鍋爐倉(cāng)泵是鍋爐輸灰系統(tǒng)的重要組成部分，其直接影響輸灰系統(tǒng)的除灰效果。轉(zhuǎn)化果平臺(tái)推薦的《提高鍋爐倉(cāng)泵儀表穩(wěn)定運(yùn)行性研究》，針對(duì)倉(cāng)泵儀表故障頻繁問題，從設(shè)備、環(huán)境等方面對(duì)故障現(xiàn)象進(jìn)行原因分析，制定相應(yīng)方案對(duì)策并逐一進(jìn)行實(shí)施，有效減少了倉(cāng)泵的檢修次數(shù)，降低了勞動(dòng)程度，取得較好經(jīng)濟(jì)效益。

　　The boiler compartment pump is an important component of the boiler ash conveying system, which directly affects the ash removal efficiency of the ash conveying system. The "Research on Improving the Stable Operation of Boiler Warehouse Pump Instruments" recommended by the Conversion Fruit Platform analyzes the causes of frequent failures in warehouse pump instruments from equipment, environment, and other aspects. Corresponding solutions and countermeasures are formulated and implemented one by one, effectively reducing the number of maintenance times for warehouse pumps, lowering labor levels, and achieving good economic benefits.

　　一、研究背景

　　1、 Research background

　　鍋爐輸灰系統(tǒng)專門用于處理鍋爐排向大氣煙氣中的粉塵，經(jīng)過除塵器、倉(cāng)泵、灰?guī)靸?chǔ)運(yùn)外運(yùn)等環(huán)節(jié)完成對(duì)粉塵的處理。倉(cāng)泵運(yùn)行狀態(tài)直接影響輸灰系統(tǒng)的除灰效果，故障率高會(huì)對(duì)環(huán)保產(chǎn)生不利，增加運(yùn)行成本，并影響鍋爐的安全運(yùn)行，因此倉(cāng)泵的穩(wěn)定運(yùn)行尤為重要。 項(xiàng)目研究目標(biāo)：實(shí)現(xiàn)降本增效、節(jié)能降耗要求，解決倉(cāng)泵頻繁加壓超時(shí)的現(xiàn)象，降低倉(cāng)泵儀表故障次數(shù)，提高倉(cāng)泵運(yùn)行穩(wěn)定性，達(dá)到安全環(huán)保高效運(yùn)行。

　　The boiler ash conveying system is specifically designed to handle the dust emitted from the boiler into the atmosphere. The dust is processed through processes such as dust collectors, bin pumps, and ash storage and transportation. The operating status of the silo pump directly affects the ash removal efficiency of the ash conveying system. A high failure rate can be detrimental to environmental protection, increase operating costs, and affect the safe operation of the boiler. Therefore, the stable operation of the silo pump is particularly important. Project research objective: To achieve the requirements of cost reduction, efficiency improvement, energy conservation and consumption reduction, solve the phenomenon of frequent pressurization and timeout of warehouse pumps, reduce the number of instrument failures of warehouse pumps, improve the stability of warehouse pump operation, and achieve safe, environmentally friendly and efficient operation.

　　某單位月度鍋爐倉(cāng)泵檢修統(tǒng)計(jì)表

　　Monthly Boiler Storage Pump Maintenance Statistics Table for a Certain Unit

　　二、研究?jī)?nèi)容

　　2、 Research content

　　1.要因分析

　　1. To analyze the reasons

　?。?）閥門材質(zhì)不符合工況要求

　　(1) The valve material does not meet the working condition requirements

　　對(duì)1#鍋爐1-3月倉(cāng)泵儀表故障進(jìn)行調(diào)查統(tǒng)計(jì)。從故障統(tǒng)計(jì)表可以看出，倉(cāng)泵故障現(xiàn)象中，原因最多的是閥門故障，其占比最多。

　　Conduct investigation and statistics on the instrument failures of the storage pump in boiler 1 from January to March. From the fault statistics table, it can be seen that the most common cause of warehouse pump faults is valve failure, which accounts for the largest proportion.

　　改造之前選用的出料閥閥芯是鑄鋼材質(zhì)，易沖蝕，密封性差，壽命短。閥門預(yù)期壽命為180天，而實(shí)際情況由于閥門動(dòng)作頻繁、物料沖蝕等原因，導(dǎo)致閥門實(shí)際使用壽命短，實(shí)際與預(yù)期工作壽命相差較大，要頻繁檢修更換閥門。

　　The discharge valve core selected before the renovation is made of cast steel material, which is prone to erosion, has poor sealing performance, and has a short service life. The expected service life of the valve is 180 days, but in reality, due to frequent valve movements, material erosion, and other reasons, the actual service life of the valve is short, and there is a significant difference between the actual and expected working life, requiring frequent maintenance and replacement of the valve.

　　（2）儀表接地、隔離措施不規(guī)范

　　(2) Improper grounding and isolation measures for instruments

　　物料在倉(cāng)泵內(nèi)流動(dòng)過程中會(huì)產(chǎn)生靜電，靜電通過倉(cāng)泵遠(yuǎn)傳壓力變送器信號(hào)回路傳輸至PLC控制柜內(nèi)造成控制柜內(nèi)電壓波動(dòng)大。由于儀表接地、隔離措施不規(guī)范，易損壞PLC控制模塊和壓力變送器等，致使倉(cāng)泵頻繁加壓超時(shí)，產(chǎn)生報(bào)警，無法正常投運(yùn)。

　　During the flow of materials in the warehouse pump, static electricity is generated, which is transmitted to the PLC control cabinet through the remote pressure transmitter signal circuit of the warehouse pump, causing large voltage fluctuations in the control cabinet. Due to non-standard grounding and isolation measures for instruments, it is easy to damage PLC control modules and pressure transmitters, resulting in frequent pressurization timeouts of the bin pump, generating alarms and preventing normal operation.

　?。?）壓力變送器安裝位置不當(dāng)壓力變送器安裝于控制柜內(nèi)，與倉(cāng)泵相連接的導(dǎo)壓管過長(zhǎng)容易積灰，致使倉(cāng)泵壓力測(cè)量不準(zhǔn)，導(dǎo)致倉(cāng)泵頻繁加壓超時(shí)故障報(bào)警。

　　(3) Improper installation position of pressure transmitter. The pressure transmitter is installed in the control cabinet, and the pressure pipe connected to the bin pump is too long, which can easily accumulate dust, resulting in inaccurate pressure measurement of the bin pump and frequent pressure exceeding fault alarms.

　　從人、機(jī)、料、法、環(huán)五個(gè)方面集思廣益對(duì)故障現(xiàn)象（頻繁加壓超時(shí)）可能發(fā)生的原因進(jìn)行徹底的分析。最終得到了：閥門材質(zhì)不符合工況要求、壓力表安裝位置不合理、儀表接地隔離措施不規(guī)范的三條主要原因。

　　Thoroughly analyze the possible causes of the fault phenomenon (frequent pressure exceeding the time limit) from five aspects: human, machine, material, method, and environment. Finally, three main reasons were identified: valve material not meeting operating requirements, unreasonable installation position of pressure gauges, and non-standard grounding and isolation measures for instruments.

　　2.制定實(shí)施對(duì)策（1）閥門重新選型通過查閱資料，選擇合適的耐沖蝕的陶瓷材質(zhì)閥門；安裝、配置氣源管、調(diào)試閥門，確保閥門動(dòng)作正常。

　　2. Develop implementation strategies: (1) Re select valves by consulting relevant materials and selecting suitable ceramic valves that are resistant to erosion; Install and configure the gas source pipe, debug the valve, and ensure that the valve operates normally.

　　實(shí)施效果：

　　Implementation effect:

　?、俑鼡Q完耐沖蝕陶瓷閥后查看閥門趨勢(shì)，開關(guān)正常且規(guī)律；②有效解決了流灰對(duì)閥內(nèi)件的沖蝕，閥門使用周期從20多天增長(zhǎng)為200多天，使用壽命大幅提升；確保了閥門良好的密封性，解決倉(cāng)泵因出料閥密封不嚴(yán)而泄露的問題，保證整個(gè)系統(tǒng)連續(xù)穩(wěn)定運(yùn)行。

　?、?After replacing the erosion resistant ceramic valve, check the valve trend and ensure that the opening and closing are normal and regular; ② Effectively solved the erosion of valve internals caused by flowing ash, and the service life of the valve increased from over 20 days to over 200 days, significantly improving its service life; Ensure good sealing of the valve, solve the problem of leakage of the bin pump due to poor sealing of the discharge valve, and ensure the continuous and stable operation of the entire system.

　?。?）儀表回路增加安全柵、現(xiàn)場(chǎng)增加接地

　　(2) Add safety barriers to the instrument circuit and increase grounding on site

　　確認(rèn)控制柜安全柵供電方式及型號(hào)；對(duì)選型好的安全柵進(jìn)行組態(tài)、安裝、接線、調(diào)試；對(duì)控制柜及現(xiàn)場(chǎng)儀表增加接地。實(shí)施效果：①安全柵可以起到很好的隔離高電壓、大電流的作用。增加安全柵，以次消除靜電，保護(hù)電路和設(shè)備；②增加儀表接地，將靜電與儀表設(shè)備有效隔離，從根本上消除現(xiàn)場(chǎng)靜電對(duì)控制柜PLC模塊的不良影響，避免壓力變送器的損壞，消除故障報(bào)警。（3）壓力變送器重新安裝

　　Confirm the power supply mode and model of the control cabinet safety barrier; Configure, install, wire, and debug the selected safety barriers; Add grounding to the control cabinet and on-site instruments. Implementation effect: ① Safety barriers can effectively isolate high voltage and high current. Add safety barriers to eliminate static electricity and protect circuits and equipment; ② Add instrument grounding, effectively isolate static electricity from instrument equipment, fundamentally eliminate the adverse effects of on-site static electricity on the control cabinet PLC module, avoid damage to pressure transmitters, and eliminate fault alarms. (3) Reinstall the pressure transmitter

　　考慮到導(dǎo)壓管過長(zhǎng)，容易堵塞造成壓力表測(cè)量不準(zhǔn)，將變送器由原來控制柜內(nèi)移至倉(cāng)泵取壓口上方；安裝方式由水平安裝改為垂直安裝。

　　Considering that the pressure pipe is too long and prone to blockage, causing inaccurate measurement of the pressure gauge, the transmitter was moved from the original control cabinet to above the pressure tap of the bin pump; The installation method has been changed from horizontal installation to vertical installation.

　　實(shí)施效果：同比活動(dòng)前，壓力變送器故障次數(shù)下降明顯，在10月、11月次數(shù)為零，從根本上解決了變送器積灰、測(cè)量不準(zhǔn)及導(dǎo)壓管過長(zhǎng)堵塞的問題。

　　Implementation effect: Before the year-on-year activity, the number of pressure transmitter failures decreased significantly, reaching zero in October and November, fundamentally solving the problems of transmitter dust accumulation, inaccurate measurement, and long and blocked pressure pipes.

　　三、應(yīng)用效果

　　3、 Application effect

　　1.改造效果

　　1. Transformation effect

　　根據(jù)對(duì)改造前后故障現(xiàn)象加壓超時(shí)頻次及倉(cāng)泵故障次數(shù)對(duì)比統(tǒng)計(jì)，加壓超時(shí)頻次呈逐漸遞減趨勢(shì)，在11月份開始趨于穩(wěn)定狀態(tài)。故障現(xiàn)象逐漸減少，倉(cāng)泵的故障次數(shù)也在遞減，降低了倉(cāng)泵儀表故障次數(shù)。2.經(jīng)濟(jì)效益改造前出料閥每月平均消耗2.3臺(tái)，每臺(tái)閥門單價(jià)8600元，共累積維修費(fèi)用約24萬元；改造后統(tǒng)計(jì)出料閥每月平均消耗0.3臺(tái)，每臺(tái)閥門單價(jià)12000元，累計(jì)維修費(fèi)用約4萬元，每年節(jié)約費(fèi)用約19萬元。3.社會(huì)效益通過改造，降低了倉(cāng)泵故障次數(shù)，有效減少人員檢修頻次，降低了傷害的風(fēng)險(xiǎn)，減少了非計(jì)劃停車，倉(cāng)泵處于良好的工作狀態(tài)，避免粉塵泄露問題，有效提高周圍環(huán)境質(zhì)量。

　　According to the comparison and statistics of the frequency of pressure exceeding and the number of warehouse pump failures before and after the renovation, the frequency of pressure exceeding gradually decreased and began to stabilize in November. The occurrence of faults is gradually decreasing, and the number of faults in the warehouse pump is also decreasing, reducing the number of instrument faults in the warehouse pump. Before the economic benefit transformation, the average monthly consumption of discharge valves was 2.3 units, with a unit price of 8600 yuan per valve, and the cumulative maintenance cost was about 240000 yuan; After the renovation, the average monthly consumption of discharge valves is 0.3 units, with a unit price of 12000 yuan per valve. The cumulative maintenance cost is about 40000 yuan, and the annual cost savings are about 190000 yuan. 3. Social benefits: Through renovation, the number of pump failures in the warehouse has been reduced, the frequency of personnel maintenance has been effectively reduced, the risk of injury has been lowered, unplanned parking has been reduced, the warehouse pump is in good working condition, dust leakage problems have been avoided, and the surrounding environmental quality has been effectively improved.