voltage 5.1VDC±3%, 24.5VDC±5%

2 power consumption 3W@MAX

3 Protocol Profibus-DP

4 communication rate 9.6kbps, 19.2kbps, 45.45kbps,

93.75kbps, 500kbps optional

signal channel

5 signal type Thermocouple signal or general millivolt signal

6 input resistance Greater than 1MΩ

7 stability 0.1%FS

8 Conversion accuracy (25°C) 0.2% FS

9 Sampling Response Time (8 Channels) 500ms, 1s, 1.5s etc. optional

10 Differential Mode Rejection Ratio (50Hz) Better than 60dB

11 Common Mode Rejection Ratio (50Hz) Better than 120dB

12 Isolation voltage between input and output Not less than 500VAC (1 minute)

13 Circuit isolation voltage Not less than 250VAC (1 minute)

14 temperature drift ±50ppm/℃

1.6 DCS system software

1.6.1. In engineering, each computer has different tasks, generally divided into engineer station, server and operator

The "server" is responsible for processing and storing data and responding to customer requests; the "operator station" is responsible for monitoring and viewing real-time

Data, operating equipment; "Engineer Station" is mainly responsible for offline configuration, online download and debugging. so on each computer

When installing HOLLiAS MACS software, different components need to be installed according to their functions.

a) Components corresponding to the engineer station: engineer station, offline query, public components, AutoThink, and scripts.

b) Components corresponding to the operator station: operator online, public components, and scripts.

c), history station: real-time station, history station, IOServer, public components.

d), report printing service: report printing service, public components.

e), communication station: communication station, public components.

1.6.2 The default software installation path of HOLLiAS_MACS system is: <C:\ HOLLiAS_MACS\> under its installation path

28
The functions of the main folders are:

a), AutoThink: install algorithm configuration components.

b), Common: Common components of system operation, including configuration files, dynamic link libraries, and network node diagnosis and network

Client time service and other programs.

c), ENG: engineering station configuration components. Among them, the [user] subdirectory stores the projects created by users, and all project configuration information

and compiled content are stored in the corresponding project directory.

d), HDB: Install the historical library service component. On the node computer set up as the history library service (HDBServer), [start]

The subdirectory receives and saves the history library service running information downloaded from the engineer station.

e), help: place the online help file of the software.

f), IOServer: Install IO service components. On the node computer set up as the IO service (IOServer), [start]

The subdirectory receives and saves the IO service running information downloaded from the engineer station.

g), Log: Store the running log files of the MACS system.

h) , Offline: Install offline query components.

i), OPCClient: Install OPC client components. The software conforms to the OPC2.0 specification and is used to communicate with other factories that meet this standard

The vendor's OPC server software for data communication.

j), Ops: install the operation station components. On the node computer set as the operation station, the [start] subdirectory receives the saved tool

The operation information of the operator station downloaded from the engineer station.

k)|, Printer: Install the print service component.

l), RTDB: Install real-time library components. On the node computer that is set up as the real-time service (RTDBServer), [start]

The subdirectory receives and saves the real-time service running information downloaded from the engineer station.

m), Script: Install script components.

n), HDBDATAS: store historical database data by default. This folder is only created on the computer where the history library service is started, and the

Store historical data. The storage path of the historical library can be modified when installing the software.

1.7 Hardware working principle

2 Maintenance category and cycle

2.1. The maintenance work of the thermal distributed control system (DCS) is divided into A, B, C level maintenance, routine inspection and defect elimination, equipment

Periodic maintenance check.

2.2. A, B, and C-level maintenance of thermal distributed control system (DCS) are carried out along with the major and minor repairs of the main unit equipment.

2.3. During the daily patrol inspection, the person in charge of the equipment should inspect the control cabinets of the distributed control system (including remote I/O cabinets) as required. ,

29
The control room, engineer station and its equipment are inspected once a day, and the on-site instruments and panel cabinets (transmitter cabinets) are inspected at least once a week.

Time, and do a good record of patrol inspections, and report to the team leader in time for any abnormalities found. Squad leader or team technicians should

Check and record the results for inspection and acceptance.

2.4. Regular maintenance and calibration

2.4.1. The measurement parameters of the DAS data acquisition system should be checked regularly on site, and the error should not be greater than the overall error of the system

2/3; The error of the main steam temperature and main steam pressure within the range of the common section should not be greater than 1/2 of the accuracy level of the table. main

For thermal instrumentation and DAS system measurement parameters, on-site spot checks are conducted once a month, and the quantity is not less than 5 pieces (points) for each unit.

2.4.2. The automatic adjustment system should be tested regularly, generally after major or minor repairs of the unit. The test date should be included in the test report

The period, test personnel, reviewers and test data are complete and standardized, and the corresponding trend curves are attached. Test report preservation

Three cycles for future reference.

2.4.3. Transmission test of protection system

a) When the unit encounters a shutdown opportunity such as temporary repair or mediation, and the time since the last protection drive test is more than three months, the unit shall be

Carry out the transmission test of the thermal main protection system.

b) When the unit encounters a shutdown opportunity such as temporary maintenance or mediation, during which the overhaul of the thermal protection system is carried out, the unit will

The protective transmission test of the relevant system should be carried out before starting.

c) For whatever reason, if the unit is out of operation for more than seven days, the transmission test of the main thermal protection system shall be carried out before the unit starts.

d) The dynamic (closed-loop) test of the boiler safety monitoring system should be carried out before and after major and minor repairs of the unit, and the interval should not exceed three years.

3 maintenance items

3.1. The A-repair of the thermal control distributed control system (DCS) is carried out along with the A-repair of the main unit equipment, usually once every five years. Projects should be based on

The actual operation situation is analyzed by the thermal control professional, and the specific maintenance plan is written, which is reviewed by the production technology department of B factory.

Approved by the supervisor of factory B. However, the standard maintenance items of the DCS system during A maintenance must include the following maintenance contents.

3.1.1. Conduct a comprehensive inspection of the DCS system and keep records

3.1.2. On-site control station project configuration modification, compilation, download, backup, project compilation and server, operator station download

3.1.3. Verify the logo and address of the module

3.1.4. Clean the control cabinet power supply and modules

3.1.5. Clean the dust filter of the cabinet

3.1.6. Check and fasten the signal wiring and fixing screws of the control cabinet

3.1.7. Check the insulation of all signal cables of the DCS system

3.1.8. Check and replace the control cabinet and computer cooling fan

3.1.9. Eliminate equipment defects that cannot be handled during operation

3.1.10. System safety performance test required by technical supervision and acceptance test regulations

30
a), DCS system grounding test

b), DCS system total power supply capacity error switching test

c), On-site control station DPU power supply redundancy switching test

d), On-site control station main control, tracking DPU redundancy switching test

e), communication network redundancy switching test

f), server redundancy switching test

g), module maintainability (plug-in) test

h), system reset ability test

i), anti-radio frequency interference test

j), DAS data acquisition function test (I/O channel test, etc.)

3.1.11. Field equipment maintenance

3.1.12. Protection interlock test

3.1.13. Inspection and replacement of cables, pipelines and their accessories

3.2 C repair of thermal DCS system is carried out with small C repair of the group, generally once a year. The project should be based on the actual operating conditions by the thermal

Control professional to conduct equipment analysis, write specific maintenance plan items, which will be reviewed by the production technology department of factory B and approved by the supervisor of factory B.

However, the standard maintenance items of the DCS system during C maintenance must include the following maintenance contents.

3.2.1. Clean the dust filter of the cabinet

3.2.2. Check and replace the control cabinet and cooling fan of the main computer

3.2.3. Control cabinet power supply and module working status inspection

3.2.4. System safety performance test required by technical supervision and acceptance test regulations (see overhaul project for details)

3.2.5. Eliminate equipment defects that cannot be handled during operation

3.2.6. Some on-site equipment maintenance

3.2.7. Main unit, auxiliary protection and interlocking test

3.2.8. I/O module sampling system test

3.2.9. On-site control station engineering configuration backup

4 Maintenance steps, process methods and quality standards

4.1. Maintenance

4.1.1. DCS system configuration project backup

4.1.1.1 Process steps

a. The backup work can only be performed on the engineer station.

B. Exit the engineer station operator station online.

C. Exit the configuration management of the engineer station and close the project.

D. 4. Open C:\HOLLiAS_MACS\ENG\USER\, and make a full backup of DTDC0 and DTDC1 under the directory.

31
4.1.1.2 Quality standards

a. It is strictly forbidden to perform project backup on the operator station other than the engineer station.

b. It is strictly forbidden to perform project backup when the operator station of the engineer station is online.

c. It is strictly forbidden to make a backup when the configuration management of the engineer station is running.

d. Make a full backup of DTDC0 and DTDC1 under the USER directory.

e. The project should be sorted and named according to the date and the project should be backed up on a dedicated backup disk other than the C drive of the engineer station.

f. After the backup is completed, compare it with the original project. The size, occupied space, included files and folders should be consistent.

g. Compress the backup, export it to an external storage (special-purpose hard drive) and burn it to a CD for long-term archiving.

h. This work is completed by the engineer station administrator.

4.1.2. DCS system control cabinet grounding inspection

4.1.2.1 Process steps

a. Check the connection between the ground wire and the cabinet connection point, between the ground wire and the common connection plate, and between the common ground connection plate of the main grounding line

point.

b. Measure the grounding resistance at the grounding screw of the I/O cabinet and the shielding ground and logic grounding bus bar.

4.1.2.2 Quality standards

a. Copper gaskets and copper bolts are fastened without rust.

b. The grounding resistance at the grounding screw of the I/O cabinet and the shielding ground and logic ground bus bar is less than 4 ohms.

4.1.3. DCS system control cabinet grounding inspection

4.1.3.1 Process steps

a. The DCS system should operate with continuous power supply, and the power supply of the corresponding control station equipment should be stopped for partial maintenance.

b. Do the following work well before the DCS power failure:

(1) Check whether there is a mandatory point in the running configuration file, and make a record if any problem is found, so that corresponding measures can be taken for verification and recovery

Shi;
(2) Check whether there is equipment in operation at the control station that needs to be powered off, and if so, safety technical measures should be taken to prevent equipment malfunction.

(3) Check the working status of the power supply and modules;

(4) Back up the DCS system engineering.

c. DCS system maintenance power failure.

d. After the overhaul is completed and the equipment resumes power transmission, the safety technical measures shall be resumed after the DPU operates normally.

4.1.3.2 Quality standards

a. Check and confirm the control station and operator station that need to be powered off.

32
b. For those found to be mandatory, confirm whether it can be released; if there is a running device, switch the device to local operation.

c. Power supply, I/O module operation indicator light and communication indicator light indicate normal.

d. The project backup should be sorted and named according to the date, and the project should be backed up on a dedicated backup disk other than the C drive of the engineer station.

e. After the backup is completed, compare it with the original project. The size, occupied space, included files and folders should be consistent.

f. When the power is off, carefully check the nameplate of the equipment, and follow the sequence of stop DPU power supply, stop 48VDC power supply, stop, 24VDC power supply, stop wind

The fan power supply and the cabinet power supply are executed in sequence.

g. After the overhaul is completed, the nameplate of the power supply is complete and there is no shortage.

h. The power supply of the equipment is executed in the order of cabinet power supply, fan power supply, 24VDC power supply, 48VDC power supply, and DPU power supply.

i. After the modules and DPU are running normally, restore the safety technical measures one by one.

4.1.4. Overhaul of cooling fan

4.1.4.1 Process steps

a. Stop the power switch of the control cabinet where the cooling fan to be replaced is located.

b. Replace the fan after checking that the technical parameters are consistent.

c. Power transmission test.

4.1.4.2 Quality standards

a. Carefully check the nameplate to ensure that the power failure is correct.

b. The voltage, power and speed of the replaced fan are the same as those of the original fan.

c. The power supply and wiring of the fan must be firm and reliable;

d. The rotation direction of the fan is correct; there is no jamming and no obvious noise during the rotation of the fan.

e. After the fan is replaced, make maintenance records so as to determine the replacement cycle of the fan.

4.1.5. Purging and cleaning of modules

4.1.5.1 Process steps

a. The control system is powered off. Stop the controller first, then the power module, and finally the total power supply of the shutdown cabinet.

b. Pull out the control card.

(1) When cleaning the modules, mark the position of the modules and record the positions of various dial switches and jumpers for cleaning

Check it later.

(2) The staff must wear an anti-static grounding ring when plugging and unplugging the modules, and try not to touch the circuit part as much as

possible. (3) The unplugged card is temporarily stored in a special anti-static protective bag.

c. Use a hair dryer or leather tiger to blow off the dust accumulated on the surface of the card. After the module is purged, deal with the module's circuit board connector and purge

Clean the parts that still have dirt after sweeping with a special cleaning agent.

33
d. Use a vacuum cleaner to clean the floating dust in the control cabinet.

e. Check the control card, observe whether the electronic components of each component are aging, and replace the aging card

Change. After inspection is complete, replace all cards.

4.1.5.2 Quality standards

a. Module cleaning must be done after power failure. Do a good job of project backup before power outage;

recognize.

b. The cards are completely marked, the DIP switches and jumpers are recorded correctly, and the temporary storage of the cards meets the requirements.

c. The card parts are cleaned and free from dust accumulation.

d. The inside of the control cabinet is clean and free of dust.

e. The wiring plug inside the cabinet is fastened without looseness.

f. After the card is powered on, it works normally, and the corresponding operation and communication indicator lights indicate normal.

4.1.6. Control cabinet signal cable insulation inspection

4.1.6.1 Process steps

a. Get rid of the wiring at both ends of the signal cable terminal to be measured (local terminal box and cabinet terminal board channel).

b. Use a 500MΩ megger to measure the interphase insulation of the signal cable.

c. Use a 500MΩ megger to measure the insulation of the signal cable to the ground.

4.1.6.2 Quality standards

a. It is strictly forbidden to measure the insulation of the signal cable with load. The signal cable shield must be grounded at one end at the cabinet.

b. Phase-to-phase insulation of signal cables ≧10M ohms.

c. The insulation of the signal cable to the ground is ≧10M ohms.

4.1.7. I/O channel test

4.1.7.1 Process steps

a. At the local primary component, use a short wire to short-circuit the positive and negative poles of the DI signal channel, and observe the signal light of the channel.

b. In the configuration software, scan and cut off the DO signal to be tested, force the output signal to be "1" and "0", observe the channel signal light,

and measure the output of the terminal.

c. Use the qualified standard electronic potentiometer, resistance box, 4~20mA signal source and other calibration instruments to check the corresponding

Input the signals of 0%, 25%, 50%, 75%, and 100% of the range respectively on the terminals of the

The displayed value of the point, compared to the standard value entered.

34
d. Through the operator station (or engineer station), set the output value of each point according to 0%, 50% and 100% of the range, and set the output value at the I/O

Measure the AO output terminal of the corresponding module of the station with a standard tester and read the indicated value of the output signal;

Compare.

4.1.7.2 Quality standards

a. The I/O channel test must be carried out by adding signals from the local primary components. It is strictly forbidden to add signals to the terminal channels of the control cabinet to avoid

The combined error of the measurement system.

b. Calculation of measurement error should meet current: ≤0.1%, voltage: ≤0.1%, thermal resistance: ≤0.2%, thermocouple: ≤0.2%,

Pulse: ≤0.2% requirement.

c. To calculate the measurement error, the corresponding AO output of the I/O module should meet the accuracy requirement of ≤0.25%.

4.1.8. SOE Incident Recall Test

4.1.8.1 Process steps

a. Use a dedicated SOE digital signal generator for testing.

b. The test should be carried out as follows:

(1) Sequence of events recording resolution of the same DPU and the same SOE card.

(2) Sequence of events recording resolution of the same DPU but different SOE cards.

(3) The recording resolution of SOE sequence of events obtained by different DPUs.

c. Use the SOE signal generator to change the pulse signal time interval T (resolution) according to 3ms, 2ms, 1ms until the event

Sequential records are indistinguishable.

4.1.8.2 Quality standards

a. The resolution shall not exceed 1ms.

b. The minimum resolution time should be able to reproduce stably.

c. When the interval time is 1ms, the absolute error is ≤0.01ms.

4.2 Test

4.2.1 DCS system power supply fault test.

4.2.1.1 Test method

a. Artificially cut off the total power supply of the DCS system.

b. The backup power supply of the DCS system is automatically put into operation.

4.2.1.2 Quality standards

a. During the power switching process, the control system should work normally, and the intermediate data and accumulated data will not be lost.

4.2.2 DPU power switching test

35
4.2.2.1 Test method

a. Artificially shut down the redundantly configured DPU power modules on the I/O control station respectively.

4.2.2.2 Quality standards

a. The DPU and the entire I/O control cabinet are in normal operation, no error alarm and no data loss.

4.2.2 Redundant DPU bumpless switching test

4.2.2.1 Test method

a. Reset the pair of redundant DPU main control units on the field I/O control station respectively.

b. The DPU main control unit can be reset by pressing the "RESET" button on the card and pulling out the DPU card with power on.

4.2.2.2 Quality standards

a. During the test, the tracking main control unit in the system should be able to switch to the main control normally, without disturbance, and quickly;

b. DCS fault diagnosis display is correct;

c. The calculation result of the DCS system does not change before and after switching.

4.2.3 Network redundancy switching test

4.2.3.1 Test method

a. Unplug the system network snet lines 1 and 2 of the redundant configuration on the main control DPU;

b. Unplug the system network snet lines 1 and 2 that track the redundant configuration on the DPU respectively;

c. Artificially cut off a communication bus on any node (operator station, engineer station, server, switch, etc.).

4.2.3.2 Quality standards

a. During the test, the DCS system is operating normally, the DCS alarm screen is displayed correctly, and the communication failure light corresponding to the DPU card is on

Bright;

b. The data transmission between the I/O station and the operator station, server, and engineer station is normal;

c. The DCS system must not have errors or crashes;

d. After the network plug is restored, the communication system automatically returns to normal operation.

4.2.4 Server redundancy switching test

4.2.4.1 Test method

a. Artificially quit the running server in the redundant server.

4.2.4.2 Quality standards

a. The standby server is put into operation automatically, the DCS communication is normal, the stored data is not lost, and the data displayed on the DCS monitoring screen is normal.

Functionality is not affected.

4.2.5 Module plug-in test

36
4.2.5.1 Test method

a. When the DCS system is running, each I/O control cabinet is charged to pull out one module of AI, AO, DI, and DO respectively for pulling out

Insert test.

4.2.5.2 Quality standards

a. After the module is pulled out, the DCS system monitoring screen can display the fault status of the module.

b. During the process of pulling out and restoring the module, the signal connected to the I/O module has no jump, and other functions of the control system are not affected.

affected, the DCS system remains in normal operation.

4.2.6 Reset ability test

4.2.6.1 Test method

a. When the DCS system is running, cut off and restore the peripheral equipment of the system, such as: stop the power supply of the electric actuator.

4.2.6.2 Quality standards

a. There should be no abnormality in the control system.

4.2.7 Anti-radio frequency interference test

4.2.7.1 Test method

a. Select the display screen with thermocouple signal on the operator station, and record the current display value.

b. Use a walkie-talkie with a frequency of 400~500Mhz and a power of 5W, at a distance from the I/O control station (open cabinet) where the measuring point is located

Use the walkie-talkie at a distance of 1.5 meters at a normal volume, and use it as an interference source to send out radio frequency interference signals for testing.

4.2.7.2 Quality standards

a. During the test, the DCS system should work normally, and the change range of the measurement signal indication value should not be greater than the allowable error of the measurement system.

2 times.

4.2.8 Output power-down protection test

4.2.8.1 Test method

a. On the DCS, select an analog output point with a safe mode (hold or return to zero) design.

b. Change the output value by adding a signal or forcing it to be set, and make a record.

c. Turn off the power supply of the redundant DPU of the I/O control station where the signal is located, and then turn it on again.

4.2.8.2 Quality standards

a. The tested analog output signal can control the external equipment to ensure the safety of the process system according to the preset safety mode.

full run.

4.2.9 Public system monitoring and locking test

4.2.9.1 Test method

37
a. Set the operation authority of domain #0 to the DCS system of unit #1, and set the public system equipment of domain #0 on the operator station of unit #2

If the operation is performed, the operation is invalid and the DCS system is normal.

b. Set the operation authority of domain #0 to the DCS system of unit #2, and set the public system equipment of domain #0 on the operator station of unit #1

If the operation is performed, the operation is invalid and the DCS system is normal.

4.2.9.2 Quality standards

a. In any case, only the operator of one unit is allowed to effectively monitor the public system.

4.2.10 DCS system real-time test

4.2.10.1 Test method

a. Randomly select 10 pictures on the operator station for testing.

b. Use a stopwatch to measure the time from the completion of the last calling operation on the operator station to the display of all the contents of the picture.

4.2.10.2 Quality standards

a. The average response time of 10 pictures should be less than 1.5s.

b. The general picture is not longer than 1s, and the complex picture is less than 2s.

4.2.11 Unit protection interlock test

4.2.11.1 Test method

a. The test procedure should comply with the requirements of the field test program. For details, refer to the chapter on unit protection interlocking in this regulation.

4.2.11.2 Quality standards

a. The test standard should meet the requirements of the on-site test program. For details, see the chapter on unit protection interlocking in this regulation.

5 Dangerous point analysis and pre-control

serial number danger point Pre-control measures

1. The person in charge of the work must check whether the position and model of the card are correct.

indeed.

2. It must be confirmed that the plug-in dial address is set correctly.

3. Staff must wear anti-static wristbands.

1. The person in charge must be supervised when modifying the logic.

2. Before modifying the logic, there must be a written, approved by relevant departments and

Application for logic modification approved by the chief engineer (or deputy director) of the factory department.

3. After the logic modification is completed, it must pass the on-site logic transmission test.

And it has passed the three-level quality inspection.

38
 4. After the logic modification is completed and the test is qualified, the logic should be prepared in time.

share.

1. Power off the control cabinet before cleaning.

2. Do not wipe the terminal board and circuit board with a wet cloth.

3. When using electric tools, use a leakage protection with a certificate of conformity.

protector.

4. Staff must wear insulating shoes.

5. The staff must use a qualified electroscope pen when testing electricity.

1. Before the power failure of the I/O control cabinet, check whether there is equipment running,

Work can only be started after safety technical measures are taken.

2. During the on-site logic transmission test, confirm that the controlled equipment is under test

Check location.

1. The cuffs of the overalls should be fastened.

2. It is forbidden to place any part of the body in the cooling fan of the cabinet to rotate

part.

3. The physical and mental condition of the staff is good, and they are competent for their duties.

work.

6 Safety, health and environmental protection requirements

6.1 Security

6.1.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. It must be dealt with when it involves withdrawal of the principal and auxiliary protection

Protect the return application form.

6.1.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

6.1.3 When two or more people work, one person in charge must be identified.

6.1.4 There should be sufficient lighting on the site and meet the requirements of the "Safety Regulations".

6.1.5 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

Tools.

6.1.6 When cleaning and refueling, prevent fire.

6.1.7 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

6.1.8 Seriously abide by the safety regulations of lifting and handling.

39
6.1.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

6.1.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

6.1.11 Clean up flammable and explosive debris at the work site.

6.2 Health

6.2.1 Precautions must be taken when contacting chemicals that are toxic, harmful or pungent to the human body.

6.3 Environmental protection

6.3.1 The replaced waste products must be poured into the designated dustbin, and should not be dumped casually.

6.3.2 Discarded or leftover chemicals after use must be placed in designated locations, and should not be discarded casually. must be done after

"Complete work, clean materials, clean site" .

6.3.3 Work must consciously abide by the ISO14001 environmental management standard and the ISO9001 quality management system.

40
 Chapter 3 Digital Electro-hydraulic Control System (DEH)

1 Equipment overview and parameters

1.1 Equipment overview

The steam turbine control system of Shenhua Shendongdianta Power Generation Company B Plant 2×660MW is produced by American EMERSON Company

WDPF Ovation digital electro-hydraulic control system, the control system takes the computer as the core and uses high-pressure anti-fuel as the executive action

Force, by controlling the electro-hydraulic servo valves of the high-pressure main valve, medium-pressure main valve, high-pressure steam valve, and medium-pressure steam valve of the steam turbine, to achieve

To control the start of the steam turbine, speed up, grid connection, initial load, full load, and participation in primary frequency regulation, etc., in order to achieve

The purpose of stable operation of the steam turbine.

DEH system is mainly composed of computer control part and EH oil control part. DEH partially completes the control logic, algorithm and

man-machine interface.

1.2 Equipment parameters

2 Maintenance category and cycle

2.1 The A-repair of the DEH system is carried out along with the A-repair of the main unit equipment, usually once every five years. The project should be based on the actual operating conditions by the thermal

Control professional to conduct equipment analysis, write specific maintenance plan items, which will be reviewed by the production technology department of factory B and approved by the supervisor of factory B.

2.2 The C maintenance of the DEH system is carried out along with the C maintenance of the main unit equipment, usually once a year. The project should be based on the actual operating conditions by the thermal

Control professional to conduct equipment analysis, write specific maintenance plan items, which will be reviewed by the production technology department of factory B and approved by the supervisor of factory B.

3 maintenance items

3.1 A-level maintenance standard items

3.1.1. Primary component verification

3.1.2. Control cabinet sanitation cleaning

3.1.3. Control cabinet terminal fastening inspection

3.1.4. On-site control circuit terminal tightening inspection

3.1.5. DEH system hardware check

3.1.6. DEH system software inspection

3.1.7. DEH system function test

3.1.8. OPC Solenoid Valve Test and Inspection

3.1.9. DEH system sampling pipeline, sampling point inspection

3.1.10. DEH signal cable insulation test

41
3.1.11. Watt temperature component inspection

3.1.12. Relay inspection

3.1.13. Channel accuracy test

3.1.14. LVDT inspection

3.1.15. Travel switch inspection

3.1.16. DEH speed probe calibration check

3.1.17. Valve static test

3.1.18. Protection chain drive

3.1.19. DEH system redundancy switching test

3.2 C-level maintenance standard items

3.2.1 Important Primary Component Verification

3.2.2 Sanitary cleaning of the control cabinet

3.2.3 Fastening inspection of control cabinet terminals

3.2.4 OPC Solenoid Valve Test and Inspection

3.2.5 LVDT inspection

3.2.6 Travel switch inspection

3.2.7 Valve static test

3.2.8 Protection of chain drives

3.2.9 DEH system redundancy switching test

4 Maintenance steps, process methods and quality standards

4.1 Maintenance

4.1.1. Primary component verification

4.1.1.1 Process steps

a.

b.

c.

d.

4.1.1.2 Quality standards

a.

b.

42
c.

d.

e.

f.

g.

4.1.2. DEH system I/O card cleaning

4.1.2.1 Process steps

a. The control system is powered off. Stop the controller first, then the power module, and finally the total power supply of the shutdown cabinet.

b. Pull out the control card.

(1) When cleaning the modules, mark the position of the modules, and record the positions of various dial switches and jumpers for cleaning

Check it later.

(2) The staff must wear an anti-static grounding ring when plugging and unplugging the modules, and try not to touch the circuit part as much as possible.

(3) The unplugged card is temporarily stored in a special anti-static protective bag.

c. Use a hair dryer or leather tiger to blow off the dust accumulated on the surface of the card. After the module is purged, deal with the module's circuit board connector and purge

Clean the parts that still have dirt after sweeping with a special cleaning agent.

d. Use a vacuum cleaner to clean the floating dust in the control cabinet.

e. Check the control card, observe whether the electronic components of each component are aging, and replace the aging card

Change. After inspection is complete, replace all cards.

4.1.2.2 Quality standards

a. Module cleaning must be done after power failure. Do a good job of project backup before power outage;

recognize.

b. The cards are completely marked, the DIP switches and jumpers are recorded correctly, and the temporary storage of the cards meets the requirements.

c. The card parts are cleaned and free from dust accumulation.

d. The inside of the control cabinet is clean and free of dust.

f. The wiring plug inside the cabinet is fastened without loosening.

g. After the card is powered on, it works normally, and the corresponding operation and communication indicator lights indicate normal.

4.1.3. Fastening of control cabinet terminals

4.1.3.1 Process steps

a. Retighten the wiring of the DEH terminal cabinet; b. Retighten the

wiring of the terminal junction box of the DEH system:

43
c. Retighten the wiring of DEH local primary parts (pressure switch, LVDT, travel switch).

4.1.3.2 Quality standards

a. The terminals are not loose or corroded, the wiring is firm, neat and beautiful, and the cable identification plates are complete.

b. The wiring diagram inside the cabinet is correct and clear.

4.1.4. OPC solenoid valve test check

4.1.4.1 Process steps

a. Measure the resistance value of the OPC solenoid valve; b. Measure the

insulation resistance of the solenoid valve to the ground.

4.1.4.2 Quality standards

a. The OPC resistance value is about 750 ohms;

b. Solenoid valve insulation resistance to ground ≧ 20M ohms (500V shaker)

4.1.5. DEH system sampling pipeline, sampling point inspection

4.1.5.1 Process steps

a. Check the EH oil system sampling pipeline, sampling point and the fixing place of the pipe clamp.

4.1.5.2 Quality standards

a. The laying of each sampling pipeline is beautiful, tidy, without friction, without shaking, and there is no leakage at the joint.

4.1.6. DEH signal cable insulation test

4.1.6.1 Process steps

a. Get rid of the wiring at both ends of the signal cable terminal to be measured (local terminal box and cabinet terminal board channel).

b. Use a 500MΩ megger to measure the interphase insulation of the signal cable.

c. Use a 500MΩ megger to measure the insulation of the signal cable to the ground.

4.1.6.2 Quality standards

a. It is strictly forbidden to measure the insulation of the signal cable with load. The signal cable shield must be grounded at one end at the cabinet.

b. Phase-to-phase insulation of signal cables and ground insulation of measurement signal cables≧10M ohms

4.1.7.1 Process steps

a. At the local primary component, use a short wire to short-circuit the positive and negative poles of the DI signal channel, and observe the signal light of the channel.

b. In the configuration software, scan and cut off the DO signal to be tested, force the output signal to be "1" and "0", observe the channel signal light,

and measure the output of the terminal.

c. Use the qualified standard electronic potentiometer, resistance box, 4~20mA signal source and other calibration instruments to check the corresponding

Input the signals of 0%, 25%, 50%, 75%, and 100% of the range respectively on the terminals of the

The displayed value of the point, compared to the standard value entered.

44
d. Through the operator station (or engineer station), set the output value of each point according to 0%, 50% and 100% of the range, and set the output value at the I/O

Measure the AO output terminal of the corresponding module of the station with a standard tester and read the indicated value of the output signal;

Compare.

4.1.7.2 Quality standards

a. The I/O channel test must be carried out by adding signals from the local primary components. It is strictly forbidden to add signals to the terminal channels of the control cabinet to avoid

The combined error of the measurement system.

b. Calculation of measurement error should meet current: ≤0.1%, voltage: ≤0.1%, thermal resistance: ≤0.2%, thermocouple: ≤0.2%,

Pulse: ≤0.2% requirement.

c. To calculate the measurement error, the corresponding AO output of the I/O module should meet the accuracy requirement of ≤0.25%.

4.1.8. LVDT Sensor Check

4.1.8.1 Process steps

a. Test and check the resistance value of LVDT sensor;

b. LVDT sensor coil insulation test;

c. LVDT sensor core wear inspection.

4.1.8.2 Quality standards

a. The resistance of the primary coil of the high-profile main valve is about 290 ohms, and the resistance of the secondary coil is about 150 ohms; the resistance of the primary coil of the high-profile valve is about

The value is about 160 ohms, the secondary coil resistance is about 240 ohms;

The coil resistance is approximately 390 ohms.

b. LVDT sensor coil to ground insulation resistance ≧ 20M ohms (500V shaker)

c. The fixed iron core screws and spring pads are complete, the screws are firm and not loose; the iron core has no obvious wear and bending, and the zero position and full scale are marked

Clear; core and coil sleeve concentric.

4.2 Test

4.2.1 DEH valve static test

4.2.1.1 Test method

a, b,

4.2.1.2 Quality standards

a.

4.2.2 Controller Redundancy Switchover Test

4.2.2.1 Test method

a. Reset the pair of redundant DPU main control units on the field I/O control station respectively.

45
4.2.2.2 Quality standards

a. During the test, the tracking main control unit in the system should be able to switch to the main control normally, without disturbance, and quickly;

b. DEH fault diagnosis display is correct;

c. There is no change in the calculation results of the DEH system before and after switching.

4.2.2 Network redundancy switching test

4.2.2.1 Test method

a. Artificially cut off a communication bus on any node (operator station, engineer station, server, switch, DPU, etc.).

4.2.2.2 Quality standards

a. During the test, the DEH system is operating normally, the DEH alarm screen is displayed correctly, and the communication failure light corresponding to the DPU card is on

Bright;

b. The data transmission between the I/O station and the operator station, server, and engineer station is normal;

c. The DEH system must not have errors or crashes;

d. After the network plug is restored, the communication system automatically returns to normal operation.

4.2.3 DEH power switching test

4.2.3.1 Test method

a. Cut off the main power supply of the DEH system, and the backup power supply of the DEH system will be put into operation automatically.

4.2.3.2 Quality standards

a. During the power switching process, the control system should work normally, and the intermediate data and accumulated data will not be lost.

4.2.4 DEH system module hot plug test

4.2.4.1 Test method

a. When the DEH system is running, each I/O control cabinet is charged to pull out one module of AI, AO, DI, and DO respectively, and the

Insert test.

4.2.4.2 Quality standards

a. After the module is pulled out, the DEH system monitoring screen can display the fault status of the module.

b. During the process of pulling out and restoring the module, the signal connected to the I/O module has no jump, and other functions of the control system are not affected.

affected, the DEH system remains in normal operation.

4.2.5 DEH system OPC protection overspeed test

4.2.5.1 Test method

4.2.5.2 Quality standards

4.2.6 DEH system 110% overspeed protection test

46
4.2.6.1 Test method

4.2.6.2 Quality standards

5 Dangerous point analysis and pre-control

serial number danger point Pre-control measures

1. The person in charge of the work must check whether the position and model of the card are correct.

indeed.

2. It must be confirmed that the plug-in dial address is set correctly.

3. Staff must wear anti-static wristbands.

1. The person in charge must be supervised when modifying the logic.

2. Before modifying the logic, there must be a written, approved by relevant departments and

Application for logic modification approved by the chief engineer (or deputy director) of the factory department.

3. After the logic modification is completed, it must pass the on-site logic transmission test.

And it has passed the three-level quality inspection.

4. After the logic modification is completed and the test is qualified, the logic should be prepared in time.

share.

1. Power off the control cabinet before cleaning.

2. Do not wipe the terminal board and circuit board with a wet cloth.

3. When using electric tools, use a leakage protection with a certificate of conformity.

protector.

4. Staff must wear insulating shoes.

5. The staff must use a qualified electroscope pen when testing electricity.

1. Before the power failure of the I/O control cabinet, check whether there is equipment running,

Work can only be started after safety technical measures are taken.

2. During the on-site logic transmission test, confirm that the controlled equipment is under test

Check location.

1. The cuffs of the overalls should be fastened.

2. It is forbidden to place any part of the body in the cooling fan of the cabinet to rotate

part.

3. The physical and mental condition of the staff is good, and they are competent for their duties.

47
 work.

4. During the DEH field static test, no one is working at the local valve and

There are special personnel to supervise on the spot.

5. Qualified safety belts must be used for high-altitude operations, and they must be hung high and low.

6 Safety, health and environmental protection requirements

6.1 Security

6.1.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. It must be dealt with when it involves withdrawal of the principal and auxiliary protection

Protect the return application form.

6.1.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

6.1.3 When two or more people work, one person in charge must be identified.

6.1.4 There should be sufficient lighting on the site and meet the requirements of the "Safety Regulations".

6.1.5 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

Tools.

6.1.6 When cleaning and refueling, prevent fire.

6.1.7 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

6.1.8 Seriously abide by the safety regulations of lifting and handling.

6.1.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

6.1.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

6.1.11 Clean up flammable and explosive debris at the work site.

6.2 Health

6.2.1 Precautions must be taken when contacting chemicals that are toxic, harmful or pungent to the human body.

6.3 Environmental protection

6.3.1 The replaced waste products must be poured into the designated dustbin, and should not be dumped casually.

6.3.2 Discarded or leftover chemicals after use must be placed in designated locations, and should not be discarded casually. must be done after

"Complete work, clean materials, clean site" .

6.3.3 Work must consciously abide by the ISO14001 environmental management standard and the ISO9001 quality management system.

48
 Chapter 4 Steam Turbine Testing and Instrumentation System (TSI)

1 Equipment overview and parameters

TSI system (namely steam turbine shaft monitoring and protection system) is used to monitor certain parameters of steam turbine shafting, such as: shaft

Displacement, high, medium and low pressure cylinder expansion difference, speed, eccentricity, vibration, etc. When the measured parameters exceed the operating limit value, the system will send

Send an alarm signal to remind the operating personnel to pay attention and send a trip signal to the emergency interruption system to trip the unit to avoid causing damage to the host equipment

damage.

1.1 Equipment overview

1.1.1 System functions

The TSI system of #1 and #2 units of Dianta Power Plant B is supplied by Harbin Steam Turbine Works, and the American BENTLY

The 3500 series products produced by NEVADA, this system can continuously measure and monitor various monitoring parameters, and can provide continuous

Continued, online monitoring function, suitable for machinery protection applications, providing important information for early identification of machinery failures.

Utilizing the latest in microprocessor technology, the 3500 is a feature in Bently Nevada's traditional frame form factor

The strongest and most flexible system with a wide range of performance and advanced features not found in other systems.

The 3500 monitoring system adopts Windows-based operator display software, which can be conveniently displayed on the installation site through the software.

Easily adjust monitor options, alarm logic voting, and relay configuration. The modules in the 3500 frame use

Live plug-in components and internal and external terminals for easy maintenance and expansion.

1.1.2 Monitoring content

The main monitoring contents of the TSI of units #1 and #2 in Plant B of Dianta Power Generation Company include: #1〜#9 bearings in the X direction and Y direction

Relative vibration, absolute vibration of #1 to #9 bearing caps, key phase, rotational speed, eccentricity, absolute expansion of high-pressure cylinders (left and right sides),

High pressure cylinder differential expansion, low pressure cylinder differential expansion, axial displacement.

1.1.3 Range of TSI monitoring parameters:

1.1.3.1 Relative vibration of bearing: 0~500μm

1.1.3.2 Absolute vibration of bearing cover: 0~200μm

1.1.3.3 Key phase: 0~5000rpn

1.1.3.4 Speed: 0~5000rpn

1.1.3.5 Eccentricity: 0~500μm

1.1.3.6 Absolute expansion of high pressure cylinder: 0~50mm

1.1.3.7 Differential expansion of high pressure cylinder: -5~+20mm

1.1.3.8 Differential expansion of low-pressure cylinder: -5~+: 35mm

49
Translated from Chinese (Simplified) to English - www.onlinedoctranslator.com

Chapter 4 Steam Turbine Testing and Instrumentation System (TSI)

1 Equipment overview and parameters

TSI system (namely steam turbine shaft monitoring and protection system) is used to monitor certain parameters of steam turbine shafting, such as: shaft

Displacement, high, medium and low pressure cylinder expansion difference, speed, eccentricity, vibration, etc. When the measured parameters exceed the operating limit value, the system will send

Send an alarm signal to remind the operating personnel to pay attention and send a trip signal to the emergency interruption system to trip the unit to avoid causing damage to the host equipment

damage.

1.1 Equipment overview

1.1.1 System functions

The TSI system of #1 and #2 units of Dianta Power Plant B is supplied by Harbin Steam Turbine Works, and the American BENTLY

The 3500 series products produced by NEVADA, this system can continuously measure and monitor various monitoring parameters, and can provide continuous

Continued, online monitoring function, suitable for machinery protection applications, providing important information for early identification of machinery failures.

Utilizing the latest in microprocessor technology, the 3500 is a feature in Bently Nevada's traditional frame form factor

The strongest and most flexible system with a wide range of performance and advanced features not found in other systems.

The 3500 monitoring system adopts Windows-based operator display software, which can be conveniently displayed on the installation site through the software.

Easily adjust monitor options, alarm logic voting, and relay configuration. The modules in the 3500 frame use

Live plug-in components and internal and external terminals for easy maintenance and expansion.

1.1.2 Monitoring content

The main monitoring contents of the TSI of units #1 and #2 in Plant B of Dianta Power Generation Company include: #1〜#9 bearings in the X direction and Y direction

Relative vibration, absolute vibration of #1 to #9 bearing caps, key phase, rotational speed, eccentricity, absolute expansion of high-pressure cylinders (left and right sides),

High pressure cylinder differential expansion, low pressure cylinder differential expansion, axial displacement.

1.1.3 Range of TSI monitoring parameters:

1.1.3.1 Relative vibration of bearing: 0~500μm

1.1.3.2 Absolute vibration of bearing cover: 0~200μm

1.1.3.3 Key phase: 0~5000rpn

1.1.3.4 Speed: 0~5000rpn

1.1.3.5 Eccentricity: 0~500μm

1.1.3.6 Absolute expansion of high pressure cylinder: 0~50mm

1.1.3.7 Differential expansion of high pressure cylinder: -5~+20mm

1.1.3.8 Differential expansion of low-pressure cylinder: -5~+: 35mm

49
1.1.3.9 Axial displacement: -2~—+2mm

1.2 3500 device introduction

1.2.1 3500 System Features

1.2.1.1 Enhanced operator information: WINDOWS-based operator display software, data can be displayed in multiple points.

1.2.1.2 Improve the integrity of the control computer system: the communication channel supports MODBUS and MODBUS/TCP protocols, and time synchronization

Vibration and process information.

1.2.1.3 Improve system reliability: backup power supply, protection against single point failure, triple module redundant relay cards,

Alternate communication network.

1.2.1.4 There are three independent interfaces: data management interface, configuration/data interface, and communication channel interface.

1.2.1.5 Parameter and status display methods: remote display panel, communication with DCS, PLC display monitor.

1.2.1.6 Hot plugging and unplugging of modules: Any main module can be plugged in while live without affecting the operation of other modules.

1.2.1.7 Buffer output: provide the dynamic input signal of each channel through the buffer output port on the front panel of the module.

1.2.1.8 Security of software configuration: All monitoring modules can be configured through the software of the 3500 rack module.

The rack modules are key lockable to prevent unauthorized tampering.

1.2.1.9 Analog communication mode: All monitoring channels provide 4~20mA output.

1.2.1.10 Relay module: software programmable action logic, can provide 4-channel and 16-channel version, and provide three

Choose two for triple redundancy.

1.2.1.11 Rack interface module: provides configuration interface, and can communicate with System 1 through traditional wired or wireless Ethernet

The software is implemented but the cable is connected to ensure that the data of all channels in the rack are collected synchronously.

1.2.2 3500 structure

The standard 3500TSI monitoring system includes: 500/05 meter frame, 3500/15 power supply, 3500/20 frame interface

module, 3500/25 key phaser module, 3500 rack configuration software, 3500/XX monitor module, 3500/32 relay

Electrical module, 3500/34 triple redundant relay module, 3500/92 communication gateway module, 3500/93, 3500/94,

3500/95 display unit, internal (or external) intrinsically safe barrier, etc.

1.2.2.1 3500/05 frame structure

The 3500/05 frame is used to mount all monitor modules and frame power supplies. It is 3500 mutual between each frame

Communications provide backplane communications and provide the required power to each module. The power module and frame interface module must be installed in the

The leftmost position of the frame, the remaining 14 frame positions can be occupied arbitrarily, the triple module redundancy system

Locations are limited.

1.2.2.2 3500/15 Power Module

50
 The 3500/15 power supply modules are half-height modules, available in either alternating current (AC) or direct current (DC). When the frame is fitted with two

During power supply, the lower cloth notch is the main power supply, and the upper cloth notch is the backup power supply. Each power supply can independently power the entire frame.

1.2.2.3 3500/20 Rack Interface Module

The 3500/20 frame interface module is a full-height module, which is the basic interface of the 3500 frame and must be placed on the frame

in the first slot (next to the power supply). It supports Bently Nevada's dedicated

There is a protocol, the main function is to communicate with the computer, Bently Nevada communication processor, and other modules in the frame, and it can also manage

Manage system event list and alarm event list. A framework interface module is required in each framework.

1.2.2.4 3500/25 speed, key phaser module

The 3500/25 Improved Key Phaser Module is a half-height, 2-channel module designed to monitor

The converter module provides the key phase signal. This module accepts input signals from eddy current or electromagnetic sensors and converts

This signal is a digital keyphase signal that indicates when the keyphase mark on the shaft passes the keyphase probe. Every

Each key phase module has 2 input channels, 3500 mechanical protection system can install 2 key phase module, receive 4 key phase

Signal

1.2.2.5 3500/40M eccentricity, shaft displacement, vibration monitor

The 3500/40M Displacement Monitor is a four channel monitor. It can accept the signal output from the non-contact sensor to the signal

Signals are processed to generate various vibration and displacement measurements, and the processed signals are compared with the alarm value and dangerous value set by the user.

After the comparison, the alarm is driven. The monitor channels are configured in pairs so that up to 2 of the above functions can be performed at a time. use 3500

Frame configuration software configures 3500/40 so that it has the following functions:

a) radial vibration;

b) Axial displacement;

c) shaft eccentricity;

d) differential expansion;

1.2.2.6 3500/42M displacement, velocity acceleration monitor

3500/42M Displacement/Velocity Acceleration Monitor has similar functions to 3500/40M, it is also a 4-channel monitor, connected

It receives signals from displacement, velocity and acceleration sensors, and by processing these signals, it can complete various

Vibration and position measurements, and the processed signal is compared to user programmed alarm values. Use 3500 frame configuration software

Perform programming to complete the following functions:

a) Radial vibration

b) Axial displacement

c) Differential inflation

51
d) Eccentricity

e) REBAM.

f) Acceleration

g) speed

h) Shaft absolute vibration

i) Circular acceptance zone

1.2.2.7 3500/45 cylinder expansion and differential expansion monitor

The 3500/45 Differential Expansion/Axial Position Monitor is a proximity sensor, eddy current sensor, rotary position sensor

(RPT), DC Linear Variable Differential Transformer (DCLVDT), AC Linear Variable Differential Transformer (AC LVDT), and Rotary Potentiometer

4-channel monitor of input signal. The type of measurement and associated sensor input will determine which input/output (I/O) is required

module. Using 3500 frame configuration software, 3500/45 can be programmed to complete the following functions:

a) Axial (lateral) position

b) Differential inflation

c) Standard single slope differential expansion

d) Non-standard single slope differential expansion

e) Double slope differential expansion

f) Compensating differential expansion

g) shell expansion

h) Valve position

1.2.2.8 3500/50 Speed Module

The 3500/50 Tachometer Module is a two-channel module that accepts

externally marked) signal to determine the rotational speed of the shaft, the acceleration of the rotor, or the direction of the rotor. Can be configured as a 3500 frame

The back panel provides the key phase signal for use by other monitors; 3500/50 also has a peak hold function, which can store the machine's previous

The maximum rotational speed, maximum reverse speed or number of reverses achieved.

1.2.2.9 3500/53 Overspeed Detection Module

Bently Nevada's 3500 Series Mechanical Inspection System's electronic overspeed detection system is highly reliable and fast responding

Redundant tachometer system, specially used for mechanical overspeed protection. Each overspeed detection module receives an eddy current sensor or magnetic

For the signal of the sensor, use 3500/53 modules to form a 2-to-2 or 3-to-2 (push voting system.

1.2.2.10 3500/32 Channel Relay Module

The Four Channel Relay Module is a full height module that provides four relay outputs. any amount

The 4-channel relay module can be placed in any slot on the right side of the frame interface module. 4-channel relay module's

Each output can be independently programmed to implement independent voting logic.

52
1.2.2.11 3500/92 communication interface

The 3500/92 communication gateway has a wide range of communication capabilities, through Ethernet TCP/IP and serial

(RS232/RS422/RS485) communication protocol to communicate all frame monitoring data and status with process control and other automation systems

integrated. It also supports Ethernet communication with 3500 frame configuration software and data acquisition software.

1.3.3500 sensor working principle and main technical parameters

1.3.1. Eddy current displacement sensor

1.3.1.1. Working principle

The eddy current sensor is a non-contact displacement and vibration sensor based on the high-frequency eddy current effect. preamp medium high

The high-frequency oscillating current flows into the probe coil through the extension cable, and an alternating magnetic field is generated in the coil of the probe head. if in this

If there is no metal material close to the effective range of the alternating magnetic field, the energy of this magnetic field will be completely lost;

Near this magnetic field, an eddy current is generated on the metal surface, thereby reducing the impedance of the coil. through the preamp electronics

Processing, the change of coil impedance, that is, the change of the distance between the head body coil and the metal conductor is converted into a change of voltage or current.

The size of the output signal changes with the distance between the probe and the surface of the measured object. The eddy current sensor is based on this principle.

Now it is used to measure the displacement, vibration and other parameters of metal objects.

1.3.1.2 Type and sensitivity of eddy current sensor

a) 8mm probe: linear range 2mm (80mils), sensitivity coefficient is 7.874V/mm;

b) 11mm probe: linear range 4.0mm (160mils); sensitivity 3.94 V/mm ( 100mV/mil );

c) 25mm probe: linear range 12.7 mm (500 mil), sensitivity 0.787 V/mm (20 mV/mil);

d) 50mm differential expansion sensor: linear range 27.9mm (1.1in); sensitivity 0.394±0.008 V/mm.

1.3.2 Speed sensor

1.3..2.1. Working principle

The Seismoprobe. series speed sensor is a two-wire structure, using moving coil technology, providing a direct proportional to the sensor

Voltage output for vibration velocity. Unlike solid-state velocity sensors, which are essentially integrating electronics embedded in an accelerometer,

Moving coil sensors are less sensitive to shock or pulse excitation and are a better application choice. Furthermore, since they do not require

external power supply, so making portable measurement applications more convenient. All Seismoprobe. Speed sensors are mounted at angles from

Viewed from the drive end, 0° is the vertical direction.

1.3.2.2 Speed sensor type and sensitivity

a) 9200, 74712, 47633 Seismoprobe® Speed Sensor System

Sensitivity: 20 mV/mm/s at 100 Hz (6,000 cpm) (500

mV/in/s) ±5%, at 100 Hz (6,000 cpm) 25 mm/s (1 in/s) ±5%.

53
b) Velomitor® piezoelectric speed sensor

Sensitivity: 3.94mV/mm/s (100 mV/in/s) ±5%

c) 330525 Velomitor® XA Piezoelectric Speed Sensor

Sensitivity: 4mV/mm/s (100 mV/in/s) ±5%

1.3.3 Case expansion sensor

1.3.3.1 Working principle

The operating principle of the enclosure expansion sensor is that the enclosure expansion sensor system uses an LVDT to measure the thermal expansion of the enclosure.

LVDTs have a probe rod attached to the machine. As the case expands, the probe rod moves within the LVDT, causing the LVDT signal to change.

change. After the signal is conditioned, it is output to the monitor for display and alarm.

1.3.3.2 Expansion sensor type and sensitivity

a) 24765-01: Scale factor 0.346 V/mm (8.79 V/in); linear range 25.4 mm (1.0 in).

b) 24765-02: 0.404 V/mm (10.25 V/in); linear range 50.8 mm (2.0 in).

c) 24765-03: 0.143 V/mm (3.63 V/in); linear range 101.6 mm (4.0 in).

2 Maintenance category and cycle

2.1. The maintenance work of the thermal TSI system is divided into A, B, C level maintenance and daily patrol inspection.

2.2. A, B, and C level overhauls of the thermal TSI system (DCS) are carried out along with major and minor overhauls of the main unit equipment.

2.3. During the daily patrol inspection, the person in charge of the equipment should conduct a daily patrol inspection of the TSI system control cabinet and its equipment as required.

Check whether there is an alarm on the detection card, and the TSI data in the DEH shows whether there is any abnormality and alarm, and report the abnormal situation to the class in time

Team leader reports.

3 maintenance items

3.1. Standard maintenance items and standards for A-level maintenance of TSI system

3.1.1. Cabinet cooling fan inspection.

3.1.2. Check the cabinet power supply and power module.

3.1.3. Purge cabinets and clamps.

3.1.4 .TSI system logic configuration check backup.

3.1.5. Cabinet wiring inspection (including terminal board and network cable plug, terminal board power supply wiring, etc.).

3.1.6. Check the grounding condition of the cabinet.

3.1.7. Cable insulation test.

3.1.8. TSI card verification.

3.1.9. Wiring inspection and sanitation cleaning of local junction box.

54
3.1.10. Laboratory calibration, on-site debugging 1#~9# shaft vibration X/Y direction vibration probe, front-end device and extension cable.

3.1.11. Check the 1#~9# bearing vibration probe.

3.1.12. Laboratory calibration, on-site debugging of high-pressure cylinder differential expansion and low-pressure cylinder differential expansion probes, front-end devices and extension cables.

3.1.13. Laboratory calibration, on-site debugging axial displacement probe, front end device and extension cable.

3.1.14. Laboratory calibration, on-site debugging eccentricity, key phase, zero speed, overspeed probe, front end device and extension cable.

3.1.15. Absolute expansion of left and right high-pressure cylinders for laboratory calibration and on-site debugging.

3.2. Standard items for level C inspection

3.2.1. Check the cabinet cooling fan.

3.2.2. Check the cabinet power supply and power module.

3.2.3.TSI system logic configuration backup.

3.2.4. Cabinet wiring inspection (including terminal board and network cable plug, terminal board power supply wiring, etc.).

3.2.5. Inspect the wiring of the junction box on site and clean it up.

3.2.6. Card verification.

4 Maintenance steps, process methods and quality standards

4.1 Maintenance

4.1.1 Disassembly and Calibration of Vibration Sensor and Preamplifier

4.1.1.1 Process steps

a. After the TSI system is powered off.

b. The removed sensor, front-end device and extension cable are marked according to the measurement position, and the sensor and front-end device are recorded when they leave the factory.

Numbering.

c. After the signal wiring of the terminal box front device is removed, mark it and wrap it with insulating tape, white cloth tape and plastic tape as a whole;

Use adhesive tape (or white cloth tape) to seal the threading holes.

d. Use precision instrument cleaning agent (or alcohol) to clean the dirt on the sensor and front-end device.

e. Send the sensor to the relevant qualification unit for inspection according to the technical supervision regulations.

f. Replace unqualified sensors, front-end devices, and extension cables with a complete set.

4.1.1.2 Quality standards

a. Use a tester to confirm that the TSI system has been powered off.

b. Shaft vibration and bearing vibration of #1~#9, each set is clearly marked and recorded completely.

c. There is no bare leak in the cable signal line; the threading holes are tightly sealed.

d. The appearance of the equipment is clean and free of dirt.

55
e. The sensor has passed the calibration, and those that fail to pass the appraisal are not allowed to be used.

f. Make maintenance records for new measuring devices (including factory serial number, place of use, replacement date, etc.).

4.1.2 Control Cabinet Cleaning

4.1.2.1 Process steps

a. Disconnect the TSI system power supply. Stop the shunt power supply of the TSI cabinet first, and then stop the TSI power supply of the thermal control panel.

b. Pull out the control card

(1) Mark the position of the module when cleaning the module.

(2) The staff must wear an anti-static grounding ring when plugging and unplugging the modules, and try not to touch the circuit part as much as possible.

(3) The unplugged card is temporarily stored in a special anti-static protective bag.

c. Use a brush, hair dryer or leather tiger to blow off the dust accumulated on the surface of the card. After the module is purged, plug the circuit board of the module

Use a special cleaning agent to clean the device and the parts that still remain dirty after purging.

d. Use a vacuum cleaner to clean the floating dust in the control cabinet. Check the wiring inside the cabinet after purging.

e. Check the control card, observe whether the electronic components of each component are aging, and replace the aging card

Change. After inspection is complete, replace all cards.

4.1.2.2 Quality standards

a. Before the power outage, make a backup of the project; record the displayed values on the DEH;

b. Cards are fully marked, and the temporary storage of cards meets the requirements.

c. There is no dust or stain on the surface of the card.

d. The inside of the control cabinet is clean and free of dust.

e. The wiring plug inside the cabinet is fastened without looseness.

f. After the card is powered on, it works normally, and the corresponding operation and communication indicator lights indicate normal; the DEH indicator shows no change.

4.1.3 Control Cabinet Fan Replacement

4.1.3.1 Process steps

a. Stop the cooling fan power switch.

b. Replace the fan after checking that the technical parameters are consistent.

c. Power transmission test.

4.1.3.2 Quality standards

a. Carefully check the nameplate to ensure that the power failure is correct.

b. The voltage, power and speed of the replaced fan are the same as those of the original fan.

c. The power supply and wiring of the fan must be firm and reliable;

56
d. The rotation direction of the fan is correct; there is no jamming and no obvious noise during the rotation of the fan.

e. After the fan is replaced, make maintenance records so as to determine the replacement cycle of the fan.

4.1.4 Logical backup

4.1.4.1 Process steps

a. Use the communication cable to connect the TSI frame and the computer.

b. Open the 3500 communication software and set the computer communication port.

c. Open the 3500 configuration software and connect to the TSI frame.

d. Upload the TSI frame configuration to the computer and save it.

4.1.4.2 Quality standards

a. Use RS232 interface.

b. Use the computer COM1 port and check that other programs do not use this port.

c. The address is correct.

d. The file name includes the backup date and unit and equipment numbers.

4.1.5 Signal cable insulation inspection

4.1.5.1 Process steps

a. Use a 500MΩ megger to measure the phase-to-phase insulation of the signal cable.

b. Use a 500MΩ megger to measure the insulation of the signal cable to the ground.

4.1.5.2 Quality standards

a. Phase-to-phase insulation of signal cables ≧10M ohms.

b. The insulation of the signal cable to the ground is ≧10M ohms.

4.1.6 On-site debugging of shaft vibration, eccentricity and key phase sensors

4.1.6.1 Process steps

a. Fix the sensor mounting bracket.

b. Adjust the installation gap voltage between the sensor and the measuring surface to -10VDC for shaft vibration, -10VDC for eccentricity, -10VDC for key phase,

The dynamic display value is 0μm, tighten the nut.

c. Lock the extension cable joint with a special heat-shrinkable tube and wrap it with a white cloth tape, and use a white cloth tape to fix the clip of the extension cable

Wrapping and extending the cable out of the bearing box should be sealed with a rubber plug.

d. Check card configuration.

4.1.6.2 Quality standards

a. The bracket is firmly fixed, and the fixing screw is pressed by a spring washer.

57
b. The extension cable connector is fastened without looseness, the signal cable is not worn, and the threading hole has no oil leakage.

c. Sensor signal, sensitivity parameters, measurement range, usage and other parameters are correct.

4.1.7 On-site commissioning of tile vibration

4.1.7.1 Process steps

a. Install the tile vibration sensor firmly, and tighten the fixing screw with a wrench slightly to avoid damage to the probe by excessive force

b. The wiring terminal of the sensor base should be firmly connected and wrapped with insulating tape to avoid grounding from affecting the measurement.

c. Check card configuration.

4.1.7.2 Quality standards

a. The sensor is firmly fixed without loosening

b. Reliable wiring without grounding.

c. Sensor signal, sensitivity parameters, measurement range, usage and other parameters are correct.

4.1.8 On-site debugging of speed

4.1.8.1 Process steps

a. Use a feeler gauge to measure the gap between the probe and the speed measuring pool to be 1mm, and tighten the nut.

b. Wrap the extension cable connector with insulating tape to prevent the connector from being worn and grounded.

c. Check card configuration.

4.1.8.2 Quality standards

a. The gap is accurate.

b. The wiring is reliable.

c. Sensor signal, sensitivity parameters, measurement range, usage and other parameters are correct.

4.1.9 On-site debugging of axial displacement

4.1.9.1 Process steps

a.

b.

c.

4.1.9.2 Quality standards

a.

b.

c.

4.1.10 On-site commissioning of high-pressure cylinder differential expansion

58
4.1.10.1 Process steps

a.

b.

c.

4.1.10.2 Quality standards

a.

b.

c.

4.1.11 On-site commissioning of low-pressure cylinder differential expansion

4.1.10.1 Process steps

a.

b.

c.

4.1.10.2 Quality standards

a.

b.

c.

4.2 Test

4.2.1 Power supply module redundancy switching test

4.2.1.1 Test method

a. Cut off the working power circuit, and check that the backup power supply must be automatically put into operation;

4.2.1.2 Test standard

a. During the test, the TSI control system should work normally, the data should not be lost, the fault diagnosis display should be correct, the system should not

Initialization, errors, crashes, or other abnormal phenomena may occur.

4.2.2 Vibration protection output signal test

4.2.2.1 Test method

a. Steam turbine hanging brake;

b. Short-circuit the output of the vibration protection action value, so that the relay panel sends out a vibration interruption signal.

c. The protection action, the main steam valve is closed.

59
d. Several tests should be carried out according to the specific protection configuration.

4.2.2.2 Test standard

a. The two signals are output to the ETS system and all of them operate normally. (Specifically, according to the ETS protection test program)

4.2.3 Axial displacement protection output signal test

4.2.3.1 Test method

a. Steam turbine hanging brake;

b. Short-circuit the axial displacement measurement channel to the protection action value, so that the relay panel sends an axial displacement interruption signal.

c. The protection action, the main steam valve is closed.

d. The test should be carried out several times according to the relationship between the serial shaft protection first or later.

4.2.3.2 Test standard

a. The two signals are output to the ETS system and all of them operate normally. (Specifically, according to the ETS protection test program)

5 Dangerous point analysis and pre-control

serial number danger point Pre-control measures

1. The person in charge of the work must check whether the position and model of the card are correct.

indeed.

2. Staff must wear anti-static wristbands.

1. The person in charge must be supervised during TSI configuration.

2. Tandem shaft, high-pressure cylinder expansion difference, and low-pressure cylinder expansion difference can only be adjusted on site

It is necessary to re-modify the current parameters during the test, and other monitoring items only need to

Just configure once and make a backup.

3. After modification of string axis and differential expansion series, it must go through on-site debugging.

The error is within the allowable range, and has passed the three-level quality acceptance.

1. Power off the control cabinet before cleaning.

2. Do not wipe the terminal board and circuit board with a wet cloth.

3. When using electric tools, use a leakage protection with a certificate of conformity.

protector.

4. Staff must wear insulating shoes.

5. The staff must use a qualified electroscope pen when testing electricity.

1. The cuffs of the overalls should be fastened.

60
 2. It is forbidden to place any part of the body in the cooling fan of the cabinet to rotate

part.

3. The physical and mental condition of the staff is good, and they are competent for their duties.

work.

4. It is strictly forbidden to stand or stay under heavy lifting objects during on-site debugging.

5. It is strictly forbidden to cross work, fasten the helmet belt.

1. On-site debugging When working on the bearing box, put the contents of the work clothes pocket

The product is taken out and stored in the tool bag;

2. The tools and utensils should be counted in time after the work is completed

3. It is strictly forbidden to drop tools and sundries into the bearing box.

Things should be cleaned up in time.

6 Safety, health and environmental protection requirements

6.1 Security

6.1.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. It must be dealt with when it involves withdrawal of the principal and auxiliary protection

Protect the return application form.

6.1.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

6.1.3 When two or more people work, one person in charge must be identified.

6.1.4 There should be sufficient lighting on the site and meet the requirements of the "Safety Regulations".

6.1.5 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

Tools.

6.1.6 When cleaning and refueling, prevent fire.

6.1.7 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

6.1.8 Seriously abide by the safety regulations of lifting and handling.

6.1.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

6.1.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

6.1.11 Clean up flammable and explosive debris at the work site.

6.2 Health

6.2.1 Precautions must be taken when contacting chemicals that are toxic, harmful or pungent to the human body.

6.3 Environmental protection

61
6.3.1 The replaced waste products must be poured into the designated dustbin, and should not be dumped casually.

6.3.2 Discarded or leftover chemicals after use must be placed in designated locations, and should not be discarded casually. must be done after

"Complete work, clean materials, clean site" .

6.3.3 Work must consciously abide by the ISO14001 environmental management standard and the ISO9001 quality management system.

62
 Chapter 5 Thermal Control Protection System (ETS/ FSSS)

1 Technical Regulations for Maintenance of Emergency Trip System (ETS) of Steam Turbine

1.1 Equipment overview and parameters

1.1.1 Equipment overview

1.1.1.1 The critical blocking system (i.e. safety protection system) is used to monitor certain parameters of the steam turbine exceeding its operating limit value

When the AST solenoid valve is de-energized, the main steam valve of the high and medium pressure of the steam turbine and the high and medium pressure regulating valve are closed, and the steam turbine stops.

1.1.1.2 In terms of system hardware, ETS uses the same hardware as DEH, and adopts a pair of mutually redundant DPUs for separate configuration.

(See DEH section for ETS hardware description)

1.1.1.3 The main protections included in the ETS system of Plant B of Dianta Power Generation Company are:

a Condenser vacuum is low (high back pressure) (The content of logical judgment needs to be added)

b Condenser vacuum is low (low back pressure)

c Bearing lubricating oil pressure is low

d Resistance to low fuel pressure

e Unit overspeed

f differential expansion

g DEH request tripping (110 overspeed

h Generator failure

i ASP low oil pressure

j Manual trip

k High-pressure exhaust steam temperature jump machine

l Boiler MFT

m The relative vibration of the major axis is large

n large axial displacement

o High bearing metal temperature

1.2 Maintenance category and cycle

1.2.1. The repair of ETS system A is carried out with the repair of the main equipment of the group.

1.2.2 .ETS system C maintenance is carried out with the main equipment C maintenance of the group.

1.3 Maintenance items

1.3.1 Minor repair standard items

1.3.1.1 Clean the control cabinet of the ETS system and check that the fan function is normal.

63
1.3.1.2 ETS system power unit inspection.

1.3.1.3 ETS system pressure switch and pressure gauge calibration.

1.3.1.4 ETS system control cabinet module inspection, I/O channel test.

1.3.1.5 ETS system digital speed channel verification, electrical overspeed value setting.

1.3.1.6 ETS system function test.

1.3.1.7 On-site protection transmission test of ETS system.

1.3.2 Overhaul standard items

1.3.2.1 Clean the control cabinet of the ETS system and check that the fan function is normal.

1.3.2.2 ETS system cable insulation inspection.

1.3.2.2 ETS system power unit inspection.

1.3.2.3 ETS system pressure switch and pressure gauge calibration.

1.3.2.4 ETS system solenoid valve group inspection.

1.3.2.4 ETS system control cabinet module inspection, I/O channel test.

1.3.2.5 ETS system digital speed channel calibration, electrical overspeed value setting.

1.3.2.6 ETS system protection logic inspection.

1.3.2.7 ETS system function test.

1.3.2.8 On-site protection transmission test of ETS system.

1.4 Maintenance steps, process methods and quality standards

1.4.1 Maintenance

1.4.1.1 ETS system control cabinet sanitation cleaning

A test method

a Disconnect the ETS system power supply.

b Pull out the control card

(a) Mark the position of the modules when cleaning them.

(b) The staff must wear an anti-static grounding ring when plugging and unplugging the modules, and try not to touch the circuit part as much as possible.

(c) The unplugged card is temporarily stored in a special anti-static protective bag.

c Use a brush hair dryer or leather tiger to blow off the dust accumulated on the surface of the card. After the module is purged, deal with the module's circuit board connector

Clean the parts that still have dirt after purging and cleaning with a special cleaning agent.

d Use a vacuum cleaner to clean the floating dust in the control cabinet. Check the wiring inside the cabinet after purging.

e Check the control card, observe whether the electronic components of each component are aging, and replace the aging card.

After inspection is complete, replace all cards.

B test standard

64
a Make a backup of the project before the power outage; the electric test pen confirms that it is correct.

b The cards are completely marked, and the temporary storage of the cards meets the requirements.

c No dust stains.

d The inside of the control cabinet is clean and free of dust.

e The wiring plug inside the cabinet is fastened without looseness.

f After the card is powered on, it works normally, and the corresponding running communication indicator light indicates normal.

1.4.1.2 ETS system pressure switch pressure gauge calibration

A test method

a Disconnect the corresponding pressure switch wiring on the terminal in the ETS cabinet, and wrap it with insulating tape.

b Mark the pressure switch and close the secondary door for sampling the pressure switch.

c Disconnect the pressure switch, and make a record, wrap the signal wire end with insulating tape, and seal the sampling tube.

d After dismantling the pressure switch, clean it up so that the outside of the pressure switch is clean and the signs are clear.

e Send the pressure switch to the standard measurement room for verification according to the verification regulations, and make original records.

f After passing the calibration of the pressure switch, the certificate of qualification shall be pasted.

B test standard

a The line is cast correctly and there is no short circuit.

b The secondary door is closed and the pressure switch is clearly marked.

c There is no short circuit in the signal line, and the sampling tube is tightly sealed.

d The calibration conforms to the specification, the fixed value is accurate, and the error is within the allowable range.

e See the original color of the equipment.

f Replacement certificate.

1.4.1.3 ETS system control cabinet module inspection I/O channel test

A test method

a At the local primary element, use a short wire to short-circuit the positive and negative poles of the DI signal channel, and observe the signal light of the channel.

b In the configuration software, scan and cut off the DO signal to be tested, force the output signal to be "1" or "0", observe the channel signal light,

and measure the output of the terminal.

B test standard

a The channel signal light is on when it is short-circuited, otherwise it is off.

b When it is forced to be "1", the channel signal light is on; when it is forced to be "0", the channel signal light is off.

1.4.1.4 ETS system cable insulation inspection

65
A test method

a. Disconnect the wiring of the cable from the external switch to the inside of the cabinet, ground one end of the megohmmeter, and connect the other end to the cable to be measured.

B test standard

a signal cable phase-to-phase insulation resistance ≥ 20MΩ.

b The insulation resistance of the signal cable to the ground is ≥20MΩ.

C The cable insulation of the trip solenoid valve is ≥20MΩ.

1.4.1.5 ETS system test valve group inspection

A test method

a Remove the test block, and wrap the sampling tube tightly.

b Clean the external sanitation of the test block, then soak it in kerosene, and use the suction ear ball to flush the internal oil pipeline,

Make sure the tubing is clear.

C Test block is reassembled.

d Check all sampling doors on the test block for leakage.

B test standard

a When the equipment is dismantled, the on-site sampling pipeline shall be tightly sealed.

b Retighten all joints of the test valve group, and replace unqualified gaskets (rings).

ETS system digital speed channel calibration protection setting value setting

ETS system protection logic check

1.4.2 Test

1.4.2.1 Control system function test: system power supply fault test DPU power switch test redundant DPU non-disturbance switch test

Network redundancy switching test Module plug-in test Reset capability test Anti-radio frequency interference test Output power-down protection test and other functions

The performance test shall be carried out according to the requirements of the DEH part. .

1.4.2.2 Field protection logic drive test

A test method

Carry out item by item according to the on-site protection test program approved by the factory.

B test standard

(1) The field protection test must be carried out after the DEH static test is completed and the brakes are allowed to be hung.

(2) All protection tests must be carried out with a signal from the local primary element.

(3) For logical judgments such as two out of three, multiple tests must be carried out.

(4) Three levels of acceptance must be carried out at the end of each protection test.

66
1.5 Analysis and pre-control of dangerous points

serial number danger point Pre-control measures

1. The person in charge of the work must check whether the position and model of the card are correct.

indeed.

2. Staff must wear anti-static wristbands.

1. The person in charge must be supervised during ETS configuration.

2. After the modification of the ETS series, it must go through on-site debugging, and after

Three-level quality acceptance.

1. Power off the control cabinet before cleaning.

2. Do not wipe the terminal board and circuit board with a wet cloth.

3. When using electric tools, use a leakage protection with a certificate of conformity.

protector.

4. Staff must wear insulating shoes.

5. The staff must use a qualified electroscope pen when testing electricity.

1. The cuffs of the overalls should be fastened.

2. The physical and mental condition of the staff is good, and they are competent for their duties

work.

3. It is strictly forbidden to stand or stay under heavy lifting objects during on-site debugging.

4. It is strictly forbidden to cross work, fasten the helmet belt.

5. During the on-site protection test, the main steam valve and regulating valve of the steam turbine shall be

There is no one to work and there is a special person to supervise.

1.6. Safety, health and environmental requirements

1.6.1 Security

1.6.1.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. Necessary for withdrawal of principal and secondary protection

Application form for surrender and withdrawal of physical protection.

1.6.1.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

1.6.1.3 When two or more people work, one person in charge must be specified.

1.6.1.4 Sufficient lighting should be provided on the site and meet the requirements of the "Safety Regulations".

67
1.6.1.5 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

tools.

1.6.1.6 When cleaning and refueling, prevent fire.

1.6.1.7 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

1.6.1.8 Seriously abide by the safety regulations on lifting and handling.

1.6.1.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

1.6.1.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

1.6.1.11 Clean up flammable and explosive debris at the work site.

1.6.2 Health

1.6.2.1 Precautions must be taken when coming into contact with chemicals that are toxic, harmful or irritating to the human body.

1.6.3 Environmental protection

1.6.3.1 The replaced waste products must be poured into the designated dustbin, and dumping is not allowed.

1.6.3.2 Discarded or leftover chemicals after use must be placed in designated locations and not thrown away casually. must do after

To "completion of work, clean materials, clean site" .

1.6.3.3 Work must consciously abide by ISO14001 environmental management standards and ISO9001 quality management system. 2

Overhaul process regulations for boiler furnace safety monitoring system (FSSS)

2.1 Equipment overview and parameters

2.1.1 The boiler furnace safety monitoring system (furnace safeguard supervisory sgstem, referred to as FSSS) is a large

It is an important part of the automatic protection and automatic control system of thermal power units. According to the boiler protection function and combustion

Burner control function, FSSS is often divided into two parts: Boiler Furnace Safety System (FSS for short) and burner control

control system (referred to as BCS). FSSS control logic is divided into public control logic, fuel control logic and coal combustion control logic

part.

Common control logic part contains all contents of boiler protection, namely oil leakage test, furnace purging, main fuel tripping

(MFT) and oil fuel trip (OFT) and memory of first out cause, ignition condition, ignition energy judgment, RB, etc.

Common control logic also includes control of FSSS common equipment (such as fire detection cooling fan, sealing fan, main trip valve).

The fuel control logic includes the fuel oil burner input and cut control and the layer input and cut control. Coal combustion control logic includes each pulverization system

(coal seam) sequence control and control of individual equipment. As a part of DCS, the FSSS operation interface is mainly the operation station CRT

picture. As a protection system, FSSS also has backup hard-hand operated MFT buttons.

2.1.2 The main functions of FSSS are:

2.1.2.1 Furnace purging. Before the boiler is ignited and after the shutdown, the furnace must be continuously purged.

Certain purging conditions must be met to ensure that no combustibles will accumulate in the boiler furnace and flue, and the purging must be cut off

All fuel sources entering the furnace, and at least 25% - 30% of the rated air volume ventilation, the purging time should not be less than

68
5min. When there is a fuel oil leakage test, the timing is started after the oil system leakage test is successful, so as to ensure a 5min furnace

The purging is performed in the absence of fuel leaks. During the purge timing period, if any of the purge conditions is not satisfied

If it is insufficient, it is considered that the purge failed.

2.1.2.2 Oil burner control. After the pre-ignition purge is completed, the furnace is ready for ignition, and the operator can

Put in and out of the oil gun inside.

2.1.2.3 Boiler furnace flame monitoring.

2.1.2.4 Program start-stop of coal mill unit and protection logic of coal feeder and coal mill.

2.1.2.5 Boiler MFT. The main fuel trip is an important part of the boiler safety monitoring system, which continuously monitors the predetermined

Whether the various safe operating conditions of the boiler are met, and once there is a dangerous situation that may endanger the safe operation of the boiler, it will be cut off quickly.

Fuel into the furnace to avoid equipment damage accidents, or to limit the further expansion of the accident.

2.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

2.3 Maintenance items

2.3.1 Inspection before unit shutdown

2.3.1.1 Inspection of control system

2.3.1.2 Check the flame display status of each channel of the flame detection system, and record the abnormal situation.

2.3.1.3 Check equipment status display and print records during load reduction and shutdown, and make records for abnormal situations.

2.3.2 Basic maintenance and requirements after system shutdown.

2.3.2.1 Control system hardware maintenance shall be carried out according to the DCS maintenance requirements, and the hardware that does not meet the quality indicators shall be replaced after the maintenance.

2.3.2.2 Control system power supply and circuit maintenance shall be carried out in accordance with relevant requirements of DCS maintenance.

2.3.2.3 Inspection and calibration of flame detection system, peripheral measurement and execution equipment.

2.3.2.4 The insulation resistance test of system components, equipment and lines shall meet the specified insulation level requirements.

2.3.2.5 Handling of defects recorded in pre-shutdown inspections.

2.3.2.6 Check the control logic of FSSS system, which is to comply with the requirements of DL/435. For each control logic, criterion signal,

During the correctness check of the fixed value and parameter setting, if modification is required, it shall be carried out according to the prescribed modification procedure, and a backup shall be made.

2.3.2.7 The related screen inspection of each control system should be correct.

2.3.2.8 The control logic should be backed up once before and after maintenance, and marked and stored in the specified place.

2.4 Maintenance steps, process methods and quality standards

2.4.1 Testing of control devices and modules.

2.4.2 Basic performance and functional tests of the control system.

69
2.4.3 The test and inspection results of all relays should meet the following requirements:

(1) Appearance without overheating or burnout;

(2) The contact resistance, action and release time and voltage range of the contacts comply with the manufacturer's regulations;

(3) Reliable switching of contact action without jitter;

(4) The number of actions and service life of the contacts are within the allowable range;

2.4.4 Check the opening, closing and rotation direction of the control object, which should be consistent with the display screen and meet the actual process requirements;

Test the full stroke action time of each valve and flapper in the direction of opening and closing. The test method is as follows, and the value should be consistent with the control logic setting.

corresponding to the actual value.

2.4.5 After sending out the command (for those with conditional restrictions, it can be carried out after taking a forced signal), check the action direction of the control object and

The actual position of the valve (or baffle) should be consistent with the display screen and meet the actual process requirements.

2.4.6 After the open command is issued, the time from the loss of the closed feedback signal of the control object to the appearance of the open feedback signal is the time for the control object

Full travel time.

2.4.7 After the close command is issued, the time from the loss of the open feedback signal of the control object to the appearance of the close feedback signal is the time for the control object

Close full travel time.

2.4.8 Check to confirm that the full-stroke action of the control object on opening and closing should be smooth and free from jamming; each stroke switch and torque switch

The action of the contact should be correct and reliable.

2.4.9 The setting value of the opening and closing allowable time set in the approval control logic should be greater than the test value (2~5)s.

2.4.10 Various soft manual functions connected with the automatic adjustment system have been tested to be normal.

2.4.11 For the system after overhaul, it should be confirmed before the test

(1) The relevant maintenance and electrical maintenance work has been completed;

(2) The unit test of the relevant equipment is qualified, and the relevant conditions of the system test items are met;

(3) The control device has been restored and powered on and is working normally after inspection;

(4) The logic check and modification work is completed;

(5) The power supply and air source of the damper, baffle plate, oil pump, pneumatic valve, electric valve, etc. are normal;

(6) For the auxiliary machinery with the "test" position, only its control power supply should be supplied, and the power supply switch should be placed at the "test" position;

(7) The on-site and centralized control room manual start and stop control tests have passed.

2.4.12 General requirements for testing

(1) When testing machines, furnaces, electrical chains and linkages, all logic must be included in the tests of related systems;

(2) The test should be carried out step by step according to the test operation card, make detailed test records and establish test files;

(3) If an abnormal situation occurs during the test, the test should be stopped immediately and the system should be restored to its original state; the test should be repeated after the fault is eliminated;

(4) After the test is over, do a good job in the recovery of the system and equipment;

(5) The test items and logical conditions shall be based on the design of each unit.

2.4.13 Functional test of the fuel system before starting.

2.4.13.1 Fuel oil trip valve opening, trip interlocking test

70
2.4.13.2 Fuel oil leakage test

oil leak test

(1) The pressure of the main fuel pipe before the fuel supply trip valve is normal; all the solenoid valves of the fuel guns are closed; the fuel inlet quick-closing valve is closed;

The valve is closed.

(2) Fuel oil leakage test procedure:

Step 1: Fill the pipeline with oil for 30 seconds, close the quick-closing valve of the oil inlet and outlet bypass of the boiler ignition oil system, open the quick-closing valve of the oil inlet and the oil return

Close the valve and the oil inlet regulating valve (the opening is controlled at 15%), with a delay of 30s;(Boiler ignition oil system inlet and outlet oil bypass quick shut-off valve

Status 10EGD22AA001ZC, boiler ignition oil system oil inlet quick-closing valve open status 10EGD10AA001ZO, boiler ignition oil system

The opening state of the oil return quick-closing valve 10EGD20AA001ZO, the position feedback of the boiler ignition oil inlet flow regulating valve

10EGD10AA101ZZ)

Step 2: Pressurize the pipeline for 60s, close the oil return quick-closing valve, and delay for 60s; if within 60s, the fuel leakage test pressure is allowed

If the Xu signal is satisfied (the oil supply pressure before the furnace is 10EGD10CP101, greater than 3.2MPa, the fixed value is to be determined), the pressure filling is successful; if

If the oil pressure signal is not satisfied within 60 seconds, the pressure charging will fail, and an alarm will be issued indicating that the fuel leakage test has failed;

Step 3: After the pressure is successfully charged, close the oil inlet quick-closing valve;

Step 4: The first stage of the test, timing 180S: check the fuel main pipe, each layer of oil angle valve, oil return quick-closing valve qualified; if

When 180S is counted up, the oil pressure drop difference of the main pipe is less than 0.3 0.1MPa (the oil supply pressure before the furnace is 10EGD10CP101) , then the first

The first-stage test is successful; (the pressure difference is confirmed by the boiler manufacturer! )
Step 5: After the first phase of the test is successful, open the oil return quick-closing valve;

Step 6: Release the pressure of the pipeline for 60s; if within 60s, the oil pressure of the main pipe drops to the specified value (the oil supply pressure in front of the furnace is low

10EGD10CP004), the pressure relief is successful; if the oil pressure of the main pipe does not drop to the specified value within 60S, the pressure relief fails and a

An alarm display indicating failure of the fuel leak test;

Step 7: After the pressure relief is successful, close the oil return quick-closing valve;

Step 8: The second stage of the test, timing 300S: check that the oil inlet quick-closing valve is qualified; if the timing is up to 300S, the main pipe oil pressure is on

The rise difference is less than 0.3 0.1MPa (the oil supply pressure before the furnace is 10EGD10CP101), the second stage test is successful;

Fuel leak test completed

2.4.14 Functional test of pulverizing system before start-up

2.4.14.1 Function test of coal mill lubricating oil pump

a Grinding main bearing low speed oil pump

Startup permission conditions:

If all the following conditions are met, it is considered that the low-speed oil pump of the main bearing of the mill is allowed to start:

The low-speed oil pump of the main bearing of the mill has no fault status

The oil level of the grinding oil tank is not low

Stop allowing conditions:

If the following conditions are satisfied, it is considered that the low-speed oil pump of the main bearing of the grinding mill is allowed to stop:

71
300s after the coal mill trips

The high-speed oil pump of the main bearing of the mill is running and the lubricating oil pressure of the main bearing of the mill is not low

b Grinding main bearing high speed oil pump

Startup allows:

The lubricating oil pressure of the grinding main bearing is normal

The high-speed oil pump of the main bearing of the mill has no faults

Any main bearing low-speed oil pump runs for 60s

Protection stops:

The low-pressure oil pump of the grinding main bearing is completely stopped

The coal mill is out of operation or the state of grinding slow transmission and closing position disappears, with a delay of 180s

2.4.14.2 Start-stop function test of coal mill unit

(1) Coal mill start-up allowable function test

When the following conditions are met, it is allowed to start the coal mill on the display screen, and check that the coal mill should be turned on normally, and the state

displayed correctly.

No coal mill trip command.

The coal mill motor is in the remote position.

Any sealed fan runs.

Coal mill lubricating oil pressure ≥ 0.12MPa.

The oil temperature of the coal mill oil station is less than 45°C.

Coal mill top shaft oil pressure ≥ 8MPa. The temperature of the free end bearing of the coal mill is less than 50°C.

Bearing temperature at the drive end of coal mill motor < 85°C

The temperature of the free end bearing of the coal mill motor is less than 85°C

Coal mill motor winding temperature <135°C

Coal mill ventilation is normal (≥40 tons/hour)

All the quick-closing doors at the separator outlet are opened.

All the purge doors of the powder feeding pipeline are closed.

The coal mill ignition energy is sufficient.

Coal burner ignition allowed.

The slow motor stops.

The primary air shut-off baffle of the coal mill has been opened.

Corresponding to the operation of the large gear cover sealing fan of the coal mill.

The coal feeder stops.

Coal mill separator outlet temperature <110°C

(2) Coal mill trip function test

72
MFT.
Manual trip (soft hand operation) .
The lubricating oil pressure of the coal mill is low (≤0.08MPa).

Two primary fans were out of service.

When there are more than four quick-closing doors at the exit of the coal mill.

When no flame is detected by the coal and oil fire detectors of a single burner, the burner will trip (close the separator outlet and close the door quickly), when there are three

The coal mill trips when the burner coal and oil fires cannot detect flames.

The air pressure of the mill seal and the primary air pressure of the mill entrance are less than 2kPa.

The temperature of the main bearing of the coal mill reaches 55°C.

Grind once and the wind-off baffle is closed.

The main pipe pressure of the primary air inlet is low.

Coal feeder A1, A2 all jump.

The temperature of the grinding motor coil is high.

The outlet temperature of the coal mill separator is as high as 120°C.

2.4.14.3 Start-stop function test of coal feeding unit

(1) Coal feeder start-up permission function test

When the following conditions are met, it is allowed to start the coal feeder, and check to confirm that the coal feeder should be turned on normally and the status display is correct.

There is no abnormality of the belt motor of the coal feeder;

No coal feeder cleaning chain motor is abnormal;

No overheating inside the coal feeder;

Closing state of coal mill;

The temperature of the air powder mixture at the mill outlet is better than 65°C and at least one of the two measuring points is better;

Fully open the coal valve at the outlet of the coal feeder;

Feedback of coal feeding rate of coal feeder <5%;

(2) Coal feeder trip function test

When any of the following conditions are met, the coal feeder should trip, send the above signals one by one, check and confirm that the powder feeder trips, the status

Status and alarm display should be correct.

MFT;
Corresponding coal mill tripping;

The coal feeder outlet is blocked with coal and the coal feeder belt motor is running, with a delay of 5s and a delay of S when the coal feeder outlet door is not fully opened;

2.4.14.4 Functional test before start-up of other systems

2.4.15 Functional test of fire detection cooling air system

Start manually:

The flame detection cooling fan A can be started by pressing the "Start" button on the operation screen.

73
Interlock start:

(1) When the fire detection cooling fan A is in the standby state and the fire detection cooling fan B trips, start the fire detection cooling fan A in interlock;

(2) When the flame detection cooling fan A is in the standby state and the flame detection cooling fan B is running and the pressure of the flame detection cooling air main pipe is lower than the constant

value (there is no normal signal of the flame detection cooling air pressure), the interlock starts the flame detection cooling fan A.

Manual outage:

(1) When the MFT trips, the fire detection cooling fan A can be stopped by pressing the "Stop" button on the operation screen;

(2) When all the following conditions are met, the fire detection cooling fan A can be stopped by pressing the "Stop" button on the operation screen:

Fire detection cooling fan B running

MFT signal

(The control logic of fire detection cooling fan B is the same as that of A)

2.4.16 Main fuel trip function test

2.4.16.1 MFT operating condition test

(1) When any of the following conditions are met, the unit MFT should trip:

Two blowers tripped.

Two induced draft fans tripped.

Two air preheaters tripped.

Two primary fans (running without starter nozzles) tripped.

The air volume is less than 25% of the total air volume.

The furnace pressure is high + 3KPa (choose two from three).

The furnace pressure is as low as -3KPa (choose two from three).

The turbine trips and the boiler load is greater than 40%.

The main steam pressure is as high as 28.62MPa (choose two from three).

The feed water flow is lower than 356.16 T/h for 20 seconds or lower than 267.12 T/h for more than 2 seconds.

All feed water pumps are fully stopped with a delay of 2 seconds.

The two fire detection cooling fans trip, with a delay of 2 seconds.

The main pipe pressure of the cooling air outlet of the fire detection is low (3.23KPa).

When the reheater loses protection, the action will be delayed for 10 seconds, and the following conditions are all met:

High and low pressure bypass valve opening <5%.

The high and low pressure main steam valves or trim valves are closed.

Any coal seam operation or boiler load > 30%.

During ignition, delay ignition, the following conditions are established:

Three misfires after MFT reset.

MFT reset, 1800 seconds after the ignition oil quick shut valve is opened, there is no any ignition oil layer running.

Manual MFT button.

74
All flames are lost.

All fuel is lost.

MFT relay tripped.

(2) Send out the above signals one by one, check and confirm that the unit MFT trips, and the display of status, alarm and first outgoing signal should be correct.

2.4.16.2. Linkage function test after MFT action

(1) Check the system. When the MFT signal is sent out, the following actions should be linked:

Fully close the reheater desuperheating water regulating door and electric door.

Fully close the superheater desuperheating water regulating door and electric door.

Close the oil quick release valve.

Fully close the oil leakage test valve.

All coal feeders trip.

Close the two primary fan inlet guide vanes.

All primary fans trip.

All coal mills tripped.

Close all pulverizer outlet dampers.

Oil burners for joint operation.

Superheater, reheater flue gas baffle to 50%.

The secondary air baffle is set to the purge position.

Combined electric dust removal.

Turbine tripped.

Joint jump boiler soot blower (when put into operation) .

(2) Check one by one to confirm that the corresponding status, alarm and signal display should be correct.

2.4.16.3 Furnace purging function test

a When the furnace is being purged, all of the following conditions must be met.

1. Primary purging conditions:

MFT relay tripped

OFT Trip

All coal mills out of service

All coal feeders out of service

All pulverizer exit doors closed

All oil valves and purge valves are fully closed

One fan stop

Any induced draft fan running

Any blower is running

75
Any air preheater running

No MFT trip condition exists

No flame in the whole furnace

2. Secondary purging conditions:

40%>Furnace air volume>30%

All secondary/tertiary dampers open (4/6)

Ignition oil leak test was successful

When the purging conditions are all satisfied, the "purge ready" signal is indicated on the CRT, and the operator can start purging at this time.

b Purging process

After the main fuel trip (MFT), the "request furnace purge" signal is automatically generated.

When the purging permission condition is met, the "purge ready" signal is automatically generated. The operator issues a "Start Furnace" on the CRT

Furnace purging" command, the furnace purging starts, the CRT indicates "furnace purging in progress", the purge timer starts counting down,

The time is 300 seconds.

In order to make the furnace purging thoroughly and clean, the purging process must last for 5 minutes at an air volume above 30% of the rated air volume. 5 minute blow

Sweeping can make the furnace get more than 4 air changes.

During the purge, the FSSS logic continuously monitors the primary purge allowable condition and the secondary purge allowable condition. One purge allowed

Conditions are the conditions that must be met for the FSSS system to enter the purge mode;

A must-have condition. When the permissible conditions for secondary purging (such as boiler air volume>30% of rated air volume) are not met during the purging process,

The purge timer will be cleared, but the purge will not be interrupted. After the second purge allowable condition is met, the purge timer will automatically start again.

However, if a certain purge permission condition is not met, it will cause the purge to be interrupted, and the purge timer will be cleared at the same time.

If the purge is interrupted, the operator will have to restart the purge sequence.

When all the purging conditions are met and last for 5 minutes, the purging is completed, and the "furnace purging successful" signal is indicated on the CRT,

Purge is complete.

The "furnace purge successful" signal is necessary to reset the MFT.

When MFT occurs, the "furnace purge successful" signal is cleared by an MFT pulse signal. In addition, the furnace purge command can also be

Reset the "furnace purge successful" signal.

2.4.17 Dynamic test of boiler safety monitoring system

2.4.17.1 Preparations before the test:

(1) The test protocol has been reviewed and approved;

(2) Do a good job of local isolation without affecting the safety of other operating equipment;

(3) For possible problems in the test, anti-accident measures have been prepared;

(4) The relevant measuring instruments are recalibrated, and the accuracy meets the requirements;

(5) The static test of the tested system is qualified.

2.4.17.2 MFT dynamic test

76
 (1) Adjust the normal operation of the unit at the test load;

(2) Adjust the operating conditions of the boiler (such as stopping all powder sources and closing the fuel oil trip valve) to achieve MFT action;

(3) Check the action status of all control objects after the MFT trips, which should meet the requirements;

(4) Check "boiler fire extinguishing","MFT Trip", The "Loss of Fuel" signal time and sequence of tripping events should be recorded correctly.

indeed;

(5) Check the rationality of the furnace pressure protection setting through the furnace pressure change curve;

(6) Through the furnace flame change curve (flame detector analog signal) , to test the reliability of flame signal protection;

(7) Check and record the purge process and purge time to meet the requirements.

The dynamic test of the FSSS system has certain potential hazards to the unit, so unless the unit is newly installed or the control system has major repair

, should
The modified unit should be carried out, be confirmed by static test method;

The FSSS system dynamic test that must be carried out should be carried out during the start-up and stop of the unit;

During the dynamic test, if any abnormal situation occurs, the test should be stopped immediately and the original operation mode of the equipment should be restored; find out the cause of the failure and

After elimination, the test can only be continued with approval.

2.4.18 Operation and maintenance standards

(1) Regularly check the status of each working indicator light of the module and the alarm screen, and deal with any defects or abnormal alarms in time.

(2) Regularly calibrate the measuring elements, sensors, transmitters and modules in the system.

(3) Regularly check the control and measurement pipelines, and there should be no leakage.

(4) Keep the air source dry, the pressure stable, the pipeline free of leakage, and the blowdown of the filter pressure reducing valve should be at least once a month.

(5) Regularly carry out protection and interlocking tests in the system. Important protection systems should be tested every quarter and before each unit maintenance.

Perform a static test to confirm that the trip logic, alarm and protection action values are correct and reliable.

(6) Keep the operating equipment clean and the display value clear.

(7) Strengthen the maintenance and management of the system to prevent problems such as blockage of the measurement pipeline, probe burnout or failure after contamination.

(8) Regularly check the waterproof, anti-dust blocking, anti-freeze, anti-vibration and anti-manual misoperation facilities of the equipment, which should be reliable.

2.5 Dangerous point analysis and pre-control

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

3 Charged area possible electric shock 2 Do not touch the power switch at will

77
 Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

78
 All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery cover, set up the stove to protect against wind and remove

15 winter work 4
fall Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

Any dismantling or modification

When dismantling or modification is necessary, the

17 hole covers, railings, prone to falls 2

Go through the application procedures first, as required

Safety Net Safety Facilities

Ask for remedial safety measures

79
 After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

When preparing the instrument, handle it with care

put. Take special care not to place the

The watch hit the building, and even fell to the ground

Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

Equipment damage, equipment on-site maintenance and the indicator is not allowed to use the car

twenty one Disassemble the device Improper use of tools, causing personnel 4 Propel. At the same time, it is not allowed to stack and move

harm transport

Use qualified power tools,

The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

80
 Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation If there is a little difference in the middle of the test

25
test middle protection failure Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

81
 Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

29 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

30 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Thermal instruments and protection devices

After overhaul, the signs are incomplete, and the operator After the overhaul, it should be kept clean and complete.

31 After overhaul sign

Operators are prone to operating errors Well, the logo should be correct and clear,

complete

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

82
 Chapter 6 Analog Control System (MCS)

1 Technical specification for maintenance of water supply control system

1.1 Equipment overview and parameters

The water-to-coal ratio of the once-through boiler is an extremely important control parameter. This design adopts the control method of water and coal. When the boiler fuel

When the volume command changes, the set value of the feed water flow will be automatically changed according to the calorific value of the designed coal type. If the calorific value of the coal type changes or

The influence of other factors causes the water-coal ratio to deviate from the design value, and then the feed water flow rate is used to control the steam temperature at the inlet of the steam-water separator of the boiler.

Correction. The set value of the inlet temperature of the steam-water separator of the boiler is automatically given by the function generator according to the outlet pressure of the steam-water separator.

And if necessary, the bias can be set manually by the operator, and the minimum superheat of the steam temperature at the inlet of the steam-water separator is considered in the design

degree limit, when the ratio of superheater water injection flow to total feed water flow deviates too much from the design value, the steam-water separator inlet

The steam temperature set point is increased or decreased in small ranges.

The differential function of the main regulator is separated separately, and the differential gain, differential time, proportional gain and integral speed are automatically adjusted according to the unit load.

dynamic change.

The output of the main regulator is used as the set value of the feed water flow, the output of the sub-regulator is used as the common command of the feed water pump, and the proportional increase of the sub-regulator

The benefit and integral speed are automatically changed according to the unit load.

The deviation between the set value of the boiler feed water flow and the inlet flow of the boiler economizer is output by the regulator as the common command of the feed water pump.

The common command of the feed water pump plus the offset set by the operator is used as the control command of the feed water pump.

1.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

1.3 Maintenance items

1.3.1 Basic maintenance items and quality requirements

1.3.1.1 Feedwater flow transmitter, each superheated and desuperheated water flow transmitter, main steam pressure transmitter, steam-water separator water storage tank

Pressure transmitter, inlet flow transmitter of each feed water pump, outlet pressure transmitter of each feed water pump, pressure transmitter of jellyfish pipe

For the maintenance items and quality requirements, see the transmitter part of this regulation.

1.3.1.2 For the basic maintenance items and quality requirements of the measurement system of feed water temperature and outlet header temperature of the water wall, please refer to the thermocouple in this regulation

part.

1.3.1.3 For the basic maintenance items and quality requirements of the minimum flow recirculation actuator of the feed water pump, see the actuator part of this regulation.

1.3.1.4 For the basic maintenance items and quality requirements of the scoop tube actuator of the electric feed water pump, see the electric actuator part of this regulation.

1.3.1.5 For the basic maintenance items and quality requirements of the DCS system modules and software related to the water supply control system, see the DCS control in this regulation

system part.

83
1.3.2 Test items and technical standards

Characteristic test of feedwater bypass regulating valve: The feedwater bypass regulating valve newly put into use or overhauled shall meet the following quality requirements

beg:
The maximum flow rate when the feedwater bypass regulating valve is fully open should meet the flow requirement under 15% unit load, and there is a 10% margin;

When the regulating valve is fully closed, the leakage flow should be less than 10% of the maximum flow of the regulating valve; the linear working section of the characteristic curve of the regulating valve should be greater than

70% of the full stroke, the return stroke error is not greater than 3% of the maximum flow of the regulating valve; the dead stroke of the regulating valve should be less than the full stroke

5%.
The basic method of the flow characteristic test of the feedwater bypass regulating valve: before the test, check whether the feedwater pressure reaches

Rated value, otherwise the water supply pressure should be increased by adjusting; during the test, set the water supply adjustment to manual control mode; when the unit is running

When the working condition is stable, open the large regulating valve intermittently in one direction manually, preferably at a rate of 10% each time, until the regulating valve is fully opened;

Then turn it down in the same way until it is fully closed; every time you reduce or open up, you must wait for the flow to stabilize.

Characteristic test of electric hydraulic couple speed regulating feedwater pump: for newly put into use electrohydraulic couple speed regulating feedwater pump, it is advisable

The relationship between the feed water outlet pressure and the feed water flow rate under the speed pump spoon tube position opening) is tested. Its quality requirements: hydraulic joint

The speed regulation range of the shaft joint should reach 25% to 100%;

The return error should not be greater than 2%; within the range of speed regulation, the water supply pressure and flow characteristics of the pump outlet should conform to the manufacturer's technical specifications.

technical requirements.

Feed water pump minimum flow recirculation control gate characteristic test: for newly put into use feed water pump minimum flow recirculation control gate

characteristics to test. Its quality requirements: the recirculation control flow rate should be higher than the minimum design flow rate of the feed water pump; the recirculation valve can instantly

Increase the valve opening by 30% (adjustable); when the recirculation flow is cut off, the recirculation valve can be closed instantly, isolating 10% of the recirculation

circulation flow.

Conditions for putting the control system into operation: the boiler is operating normally and meets the conditions for sending steam to the steam turbine; the main water supply pipeline is in normal operation

status; main parameters such as steam flow and feed water flow are operating normally, with accurate indications and clear records; the M/A operation station is working normally,

The tracking signal is correct and there is no manual signal; the minimum flow recirculation control and protection system of the feed water pump is put into operation with the corresponding feed water pump

run.
Inspection and acceptance: After the boiler is overhauled, the following test reports should be provided: the newly put into use feed water pump outlet regulating valve, electric

The test report shall be provided for the characteristics of the dynamic-hydraulic couple speed-adjustable feed water pump and the minimum flow recirculation control door of the feed water pump;

1.4 Maintenance steps, process methods and quality standards

1.4.1 Operation and maintenance standards

1.4.1.1 The working condition of the control system should be analyzed according to the record curve of steam flow and feed water flow every day, if any problem is found

should be promptly eliminated;

1.4.1.2 Regularly compare the output values of the triple redundant transmitters for steam flow and feed water flow, and take the median value as the control system

Feedback signal to eliminate faults in time for out-of-tolerance transmitters;

1.4.1.3 Regularly check the correctness of sampling points and measurement signals;

1.4.1.4 Regularly check the characteristics of the actuator and the adjustment mechanism;

84
 1.4.1.5 Regularly check the control quality record curves of the system under various working conditions, and deal with any abnormalities immediately to ensure that the system is in good condition.

in good condition.

1.4.1.6 When the steady-state quality index is out of tolerance during operation, a constant value disturbance test should be carried out.

1.4.1.7 When the unit is running, the automatic water supply can be removed in the following situations:

The water supply pressure is lower than the allowable minimum pressure;

When the boiler load is stable, the water level exceeds the alarm value;

The feedwater control system has failed.

1.5 Analysis and pre-control of dangerous points

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Not wearing a seat belt or Must be fastened before work

7 Leading to the fall incident and the expansion of its consequences 2
Incorrect hook The safety belt can only be used for work;

85
 It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

when using power tools When using power tools you must
Prone to electric shock and debris damage to the eyes

14 not wearing protective glasses, 1 Wear protective glasses, insulated hands

eye accident

insulating gloves; electric sets, electric tools should be delivered regularly

86
 Tools are inspected irregularly Check to ensure that the power cord, electric

The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery cover, set up the stove to protect against wind and remove

15 winter work 4
fall Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 The power supply, the electric test confirms that there is no electricity

Electric shock accident caused by direct current

After that, you can work, and do a good job of belt

87
 Capacitor device discharge operation, Pro

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

When preparing the instrument, handle it with care

put. Take special care not to place the

The watch hit the building, and even fell to the ground

Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

transport

Equipment damage, equipment on-site maintenance

Use qualified power tools,

twenty one Disassemble the device Improper use of tools, causing personnel 4
The staff must be able to use the appropriate

harm
of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

twenty four Equipment investment

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

88
 Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation If there is a little difference in the middle of the test

25
test middle protection failure Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire

Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

89
 Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

2 Overhaul process regulations for steam temperature control system

2.1 Equipment overview and parameters

2.1.1 Primary desuperheating control of boiler superheated steam

The superheated steam temperature of the boiler is controlled by two-stage water spraying for desuperheating, and each stage is divided into A and B sides for water spraying and desuperheating. control knot on both sides

The structure is basically the same, and the following only takes side A as an example for illustration.

The boiler superheated steam primary temperature reduction control system adopts a cascade regulation system, and both the main and auxiliary regulators use PID regulators.

Both the adjustment parameters of the main regulator and the sub-regulator can be changed automatically according to the unit load. Using the given load signal of the unit as a

Feedforward signal for stage cooling control.

The anti-integral windup function of the main regulator is considered in the system design. It is also considered to prevent the temperature from entering after the first-stage water spray desuperheating

function in the saturation region.

According to the given load of the unit, the set value of the inlet header temperature of the secondary desuperheater is automatically generated. If the water injection valve of the secondary desuperheater is adjusted

If the opening is too large or too small, the setting value of the first-stage temperature reduction will be corrected automatically. When the boiler MFT is activated, the main steam stage of the boiler desuperheats

The water adjustment door is forced closed to 0%.

2.1.2 Secondary temperature reduction control of boiler superheated steam

The boiler superheated steam secondary temperature reduction control system adopts a cascade regulation system, and both the main and auxiliary regulators use PID regulators.

Both the adjustment parameters of the main regulator and the sub-regulator can be changed automatically according to the unit load. Use the given load signal of the unit as the second

Feedforward signal for stage cooling control. The anti-integral windup function of the main regulator is considered in the system design. Consideration was also given to preventing secondary

The function that the temperature enters the saturation zone after spraying water to reduce the temperature.

The control target of the secondary water spray desuperheating is the temperature of the superheated steam at the boiler outlet.

The setting value of the superheated steam temperature at the outlet of the boiler can be manually set by the operator. When the boiler MFT operates, the boiler main steam secondary

90
The desuperheating water adjustment door is forced to close to 0%.

2.1.3 Boiler reheater flue gas baffle control

There are two ways to control the reheat steam temperature of this boiler. Under normal circumstances, the flue gas baffle is used to control the reheat steam temperature.

Spraying water for desuperheating is used as an accidental desuperheating method for reheating steam. The reheated flue gas baffle and overheated flue gas baffle in the flue on both sides adopt a

There are two manipulators, the direction of action is opposite, under any working conditions, there should be a certain flow surface for the overheated flue gas baffle and the reheated flue gas baffle.

product. When using the flue gas baffle to control the reheat steam temperature, a single-loop control system is adopted, and the set value of the reheat steam temperature can be determined by

Operators set manually on the flue gas baffle operator. Taking into account the feed-forward of the flue gas baffle when the unit load changes, the regulator

Considering random group load differences automatically changes the regulator parameters. When the boiler MFT operates, the main boiler reheater flue gas baffle

Force manual and open to 50%.

2.1.4 Control of emergency desuperheating water (A, B side) of boiler reheater

The reheater sprays water as a backup control method for the reheat steam temperature, and is divided into A and B sides. Reheater spray water desuperheating control

Cascade control system is adopted. Both the main and auxiliary regulators use PID regulators. Both the adjustment parameters of the main regulator and the sub-regulator can be

Automatically change according to unit load. The given load signal of the unit is used as the feed-forward signal for the reheat spray water temperature reduction control.

The anti-integral windup function of the main regulator is considered in the system design. The design also takes into account the temperature of the water after cooling to prevent reheating

Functions that enter the saturation region. When the flue gas baffle is in the automatic control mode, the set value of reheat spray water desuperheating will automatically add a certain amount

Bias to ensure that the reheat spray valve is fully closed. If the reheat steam temperature is too high, the flue gas baffle will lose its adjustment margin or the smoke

When the air baffle is under manual control, the bias is automatically switched to zero. When the boiler MFT operates, the boiler reheater accident desuperheating water adjustment

The door is forced manually and closes to 0%.

2.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

2.3 Maintenance items

2.3.1 Basic maintenance items and quality requirements

For the basic maintenance items and quality requirements of each temperature measurement system, see the thermocouple part of this regulation.

For the basic maintenance items and quality requirements of each water spray desuperheating actuator, see the electric actuator part of this regulation.

For the basic maintenance items and quality requirements of the oscillating burner actuator, see the pneumatic actuator part of this regulation.

See the transmitter part of this regulation for the basic maintenance items and quality requirements of the pressure transmitter.

2.4 Maintenance steps, process methods and quality standards

2.4.1 Test items and technical standards

2.4.1.1 Main steam temperature dynamic characteristic test (if necessary)

(1) The test content mainly includes the main steam temperature under the disturbance of the second-stage desuperheating water, the dynamic characteristics of the steam temperature before the second-stage desuperheating, the first-stage desuperheating

91
Under water disturbance, the temperature of the middle point, the dynamic characteristics of the first-stage pilot steam temperature, etc.; the test should be carried out under two loads of 70% and 100%, respectively.

The test under each load should not be less than twice.

(2) Set the temperature reduction control in the manual control mode. When the unit is in stable operating conditions, manually turn off the temperature reduction (step) at one time.

It is advisable to reduce the opening of the warm water regulating valve by 10% to reduce the flow of warm water. Record the temperature change of the main steam.

End the test when the steam temperature rises (falls) and stabilizes at the new value.

2.4.1.2 Reheat steam temperature dynamic characteristic test (conducted when necessary)

The test content mainly includes the dynamic characteristics of the reheat steam temperature under the flue gas baffle tilt angle swing, the temperature dynamic characteristics of the reheat steam under the disturbance of desuperheating water

Dynamic characteristics of reheat steam temperature; the test should be carried out under two loads of 70% and 100%, and the test under each load should not be less than two

Second-rate.

2.4.1.3 Characteristic test of desuperheating water regulating valve

This test shall be carried out for all regulating valves newly put into use, and its quality requirements are as follows:

The maximum flow rate of the regulating valve should meet the maximum load requirements of the boiler, and there is about 10% margin;

The leakage flow of the regulating valve should be less than 10% of its maximum flow;

The characteristic curve of the regulating valve should be linear, the working section should be greater than 70%, and the return error should be less than 3% of the maximum flow;

The dead stroke of the regulating valve should be less than 5% of the full stroke.

When the operating condition of the unit is stable, it is advisable to manually open the large desuperheating water regulating valve in one direction, each time by 10%.

until the regulating valve is fully opened; then turn it down in the same way until it is fully closed; every time you reduce or open the operation, you must wait for the flow to stabilize

To be carried out later.

In the test, if the desuperheating water flow rate is too large and the steam temperature may be lower than the allowable range, in order to ensure the safety of the unit, it should be changed to

Under different operating conditions, carry out the characteristic test in sections according to the above method. In order to prevent the main steam temperature from exceeding the allowable range, it has been tested

Monitoring should be strengthened during the process, and the test should be terminated immediately if the steam temperature is seriously exceeded or out of control, and the valve opening should be quickly restored to the test value.

previous position until the parameters are stable.

2.4.2 Control system input conditions

The main steam temperature at all levels and reheat steam temperature are accurately indicated and recorded clearly;

There is sufficient adjustment margin for the desuperheating water regulating valve and the inclination angle of the burner;

The M/A operator station is working fine, tracking signals are correct, no manual signals have been cut.

2.4.3 Quality index (load range 70%~100%)

Steady-state quality indicators: superheated steam temperature is ±3°C; reheated steam temperature is ±4°C; the actuator should not operate frequently.

When the given values of main steam temperature and reheat steam temperature change by ±5°C, the transition process decay rate Ψ=0.75〜1, and the stabilization time is less than

20min;

2.4.4 Inspection and acceptance

After the boiler is overhauled, the following test reports shall be provided:

The desuperheating water regulating valve newly put into use shall provide a qualified report of the characteristic test;

Qualification report of dynamic and steady-state quality indicators for main steam temperature and reheat steam temperature control;

92
 Dynamic characteristic test report of main steam temperature/reheat steam temperature (on request) .
2.4.5 Operation and maintenance standards

2.4.5.1 Learn from the operation staff on duty every day and analyze and control according to the main steam temperature and reheat steam temperature record curve

The operation of the system, if any problems are found, they should be eliminated in time;

2.4.5.2 Regularly check the correctness of the measurement signal;

2.4.5.3 Regularly check the characteristics of the actuator and the adjustment mechanism;

2.4.5.4 Regularly check the control quality record curves of the system under various working conditions, and deal with any abnormalities immediately to ensure that the system is in good condition.

in good condition.

2.4.5.5 In-service test

When necessary, conduct the desuperheating water flow disturbance test;

When necessary, carry out the main steam temperature and reheat steam temperature fixed value disturbance test.

2.4.5.6 Removal of control system

Automatic withdrawal may be considered in the following situations:

When the boiler is running stably, the main steam temperature and reheat steam temperature exceed the alarm value;

The desuperheating water regulating valve is fully opened, but the steam temperature continues to rise, or the desuperheating water regulating valve is fully closed, but the steam temperature continues to drop;

The control system works unstable, the desuperheating water flow fluctuates greatly, and the steam temperature fluctuates periodically without attenuation;

The leakage flow rate of the desuperheating water regulating valve is greater than 15% of its maximum flow rate;

The boiler is not operating normally, and the main steam temperature and reheat steam temperature parameters are lower than the rated value.

2.5 Risk Analysis and Pre-control

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

93
 must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

12 Use of tools and utensils prone to fall 3

The tool with larger time should be protected

The dangerous rope is hung on a firm place, the smaller

94
 tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery cover, set up the stove to protect against wind and remove

15 winter work 4
fall Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

18 scald Water leakage and steam from high-pressure equipment cause death 1 Open the work ticket when doing homework, close

95
 burns Close the controller once and open the door

Blowdown door, make sure the equipment is not pressurized

Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

When preparing the instrument, handle it with care

put. Take special care not to place the

The watch hit the building, and even fell to the ground

Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

Equipment damage, equipment on-site maintenance transport

twenty one Disassemble the device Improper use of tools, causing personnel 4 Use qualified power tools,

harm The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

96
 Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation If there is a little difference in the middle of the test

25
test middle protection failure Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electric hammers are not allowed on ladders

Improper use of ladders causing personal falls Ladders used must be strong,
27 Improper use of ladders
fall damage There are escalators and special supervisors

fasten your seat belt

97
 Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

29 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

30 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Thermal instruments and protection devices

After overhaul, the signs are incomplete, and the operator After the overhaul, it should be kept clean and complete.

31 After overhaul sign

Operators are prone to operating errors Well, the logo should be correct and clear,

complete

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

2.6. Safety, health and environmental protection requirements

2.6.1 Security

2.6.1.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. Necessary for withdrawal of principal and secondary protection

Application form for surrender and withdrawal of physical protection.

2.6.1.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

2.6.1.3 When two or more people work, one person in charge must be identified.

98
2.6.1.4 Sufficient lighting should be provided on the site and meet the requirements of the "Safety Regulations".

2.6.1.5 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

tools.

2.6.2.6 When cleaning and refueling, prevent fire.

2.6.1.7 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

2.6.1.8 Seriously abide by the safety regulations on lifting and handling.

2.6.1.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

2.6.1.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

2.6.1.11 Clean up flammable and explosive debris at the work site.

2.6.2 Health

2.6.2.1 Precautions must be taken when coming into contact with chemicals that are toxic, harmful or pungent to the human body.

2.6.3 Environmental Protection

2.6.3.1 The replaced waste products must be poured into the designated dustbin, and dumping is not allowed.

2.6.3.2 Discarded or leftover chemicals after use must be placed in designated locations and not thrown away casually. must do after

To "completion of work, clean materials, clean site" .

2.6.3.3 Work must consciously abide by ISO14001 environmental management standards and ISO9001 quality management system. 3 Technical rules for

maintenance of combustion control system

3.1 Equipment overview and parameters

The combustion control system includes fuel oil pressure control, primary air pressure control, air volume and oxygen volume control, furnace pressure control (induction fan static

leaf regulation), coal mill control (cold primary air regulation, hot primary air regulation).

3.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

3.3 Maintenance items

3.3.1 Fuel pressure regulation

Furnace fuel oil pressure dynamic characteristic test.

Check the fuel pressure regulating valve position feedback device;

Check the action direction, travel time and travel error of the fuel pressure regulating valve actuator;

The working condition of the control system should be analyzed frequently according to the fuel pressure record curve, and any abnormality should be eliminated in time.

99
Translated from Chinese (Simplified) to English - www.onlinedoctranslator.com

Restore the analog signal; after the set delay time, the water spray valve of the high-pressure steam trap should be automatically closed;

Exit sprinkler valve automatically.

1.4.8.5 Confirmation test procedure for condensate pump protection

Check that the condensate pump meets the test conditions; send the 6KV switch of the condensate pump to the test position

Thermal workers confirm that the protection signal is correct when the on-site simulation protection conditions are met item by item according to the protection test operation card.

Set the motor switch of the condensate pump to the "test start" position. When any protection signal is sent from the field side, the motor switch of the condensate pump should be controlled by "test

The "start" position trips to the "stop" position.

At the end of the test, the relevant systems and equipment shall return to the position before the test.

1.4.8.6 Interlocking test of condensate pump

When the condensate pump test conditions are met, set the condensate pump motor switch to the "test" position; set the condensate pump interlock to "automatic".

Open the inlet valve of the condensate pump and close the outlet valve; open the inlet and outlet valves or bypass valves of the condensate fine treatment and shaft plus inlet and outlet valves or bypass

valve.

Forced hot well water level, condensate jellyfish tube pressure, condensate flow signal.

Start a condensate pump. Send the water level high signal of the hot well; the backup pump should start automatically, and the outlet valve should be opened in conjunction.

Stop a condensate pump, its outlet valve should be automatically closed; restore the pressure signal of the condensate jellyfish pipe, the standby pump should start automatically, and its outlet valve should be connected

Automatically open; restore the pressure signal of the condensed jellyfish tube;

Shut down a condensate pump; send a protection signal for the running pump, and the running pump should trip; check the self-starting of the standby pump.

Shut down the running pump; the standby pump should start automatically; restore the analog signal.

After the test is over, restore the relevant systems and equipment to the position before the test.

1.4.8.7 Sequential control function group test of condensate system

Forced hot well water level, condensate jellyfish tube pressure and flow signal

The start-up conditions of the condensate pump sequence control are met, the condensate pump sequence control is set to the "automatic" and "open" positions, and the condensate pump and its inlet valve are logically corresponding

automatically turned on.

The operation of the condensate pump is controlled to shut down, and the related equipment should be shut down as required.

Resume forcing signal. Exit the condensate pump sequence control, and the equipment returns to the state before the test.

1.4.8.8 Operation process and requirements

a) The electric actuator of the condensate system, the condensate delivery pump, and the condensate pump are powered on, and the thermal device and signal system work normally.

b) Turn on the condensate delivery pump, fine treatment inlet and outlet valves or bypass valves, shaft plus inlet and outlet valves or bypass valves, and condensate pump inlet valves in sequence.

Mouth valve.

c) After confirming that the start-up conditions of the condensate pump are met, enable the condensate pump protection, start the condensate pump, and enable the condensate pump interlock.

d) On site and on the CRT, check that each device operates normally, and the status and parameters are displayed correctly.

f) Regularly conduct condensate pump switching tests to ensure that the interlock is normal.

1.4.9 Condenser vacuum system subgroup

1.4.9.1 Interlock test procedure for inlet valve and bypass valve of vacuum pump atmospheric ejector

149
Send vacuum pump running signal. Open the injector bypass valve and close the injector inlet valve.

The inlet valve of the atmospheric ejector of the vacuum pump and the bypass valve are interlocked and cut off automatically.

Send a signal that the inlet pressure of the vacuum pump is not high, the ejector bypass valve should be automatically closed, and the inlet valve should be automatically opened.

When the vacuum pump inlet pressure high signal is restored, the ejector bypass valve should automatically open and the ejector inlet valve should automatically close.

Restore the vacuum pump operation signal, exit the vacuum pump atmospheric ejector inlet valve and the bypass valve interlock automatically. Close the injector bypass valve.

1.4.9.2 Vacuum pump protection confirmation test

Meet the vacuum pump test conditions. The 6KV switch of the vacuum pump is set to "test: position.

According to the protection confirmation list, the thermal workers send analog signals to the site side one by one to confirm that the protection signals are correct.

The vacuum pump motor switch is set to the "test start" position. If any protection signal is sent from the field side, the motor switch of the vacuum pump should be controlled by "test

The "start" position trips to the "stop" position.

After the test is over, restore the relevant systems and equipment to the position before the test.

1.4.9.3 Test procedure for vacuum pump interlock test

Check that the vacuum pump meets the test conditions. The vacuum pump motor switch is set to the "test" position.

Disconnect the high vacuum signal of the condenser, short-circuit the high differential pressure signal before and after the inlet valve of the vacuum pump, and the vacuum pump will be interlocked and cut off automatically. large vacuum pump

Air injector inlet valve and bypass valve are interlocked and cut off automatically.

Turn on the vacuum pump inlet valve and a vacuum pump. To restore the high vacuum signal of the condenser, the standby pump should start automatically, and its ejector bypass valve should

Linkage is on.

Restore the high vacuum signal of the condenser, stop a vacuum pump; send a protection signal for the running pump, and the running pump should trip. The spare pump should be

start.

Remove the protection signal and stop the pump; the standby pump should start automatically. Resume forcing signal.

After the test is over, restore the relevant systems and equipment to the position before the test.

1.4.9.4 Vacuum system sequential control function group test

Satisfy the vacuum pump sequence start condition. Vacuum pump atmospheric ejector inlet valve and bypass valve interlock switch set to "automatic" .
Set the sequence control switch of the vacuum pump to the "automatic" position, turn on the vacuum pump, the vacuum pump, its outlet valve, and the bypass valve of the ejector should operate according to the logic

Enable accordingly.

The sequence control switch of the vacuum pump is set to the "off" position, and the related equipment should be turned off as required

The forced signal is restored, the vacuum pump sequence control is exited, and the equipment returns to the state before the test.

1.4.9.5 Operation process and requirements

The vacuum pump equipment of the vacuum system has passed the insulation test and has been powered on.

The air source of the pneumatic actuator is normal, the solenoid valve has been powered, and the thermal equipment and signal system have been put into normal operation.

Satisfy the starting conditions of the vacuum pump, turn on the vacuum pump protection, and turn on the vacuum pump. Put into each interlock of the vacuum system.

Check the operating status and parameters of each device on the site and on the CRT, and they should be normal.

The vacuum pump switching test needs to be done regularly to ensure that the interlock is normal.

1.4.10 Turbine shaft seal system subgroup

150
1.4.10.1 Interlock test procedure of shaft seal desuperheating water isolation valve

Disconnect the shaft seal pressure low signal. The shaft seal desuperheating water isolation valve switch is set to "automatic" position. Shaft seal desuperheating water isolation valve should be opened.

Restore the low pressure signal of the shaft seal, and check that the desuperheating water isolation valve of the shaft seal is closed.

Exit the shaft seal desuperheating water isolation valve automatically.

1.4.10.2 Operation process and requirements

The electric actuator of the shaft sealing system shall be powered after the insulation test is passed.

Pneumatic actuator air source, control device, thermal signal, etc. have all been put into normal operation.

Check the normal operation, status and parameters of each device on site and on the CRT, and they should be normal.

1.4.11 Low Pressure Heater Subgroup

1.4.11.1 Conditions to be met before the test

The maintenance and electrical maintenance work of the low-pressure heating system has been completed.

The air source of the actuator is normal; the pneumatic and electric actuators of the low-pressure heating system have passed the unit test and have been powered on.

The thermal equipment and signal system have been put into normal operation, and the logic modification work has been completed.

1.4.11.2 #5, #6 low plus hydrophobic interlocking test

Force the main steam valve to close the signal, set the #5 (#6) low pressure drain switch to "automatic", open the #5 (#6) low pressure inlet and outlet valve, and close

#5 (#6) low plus bypass valve.

Send #5 (#6) low and high signal, #5 (#6) emergency trap should be opened automatically.

Restore the #5 (#6) low plus high signal, and the #5 (#6) emergency trap should automatically close.

Send #5 (#6) low plus high high signal, #5 (#6) low plus emergency trap should open, #5 (#6) low plus normal trap, inlet

The outlet valve should be closed. #5 (#6) LP bypass valve should be open.

When sending #6 low plus high high signal, #5 low plus emergency trap should also be opened, and #5 low plus normal trap should be closed.

All signals restored. The equipment returns to the state before the test.

1.4.11.3 #5, #6 low-voltage emergency isolation interlock test

Forced main steam valve close signal; #5 (#6) low pressure drain set to "auto", open #5 (#6) low pressure inlet and outlet valves, close #5 (#6)

Low plus bypass valve.

Press #5 (#6) low plus "emergency isolation" button; #5 (#6) low plus normal drain valve should be closed, #5 (#6) low plus emergency drain

The water valve should be opened, the inlet and outlet valves of #5 (#6) should be closed, and the bypass valve of #5 (#6) should be opened.

When the #6 LP emergency isolation button is pressed, the #5 LP normal trap should close and the #5 emergency trap should open.

Release the #5 (#6) low plus emergency isolation button to restore the forced signal.

The equipment returns to the state before the test.

1.4.11.4 #7, #8 low plus hydrophobic interlocking test

Forced main steam valve close signal; #7, #8 low plus drain set "automatic" , open #7, #8 low plus inlet and outlet valves, close #7, #8

Low plus bypass valve.

Send #7, #8 low and high signal, #7, #8 emergency trap should be opened automatically.

151
Restore #7, #8 low and high signal, #7, #8 emergency trap should be closed automatically.

Send #7 low plus high high signal, #7 low plus emergency trap should be opened, #7 low plus normal trap should be closed, #7, #8 low plus

Outlet valves should be closed, #7, #8 LP bypass valves should be open, #6 LP emergency trap should be open, #6 LP normal trap

should be closed.

Restore #7 low plus high high signal, open #7, #8 low plus inlet and outlet valves, close #7, #8 low plus bypass valves.

Send #8 low plus high high signal, #8 low plus emergency trap should be opened, #8 low plus normal trap should be closed, #7, #8 low plus

Outlet valve should be closed, #7, #8 LP bypass valve should be open, #7 LP emergency trap should be open, #7 LP normal trap

should be closed.

All signals are restored; restore the state of the equipment before the test.

1.4.11.5 #7, #8 LPS emergency isolation interlock test

Forced main steam valve close signal, #7, #8 low plus drain switch set to "automatic" , open #7, #8 low plus inlet and outlet valves, close #7, #8

# 8 Low plus bypass valve.

Press #7, #8 low plus "emergency isolation" button, #8 low plus normal trap should be closed, #8 low plus emergency trap should be opened,

#7 LP normal trap should be closed, #7 LP emergency trap should be open, #6 LP normal trap should be closed, #6 LP emergency trap should be closed, #6 LP emergency trap should be closed,

The emergency trap should be opened, the #7 and #8 LP inlet and outlet valves should be closed, and the #7 and #8 LP bypass valves should be opened.

Release the #7 and #8 low plus emergency isolation buttons to force the signal to recover. The equipment returns to the state before the test.

1.4.11.6 Main steam valve closed low plus interlock test procedure

Forced main steam valve close signal, open #5, #6, #7, #8 low pressure normal traps, close #5, #6, #7, #8 low pressure critical

Traps.

Restore main steam valve close signal, #8 low pressure emergency trap opens, #8 low pressure normal trap closes, #7 low pressure normal drain

Valve closed, #7 LP emergency trap open, #6 LP normal trap closed, #6 LP emergency trap open, #5

The LP normal trap is closed and the #5 LP emergency trap is open.

1.4.11.7 Operation process and requirements

The insulation test of the electric actuator of the low heating system is qualified, and the power is sent.

The air source of the pneumatic actuator is normal, the solenoid valve has been powered,

The thermal equipment and signal system have been put into normal operation, and the logic modification work has been completed.

After satisfying the input conditions of low-increase, invest in low-increase.

Check the operating status and parameters of each device on site and on the CRT and they should be normal.

1.4.12 High pressure heater subgroup

1.4.12.1 High plus hydrophobic interlocking test

High plus drain switch set to "automatic" .

Send #1 high plus high signal, #1 high plus emergency trap should automatically open; restore #1 high plus high signal, #1 high plus emergency trap

should close automatically.

Send #2 high plus high signal, #2 high plus emergency trap should automatically open; restore #2 high plus high signal, #2 high plus emergency trap

152
should close automatically.

Send #3 high plus high signal, #3 high plus emergency trap should automatically open; restore #3 high plus high signal, #3 high plus emergency drain

The valve should close automatically.

Send the deaerator water level high high high signal, the #3 high plus emergency trap should be automatically opened, and the #3 high plus normal trap should be automatically closed.

Restore the high-high signal of the water level of the deaerator; the equipment returns to the state before the test.

1.4.12.2 High water level protection test

Set the high-fill drain switch to "automatic", close the high-fill water side discharge valve, close the high-fill water side control valve, and open the high-fill water inlet and outlet valves.

Send #1 high-high high-high signal, high-fill water side control valve should be opened, high-fill water inlet and outlet valves should be closed, feed water bypass, high-fill water

The side bleed valve should be open and the #1 high pressure accident trap should be open.

Restore the high-high signal of #1, close the high-fill water side discharge valve, close the high-fill water side control valve, and open the high-fill water inlet and outlet valves.

Send #2 high-high high-high signal, high-fill water side control valve should be opened, high-fill water inlet and outlet valves should be closed, feed water bypass, high-fill water

Side bleed valve should be open, #2 high pressure accident trap should be open, #1 high pressure accident trap should be open, #1 high pressure normal drain

The valve should be closed;

Restore the high-high signal of #2, close the high-fill water side discharge valve, close the high-fill water side control valve, and open the high-fill water inlet and outlet valves.

Send #3 high-high high-high signal, high-fill water side control valve should be opened, high-fill water inlet and outlet valves should be closed, feed water bypass, high-fill water

Side bleed valve should be open, #2 high pressure accident trap should be open, #3 high pressure accident trap should be open, #2 high pressure normal drain

The valve should be closed.

The signal is restored, and the equipment returns to the state before the test.

1.4.12.3 High plus emergency isolation interlock test

Set the high-fill drain switch to "automatic", close the high-fill water side discharge valve, close the high-fill water side control valve, and open the high-fill water inlet and outlet valves.

Press the "Emergency Isolation" button of the high-pressure tank, the control valve on the water side of the high-power tank should be opened, the inlet and outlet valves of the high-power tank should be closed, and the water supply will be bypassed.

Fill side bleed valve should open, #3 high fill accident trap should open, #2 high fill accident trap should open, #1 high fill accident

The trap should be open.

Release the high plus emergency isolation button, and the equipment returns to the state before the test.

1.4.12.4 Interlocking test of the desuperheating water valve of the drain expansion vessel for high-heating accidents

Close #, #2, #3 high-pressure accident traps, and close the boiler 5% bypass valve. Fully open any high-pressure accident trap and do not close, reduce the temperature

The water valve protection is open. The desuperheating water valve switch is set to "automatic;

Send a high-temperature signal to the emergency drain expander, and the desuperheating water valve should automatically open. Restoring the high temperature of the accident drain expansion vessel

signal, the desuperheating water valve should be automatically closed.

When the 5% bypass valve of the boiler is fully opened, the desuperheating water valve is protected and opened; when the 5% bypass valve of the boiler is closed, the desuperheating water valve should be automatically closed.

Fully open the high row ventilation valve, check the protection of the desuperheating water valve is open; close the high row ventilation valve, the desuperheating water valve should be automatically closed.

Open the #1 high pressure accident trap, the desuperheating water valve protection is open; close the #1 high pressure accident trap, the desuperheating water valve should automatically close

close.

Open the #2 high pressure accident trap. The desuperheating water valve protection is opened. Close the #2 high pressure accident trap, the desuperheating water valve should automatically close

153
close.

Turn on the #3 high-pressure accident trap, and the desuperheating water valve will be protected; close #3 high-pressure accident trap, and the desuperheating water valve will automatically close

close.

The equipment returns to the state before the test.

1.4.12.5 Operation process and requirements

Check that the air source of the pneumatic actuator is normal and the solenoid valve has been powered on

Thermal personnel check that the control device and thermal signal have been put into normal operation.

After checking that the input conditions of the high increase are met, input the high increase.

Check on site and on the CRT that each device is running normally, and the status and parameters are normal.

1.4.13 Generator stator cooling water

1.4.13.1 Interlocking test of generator cooling water pump

Disconnect the low differential pressure signal at the inlet and outlet of the constant cooling pump, set the generator constant cooling water pump switch to the "test" position, and start a constant cooling pump.

The interlock switch of the constant cooling pump is switched to ,"automatic"

stop pump A, standby pump B should start automatically; stop running pump B, standby pump A should start automatically.

Resume the low differential pressure signal at the inlet and outlet of pump A, disconnect the low differential pressure signal at the inlet and outlet of pump B, and stop pump B.

Restore the low differential pressure signal at the inlet and outlet of pump B, and pump A should start automatically; disconnect the low differential pressure signal at the inlet and outlet of pump B, and stop pump A.

Resume the low signal of differential pressure between the inlet and outlet of pump A, and pump B should start automatically.

All signals are restored, and the equipment returns to the state before the test.

1.4.13.2 Confirmation test of generator water cut-off protection

, put
Release the generator water cut-off protection, and the generator constant cold water inlet and outlet differential pressure low low signal (three) into generator water cut-off protection.

Arbitrarily restore two of the three signals of the constant cold water inlet and outlet differential pressure low of the generator, and check the power generation after a period of delay.

The water cut-off protection of the machine should act.

Restore all signals, and the equipment returns to the state before the test

1.4.13.3 Operation process and requirements

The fixed cooling water system and the fixed cooling pump equipment will be powered on after passing the insulation test.

After checking that the start-up conditions of the constant cooling pump are met, start a constant cooling water pump. Put into constant cooling water pump interlock and generator water cut-off protection.

Check the operating status and parameters of each device on the site and on the CRT, which should be consistent with the actual situation.

It is necessary to conduct regular cooling pump switching tests to ensure that the interlock is normal.

1.4.14 Generator seal oil system

1.4.14.1 Interlocking test of generator air side sealed oil pump

Release the low differential pressure signal at the inlet and outlet of the airside sealed oil pump, and set the switch of the airside sealed oil pump of the generator to the "test" position.

Start one airside seal oil pump, and set the airside seal oil interlock switch to the "automatic" position.

When pump A is stopped, standby pump B should start automatically; when pump B is stopped, standby pump A should start automatically.

Resume the low differential pressure signal at the inlet and outlet of pump A, release the low differential pressure signal at the inlet and outlet of standby pump B, and stop the pump.

Resume the low signal of differential pressure between the inlet and outlet of the pump, and the standby pump should start automatically.

154
Restore all signals and restore the equipment to the state before the test.

1.4.14.2 Interlocking test of smoke exhaust fan of air side sealed oil tank of generator

Release the low vacuum signal of the air-side sealed oil tank, and set the exhaust fan switch of the air-side sealed oil tank of the generator to the "test" position.

Start one airside sealed fuel tank smoke exhaust fan, and set the airside sealed fuel tank smoke exhaust fan interlock switch to the "automatic" position.

When pump A is stopped, the standby pump should start automatically; when pump B is stopped, standby pump A should start automatically.

Restore the low vacuum signal of the air side sealed fuel tank, and the standby pump should start automatically;

The equipment is restored to the state before the test.

1.4.14.3 Operation process and requirements

Pass the insulation test of the sealed oil system cooling pump and fan equipment, and then send power.

The equipment and signals in the thermal control and measurement systems have all been put into normal operation.

Start an airside sealed oil tank smoke exhaust fan; after the airside sealed pump and hydrogen side sealed oil pump start conditions are met, start the hydrogen side sealed

seal oil pump and one airside seal oil pump.

Put into airside sealed oil pump interlock and smoke exhaust fan interlock.

Check the operation status and parameters of each device on the site and on the CRT without abnormalities

Regularly conduct switching tests on the short side seal oil pump and exhaust fan to ensure that the interlock is normal.

1.4.15 Anti-fuel system

1.4.15.1 Anti-fuel (EH oil) pump interlock test

Release the anti-fuel (EH oil) fuel tank low-low signal and low oil pressure signal. Anti-fuel (EH oil) pump switch set to "test"

Location.

Start one anti-fuel (EH oil) pump and set the anti-fuel (EH oil) pump interlock switch to the "AUTO" position.

Stop running pump A, and standby pump B should start automatically. Stop pump B. Standby pump A should start automatically

Recover low oil pressure signal, standby pump should start automatically

Restore all signals, and the equipment returns to the state before the test

1.4.15.2 Confirmation test for anti-fuel (EH oil) pump protection

Release the anti-fuel (EH oil) fuel tank low-low signal, and set the anti-fuel (EH oil) pump switch to the "test" position.

Start anti-fuel (EH oil) pump, restore anti-fuel (EH oil) tank level low signal, check anti-fuel (EH oil) pump trip.

Restore all signals, and the equipment returns to the state before the test

1.4.15.3 Operation process and requirements

The insulation test of the fuel oil (EH oil) system oil pump equipment passed the test, and the power was sent.

Thermal control devices, equipment and thermal signals have all been put into normal operation

After satisfying the anti-fuel (EH oil) pump starting conditions, start one oil pump after putting in the oil pump, and put in the fuel (EH oil) pump to interlock.

Check the operating status and parameters of each device on the site and on the CRT should be normal.

It is necessary to conduct regular anti-fuel (EH oil) pump switching tests to ensure that the interlock is normal

1.4.16 Jacking shaft oil pan car system

155
1.4.16.1 Test steps for crank motor protection

Release the low lubricating oil pressure, low jacking shaft oil pressure and cranking coupling signals, and set the jacking shaft oil pan motor switch to the "test" position.

Start the crank motor, restore the lubricating oil pressure signal, and stop the crank motor

Remove the lubricating oil pressure signal, restart the crank motor, restore the top shaft oil pressure signal, and check that the crank motor is out of operation.

Restore cranking coupling signal, check cranking motor outage

Restore all signals, and the equipment returns to the state before the test

The test should be carried out on the site control panel and DCS respectively.

1.4.16.2 Operation process and requirements

Check the insulation of the crank motor equipment to pass the test and send power.

Thermal control devices, equipment and signal systems have all been put into normal operation.

Turn on the oil system of the main engine and start the jacking oil pump after meeting the starting conditions of the jacking oil pump.

Confirm that the cranking control air source is normal, start the cranking, and check that it should be coupled well, and put it into cranking automatic.

Check the operation status and parameters of each device on the site and on the CRT. There should be no abnormalities.

It is necessary to do the turning test of the turning motor regularly to ensure that the turning device is normal

1.4.17 Turbine extraction system

1.4.17.1 #1, #2, #3 extraction interlock test (in the following tests, the tested extraction interlock test is referred to as this level for short)

Release the main steam door close signal, open the extraction check door and the electric door of the same stage, open the signal of the extraction check door of the same stage, and close the extraction check of the same stage

Drain valve in front of the door (there is no such item in the #2 extraction check door test) and a steam trap behind the electric door.

Send #1 high water level high high signal. The steam extraction check door and electric extraction door of this stage shall be automatically closed, and the steam extraction check door of this stage shall be drained

valve (there is no such item in the #2 extraction check door test), and the drain valve behind the extraction electric door should be automatically opened.

Restore the high-high water level signal of #1, open the steam extraction check door and electric door of this stage, and close the steam trap in front of the extraction check door of this stage

(There is no such item in #2 extraction check door test) and the steam trap behind the electric door

Send #2 high water level high signal. The steam extraction check door and electric door of this stage shall be closed automatically, and the steam trap in front of the steam extraction check door of this stage shall be closed automatically.

(No item for #2 extraction check valve test) , The steam trap behind the electric door should be opened automatically

Restore the high-high water level signal of #2, open the steam extraction check door and electric door of the current stage, and close the steam trap in front of the steam extraction check door of the current stage

(There is no such item in #2 extraction check door test) and the steam trap behind the electric door

Send #3 high water level high signal. The steam extraction check door and electric door of this stage shall be closed automatically, and the steam trap in front of the steam extraction check door of this stage shall be closed automatically.

(No item for #2 extraction check valve test) , The steam trap behind the electric door is opened

Restore #3 high water level high signal, open the steam extraction check door and electric door of this stage, close the steam trap in front of the steam extraction check door of this stage

(There is no such item in #2 extraction check door test) and the steam trap behind the electric door

Operate the high-pressure emergency button to check that the steam extraction check door and the electric door of the current stage should be automatically closed, and the steam trap in front of the steam extraction check door of the current stage (#2

There is no such item in the extraction check door test) , The steam trap behind the electric door should be opened automatically.

Loosen the high-pressure emergency button, open the steam extraction check door and the electric door of the current stage, and close the steam trap in front of the steam extraction check door of the current stage (#2 extraction

There is no such item in the steam check door test) and the steam trap behind the electric door

156
Restore the master steam door close signal. The steam extraction check door and electric door of this stage shall be closed automatically, and the steam trap in front of the steam extraction check door of this stage (#2

There is no such item in the extraction check door test) , The steam trap behind the electric door should be opened automatically

All signals restored. The equipment returns to the state before the test.

# 1, #2, #3 extraction interlock tests are carried out separately.

1.4.17.2 #4 extraction interlock test procedure

Release the main steam door close signal, open #4 stage extraction #1, #2 extraction check valve and electric door, force #4 extraction #1, #2 extraction check

Door open signal, close #4 extraction steam check valve before the door trap and electric door after the steam trap

Send high-high signal of deaerator water level, #4 extraction steam #1, #2 check door, electric door should be closed automatically, #4 extraction steam check door front

The steam trap and the steam trap behind the electric door should be opened automatically.

Restore the high-high signal of the water level of the deaerator, open the #4 stage extraction steam #1, #2 check door and electric door, close the #4 extraction steam check door

Front steam trap and electric door rear steam trap

Operate the emergency button of the deaerator, the #1, #2 check door and electric door of the #4 extraction steam will be automatically closed, and the #4 extraction steam check door

Water valves and electric doors should open automatically.

Loosen the emergency button of the deaerator, open the #1, #2 check door and electric door of the #4 extraction steam, and close the drainage in front of the #4 extraction steam check door

valve and the steam trap behind the electric door.

Restore main steam door close signal, #4 stage extraction steam #1, #2 check door, electric door should be closed automatically, #4 extraction steam check door front drain

The drain valve behind the valve and electric door should be opened automatically.

All signals are restored; the equipment returns to the state before the test.

1.4.17.3 #5, #6 extraction interlock test procedure

Force main steam door close signal, open #5 extraction check door and electric door, force #5 extraction check door open signal, close #5 extraction check

Door front steam trap and electric door rear steam trap

Send #5 low water level high-high signal, #5 extraction steam check door, electric door should be closed automatically, #5 extraction steam check door front drain valve, electric valve

The trap behind the door is open.

Restore the #5 low water level high-high signal, open the #5 extraction check door and electric door, close the #5 extraction check door front steam trap and electric valve

door trap

Operate the low plus emergency button, the #5 extraction steam check door and electric door should be automatically closed, and the #5 extraction reverse steam stop door front trap, electric door

Back trap open

Loosen the emergency button of the low-pressure heater, open the #5 extraction check door and the electric door, close the #5 extraction check door front trap and the electric door rear drain

water valve.

Restore main steam door close signal, #5 extraction steam check door, electric door should be closed automatically, #5 extraction steam check door front trap, electric door

The rear trap opens.

All signals are restored; the equipment returns to the state before the test.

#6 extraction interlock test same as #5 level.

1.4.17.4 Operation process and requirements

157
The insulation test of the electric actuator of the steam extraction system is qualified, and the power is sent.

The gas source of the pneumatic actuator is normal; the solenoid valve is powered; the thermal control device, equipment and signal system have all been put into normal operation.

After checking that the extraction steam input conditions are met, start the extraction steam.

On site and on the CRT, check that each device is running normally, and the status and parameters are normal.

1.4.18 Main steam pipeline drainage system

1.4.18.1 Interlocking test of steam traps in main steam pipeline

Mandatory main steam valve signal and low load Ⅰ value signal, main steam pipe drain is set to "auto" position; main steam main pipe drain valve, #1,

# 2 The steam trap in front of the main steam valve and the steam trap in front of the high bypass valve should be closed.

Restore load low I value signal. Main steam main steam trap, #1 and #2 main steam valve front traps, and high side valve front traps should all be opened

start.

Forced load low Ⅰ value signal, main steam main steam trap, #1, #2 main steam steam trap, and high bypass valve front steam trap should all be closed

close.

Restore the main steam valve close signal, the main steam main steam trap, #1 and #2 main steam valve front traps, and the high bypass valve front traps should all be opened

Restore all signals; restore equipment to pre-test state.

1.4.18.2 Interlocking test of hot resteam piping traps

Force the main steam valve signal and low load Ⅰ value signal, set the hot resteam pipe drain to "automatic" position, check #1, #2 medium pressure

The steam trap before the main steam valve and the low bypass valve should be closed.

Restore the low load I value signal, and the steam traps in front of the medium pressure main steam valve of #1 and #2 and the steam traps in front of the low bypass valve should all be opened.

Forcibly load the low I value signal, check that the steam traps in front of the medium pressure main steam valve of #1 and #2 and the steam traps in front of the low bypass valve should all be closed.

Restore the main steam valve close signal, and the steam traps in front of the 1 and #2 medium pressure main steam valves and the low bypass valve should all be opened.

Restore all signals; restore the equipment to the state before the test.

1.4.18.3 Interlocking test of steam traps in cold resteam pipeline

Set the drain of the cold resteam pipeline to the "automatic" position,

Close the high water level signal of the drainage bag in front of the high-row check door on site, and open the drain valve of the drain bag in front of the high-row check door;

Restore the high water level signal of the drainage bag in front of the high-row check door, and close the drain valve of the drain bag in front of the high-row check door.

After the high-row check door is closed on site, the water level of the drainage bag is high, and the drain valve of the drain bag behind the high-row check door should be opened;

Restore the high water level signal of the drainage bag behind the high-row check door, and the drain valve of the drain bag behind the high-row check door should be closed.

Close the high water level signal of the cold re-drain bag on site, and open the trap valve of the cold re-drain bag;

Recover the high water level signal of the cold re-drainage bag, and the high-cold re-drainage bag trap should be closed.

At the end of the test, restore the equipment to the state before the test

1.4.18.4 Operation process and requirements

Check that the air source of the pneumatic actuator is normal and the solenoid valve has been powered on.

Thermal control devices, equipment and thermal signals have all been put into normal operation.

The main steam pipe drainage is set to "automatic" , Hot re-steam pipeline drainage is set to "automatic" , cold re-steam pipeline drainage is set to "automatic" .

158
Check that the status of each trap should meet the requirements;

Check the operating status and parameters of each device on the site and on the CRT should be normal.

1.4.19 Turbine steam pipeline steam trap subgroup

1.4.19.1 High-pressure drainage interlocking test of the turbine body

Force the main steam valve to close the signal and the low load I value signal, set the high-pressure drain of the turbine body to the "automatic" position, and adjust the stage drain of the high-pressure cylinder

The water valve and the high-pressure outer cylinder drain valve should be closed, and the #1 and #4 high-pressure steam guide pipe traps and #2, #3, #5, and #6 high-pressure steam guide pipe drain valves should be closed.

The water valve should be closed.

Restore the low Ⅰ value signal of the load, and the steam traps of the regulating stage of the high-pressure cylinder and the steam traps of the high-pressure outer cylinder should be opened; #1 and #4 high-pressure steam guide pipes

Traps should be open with #2, #3, #5, #6 high pressure steam line traps.

Forced load low 1 value signal, high-pressure cylinder regulating level steam trap, high-pressure external cylinder steam trap should be closed, #1, #4 high-pressure steam guide pipe

Traps closed and #2, #3, #5, #6 high pressure steam line traps closed.

Restore the main steam valve close signal, the high-pressure cylinder regulating level steam trap and the high-pressure external cylinder steam trap should be opened, and the #1 and #4 high-pressure steam guide pipes should be drained.

Water valves and #2, #3, #5, #6 high-pressure steam guide pipe traps should be opened

Restore all signals; restore the equipment to the state before the test.

1.4.19.2 Medium-pressure hydrophobic interlocking test of the turbine body

Forced main steam valve close signal and low load II value signal, the medium pressure drain of the turbine body is set to "automatic" position, the medium pressure outer cylinder drain valve,

Both the #1 IP steam line trap and the #2 IP steam line trap should be closed.

Restore the low load II value signal, and open the traps of the medium-pressure external tank and #1 and #2 medium-pressure steam guide pipe traps.

Forced load low II value signal, medium pressure external tank traps, #1, #2 medium pressure steam guide pipe traps should all be closed.

Restore the main steam valve close signal, and the traps of the medium-pressure external cylinder and the traps of #1 and #2 medium-pressure steam guide pipes should all be opened.

Restore all signals and restore the state of the equipment before the test.

1.4.19.3 Operation process and requirements

Check that the air source of the pneumatic actuator is normal and the solenoid valve has been powered on.

Thermal personnel check that control devices and thermal signals have been put into normal operation

The steam turbine steam pipe drain, hot re-steam pipe drain, and cold re-steam pipe drain switches are all set to "automatic" .
Check that each steam trap is in correct condition

Check the operating status and parameters of each device on the site and on the CRT should be normal.

1.4.20 Acceptance

1.4.20.1 Acceptance in cold state

The first-time component acceptance of each sequence control system requires complete adjustment records, accuracy and response values in line with brand requirements; beautiful installation, and

put into service.

The check and acceptance of the actuators of each sequence control system requires that the cold operation is normal, the status display is correct, and the switching time of the actuators is tested.

After the record is complete.

Each motor of each sequential control system rotates normally in cold state, and the status display is correct.

159
 The control loops and signal loops of each sequential control system have passed the test, and the loop inspection records are complete.

The inspection and maintenance quality of each sequence control system control device meets the requirements, and it works normally after power-on.

Each sequential control system logic, setting value, fixed value modification is correct, and the modification record is complete.

The interlock protection test of each sequential control system is normal, and the test records are complete.

The cold state of each sequential control system needs to pass the graded acceptance.

1.4.20.2 Thermal acceptance

The primary components of each sequential control system work normally, the CRT display is correct, and there is no defect.

The thermal state actions of the actuators of each sequence control system are normal, and the status display is correct.

Each motor of each sequential control system rotates normally in thermal state, and the state display is correct.

All sequential control system control devices and logic thermal states work normally.

Each sequential control system, each sequential control subgroup, interlock and protection thermal state can be put into operation and work normally.

1.4.21 Operation and maintenance

The primary measuring elements, actuators, and solenoid valves used in each sequential control system need to be checked or fixed regularly after they are put into operation.

period adjustment.

After the cards used for the control of each sequence control system are put into operation, it is necessary to regularly check whether the work indicators of the cards are working properly.

often.

In the sequence control system, if the relevant interlocks are put into operation, switching tests need to be done periodically, and the tests should be carried out in strict accordance with the requirements.

Ensure that the interlock can work normally after it is put into operation.

The thermal equipment used in each sequential control system should be kept clean and free from leakage during operation.

Each sequential control system must deal with defects found during operation in a timely manner.

1.5 Risk Analysis and Pre-control

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1
Remove sundries from the platform channel, feet

160
 Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

12 Use of tools and utensils prone to fall 3 A safety rope should be configured so that

The tool with larger time should be protected

161
 The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery cover, set up the stove to protect against wind and remove

15 winter work 4
fall Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

162
 Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

When preparing the instrument, handle it with care

put. Take special care not to place the

The watch hit the building, and even fell to the ground

Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

Equipment damage, equipment on-site maintenance

transport

twenty one Disassemble the device Improper use of tools, causing personnel 4
Use qualified power tools,
harm
The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

163
 120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation If there is a little difference in the middle of the test

25
test middle protection failure Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

Improper use of ladders causing personal falls

27 Improper use of ladders hammer

fall damage
Ladders used must be strong,

164
 There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

165
 Chapter 8 Auxiliary Network and PLC Control System

1 Water network control system

1.1 Equipment overview and parameters

Programmable controller is also called programmable program control device, referred to as PLC. It is an electronic system for digital operations

system, is designed for use in industrial environments. It uses programmable memory to store execution logic in its internal

Instructions for operations such as logic operations, sequence control, timing, counting, and arithmetic operations, and through digital and analog input and output

out, control various types of production processes.

Our factory PLC control system adoptsXXSeries of products, including PLC mainframe with program control system, I/O module, network communication

Communication modules, power cabinets, switches, adapters, communication cables, optical cables and a full set of PLC hardware and software control equipment and related network

network device.

I/O module: Converts input loop signals to standby board-level signals or converts backplane signals to output loop-level signals.

Network communication module: Provides ports for I/O adapters with computers, other PLC processors, or other locations

communication between. In I/O racks remote from the processor, the communication module can provide a port for

The I/O module is connected to the processor in another location, divided into Ethernet card 1756-ENBT; CONTROLNET network card 1756-CNB

or 1756-CNBR (redundancy module).

1.2 Maintenance category and cycle

Maintenance category Class A Overhaul Class B Overhaul Class C Overhaul

Maintenance cycle 12-24 months 6-12 months 2-4 months

1.3 Maintenance items

project sequence Grade A Class B C grade

Maintenance item content

category No overhaul overhaul overhaul

Upper computer, PLC cabinet, rack, PLC module and cooling fan cleaning √ √ √
1.
overhaul

2. ground check √ √ √
3. Insulation inspection √ √ √
4. screen, self-check √ √ √
5. OS check √ √ √
6. Application software and integrity check √ √ √
7. Permission setting check √ √ √

166
 8. database check √ √ √
9. System software, data backup √ √ √
10 Check PLC backup battery √ √ √
11. Inspection of the wiring terminal block of each module √ √ √

Modules, connecting plugs, communication cable glands, splitters and splitters √ √ √

12.
wait to check

13. power-on check √ √ √

1. PLC system upgrade; △ △ △

Note: √: Items that should be carried out for maintenance; △: Items that can be determined according to specific needs (or part of the item)

overhaul)

1.4 Maintenance steps, process methods and quality standards

1.4.1 Visual inspection

1.4.1.1 The cables and wiring connections are reliable, without looseness or virtual connections.

1.4.1.2 The appearance of the control cabinet and the components inside the cabinet are neat and clean without damage.

1.4.1.3 Check that the door locks of the cabinets of each device are in good condition and there is no damage.

1.4.1.4 Check that the plugging of each cabinet and cable holes are well sealed.

1.4.1.5 Wiring in the cabinet: the cables are neatly arranged, the signs are complete, the wiring of the terminal block is standardized, and the numbers are clear.

1.4.1.6 Isolation relay inspection: the appearance is complete, the coil has no short circuit, open circuit phenomenon, and the node has no melting or arcing phenomenon.

1.4.1.7 Check that the lighting and exhaust in the cabinet are normal.

1.4.1.8 The nameplates of each cable are correct and there is no confusion.

1.4.2 Cleaning dust in the control cabinet

1.4.2.1 Preparations before maintenance: a) Back up the program and configuration of the lower computer on the upper computer first, and the backup data and content must be complete

all. B) Exit the lighting, fan, inspection socket and power supply of each power supply module. Check the electricity before working, and start after confirming that there is no electricity

Work.

1.4.2.2 Cleaning steps

167
a) Remove the template from the frame and put it away accordingly, clean each template, bottom plate and terminal strip; wipe the terminal strip with cotton cloth dipped in alcohol

Wash it clean to ensure it is clean and free of dust and traces. Use electronic cleaners to clean all modules and bottom plates.

b) Remove the fan assembly for cleaning and lubrication; the blades of the fan are clean and dust-free; the fan assembly rotates flexibly without jamming; the fan assembly

The components are installed securely, and all lead bolts, fixing screws, connectors, etc. are complete without looseness.

c) Use high-pressure argon gas to clean the terminal blocks and cables. For places that are difficult to clean, you can use Lexet cleaner, and then use

Wipe clean with cotton cloth;

d) After the work is finished, the control cabinet should be clean, the electrical components are complete and in good condition, and the writing on the cable signs should be accurate and clear

1.4.3 PLC controller maintenance

1.4.3.1 The PLC system is out of operation and the power is turned off.

1.4.3.2 Clean PLC cabinets, racks, PLC modules and cooling fans. After maintenance, the equipment should be clean and free of dust and stains. wind

The fan rotates normally, without jamming, and in the correct direction.

1.4.3.3 Check the PLC backup battery, if the battery is insufficient, replace it with a new one.

1.4.3.4 Check the fuse capacity of the channel with fuse, and it should meet the requirements. If the fuse is broken, find out the reason and replace it.

1.4.3.5 Unscrew the fixing screws of each module terminal block, pull out the terminal block, and check.

a) The wiring of each terminal block should be tight and neat, and the wiring numbers should be complete.

Looseness; all I/O terminals are fastened one by one without looseness, and the wiring is tidy and beautiful, with no exposed wires.

b) The electronic components in the PLC module should have no burn marks, no damage, no loose solder joints of components, no deformation or wear of pins;

Check the pins on the card installation base plate, correct the deformed pins, and replace the base plate with broken pins;

The bottom plate is firmly fixed, the pins are complete, and there is no deformation or breakage.

c) Check the communication cable joints of all PLC I/O cabinets and intermediate cabinets, separators and branches should be well connected, especially

The shielded wire inside the connector is firmly fixed.

d) Restore the system and check the circuit wiring and plug-ins of each I/O card. It is required that the plugs are not loose and the modules are not loose. check each

Setting switches (DIP switches) and jumpers are set correctly.

1.4.3.6 After checking the cable connection is correct, restore the power supply, the indicator of the power supply module should be normal, and the communication indicator of the PLC communication module should be normal.

Normal flashing; the communication indicator of the I/O cabinet communication module is normal, and confirm on the CRT that the communication of all PLC local cabinets is normal;

The working inspection indicator lights of each module should indicate normal and no alarm signal.

1.4.3.7 Check that the communication between stations and DCS is normal, and check that the communication between input and output modules and CPU is normal.

1.4.3.8 Check that the communication between the remote I/O subsystem and the controller is normal, and check that the communication between the host computer and the control station is normal.

1.4.4 PLC control module inspection and verification

1.4.4.1 Digital module inspection;

168
 The output circuit requires the reliable action of the output relay, the correct action of the equipment, and the correct status indication of the I/O module. Host computer display

is correct. The input circuit requires that each feedback is correct, and the indicator lights of the module indicate correctly. The upper computer and the lower computer equipment feedback can be one by one

Corresponding, accurate.

1.4.4.2 Analog module inspection

It is required that the analog input and output circuits are correct and reliable; the upper computer display corresponds to the input analog value, and the conversion error

Within the allowable range; the calibration report of each channel is complete and clear.

1.4.5 Host computer

1.4.5.1 Check that the inside and outside of the monitor and the main unit are clean and dust-free, and the brightness and chromaticity of the display screen are moderate.

1.4.5.2 Each screen should communicate with the lower computer normally. The status of the screen is consistent with the status of the field equipment, and the screen switching is normal.

1.4.5.3 The software systems of the upper computer and the lower computer are running normally. No crashes. All properties are displayed correctly.

1.4.5.4 There is no trace of damage on the appearance of each network device and upper computer, and the status is normal under static conditions.

1.4.6 Grounding and insulation inspection

1.4.6.1 Instruments, cables, and modules are well grounded, and the grounding resistance meets the requirements.

1.4.6.2 The equipment is well insulated and the insulation resistance meets the requirements.

1.4.6.3 Cabinet grounding: The cabinet grounding wires of each backplane of the PLC module are firmly connected and well grounded.

1.4.6.4 Power grounding: The grounding terminals on each power connector are well connected and reliable, and the grounding meets the requirements.

1.4.6.5 Insulation inspection: Check the insulation of cables and equipment to the ground, and the insulation resistance is greater than 10 megohms.

1.4.6.6 Control circuit and power circuit insulation inspection; use 500V megger to check insulation, control circuit and power circuit

The insulation resistance to ground should not be less than 2 megohm.

1.4.7 Power check

1.4.7.1 220VAC, 24VDC within the specified range

1.4.7.2 Each UPS power supply and working power supply should be cleaned with air or brush to ensure no dust accumulation.

1.4.7.3 Check whether the UPS of the power cabinet works normally; the power input and output work normally

1.4.7.4 Check each power switch; it works normally, and the fuse capacity is complete.

1.4.7.5 Insulation inspection of power cables; the insulation of power cables is in good condition, and the insulation resistance value shall not exceed 20 megohms.

1.4.7.6 Power supply quality inspection; the configuration of the fuse should meet the requirements, and the capacity of the shunt fuse should not be greater than that of the main fuse

capacity, check whether the incoming power supply of each channel is normal 180-220VAC; measure the voltage at all levels in turn to ensure that it is normal and meets the requirements

beg.

1.4.7.7 24VDC power supply inspection steps

a) Disconnect the power connector, untie the input and output of the 220V/24VDC transformer.

169
b) Measure the primary and secondary side resistance to meet the specification requirements.

c) Use a megohmmeter to measure the insulation between the primary and secondary transformers and the ground insulation should meet the requirements.

d) Restore the wiring and perform power-on test.

1.4.8 Relays

1.4.8.1 Relay maintenance

a) The dust removal of each relay and isolator should be clean and free of dust.

b) Check the contacts; the contacts should be wiped with a special cleaner or metallographic sandpaper, the contacts should have no burns and burrs, and the contacts should be in good condition

Good; the contact gap is roughly not less than 1mm. After reassembly, the contact resistance of the contacts is ≤0.1Ω.

c) coil inspection

d) The error between the measured value of the DC resistance of the relay coil and the manufacturer's standard value should be within the allowable value.

e) The insulation of the measuring coil should be above 10MΩ, the contact resistance of the contact point should be less than 0.4Ω, and the resistance of the measuring coil should be 48V relay.

About 3.25KΩ, 24V relay is about 0.68KΩ.

f) Action test; when the coil power is loaded according to the nameplate of the relay, the action of each contact point of the relay is accurate; the time relay, its

The action delay time should correspond to the scale of the relay.

g) Installation inspection; each installation fixing screw should be tightened without loosening.

1.4.9 Inspection of each cable in the backbone network

1.4.9.1 Check the main cable; the insulation is qualified, the connection is firm and fastened.

1.4.9.2 Check the communication cable; the insulation is qualified and the connection is correct.

1.4.9.3 Check the network splitter; the connection is correct and tight.

1.4.9.4 Check the RIO branch; the connection is correct and tight.

1.4.9.5 Check the RIO branch cable; the insulation is qualified and the connection is correct.

1.4.9.6 RIO backbone cable inspection; insulation is qualified, connection is firm and fastened.

1.4.9.7 Check the cable repeater; the status is normal, the function is complete, and the connection is correct.

1.4.9.8 Cable terminator check; connection is correct.

1.4.9.9 Network joint debugging; check whether the entire network communication is normal. Remote operation in the central program control room. Operation of remote equipment can be normal

Normal action, each screen display is consistent with the action of the field equipment.

1.5 Analysis and pre-control of dangerous points

1.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

170
1.5.2 The risk of cross-operating personnel in on-site work. During the maintenance period, personnel entering the site must dress according to safety regulations and pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

1.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

1.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

1.5.5 Health

1.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

1.5.5.2 Frostbite caused by cold in winter, heat stroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season

Two people must be supervised when carrying out work in bad times;

1.5.6 Environment

1.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage is sorted and stored in time after the overhaul is completed.

2 Gray net control system

1.1 Equipment overview and parameters

1.2 Maintenance category and cycle

1.3 Maintenance items

1.4 Maintenance steps, process methods and quality standards

1.5 Analysis and pre-control of dangerous points

3 Coal handling control system

1.1 Equipment overview and parameters

1.2 Maintenance category and cycle

1.3 Maintenance items

1.4 Maintenance steps, process methods and quality standards

1.5 Analysis and pre-control of dangerous points

4 Air Conditioning Control System

171
 Chapter 9 Other Thermal Control Systems

1 Inspection and maintenance process regulations for boiler flame monitoring system

1.1 Equipment overview and parameters

The boiler flame detection system is an important detection equipment to ensure the safe operation of the boiler. Our factory uses ABB company's programmable all

Font combustion monitoring system UVISOR. The flame detection unit is UVISOR MFD, UVISOR MFD is a kind of

Advanced dual amplifier flame signal detection smart unit on power plant boiler. It processes flame signals simultaneously through two probes,

Regardless of the range of the sensor spectrum (UV or IR) or the electrical type of signal (amplitude/FM signal or pulse rate signal).

It can accurately detect various fuel flames in multi-burner boilers, and can compare the flame of a certain burner with the background light source and other flames.

It distinguishes the flame of the burner, and at the same time can detect a stable signal of the ignition state. In various boiler loads and complex

Under complex working conditions, analyze the flame flicker spectrum through appropriate calculations, and adjust the parameters of the amplifier to obtain the best detection

Effect. The probe models are UR600 1000IR and UR600 2000IR/ER-A, a quartz lens is installed in the probe,

A PbS infrared sensing element and a signal conditioning/preamplifier printed circuit board. Terminals to control unit with screw

The way the nails are fastened.

1.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

1.3 Maintenance items

System sanitation:

Fire detection cabinet power inspection:

Fire detection cabinet grounding system inspection

On-site equipment maintenance of fire detection system

UVISOR MFD parameter check

1.4 Maintenance steps, process methods and quality standards

1.4.1 System sanitation:

Put the upper power switch of the fire detection cabinet in the "off" position, and hang the "someone is working, no closing" sign;

Put the power switch in the fire detection cabinet in the "off" position, and hang the signboard of "someone is working, it is forbidden to switch on";

Cabinet sanitation cleaning, filter cleaning;

The cabinet fan is cleaned, and the fan rotates normally without noise;

Sanitary cleaning and fastening of the cabinet terminal row;

Sanitary cleaning of system cards;

172
Fire detection cabinet power inspection:

;
The insulation of the power cable of the fire detection cabinet should be greater than 20MΩ.

Measure the power supply voltage and frequency of UPS and security section respectively, the voltage fluctuation is not more than 10%, the frequency is within the range of 50+0.5Hz, and

Make detailed records.

1.4.2 Check the grounding system of the fire detection cabinet:

Check the ground wire of the cabinet, the crimping is firm and there is no corrosion.

Measure the grounding resistance of the cabinet, the resistance value is less than 0.5Ω, and make detailed records.

1.4.3 On-site equipment maintenance of the flame detection system:

The flame detection probe should be cleaned hygienically, and there should be no dirt on the surface of the probe.

Clean the probe lens, the surface of the lens should be free of dirt.

The fire detection inspection hole is cleaned and inspected, and the compressed air is used for blowing to ensure that there is no blockage and dirt in the pipeline.

Check the probe cooling air duct, the duct should be smooth and free of dirt.

Check that the probe wiring is correct and there is no looseness.

1.4.4 UVISOR MFD parameter inspection:

After the UVISOR MFD is powered up, turn on the graphic display backlight and run diagnostic tests. When the diagnosis is passed, the screen will display

Basic information of the block, MFD model: D for dual channel, S for single channel, MFD tag name, firmware version number and ModDus section

Dot; after one minute, if there is no keypad operation, the MFD turns off the backlight and the graphic screen shows an overview of the flame status.

Press the "Enter" key when the MFD displays basic information, and the system will display "NAME" (the display range is AZ,0-9) ,use
Press down "arrow" key and the system will display "ID NODE" (display range is 1-40), "DAUD RATE" (display range

Circumference is 300, 600, 1200, 2400, 4800, 9600) ,"NETWORK AC CESS" (display range is ENADLED; DISADLED),
"ANALOG OUTPUTS" (display range is 0-10V; 4-20mA) , “OUTPUT RANGE” (the display range is 0/+20;
0/+30; -30/+30), "TEMP" (the display range is 0-500), "LANGUAGE" (the display range is ENGLISH;

ITALIAN; FRANCE; GREMAN; SPANISH; CHINESE), press the "Esc" key to exit.

1.4.5 Channel configuration check, when the MFD turns off the backlight one minute after power on and the graphic screen shows the general picture of the flame state,

Press the "Enter" key, the system will display "CHANNEL: 1"(Channel 1 configuration check), press the "Enter" key, the system displays

"CHANNEL: 1 SET 1", press the "Enter" key, the system enters the SET1 menu;

Second display "DG=" (background value, display range is 0-80dD, default setting +20dD), "PA=" (marginal alarm, fire

Flame signal critical value, the display range is 0-40 dD, the default setting is +5dD), "Dw=" (flame relay power-off delay, display

The display range is 1-5S, the default setting is 1S), "Up=" (flame relay power-on delay, the display range is 1-9S, the default setting

Set 0S), "LF=" (low cut frequency, display range is 20-640Hz, default setting is 125 Hz), "HF=" (high cut

In addition to the frequency, the display range is 30-2K5, the default setting is 1K1 Hz), press the "Esc" key to exit. Channel 2 configuration check

When the system displays "CHANNEL: 1", press the down "Arrow" key, and when the system displays "CHANNEL: 2", press "Enter"

key, the system displays "CHANNEL: 2 SET 1", and the rest of the steps are the same as above.

1.5 Analysis and pre-control of dangerous points

173
 Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

on scaffolding Possible shelf collapse or personnel
9 3 Careful inspection, especially for the first time

Operation come down

The application shall be fully inspected and accepted;

174
 It can be used only after it is received as qualified.

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery

15 winter work 4 cover, set up the stove to protect against wind and remove

fall
Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

175
 For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

Equipment damage, equipment on-site maintenance

When preparing the instrument, handle it with care

twenty one Disassemble the device Improper use of tools, causing personnel 4
put. Take special care not to place the
harm
The watch hit the building, and even fell to the ground

176
 Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

transport

Use qualified power tools,

The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

Equipment instrument protection test The protection test is out of control, causing the operation In the case of electric overspeed protection, the splitter

25
test middle protection failure The staff should be on site to monitor and test

177
 The content must be all correct.

If there is a little difference in the middle of the test

Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

178
 Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

2 Process regulations for furnace tube leakage inspection and repair

2.1 Equipment overview and parameters

The furnace tube leakage automatic alarm device consists of three parts: signal acquisition system, signal processing monitoring system and ash removal system.

The signal acquisition system is installed on the boiler body, including the acoustic wave sensor and the acoustic wave conduction tube. Acoustic wave conduction tube according to the "measuring point layout

The requirements of "Setting Plan" are distributed in the four tubes and the large casing area of the boiler. Each measuring point contains a sonic sensor and a sonic

Conduit, the sound wave sensor is fixed on the tail of the sound wave conduction pipe. The acoustic wave sensor converts the audio frequency signal in the furnace into a current signal,

Through the six-core signal cable, it is sent to the signal processing and monitoring system.

The signal processing and monitoring system is installed in the centralized control room or electronic room, and usually the signal processing and monitoring system is arranged in the monitoring cabinet.

Displays, industrial control mainframes, printers, dedicated power supplies for sensors, terminal blocks, etc. are arranged in the cabinet.

The ash removal system is arranged on the boiler, leading from the main gas source pipeline of the power plant, and controlling each branch pipeline through a solenoid valve.

The valve controls 4-7 measuring points.

2.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

2.3 Maintenance items

The overhaul of the furnace tube leakage monitoring system includes regular overhaul and the overhaul carried out by random group planned overhaul. The regular overhaul includes: each measuring point

Dust blocking inspection and cleaning. Random group planned maintenance items include: acoustic sensor calibration, control system inspection, solenoid valve insulation

Check transmission, acoustic wave conduction tube maintenance, etc.

2.4 Maintenance steps, process methods and quality standards

2.4.1 Sonic tube maintenance

2.4.1.1 The pipe fittings of the sound wave conduction pipe are tightly connected without looseness, and the surface of the conduction pipe is smooth and free of scars;

2.4.1.2 The sound wave conduction tube is firmly welded to the boiler, and the conduction tube has no inclination or direction change;

2.4.1.3 The inner wall of the acoustic wave conduction tube is smooth, without coking and dust accumulation;

2.4.2 Historical data backup

According to the operation status of the unit before shutdown, back up one-year historical data for future analysis. This backup can replace the previous

179
Backup overwrite.

2.4.3 Inspection of monitoring system

2.4.3.1 Arrange the wiring terminals of the cabinet tightly, with moderate attention to prevent damage to the wiring terminals;

2.4.3.2 The terminal sets are complete and the markings are clear;

2.4.3.3 Signal cable shielding inspection, the shielding wire is well grounded;

2.4.3.4 The cabinet is cleaned of dust, and the cabinet and all equipment components are free of dust;

2.4.3.5 Inspection of electronic equipment such as industrial computers, printers, etc., the appearance of the equipment is good, the power supply and network interface are intact and undamaged, the equipment

prepare dust;

2.4.3.6 Clean the dust of the industrial computer, open the shell of the industrial computer (personnel should take anti-static measures) and use a small brush to clean the dust inside the industrial computer

Dust, pay attention to the cleaning location away from other electronic equipment in the cabinet, to prevent dust from flying down and polluting other equipment, and the cleaning action should be light.

To prevent damage to the board, if necessary, use a precision cleaning agent to clean the slot of the board, and check that the fan of the industrial computer rotates flexibly.

Each board is fixed and fastened;

2.4.3.7 Check the cabinet fans for dust accumulation and jamming, and deal with any faults found to ensure that the fans are clean and rotate flexibly;

2.4.3.8 Insulation inspection of the power supply system of the monitoring system, disconnect the upper power supply, check the solenoid valve, cabinet lighting, fan

The fan power supply is weak and cannot be checked by this method) Check the insulation, use a 1000V megger to ground the insulation value should be greater than 50MΩ;

2.4.3.9 Measure the fuses of the terminal blocks of each signal channel, and check that the fuses are well connected;

2.4.4 Solenoid valve inspection

2.4.4.1 Check that the appearance of the solenoid valve is not damaged, and the solenoid valve is tightly sealed;

2.4.4.2 Check that the wiring of the intermediate junction box of the solenoid valve is tight, the markings are complete, the seal is tight and there is no dust, if the required

to repair and clean up;

2.4.4.3 Check that the solenoid valve is firmly installed and correct, the power cable and the solenoid valve interface are tightly sealed, the snake tube is tightly connected,

No damage;

2.4.4.4 The transmission test of the solenoid valve is flexible and the feedback is normal;

2.4.5 Acoustic Sensor Calibration

2.4.5.1 The furnace tube leakage monitoring system has been inspected and repaired, the cabinet has been powered on, and the industrial computer is running normally;

2.4.5.2 Two persons cooperate in the calibration of the acoustic wave sensor, and inform the operating personnel in advance (the sound and light alarm signal can be shielded according to the situation);

2.4.5.3 Remove the acoustic wave sensor at the boiler measuring point, add a signal with the calibrator, and contact the control room to check the real-time monitoring system

Bar graph, corresponding to the channel value, whether the alarm window is normal (including DCS system alarm);

2.4.5.4 One hour after the calibration of all measuring points is completed, check whether the historical trend curve of the monitoring system is consistent with the calibration records of this time.

Complete;

2.4.5.5 When calibrating the acoustic wave sensor, check and confirm whether the on-site mark corresponds to the measuring point on the display screen in the control room;

2.4.6 Purge solenoid valve test

2.4.6.1 After the compressed air is supplied to the purge compressed air system, manually operate the solenoid valve from the operation screen of the monitoring system.

Check whether the action of the solenoid valve is normal, and check whether there is any compressed air leakage in the purge pipeline of the measuring point controlled by the solenoid valve;

180
 2.4.6.2 Modify the regular purge time from the control program of the monitoring system, check whether the program control switch of the solenoid valve is normal,

Whether the magnetic valve feedback is normal;

2.5 Dangerous point analysis and pre-control

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

181
 Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Easy to frostbite, bruised hands and feet, slippery Winter should wear antifreeze clothes,
15 winter work 4
fall Wear a warm helmet and hands

182
 cover, set up the stove to protect against wind and remove

Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

twenty one Disassemble the device Equipment damage, equipment on-site maintenance 4 Put an end to brutal construction, dismantle equipment

183
 Improper use of tools, causing personnel When preparing the instrument, handle it with care

harm put. Take special care not to place the

The watch hit the building, and even fell to the ground

Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

transport

Use qualified power tools,

The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

twenty four Equipment investment Bad Personnel responsible for start-up

The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

184
 Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation If there is a little difference in the middle of the test

25
test middle protection failure Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

185
 The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

4 TDM maintenance process regulations

5 Boiler soot blowing maintenance process regulations

5.1 Equipment overview and parameters

5.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

5.3 Maintenance items

5.3.1 Check the appearance of the soot blowing system relay, there should be no overheating or burnout phenomenon, and the number of actions and use should be within the allowable range

Inside.

5.3.2 Check the correctness of each criterion signal of the soot blowing logic, and each logic, signal setting and delay time shall comply with the design or operation

line request.

5.3.3 Inspection of control and signal circuit requires that the circuit is correct, the wiring is firm, and the marking is clear.

5.3.4 Soot blowing system related control devices, power supply, electrical, signal circuit, pneumatic components, transmitters, logic switches, electrical

Solenoid valve, actuator.

5.3.5 The insulation resistance of each device, power supply, control and signal cables of the soot blowing system.

5.3.6 According to the requirements of operation and actual working conditions, modify the logic, fixed value, and set value, and make a backup; logic modification

The requirements are reasonable, and the fixed value and the modification of the set value must be correct.

5.4 Maintenance steps, process methods and quality standards

5.4.1 Maintenance items and quality requirements

5.4.1.1 Soot blowing system related control devices, power supply, electrical, signal circuit, pneumatic components, transmitters, logic switches,

186
Maintenance of solenoid valves and actuators.

5.4.1.2 The insulation resistance of each device, power supply, control and signal cables of the soot blowing system.

5.4.1.3 According to the requirements of operation and actual working conditions, modify the logic, fixed value and setting value, and make a backup;

The modification requirements are reasonable, and the fixed value and setting value modification must be correct.

5.4.1.4 To overhaul or replace faulty clamps, it is required that the clamps work normally and the indication status is normal.

5.4.1.5 Soot blowing system monomer, system test and test items are complete, and the tests and tests are normal.

5.4.1.6 Control device, card performance, redundant card, redundant power supply, analog signal channel, switch signal channel

Test after power on.

5.4.1.7 Testing of primary components, actuators, solenoid valves and pneumatic components used in the soot blowing system.

5.4.1.8 The action test of the relay should be reliable and free from jitter, and the contact resistance of the contacts should meet the requirements of the manufacturer.

5.4.1.9 Valve, baffle switch direction and time test: CRT sends instructions (forced signals can be used for conditional restrictions)

later) , the valve and baffle switch direction should be correct, and the valve and baffle switch status should be reliable and correct. After the CRT sends an open command,

The opening time of the valve or baffle is the time from the loss of the closed feedback signal of the valve or baffle to the appearance of the open feedback signal, and the reverse opening of the valve or baffle

The closing time of the valve or baffle plate from the loss of the feed signal to the closing feedback signal requires that the allowable time setting value of the switch in the logic be greater than

The test value (generally considered as greater than 2 to 5 seconds); the valve and baffle should be stable, flexible and free from jumping during the full stroke.

5.4.1.10 Solenoid valve switch test: The direction of the solenoid valve switch should be correct and the state of the valve switch should be reliable and normal.

indeed.

5.4.1.11 The state of starting and stopping of the motor should be consistent with the actual state of the motor, and the direction of rotation of the motor should be correct.

5.4.1.12 Send an analog signal at the signal input terminal to conduct an open-loop test on the sequential control system;

The running time and output status should meet the design requirements.

5.4.2 Thermal system test items and requirements

5.4.2.1 The maintenance and electrical maintenance work of each test system has been completed.

5.4.2.2 Each test system is ready for power transmission and has been powered on.

5.4.2.3 The air duct baffles, regulating baffles, electric actuators of valves, and motors of each test system have been tested individually.

grid.

5.4.2.4 The control device has been powered on and works normally after inspection, and the logic modification work is completed; the thermal control on-site equipment, primary components

It has been installed and put into use, and it is normal after inspection.

5.4.2.5 Test personnel have been put in place, and all test sheets are ready.

5.4.3 General requirements in the test

5.4.3.1 The test results should be consistent with the logic design.

5.4.3.2 During the test, each state, signal display, sound and light alarm, and print records should be consistent with the actual situation.

5.4.3.3 Analog and switch test signals should be sent from the site head end.

5.4.3.4 The mandatory signals in the test must be correct and the records should be complete.

5.4.2 Debugging test of single equipment

187
 Adjustment of electric isolation valve and drain valve: manually start the electric isolation valve, the local valve stroke should be in place, otherwise adjust.

Debugging of IR type sootblower: Move the hand sootblower to release the rear limit switch of the sootblower;

When the switch is turned to the "power on" position, the sootblower should move back immediately and stop automatically when it is in place; press the "Start" button to start blowing the soot

The device starts to move forward until the terminal limit switch acts (the terminal limit switch is artificially flipped or the "return" button is pressed in the process,

Sootblower is back), the sootblower moves back (whether it is automatic or manual) until the limit switch at the start end acts, and stops running.

Debugging of IK type sootblower: the process is the same as b)

5.4.3 Soot blowing program-controlled simulation test

Switch the operation switch to the simulation position, and put into the simulation test program;

The soot blowing procedure is simulated once for the air preheater, water wall, horizontal flue, tail flue, and air preheater. The sequence and status should be consistent with the design

The count is consistent.

Restore the system to the pre-test state

5.4.4 Soot blowing program-controlled interlock protection test

Soot blowing steam pressure low interlock: When the main steam supply valve is opened and the pipe warming is completed, the pressure signal of the main pipe of the soot blowing steam source is lower than the set value,

The light on the control panel should give an alarm, any working sootblower should automatically exit, and the program should be suspended until the steam pressure returns to normal.

Sootblower running overtime protection: When the sootblower advances and blows soot for more than the set time, the program-controlled device will make it retreat. If the backward timeout occurs,

Then the program will be automatically stopped and an alarm will be issued. After the alarm button is reset, the program can continue to run.

Sootblower overcurrent protection test: When the working current of the sootblower exceeds the rated current, the current relay should act and the control panel should beep

Light alarm, the sootblower should return automatically.

Sootblower overload protection test: When the overcurrent of the sootblower persists, the thermal relay should act, and the control panel will give an alarm.

Stop running, check the drive circuit, the power supply has been cut off, and the motor stops running.

5.4.5 Operation process and requirements

Turn on the power supply of the control device, soot blower and steam control valve for soot blowing, and the status of each equipment should display normal.

When soot blowing is put into operation, the boiler should operate normally, with stable combustion and no other major operations.

The sequence of soot blowing in the soot blowing system should be: air preheater—water wall—horizontal flue—tail flue—air preheater.

When blowing soot on the furnace body, it should be from bottom to top, according to the order of the first layer - the second layer - the third layer - the fourth layer - the fifth layer

Soot blowing should be carried out in sequence; between layers, the front and rear walls should be blown first, and then the walls on both sides should be blown; the flue should be soot blown pair by pair according to the flue gas flow direction.

Furnace soot blowing, horizontal flue soot blowing and tail flue soot blowing should be performed in pairs.

During the start-up and shutdown of the boiler, the air preheater should be put into continuous soot blowing, especially when the oil is fed for combustion, until the boiler is cut off for oil combustion.

5.5 Risk Analysis and Pre-control

Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Struck by falling objects, tripped over obstacles,
1 Operating Area 4 Concentrate on bypassing the work above

Walking slips or high pressure soda injuries

Area, Clearance Workplace Week

188
 Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

Careful inspection, especially for the first time

The application shall be fully inspected and accepted;

on scaffolding Possible shelf collapse or personnel

9 3 It can be used only after it is received as qualified.

Operation come down

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

10 Up and down scaffolding prone to fall 3 The upper and lower scaffolding should follow the ramp

189
 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery cover, set up the stove to protect against wind and remove

15 winter work 4
fall Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3
When the law is staggered, the parties shall agree

safety precautions, if necessary

190
 Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

When preparing the instrument, handle it with care

put. Take special care not to place the

Equipment damage, equipment on-site maintenance The watch hit the building, and even fell to the ground

twenty one Disassemble the device Improper use of tools, causing personnel 4 Electric overspeed tachometer, spring tube

harm pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

transport

191
 Use qualified power tools,

The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

In the case of electric overspeed protection, the splitter

The staff should be on site to monitor and test

The content must be all correct.

Equipment instrument protection test The protection test is out of control, causing the operation

25 If there is a little difference in the middle of the test

test middle protection failure

Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

192
 Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

193
6 Air preheater gap adjustment and maintenance process regulations

6.1 Equipment overview and parameters

This preheater gap control system is based on a new control system of PLC and industrial control computer (integrated workstation). Department

The system uses the highly reliable, convenient and flexible PLC as the main control component, which simplifies the system structure, improves the reliability and reduces the system cost.

System maintenance workload. The system is based on an industrial control computer with friendly man-machine interface, strong real-time performance, high reliability and convenient operation.

To monitor the status of the PLC system, the computer and the PLC are connected through the RS-232 serial communication line. At the same time, the system also improves

The installation form of the probe is improved, the sealing measures are added, the outlet method is optimized, and the problem that the lead wire of the probe is easily broken is overcome.

The output signal of the transmitter is changed from the original single 0-10mA to 0-10mA, 4-20mA can be set freely, which is convenient for users to use

use.
This system is a clearance control system for a three-chamber Junkers type air preheater, and this air preheater needs to be installed with 6 clearance sensors.

6.2 Maintenance category and cycle

Class A maintenance: once every 4 years;

B-level inspection: arranged in the third year of A-level inspection.

Class C Inspection: Scheduled once a year.

D-level maintenance: arranged according to equipment condition

The combination mode within the A-level maintenance interval is: A(D)-C(D)-B(D)-C(D)-A(D).

6.3 Maintenance items

In-situ probe inspection

Signal Transmitter Inspection

Air preheater gap measurement device inspection and calibration

6.4 Maintenance steps, process methods and quality standards

6.4.1 Inspection of air preheater clearance measuring device:

6.4.2 In-situ probe inspection:

The installation position of the probe should ensure that the bottom surface of the probe is 1-2mm higher than the bottom surface of the fan-shaped plate, and it should be installed horizontally;

The surface of the probe is free from wear and the lead wires are well insulated;

Probe cooling air supply is normal;

6.4.3 Signal transmitter inspection:

The wiring between the signal transmitter and the probe is firm and correct;

The output signal of the signal transmitter is correct and the wiring is firm;

6.4.4 Inspection and calibration of air preheater clearance measuring device:

Lower the fan-shaped plate, the gap between the local probe and the measured surface is 1mm, and adjust the output of the signal transmitter to 5.6mA;

Lift the fan-shaped plate, the gap between the local probe and the measured surface is 10mm, and adjust the output of the signal transmitter to 20mA;

Lift or lower the fan-shaped plate, the gap between the local probe and the measured surface is 5mm, and check that the output signal of the transmitter is about 12mA;

6.5 Analysis and pre-control of dangerous points

194
 Risk control techniques to be adopted

serial number danger point hazard description risk level

technical measures

Wear safety helmet correctly

Concentrate on bypassing the work above

Struck by falling objects, tripped over obstacles,

1 Operating Area 4 Area, Clearance Workplace Week
Walking slips or high pressure soda injuries
Garbage and sundries in the surrounding and passageways

things.

Possibility of falling into potholes Concentrate on walking

2 Potholes and other areas 3
and other events Do not cross the fence.

Do not touch the power switch at will

3 Charged area possible electric shock 2

Closed boxes, distribution cabinets, etc.

Concentrate while walking, clear

4 walk on heights tripping, falling 1 Remove sundries from the platform channel, feet

Hand tube.

must be equipped with adequate pro-

Operate at night or in poor light After temporary or permanent lighting

5 Working in low light Industry prone to falls and other hazards 2 Only then can the work be carried out, and in the construction

event Work station with a certain number of should

emergency lighting.

It is strictly forbidden to assign patients with unsuitable high

unexamined high Persons suffering from occupational illness

6 Accidents such as falling and fainting may occur 3

null work at high altitude

Must be medically qualified.

Must be fastened before work

Not wearing a seat belt or The safety belt can only be used for work;

7 Leading to the fall incident and the expansion of its consequences 2

Incorrect hook It is strictly forbidden to hang low and use high, when hanging

It should be hung in a firm and reliable place.

Comfortable clothing, sleeves, trousers

Workers don't dress

8 prone to falls, trips, etc. 3 Shall be fastened; fasten the buttons,
correct
Do not open.

Before use, carefully clean the shelf

on scaffolding Possible shelf collapse or personnel
9 3 Careful inspection, especially for the first time

Operation come down

The application shall be fully inspected and accepted;

195
 It can be used only after it is received as qualified.

When in use, the seat belt should be hung on the

Other secure places; regular inspection

Check, it is strictly forbidden to disassemble the shelves at will

The upper and lower scaffolding should follow the ramp

10 Up and down scaffolding prone to fall 3 and ladders, not along scaffolding

Pole and Structural Pole Climbing.

When passing, throwing is strictly prohibited;

11 transfer tool, item prone to falling objects 3 Use a tool bag or twine for

business transfer tool.

All tools for working at heights are

A safety rope should be configured so that

The tool with larger time should be protected

12 Use of tools and utensils prone to fall 3

The dangerous rope is hung on a firm place, the smaller

tool to wrap the safety rope around the

hand.

Do not sit during breaks between assignments

Platforms, holes back to edge, no

have to sit on the railing, not

13 break between homework fall, injury 3
lie down on the aisle for a rest or a long

Time stands in front of the gag, the law

Lan side.

When using power tools you must

when using power tools Wear protective glasses, insulated hands

not wearing protective glasses, Prone to electric shock and debris damage to the eyes sets, electric tools should be delivered regularly

14 1
insulating gloves; electric eye accident Check to ensure that the power cord, electric

Tools are inspected irregularly The tool is in good condition, the leakage protection is on

The closing action is normal.

Winter should wear antifreeze clothes,

Wear a warm helmet and hands

Easy to frostbite, bruised hands and feet, slippery

15 winter work 4 cover, set up the stove to protect against wind and remove

fall
Warm special facilities, early shifts are cleared first

Handle frost and snow on the construction site

196
 For slippery objects, soft-soled cotton shoes should be worn.

Each operator should try to stagger

Vertical cross work; none

16 Intersection operation prone to falling objects 3 When the law is staggered, the parties shall agree

safety precautions, if necessary

Interlayer isolation facilities should be erected.

Any dismantling or modification is strictly prohibited;

When dismantling or modification is necessary, the

Any dismantling or modification Go through the application procedures first, as required

17 hole covers, railings, prone to falls 2 Ask for remedial safety measures

Safety Net Safety Facilities After that, it can be removed or modified.

After the work is over, restore the

complex.

Open the work ticket when doing homework, close

Close the controller once and open the door

Water leakage and steam from high-pressure equipment cause death Blowdown door, make sure the equipment is not pressurized

18 scald 1
burns Working after no steam. homework end

After finishing, make sure the equipment is in normal operation

after leaving

Check with operators for accuracy

19 Wrong interval Accidents caused by malfunctioning equipment 1 Defective equipment, job adaptation

2 people or more

Stop working equipment before working

The power supply, the electric test confirms that there is no electricity

After that, you can work, and do a good job of belt

Cut the wrong power supply, static electricity, induction electricity,

20 electric shock injury 1 Capacitor device discharge operation, Pro

Electric shock accident caused by direct current

nearby equipment is live or may have

Work on live equipment should be

good guardian

Put an end to brutal construction, dismantle equipment

Equipment damage, equipment on-site maintenance

When preparing the instrument, handle it with care

twenty one Disassemble the device Improper use of tools, causing personnel 4
put. Take special care not to place the
harm
The watch hit the building, and even fell to the ground

197
 Electric overspeed tachometer, spring tube

pressure gauges, pressure transmitters,

and the indicator is not allowed to use the car

Propel. At the same time, it is not allowed to stack and move

transport

Use qualified power tools,

The staff must be able to use the appropriate

of electric tools.

When using electric tools, it must be connected

Electric shock protector. well connected

wire, use a hand electric drill, electric sand

Always wear protective glasses.

When overhauling equipment and meters, do not

Pressurization exceeds the amount of instrumentation equipment

120% of the range prevents the device from

Injury due to overpressure leakage of the instrument.

The equipment must be reinstalled by two people

superior

twenty two Reinstallation of equipment and instruments

The wiring of the equipment is reinstalled, causing electric shock

Before wiring, you must first check the electricity, make sure

Wiring after confirming no electricity

During the power transmission experiment of equipment and meters, the Each device should be connected separately during power transmission

power transmission, induction or equipment and Power transmission test, to determine whether the power supply

twenty three Equipment instrument debugging

instrument damage Wiring equipment can be adjusted only after the error

trial work

There are problems in the installation of equipment and meters on site Reinstalled equipment and instrumentation test completed

problem, affecting the operation and start-up of the unit Bi, to open the door once or twice,

Meter and standard instrument adjustment medium loss Send power to put it in

Bad Personnel responsible for start-up

twenty four Equipment investment
The water pressure will damage the equipment instrument or injure In the field, exclude all kinds of

people Problems with equipment and meters

Rational Test Standard Apparatus

Strictly follow the adjustment steps

Equipment instrument protection test The protection test is out of control, causing the operation In the case of electric overspeed protection, the splitter

25
test middle protection failure The staff should be on site to monitor and test

198
 The content must be all correct.

If there is a little difference in the middle of the test

Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

199
Translated from Chinese (Simplified) to English - www.onlinedoctranslator.com

The content must be all correct.

If there is a little difference in the middle of the test

Yes, do it again

After the test is completed, put into operation,

to be accounted for on the operating account

Clear, run acceptance sign off

Did not distinguish which unit equipment Two or more people must work together

to start working resulting in normal operation do

26 Wrong interval
unit failure Identify the equipment before starting work,

make sure

Electricity is not allowed on ladders

hammer

Improper use of ladders causing personal falls

27 Improper use of ladders Ladders used must be strong,

fall damage
There are escalators and special supervisors

fasten your seat belt

Before using electric tools, you must check the

Check that the power tools are qualified and easy to use

Improper use of power tools Power tools must be connected to leakage

28 power tool use

injury security device

When using a pistol electric drill or electric grinding wheel

wear protective glasses

Must start fire work ticket must

The fire ticket must be activated, and the staff should cooperate

29 Welded pipeline Welded pipes cause burns or fire Wear gloves and be prepared to fight the fire

Equipment, set up guardians, workers

Clear the tinder after the work is over

Strictly implement the instrument inspection standard

Unqualified equipment and meters cause operation Accurate, no missing items, strictly enforced

30 Unqualified equipment and meters

wrong operation Three-level acceptance system, no witnesses

not allowed to check

The timing of the calibration meter, the wiring is wrong

The timing of the calibration table must be connected

31 calibration meter errors, resulting in standard instruments and gauges

Good power and signal lines

damage

199
 Avoid crossing up and down as much as possible

homework, what must be done

Falling objects from a height, causing personal blows

32 falling objects Good protective measures, climbing work

harm
Time tools should be fixed with rope

confirm.

200
 Chapter 10 Valve Actuator

1 SIPOS 5 Electric Actuator Maintenance Regulations

1.1 Equipment overview and parameters

1.1.1 Classification of SIPOS 5 Flash series electric actuators: SIPOS 5 Flash actuators have professional type (regulating

Type) and economical (switch type) two categories.

1.1.2 Main technical and performance characteristics of SIPOS 5 Flash series variable frequency intelligent electric actuator:

1.1.2.1 The advanced and mature frequency conversion speed regulation technology is applied to the electric actuator, and the integrated frequency conversion is integrated inside it.

It can not only control the steering of the motor, but also realize the optimal control of the motor, without the need for an external motor control box.

1.1.2.2 The built-in integrated CPU and frequency converter control the steering of the motor, which is an electronic non-contact commutation.

1.1.2.3 Using large-scale and ultra-large-scale integrated circuit electronic devices to replace and realize traditional actuators only through mechanical

Functions that can only be realized by components. Therefore, on the one hand, the degree of intelligence is greatly improved (each SIPOS 5 Flash

with CPU); on the other hand, its mechanical structure is also simplified, the reliability is improved, the mechanical wear is minimal, and the maintenance amount is very small.

1.1.2.4 SIPOS 5 Flash can precisely detect its location through the signal unit and the precision plastic potentiometer. one

Once the limit position is reached, the CPU controls the frequency converter to cut off the motor power supply immediately, thereby realizing limit protection.

1.1.2.5 By detecting the current and voltage supplied by the inverter to the motor, the actual working torque can be accurately measured.

The pre-set cut-off torque, the CPU controls the frequency converter to cut off the motor power supply immediately, thus realizing over-torque protection. CPU can

Automatically store over-torque records and output alarm signals to the control system (passive dry contact signals are optional) .

1.1.2.6 The closing direction of SIPOS 5 Flash can be freely set by programming. Can automatically correct the phase sequence of the power supply, so

There is no need to consider the phase sequence of the power supply when wiring, which simplifies the installation process.

1.1.2.7 It can be parameterized and debugged in three ways, and fault self-diagnosis can be realized: a. Through the local operation panel

board; b. SIPOS 5 Flash has a standard RS232 serial communication interface, which can provide special debugging software (COM

— SIPOS), PC and SIPOS 5 Flash can realize two-way communication, so that it can be parameterized,

Debugging and fault self-diagnosis; c. For the control system using fieldbus technology and the actuator with fieldbus interface, it can

It is carried out remotely through the operating station of the control system.

1.1.2.8 For the same SIPOS 5 Flash, its cut-off torque and output shaft speed can be in a wide range (respectively

30%~100% and 1:8) are set by the user. Therefore, when designing and selecting models, only one model is required for multiple actuators.

1.1.2.9 SIPOS 5 Flash PROFITION: The same actuator can automatically run at different speeds set in advance

— Opening speed, closing speed, starting speed, speed close to limit position and opening and closing speed in case of emergency, from

To realize the optimization of the control process.

201
1.1.2.10 Separate installation: If the site installation space is not enough, the site temperature is too high, the site vibration is too large or the installation site is inconvenient

For debugging, the intelligent control unit of the frequency converter and the mechanical part can be installed separately. It can solve the above problems without affecting the

performance of the actuator.

1.1.2.11 Most SIPOS 5 Flash can choose single-phase power supply or three-phase power supply;

It adopts single-phase power supply or three-phase power supply, and its motors are all high-quality three-phase motors. Due to the built-in integrated frequency converter, therefore,

The fluctuation of supply voltage within ±15% will not have any influence on its performance and control accuracy.

1.1.2.12 An integrated radio frequency interference filter is integrated inside the actuator to prevent possible interference to the power supply caused by the frequency converter.

Interference and possible power supply interference to the frequency converter are bidirectionally isolated to ensure safe use.

1.1.2.13 The transmission part is injected with long-term lubricating oil, which can run for a long time without maintenance. Maintenance only needs to be done every 8 years.

1.1.2.14 With comprehensive motor protection functions, no additional motor protection device is required. SIPOS 5 Flash was never and never will be

Now burning motor phenomenon. The temperature sensor in the motor winding continuously detects the actual working temperature of the motor, which can realize over-temperature alarm and

Overheat protection function.

1.1.2.15 It has automatic phase correction function and protection functions such as phase failure, undervoltage, overvoltage, overcurrent and instantaneous reverse.

1.1.2.16 While supplying power to the system, its internal regulated power supply can provide 24V DC power. If you choose an external supply of 24V DC,

Then even if the AC power is cut off, the control unit can still maintain communication with the outside world.

1.1.2.17 The intelligent control unit consists of two standard circuit boards: the power board with frequency converter and the control board with microprocessor

plate. In case of failure, it is fast and easy to replace spare parts; and the two boards are highly versatile.

1.1.2.18 PROFITRON’s unique optional function: the whole stroke can be divided into 10 segments at most, and each segment can be divided into

Run at different speeds to improve the linearity of the valve and optimize the control process.

1.1.2.19 PROFITRON unique standard function: with an "emergency" digital input signal, and the highest level of response. one

Once the control signal is valid, SIPOS 5 Flash will reach the pre-set "emergency speed" at the pre-set "emergency speed".

"emergency position" and then stop.

1.1.2.20 Measure and record the torque curve function. Similar to measuring human body ECG, SIPOS 5 Flash can measure and

Store torque curves for 3 groups of valves. The torque curve of the valve can be measured at any time and compared with the normal torque curve, from

It can judge the degree of wear of the valve, and then make a maintenance plan to avoid losses caused by unexpected shutdowns.

1.1.2.21 It can automatically detect whether the 4-20mA analog control signal circuit is broken or whether the process control is faulty. In case of open circuit

or failure, it can not only maintain the original position, but also run to the set "emergency position".

1.1.2.22 Powerful fault self-diagnosis function, the internal microprocessor continuously collects various information of SIPOS 5 Flash, which can

Continuously monitor the state of the actuator, and send out various alarms and fault information through self-diagnosis, which is convenient for users to deal with in time and quickly

Fault.

202
1.1.2.23 The following main faults can be self-diagnosed: external fault of the actuator—0/4~20mA input signal fault, switch

Quantity input signal failure, position feedback signal failure, power supply failure, overvoltage, undervoltage, PROFIBUS communication failure;

Internal failure of the actuator—inverter temperature is too high, inverter overcurrent, inverter fault, motor temperature is too high, potentiometer

Cable disconnection, cable disconnection of motor temperature detection circuit, RAM failure, EEPROM failure, DualPortRAM failure, see

Door dog failure, power failure; running failure - the actuator has run beyond the limit position, is stuck during operation, is being used

The hand wheel (handle) operates the actuator, and local operation is prohibited; debugging failure - incorrect debugging, invalid end position setting,

Communication via PROFIBUS bus.

1.1.2.24 The switching times, switching frequency, torque cut-off times, travel cut-off times, motor running time, control unit

All important operating data such as unit working time and operating frequency are monitored, stored and accumulated. If the fatigue of the motor can be

The running time of the meter and the switching times of the motor are automatically recorded, even if the actuator is powered off, it will not be lost. Therefore, when executing

During the entire service life of the mechanism, the user can know the use status of the actuator well. If the user can pass the actuator

The cumulative running time of the motor is used to set the maintenance cycle of the valve. In this way, SIPOS 5 Flash can automatically remind the user how long it should be

When and when to overhaul and maintain the valve.

1.1.2.25 Debugging is extremely simple. Open the valve to the open limit position by operating the button locally, and then close to the close limit position.

The internal microprocessor can identify and store these two limit positions through the setting of the plastic conduction potentiometer. So far, the debugging work

The operation is completed; that is, as long as the fully open and fully closed positions are found and recorded, the debugging work can be completed.

1.1.2.26 The outer box of SIPOS 5 Flash is made of special aluminum alloy (SILAFONT36), which is lighter in weight and stronger than aluminum.

Higher than cast iron, excellent corrosion resistance. The screws used on the outside are made of stainless steel. Can be installed in the factory without painting

environment. Even if there are scratches on the surface of the protective paint, it will not lead to serious crevice corrosion phenomena.

1.2 Maintenance category and cycle

1.2 Operation and maintenance standards

1.2.1 Inspection and acceptance before commissioning

1.2.1.1 The visual inspection meets the quality requirements;

1.2.1.2 The number plate of the measurement circuit wiring is clear and complete, the wiring is correct and beautiful, and the wiring is not loosened by lightly pulling the wiring by hand.

the mouth is blocked;

1.2.1.3 The on-site equipment is clearly and correctly listed;

1.2.1.2 The calibration records before and after the instrument maintenance are complete and standardized, and the data is correct;

1.2.1.5 The original working circuit has been restored, turn on the power switch inside the panel, turn on the power switch of the instrument, the valve position display and the actual valve

bits match.

1.2.2 Maintenance

203
1.2.2.1 The appearance of the actuator should be intact, unobstructed within the stroke range, and the direction of the switch should be clearly marked; the nameplate and mark

The brand is intact, correct, and clearly written; and check the operating environment around the actuator, and pay attention to whether the temperature, vibration, etc. are abnormal.

1.2.2.2 Each movable part should be flexible and reliable, and there should be no shaking at the mechanical connection;

1.2.2.3 Local control selector switch, button and indicator light inspection. The selection switch is flexible, and the light bulb in the indicator light is completely

it is good

1.2.2.4 The fastening screws of the mechanical limit block shall not be loose, and the braking device shall be sensitive and reliable;

1.2.2.5 The bearings on the output shaft, the screw rod of the hand-operated mechanism, the bearings on the switching shaft and the slider, etc., every three months to half a year

Lubricating oil should be added once;

1.2.2.6 Before and after manual operation, the automatic and manual positions of the switching handle shall be switched;

1.2.2.7 Carry out regular patrol inspections, find equipment defects and deal with them in a timely manner, and make a record of defect handling;

1.2.2.8 Cleaning should be done once a month to keep the instruments and accessories clean and intact, with correct, clear and complete marks.

1.2.2.9 Deactivation

a) Turn off the instrument power switch, and turn off the power switch in the power panel;

b) For maintenance during operation, first close the front and rear isolation valves;

c) When the wiring needs to be removed for maintenance during operation, it should be marked and bandaged.

1.3 Maintenance items, steps, process methods and quality requirements

1.3.1 The appearance of the actuator should be intact, unobstructed within the travel range, and the direction of the switch should be clearly marked; the nameplate and sign

The brand is intact, correct, and clearly written; and check the operating environment around the actuator, and pay attention to whether the temperature, vibration, etc. are abnormal.

1.3.2 Regularly check that the movable parts should be flexible and reliable, and there should be no shaking at the mechanical connection.

1.3.3 The switch between manual and electric is flexible; when the hand is cranked, the handle feels even when the force is applied, and the connecting rod or transmission mechanism moves smoothly and smoothly.

no stuck;

1.3.4 The stroke of the actuator should ensure the full movement of the valve and the retainer, and meet the requirements of the system control; in general,

The full rotation angle of the output shaft of the corner actuator should be adjusted to 0°〜90°, and the variation is generally not more than 5°;

1.3.5 Open or close the actuator and observe whether there is any abnormal phenomenon.

1.3.6 The wiring is firm and not loose, and the connection between the plug and the socket is reliable,

1.3.7 Motor power control reversing contactor inspection, contactor control coil resistance is normal, good contact when closed, no buzzing

hum.

1.3.8 Inspection of the power supply board that provides power to internal equipment; the surface of the circuit board is clean and free of burns.

1.3.9 Inspection of the interface board: The surface of the circuit board is clean without burning.

1.3.10 Logic board inspection: The surface of the circuit board is clean without burning.

204
1.3.11 Check local control selector switches, buttons and indicator lights. The selection switch is flexible, and the light bulb in the indicator light is in good condition

1.3.12 Check the action value of the limit switch. Check whether the limit switch operates correctly in the open and closed positions required by the valve, and the valve

Cut off the motor in time after the door is in place. The closing position of the valve is more important. According to the requirements of the place where the valve is used, it should be closed as much as possible.

Reduce the margin of the closing position to reduce the leakage flow of the valve.

1.3.13 Check the action of the torque switch

1.3.14 Inspection of manual operation and electric operation

1.3.15 Inspection and adjustment of electric stroke and feedback signal

1.3.16 Remote electric operation (soft operation) and stroke and feedback signal inspection

1.3.17 Fuse board inspection with relays for control fuses; fuses are intact and not burned.

1.3.18 Leakage inspection of sealing ring.

1.3.19 During manual operation, the handwheel cannot be turned forcibly by adding a sleeve or inserting a stick.

1.3.20 The control hardware is DCS system, you can check all fault prompts on the CRT information window

1.3.21 In general, it is not necessary to carry out dismantling and maintenance. When dismantling and maintenance must be carried out, the relevant

stipulated.

1.4 Commissioning and trial operation

1.4.1 Economic type:

1.4.1.1 Setting parameters and commissioning

1.4.1.2 There is high voltage inside the actuator. When commissioning, remove the control panel of the control unit. avoid using fingers

Touch the printed lines or components on the circuit board, and prevent the printed lines or components on the circuit board from contacting with metal objects;

1.4.1.4 If the shut-off mode at the selected end position is not suitable for the valve, damage to the valve may result.

Harmful! ;

1.4.1.4 CMOS semiconductor components which are highly sensitive to static electricity are installed on the printed circuit board. Avoid touching printed circuits with fingers

Electronic components or printed lines on the board, preventing electronic components or printed lines on the printed circuit board from contacting metal objects.

When connecting, only a screwdriver with an insulated handle is allowed to touch the screw terminals.

1.4.1.5 Commissioning work:

a) The actuator is installed correctly.

b) All fixing screws, connectors and electrical connections are tightened.

c) Earthing and equipotential bonding are properly implemented.

d) The electrical connections are correct.

e) All measures are taken to prevent fingers from touching moving or moving parts.

205
f) Electric actuators and valves are intact.

g) The ambient temperature is within the allowable working range of the electric actuator (the heat transferred from the controlled object must be

effects are taken into account).

h) Adjust the ratio of the signal gear unit:

i) Remove the cover from the signal gear unit.

j) Determine the number of revolutions, travel distance (mm) or angle for full actuator travel. That is, to include the entire

The number of revolutions (or travel distance or angle) necessary to position the travel output shaft .

k) The number of rotations and stroke distance of the full upward round stroke (mm) , angle to the closest setting value of the next gear

(Refer to the table below for the setting value, for example, if the number of rotations in the full stroke is 30, it should be set to 36).

l) Adjust the sliding wheel (part B1) through the locking mechanism until its gear edge and one of the gears marked on the housing

values are aligned. (The 4 fixing screws of the signal gear unit can be loosened if necessary, and the signal gear unit can be taken out

Yuan, reinstall after adjustment).

m) Fit the cover of the signal gear unit.

n) Adjustment of output speed, closing torque, closing direction, closing mode, output signal and control mode (must be

Turn the DIP switch S8 to ON, and then to OFF, the system will recognize the new setting):

o) Set the output speed and closing torque with the potentiometer:

p) Output speed: 7 different speed values for selection - see the table below, the range of options depends on the model (also available

from nameplate)

q) Break-off torque in direction CLOSE: 30% - 100% max. torque for standard type; 70% - 100% max. torque/

Maximum thrust applies to modulating models.

r) Closing torque in opening direction: 30% of maximum torque; 70% of maximum torque/maximum thrust.

s) Use the DIP switch to set the closing direction, shut-off mode and control mode:

t) S1: Set the action direction of the valve. When it is in the ON position, the closing direction is counterclockwise; when it is in the OFF position, the closing direction is clockwise.

hour hand.

S2: Set the shut-off mode at the close position. When it is in the 0N position, it is the stroke shut-off mode; when it is in the OFF position, it is the torque shut-off mode.

Mode.

S3: Set the open position shut-off mode. When it is in the ON position, it is the stroke shut-off mode; when it is in the OFF position, it is the torque shut-off mode.

Mode.

S4, S5: Set the form of the output feedback contact.

S6: Set whether the control command is a long signal or a short signal (that is, whether it has self-holding or not).

206
S7: Confirm when setting the switch position. When it reaches the on or off position, turn it to the 0N position and then turn it back

OFF position to confirm.

S8: The valve debugging setting is set when it is ON, and it is set when it is turned OFF.

1.4.1.6 Precautions:

a) When starting to adjust the stroke limit of the actuator, the valve must not be in a tight state, and if necessary, use

The handle or handwheel releases the valve.

b) When the end position cut-off mode is set to torque cut-off mode, the operation of the actuator must be driven by electric means

(via the buttons on the local operation panel or the control commands from the remote end).

c) Adjustment of the mechanical position indicator:

1) Run the actuator to the fully closed position.

2) Rotate the white disc G until the red mark is aligned with the arrow on the side of the observation window on the cover.

3) Run the actuator to the fully open position.

4) Keep the white disc still, turn the transparent disc H until the green mark and the arrow next to the observation window on the cover are aligned.

together.

1.4.2 Professional type:

1.4.2.1 Commissioning of the actuator:

a) "Local/Remote" key to select locPar mode, then press "ENTER" key to confirm. Press ↑ and ↓ to select

commissioning and press "ENTER" to confirm. Display enter PIN-code, enter code 9044 after confirmation,

The first parameter (close direction) is displayed on the panel. During this process, in locPar mode,

The remote control is prohibited, and only under locPar can the parameter settings related to debugging be changed.

b) Set parameters related to the valve:

c) After inputting the code and confirming, you can continuously check and change the parameters and their setting values. The ↑ and ↓ keys are used to

Switch between numbers;

d) After pressing the ENTER key under a certain parameter, the parameter value becomes flashing, and you can use the ↑ and ↓ keys to select a new value.

After pressing the ENTER key again, the parameter value will no longer flash, indicating that the new parameter value has been confirmed.

and stored in EEPROM;

e) In the Commissioning menu, the commonly used parameters are as follows:

Close direction ( close direction ): optional clockwise ( clockwise ) , counterclockwise

(anti-clockwise) ;

Cut-off mode cl. for the closed end position and cut-off mode for the open end position (cut-off

207
mode op.): Travel-dependent and torque-off modes can be selected

(torque-dependent);

Closing torque (max.cl.torque) and opening torque (max.op.torque): select the torque in Nm, directly

The stroke parameter is (cut-off forced);

f) Adjust the end position (endpos.adjust)

g) Adjust the stroke limit of the actuator (ie: end position adjustment)

h) Notes before adjustment:

Adjustments can only be made in situ;

The valve must not be under tension until the travel limit is adjusted, if necessary, by the handle

release the valve;

In order to adjust the signal gear unit, remove the cover of the gear unit;

i) The adjustment method of the center wheel of the signal gear unit is as follows: grasp the part D (Fig. 2) of the signal gear unit by hand,

Turn part E (Fig. 2);

j) To cancel the end position adjustment, press the ↑ and ↓ keys simultaneously and press the ENTER key to confirm the subsequent check end-pos.!

information;

k) When the parameter setting of the closing mode or closing direction is changed, the setting of the end position must be re-set.

After setting the cut-off torque value, it is recommended to reset the end position;

l) Enter the endpos.adjust parameter to adjust the end position of the actuator, and select the end position to be set first

(start with pos.) is open (OPEN) or closed (CLOSE) ;Select first with the first end position and

Take the travel cut-off mode as an example:

m) Set the end position (start with pos.) to be set first as OPEN, and press ENTER;

n) Displayed as move to op.pos. (running to the fully open position), press the button to make the actuator run towards the open end position

(Short-term pressing is jogging, and the actuator will continue to run after the key is released for more than 2 seconds) , which displays

%open→open (%open→full open) , combined with the actual position of the valve, determine the open end position, close to full open

position, press the STOP key (ie ENTER key), the manual actuator will go to the fully open position, and press ENTER after 2 seconds

key;

o) Displayed as adjust of poti , adjust the center wheel of the signal gear unit, hold the D part still,

Turn the E part of the center wheel by hand, and slowly turn it in the direction to decrease the displayed value until the displayed value is 0, press

ENTER key;

p) Displayed as move to cl.pos. (running to the fully closed position), press the button to make the actuator run towards the end position of the close

208
(Short-term pressing is jogging, and the actuator will continue to run after the key is released for more than 2 seconds) , which displays

%open→close (% open→full close), combined with the actual position of the valve, determine the closing end position, close to full close

position, press the STOP key (ie ENTER key), the manual actuator will go to the fully closed position, and press ENTER after 2 seconds

key;

q) Displayed as sign.gear ratio (ratio of signal gear unit) : If its parameter value is &adjustment

ok! , then the ratio setting is appropriate, the setting value of the end position is correct, press the ENTER key to proceed to other parameters

Number setting, press Local/Remote key to end debugging; if its parameter value is increase it! (increased signal

gear unit ratio) or decrease it! (reduce the ratio of the signal gear unit), then the signal tooth should be adjusted

Adjust the end position again after changing the ratio of the wheel unit.

r) Ratio adjustment of signal gear unit:

The ratio of the signal gear unit must be adjusted to the number of revolutions (or stroke distance) that the output shaft must turn for the entire positioning stroke

or angle) to the nearest gear (for example, if the number of full stroke rotations is 30 revolutions, the ratio should be set to 36 gears).

For multi-turn and quarter-turn actuators, there is a gearbox reduction ratio on the gearbox nameplate to estimate the number of full-stroke rotations.

For example, the reduction ratio i is 51/1, which means that 51 revolutions of the input shaft output 1 revolution, if the valve (baffle) rotates 90°, it is one revolution

1/4, then the number of full-stroke rotations of the actuator is about 51/4=13 circles, and the ratio should be set to 14;

Generally, one turn of the actuator is 5~8 mm, and the number of turns of the full stroke can be determined according to the stroke. Observations can also be used to estimate the signal tooth

Wheel ratio: During the full stroke operation of the actuator, pay attention to observe the rotation angle of the center wheel, if the rotation angle is greater than

300°, the ratio of the signal gear unit should be increased; if the rotation angle is less than 120°, the ratio of the signal gear unit should be decreased

ratio. s) In the process of adjusting the end position, the following points must be paid attention to: run to the fully open position in the stroke off mode (move to

op.pos.) or run to the fully closed position (moveto cl.pos.) with the parameter value press E-button (press ENTER) ,

In the torque cut-off mode, the parameter value is until TL reached (until the cut-off torque is reached); in the torque cut-off mode, it must

Operate the actuator electrically until the cut-off torque is reached. For safety, after the first shutdown, the actuator will face in the opposite direction

run for a short time and then again in the direction of the end position to be set until the cut-off torque is reached again, which

process is shown as adaptingop.pos.-busy! (adapting to wide open position - busy) or adapting cl. pos. - busy! (suitable

Should be all off position - busy);During the process of adjusting the end position, do not press the ENTER key more than once. For example, in the above steps, the fully open position

Set it up, adjust the deviation to 0, press the ENTER key and display move to cl.pos. (run to the fully closed position) , still fully open

position, if you press the ENTER key again, the actuator thinks it is the fully closed position at this time, and the end position must be readjusted;

In the long-range shut-off mode, if the TL-OPEN activ (turn-off torque in the opening direction works) in the process of running to the end position

Or TL-CLOSE activ (closing direction closing torque is effective) is displayed on the screen, indicating that a moment of torque closing has occurred,

Reason 1: The valve or actuator has reached the mechanical limit. Shake the handle or press the corresponding key or make the actuator run back to the specified position.

209
The desired position; Reason 2: The valve or actuator is too astringent or blocked, press ↑ and ↓ at the same time to cancel and exit the end position adjustment.

t) Adjustment of the mechanical position indicator: If the ratio of the signal gear unit is changed, the end position of the actuator must be reset

Adjustment. Once the end positions have been set, do not turn the center wheel E or remove the signal gear unit by hand. end

After the end position is adjusted, adjust the mechanical position indicator, adjust H and G to make it the same as the final end position

consistent.

1.5 Safety, health and environmental protection requirements

1.5.1 Security

1.5.1.1 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

1.5.1.2 When two or more people work, one person in charge must be identified.

1.5.1.3 Sufficient lighting should be provided on the site and meet the requirements of the "Safety Regulations".

1.5.1.4 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

tools.

1.5.1.5 When cleaning and refueling, prevent fire.

1.5.1.6 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

1.5.1.7 Seriously abide by the safety regulations of lifting and handling.

1.5.1.8 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work process should be restored in time.

1.5.1.9 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

1.5.1.10 Clean up flammable and explosive debris at the work site.

1.5.2 Health

1.5.2.1 Precautions must be taken when coming into contact with chemicals that are toxic, harmful or irritating to the human body.

1.5.3 Environmental protection

1.5.3.1 The replaced waste products must be poured into the designated dustbin, and dumping is not allowed.

1.5.3.2 Discarded or leftover chemicals after use must be placed in designated locations and not thrown away casually. must do after

To "completion of work, clean materials, clean site" .

1.5.3.3 Work must consciously abide by ISO14001 environmental management standards and ISO9001 quality management system.

1.6 Dangerous point analysis and pre-control

Dangerous points are various factors that endanger personal and equipment safety in the inspection, operation, maintenance and test of equipment.

Transformer maintenance has the following four types of danger points:

1.6.1.1 Electric shock

210
 The power supply of the actuator is 380VAC, and the voltage of the control circuit is 220VAC. Power failure and power inspection must be done. avoid people

electric shock accident.

1.6.1.2 Falling from height

The maintenance part of the actuator is carried out at a height above 2.0m, sometimes on a bucket truck or a platform truck, and repeatedly up and down

It takes a lot of time to climb and climb, and it is more oily and slippery, so the risk of falling from a high altitude is greater.

1.6.1.3 Personal injury: During the maintenance of the actuator, prevent mechanical injury.

1.6.2 Pre-control measures

danger point control measures

1. Issue a work ticket, complete the organizational and technical measures to ensure safety, and pass the safety technical measures

Re-inspection shall be carried out, and the construction shall be allowed only after the maintenance personnel understand the measures.

2. The primary and secondary circuit operations of the cooler should be cut off as much as possible, wear insulating shoes, and insulate the removed wire ends in time

electric shock

The tape is wrapped well, and the tools used are insulated and reliable.

3. Strict on-site lighting and overhaul power management to prevent equipment or machines that do not meet insulation regulations from entering the site.

On-site lighting and maintenance power supply must be managed by special personnel.

1 When working above 1.5m, you must always fasten your seat belt and wear a safety helmet

2 Remove the oil stains in time, and if necessary, place a rag under the feet to prevent slipping

fall from height 3 The tools and utensils used should take measures to prevent dumping and sideslipping

4 There must be a working guardian at the workplace

5 Scaffolding must be signed and accepted by all parties and listed before it is allowed to be used.

1. Wear a hard hat, proper overalls and gloves

2. Do the lifting work according to your ability, the use of tools must comply with the regulations, and the tools should not slip, be careful

Be cautious, concentrate, work intensely and orderly, remind each other, and it is forbidden for one person to work alone at the maintenance site.

personal injury

Carry out construction under supervision to prevent personal injury.

3. The insulating oil on the ground should be cleaned and covered in time to prevent people from slipping and getting injured.

4. The use of tools and instruments must be regulated to prevent accidental injuries.

211
2 Pneumatic actuator maintenance procedures

2.1 Equipment overview and parameters

Pneumatic actuators refer to actuators powered by compressed air. Pneumatic actuators mainly include membrane type and live

There are two types of plug type, and the film actuator is the most widely used. In the pneumatic base adjustment system, the film actuator is mostly used.

Since the piston actuator can obtain a large thrust, it is suitable for high static pressure, high pressure difference and a large thrust and displacement (rotational)

angular or linear displacement). Divided into switch type and adjustment type pneumatic actuators.

2.1.1 Composition: Adjustable pneumatic actuators mainly include electrical converters, valve positioners, position transmitters, solenoid valves,

It is composed of travel switch, air filter pressure reducing valve, valve body and so on. Switching pneumatic actuators mainly include solenoid valves, stroke opening

Off, air filter pressure reducing valve and cylinder and other components.

2.1.2 Working principle

2.1.2.1 Working principle of modulating actuator

The electrical converter receives the 4~20mADC signal and converts it into a 0.02~0.1MPa air pressure signal, which is positioned by the valve

After the amplifier is amplified, the output gas is sent to the air chamber of the actuator, and the diaphragm (or piston) pushes the output rod to move, and the displacement of the valve rod passes through

The feedback device is sent to the position transmitter, and the position transmitter converts it into an output of 4-20mADC. When the valve is fully open and fully closed

The position is displayed by sending the valve fully open and fully closed signals through the on and off of the travel switch. For pneumatic actuators equipped with a safety valve

The operating mechanism can ensure that the valve position does not change when the air source, power supply and control signal disappear.

2.1.2.2 Working principle of switch type actuator

The solenoid valve accepts the switch command, and realizes the on and off of the air source through the solenoid valve, so as to inflate (or exhaust) the cylinder ,

Realize the push of the cylinder to the piston to achieve the valve switch action. In the fully open and fully closed positions of the valve, through the travel switch

Break to send the valve full open, full close signal for display.

2.1.3 Technical parameters

2.1.3.1 Electrical converter: a Input signal: 4〜20mADC, impedance (176±10)Ω. Output signal: 3〜

15psi (0.02 ~ 0.1MPa) and 6 ~ 30 psi (0.04 ~ 0.2MPa) two. b Air source pressure: at least greater than the output upper limit 5

psi(0.03 MPa), 50 psi(0.35 MPa) max. c Valve positioner: input signal: 3〜15 psi and 6〜30 psi

two kinds. Output signal: The output depends on the size required for execution, and the maximum is 95% of the air source pressure. d Air source pressure: at least greater than

Actuator required 5 psi max, 50 psi max. e Position transmitter: output signal: the normal range is 4 ~ 20mA,

The maximum is 30mADC, the load capacity is 11~30VDC, and the power supply is 0~900Ω (24VDC corresponds to 650Ω). f power supply: voltage

11~30VDC, rated voltage 24VDC, maximum power supply 20mA.

2.2 Maintenance category and cycle

2.2.1 Routine maintenance

212
2.2.1.1 Whether the gas source pipeline is leaking, whether the gas source pipeline is straight, and whether there is any flattening phenomenon.

2.2.1.2 Whether the electrical converter and the pressure reducing valve are well sealed, and whether there is water in the air source pipe.

2.2.1.3 Whether the pressure gauge is damaged.

2.2.1.4 Whether the accessories are firmly fixed, and whether the actuator has obvious damage.

2.2.1.5 Valve start and stop steps

2.2.1.6 Start-up steps: first open the air source valves of each component, and then send the power to the electrical converter.

2.2.1.7 Stopping steps: first stop the power supply of the electrical converter, and then close the air source valve.

2.2.2 General troubleshooting:

2.2.2.1 Phenomenon: The electrical converter has no input signal

Reasons: A. Cable failure; B. Card failure.

2.2.2.2 Phenomenon: The valve does not move

Reasons: A. The valve is stuck; B. There is no air source; C. The electrical converter is faulty.

2.2.2.3 Phenomenon: valve jitter

Cause: The screw inside the locator is loose.

2.2.2.4 Phenomenon: the valve opening is inconsistent with the input signal

Reasons: A. The electrical converter is inaccurate; B. The locator is inaccurate; C. The air source pressure is not suitable.

2.2.3. Valve overhaul items

2.2.3.1 Air leakage inspection of connecting parts.

2.2.3.2 Overhaul of pressure reducing valve and filter.

2.2.3.3 Solenoid valve inspection, cleaning, cable testing.

2.2.3.4 Position transmitter adjustment.

2.2.3.5 Determination of the full stroke action time.

2.3 Maintenance items and their quality requirements

2.3.1 General inspection

2.3.1.1 Visual inspection

Whether the appearance of the actuator has obvious damage, whether the gas source pipeline is leaking, whether the gas source pipeline is straight, and whether it is flattened

Phenomenon, whether the pressure gauge is damaged, whether the electrical converter and the pressure reducing valve are well sealed, whether there is water in the air source pipe, and whether the accessories are

Is it firm etc.

The full stroke direction of the valve and the actuator is clearly marked, and the action direction of the actuator is specified as: when the input signal increases, the valve

When the opening increases, it is a positive action; when the input signal increases, the valve opening decreases, which is a negative action; if it does not meet the requirements for use, it should

213
The method stipulated in the manual shall be adjusted.

2.3.2 Check Calibration Before Adjustment

0%, 25%, 50%, 75%, 100% of the range are issued first through the control room operating device (hand-held device or operator station)

Output signal, then send out 100%, 75%, 50%, 25%, 0% output signal, and record the position of each calibration point in turn

Feedback values, actual positions of actuators and operating devices.

2.3.3 Cleaning and oiling

2.3.3.1 Remove the dust on the mechanical part; purge the internal module of the positioner with the ear cleaning ball;

2.3.3.2 Lubricate the connection and rotating parts with oil.

2.3.4 Insulation test:

2.3.4.1 The insulation resistance of the solenoid valve to the ground is ≥20MΩ.

2.3.4.2 The phase-to-phase insulation resistance of the cable is ≥20MΩ, and the insulation to the ground is 50MΩ.

2.3.4.3 The DC resistance value of the solenoid valve coil should meet the requirements of various equipment specifications.

2.3.5 Sanitation

2.3.5.1 The blowdown of the pressure reducing valve must be thorough and clean.

2.3.5.2 Remove the dirt in the electrical converter, valve positioner and pressure reducing valve.

2.3.6 Calibration items and technical standards

2.3.6.1 Standards for electrical converters and gas-to-electric converters

2.3.6.2 Electrical converter (I/P) range adjustment

2.3.6.3 When the I/P input current is 4mA, adjust the I/P zero potentiometer so that the I/P output gas pipelines are connected in parallel for calibration

Standard pressure gauge, indicating the specified lower limit (0.02MPa) ;When the I/P input current is 20mA, adjust the I/P zero position

Potentiometer, a standard pressure gauge for calibration that connects the I/P output gas line in parallel, indicating the specified upper limit (0.1MPa) ;

2.3.6.4 Operating the device from the control room (hand communicator or operator station), first send out the range 0%, 25%, 50%, 75%,

100% output signal, then send 100%, 75%, 50%, 25%, 0% output signal, record each calibration point in turn

I/P output air pressure and P/I output current corresponding to I/P input current value;

2.3.6.5 The basic error of the whole process is required to be no more than 2% of the measuring range.

2.3.6.6 The basic technical standard of the positioner, expressed as a percentage of the rated stroke of the actuator, shall meet the requirements in the table below.

Positioner Level Error Comparison Table

Accuracy class 2.5 2.0 1.5 1.0

Basic error limit% ±2.5 ±2.0 ±1.5 ±1.0

Hysteresis% 2.5 2.0 1.5 1.0

214
Dead zone% 1.0 0.8 0.6 0.4

Note: Grades 2.0, 1.5, and 1.0 in the table are suitable for positioners with linear travel >10mm; grades 2.5 and 2.0 are suitable for positioners with angular travel

Positioner, positioner with linear stroke ≤10mm.

2.3.6.7 Visual inspection of positioner

The surface coating of the locator should be smooth and intact, without defects such as peeling, bruises and scratches; the fasteners should not be loose or damaged.

Image; nameplate and logo content should be correct.

2.3.6.8 Calibration of positioner

a) Manually adjust the intake air to make the opening of the valve 50%, and make the connecting arm of the positioner horizontal;

b) Adjust the air supply pressure of the positioner within the specified range, and adjust the positioner’s air supply pressure when the specified input signal air source pressure

Zero point and span screws, so that the basic error of the adjustment mechanism in the whole range is not greater than the allowable error;

c) When the air source pressure deviates from the rated value by ±10kPa, the stroke change of the positioner should not exceed the absolute limit of the allowable error limit.

value.

2.3.6.9 Criteria for zero and full scale of the actuator

In the checking calibration before adjustment, if the basic error value is ≥ 2/3 of the allowable error value, the following calibration should be performed:

a) Corresponding to the control command 0%, adjust the actuator and pneumatic valve to the fully closed position, adjust the output of the position transmitter

The current is zero;

b) Corresponding to the control command 100%, adjust the actuator and pneumatic valve to the fully open position, adjust the position transmitter output

The output current is full scale;

c) Adjust zero and full scale repeatedly; until both meet the requirements.

2.3.6.10 Calibration of limit switch action

a Corresponding to the control command 0%, when the actuator reaches the fully closed position, adjust the action of the lower limit limit switch;

b Corresponding to 100% of the control command, when the actuator reaches the fully open position, adjust the upper limit switch to act.

2.3.6.11 Calibration of the position transmitter

a Corresponding to the control command 0% and 100%, the output current of the position transmitter should be 4mA and 20mA respectively;

b The basic error of the position transmitter is not greater than the permissible error of the actuator.

3.2.6 Calibration of the basic error and return error of the actuator

a Same as checking calibration before adjustment;

b The basic error of the actuator should be less than ±1.5% of the rated travel, and its return error should be less than 1.5% of the rated travel;

c The basic error of the valve position output should be less than ±2% of the rated travel, and its return error should be less than 3% of the rated travel.

2.3.6.12 Insensitive zone (dead zone) calibration

215
 a Calibration should be carried out at 25%, 50% and 75% respectively;

b The insensitive zone of the actuator should not be greater than 0.6% of the input signal;

c The insensitive area of the valve position output should be less than 0.6% of the rated stroke.

2.3.6.13 No-load full travel time verification

When the input signal is changed step by step, the full travel time of the actuator from the lower limit to the upper limit or from the upper limit to the lower limit should meet the requirements in the table below

beg. Empty full trip schedule

Output torque N×m 160〜400 600〜1600 2500〜6000 8000〜16000

Full travel time less than s ≤5 ≤12 ≤30 ≤60

2.3.6.14 Self-locking performance calibration

a The input signal is 50%, and the actuator is in working condition;

b When the power supply, air source or signal is suddenly cut off, the actuator should be able to lock itself, and the valve position should not change more than 5% of the full stroke per hour;

c After the power-off signal is given, the self-locking of the actuator should be completed within 1s;

d The change of the valve position after self-locking should not exceed ±10% of the measuring range per hour;

e Adjusting the manual knob on the pneumatic self-locking valve can change the locking pressure, but the adjustment of the locking pressure should not be lower than 0.3MPa.

2.3.6.15 Effect test of gas source pressure change

The input signal is 50%, and the adjusted air source pressure deviates from the rated working pressure by ±10%, the change of the output rotation angle of the actuator should be

Not greater than ±1% of the rated rotation angle.

2.4 Debugging and trial operation of ABB pneumatically adjustable positioner

2.4.1 Gas circuit connection: Use the standard interface marked on the gas source port of the positioner to connect the gas source, connect the output of the positioner to the

Cylinders for pneumatic actuators.

2.4.2 Electrical connection: perform corresponding wiring according to the following wiring terminal diagram and design requirements (generally only connect to command +11,

- 12; Feedback +31, -32 is fine)

+ 11 - 12 Control signal input terminal (DC4~20mA, load resistance Max410 ohms)

+ 31 - 32 Position feedback output terminal (DC4~20mA, DCS+24V power supply)

+ 41 - 42 Full close signal output terminal (photocoupler output)

+ 51 - 52 Fully open signal output terminal (photocoupler output)

+81 - 82 Switch signal input terminal (photocoupler input)

+83 - 84 Alarm signal output terminal (photocoupler output)

216
 + 41 - 42 Low signal output terminal (reed switch contact output, 5-11VDC, <8mA)

+ 51 - 52 High signal output terminal (reed switch contact output, 5-11VDC, <8mA)

2.4.3 Commissioning steps

Connect the air source, and check whether the pressure behind the pressure reducing valve meets the requirements of the nameplate parameters of the actuator. Connect 4~20mA input signal.

(The working power of the positioner is taken from the input signal) Check the installation angle of the position feedback lever: press and hold the MODE key;

Press the ↓ or ↑ key until the operation mode code 1.3 is displayed; release the MODE key; use the ↑ or ↓ key to operate

The detector runs to two terminal positions respectively, and records the angles of the two terminals

The application range of straight travel is within -28°—+28°

Angular stroke application range is within -57°—+57°

The full stroke angle should not be less than 25°

Switch to configuration function level

a Press and hold the ↓ and ↑ keys simultaneously

b Press the ENTER key

c wait for 3 seconds, the counter counts from 3 to 0;

d Release the ↑ and ↓ keys

The program automatically enters the P1.-Configuration bar

e Use the ↑ and ↓ keys to select the positioner installation type as straight stroke or angular stroke, angular stroke installation type: the positioner has no feedback

Rod, its feedback shaft is coaxial with the output shaft of the angular displacement of the actuator, and the general angular displacement is 90°, such as double valves for butterfly valves and ball valves

cylinder actuator;

Straight stroke installation form: the positioner must drive the rotation axis of the positioner through the feedback rod, and the angular displacement of the general positioner is small

At 60°, it is used to drive pneumatic actuators for straight-stroke valves. Note: Before performing automatic adjustment, the installation form must be confirmed,

Because the positioner defines the stroke end of the actuator differently during the automatic adjustment process, and the linearization correction database is different,

Can lead to large non-linear errors

f Start the autotuning procedure:

Press and hold the MODE key;

Click the ↑ button one or more times until "P1.1" is displayed;

Release the MODE key;

Press and hold the ENTER key for 3 seconds until the counter counts down to 0;

Release the MODE key, and the automatic adjustment program starts to run (the display shows the program statement number in progress) ;

217
After the auto-adjustment process has successfully completed, the display will show "COMPLETE" ;

If there is a fault in the process of automatic adjustment, the program will be forced to terminate and a fault code will be displayed, which can be detected according to the fault code

Find out the cause of the failure. It is also possible to artificially forcibly interrupt the automatic adjustment program.

g If necessary, enter "P1.2" to adjust the control deviation band (or dead zone) .

h If necessary, enter "P1.3" to test the setting effect.

i Store the setting result:

Press and hold the MODE key;

Click the ↑ button one or more times until "P1.4" is displayed;

Release the MODE key;

Use ↑ key or ↓ key to select NV-SAVE (if you select "CANCEL" , previous modifications will not be saved)

Press and hold the ENTER key for 3 seconds until the counter counts down and release it. Measured in the previous setting and automatic adjustment

The parameters will be stored in EEPROM and the positioner switches to the previously selected run level operating mode.

Selection of run-level operating modes

0 mode: adaptive control mode

Press and hold the MODE key;

Click the ↑ key one or more times until "1.0 CTRL-ADP" is displayed;

Release the MODE key

The display shows the valve position percentage such as "50.0% POSITION"

a) Mode: fixed control mode

Press and hold the MODE key;

Click the key one or more times until "1.1 CTRL-FIX" is displayed;

Release the MODE key;

The display shows the valve position percentage such as "50.0% POSITION"

b) mode: manual control over the actual full travel range of the actuator

Press and hold the MODE key;

Click the ↑ button one or more times until "1.2 MANUAL" is displayed ;

Release the MODE key;

The display shows the valve position percentage such as "50.0% POSITION"

(The initial setting of the positioner is suitable for direct acting valves, if the actual driving valve is in the form of reverse acting, that is, the valve stem goes up to close the valve

door, but need to confirm P2.3=Reverse)

218
Generally, this parameter has been modified before the valve leaves the factory and does not need to be modified by the user, but it can be checked by the following methods. locator from

The starting position can be any way in the running mode

c) switch to configuration function level

(a) Press and hold the ↑ and ↓ keys at the same time;

(b) Press the ENTER key;

(c) Wait for 3 seconds, the counter counts down from 3 to 0;

(d) Release the ↑ and ↓ keys;

The display shows "P1.0 ACTUATOR"

d) Select the second set of parameters from the configuration function level

Press and hold the MODE and ENTER keys simultaneously;

Click the ↑ key;

The display shows "P2.- SETPOIT";

Release the MODE and ENTER keys;

Display shows "P2.0-MIN-PGE"

e) Select the valve action mode P2.3 from the second set of configuration parameters

Press and hold the MODE key;

Click the ↑ key 3 times;

The display shows "P2.3 ACTION";

Release the MODE key

f) Change the valve action mode

Click the ↑ button to select "REVERSE"

g) Switch to "P2.7 EXIT" store and exit

Press and hold the MODE key;

Click the ↑ key several times until the display shows "P2.7 EXIT";

Release the MODE key;

Use ↑ or ↓ key to select "NV-SAVE";

Press and hold the ENTER key until the counter counts down and release it

The parameters measured in the previous setting and automatic adjustment will be stored in EEPROM, and the positioner will switch to the previously selected

selected operating mode.

h) Program function diagram of TZID-C series intelligent locator

219
(a) Functional level classification:

Running operation level: suitable for initial adjustment and daily maintenance inspection or on-site switch operation

Parameter configuration level: suitable for parameter setting and tuning in initial commissioning

(b) To run the operational level:

Three-level function classification and display Functional description

text description

1.0CTRL-ADP Select adaptive control mode (remote control)

1.1 CTRL-FIX Select fixed control mode (remote control)

1.2 MANUL Switch to live key operation (on or off)

1.3 MAN-SENS Used to detect whether the displacement range is appropriate

In general, select 1.0 for remote automatic control, only when the actual stroke of the actuator is very small and the speed of the actuator is too high.

Fast, select 1.1 control mode when control oscillation occurs, but its control precision is low.

Both 1.2 and 1.3 in the operation mode can use the keyboard to open or close the actuator, but 1.2 is dedicated to manual operation, while 1.3

It is specially used to detect whether the actual operating range of the positioner feedback lever exceeds the maximum detection range of the sensor, so as to correct the feedback lever

connection for optimal control.

(c) Parameter configuration level:

Parameter configuration is divided into 11 groups, represented by "P1.-, P2.- —P11.- (P is the initial letter of PARAMETER), and each group

It is divided into several items, such as P1.- is divided into P1.0, P1.1-P1.4 is divided into 5 items, P2.- is divided into P2.0, P2.1-P2.7 is divided into 8 items.

Some items can be divided into several sub-items for selection. For example, in P1.0, LINEAR can be selected for linear actuators. Select

ROTORY is used for quarter-turn actuators, and NV-SAVE (NON-VOLATILE SAVE) can be selected for saving in P1.4 EXIT

Exit or CANCEL to exit without saving. /

Some items only have numerical values for adjustment. For example, the given signal in split-range adjustment is 4-12mA, then the numerical value in P2.0 should be set to

4mA, and the value in P2.1 should be set to 12mA, if the given signal is 4-12mA, then the value in P2.0 should be set to 12mA,

And the value in P2.1 should be set to 20mA.

Secondary functional grouping Three-level functional classification and display Functional description

word description

P1.0 ACTUATOR Define the positioner installation form

P1.1 AUTO ADJ auto-adjust

P1.2 TOL-BAND set deviation band

220
P1.3 TEST Modification of Results Test

P1.4 EXIT Exit to run operation level

P2.0 MIN-RGE Set the minimum value of the given signal (default is 4mA)

P2.1 MAX-PRG Set the maximum value of the given signal (default is 20mA)

P2.2 CHARACT Set special control curve

P2.3 ACTION Set the positive action mode of the valve

P2.4 SHUT-OFF Set valve opening threshold

P2.5 RAMP set opening speed

P2.6 RAMP Set closing speed

P2.7 EXIT Exit operating level

P3.0 MIN-RGE Adjust the initial opening of the curve (default is 0%)

P3.1 MAX-RGE Adjust the end opening of the curve (default is 100%)

P3.2 ZERO POS Starting point setting (the default is fully closed, that is, the feedback lever is counterclockwise

Towards)

P3.3 EXIT Exit to run operation level

P4.0 TIME-OUT positioning timeout

P4.1 POS-SW1 First position signal set point

P4.2 PSO-SW2 second position set point

P4.3 SW1-ACTV Valid above or below the first position signal

P4.4 SW2-ACTV Valid above or below the second position signal

P4.5 EXIT Exit to run operation level

P5.0 LEACKAGE Start actuator cylinder leak alarm

P5.1 SP-RGE Start given signal timeout alarm

P5.2 SENS-RGE Start zero drift alarm

P5.3 CTRLER Start the alarm when the remote control is switched

P5.4 TIME-OUT Start positioning timeout alarm

P5.5 STRK-CTR Start adjustment stroke over limit alarm

P5.6 TRAVEL Start total stroke overrun alarm

P5.7 EXIT exit run to operational level

221
P6.- P6.0 MIN-VR Manually set the valve fully closed position

MAN-ADJ P6.1 MAX-VR Manually set valve fully open position

manual adjustment P6.2 ACTUATOR Select actuator form

P6.3 SPRNG-Y2 Sets the rotation direction of the positioner feedback lever when the actuator spring is extended.

Towards

P6.4 ADJ-MODE Select the items to be detected by automatic adjustment

P6.5 EXIT Exit to run operation level

P7.0 KP

P7.1 KP

P7.2 TV

P7.3 TV

P7.4 GOPULSE

P7.5 GOPULSE

P7.6 Y-OFFSET^

2.5 Safety, health and environmental protection requirements

2.5.1 Security

2.5.1.1 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

2.5.1.2 When two or more people work, one person in charge must be identified.

2.5.1.3 Sufficient lighting shall be provided on site and shall comply with the requirements of the "Safety Regulations".

2.5.1.4 When using electric tools, leakage protectors must be used, and the regulations on the use of electric tools must be followed. Do not use defective

tools.

2.5.1.5 When cleaning and refueling, prevent fire.

2.5.1.6 When working at heights, safety belts and tools must be used correctly, and the transfer of materials must comply with safety regulations.

2.5.1.7 Seriously abide by the safety regulations of lifting and handling.

2.5.1.8 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

2.5.1.9 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

2.5.1.10 Clean up flammable and explosive debris at the work site.

2.5.2 Health

2.5.2.1 Precautions must be taken when coming into contact with chemicals that are toxic, harmful or irritating to the human body.

222
2.5.3 Environmental protection

2.5.3.1 The replaced waste products must be poured into the designated dustbin, and dumping is not allowed.

2.5.3.2 Discarded or leftover chemicals after use must be placed in designated locations and not thrown away casually. must do after

To "completion of work, clean materials, clean site" .

2.5.3.3 Work must consciously abide by ISO14001 environmental management standards and ISO9001 quality management system.

2.6 Dangerous point analysis and pre-control

Dangerous points are various factors that endanger personal and equipment safety in the inspection, operation, maintenance and test of equipment.

Transformer maintenance has the following four types of danger points:

2.6.1.1 Electric shock

The power supply of the actuator is 380VAC, and the voltage of the control circuit is 220VAC. Power failure and power inspection must be done. avoid people

electric shock accident.

2.6.1.2 Fall from height

The maintenance part of the actuator is carried out at a height above 2.0m, sometimes on a bucket truck or a platform truck, and repeatedly up and down

It takes a lot of time to climb and climb, and it is more oily and slippery, so the risk of falling from a high altitude is greater.

2.6.1.3 Personal injury: During the maintenance of the actuator, prevent mechanical injury.

2.6.2 Pre-control measures

223
 danger point control measures

1. Issue a work ticket, complete the organizational and technical measures to ensure safety, and pass the safety technical measures

Re-inspection shall be carried out, and the construction shall be allowed only after the maintenance personnel understand the measures.

2. The primary and secondary circuit operations of the cooler should be cut off as much as possible, wear insulating shoes, and insulate the removed wire ends in time

electric shock

The tape is wrapped well, and the tools used are insulated and reliable.

3. Strict on-site lighting and overhaul power management to prevent equipment or machines that do not meet insulation regulations from entering the site.

On-site lighting and maintenance power supply must be managed by special personnel.

1 When working above 1.5m, you must always fasten your seat belt and wear a safety helmet

2 Remove the oil stains in time, and if necessary, place a rag under the feet to prevent slipping

fall from height 3 The tools and utensils used should take measures to prevent dumping and sideslipping

4 There must be a working guardian at the workplace

5 Scaffolding must be signed and accepted by all parties and listed before it is allowed to be used.

1. Wear a hard hat, proper overalls and gloves

2. Do the lifting work according to your ability, the use of tools must comply with the regulations, and the tools should not slip, be careful

Be cautious, concentrate, work intensely and orderly, remind each other, and it is forbidden for one person to work alone at the maintenance site.

personal injury

Carry out construction under supervision to prevent personal injury.

3. The insulating oil on the ground should be cleaned and covered in time to prevent people from slipping and getting injured.

4. The use of tools and instruments must be regulated to prevent accidental injuries.

224
 Chapter 11 Measuring Instruments

1 Thermocouple Maintenance Regulations

1.1 Equipment overview and parameters

Thermocouple is one of the temperature sensing elements commonly used in industry. It converts the temperature signal into a thermoelectric potential signal, and it is equipped with a display instrument

And transmitter, can realize temperature measurement and signal conversion.

The thermocouple models used in our factory are K graduation number (nickel-chromium---nickel-silicon) and E graduation number (nickel-chromium---constantan).

Technical requirements: see Table 1

Thermocouple name grade Use range ℃ Allowable error

0〜400 ±1.6℃

400〜1100 ±1.5℃ or ±0.4%t

0〜400 ±3℃

400〜1300 ±2.5℃±0.75%t

I - 40〜800 ±1.5℃ or ±0.4%t

II - 40〜900 ±2.5℃ or ±0.75%t

III - 200〜40 ±2.5℃ or ±1.5%t

I - 40〜350 ±0.5℃ or ±0.4%t

II - 40〜350 ±1°C or ±0.75%t

III - 200〜40 ±1°C or ±1.5%t

( Table I)

The thermal electromotive force of the thermocouple (within the specified temperature range, when the reference junction temperature is 0°C) allowable error, expressed in temperature

Values should be expressed in accordance with the provisions of "Table 1".

Working principle: The principle of thermocouple temperature measurement is based on the fact that when the two ends of the conductors with different components are connected into a loop, such as the temperature at the two connection points

If the temperature is different, the physical phenomenon of thermoelectric potential will be generated in its circuit. Conductors of different compositions constitute the two electrodes of the thermocouple, and the two

The greater the temperature difference between the junctions, the greater the thermoelectric potential generated. The three basic principles of thermocouples are: the law of homogeneous conductors, the middle

Conductor law, intermediate temperature law.

225
 A electrode

t0 t1

t0 I

B electrode

Figure 1 Thermocouple temperature measurement principle

1.2 Maintenance category and cycle

Thermocouples are generally carried out at random group C-level maintenance cycles.

1.3 Maintenance items

1.3.1 Check the insulation of the thermocouple: input-ground ≥ 40MΩ

Input—Power ≥20MΩ

Power supply - ground ≥ 20MΩ

1.3.2 Check whether the electrode has cracks, delamination, wear, whether there are small holes in the working end, and whether the surface is smooth.

1.3.3 Metallographic inspection of the protective casing: In addition to the surface inspection, it should be sent to the metal laboratory for flaw detection. Those that fail must be replaced.

1.3.4 The thermocouple should have a chrome plate and have the following signs: name or logo of the manufacturer, thermocouple model, graduation number, allowable deviation

Poor grade, applicable temperature range, date of manufacture and serial number.

1.4 Maintenance steps, process methods and quality standards

1.4.1 Put the thermocouple to be calibrated and the standard thermocouple together in the middle of the verification furnace. The standard thermocouple should be covered with a porcelain sleeve, and

The connection of the compensation wire is placed in the freezing point tank. The total number should not exceed 10, the check point includes the common point, and the upper limit point should be

5°C higher than the highest temperature point used.

1.4.2 In order to ensure the verification quality, the thermocouple automatic verification device should meet the following technical conditions:

1.4.2.1 In addition to the furnace installation and wiring of thermocouples, the whole process of temperature rise, constant temperature, measurement and recording of the verification furnace can be completely

It can be carried out automatically, or partially automatically, but the whole verification process must be able to be carried out according to the predetermined procedure,

And it should be accurate and reliable, and there must be no misoperation.

1.4.2.2 The temperature in the verification furnace is compared with the temperature of the verification point, and the deviation shall not exceed ±5°C

1.4.2.3 When the verification furnace reaches a constant temperature, during the process of measuring and recording the thermocouple potential, the furnace temperature fluctuation should be less than 0.2°C

/min.

226
1.4.2.4 The accuracy of the instruments used for automatic measurement and automatic recording of thermoelectric potential shall be comparable to that of 0.05 (or 0.02) DC low current

Potential potentiometers have the same accuracy.

1.4.2.5 The resolution of the instrument used for automatic measurement and automatic recording of thermoelectric potential shall not be greater than 10 when verifying base metal thermocouples

μV.

1.4.2.6 To verify the parasitic potential of the automatic transfer switch of multiple thermocouples, it should be less than 1 μ when verifying the base metal thermocouple

V.

1.4.2.7 There must be automatic protection devices, such as automatic alarms, automatic power cut-off devices, etc.

1.4.2.8 The printing function includes printing the standard potential, temperature, thermoelectric potential and temperature error of each calibration point of each thermocouple under test

value.

1.4.2.9 It takes about 30 minutes for each test point to heat up, keep the temperature and test.

1.4.2.10 The temperature test of the verification furnace can be carried out.

Working process: Connect the system connection according to the requirements of the object to be inspected, and then press the type selection key (corresponding to the thermocouple model) to confirm

Calibration method (use the calibration key to select the fixed point defined by the whole Baidu or temperature scale), and then input the necessary parameters through the keyboard. press

Press the run button, and the device will start to automatically check the working conditions.

1.5 Analysis and pre-control of dangerous points

1.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

1.5.2 The risk of cross-operating personnel in on-site work. During the maintenance period, personnel entering the site must dress according to safety regulations and pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

1.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

1.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

1.5.5 Health

1.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

1.5.5.2 Frostbite caused by cold in winter, heat stroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season

Two people must be supervised when carrying out work in bad times;

1.5.6 Environment

227
1.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage is sorted and stored in time after the overhaul is completed.

2 Maintenance procedures for thermal resistance

2.1 Equipment overview and parameters

Thermal resistance is a commonly used temperature measuring element in power plants, commonly used are platinum thermal resistance and copper thermal resistance such as Pt100, Cu50 and Cu100

etc., the use range is -200〜+850℃.

Principle of temperature measurement: Thermal resistance is based on the fact that the resistance value of most metals increases with the increase of temperature, and the resistance of semiconductors increases with temperature.

The temperature increases and the resistance decreases as a function of the temperature to make a temperature-sensing element for measuring temperature.

Composition of thermal resistors: Thermal resistors are divided into two types according to their shape and structure: ordinary industrial thermal resistors and armored thermal resistors. Most of the thermal resistors in our factory are

Armored thermal resistance. It consists of temperature sensing element, metal sleeve, metal lead wire, insulating material and junction box.

Industrial thermal resistance allowable error table:

R0Nominal resistance value

RTD name Graduation number Resistance ratioR100/R0

Ω

I
Pt100 100.00 1.3851±0.05% - 200〜500 ±(0.15+0.2%|t|*)
class

II
Pt100 100.00 1.3851±0.05% - 200〜500 ±(0.30+0.5%|t|)
class

Copper thermal resistance Cu50 50 - 50〜150 ±(0.30+0.6%|t|)

1. Note 1: |t| in the table is the absolute value of the temperature, in °C

Note 2: Level I allowable errors are not applicable to platinum thermal resistances using two-wire system.

2.2 Maintenance category and cycle

Thermal resistance is generally carried out at random group C level maintenance cycle.

2.3 Maintenance items

2.3.1 RTD adjustment items and technical requirements

228
2.3.1.1 Assembly quality and visual inspection

2.3.1.2 Use a multimeter to check whether the thermal resistance has open circuit or short circuit, and use visual inspection for the rest of the assembly quality and appearance inspection.

Check whether the porcelain sleeve of the temperature sensing element is complete, whether the resistance wire is damaged or corroded, and whether the protective sleeve is intact.

2.3.1.3 Measurement and requirements of insulation resistance: use a 100V megohmmeter to measure the insulation resistance of thermal resistance.

The terminals of the resistance are shorted to each other and connected to one terminal of the megohmmeter, and the wire of the other terminal of the megohmmeter is connected to

On the protection tube of the thermal resistance.

a) Requirements for the insulation resistance value of thermal resistance:

b) The insulation resistance value between the platinum resistance temperature sensing element and the protective casing should not be less than 100MΩ;

c) The insulation resistance value between the copper resistance temperature sensing element and the protective sleeve should not be less than 20MΩ;

d) The thermal resistance input terminal is ≥40 MΩ to ground;

e) The thermal resistance input terminal is ≥20 MΩ to the power supply;

f) Power terminal to ground ≥ 20 MΩ.

2.4 Maintenance steps, process methods and quality standards

2.4.1 Second-class standard platinum resistance thermometers. To test the copper thermal resistance, a second-class standard mercury thermometer can also be used.

2.4.2 According to different electrical measuring equipment, the following auxiliary equipment can be selected: 0.01 grade 10Ω and 100Ω standard resistors, one each

2.4.3 Freezing point bath.

2.4.4 Water constant temperature bath or oil constant temperature bath. Meet the following technical requirements: the maximum temperature difference between the sockets of the water constant temperature tank is not greater than

0.01°C, the vertical temperature difference in the working area of the oil constant temperature tank is not greater than 0.02°C; the horizontal temperature difference is not greater than 0.01°C.

2.4.5 100V megger

2.4.6 Thermal resistance automatic calibration device.

When verifying, insert the thermal resistance together with the glass test tube into the medium, and the insertion depth of the test tube should not be less than 300mm. Measure the thermal resistance at

When the resistance value is 100°C, the temperature deviation of the oil constant temperature tank should not exceed 2°C; every 10 minutes the temperature change should be

Not more than 0.04°C.

2.4.7 Verification of thermal resistance

2.4.7.1 Block diagram of automatic calibration of thermal resistance:

229
 Being schooled

Calibration Furnace Subtractor Logger Regulator

standard

function

generator

program controller

Principle: During the verification process, the function of the program controller is to make the whole verification process automatically proceed according to the predetermined procedure, which includes

It includes three parts: temperature rising indicator, constant temperature time controller and recording controller. The indicator is used to control the heating process to reach the verification point

Send a signal when the temperature reaches the specified temperature - send a signal when the constant temperature indicator works to the specified level - record the controller's work to reach the specified condition

Send a signal when there is an event - cycle until the end of the program, the recording controller sends a signal to automatically cut off the power supply.

2.4.8 Technical requirements for automatic verification device

2.4.8.1 After the oil tank reaches the constant temperature of the verification point, during the process of measurement and recording, the temperature fluctuation should be less than 0.2°C/min

2.4.8.2 The accuracy of the instruments used for automatic measurement and automatic recording shall be comparable to that of the 0.05 level (0.02 level) DC low potential potentiometer

of the same accuracy.

2.4.8.3 There must be an automatic protection device, such as an automatic alarm and an automatic power cut-off device.

2.4.8.4 It takes about 30 minutes for the test point to heat up and keep the temperature constant.

2.4.9 Working process

According to the requirements of the object to be tested (thermal resistance) (two-wire system, three-wire system), connect the system connection, and then press the type selection key (corresponding to

Resistor model) to determine the calibration method, and then enter the necessary parameters through the keyboard, press the run key, the device will start automatic calibration

working conditions.

2.4.10 Cause Analysis and Treatment of Common Faults of Thermal Resistance Temperature Sensing Elements

2.4.10.1 The instrument indication is lower than the actual temperature or the indication is unstable

Analyze the reasons :

a) There is water in the protective sleeve

b) Metal shavings or dust in the junction box

c) Short circuit between thermal resistors or contact grounding

230
2.4.10.2 The indicator indicated by the instrument is higher than the actual temperature or indicated to the upper limit

Analysis reason: poor contact or open circuit between thermal resistors

Treatment: According to the above reasons, deal with it accordingly. If it is still unqualified after treatment, the components should be replaced.

2.5 Dangerous point analysis and pre-control

2.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

2.5.2 On-site work cross-operating personnel risks, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

2.5.3 If the equipment driving personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and the equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

2.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

2.5.5 Health

2.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

2.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season

Two people must be supervised when carrying out work in bad times;

2.5.6 Environment

2.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed and sorted and stored.

3 Pressure (differential pressure) transmitter maintenance procedures

3.1 Equipment overview and parameters

The measured medium of the pressure transmitter enters the pressure chamber through the sampling tube, and the pressure of the low-pressure chamber of the pressure transmitter and absolute pressure transmitter

The force is atmospheric pressure or vacuum, and the medium of the differential pressure transmitter acts directly on both sides of the isolation diaphragm for the medium on the high and low pressure sides. pressure on

On the isolating diaphragm of the delta element (that is, the sensitive element), it is transmitted to both sides of the measuring diaphragm through the filling liquid in the isolating film, and its two sides are insulated

The electrodes on the chip each form a capacitor. When the pressure on both sides is inconsistent, the measuring diaphragm will be displaced, so the capacitance on both sides

The amount is not equal, and through the oscillation and demodulation links, it is converted into a signal proportional to the pressure. The demodulator's

The current is converted into a digital signal whose value is used by the microprocessor to determine the input pressure value. Microprocessor, A/D are set in the transmitter

converter etc. The microprocessor is responsible for linearizing the sensor data and resetting the measuring range. Engineering unit conversion, damping, square root,

Operations such as sensor trimming, as well as diagnostics and digital communications. There is 16 bytes of program RAM in the microprocessor, and there are three 16

231
Bit counters, one of which performs A/D conversion. The D/A converter converts the corrected digital signal from the microprocessor to the

Tuning data, which can be modified by the transmitter software. The data is stored in EEPROM, even if the transmitter is powered off, it can be permanently

Save for a long time. The digital communication line provides a connection between the transmitter and external equipment (such as 205 intelligent communicator or HART375

protocol control system) connection interface. This line is a 1100-2200 high-frequency signal, superimposed on the 4-20mA signal

word signal and transmit the required information through the loop.

3.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

3.3 Maintenance items

project sequence Grade A Class B C grade

Maintenance item content

category No overhaul overhaul overhaul

1. Pressure (differential pressure) transmitter calibration; √ √ √

2. Meter sampling pipeline blowdown; √ √ √

Measurement system overhaul √ √ √

3.

1. Pressure (differential pressure) transmitter sampling line transformation; △ △ △

2. Add sampling and install a pressure (differential pressure) transmitter in the thermal system; △ △ △

Note: √: Items that should be carried out for maintenance; △: Items that can be determined according to specific needs (or part of the item)

overhaul)

3.4 Maintenance steps, process methods and quality standards

3.4.1 Calibration before adjustment

3.4.1.1 When calibrating the low-range transmitter, attention should be paid to eliminating the influence of liquid column difference; if there is water column correction, water column should be added during calibration

Correction value; when the pressure transmission medium is liquid, the geometric center of the pressure tap of the transmitter and the lower piston of the piston pressure gauge should be kept

The end face (or the geometric center of the pressure tap of the standard) is on the same horizontal plane. Calibration is performed on major tick marks or integer points;

Unless otherwise specified, the number of check points shall not be less than 5 points including the upper limit, lower limit and common points.

3.4.1.2 Calibration starts from the lower limit value, and gradually increases the input signal, so that the pointer or display number slowly stops at each

On the main scale value of the meter (to avoid any overshoot and return phenomenon), up to the upper limit of the range, and then gradually reduce the input signal

232
No. Carry out the verification of the downstroke until the lower limit of the range. During the process, read and record the indicated value of the standard device (except for pressure gauge calibration)

outside). Among them, the upper limit value only checks the up stroke, and the lower limit value only checks the down stroke

3.4.1.3 The non-faulty instrument under test shall not be adjusted in any form before the pre-adjustment calibration is completed

3.4.2 Transmitter tightness inspection After the transmitter is tightly connected to the pressure calibrator, boost the pressure (or evacuate) in a balanced manner to make the transmitter

After the pressure in the measuring chamber of the instrument reaches the upper limit of measurement (or the degree of evacuation of 90% of the local atmospheric pressure), close the isolation valve and seal it for 15 minutes.

In the last 5 minutes, the pressure drop (or rise) shall not exceed 2% of the upper measurement limit; the differential pressure transmitter shall be tested for tightness

During the test, the high and low pressure chambers are connected, and the rated working pressure is added to observe

3.4.3 Zero and full scale calibration:

When calibrating the low-range transmitter, attention should be paid to eliminate the influence of liquid column difference; if there is water column correction, the correction of water column should be added during calibration

value; when the pressure transmission medium is liquid, the geometric center of the pressure tap of the transmitter and the lower end surface of the piston of the piston pressure gauge (or

The geometric center of the pressure port of the standard instrument) is on the same level; when the lower limit pressure signal is input, adjust the output current of the transmitter to

Physical zero position; when pressurized to the upper limit pressure signal value, adjust the output current to full scale, and adjust repeatedly until both of them reach the required value.

According to the operation requirements, the positive or negative shift of the zero point should be carried out; when the smart transmitter is calibrated for the first time, the measured physical quantity should be applied.

Calibration, and subsequent calibration can be performed through the handheld. In principle, pressurized calibration is required for referee verification.

3.4.4 Basic error and return error

The basic error value, return error value and output disconnection range change of the calibration transmitter should meet the requirements in Table 3. flow transmitter

When the differential pressure signal is below 9%, the basic error value and return error value are not counted

surface1Transmitter allowable error value table

level of accuracy 0.25 0.5 1.0 1.5 2.5

Basic error (%) ±0.25 ±0.5 ±1.0 ±1.5 ±2.5

Return error (%) 0.2 0.4 0.8 1.2 2.0

Output break range change (%) 0.1 0.25 0.4 0.6 1.0

3.4.5. System/equipment data collection scope before maintenance; calibration data before adjustment

3.4.6 Test items and standards after maintenance;

Meters installed on site, and affixed with valid metering labels;

Calibration records before adjustment and after adjustment;

Install the transmitter back in place and wire it correctly.

Check the calibration report. For the pressure transmitters that have been randomly checked and verified, the re-inspection should be 100% qualified.

3.5 Dangerous point analysis and pre-control

233
3.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

3.5.2 The risk of cross-operating personnel in on-site work. During the maintenance period, personnel entering the site must dress according to safety regulations and pay attention to observation.

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

3.5.3 If the equipment driving personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and the equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

3.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

3.5.5 Health

3.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

3.5.5.2 Frostbite caused by cold in winter, and heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season,

Two people must be supervised when carrying out work in bad times;

3.5.6 Environment

3.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage is sorted and stored in time after the overhaul is completed.

4 Pressure switch maintenance procedures

4.1 Equipment overview and parameters

The pressure switch used in our factory is mainly SOR brand. The pressure sensing element of the pressure switch of SOR company is a pair of force balance

Type, piston-driven assembly, sealed by an elastomeric diaphragm and static O-ring seals. Only the following parts are in this structure

Wetted media: pressure port, diaphragm and O-ring. An optional welded pressure port and diaphragm assembly eliminates

the O-ring. Also available in a range of wetted materials for compatibility with process media. medium acting on the piston

Mass pressure against the elastic force of the adjustable range spring, so that the piston shaft moves only a few thousandths of an inch to directly start the electric motor.

Move the switch element.

4.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

4.3 Maintenance items

4.3.1 Disassembly of the pressure switch: Dismantle the signal wire of the pressure switch, wrap it up, stick a mark on the end of the wire and record the wire number; pull out the cable and

Bind it on the nearby bracket, unscrew it counterclockwise to remove the pressure switch connector, and wrap the pressure switch sampling nozzle. wipe pressure switch

Dust and oil are transferred to the thermal control standard room.

234
4.3.2 Appearance inspection: The surface of the instrument (or device) casing and exposed parts (terminal buttons, panels, switches, etc.) under inspection should be polished.

Clean and intact, the chrome sign should be clear; all parts should be clean and dust-free, intact, without rust or deformation. switch or control

The micro switch or mechanical contact inside the device should have no obvious oxidation and burning, and the closing and releasing actions are accurate and reliable

4.3.3 Hygienic cleaning, no dust accumulation outside the instrument.

4.3.4. Meter calibration

4.3.4.1 Select appropriate standard calibration instruments: pressure calibration bench, standard table

4.3.4.2 Original value check: true and accurate.

4.3.4.3 Fixed value verification: (attached verification report)

4.4 Maintenance steps, process methods and quality standards

4.4.1 Calibration before adjustment:

Connect the switch or controller contact with an external circuit that can display its on-off status;

4.4.2 Pressure switch or controller calibration:

Connect the switch or controller tightly to the pressure calibrator; apply pressure slowly and smoothly (avoiding any overshoot and backstroke),

until setpoint action (or recovery) , record the set point action (or recovery) value; continue to pressurize to the upper limit of the measurement, close the calibration

The valve from the calibrator to the switch under test shall be pressure-resistant for 3 minutes and there should be no leakage; then reduce the pressure slowly and steadily until the set point is restored (or

action), record the set point recovery (or action) value

4.4.3 Differential pressure switch or controller calibration:

Closely connect the pressure calibrator with the positive pressure chamber (positive pressure switch) or negative pressure chamber (negative pressure switch) of the differential pressure switch or controller;

Pressurize slowly and steadily (to avoid any overshoot and backstroke phenomenon) until the set point operates, and record the set point action value;

Then reduce the pressure slowly and steadily until the set point moves again, record the set point recovery value; the positive and negative pressure chambers of the differential pressure switch are simultaneously activated

1.25 times of the upper allowable working pressure, close the valve of the calibrator leading to the tested switch, and there should be no leakage after pressure resistance for 3 minutes

4.4.4 Vibration test inspection:

Before and after the switching of the switch set point, if the switch is slightly vibrated, the contacts should not vibrate

4.4.5 Adjustment of action difference and recovery difference of set point:

Check the results before adjustment, if the action error value of the set point is ≥ 2/3 of the allowable basic action error, it must be adjusted; repeated adjustments,

Until the action difference and recovery difference of the set point meet the accuracy requirements.

4.4.6 Calibration of set point action difference and recovery difference:

It is not allowed to adjust again during the calibration process, and the calibration method before adjustment shall be continuously measured for 3 times, and the action difference of the set value shall not be greater than

The allowable operating error of the set value given on the switch or controller nameplate. If there is no accuracy grade or graduation value on the nameplate

For off-and-off controllers, the action difference of the set point should not be greater than 1.5% of the absolute value of the set point, and the switching element whose recovery difference cannot be adjusted,

235
Its recovery difference should not be greater than twice the absolute value of the allowable action difference of the set value. For switching elements with adjustable recovery difference, the recovery difference should not exceed

1.5 times greater than the allowable action difference of the set value.

4.4.7 Repeatability error calibration, its value should not be greater than the absolute value of the allowable set value error of the switch or controller

4.4.8 The scope of system/equipment data collection before maintenance;

Calibration data before adjustment

4.4.9 Test items and standards after maintenance;

4.4.10 The instruments installed on site shall be affixed with effective measurement labels;

4.4.11 Calibration records before adjustment and after adjustment;

4.4.12 Reinstall the instrument to its original position

4.4.13 Check the calibration report. The pressure switch for sampling inspection shall be 100% qualified in re-inspection.

4.5 Analysis and pre-control of dangerous points

4.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

4.5.2 On-site work cross-operating personnel risk, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

4.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

4.5.4 Risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

4.5.5 Health

4.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

4.5.5.2 Frostbite caused by cold in winter, heat stroke in summer, personnel should take anti-freezing and heatstroke prevention measures according to the season, bad weather

Two people must be supervised when carrying out work in bad times;

4.5.6 Environment

4.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed and sorted and stored.

5 Zirconia Oxygen Analysis Maintenance Regulations

5.1 Equipment overview and parameters

The oxygen measuring instrument used by our company is Oxymitter4000 plug-in zirconia analyzer, which is used to measure the

236
Oxygen content of flue gas2%.

The structure of the plug-in zirconia analyzer: it consists of two parts: the sensor unit (probe) and the transmission unit, that is, the split

Type structure, and provide the original special cable connecting the probe and transmitter, and external protection cabinet.

The technical indicators that the whole set of instruments meet:

a) Accuracy: ±0.75% of reading

b) Repeatability: ± 0.5% of full scale

c) Protection class: IP65

d) T90 time is less than 5s

e) Response time: 0.5 seconds

5.2 Maintenance category and cycle

Calibration of the indicated value of the whole set of instruments shall be carried out once a year. Calibration maintenance items are included in A-level maintenance standard items.

5.3 Maintenance items

Disassembly, cleaning; sampling line inspection; probe inspection; insulation inspection; reassembly; calibration.

5.4 Maintenance steps, process methods and quality standards

5.4.1 Inspection of sampling gas system

5.4.1.1 The sampling flue should be smooth, free of air leakage, and well insulated; if it is a bypass flue, it should be purged to ensure the smooth flow of the pipe;

5.4.1.2 The air pump, air filter, and flow meter should be in good condition. If necessary, they should be disassembled and cleaned to ensure their cleanliness, smoothness and sealing

sex.

5.4.2 Zirconia probe inspection

5.4.2.1 Appearance inspection: the air permeability of silicon carbide dust filter should be good, without blockage, dust accumulation and mechanical damage; zirconia tube

It should be clean and free from cracks, bends, severe wear and corrosion; platinum electrodes should have good lead wires and no adhesive falling off; zirconia tubes and

The sealing of the alumina tube should be tight and airtight; the flange joint surface should be free of corrosion, the gasket should be intact, and the flange screws should be fastened; the junction box should be

There should be no serious dust accumulation and rust;

5.4.2.2 Inspection of internal resistance of the probe: when the temperature of the probe is 700°C, the measuring probe based on the ion conduction mode, its

The internal resistance should generally not be greater than 100Ω

5.4.2.3 Inspection of the background potential of the probe: when the temperature of the probe is 700°C, the

300ml/h of clean air, the background potential of the measuring probe should not be greater than ±5mV;

5.4.2.4 After the probe is installed, the reference air hole and the standard air hole should face downward; the shielding wire from the probe to the converter should be intact.

5.4.3 Insulation inspection

5.4.3.1 At room temperature, use a 500V megohmmeter to measure the insulation resistance of the probe, and the insulation resistance of the thermocouple to the shell should be greater than 100M

237
Ω, the insulation resistance of the heating wire to the shell should be greater than 500MΩ, and the insulation resistance of the inner electrode lead to the shell should be greater than 20MΩ;

5.4.3.2 At room temperature, use a 500V megohmmeter to measure the insulation resistance of the transmitter, and it should not be less than 40MΩ.

5.4.4 Calibration items and technical standards

5.4.4.1 Temperature Control Accuracy Calibration:

Raise the temperature of the probe to a given point, stabilize it for 30 minutes, measure the temperature of the thermocouple, and the difference between the value and the given value should not be greater than ±5°C.

5.4.4.2 Temperature Stability Calibration:

Measure the temperature of the thermocouple every 5 minutes for 10 consecutive measurements. The maximum difference between 10 readings should not be greater than ±4°C.

5.4.4.3 Calibration of the converter:

Use a potentiometer to input the corresponding oxygen content of O.5%, 2%, 4%, 6%, and 8% respectively at the input terminal of "oxygen potential" (concentration potential)

and 10% of the millivolt signal (look-up table value plus probe background potential value), measure and record the output current value of the converter, and its value is consistent with the standard

The maximum value of the difference between the output values should not be greater than the basic error of the converter, otherwise it should be adjusted.

5.4.4.4 Constant current performance calibration:

When the output current is at full scale, the output current should not change more than 0.1mA for every 1kΩ change in the load resistance within the specified range.

5.4.4.5 Indication calibration of the whole set of instruments:

a) After adjusting the start point and end point indication of the display device, use the standard gas within the shelf life and follow the flow rate specified by the manufacturer (such as

If the flow rate is not specified by the manufacturer, a flow rate of 300mL/min) will be passed into the probe to calibrate the indication value of the whole set of instruments.

Calibration of the range:

b) Unscrew the standard air screw plug of the probe, let in 20.6% fresh air, observe the display reading of the secondary instrument (or CRT), and wait until it stabilizes.

If there is a deviation after setting, adjust the range fine-tuning to display 20.6%;

c) Calibration of zero point: replace with a standard gas with an oxygen content of about 2%, observe the reading displayed by the secondary instrument (or CRT), and wait for it to stabilize

Afterwards, if there is a deviation, adjust the zero point fine-tuning to display the value corresponding to the oxygen content of the standard gas;

d) Repeat the calibration of the range and zero position until the range and zero position meet the requirements (the fine-tuning range of the range and zero position should not be too large, so as to

without affecting the reference voltage);

e) Accuracy check: After the range and zero position are calibrated, observe the display value of the display device in the air, and the display value will be displayed after the indication is stable

The difference should not be greater than ±5%O2 of the range (10%).

5.4.5 Reproducibility calibration of the indicated value of the whole set of instruments:

When calibrating the indication value of the above-mentioned whole set of instruments, the maximum difference of the readings between each two times should not be greater than ±0.2%O2 of the range.

5.4.6 Scope of system/equipment data collection before maintenance;

The background potential value before correction.

5.4.7. Test items and standards after maintenance;

238
The calibration report is qualified and the instrument accuracy is qualified.

5.4.7.1 The surface of the tested instrument casing and exposed parts should be smooth and intact, and the chrome plate mark should be clear;

5.4.7.2 The instrument numbers and other marks should be complete, clear and accurate; the glass on the dial should be kept transparent without affecting the use

and measurement performance deficiencies;

5.4.7.3 All parts should be clean, dust-free, intact, free from rust and deformation;

5.4.7.4 Fasteners should be firm and reliable, without loosening or falling off, and the movable parts should rotate flexibly and in balance without

stuck;

5.4.7.5 Each regulator part should be sensitive to operation, correct in response, and have corresponding functions and certain

Adjustment range;

5.4.7.6 The wiring marks on the terminal board should be clear; the lead hole, meter door and glass should be well sealed.

5.4.7.7 The power supply fuse capacity meets the requirements;

5.5 Analysis and pre-control of dangerous points

5.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

5.5.2 On-site work cross-operating personnel risks, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

5.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

5.5.4 Risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

5.5.5 Health

5.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on the site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

5.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season, and

Two people must be supervised when carrying out work in bad times;

5.5.6 Environment

5.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed, and the garbage should be sorted and stored.

6 Maintenance procedures for tachometer

6.1 Equipment overview and parameters

239
 The Bentley 3500/50 Tachometer Module is a two-channel module that accepts signals from eddy current or magnetic sensors (except

not otherwise specified) to determine the rotational speed of the shaft, the acceleration of the rotor, or the direction of the rotor. It combines these measurements with

Compared with user-programmable alarm points, an alarm is issued when the alarm point is exceeded. 3500/50 tachometer module available in 3500 frame

It can be programmed with rack configuration software, and it can be configured into the following four different types:

1. Speed monitoring, set point alarm and speed band alarm

2. Speed monitoring, set point alarm and zero speed indication

3. Speed monitoring, set point alarm and rotor acceleration alarm

4. Speed monitoring, set point alarm and reverse indication

The 3500/50 can be configured to provide key phase signals to the 3500 frame backplane for use by other

Install the key phase module inside the frame. The 3500/50 also has a peak hold function; it stores the highest

Rotational speed, maximum reverse speed or number of reverses (depending on channel type selected). These peaks can be reset by the user.

6.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

6.3 Maintenance items

6.3.1 Removal of tachometer:

After removing the fixing screws, remove the wires, mark them and wrap them with insulating tape.

6.3.2 Visual inspection:

The surface of the tested instrument (or device) casing and exposed parts (terminal buttons, panels, switches, etc.) should be smooth and intact, and the chrome plate mark should be

Clear; all parts should be clean, dust-free, intact, free from corrosion and deformation; the wiring marks on the terminal board should be clear;

6.3.3 Hygienic cleaning, no dust accumulation outside the instrument.

6.3.4. Meter calibration

6.3.4.1 Selecting an Appropriate Standard Calibration Instrument: Frequency Generator

6.3.4.2 Original value check: true and accurate.

6.3.4.3 Fixed value verification: (attached verification report)

6.4 Maintenance steps, process methods and quality standards

6.4.1 The input terminal is connected with a frequency generator, and the frequency generator is uniformly selected over the entire measured range 0 to 3600Hz, including common points.

Not less than 5 points. Smoothly increase or decrease the input frequency signal to each calibration point, read and record each calibration point of the transmitter

output current.

6.4.2 Zero position and span adjustment For instruments with adjustable zero position and full scale, when the results are checked before adjustment, the indication value is basically wrong.

When the difference is greater than 2/3 of the allowable error limit of the indication value, adjust the zero point and the span repeatedly according to the requirements of the manual until both are equal.

240
Less than the allowable error of the indicated value, and minimize the error of each calibration point.

6.4.3 Calibration of basic error of indication and return error

The value is used as the basic error of the indication value and the return error. The basic error of the indication value of the instrument should not be greater than the allowable error of the instrument, and the return error of the instrument

The process error should not be greater than 1/2 of the absolute value of the allowable error of the instrument

6.4.4 Contact resistance measurement, contact resistance ≤0.1Ω

6.4.5 Insulation measurement between contacts to ground (shell) contacts, insulation value ≥ 20MΩ

6.4.6 Instrument installation: install the magnetic resistance transmitter on the speed measuring bracket, the gap between the magnetic axis and the tooth top of the speed measuring gear should be within

Within the range of 0.8 ~ 1.2mm, the wiring head is clear and correct, and the crimping wire is tight.

6.4.7 Inspection of protective tube: it is firm without leakage.

6.4.8 Inspection of terminals and signs, clear and accurate.

6.4.9 Check the switch information, it is correct.

6.4.10. System/equipment data collection scope before maintenance; calibration data before adjustment

6.4.11 Test items and standards after maintenance;

For instruments installed on site, the exposed zero position, range and alarm value adjustment mechanisms should be painted and sealed with effective measurement labels;

Calibration records before adjustment and after adjustment;

Put the meter back in place and restore the wiring.

Check the calibration report. The re-inspection of the tachometer for random inspection shall be 100% qualified.

6.5 Analysis and pre-control of dangerous points

6.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

6.5.2 On-site work cross-operating personnel risks, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

6.5.3 If the equipment driving personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and the equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

6.5.4 Risk of wet and slippery personnel on site in rainy and snowy weather. On-site work can be suspended in rainy and snowy weather. If necessary, the staff should take precautions.

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

6.5.5 Health

6.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

241
6.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season, and

Two people must be supervised when carrying out work in bad times;

6.5.6 Environment

6.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed, and the garbage should be sorted and stored.

7. Conductivity meter maintenance procedures

7.1 Equipment overview and parameters

The conductivity meter is a digital representation of the ability of a solution to conduct an electric current. The conductivity of water and the amount of inorganic acids, alkalis, and salts it contains

There is a certain relationship. When their concentration is low, the conductivity increases with the increase of concentration. Therefore, this index is often used in

Estimate the total concentration of ions or salinity in water.

7.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

7.3 Maintenance items

Disassembly, cleaning; sampling line inspection; calibration; insulation inspection; reassembly.

7.4 Maintenance steps, process methods and quality standards

7.4.1 General inspection and maintenance:

7.4.1.1 Carry out instrument cleaning and routine inspection.

7.4.1.2 Check the flow meter float, it should move up and down flexibly, tight and leak-proof.

a) The wiring between the primary element (conductivity electrode) and the converter should be intact.

b) Check the tightness of the pipelines, valves, and joints of the entire water sample measurement system, and there must be no leakage or leakage.

7.4.2 Calibration of the converter:

a) Use two AC standard resistance boxes with an accuracy better than 0.1 to simulate temperature compensation resistance and solution equivalent resistance respectively as

Verify the signal and calibrate the converter.

b) After the meter under test is energized and preheated for 15 minutes, input the equivalent analog resistance signal to the converter according to the calculation result of formula (6).

c) Input the standard value three times for forward and reverse preheating, the converter error -max. According to the formula (7) to calculate the mechanical:

-max=[(kS-kL)max/M]×100%%(FS)

In the formula:

-max —converter error, %(FS);

kS —Indicator value, -S/cm;

kL —theoretical conductivity value, -S/cm;

M — the maximum value within the range, -S/cm

242
7.4.3 Primary element (conductivity electrode) constant calibration:

7.4.3.1 Standard solution method:

a) When testing conductivity electrodes with different cell constants, the selected standard solution should have an equivalent resistance of 1×103Ω—

Choose between 1×104Ω.

b) Place the tested electrode into a standard solution with a known standard conductivity value, and measure its conductance or resistance with a conductivity meter or an AC bridge

value (if a conductivity meter is used for measurement, the cell constant of the meter can be adjusted to the position of J=1) .

7.4.3.2 Standard electrode method:

a) Put the electrode whose cell constant is J1 into a water sample solution, and measure its conductance as G1 or resistance as R1.

b) Put the electrode of the instrument under test (set the electrode constant as JX) into the above water sample, and measure its conductance as G2 or resistance as R2.

7.4.3.3 Soak and clean the conductivity cell with 50% warm detergent, and then clean it with desalinated water.

7.4.3.4 For the conductivity meter equipped with H+ exchange column, the exchange resin should be checked regularly; the failed resin should be replaced immediately

Change.

7.4.4 Maintenance:

7.4.4.1 Inspection and acceptance before commissioning:

a) The primary element (conductivity electrode) should avoid direct contact with hands during installation.

b) Check that the primary components (conductivity electrodes), connecting wires and converters should meet the requirements for commissioning.

c) For newly installed instruments, check that the temperature of the sampling point meets the requirements.

d) Turn on the power supply and adjust the flow rate of the measured medium to about 150mL/min.

7.4.4.2 Instrument maintenance:

a) Keep the environment of the instrument operating place clean.

b) When the instrument is put into operation for the first time, it is advisable to observe the flow rate and indication value of the instrument every day.

c) It is advisable to check the basic error and temperature compensation error of the instrument system once every 3 months.

d) It is advisable to inspect the converter and primary components once every 6 months.

e) Check the error of the conductance cell constant every 6 months.

7.4.4.3 Deactivation:

a) Cut off the power supply of the instrument.

b) Close the measured medium flow.

7.5 Dangerous point analysis and pre-control

7.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

243
7.5.2 On-site work cross-operating personnel risk, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

7.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

7.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather can suspend on-site work in rainy and snowy weather.

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

7.5.5 Health

7.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on the site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

7.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season, and

Two people must be supervised when carrying out work in bad times;

7.5.6 Environment

7.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed and stored in categories.

8 Maintenance procedures for acidity meter

8.1 Equipment overview and parameters

The industrial online acidity meter is actually a high-impedance DC amplifier, which cannot be used alone. It must be matched with the acidity dispenser.

When the pH value of the measured solution changes, the high-insulation shielded cable is introduced into the high-impedance DC amplifier, and the electrode composition is composed of

Chemical primary battery, the potential of the pH measuring electrode corresponds to the pH value in the water sample, and the reference electrode provides a stable electric potential

After the two are compared, a potential difference is formed, which is provided to the preamplifier, and its electrode potential conforms to the Nernst formula:

RT
E.-E.0- pH
f
E: The potential difference between the pH electrode and the reference electrode

E0: standard electrode potential

R gas constant: 8.314J/(mol K)

T: Thermodynamic temperature: K

F: Faraday constant: 9.648C/mol

PH: PH value of solution in water

After simplification: E=E0-0.19843T·PH

8.2 Maintenance category and cycle

244
The random group underwent A, B, and C-level maintenance.

8.3 Maintenance items

Disassembly, cleaning; sampling line inspection; calibration; insulation inspection; reassembly.

8.4 Maintenance steps, process methods and quality standards

8.4.1 General inspection and maintenance:

8.4.1.1 Check the appearance and clean it. Check that the liquid crystal display of the converter should be clear, complete and clean.

8.4.1.2 Check that the float of the flowmeter should be tight and leak-proof, move up and down flexibly, and have no jamming.

8.4.1.3 Check that the wires and connectors of the measuring electrode, reference electrode and converter should be intact.

8.4.1.4 Check that the filling liquid of measuring electrode and calomel electrode should meet the requirements.

8.4.1.5 Check that the shells of measuring electrodes and calomel electrodes are free of cracks and damages.

8.4.1.6 Check the tightness of the pipelines, valves and joints of the entire water sample measurement system, and there must be no leakage or leakage.

8.4.2 Insulation resistance inspection should meet the requirements.

8.4.3 Calibration items and technical standards:

8.4.3.1 Converter Error Checking

a) Connect the instrument as required, and adjust the verification device so that the output is zero. For the regulating instrument with equipotential, it can be adjusted

On the PH value of the potential, the resistance box is set according to the equivalent resistance at 25°C.

b) Adjust the output signal of the verification device, verify the upstroke and downstroke of the conversion instrument, and record the indicated values respectively.

c) The basic error and return difference of the indicated value should not be greater than the allowable difference of the indicated value specified in Table 7.

8.4.3.2 System error check:

a) Standard solution test method: place the sensor of the instrument under test in the standard solution corresponding to the instrument, and set the value of the instrument under test

meter, then clean the sensor, place the sensor in another standard solution, and accurately record the indicated value of the meter under test

(Si), and repeated three times, the error is calculated according to the formula (12):

-W=Si-BZ

In the formula:

-W-system error, PH value or ug/LNa+ ion;

Si - record the indicated pH value or ug/L sodium ion of the instrument under test;

Bz - the pH value or ug/L sodium ion of the second standard solution under the measurement conditions;

Note: Power on and preheat for 30 minutes, the temperature compensation resistance value is set according to the standard analog resistance value at a temperature of 25°C.

b) Comparison verification method: connect the sensor of the standard meter to the flow path of the sensor of the meter under test nearby, and wait for the meter to show a stable value.

After setting, accurately record the indication value BZ of the standard instrument, the indication value of the instrument under test is taken as Si, and the error is calculated according to the formula (13):

245
-W=Si-BZ

In the formula:

BZ—Indicated value PH or ug/L sodium ion of the test standard instrument.

8.4.3.3 Measuring electrode (glass electrode) performance test:

a) Direct measurement method: Put the electrode under test into saturated potassium chloride solution at 25°C, and use a test lead of a special high-resistance measuring instrument

Connect it to the electrode lead, and insert another test lead into the potassium chloride solution above, and its value should be between 5 MΩ—20 MΩ (low resistance) or

Between 100MΩ—250MΩ.

b) Indirect measurement method: soak a glass electrode after 24h soaking treatment and a qualified calomel electrode at the same time

Put it into (25-0.5) ℃ standard solution, measure the potential difference as E1 with a high-resistance potentiometer, and then use a 300MΩ-500MΩ

(The error is within -5%) The resistance R short-circuits the above-mentioned primary battery group composed of glass electrodes and calomel electrodes, and the measured short-circuit

The final potential difference is E2, and the internal resistance (RN) of the glass electrode is calculated according to the formula (14), and its value should be 5-20 MΩ (low resistance)

Or between 100-250 MΩ.

RN=(E1-E2)/E2·R

8.4.3.4 Reference electrode (calomel) performance test:

a) Internal resistance calibration: Put the tested calomel electrode and a metal rod with good conductivity into the same potassium chloride solution, and use a special electric

The two test leads of the bridge or high impedance meter are respectively connected to the calomel electrode and the metal rod, and the measured resistance value is the internal value of the calomel electrode.

resistance.

b) Stability test of calomel electrode: immerse a standard calomel electrode and the tested calomel electrode in a saturated temperature of 25°C-1°C at the same time

In the potassium chloride solution, measure the potential with a potentiometer or a high-resistance digital voltmeter, and then compare it.

c) Penetration performance test of filling liquid in the junction: remove the protective sleeve of the calomel electrode, fill the inside of the electrode with potassium chloride solution, and then

Hang the tested electrode vertically to observe the penetration of the solution at the junction.

d) Use filter paper to absorb the surface solution at the junction.

e) Wait for 5 minutes and then wipe with filter paper. It is normal if there should be wet marks.

8.4.3.5 Temperature compensation error check:

a) Pour the standard solution into a beaker of appropriate capacity, and put the calibration electrode and thermometer into the beaker.

b) Record the temperature of the water sample and the measured value.

c) Place the beaker in an adjustable constant temperature pretreatment device, the water temperature changes within 25°C-10°C, and the change range of the water sample temperature is

10°C.

d) After the temperature changes by 10°C, record the temperature of the water sample and the indicated value of the meter under test.

e) Temperature compensation error of acidity meter and sodium ion monitor;

246
 -i = pHI-pHJ

-t= pNaI-pNaJ

In the formula:

-i, -t—the temperature compensation error of acidity meter and sodium ion monitor respectively;

pHI, pNaI—the value indicated by the acidity meter before and after the temperature change;

pHJ, pNaJ—the value indicated by the sodium ion detector before and after the temperature change.

8.4.3.6 Inspection and cleaning of water sample flow cell:

a) Check whether the sealing performance of the inlet and outlet pipes of the water sample flow cell is good, and replace the sealing ring if necessary.

b) For the sodium ion monitor, check whether the water sample switching valve is flexible and whether the seal is good.

c) The dirt in the water sample flow cell can be cleaned with 1% dilute hydrochloric acid solution, and then rinsed with desalinated water.

d) Replace the diffusion tube and diffusion liquid of the sodium ion monitor.

8.4.4 Inspection and acceptance before commissioning;

8.4.4.1 Check whether the connecting wires and converters of the measuring electrodes and reference electrodes meet the requirements.

8.4.4.2 The working parts of measuring electrodes and reference electrodes should avoid contact with hands during installation.

8.4.4.3 For newly installed instruments, check whether the temperature of the sampling point meets the requirements.

8.4.4.4 Adjust the flow rate of the tested water sample to about 150mL/min.

8.4.4.5 Prepare enough standard pH buffer solution and pNa standard solution.

8.4.4.6 System calibration: select different pH buffer solutions or pNa standard solutions according to the detection items of the water samples to be tested, and calibrate the instrument

Calibrate the "positioning" and "slope" of the meter, and put it into operation after passing the calibration.

8.4.5 Maintenance:

8.4.5.1 Keep the instrument operating place clean.

8.4.5.2 For the instrument put into operation for the first time, it is advisable to observe the flow rate and indication value of the instrument every day.

8.4.5.3 Calibration should be done once a month.

8.4.5.4 It is advisable to calibrate the system indication error, reproducibility and temperature compensation error of the instrument once every 3 months.

8.4.5.5 It is advisable to inspect the indication error caused by the measuring electrode, reference electrode and input impedance once every 6 months.

8.4.5.6 Replace the measuring electrodes every year.

8.4.6 Deactivation:

8.4.6.1 Cut off the power supply of the instrument and close the flow rate of the measured water sample.

8.4.6.2 The measuring electrode and reference electrode should be removed for long-term suspension, cleaned with high-purity water, and then covered with an electrode sheath to keep moist.

8.5 Analysis and pre-control of dangerous points

247
8.5.1 In case of electric shock or damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

8.5.2 On-site work cross-operating personnel risks, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observation

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

8.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

8.5.4 Risk of wet and slippery personnel on site in rainy and snowy weather. On-site work can be suspended in rainy and snowy weather. If necessary, the staff should take precautions.

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

8.5.5 Health

8.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

8.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season,

Two people must be supervised when carrying out work in bad times;

8.5.6 Environment

8.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up and stored in a timely manner after the overhaul is completed.

9 Maintenance procedures for dissolved oxygen analyzer in water

9.1 Equipment overview and parameters

The measurement of dissolved oxygen is based on the well-known Clark cell principle, using the principle of polarographic analysis. dissolved oxygen permeable membrane

The pole is isolated from the sample water, thus eliminating the need for conditioning of the sample. In this way, the measurement will not be interfered by other ions, because it

They cannot pass through the oxygen permeable membrane.

The meter's sensor consists of gold and silver electrodes. A constant polarization voltage is applied to the two electrodes, and the electric

The flow is directly proportional to the dissolved oxygen concentration in the solution. In this way, the concentration of dissolved oxygen in the solution can be measured by detecting the magnitude of the current.

Spend.

A gold working electrode (cathode) reduces dissolved oxygen to hydroxyl ions:

O2+2H2O+4e→4OH-

An oxidation reaction occurs on the surface of the tubular silver electrode (anode):

4Ag++4Br-→4AgBr+4e-

The reduction of oxygen results in a current limiting reaction, thus generating an electrode current that is linearly proportional to the dissolved oxygen concentration.

Electrochemical reactions and permeability are temperature sensitive, so the measuring electrode is equipped with a temperature sensor for automatic temperature compensation.

248
9.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

9.3 Maintenance items

Disassembly, cleaning; sampling line inspection; calibration; insulation inspection; reassembly.

9.4 Maintenance steps, process methods and quality standards

9.4.1 General inspection and maintenance:

9.4.1.1 Carry out instrument cleaning and routine inspection

9.4.4.2 Check that the floater of the flowmeter should move up and down flexibly without being stuck, and the sampling flow path should be tight and leak-free.

9.4.1.3 Check that the filling fluid in the sensor should meet the requirements.

9.4.1.4 Check the tightness of the pipelines, valves and joints of the entire water sample measurement system, and there should be no leakage or leakage.

9.4.1.5 Insulation resistance inspection shall meet the requirements.

9.4.2 Calibration items and technical standards:

9.4.2.1 Online Dissolved Oxygen Meter. System basic error calibration: use newly prepared 50g/L-100g/L sodium sulfite (Na2SO3)

standard solution for testing.

9.4.2.2 Standard solution method:

a) Adjust the electrical zero point of the instrument after the electrode polarization is completed, so that the instrument enters the running state;

b) Control the temperature of the newly prepared (50-100) g/L sodium sulfite (Na2SO3) standard solution at 40°C,

In the exported 10L volumetric flask;

c) Connect the outlet of the volumetric flask to the inlet of the sensor, and continuously inject samples for more than 5 minutes;

d) Record the reading of the instrument after the indicated value of the instrument under test is stable.

9.4.3 Inspection and acceptance before commissioning:

9.4.3.1 For dissolved oxygen meters:

a) Prepare a sufficient amount of freshly prepared saturated sodium sulfite (Na2SO3) solution;

b) Check the tightness of the flow path system to ensure that the detection components are isolated from the atmosphere;

c) The instrument power supply should comply with the regulations, and the anti-interference measures should be intact;

d) There should be no air bubbles between the sensor and the soaking membrane during installation;

e) Send the power supply and adjust the flow rate of the tested water sample to about 150mL/min;

f) System zero calibration: Put the sensor into the newly prepared sodium sulfite (Na2SO3) solution to make the meter display zero;

g) System air calibration: Unscrew the dissolved oxygen electrode, put it close to the flow cell but not in contact with the water sample, start air calibration, wait for the display

End the program after the value stabilizes;

249
h) Put the sensor back into the flow cell and put it into operation.

9.4.3.2 For hydrazine tables.

a) Turn on the power and adjust the flow rate of the tested water sample to about 150mL/min;

b) Calibration of zero position of the instrument: disconnect the wiring at one end of the measuring electrode, wait for the indication to be stable, and adjust the "ZERO" on the instrument panel ,

Until the display is zero, connect back the measuring electrode wiring;

c) Meter slope calibration: record the reading A1 when the meter is running stably. Analyzing the tested water sample in the laboratory is recorded as C1;

d) Write down the second reading as A2, and calculate the value of C2 according to the formula (17);

C2=(C1/A1)×A2(17)

e) Adjust the "slope" (SLOPE)" on the instrument panel to make the instrument display value C2;

f) "Calibration" is over, and the instrument is put into operation.

9.4.4 Maintenance:

9.4.4.1 Keep the instrument working environment clean.

9.4.4.2 The basic error calibration of the system should be performed once a month.

9.4.4.3 System stability calibration every 3 months.

9.4.4.4 It is advisable to clean the oxygen electrode and the oxygen permeable membrane with a soft paper towel once every six months.

9.4.4.5 It is advisable to replace the oxygen permeable membrane and fill the electrolyte once a year.

9.4.5 Deactivation:

9.4.5.1 Cut off the power supply of the instrument.

9.4.5.2 Close the flow rate of the measured water sample.

9.4.5.3 The measurement sensor should be removed for long-term shutdown, cleaned with high-purity water, and then covered with an electrode sheath for wet storage.

9.5 Dangerous point analysis and pre-control

9.5.1 In case of electric shock or damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs,

When plugging and unplugging the card, it is equipped with a grounding ring to prevent static electricity from damaging the card;

9.5.2 On-site work cross-operating personnel risk, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observe

The surrounding conditions of the work site, if there are people working above the work site, they can temporarily work at other components, if the work must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

9.5.3 If the equipment transmission personnel get an electric shock or damage the equipment, check and confirm that all work has been completed and all equipment has been restored before the equipment is powered on.

The personnel cannot touch the live parts of the equipment during the transmission;

9.5.4 Risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should take precautions

Slippery measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

250
9.5.5 Health

9.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If it is necessary to carry out

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

9.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season, and

Two people must be supervised when carrying out work in bad times;

9.5.6 Environment

9.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed, and the garbage should be sorted and stored.

10 Maintenance procedures for silicate analyzer

10.1 Equipment overview and parameters

SiO2 dissolved in water reacts with ammonium molybdate under acidic conditions to form a yellow silicomomolybdate complex, which is then reduced to

Light blue molybdenum blue compound, and then use the photoelectric detection method to measure the silicon molybdenum blue complex, and finally get the silicon content in the sample

content.

10.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

10.3 Maintenance items

Disassembly, cleaning; sampling line inspection; calibration; insulation inspection; reassembly.

10.4 Maintenance steps, process methods and quality standards

10.4.1 Inspection and maintenance

10.4.1.1 During the normal operation of the instrument, it is necessary to pay attention to whether the instrument is broken.

10.4.1.2 Always listen carefully to see if the peristaltic pump is working normally and if there is any abnormal sound.

check.

10.4.1.3 Print the measured data frequently to judge whether the measured value is stable.

10.4.1.4 Pay attention to the tightness of the peristaltic pump card. Generally, it is advisable for the reagent to rise steadily. The drug feeding speed of the four reagents should be

be consistent.

10.4.1.5 Pay attention to the wear and extrusion of the peristaltic pump tube and whether the reagent is stable, otherwise it should be replaced immediately, usually a set

The operating cycle of the peristaltic pump tubing is 90 days.

10.4.1.6 Before the instrument is shut down, the countersunk heads of the four reagent barrels should be taken out and put into 10% ammonia cleaning solution for cleaning for about 4

hours, and then rinsed in desalinated water for 4 hours. This avoids deposition of reagent crystals in the delay tube and

measuring pool.

10.4.1.7 Stop the power supply of the equipment, remove the peristaltic pump card and pump tube, and remove the reagent tube, so that it can be used at any time when the machine is started next time.

251
10.4.1.8 Seal up unused reagents and calibration solutions and store them in a cool, dry place.

10.4.1.9 Commissioning during start-up, commissioning of the analyzer or after long periods of inactivity

a) Adjust the sample flow rate with the sample needle valve to ensure a uniform sample flow without air bubbles. Adjust the needle valve,

Allow water to overflow from the vent valve.

b) Repeat the above operation for each sample.

c) Press the SELECT key to move the cursor to the SERVICE submenu, then press the ENTER key. Press the TUBES key, press CONTINUE

key.

d) Fill the beaker with deionized water.

e) Starting from the back, one at a time, remove the pipe end from the threaded pipe joint, and immerse the pipe end in a beaker of water, when flushing

When changing from flushing to complete, the pump tubing can be replaced. The pump can be connected to or disconnected from the power supply by PUMP and STOP, so that

Adjust the pressure on the pump tubing to get the correct flow.

f) When all 5 cams have been adjusted, the unit can be tested and must be tested for a few hours, preferably if possible

Do not calibrate the analyzer overnight. After the measurement work is stabilized, the test run can be ended and the calibration can be performed.

10.5 Analysis and Pre-control of Dangerous Points

10.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs

Identification, with a grounding ring when plugging and unplugging the card to prevent static electricity from damaging the card;

10.5.2 On-site work cross-operating personnel risk, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observe

Observe the surrounding conditions of the work site. If there are people working above the work site, they can temporarily work at other components. If it must be carried out at the same time

Measures should be taken to prevent falling objects from heights.

10.5.3 If the equipment driving personnel get an electric shock or damage the equipment, check and confirm that all work has been completed before the equipment is powered on

Recovery, personnel cannot touch the live parts of the equipment during the transmission;

10.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should do a good job

Anti-slip measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

10.5.5 Health

10.5.5.1 The dust on the maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If necessary

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

10.5.5.2 Frostbite caused by cold in winter, heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season, weather

When working in bad times, two people must be supervised;

10.5.6 Environment

10.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage should be cleaned up in time after the overhaul is completed and sorted and stored.

252
11 Maintenance procedures for micro-sodium monitor

11.1 Equipment overview and parameters

The sodium ion content in water was measured by potentiometric analysis. The instrument consists of a reference electrode, a sodium ion indicator electrode and a temperature compensation

Compensation electrode composition. The sensitive electrode responds logarithmically to changes in sodium ion concentration, and this response can be described by the Nernst equation:

2.3RT C
E.-E.0- -LG
f Ciso
The above formula shows that the measured potential is related to temperature and concentration changes of the ions concerned. In order to eliminate the temperature fluctuation of the sample, the

The instrument uses the parameters measured by the temperature compensation electrode to continuously perform temperature compensation.

From the Nernst equation, it can be seen that when the concentration of the sodium ion selective electrode pair changes 10 times at a temperature of 25°C, its theoretical

The response value is 59.16mv, which is called the slope of the electrode. But actually need to correct. In order to avoid the influence of H+ on the measurement, adopt

Adjust the pH value by adding alkali to reduce the influence of H+.

11.2 Maintenance category and cycle

The random group underwent A, B, and C-level maintenance.

11.3 Maintenance items

Disassembly, cleaning; sampling line inspection; calibration; insulation inspection; reassembly.

11.4 Maintenance steps, process methods and quality standards

11.4.1 Whether the flow rate of the water sample is 35-45mL/min, if the flow rate is required to change, use the flow adjustment knob to adjust it.

11.4.2 Check the device for leaks. If the reagent liquid level rises, it indicates that the diffusion tube is leaking.

11.4.3 Check whether there is any error display and whether the concentration display is reasonable.

11.4.4 Check whether the reference electrolyte is sufficient. (A bottle lasts at least a few months)

11.4.5 To adjust the sodium electrode, immerse the sodium electrode in the corrosion solution for about 1 minute, take it out and clean it with deionized water, and then restore it

The electrodes are connected to the cable, and then the calibration of the electrodes is performed.

11.4.6 For the replacement of the filling liquid in the reference electrode, refer to the replacement method in the instruction manual.

11.4.7 For the replacement and cleaning of the water sample filter, refer to the instrument manual.

11.4.8 Replacing the O-rings on the reagent, diffuser and flow cell manifolds.

11.4.8.1 Unscrew the thumb nut 23 and remove the reagent bottle/connector from the flow cell assembly.

11.4.8.2 In a fume hood or outdoors, unscrew the cap 24 and remove the accessory from the bottle.

11.4.8.3 Unplug the two ends of the old diffuser tube from the joint 25 of the connector, and dispose of the spent reagent and diffuser tube properly.

11.4.8.4 Slide the two ends of the new diffuser tube over the fittings of the reagent bottle connector.

11.4.8.5 Carefully unpack the new diethylpropylamine in the fume hood, making sure there is an O-ring 26 between the bottle and the connector.

253
11.4.8.6 The duckbill inspection valve must be used in a cut-off mode to prevent damage to the diffusion pipe.

11.4.8.7 Make sure there are three O-rings on the flow cell assembly. Attach the vial connector/reagent assembly to the flow cell, twist

Tighten the bolt, and tighten the nut 23, and the connector on the bottle is screwed to the correct position of the instrument.

11.4.9 Annual inspection and maintenance

11.4.9.1 Replace the Reference Electrode (#100058) and Indicator Electrode (#100048) .

11.4.9.2 Replacing the O-ring and restrictor tube

11.5 Analysis and Pre-control of Dangerous Points

11.5.1 In case of electric shock and damage to equipment, personnel shall apply for work tickets before maintenance, power off the PLC system and hang relevant warning signs

Identification, with a grounding ring when plugging and unplugging the card to prevent static electricity from damaging the card;

11.5.2 On-site work cross-operating personnel risks, personnel entering the site during maintenance must dress according to safety regulations, pay attention to observe

Observe the surrounding conditions of the work site. If there are people working above the work site, they can temporarily work at other components. If it must be carried out at the same time

Measures should be taken to prevent falling objects from heights;

11.5.3 If the equipment driving personnel get an electric shock or damage the equipment, check and confirm that all work has been completed before the equipment is powered on

Recovery, personnel cannot touch the live parts of the equipment during the transmission;

11.5.4 The risk of wet and slippery personnel on site in rainy and snowy weather, on-site work can be suspended in rainy and snowy weather, if necessary, the staff should do a good job

Anti-slip measures, two people monitor the work on site, and stop on-site work if there is a strong wind above level six;

11.5.5 Health

11.5.5.1 The dust on the inspection and maintenance site greatly affects the health of personnel. When there is dust on site, the work in the standard room can be adjusted. If necessary

The staff wear masks when working on site, and must wear masks when cleaning the card dust;

11.5.5.2 Frostbite caused by cold in winter, and heatstroke in summer, personnel should take antifreeze and heatstroke prevention measures according to the season.

When working in bad times, two people must be supervised;

11.5.6 Environment

11.5.6.1 The overhaul garbage pollutes the environment, and the on-site garbage is sorted and stored in time after the overhaul.

12 Belt scale and cyclic chain code verification device

12.1 Equipment overview and parameters

12.1.1 Device overview

The furnace coal belt scale and its circular chain code verification device of B plant of Dianta Power Generation Company were produced by Beijing Tongni Technology Co., Ltd.

Produce. WE-full suspension belt scale is composed of weighing bridge, belt roller, load cell, speed sensor, display instrument, etc.

to make. TC--510 dynamic cycle chain code verification device consists of standard cycle chain code, cycle chain code support, lifting system, chain code driver

It is composed of 6 parts including device, speed sensor (chain code velocimeter), control system (including control display instrument).

254
12.1.2 Working principle of the device

12.2.1 Working Principle of Belt Scale

Fix the weighing bridge frame equipped with the weighing sensor on the longitudinal beam of the belt conveyor, and support or suspend it through the weighing sensor

The hanging weighing bridge and the belt idler detect the weight of the material on the belt, and generate an electrical output signal proportional to the belt load.

At the same time, the speed sensor generates a series of pulse signals through the synchronous rotation of the roller and the conveyor belt. Each pulse represents

A belt length, the length of the pulse is proportional to the belt speed, and the integrator uses the above two signals to integrate the belt speed

Speed and belt load are integrated, and converted into optional engineering units, the display shows the instantaneous flow and

Cumulative amount.

12.2.2 Working principle of cyclic chain code verification device

According to the chain code simulating the real thing to check the belt scale, first the chain code falls and rotates, so that the chain code and the leather

Belt rotation synchronization, according to the belt speed measured by the PLC and the calibration time set, the PLC automatically calculates the instantaneous flow rate within the calibration time

Time value, cumulative value. Compare the instantaneous flow and cumulative flow displayed on the belt scale with the value displayed on the chain code meter,

Find out the error and correct the belt scale.

12.3 Technical parameters

12.3.12. Technical specification of electronic belt scale

Device name: Electronic Belt Scale

model: WE-520

Weighing accuracy: Class 0.5 (verification accuracy: ±0.25%, use accuracy: ±0.5%)

Minimum Cumulative Value: 10kg

Applicable bandwidth: 400~2600mm

Belt speed range: 0-5m/s

temperature range: - 30℃〜+55℃

Conveyor inclination: 0-18°

voltage: 〜220±10%, 50HZ −3%, the transient change can reach ±5%

Load Cell Model SQB-500

Speed sensor model SPT-11

Dimensions: 6260mm×1600mm×557mm

Total power: 1kw

Total weight of equipment: 800kg

255
 manufacturer: Beijing Tongni Technology Co., Ltd.

12.3.2. Technical specification for cyclic chain code verification device

project parameter project parameter

model TC-510 model SPT-12

Adapt to belt speed 2.5m/s Pulse/turn 500P/R

Dynamic precision of the whole machine

0.05% Accuracy/Error 2mm/R

Spend

system power AC power resolution ±0.5mm/P

Voltage 380V
degree of protection IP54

frequency 50HZ type horizontal tension

Energy consumption of the whole machine

15kw power 4KW

Rate
type LCD journey 800mm

Accuracy/Error 0.01% degree of protection IP54

Linearity 0.01% number of lines 2 pieces

temperature sensitivity 0.15μV/℃ Number of blocks 180 pieces/bar

minimum bill of measure

1kg weight 2×35kg/m

bit
degree of protection IP54 length 212.188m

Flame retardant shielded electric

Cable model width 130mm

cable

factory
Beijing Tony precision M2 class

12.3.3 Main Characteristic Parameters of Belt Scale

When the belt scale shows that the instrument is in standby state, press it (for about 0.3s) to enter the parameter setting state, and input correctly

After entering the operation password, you can set 【basic parameters】 and 【characteristic parameters】. 【Characteristic parameter】With adjustment control function

Use it when you use it, so only [basic parameters] will be introduced.

sequence factory initial

parameter meaning scope unit note
No value

It is related to the instantaneous flow scale transformation, usually

00 flow gain 0.500

Obtained through calibration

256
 It is related to the displayed value of the instantaneous flow rate.

01 zero cut 0.500 t/h When the flow is less than this value, the instantaneous flow will display

Display value is 0

002 Gain factor 10.00

03 weight zero 00000

Driven Roll Increase Belt Thickness Corrected

04 belt circumference 600.00 mm
perimeter

05 belt length 4000.0 mm Belt circumference for automatic calibration

Related to the belt line speed scale transformation,

06 speed gain 60.000 mm/kp
Calibration obtained

The belt corresponding to the 100% opening of the main control output

07 Rated line speed 60.000 mm/s

Line speed

When the speed is automatically calibrated, the belt runs for one

08 lap time 100 0~1000 the s

time required to circle

After starting to run, the material is covered with the whole meter

The time required by the scale to suppress the

09 cloth time 030 100 the s

When the machine was first started, the surface guide was not filled with the material

Alarms such as flow lower limit

Related to automatic tare operation, used to control

10 Peeling opening 080 0~100 % Belt running speed when automatic tare is executed

Spend

Related to automatic tare operation, used to control

11 Number of peeling circles 03 0~99 lock up to control the amount of time the belt runs when performing automatic tare

time
Only meaningful under custom feeding mode,

12 Advance 0.000 t Corrected final feeding target to be: target

amount - advance amount

Rear door to control all alarm disarms

Threshold calculation method for alarm release

Yes: low limit alarm, alarm threshold (1+

13 Hysteresis setting 10.0 0~100 %
Hysteresis %); high limit alarm, alarm threshold

(1-return difference%). used to prevent the alarm

Oscillate around the threshold.

257
 rated to be one
14 00100 The maximum load capacity of the weighing section

kind

15 Rated Taiwanese production 150.00 Calculating the maximum feeding volume of the belt scale

Set Taiwanese production

16 00000
lower limit

Set Taiwanese production

17 65535
upper limit

Instantaneous flow

18 00000
lower limit

Instantaneous flow

19 004095
upper limit

20 proportional band 010

twenty one Integration time 01
twenty two Ascent rate 0.111

twenty three drop rate 0.111

weight filtering
twenty four 04 Upper stage weight filter
coefficient

traffic smoothing

25 01 Instantaneous flow display filter

coefficient

flow alarm
26 010
upper limit

flow alarm
27 010
lower limit

load alarm
28 010
upper limit

load alarm
29 010
lower limit

outside alarm
30 010
limit

Outside alarm
31 010
limit

12.3.4 Belt scale, cycle chain code verification

It is the only accurate calibration method for belt scales to use the circular chain code device to calibrate the belt scales in kind.

12.3.4.1 The operator starts the # belt and runs it for more than 3 minutes with no load to ensure that there is no residual coal on the belt.

258
12.3.4.2 Perform belt scale tare calibration (zero adjustment). Unlock the belt scale, select [initialization parameters], enter the password to confirm

After confirmation, enter the [System Calibration] interface, select [Tare Calibration] and confirm, the belt scale will follow the preset parameters [10

Tare opening], [11 number of peeling circles] to execute tare, after successful tare, the buzzer beeps for a long time, and the display interface prompts

The tare is successful, and the zero point obtained by tare is saved in [03 Weight zero point] parameter. The next step can only be performed after the tare calibration is successful.

step calibration, otherwise proceed to tare calibration.

12.3.4.3 The operator stops the # belt, and the loop chain code device controls the system, the display system, and the drive system to send power. far away

Start the electric push rod on the process control cabinet, and place the verification chain code on the belt. Restart #belt.

12.3.4.4 Press the [Calibration] button on the display instrument of the cyclic chain code device, and enter the [System Calibration] interface of the belt scale at the same time,

Select [Physical Calibration] and confirm. At this time, the belt scale and the cycle chain code will be calibrated synchronously according to the set calibration time. arrive

After checking the time, the belt scale and ring chain code device will automatically stop accumulating. Press the belt scale [ENTER] key to enter the cycle.

For the standard value displayed by the chain code, press the [ENTER] key to automatically correct [00 flow gain].

12.3.4.5 After the verification is completed, calculate the equivalent error: (display value of belt scale - display value of cyclic chain code)/display value of cyclic chain code

×100%, error ≤±0.5% is qualified, otherwise proceed to physical calibration.

12.3.4.6 Fill out the calibration report, back up the belt scale data, and lock the belt scale.

12.3.4.7 Lift the cyclic chain code, the cyclic chain code device is powered off, and the verification is completed.

12.3.5 Common Fault Analysis of Belt Scale

sequence

Fault reason deal with

No
1 a) There is dust or abnormality on the scale frame a) Clean the dust on the scale frame or take out the card

Stuck live foreign body

b) Belts and weighing idler stickers b) check the alignment of the scale frame,when necessary

zero change change in compatibility Adjustment of the scale frame

c) There is material sticking to the belt c) Clean the sundries on the belt

d) Sensor zero drift d) Adjust the balance of the sensor

e) Amplifier zero drift e) Adjust the operating point of the amplifier

a) Belt tension changes a) Check whether the belt tensioning device is abnormal

b) Abnormality of the speed measuring roller b) Check the speed sensor device

c) Belt slippage c) Dealing with slippage

d) Occurrence of alignment of weighing idlers d) Check the alignment of the weighing rollers,Heavy when necessary

2 Range changes
Variety new adjustment

e) Load cell linearity e) Check the load cell and replace it if necessary

change f) Contact for maintenance and treatment

f) Electronic circuit failure

259
 a) The sensor connector is disconnected a) Connect the joints or deal with water inflow and inflow

or water or dust dust, eliminate grounding or short circuits

b) A sensor loses power supply b) Check each bridge power supply and
Display value when weighing
3 Voltage recover

Vibrating or incorrect
c) A sensor is damaged c) Measure the output millivolt value after loading, judge

d) A/D board or other interface damage Break off the good and bad, and then replace d) check

Bad Check the A/D board and its interface and restore

a) There is a stuck place on the scale body a) Eliminate the possibility of additional force on the scale body

Weighing display value is obviously small

4 b) The sluice door is not tight and there is coal leakage object
Into the amount of coal

elephant b) Close the gate again

a) Short warm-up time a) Extend the warm-up time

b) There is coal in the hopper b) Stop adding coal to the hopper

Zero point changes large scale c) The sluice door is not tight and there is coal leakage c) Close the ram door in place and take the zero point again

5
unstable elephant d) After stopping the maintenance work, take the zero point again

d) There are maintenance personnel on the scale body

do

a) The belt scale itself is faulty a) Repair belt scale

6 The belt scale is seriously out of tolerance

b) Hopper scale failure b) Verify the hopper scale with the hanging code method and repair it

7 Over-tolerance during hanging code verification system error Contact maintenance treatment

12.2 Maintenance category and cycle

12.2.1 There is no major repair for belt scales and circulating chain code devices.

12.2.2 Defects in belt scales and circular chain code devices shall be eliminated in time according to the "Defect Management System".

12.2.3 A pair of belt scales shall be zeroed once a week, and a physical calibration of the belt scales shall be performed every Friday.

12.2.4 Check the weighing section of the belt scale once a week, and clean the equipment in the weighing section.

12.2.5 Cooperate with the authorized unit of the National Quality Supervision Bureau to calibrate the circular chain code once a year.

12.3 Maintenance items

12.3.1 Check the weighing section of the belt scale.

12.3.2 On-site junction box inspection of belt scales.

12.3.3 Inspection of belt scale instrument and cycle chain code instrument.

12.3.4 Cycle chain code speed sensor inspection.

12.4 Maintenance steps, process methods and quality standards

12.4.1 Check the weighing section of the belt scale.

260
12.4.12.1 Regularly clean up the dust and material blocks in the scale area of the belt scale every week to keep the weighing frame, idler rollers and speed measuring wheels

Clean and clean.

12.4.12.2 Regularly check the contact between the measuring wheel and the belt of the speed measuring sensor of the belt scale every week. The axis of the measuring wheel should be in contact with the object

The running direction of the material is kept vertical and in good contact with the belt.

12.4.2 On-site junction box inspection of belt scales.

12.4.2.1 The on-site junction box is firmly fixed, the locks are complete and complete, and the dustproof and waterproof seal is good.

12.4.2.2 The wiring in the junction box is neat, the wire number is clear, and there is no short circuit or open circuit.

12.4.3 Inspection of belt scale instrument and cycle chain code instrument.

12.4.3.1 Calibrate the chain code of the belt scale instrument once a week, and adjust the zero point and span coefficient of the belt scale so that

The measurement error of the belt scale is within ±0.5%, and a calibration report shall be filled in.

12.4.3.2 Clean the internal circuit boards of belt scale instruments and cycle chain code instruments once every six months to prevent static interference.

12.4.3.3 Cooperate with the quality supervision department to calibrate the circular chain code once a year, and obtain the plan issued by the quality supervision department

Quantity certificate.

12.4.4 Cycle chain code speed sensor inspection.

12.4.4.1 The speed sensor is tightly coupled to the rotating wheel and in good contact with the belt.

12.5 Analysis and Pre-control of Dangerous Points

serial number danger point Pre-control measures

1 Mishandling the running device 1. Apply for a work ticket and take safety measures before starting work.

1. Staff must wear insulated shoes.

2. The staff must use a qualified electroscope pen when inspecting electricity.

3. When using electric tools, use a leakage protection with a certificate of conformity.

protector

1. The cuffs of the overalls should be fastened.

2. It is forbidden to place any part of the body on the rotating part of the rotating machine

point.

3. The physical and mental condition of the staff is good, and they are competent for their duties.

work.

4. It is strictly forbidden to cross work, fasten the helmet belt.

5. It is strictly forbidden to stand and walk on the coal conveyor belt; cross the coal conveyor belt

Take the special escalator.

12.6 Safety, health and environmental protection requirements

261
12.6.1 Security

12.6.12.1 On-site work must apply for a work ticket, and work can only start after taking safety measures. Involving withdrawal of primary and secondary protection must

Handle the protection application form.

12.6.12.2 When entering the site, you must dress and use safety protective equipment in accordance with the "Safety Regulations".

12.6.12.3 When two or more people work, one person in charge must be specified.

12.6.12.4 Sufficient lighting shall be provided on site and shall meet the requirements of the "Safety Regulations".

12.6.12.5 Leakage protectors must be used when using electric tools, and the use regulations of electric tools must be followed. must not be used

sunken tools.

12.6.12.6 When cleaning and refueling, prevent fire.

12.6.12.7 Safety belts and tools must be used correctly for high-altitude operations, and the transfer of materials should comply with safety regulations.

12.6.12.8 Seriously abide by the safety regulations on lifting and handling.

12.6.12.9 After the work is completed, the protective facilities such as railings, protective covers, and ditch covers that have been removed during the work should be restored in time.

12.6.12.10 At the end of the work, check the personnel and tools, take back the remaining materials, eliminate the fire, and clean the work site.

12.6.12.11 Clean up flammable and explosive debris at the work site.

12.6.2 Health

12.6.2.1 Precautions must be taken when contacting chemicals that are toxic, harmful or pungent to the human body.

12.6.3 Environmental protection

12.6.3.1 The replaced waste products must be poured into the designated dustbin, and dumping is not allowed.

12.6.3.2 Discarded or leftover chemicals after use must be placed in designated locations and not thrown away casually. after the end must

Achieve "completion of work, clean materials, and clean site".

12.6.3.3 Work must consciously abide by ISO14001 environmental management standards and ISO9001 quality management system.

262