环缝洗涤塔说明书2801956-D050_TANGSHANBF2CHIN_ENG

Prepared : ECN 作者： ECN
TANGSHAN IRON & STEEL CO
Blast Furnace No 2 Revamping
GAS CLEANING SYSTEM
SCRUBBER AND DEMISTER
OPERATION & MAINTENANCE MANUAL
0 First bilingual version 22.05.2005 CLASSEN WOLSFELD D AVIDI/EGNER Rev.
No.
Description of Revision Date Prepared Checked Approved Title of Document / Designation: Drawing Number:
2801956-D050_CHIN_ENGL.doc2801956-D050
Order Number: Reference Documents: 2801956•2801956-0001 P&I diagram
唐山钢铁有限公司
2号高炉
煤气净化系统
洗涤器和脱水器
操作、维护手册
0 双语第一版22.05.2005 CLASSEN WOLSFELD D AVIDI/EGNER
版本号版本修改说明日期编写审核审批
文件名称: 图号:
2801956-D050_CHINESE_xxx.doc2801956-D050
订货号: 参考文件:
2801956•2801956-0001 P&I 图
Prepared : ECN 作者： ECN
1Preface (4)
2Functional Description and Process Data (4)
2.1Pre-Scrubber and Annular Gap Scrubber (4)
2.2The Demister (7)
2.3Plant Process Data (7)
3Inspection, Pressurizing and Adjustment (9)
4Safety Requirements (10)
5Re-Commissioning after Long Time Shut Down (11)
5.1Rotation Control (11)
5.2Filling of Media (12)
5.2.1Filling of Oil (12)
5.2.2Filling of Water (13)
5.2.3Filling of Grease (15)
5.3Pressurizing of Hydraulic System (18)
5.4Standard Setting on Eletronical Components (19)
5.5Water Control Valve Positioner Adjustment (21)
5.6AG-Element Adjustment (22)
5.6.1Execution of Positioner Adjustment (23)
5.6.2Interlockings (25)
5.7Water Run (26)
6Start Up Gas Cleaning Plant (28)
6.1Sequence of Start-Up (28)
6.2Blanketing of GCP (29)
6.3GCP Operation (29)
6.4Clarified Water Pumps (30)
6.5Field Monitoring (30)
6.5.1Local Pressure at Inlet of Spray Nozzles (31)
6.6Control Room Monitoring (32)
6.6.1Admissible Deviations: (33)
7Gas Cleaning Plant Safety (34)
7.1Water Supply Failure (34)
7.2Hydraulic Failure (35)
7.3Deviation of the position of AG-Elements (36)
7.4Deviation of Blast Furnace Gas Outlet Temperature (37)
7.5Deviation of the Clean Gas Dust Content (37)
7.6Deviation of Electric and Control ................................................... 381前言 (4)
2功能描述和工艺参数 (4)
2.1预洗涤塔和环缝洗涤塔 (4)
2.2脱水器 (7)
2.3系统工艺参数 (7)
3检查、加压和调整 (9)
4安全要求 (10)
5长时间停车后的再开车 (11)
5.1转动控制 (11)
5.2介质的充入 (12)
5.2.1加油 (12)
5.2.2加水 (13)
5.2.3加润滑脂 (15)
5.3液压系统的加压 (18)
5.4电器部件的标准设置 (19)
5.5水位调节阀位置调节 (21)
5.6环缝元件调节 (22)
5.6.1位置传感器的调节 (23)
5.6.2联锁 (25)
5.7试水 (26)
6煤气净化系统的开车 (28)
6.1开车顺序 (28)
6.2煤气净化系统的密封 (29)
6.3煤气净化系统操作 (29)
6.4净化水水泵 (30)
6.5现场监控 (30)
6.5.1喷嘴入口就地压力显示 (31)
6.6控制室监控 (32)
6.6.1容许偏差 (33)
7煤气净化系统安全 (34)
7.1水供应故障 (34)
7.2液压故障 (35)
7.3环缝元件的位置偏差 (36)
7.4高炉煤气出口温度的偏差 (37)
7.5净煤气灰尘含量的偏差 (37)
Prepared : ECN 作者： ECN
8Shut Down (38)
9Maintenance Instructions (39)
9.1Raw Gas Pipe (39)
9.2Raw Gas Pressure Relief Valve (41)
9.3Spray Nozzles (42)
9.4Water Guiding Pipes (42)
9.5Pre Scrubber (44)
9.6Annular Gap Scrubber (44)
9.7Stuffing Box (45)
9.7.1Replacement of Stuffing Box Parts (46)
9.8Greasing System (48)
9.9Recirculation Pumps (49)
9.10Hydraulic Station (49)
9.11Level Tanks (50)
9.12Demister (50)
9.13Water valves (51)
9.14Condensation Traps (51)
10Clarified Water Quality (52)
10.1Clarified Water Requirements (52)
10.1.1General (52)
10.1.2Chemical Reactions in the Scrubber (53)
10.2Clarified Water Outlet Conditions (54)
10.3Clarified Water Inlet Conditions (54)
11Turbine and None Turbine Operation (55)
12Annex ............................................................................................ 567.6电气和控制偏差. (38)
8停车 (38)
9维护说明 (39)
9.1粗煤气管道 (39)
9.2粗煤气放散阀 (41)
9.3喷嘴 (42)
9.4水导向管 (42)
9.5预洗涤塔 (44)
9.6环缝洗涤塔 (44)
9.7密封箱 (45)
9.7.1密封箱部件的更换 (46)
9.8润滑系统 (48)
9.9循环泵 (49)
9.10液压系统 (49)
9.11水位罐 (50)
9.12脱水器 (50)
9.13水阀 (51)
9.14冷凝水收集器 (51)
10净化水质量 (52)
10.1净化水要求 (52)
10.1.1概述 (52)
10.1.2洗涤塔中的化学反应 (53)
10.2净化水出口条件 (54)
10.3净化水进口条件 (54)
11TRT工作和TRT不工作 (55)
12附件 (56)
Prepared : ECN 作者： ECN
1 Preface
When starting operation for Gas Cleaning Plants (GCP) the instructions of this operational Handbook shall be followed from the first day on in order to avoid unsafe operation, damages or unduly wear of components.
Beside the normal operation two start-up situations will be explained:
Re commissioning after long time shut down
Start up after short outage
For efficient operation the instructions for start up situations as well as the maintenance obligations for all components must be followed.
2 Functional Description and Process Data
2.1 Pre-Scrubber and Annular Gap Scrubber
The BF gas stream coming from the dry gas cleaning enters the scrubber from the top. The gas enters the spraying zone of the scrubber and passes through the water curtains emitted by the injecting nozzles. The coarse dust particles contained in the gas stream are embedded in the water droplets produced by the spray nozzles. The dust laden water droplets are collected in the sump of the spraying chamber and discharged to the water treatment plant.
After having passed the water curtains, the gas is pre-cleaned. A certain 1 前言
为了避免不安全的操作、损伤和不适当的零件磨损，当开始运行煤气净化系统操作时，从最开始必须严格按照本操作手册说明进行操作。

除了正常的操作之外，还有两种开车情况需要说明：
长时间停车后的再开车
短时间断电后的启动
为了设备的有效运行，必须严格遵守启动状况的说明以及所有部件的维护要求。

2. 功能描述与工艺参数
2.1 预洗涤塔和环缝洗涤塔
经过干法除尘步骤的高炉煤气从顶部进入洗涤塔。

煤气进入洗涤塔的喷雾区后通过由喷嘴喷出的水帘。

气体中的粗灰尘颗粒就进入了由喷嘴产生的水滴中。

装满灰尘的水滴收集在洗涤上段的排水锥里，然后排放到污水处理厂。

气体经过水帘后就已经完成预清洗了。

一定量的预清洗煤气可以用来为无
Prepared : ECN 作者： ECN
amount of the pre-cleaned gas can be used for pressurizing of the hopper of the bell-less top.
The key parts of the ANNULAR GAP SCRUBBER are the PAUL WURTH Annular Gap Elements.
ATTENTION: In order to achieve an optimum cleaning efficiency and minimum of wear it is extremely important that the distribution of the gas flow through the annular gap element has to be exactly even and symmetric.
Down stream the spraying chamber, the gas flows through the annular gap passage. Here, water is injected on top of the annular gap elements before the gas flows through the annular gap. When entering the annular gap the gas flow is accelerated. The high gas velocity produces strong turbulence, so that the gas is mixed with the injected water. During this mixing, even very small dust particles are embeded by the water droplets and removed from the gas. Please also refer to Fig 1 below. 料钟炉顶的料罐均压。

环缝洗涤塔的关键部件是PAUL WURTH 环缝元件。

注意：为了达到最佳的清洗效果和最小的磨损，以十分均匀和对称的气流通过环缝元件是非常重要的。

从预洗段下来的煤气流过环缝通道。

在这里在煤气流过环缝之前将水从环缝元件的顶部注入。

当煤气通过该环缝时煤气流被加速了，高的煤气流速产生强烈的湍流，从而煤气可以与注入的水混合。

在此混合过程中即使很小的灰尘颗粒也可以被水滴包住从而从煤气中除去。

此过程也可以参考图1
Prepared : ECN 作者 ： ECN
Water film
Gas
Annular mist flow Outer cone
Movable inner cone
Mechanism of droplet formation inside the annular gap
( detail I )
gas
gas gas gas gas
1
2345
Nozzle
detail I Water Gas
Operation Mode of the PW Annular Gap Scrubber
Operation Mode of the PW Annular Gap Scrubber Gas
Figure 1:
If e.g. the gas stream is interrupted due to clogging of dust, it is obvious that the water film on the cone is not evenly distributed on the
circumference. The flow of the gas will therefore also not be distributed properly and high wear of the cone is unavoidable. This results in a changing L/G ratio (mass flow of water to mass flow of gas) over the circumference of the annular gap.
The L/G ratio for the optimized cleaning efficiency is 1; i.e. 1 l of water has to be injected per 1 Nm3 of gas. In the case of misalignment between the cone and the venturi the L/G ratio will be lower than 1 at locations with higher gap width and higher than 1 at locations with lower gap width and the performance of the gas cleaning plant would get worse The dust-laden water is collected in the annular gap zone sump and
flows to the demister sump. From there it is recycled to the spray nozzles at the top of the scrubber via recirculation pumps. The clean gas that may still contain free water droplets leaves the scrubber in direction of
Water film
Gas
Annular mist flow
Outer cone
Movable inner cone
Mechanism of droplet formation inside the annular gap
( detail I )
gas gas gas gas gas
1
2345
Nozzle
detail I
Water Gas
Operation Mode of the PW Annular Gap Scrubber
Operation Mode of the PW Annular Gap Scrubber Gas
图 1: PW 环缝洗涤塔工作模式
如果由于灰尘的堵塞而导致煤气流的中断，那么很明显环缝元件锥芯上的水雾不会很均匀地分布在周围。

因此煤气的分布不均匀，从而环缝元件锥芯的磨损将不可避免。

这将导致在环缝圆周方向上的液气比L/G （水的质量流量与煤气的质量流量之比）的变化。

最佳净化效率的液气比为1，也就是说1标准立方米的煤气中要注入1升水。

如果环缝元件锥芯与文丘里管没有准对中，那么在环缝宽度较大的地方液气比就会小于1，而在环缝宽度较小的地方液气比就会大于1，从而煤气净化系统的性能就会变差。

带有灰尘的水收集在环缝洗涤段的排水锥内，然后流到脱水器下部集水池内。

水通过循环泵从那里回到洗涤塔顶部的喷嘴。

仍可能含有机械水的净化煤气从洗涤器流到脱水器。

Prepared : ECN 作者： ECN the demister.
2.2 The Demister
The gas enters the demister from top. The vertical demister ensures the optimized separation and droplets, which are separated at the demister shell, are not re-entering the gas stream.
The gas passes through vanes that give the gas stream an angular momentum. Centrifugal forces move the water droplets contained in the gas stream to the wall. Here the water is collected at the end of the demister and flows down into the sump from where it is drained to the recirculation main.
2.3 Plant Process Data
1 BF data
Useful volume: 2000 m3 Normal top pressure: 2 bar, g Max design pressure: 2,2 bar, g Min top gas flow rate: 220000 Nm3/h Normal top gas flow rate: 330000 Nm3/h Max. top gas flow rate: 350000 Nm3/h Normal top gas temperature: 250 °C Max top gas temperature 400 °C Average particle density 1500 Kg/m3 Top gas dust content 15 g/Nm3 Moisture content of BF gas: 30 g/Nm32.2脱水器
煤气从顶部进入脱水器。

立式脱水器有较优的分离效果，而且在脱水器筒体分离出的水滴也不会在进入煤气流。

煤气通过能给予它角动量的叶片。

离心力使煤气中的水滴甩向内壁。

水在脱水器的末端收集起来然后流向下集水池，流到循环水总管。

2.3系统工艺参数
1 高炉参数
有效体积: 2000 m3 正常顶部压力: 2 bar, g 最大设计炉顶压力: 2,2 bar, g 最小煤气流量: 220000 Nm3/h 正常煤气流速: 330000 Nm3/h 最大煤气流速: 350000 Nm3/h 正常炉顶煤气温度: 250 °C 最大炉顶煤气温度400 °C 平均颗粒含量1500 Kg/m3旋风除尘器入口煤气含尘量15 g/Nm3高炉煤气含水量: 30 g/Nm3
Prepared : ECN 作者： ECN - Gas analysis
CO 22,5 vol % CO219 vol % H20,5 vol % N256 vol %
Below figures are based on normal gas inlet
temperature, pressure and flow rate
2 Annular Gap Scrubber
Water flow rates and water conditions
Total clarified water requirement 500 m3/h Recirculation flow rate 330 m3/h
Inlet conditions water
Clarified water inlet temperature 20 °C Suspended solids < 100 mg/l Hardness (CaCO3) < 1000 mg/l Chloride content < 400 mg/l
Inlet/ Outlet conditions cyclone - 煤气成分
CO 22,5 vol % CO219 vol % H20,5 vol % N256 vol %
以下数据基于正常的煤气温度、压力和流速
2 环缝洗涤塔
水流速及水的条件
净化水总的需求量500 m3/h 循环水流量330 m3/h
入口条件—水质
净化水入口温度20 °C
固体悬浮物< 100 mg/l 硬度 (CaCO3) < 1000 mg/l 氯含量< 400 mg/l
Prepared : ECN 作者： ECN
Dust content at cyclone inlet < 15 g/Nm3 Dust content at cyclone outlet <2,25 g/Nm3
3 Vertical Demister
Dust content at normal operation pressure 5 mg/Nm3 Demister outlet pressure with TRT in operation 1,86 bar, g Clean gas pressure 0,1 bar, g Cleaning efficiency85-90 %
Clean gas temperature<40 °C
4 Gas Cleaning Plant General Conditions
Noise (TRT not in operation) of annular gap scrubber and
vertical demister 1 m outside gas cleaning plant.
- dB (A)
BF top pressure control accuracy if TRT is not in operation
and annular gap elements controlling the top pressure.
- kPa
3 Inspection, Pressurizing and Adjustment
For the start-up of gas cleaning plant the following points have to be checked and recorded:
•Foreign parts in the plant, for instance metal- wooden-, plastic material, glass parts as well as screws, wires, bottles, cans,
insulating material, tools, scaffold etc. have to be removed
旋风除尘器入口出口条件
入口含尘量< 15 g/Nm3出口含尘量<2,25 g/Nm3
3 立式脱水器
正常运行压力时含尘量 5 mg/Nm3 TRT运行时脱水器出口压力1,86 bar, g 净化后煤气压力0,1 bar, g 净化效率85-90 %
净化后煤气温度<40 °C
4 煤气净化系统总体条件
环缝洗涤塔及煤气净化系统1米外的立式脱水器的噪音（TRT
不运行时）
- dB (A)
当TRT不运行以及由环缝元件控制炉顶压力时，高炉炉顶压
力的控制精确度。

- kPa
3检查、加压和调整
为了煤气净化系统的开车以下几点必须进行检查和记录：
•系统内的外来物：如金属材料、木制材料、塑料、玻璃器件以及螺
Prepared : ECN 作者： ECN
•The pipe work must be flushed and the cleaned from foreign parts •Mud agglomeration or dust deposits have to be removed
•All manholes, openings and inspection holes must be closed and gas tight
•The greasing system must be ready for operation and the stuffing boxes of the rods must be checked for tightness
•The shut-off devices on the discharge side of the pump must be closed
•The hydraulic and electric actuated water valves must be checked and ready for operation
•All primary shut-off valves and other fittings to measurement and instrumentation must be opened
•All pumps must be ready for operation
•All measuring-, control- and regulation instruments must be checked and ready for operation
•All required utilities and consumables, like water, grease, lubricants, nitrogen, steam etc must be available for filling in •The inert gas connection must be ready for operation
4 Safety Requirements
For safety reasons the site should be in clean condition. Stairways platforms and direct surrounding of the Gas Cleaning Plant shall be clear and scaffolding and hoisting equipment should be removed.
The inside of the scrubber bottom as well as all stairways platforms and surrounding areas of the GCP need to be illuminated by sufficient
钉、电线、瓶子、罐头、绝缘材料、工具、脚手架等必须清除•管道必须清洗干净，没有外来部件。

•泥团和灰尘必须清除
•必须关闭所有人孔、开口及观察孔，并保持气密性。

•干油润滑系统须做好运行准备，要检查支承杆的密封箱是否紧密。

•必须将泵出口端的旁通装置处于关的状态。

•必须检查液动和电动水阀处于准备运行状态。

•所有主要的短路阀门及其它的测量器件及仪表必须打开
•所有的泵做好运行准备
•必须检查所有测量仪器、控制仪器以及调解仪器准备运行
•所有需要的介质及消耗品，例如水、油脂、润滑油、氮气、蒸汽等随时准备添加
•内通气体管线必须准备运行
4安全要求
为了安全起见，现场必须保持干净。

楼梯平台和煤气净化系统的周围环境必须保持清洁，脚手架和提升设备必须清除。

Prepared : ECN 作者： ECN
lighting.
5 Re-Commissioning after Long Time Shut Down
After the measures required under chapter 5 have be carried out and the requirements for commissioning of all plant parts according to the instructions of the manufacturer are fulfilled, the entire plant can be putting into operation as described below.
The safety technical regulation to the individual plant components have to be considered. To avoid explosive gas mixture the gas-bearing components are to be purged oxygen-free. As inert gas is nitrogen or steam required. The blanketing of the plant is required before first commissioning at least and always when the plant for walkways or inspection is made gas-free.
The entire plant has to be put into operation as follows:
•Hydraulic system
•Measuring and control devices
•Water cycle system
•Gas cleaning system
5.1 Rotation Control
In case of replacement of rotating equipment a rotation test has to be done before re-commissioning.
Pumps or other rotating equipment shall be checked for rotation direction of motor resp. impeller. This is to avoid damages and proper cooling is warranted.
The hydraulic pumps shall be switched on only for a short time to prevent
洗涤塔底部以及所有的楼梯平台和煤气净化系统周围区域必须保持有充足的照明。

5长时间停车后的再开车
当第五章要求的方法已经执行，以及系统内所有的设备都根据生产厂家的说明书上的要求调试后，整个系统就可以根据以下程序投入运行
必须考虑系统内单个设备的安全技术规程。

为了防止易爆气体的混合，含有煤气的部件必须保证处于无氧状况。

要求内通氮气或蒸汽。

至少在第一次开车前系统要求密封，当需要进行无煤气条件下的检查时系统必须一直密封。

整个系统需依照如下顺序投入运行：
•液压传动系统
•测量和控制装置
•水循环系统
•煤气净化系统
5.1转动控制
在更换了转动设备的情况下，在再次开车前必须对转动设备进行转动测试。

为了防止损坏泵或其它转动设备，在运转前必须检查电机的转动方向，另
Prepared : ECN 作者： ECN
damages in case of wrong rotation.
For water pumps the pump manual shall be checked to find out if it is required by the manufacturer to disconnect the coupling to separate motor from the impeller.
The pump manual has to be checked in any case for additional advises and further manufacturer demands. For instance a few greasing pumps have optional rotation direction but with regard to the gear tooth system right rotation is recommended.
5.2 Filling of Media
As far as piping or components has been renewed the piping system should be inspected for tightness of all flange connections. All pipes should have been cleaned from debris and flushed by water or chemicals in case of stainless steel material to be pickled. A pressure test with water (or oil in case of hydraulic pipes) for new pipe sections should have been done with all water as test medium drained. After these test procedures media can be filled to the system.
5.2.1 Filling of Oil
If the hydraulic system has been renewed or modified and a refill is required the following items should be checked before the specified oil is filled to the hydraulic oil tank:
•The hydraulic oil tank is cleaned
•The sealings and the paint is resistant to hydraulic oil
•Filters with specified mesh size are installed
•Filters are installed in flow direction 外必须保证有适当的冷却。

为了防止在错误的转动方向下运转造成损坏，液压泵只能短时间试转。

对于水泵，使用前必须检查操作手册看厂家是否要求断开联轴器以使电机和叶轮分开。

无论如何必须检查泵的操作手册以便得到其它的一些建议、及生产厂家的其它要求。

例如一些润滑泵可以任意方向旋转，但是若是齿轮啮合系统则推荐向右转动。

5.2介质的充入
当管道或者部件更新时，必须检查管道系统、所有法兰连接处的气密性。

所有管道上的碎片杂物须清除、用水冲洗，不锈钢材料可用化学药品清洗。

必须用水（当是液压管道时则用油）进行试压，当试压介质是水时试压完毕将水排放干净。

经过这些测试后工作介质就可以充入系统了。

5.2.1加油
如果液压系统进行了更新或改进而需要进行重新加油时，在往液压油箱中加油之前必须检查以下项目：
•液压油箱是否清洁
•密封和油漆是否是耐油的
•是否安装指定网孔尺寸的过滤器
Prepared : ECN 作者： ECN
•Measuring devices have to be checked and ready for operation •Electrical connections to MCC and from MCC to consumers have to be checked and ready for operation
•The accumulators are filled with nitrogen t the specified pressure After checking these items hydraulic oil can be filled up to the upper oil level mark.
5.2.2 Filling of Water
After checking the cleanliness of all pipes, tanks and pumps water shall be filled into the systems installed on ground level up to the highest spray nozzle. The water will be fed by using the pressurized cold water supply system. The following safety measures have to be taken care of to protect the pump:
•Assure that sealing water lines are connected and the sealing system is in operation (mech. seal) or that the gland packing is
properly packed and not tightened unevenly.
•Regulate flow rate with const. velocity to avoid water hammer and at discharge side only
•If no bypass line is integrated (minimal flow) pump shall not be operated longer than 2 min with discharge valve closed.
•过滤器是否安装在流动方向
•必须检查测量装置是否准备运行
•必须检查连接主控制台以及从主控制台到用电设备之间的线路是否准备运行
•蓄能器充氮至指定的压力
检查了这些项目后，就可以将液压油加至油液位刻度的上限标志。

5.2.2加水
经过检查所有的管道、液位罐和泵保持清洁后，就可以往系统中加水。

可以通过加入冷却水供给系统向系统加水。

为了保护泵，须采取以下的安全措施：
•保证密封水管的连接和密封系统（机械密封）的运行，保证密封垫正确包覆以及紧固的均匀性。

•为了防止出现水锤，必须保证水流速度的恒定
Prepared : ECN 作者： ECN
•The number of pump starts and stops per hour should not exceed the value given in the manufacturer manual
•Before re-starting make sure that the pump shaft is at rest and does not rotate in opposite direction.
All valves should be in normal operation position during this procedure. Secondary water supply lines like i.e. flushing water to level tanks shall remain closed. Venting valves of pumps, tanks and pipes shall be watched carefully and if bubble free water escapes from them they should be closed.
The demister overflow or an inspection hole at the demister can be opened during water filling for the use of over flow in order not to overfill the system.
ATTENTION: The venting valves on top of the level tanks must be closed after water filling otherwise clean gas can be blown out during hot commissioning. Nevertheless the balance line between tank and scrubber must always be open.
Conditions of shut off valves to start the water cycles:
No Description GCP- Code Status
1 Nozzle water valves pre-sc.
2 GNU06 AA103-105 OPEN
2 Nozzles water valves pre-sc. 2 GNK02 AA101-10
3 OPEN
•当管线中没有旁路时（最小流量），在出口阀门关闭的情况下泵的运行时间不能超过2分钟。

•每小时开泵和停泵的次数不应该超过生产厂家操作手册中规定的值。

•在重启前必须保证泵轴是静止的而且不会反方向转动。

在此程序中，所有的阀门必须处于正常的运行状态。

辅助供水，如水位罐的冲洗水管，应该保持关闭。

泵、水位罐和管道的排气阀必须密切观察，一旦有无水的气泡从这冒出就应该关闭。

为了不使系统装得过满，可以打开脱水器的溢流管或脱水器上的一个检查孔。

注意：当水加满后水位罐顶部的放空阀必须关闭，否则在热启动时净煤气会从该阀冒出。

尽管如此，水位罐与洗涤塔之间的平衡管必须保持常开。

开启水循环时开关阀的状态:
Prepared : ECN 作者： ECN
3 Nozzles water valves AG-sc. 2 GNK03 AA101-103 OPEN
4 Disch. level tank vent valve 2 GNS02 AA 581 CLOSE
5 Disch. level tank gas valves 2 GNS02-03 AA 101 OPEN
6 Reci level tank gas valves 2 GNU02-03 AA 101 OPEN
7 Reci level tank vent valve 2 GNU02 AA 581 CLOSE
8 Disch. level tank drain valves 2 GNS02,03 AA 102 OPEN
9 Reci level tank drain valves 2 GNU02,03 AA 102 OPEN
10 Reci station isolation valves 2 GNU06 AA 101-112 OPEN
11 Discharge station isol. valves 2 GNS01 AA101-112 OPEN
12 Reci pumps isolation valves 2 GNU04,05 AA 101,102 OPEN
13 Demister drain valve 2 GNG01 AA 102 CLOSE
14 Demister isolation valves 2 GNU01 AA 101,102 OPEN
15 Condensate traps isol. valve 2 GNU01 AA 103 OPEN
16 Water supply valve (nozzles) 2 GNK01 AA 201 OPEN
17 Reci station control valve 2 GNU06 AA 221 OPEN
18 Recirculation drain s/o valve 2 GNG01 AA 021 CLOSE
19 Recirculation drain isolation 2 GNG01 AA101 OPEN
20 Level tank first filling valves 2 GNF02-06 AA151 CLOSE
21 Reci water by pass valve 2 GNU06 AA 021 CLOSE
22 Disch. water bypass valve 2 GNS01 AA 031 CLOSE
23 Disch. water shut off valves 2 GNS01 AA 021 OPEN 5.2.3 Filling of Grease
Grease need to be filled into two areas:
编
号
种类煤气净化系统编码状态
1 预洗涤塔喷嘴水阀
2 GNU06 AA103-105 开
2 预洗涤塔喷嘴水阀 2 GNK02 AA101-10
3 开
3 环缝洗涤塔喷嘴水阀. 2 GNK03 AA101-103 开
4 排水水位罐放空阀 2 GNS02 AA 581 关
5 排水水位罐煤气阀 2 GNS02-03 AA 101 开
6 循环水位罐煤气阀 2 GNU02-03 AA 101 卡
7 循环水位罐放空阀 2 GNU02 AA 581 关
8 排水水位罐排污阀 2 GNS02,03 AA 102 开
9 循环水位罐排污阀 2 GNU02,03 AA 102 开
10 循环水截止阀 2 GNU06 AA 101-112 开
11 排水截止阀 2 GNS01 AA101-112 开
12 循环泵截止阀 2 GNU04,05 AA 101,102 开
13 脱水器排污阀 2 GNG01 AA 102 关
14 脱水器截止阀 2 GNU01 AA 101,102 开
15 冷凝排水器截止阀 2 GNU01 AA 103 开
16 供水阀(喷嘴) 2 GNK01 AA 201 开
17 循环调节阀 2 GNU06 AA 221 开
18 循环岗位排污s/o阀 2 GNG01 AA 021 关
19 循环排水隔离阀 2 GNG01 AA101 开
20 水位罐一次加水阀 2 GNF02-06 AA151 关
21 循环水旁路阀 2 GNU06 AA 021 关
22 排水旁路阀 2 GNS01 AA 031 关
23 排水开关阀 2 GNS01 AA 021 开5.2.3加润滑脂
Prepared : ECN 作者： ECN •Grease tank of the automatic greasing system
•Three containments above the stuffing boxes
Grease Tank
In case of a necessary refill of the grease tank it has to be assured that the tank is clean.
In case of replacement of the level measurement (i.e. ultra sonic) it must be set up by simulating the different levels in the tank and set these values at the device by means of dip switches.
In preparation to a trial run of the greasing pump the specified grease should be filled into the tank by preferably use the screw connection at the tank. It shall be avoided to fill from the top of the tank to prevent dirt from entering the system. A filling from the top also delays the grease flow for a while if not block the flow due to air inside the pump and air bubbles in grease itself. If a filling from the top is unavoidable and the pump can not convey air oil has to be filled in to the pump chamber in order to displace the air before filling in grease. During trial run this oil is collected in a container placed under the pressure outlet of the pump at disconnected pipes.
Containment above Stuffing Box
To prevent water and dust from entering the stuffing box the containment above the welded flange of the stuffing box should have been filled with grease during first commissioning according to the LUBRICATION MANUAL. 两个地方需要填加油脂：
•自动润滑系统的油箱
•密封箱上方的三个贮油环槽
油箱
如果油箱需要重新填加干油时，首先必须保证它的清洁
如果要更换液位测量装置（例如超声波式），则必须模拟油箱上不同的油位来标定，然后将这些值标在装置上。

在准备润滑泵的试车之前，必须将指定的润滑油加入到泵内。

必须避免将润滑油从顶部加入以免赃物进入系统。

由于泵内的空气以及润滑油本身的气泡，从顶部加入润滑油即使堵塞润滑油的流动也会延迟它的流动。

如果从顶部加润滑油不可避免而且该泵不能输送空气，那么在加润滑油之前首先应往泵室内加油以驱除泵内的空气。

试车过程中这些油将用单独的管道收集在泵压力出口处的一个容器中。

密封箱上方的贮油环槽
Prepared : ECN 作者： ECN
ATTENTION: In case this first filling was not done properly or weekly greasing has been done poorly a refilling is required.
This shall be accomplished by using the two R 1” nozzles on each welded flange. The installed automatic greasing system shall not be used for this due to its small tank capacitiy and the pumps small flow rate. A ten times higher flow rate of a barrel pump (i.e. 60 l/h or more) shall be used. After the first 30 liters the hose shall be disconnected and the opposite R 1” nozzles connected to drive out all air and spread grease equally inside the containment.
To monitor the filling of grease the top of the containment is flanged. After loosing the bolts the inside of the containment is ready for inspection
Another way of filling grease i.e. by shovel from the opened top of the containment will show unsufficient results because of air caverns. These air caverns will later be filled with process water and than displace the lighter grease into the down stream systems where they clog the vibration switches and pipes. Soon water can enter the stuffing box wash out grease at the sealings and gas tightness can on longer be warranted.
After filling up the required grease amount the possible surplus grease can be driven out and cleaned up by moving the AG element up and down a few times.
ATTENTION: The filling and constant dosing of grease according to the grease manual is vital for proper function and long life of seals and bushings of the AGE rod. No rust, dust or scratches should be on the rod surface. 根据润滑操作手册，为了防止水及灰尘进入密封箱，在第一次开车前必须对密封箱的焊接法兰上方的贮油环槽加满干油。

注意: 如果第一次加油的操作不正确或者每周的润滑做得很差，那么必须进行重新填加油脂。

在每个焊接法兰必须使用两个R 1” 的喷嘴来完成加油工作。

由于自动润滑系统的油箱容积小以及泵的流量小，因此在这里不能使用自动润滑系统。

必须使用流量高10倍的桶式泵（例如60升/小时或更高）。

当加了最初的30升油后必须把软管拿掉，然后连接对面的一个R 1” 喷嘴以赶走贮油环槽的空气和使油脂在贮油环槽内分布均匀。

为了监控润滑油脂的填加情况，该贮油环槽的顶部是带有法兰的，松开螺钉后就可以观察贮油环槽内的情况。

由于空气孔穴的存在，另外一种填加润滑油脂的方法，例如从打开的贮油环槽顶部铲入就显得不够充分。

这些空气孔穴后来会被过程中的水充满，然后这些水会取代轻的润滑油脂沉到系统底部从而堵塞水位罐上的液位开关和管道。

不久这些水就会进入密封箱并将密封圈内的润滑油脂洗出，从而系统的气密性不能得到保证。

当加到规定数量的润滑油后，可以通过将环缝元件上下移动几次来将可能多余的油脂排出，并清理干净。

Prepared : ECN 作者： ECN
5.3 Pressurizing of Hydraulic System
During re-pressurizing after stand still of the hydraulic system excess personnel should be removed from the dangerous zone. Only the maintenance and operating people should be present. The following steps are executed to run the hydraulic system for a first trial: •Check oil level and if necessary add oil
•All primary shut-off valves of measuring points opened
•All manual shut off valves are set to the required position
•Switching on hydraulic oil circulation pump, heating and cooling system
•Starting main pressure pump
•Venting the air from lines at the highest point possible until the oil from the venting point is bubble free. If no oil foam is in the tank
and no jerky movements or unusual noise occur ventilation is
successful )*
•Scavenge the system until filters remain clean
ATTENTION: Scavenging must be done by shutting off all
valve racks in scrubber bottom to protect them from dirt )* •After reaching operating temperature check system under pressure (leakage)
•Constantly watch measuring equipment
•Check oil level and if necessary add oil 注意：润滑油的填充和根据操作手册确定的恒定的量加油对于密封垫、环缝元件连杆的轴衬的使用寿命是非常重要的。

支承杆表面不应该有铁锈、灰尘和划痕。

5.3液压系统的加压
当对停车后液压系统进行再加压时，所有无关人员应该离开此危险区域。

只有维护和操作人员可以在现场。

第一次试验时应根据以下步骤来运行液压系统：
•检查油位，如果需要就加油
•所有测量点阀必须打开
•所有手动截止阀打到规定的位置
•打开液压油循环泵、加热和冷却系统|
•启动主泵
•尽可能将管道中的空气从最高点放空直到从放空点排出的油里没有气泡为止。

如果油箱内没有油沫且没有冲击或不正常的噪音产生，
则排气过程结束)*
•清洗系统，直至过滤网保持干净
注意: 进行清扫时，关闭所有的洗涤塔底部的阀台截止阀，以免它们被弄脏)*。