胶球清洗装置说明书

凝汽器胶球清洗系统Condenser Gum Ball Cleaning System 安装维护使用说明书Installation and Maintenance
Manual
青岛市胶州发电设备有限公司
Qingdao Jiaozhou Power Equipment Co., LTD.
电话：0086 532 87286338 /87286299
Tel: 0086 532 87286338 /87286299
传真: 0086 532 87286078
Fax: 0086 532 87286078
地址：山东省胶州市郭家庄西工业园
Address：Shandong Jiaozhou Guojiazhuang West Industrial Park
目录
CONTENT
第一章胶球清洗系统布置和安装
ChapterⅠLayout and Installation of Gum Ball Cleaning System 第二章设备安装
Chapter II Equipment Installation
第三章胶球清洗系统运行
Chapter III Running of Gum Ball Cleaning System
第四章停用保养
Chapter IV Disable Maintenance
第五章管理
Chapter V Management
第六章检修、检查、维护
Chapter VI Overhaul, Inspection and Maintenance
第七章故障及处理
Chapter VII Failure and Solution
第一章胶球清洗系统布置和安装
ChapterⅠLayout and Installation of Gum Ball Cleaning System
一、胶球清洗系统布置方式有两种
Ⅰ. There are two layout ways of gum ball cleaning system
１、单元制系统Modular system
１、排污口２、清洗蝶阀３、二次滤网４、装球室５、球阀６、胶球泵７、收球网８、收球网板操作机构．
1. Outfall 2, Cleaning valve 3, Secondary screen 4, Ball room 5, Ball valve 6, Gum ball pump 7, Ball screen 8, Ball net plate operating mechanism.
2. Sharing system
２、共用制系统Common control system
１、排污口２、清洗蝶阀３、二次滤网４、电动机５、收球网６、装球室７、球阀８、胶球泵９、分汇器．
1. Outfall 2, Cleaning valve 3, Secondary screen 4, Motor 5, Ball screen 6, Ball room 7, Ball value 8,
Gum ball pump 9, Sub-exchange device.
胶球清洗系统安装应遵照供货单位提供的系统布置图和技术要求进行安装，不可随意增减系统中的相对位置．
The installation of gum ball cleaning system shall be subject to system layout diagram and technical requirements provided by supply unit, prohibit increase or decrease the relative position of the system arbitrarily.
二、不同布置方式的适用范围：
II. The scope of application of different layout:
a、单元制系统，适合于为100MW以上容量的机组配套使用．优点是对凝汽器各侧可同时进行清洗；另外，任何一侧的胶球清洗系统出现故障，均不会影响另一侧的正常运行．
b、共用制系统，适合于小机组使用．优点是设备少，主要缺点是当系统中共用部分发生故障时，凝汽器的任何一侧都无法清洗．
a. Modular system is suitable with the units of over 100MW. Advantage is that each side of condenser can be cleaned at the same time; Moreover, any side of the gum ball cleaning system broke down, which will not affect the normal operation of the other side.
b. Sharing system is suitable for use in small units. Advantage is less equipment, and the main drawback is that when the common parts of the system broke down, any side of the condenser can not be cleaned.
第二章设备安装
Chapter II Equipment Installation
收球网：Ball screen:
收球网尽量采用立式安装，并且收球网胶球引出管尽量高于胶球泵入口．
收球网在循环水管弯头后很近处安装时，应使操作轴与弯头方向相平行；对ＳＤ型收球网最好采用操作轴与弯头方向相垂直的布置方式，且在收球位置时，网板进口端靠在内侧筒壁．收球网若采用卧式布置时，胶球引出管应按要求在收球网底面或侧面．
Ball screen adopts vertical installation as far as possible, and ball screen gum ball extraction tube shall be higher than gum ball pump.
When installing the ball screen closed to circulating water pipe elbow, they should make the operation shaft run parallel to the direction of elbow; about SD-type ball screen, preferable to use the layout of operation axis perpendicular to the direction elbow, and in the position received the ball, head of the halftone leaning against the inner tube wall. If the ball screen adopts horizontal layout, the gum ball extraction tube should bet at the bottom or the side of the ball screen as required.
胶球泵：Gum ball pump:
胶球泵安装的相对位置不宜过高，以防气蚀．胶球泵的吸上真空高度一般为7m水柱．
The relative position of gum ball pump should be not too high to prevent gas etching. The vacuum suction height of gum ball pump is generally the water column of 7m.
装球室：Ball room:
用于贮存、更换胶球及观察胶球运动，故安装位置应便于操作人员接近，放气、放水管接至排水地沟．
For use of storage, replace of gum ball and the observation of gum ball’s movement, so the installation location should be accessible to the operator, exhaust tube and offlet connected to the drainage trench.
胶球管路及阀门：Gum ball piping and valves:
胶球管路应短直流畅，球阀或蝶阀安装位置应便于操作，装球室进口阀在装球室的进口处安装，管系严密不漏．
Gum ball piping should be short, straight and smooth. The installation location of ball valve or butterfly valve should be easy to operate. Suction valve shall be installed on the entrance of ball valve. Piping shall be tight and no leaking.
循环水系统中安装有二次滤网时，一般情况下，二次滤网出口至凝汽器间，循环水的长度有限，但布置投球管时，应遵照以下原则，且不可在凝汽器水室中布置．
When installing the secondary screen in circulating water system, generally, the circulating water is limited in length from the outlet of the secondary screen to the condenser, but arranging pitch pipes shall be subject to the following principles, and can not do in water room of the condenser.
循环水管通径DN<1200时，投球管（伸入循环水管中的胶球管路）用一根，并伸至循环水管中心，DN≥1200mm时，用两根并在循环水管同一正截面内对称布置，两管口中心在循环管同一直径上，管口间距离等于循环水管半径，投球管出口逆循环水流方向．
When the circulating water pipe diameter DN <1200, the pitch pipe (the gum ball piping stretching into the circulating water pipe) adopts one, and extended to the center of circulating water pipe. When DN ≥ 1200mm, use two to parallel in the same section of the circulating water pipe with symmetrical arrangement, centers of the two nozzles in the same diameter of the loop pipe, the distance between the nozzle is equal to the radius of the circulating water pipe, and the outlet of the pitch pipe opposes circulating flow direction.
控制装置：Control device:
控制柜或程控柜，应在通风、干燥、且靠近装球室处安装．
Control cabinets or program-controlled cabinets should be installed in ventilated, dry, and close to the ball room.
二次滤网：Secondary screen:
配装有二次滤网的胶球清洗系统中，二次滤网的安装部位，一般情况下应离开凝汽器进口一段距离，这样对于投球管的布置有利．以海水为冷却水源的电厂，二次滤网宜靠近凝汽器进口布置，以便减少二次滤网后循环水管中海生物的数量，从而减少冷却管、收球网被堵塞的机会．二次滤网的排污管路应短直流畅，尽量减少管路水阻，因为二次滤网排污是依靠循环水压差来实现的，故排污水阻大时会直接影响排污效果．
In the gum ball cleaning system with the secondary screen, the installation position of the secondary screen should keep a distance from the entrance of the condenser, so that it’s favorable for the arrangement of pitch pipe. Regard the seawater as the cooling water plant, the secondary screen should be close to the entrance of the condenser in order to reduce the number of sea creatures in the circulating water pipe after the secondary screen, thereby reducing the opportunities of the blocked cooling pipe and ball screen. The blow-off line of the secondary screen should be short, straight and smooth, minimize the water resistance of piping, as the secondary screen scavenging relies on recycled water pressure to achieve, the large sewage water resistance will affect effects of sewage directly.
胶球清洗系统的安装，应按照制造厂提供的系统布置图和技术要求进行，不可随意增减系统中配套件的数量和改变设备配套件的数量和改变设备配套件在原系统中相对位置．
The installation of gum ball cleaning system should be in accordance with layout diagram and technical requirements provided by factory, prohibit increase or decrease the number of component parts and the relative position of the system arbitrarily.
第三章胶球清洗系统运行
Chapter III Running of Gum Ball Cleaning System
运行必备条件：Running prerequisites:
１、凝汽器：Condenser:
a、水室中的涡流区、水室中隔板窜通缝隙及窄缝（由于水室四壁、水室隔板与端盖同密封垫尺寸不合适所致，将会引起积球）应于消除；水室中除循环水管外其余通往外部的管道，应在管口加装孔径小于Φ7mm的球面网罩；水室中垢片、锈片及杂物通水前清理干净．
The water in the room, water vortex zone partition channeling through cracks and narrow gap (due to water chamber walls, and cover with gasket partition size doesn't fit, will cause the ball) should eliminate product;Water in the room except the circulating water pipes to the rest of the pipeline, should be in the outer tube diameter less t han Φ 7mm installs the spherical nets mask; clean the dirty things ,rust and sundries in the room, before working with the water.
b、冷却管每种规格的管径均匀一致，管内无阻碍胶球通过的杂物；胶球清洗系统初始投运时，冷却管内壁应洁净无垢，已结硬垢的应采取措施彻底除垢；管板若涂刷环氧树脂等涂料，应严防因此缩小冷却管口通径；胀管时，管口伸出管板长度不宜超过2.5mm.
Cooling tube diameter of each specification uniform, tube unimpeded by sundry ball;when the Rubber ball cleaning systems works first, cooling tube initial operation wall should be clean, has hardened scale measures should be taken to complete removal;If a tube plate coating epoxy coating should be protected, thus narrowing cooling pipe size;When the pipe expanding, tube sheet length is out over 2.5 mm.
２.循环水及循环水管：Water and circulating water pipes:
a、循环水量宜保持在设计值的±15%范围内．亦可根据以后的清洗效果适当改变对循环水量的控制范围．
In the design of water cycle in the range of ± 15% value. Also we can change the control of the water cycle according to the appropriate after cleaning effect.
b、一次滤网（包括拦污栅、扒草机等）完好．工作正常，能保持无大于收球网栅格间距的杂物通过，否则必须配装二次滤网．
Once filter screen(including Trash rack, grilled grass machine etc)is complete Ok, in proper working order, It can keep the charge of the no more grid spacing sundry through, otherwise we must Equipped with secondary filter.
c、循环水需充满凝汽器水室，若充不满则必须采用比重大于循环水的湿态胶球（胶球吸足水后的状态）．
Circulating water should be full of the room of the condenser, if it can’t be full of ,we must use proportion than circulating wet glue ball (rubber ball absorb enough water after the state).
d、循环水管中的垢片、锈片和杂物通水前清理干净．
Clean the dirty things ,rust and sundries in the cycle water pipe before working with the water. ３、胶球：Rubber ball:
耐磨、质地柔软、富于弹性、气孔均匀贯通、硬度适中、湿态比重1.00-1.15、在5-45℃水温下及使用期内环境胀大不超标、不老化．
Hard wearing, soft,elastic,porosity evenly, hardness moderate, Wet proportion in the 5-115, 100-45 degrees Celsius temperature and use period swell not overweight, environment of aging.
４、设备：Equipment:
胶球清洗装置及配套件，安装符合要求，具备正常使用条件．
Rubber ball cleaning equipment and accessories, installation requirements, with normal conditions of use.
５、运行注意事项：Running note:
胶球清洗系统安装后，应及时进行调试；调试合格后，按规程要求经常操作运行．
After install the rubber ball cleaning system, it should be debugged on time; after debugging it successfully, make it work according to the directive rules.
６、胶球规格：Rubber ball specifications:
开始使用的胶球湿态直径比冷却管中较小一种规格的内径大1.0-2.0mm,使用中球径磨损到等于或小于上述冷却管内径时及时更换；采用金刚砂球清除冷却管硬垢时，其湿态球径比上述冷却管内径小1.0-2.0mm，待硬垢基本除净后应停用．球径及硬度还与循环水量有关．
Start using the wet cooling tube diameter bigger than cooling tube small a specification as 1.0-2.0 mm diameter, during the working, when it wears to equal to or less than the cooling tube diameter, it should be changed; when use emery ball to get rid of the hard scale of the cooling tube,the wet ball diameter less than the cooling tube diameter of 1.0-2.0 mm, after finishing get rid of it, it should be stopped to be used. The sphere diameter and the hardness are also relevant with the water cycle.
７、正常投球量：The normal work:
投入运行的胶球数量为凝汽器单侧单流程冷却管根数的7%-13%,取下限或靠近下限的数量，胶球循环一次不超过30秒．
The rubber ball into operation for single flow condenser cooling tube unilateral number of 7-13% lower limit, or close to the quantity, rubber ball cycle time does not exceed 30 seconds.
８、清洗周期和清洗时间：The cleaning cycle and cleaning time:
胶球清洗系统每天运行（清洗）一次，每次30分．用户也可根据以后的清洗效果适当改变上述数值．
Rubber ball cleaning system operation (cleaning) once every day, each time 30 minutes. The user may change the value according to the cleaning effect.
９、胶球补充周期和更换周期：Rubber ball added cycle and change cycle:
胶球清洗系统累计运行七次，补充胶球；累计运行60次，进行更换．用户还可根据各自具体情况如投球数量、实际收球率（满足投运条件、系统正常运行30分、收回的胶球数与投入运行的胶球数的百分比）,所用胶球的耐磨性能等，适当调整上述周期．个别胶球可能在水中浸泡一段时间后，胀大过多，球径超标，在检查补充和更换胶球时，均需随时换掉．
After the rubber cleaning system runs for seven times, replenish the rubber ball; after it runs 60 times, change it. The user also can according to the specific passion of their own to move the times above, such as pitching quantity、actual charge ball rate（Meet operation conditions、Normal operation system 30 points、The percent of the rubber ball back and operation of the rubber ball）、the Wear-resisting performance of the rubber ball, etc. Several rubber balls maybe swollen a lot after soaking in the water for a period of time, the ball diameter out of limits. When we check or mend or change the rubber balls, they should be changed.
安装有循环水二次过滤系统.两个系统不得同时运行；必须在循环水二次过滤系统运行结束之后，胶球清洗系统才允许投入运行．
Install a water second filtration system. The two system can’t be run at the same time; it must be u sed after the water second filtration system finish it’s running.
二次滤网的网芯网孔为7mm,所有大于7mm的污物杂质，保证不会进入凝汽器水室内，从二次滤网排污管道内排出.
The nets core and the net hole of the secondary filter are 7mm,all the dirt impurities are bigger than 7mm, can’t be entered to the cond enser room, they will row out of the sewage pipe of the secondary filter.
二次滤网排污是通过网芯前后压差值由差压变送器来实现自动排污，差压变送器动作值设置在
P(二次滤网开始运行时测得压力值+0.2MPa)，当网芯前后压差值≥P时，差压变送器开始传送排污信号，来实现排污。

Secondary filter core and drainage is through the net by differential pressure difference transmitter to realize automatic decontamination,Differential pressure transmitter action value in P (secondary filter was started to pressure value + 0.2 MPa),When the nets core values and differential
作收球．
Note:As a second charge at the end of the operation, and do not open sheet, ball will pack the ball out of indoor ball, then the above operation charge.
２、程序控制收球：Program control ball:
程序启动后，系统按程序设计要求自动进行清洗和收球．动作顺序与手控操作相同．
After starting the program design, the system according to procedures required automatic cleaning and accept the ball. The same order and manual control operation.
第四章停用保养
Disable Maintenance
胶球清洗系统较长时间停用时，应每三天活动一次各操作轴，若停用期处于冬季，应将胶球管路、球阀、泵及装球室中存水放净．
After the rubber ball cleaning system for a long time, it should be stopped once every three days of operational activities, if disable period in the axis should be the winter, piping and valves, pumps and standing in the room for the ball.
第五章管理Management
制定规章、完善制度、健全组织、加强管理、建立档案、作好记录．
Regulations, perfecting the system and improve the organization, strengthen management, establish archives, make record.
第六章检修、检查、维护
Overhaul, Inspection and Maintenance
收球网：Collect net
网板有无脱焊、变形或损坏，与轴联接有无松动，活动网板与与固定部分间是否卡碰，轴有无弯曲、能否灵活转动，执行机手动、电动运转是否正常、到位，指示是否准确，轴承是否泄露等．Sheet welding deformation, without off or damage, and the shaft coupling, activity or loose with fixed part between the plates, or whether the card can bending and axial rotation JiShou, flexible operation, electric, normal, instructions are accurate, bearing whether leak, etc.
清除板上的一切杂物．Remove all of the board.
胶球泵：Rubber ball pump
叶轮是否完好，轴转动是否灵活，电动机性能是否合格，泵壳有无杂物，电机与泵二轴是否对中动静部分有无摩擦，地脚螺母是否松动，运行中检查振轴承动及密封有无滴漏．
Whether the impeller, axis is flexible, motor performance is unqualified, pump motor and pump without sundry, whether in the second shaft part of static friction, or whether the nut, anchor operation of inspection and seal or vibration bearing drip.
装球室：Ball room
切换阀能否灵活转动，放气、放水管有无堵塞，轴承有无泄露执行机手动、电动是否正常，到位指示是否准确等．
Switch valve can be flexible rotation, gas, water, or put blocked or leak JiShou execution bearing, electric normal, whether accurate position indicator.
各阀门：Each valve:
操作是否灵活，有无泄露，执行机工作是否正常，开关指示是否准确．
The operation is flexible, without leakage, whether normal, switch machine work instructions are accurate.
控制装置：Control device:
能否正常运行，仪表、指示灯是否齐全有无破损等．
The operation is flexible, without leakage, whether normal, switch machine work instructions are accurate.
胶球管路:The line of the rubber ball：
有无泄露和堵塞．Any disclosure, and congestion.
执行机：Execute machine:
按执行机说明书要求或根据经验，定期更换润滑剂．
According to the execution machine specifications or according to experience, change regularly lubricant.
减速机构，转动齿轮：Slow, rotary gear:
润滑脂每半年补充一次，机组大小修中更换．
Once every six months, grease supplementary units in big change.
配装有二次滤网的胶球清洗系统，二次滤网也要经常检查，有污垢经常清理，发现问题及时处理，这样有利于减少水阻，保证收球效果避免恶性事故发生．
Equipped with a mesh of rubber ball cleaning system, secondary filter will often checks, have often dirt, found that the problem, so to reduce water resistance, accept the ball effect to avoid vicious accidents.
经常对设备及配套件进行检查，如有缺陷及时消除．
Frequently check for equipment and accessories, such as defective promptly eliminate.
第七章故障及处理Chapter VII Failure and Solution。