5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

5,000 TPD CMIC CEMENT PLANT

PROJECT IN CAMBODIA

Cement Proportioning Station

水泥配料站

操作说明书
Operation Specification

中信重工工程技术有限责任公司

CITIC HIC Engineering&Technology Co.,Ltd

二零一七年三月
March 2017
 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

目 录

Catalog

第一章 前 言 CHAPTER 1 PREFACE .............................................................. 1

第二章 工艺流程和工艺设备 CHAPTER 2 PROCESS FLOW AND PROCESS

EQUIPMENT ................................................................................................................. 3

第三章 系统启动前的准备 CHAPTER 3 PREPARATION BEFORE THE

STARTING OF SYSTEM ............................................................................................... 6

第四章 系统生产操作 CHAPTER 4 SYSTEM PRODUCTION OPERATION . 10

一、系统启动操作 STARTING OPERATION OF THE SYSTEM ...................... 10

二、系统正常停车操作 NORMAL STOP OPERATIONN OF SYSTEM............ 12

三、系统故障处理 SYSTEM TROUBLESHOOTING......................................... 14

第 五章 试生产阶段注意事项 CHAPTER 5 PRECAUTIONS IN TRIAL

PRODUCTION ............................................................................................................. 18

一、概述 GENERAL........................................................................................... 18

二、试生产的准备 PREPARATION FOR TRIAL PRODUCTION ..................... 18

三、试生产要领及注意事项 PRECAUTIONS OF TRIAL PRODUCTION......... 19

 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

第一章 前 言

Chapter 1 Preface

本操作说明书仅供柬埔寨 5,000 TPD CMIC CEMENT PLANT PROJECT

IN CAMBODIA 的水泥配料站操作时使用。
The operation instruction shall be only applied for the cement proportioning
stationoperating in 5,000 TPD CMIC CEMENT PLANT PROJECT IN
CAMBODIA.
水泥配料系统包括从水泥配料站仓顶卸料到水泥粉磨系统进料的工艺生产
流程，是水泥厂中重要的配料系统。为了阐明设计意图，便于系统生产操作，我
们根据国内水泥配料系统的普遍经验编写了本系统操作说明书。
This cement proportioning system is of great importance, including the
production process from the unloading of the cement proportioning bin top to the
feeding of cement grinding system. We made this operation instruction according to
the general experience of the cement proportioning system at home in order to
explain the design purpose and facilitate the production operation of the system.
本说明书旨在说明正常生产情况下水泥配料系统的基本操作方法和注意事
项。在试生产阶段，尚应注意机电设备考核和性能试验方面的某些特殊要求，并
应注意根据本厂具体情况合理确定和调整生产参数与操作方法，以满足生产需
要。
This instructionaims at illustrating the basic operation methods and precautions
of the cement proportioning system under normal production condition. During the
trial production, pay attention to some special requirements of the assessment and
performance test of the electromechanical equipment. And the production parameters
and operation methods shall be determined and adjusted reasonably according to the
specific conditions of this plant so as to satisfy the production demand.
为了保证生产顺利和提高运转率，本系统的操作维修人员应在掌握本说明书
内容的基础上，根据各设备制造厂的说明书和有关图纸深入了解各设备的构造、

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

原理和性能，熟练掌握单机操作、维护和检修技术，以便及时解决生产过程中出
现的各类问题。本说明书与现场到货的设备使用说明书有偏差时，以现场到货的
设备使用说明书为准。
In order to ensure the smoothly producing and improve the operation rate, the
operation and maintenance personnels of the system shall understand the equipment
structure, principle and performance, skillfully master the unit operation, maintenance
and repair technology according to the instructions from the manufactures for each
equipment and related drawing on the basis of grasping the contents of the instruction,
therefore to solve all kinds of the problem occurred during production process. If
there is deviation between this instruction and the operation instruction of the
delivered equipment, it shall be subject to the operation instruction of the delivered
equipment. During actual production, if there is any deviation between this operating
instruction and the actual situation, or there is any questions about the contents, please
consult with the site commissioning technicist dispatched by our company and revise
it according the actual situation.

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

第二章 工艺流程和工艺设备

Chapter 2 Process Flow and Process Equipment

一、工艺流程 Process flow

1.1 工艺流程概述 General description of process flow
1.1.1 水泥配料来料系统 Incoming materials system of cement proportioning
从熟料储存库来的熟料经过胶带输送机送入熟料配料仓(511-3B1)中。
The clinker from the clinker storing silo is sent by the belt conveyor to the
clinker proportioning bin(511-3B1).
从破碎车间过来的石膏和石灰石通过胶带输送机(K91-BC3)输送到仓顶，然
后经可逆胶带输送机（K91-BC4）分别送入到石膏配料仓和石灰石配料仓中。
Gypsum and limestone from the crushing workshop are conveyed to the top of
the bin by the belt conveyor (K91-BC3), and then transferred into the gypsum
proportioning bin and the limestone proportioning bin by a reversible belt conveyor
(K91-BC4)
在每个配料仓仓顶各设置 1 台袋式除尘器用于环境除尘。
One set of bag filter shall be equipped at the top of each proportioning bin for
environmental dust removal.
1.1.2 水泥配料站 Cement proportioning station
熟料配料仓内的熟料经过仓底的棒阀(531-NG1)由定量给料机（531-WF1)计
量后送至胶带输送机（531-BC1）。
The clinker in the clinker proportioning bin is sent to the belt conveyor(531-BC1)
through the rod gate(531-NG1) at bin bottom after being metered by the belt weigh
feeder(531-WF1).
石膏配料仓内的石膏经过仓底的棒阀(531-NG2)由定量给料机（531-WF2）
计量后送至胶带输送机（531-BC1)。
The gypsum in the gypsum proportioning bin is sent to the belt

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

conveyor(531-BC1) through the rod gate(531-NG2) at bin bottom after being metered
by the belt weigh feeder(531-WF2).
石 灰 石 配 料 仓 内 的 石 灰 石 经 过 仓 底 的 棒 阀 (531-NG3) 由 定 量 给 料 机
（531-WF3）计量后送至胶带输送机（531-BC1）。
The limestones in the limestone proportioning bin are sent to the belt
conveyor(531-BC1) through the rod gate(531-NG3) at bin bottom after being metered
by the belt weigh feeder(531-WF3).
窑灰罐车通过窑灰输送管道将窑灰打到两个粉煤灰仓（5D1-3B1、5D1-3B2)。
窑灰仓设有除尘系统，由除尘器(5D1-BF1)和除尘器(5D1-BF2)组成。窑灰仓锥斗
部分设有充气管路，充气所需气源由压缩空气站经充气管道和阀门系统供给。仓
底出料口处接阀门(5D1-SD11、5D1-SD2)，出阀门(5D1-SD11、5D1-SD2)的物料
进入螺旋输送机(5D1-SC1)，然后经过一台可逆的螺旋输送机（5D1-SD3)将物料
分为两路，一路直接去水泥磨车间，一路去散装发运
The kiln dust loaded from the bulk tanker truck be transported by self-pneumatic
pumping system of the truck and stored in two feed bins （ 5D1-3B1 、
5D1-3B2).Dedusting system is set up for kiln dust which includes dust collector
(5D1-BF1) and (5D1-BF2).aeration pipeline is arranged on the cone part of the kiln
dust bin.the air supply for air inflation is provided by pressed air station through air
inflation pipelines and valve system.
Shut-off gate(5D1-SD11、5D1-SD2) is set at the bottom of the bin,the kiln dust
in the kiln dust bin is sent to the screw conveyor(5D1-SC1) ,then through the
reversible screw conveyor (5D1-SD3) materials can be divided into two,one goes to
cement mill feeding via Series of screw conveyors and a rotary weigh
feeder(5D1-PF1).the other goes to telescopic loading bulk truck.
窑灰仓设有料位计和料位开关，起到仓满和空仓报警作用，仓顶设有人孔门，
以便于仓内检修。仓顶设有量仓孔。
There are level-sensing device and level switch for kiln dust bin, which have the
function of alarm for full and empty . There is manhole door at the top of bin in order
to inspect the inside bin, and also there are measuring hole on the top of bins.

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

熟料、石灰石和石膏按照设定的比例配料后，由胶带输送机（531-BC1）送
至水泥粉磨车间的入磨斗提（561-BE1）。
The clinker, limestones and gypsum are mixed according to the required
proportion, via the belt conveyor(531-BC1),they will be sent to the bucket
elevator(561-BE1) of thecement grinding workshop.
1.2 工艺流程图(见附图)
See attached drawing for the cement cement proportioning station process flow.
二、主要工艺设备 Main process equipment
本系统所有工艺设备主要技术参数见工艺设备表(见附表)。
See the attached table for the main technic parameters of all the processing
equipment for this system: processing equipment table

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

第三章 系统启动前的准备 Chapter 3 Preparation Before the

Starting of System

水泥配料系统的全部设备，在启动前都应作认真地检查、调整工作。从首次
启动开始，就应作为一条制度，在试生产阶段和以后的正常生产中严格执行。
All the equipment of the cement proportioning system shall be carefully checked
and adjusted before starting, which shall be taken as a system from the initial starting
and strictly performed in the trial production and the normal production in the future.
一、现场设备的检查和准备 Inspection and preparation of on-site equipment
在系统启动前应认真阅读各设备使用说明书，按各设备使用说明书要求进行
以下检查和调整工作。
Read the operating instructions of each equipment carefully before starting the
system. The following inspections and adjustments shall be performed according to
the operating instructions of each equipment.
1.1 润滑装置和润滑油的检查和调整 Inspection and adjustment of lubricating
device and lubricating oil
设备润滑对设备的长期、稳定运转起着关键作用。润滑油量既不能过多，也
不能过少。油量过多，会引起设备发热；油量过少，设备因缺油而损坏。此外，
还应定期检查、更换润滑油。用油的品种、标号不能错，而且要保证油中无水、
无杂物。
The equipment lubrication plays a key role in the long and stable operation of the
equipment. The quantity of lubricating oil shall not be too much or too little. Too
much oil may cause equipment heating, and too little oil may lead to equipment
damage. Besides, regular inspection and lubricating oil replacement shall be
conducted. The variety and grade of oil shall be correct and there shall be no water or
impurity in the oil.
主要检查项目如下：
The main inspection items are as follows:

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

1.1.1 所有设备的传动装置(包括电机、减速机、联轴器等)润滑部位均要加
油。
The transmission devices (including motors, gearboxes, couplings and so on) of
all the equipment shall be lubricated.
1.1.2 所有设备的各轴承活动部件及传动链条等部位均要加油。
The bearing moving parts and transmission chains of all the equipment shall be
lubricated.
1.1.3 所有电动阀门的执行机构均要加油。
The actuators of all the electric valves shall be lubricated.
1.1.4 主要设备的润滑点、润滑油和润滑要求见本册第八章。
See the Chapter Eight for the requirements for the lubricating points, lubricating
oil and lubrication of the main equipment.
1.2 设备内部人孔门、检查门检查及密封 Inspection and sealing of the man hole
door and inspection door inside the equipment
在系统启动前，要对设备内部进行全面检查，清除安装或检修时掉在设备内
部的杂物，以防止设备运行时卡死或打坏设备，造成不必要的损失。在设备内部
检查完后，所有人孔门、检查孔都要严格密封，防止生产时漏风、漏料、漏油。
Overall inspection shall be performed for the equipment interior before the
starting of system. Remove the foreign matters left in the equipment during
installation and maintenance to avoid the equipment jamming or breaking that may
cause unnecessary loss. After the inspection of the equipment interior, seal all the man
hole doors and inspection doors strictly to avoid air, material, and oil leakage during
production.
1.3 阀门的检查和备妥 Inspection and preparation of valve
系统内所有手动阀门要全部开到适当位置，保证料、气畅通；对于所有电动
阀门，应确认能够灵活开闭，阀轴与连杆之间无松动现象，然后由操作室遥控操
作，确认操作室与现场的开闭方向一致，开度和指示准确。如果阀门带有上、下
限位开关，要与操作室核对限位信号是否返回。
All the manual valves in the system shall be opened to the appropriate position to
ensure the smoothness of the materials and air. For the electric valves, make sure that
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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

all of them can be opened and closed flexibly and there is no looseness between the
valve shaft and connecting rod. Then the remote operation in the control room shall
be performed. The opening and closing direction in the control room shall be
confirmed to be consistent to that on site and the opening and indication are correct. If
the valve has upper or lower limit switch, verification with the control room is needed
to check if the limit signal returns.
1.4 设备紧固检查 Tightening inspection of equipment
检查设备的紧固件(如设备部件的连接螺栓、基础地脚螺栓等)，不允许出现
松动。有的设备传动连杆等部位容易松动，要特别注意进行严格检查。
Check the fasteners of equipment (such as the connecting bolts of components,
anchor bolts of foundation and so on). Looseness is not allowed. Pay special attention
to the transmission links of some equipment which are easy to loose, and strict
inspection shall be conducted.
1.5 压缩空气的检查 Compressed air inspection
检查用气点的压缩空气压力是否符合供气要求，通知现场有关人员处理。
Check compressed air pressure of gas using point to see whether it meets air
supply requirement. If not, inform field personnels to fix it.
1.6 冷却水系统的检查和调整 Inspection and adjustment of cooling water system
冷却水系统对于保护设备至关重要。在设备启动前，要检查设备冷却系统的
管路阀门是否打开，水管连接部分要保证无渗漏。对水量要合理控制。水量太小
会造成设备温度过高；水量太大，又造成不必要的浪费。
The cooling water system is crucial to the protection of equipment.. Before
starting the equipment, check whether the pipeline valves of the cooling system are
opened . Ensure the connection parts of the water pipe has no leakage. Control the
water quantity reasonably. Too little water may cause overhigh temperature of
equipment and too much water will lead to unnecessary waste.
1.7 现场仪表检查 Inspection of on-site instruments
现场设备有很多温度、压力及料位等仪表，可以帮助巡检人员及时了解设备
的运行状态。在开车前，都要进行系统的检查，并确认电源已供上，且有指示。

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如果与操作室有联系，还要与控制人员联系，核实联系信号的准确性。
The on-site equipment has many instruments measuring temperature, pressure
and material level, which can help inspectors to know the running state of equipment
in time. Before starting, check the system and confirm the power has been supplied
with indication. For the instrument that send signal to control room,inspector should
cooperate with the control room staff to verify the accuracy of the transmission signal
1.78 生产设备的调整和备妥 Adjustment and preparation of production equipment
系统启动前，对所有的生产设备，特别是重要生产设备要作好调整备妥工作，
以保证整个系统的正常启动。
Before the starting of the system, all the production equipment, especially the
important ones, shall be adjusted and prepared well, in order to ensure the normal
starting of the whole system.
二、电气设备的检查和准备 Inspection and preparation of electrical equipment
2.1 电气室的检查 Inspection of electric room
2.1.1 检查电源是否供上。
Check if the power has been supplied.
2.1.2 检查开关柜中空气开关是否合上，注意有无正在检修的设备，不能误
送电。
Check if the air switch in the switch cabinet is closed or not. The power is
not allowed to be wrongly supplied to the equipment being maintained.
2.1.3 检查 DCS 柜电源是否打开。
Check if the power of DCS cabinet is turned on.
2.2 现场电器检查 Inspection of on-site electric appliance
2.2.1 所有机旁按钮盒应选择到“自动”位置。
All the local button boxes shall be switched to the position of
“automation”.

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第四章 系统生产操作

Chapter 4 System Production Operation

本章叙述的内容，是正常生产时的启动和停车操作顺序、紧急停车操作及常
见故障处理。试生产时，根据机电设备的考核标准，有一些特殊的操作要求，望
操作时注意。在试生产阶段应在现场专家技术指导下并参阅设备操作使用说明书
操作，对生产参数进行调整和修正。
The contents described in this chapter includes the starting and stopping
operation sequences under normal production, emergency stop operation and common
fault handling. When the trial production is performed, there are some special
operating requirements needing attention during operation according to the
assessment criteria of the electromechanical device. In the trial production stage, the
production parameters shall be adjusted and modified under the technical guidance of
experts on site and referring to the operating instructions for the use of equipment.
一、系统启动操作 Starting operation of the system
表 4-1 水泥配料系统启动操作顺序
Table 4-1 Starting operation sequence of the cement proportioning system

序号 操作步骤 检查与调整
No. Operation steps Inspection and adjustment

(1)确认启动前的准备工作已完成；
Confirm that all the preparation work before
starting has been completed;
通知有关系统注意配合操作；
(2)确认所有配料仓处于低料位，可以进料。
Notify the relevant system to cooperate
1 Confirm that all the bins is in lower material
with the operation;
level that can be feed.
(3)与化验室联系，确认喂料比例。
Communicate with the testing laboratory to
confirm the feeding proportion.

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

确认物料输送系统能正常运行。
2 Confirm the materials conveying system can run
normally.

确认各阀门的位置。
3
Confirm the position of each valve.

操作室发出全系统预启动预警告信号。 各岗位人员离开设备，准备启动。
4 The control room sends the whole-system All the personnel leave the equipment
pre-start warning signal. and prepare to start.

启动水泥配料仓底出料系统：
Start the discharging system at the bottom of the
cement proportioning bin:
(1)启动风机
(511-FN6,K91-FN3,K91-FN4,5D1-FN3)；
Start the fan
(511-FN6,K91-FN3,K91-FN4,5D1-FN3);
(2)启动袋除尘器
(511-BF6,K91-BF3,K91-BF4,5D1-BF3)；
Start the bag 注意水泥配料仓料位。
5 filter(511-BF6,K91-BF3,K91-BF4,5D1-BF3)； Pay attention to the material level of
(3)启动胶带输送机(531-BC1)； the cement proportioning bin.
Start the belt conveyor (531-BC1);
(4)依次启动螺旋输送机(5D1-SC5)、
（5D1-SC4)和转子秤（5D1-PF1)
Start screw conveyor(5D1-SC5)、（5D1-SC4)
and rotary weigh feeder(5D1-PF1)one by one
(5)启动定量给料机(531-WF1，531-WF2，
531-WF3)；
Start the belt weigh feeder (531-WF1，
531-WF2，531-WF3)；

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(6)依次启动螺旋输送机(5D1-SC3)、
（5D1-SC1)和窑灰仓底的螺旋闸门
Start screw conveyor(5D1-SC3)、（5D1-S14)
and theShut-off gate(5D1-SD1、5D1-SD2) one
by one
(7)打开配料仓底棒阀。
Open the rod gate at the bottom of the
proportioning bin.

确保充气管道上对应的阀门已打开
通知压缩空气站为窑灰仓底充气，准备卸料
Make sure that the corresponding valve
Inform the pressed air station for air inflation of
6 of the inflation pipelines has been
the bottom of kiln dust binto prepare
opened
discharging

启动水泥配料仓顶进料系统：
Start the feeding system at the top of the cement
proportioning bin:
(1)启动可逆胶带输送机(K91-BC4)；
Start the reversible belt conveyor (K91-BC4); 注意水泥配料仓料位。

(2)启动风机(5D1-FN1,5D1-FN2)； Pay attention to the material level of

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Start the fan(5D1-FN1,5D1-FN2)； the cement proportioning bin.

(3)启动袋除尘器(5D1-BF1,5D1-BF2)；
Start the bag filter(5D1-BF1,5D1-BF2)；
(4)水泥罐车开始输送粉煤灰
The bulk tanker truck starts transporting kiln
dust

二、系统正常停车操作 Normal stop operation of system

本系统的正常停车操作列于表 4-2。下表的操作如与设备使用说明书不符，
以设备使用说明书为准。
The normal stop operation of this system is listed in Table 4-2. If the operation in
the following table is inconsistent with the instruction manual of equipment,

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

according to the instruction manual of the equipment.

表 4-2 水泥配料系统正常停车操作顺序表
Table 4-2 Sequence diagram of normal stop operationn of cement batching
system

序 号 检查与调整
操作步骤 Steps
No. Check and adjust

水泥配料仓顶进料系统停车：
Feeding System Shutdown of Cement proportioning bin
top :
(1)可逆胶带输送机(K91-BC4)停车；
Reversible belt conveyor (K91-BC4) shutdown; 确认输送设备上物料 已排
(2)窑灰仓充气系统停车 空。
1
Aeration system on the cone part of the kiln dust bin Make sure that no material
shutdown on the conveyor.
(3)延时 10 秒钟,袋除尘器(5D1-BF1,5D1-BF2)停车；
Delay 10 seconds, bag filter (5D1-BF1,5D1-BF2)
shutdown;

水泥配料仓底出料系统停车：
discharging system shutdown of Cement blending bin
bottom :
(1)关闭配料仓底棒阀,关闭窑灰仓底闸阀阀
确认输送设备上物料 已排
Close the rod gate at cement blending bin bottom and
空。
2 shut-off gate at kiln dust bin ;
Make sure that no material
(2) 延 时 4 分 钟 ， 定 量 给 料 机
on the conveyor.
(531-WF1,531-WF2,531-WF3) 同时 停车 ；螺 旋输送机
（5D1-SC1)停车；
Delay 4 minutes, belt weigh
feeder(531-WF1,531-WF2,531-WF3) shutdown at the

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

same time;
Screw conveyor (5D1-SC1) shutdown; 螺 旋 输 送 机
（5D1-SC3)停车；
(3)延时 5 分钟，胶带输送机(531-BC1)停车；
Delay 5 minutes, belt conveyor (531-BC1) shutdown;
Screw conveyor (5D1-SC3) shutdown;
(4)窑灰仓底的转子秤（5D1-PF1)停车；
Rotary weigh feeder(5D1-PF1)shutdown
(5)螺旋输送机（5D1-SC4)停车；
Screw conveyor (5D1-SC4) shutdown;
(6)延时 5 分钟，螺旋输送机（5D1-SC5)停车
Screw conveyor (5D1-SC5) shutdown;
(7)延时 10 秒钟, 袋除尘器
(511-BF6,K91-BF3,K91-BF4,5D1-BF3)停车；
Delay 10 seconds, bag
filter(511-BF6,K91-BF3,K91-BF4,5D1-BF3)shutdown;
(8)风机(511-FN6,K91-FN3,K91-FN4,5D1-FN3)停车；
Fan (511-FN6,K91-FN3,K91-FN4,5D1-FN3) shutdown;

水泥配料系统停车完毕，对系统进行全面的检查及修
整。
3
Cement proportioning system is shopped, and carry out a
comprehensive inspection and maintenance.

三、设备故障停车及紧急停车的处理 Treatment of Stop of Equipment Failure

and Emergency
3.1 概述 general
在设备运行过程中，当设备突然发生故障、电机过载跳闸、机电设备工作异
常或现场停车按钮被按下时，系统的部分或全部设备连锁停车。另外在紧急情况
下，为了保证人身及设备安全，也会进行紧急停车。为了在突然停车后能顺利再

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

次启动，必须按如下原则进行处理和操作。
In the process of equipment operation, due to the sudden failure of equipment or
the motor over-load trip, protective tripping and the pressing-down of on-site stop
button, the interlocking stop will occur to some equipment of system. In addition, in
certain case of emergency, in order to ensure the safety of person and equipment, the
emergency stop button will also be utilized to exert emergency stop to the
equipment .in order to ensure smooth restart, the treatment operation must be
conducted.
3.1.1 马上停止与故障设备有关的那部分设备。
Immediately stop some equipment relevant to it.
3.1.2 应尽快恢复无故障设备的运行。
Restore the operation of trouble-free equipment as soon as possible.
3.1.3 尽快查清原因，判断能否在短时间(30 分钟以内)处理完，以决定再次
启动的时间，进行相应的操作。
Find out the cause of the accident, determine whether the treatment can be
finished in a short period of time (within 30 minutes) so as to determine the restart
time, and the corresponding operation shall be performed.
3.1.4 需长时间才能恢复的，应将可运转设备上的物料排空后再停机。
If that takes a long time to recover, should evacuate the material on the workable
equipment and then stop.
3.2 常见故障的处理 handling for common fault
本系统设备常见故障及其处理见表 4-3。
Common faults and treatment of the system equipment are shown in Table 4-3.
表 4-3 常见故障处理表
Table 4-3 Table for Common troubleshooting

序 号 故障设备 现象及原因 处理方法

No. failed equipment Phenomenon and reason treatment

喂料组 喂料皮带停车； 将喂料设定值降至“0”；

1
feeding unit Feeding belt shutdown; 必须在 5~10 分钟内恢复喂料，

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

配料仓底喂料机同时停车； 否则按正常停车顺序停主机。
the feeder at the bottom of Set the feed setpoint to "0";
batch bin is stopped at the restore feeding within 5 to 10
same time; minutes, otherwise stop the host
窑灰仓给料组停车。 according to the normal stop
Feeding unit for Fly ash sequence.
stopS.

定量给料机 定量给料机计量显示物料 （1）计量元件或显示仪表故障，

2 belt weigh feeder 流量变化很大 计量皮带跑偏。
belt weigh feeder （2）料仓内结拱堵料或塌料。
measurement shows a great （3）料仓内储量不足，料位过
change in material flow 低。
（4）皮带秤设定参数可能不合
适。
(1)metering components or
display instrument in failure,
measuring belt deviation.
(2) arch plugging material in bin
of the stall or material collapse.
(3) lack of reserves in bin,
material level is too low.
(4) The setting parameter of belt
scale may not be appropriate.

胶带撕裂 （1）胶带接头断裂。 （1）检查修复胶带。

3 belt tearing The belt joint is broken. （2）更换胶带。
（2）胶带带芯脱开。 (1) check and repair belt.
Belt carcass disconnect (2) Replace belt.

收 尘器工作不正 （1）糊带。 （1）停机检查、清理、修补、

4 常，车间内冒灰或 （2）滤带破损。 更换滤带。

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

排 尘 浓 度 增 大 （3）电源发生故障。 （2）检查供电系统，恢复正常。
Dust collector （4）收尘器控制装置失灵。 （3）停车检修控制装置和工作
work abnormally, (1) belt burned. 机构。
dust concentration (2) filter belt damage. (1) stop to check, clean, repair,
in the workshop (3) The power supply is in and replace the filter bag.
increases failure. (2) check the power supply
(4) control device for dust system, and go back to normal.
collector is out of order. (3) stop to repair control device
and working mechanism.

3.3 紧急停车操作 Emergency stop operation

当出现紧急情况时，需要全部停车。设备停车后，应对喂料量设定值、阀门
等进行调整。
处理完紧急情况，再次启动时必须注意，由于系统在紧急情况下停车，各设
备内均会有积料。因此再次启动时，不能象正常情况那样立即喂入新料，要在设
备内部的积料排出后才能开始喂入新料。
When an emergency occurs, all shutdown is required. After the equipment is
stopped, the feeding volume setting value, the valve and others shall be adjusted.
It is important to pay attention after handling the emergency situation, since the
system is stopped in case of emergency, there will be accumulation in each equipment.
So when start again, it is not allowed to start feeding new material as usual
immediately, and the new material can be fed after the accumulation in equipment is
removed.

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

第五章 试生产阶段注意事项

Chapter 5 Precautions in Trial Production

一、概述 General
当所有设备安装完毕，完成单机试车和无负荷联动试车，各台设备经过全面
检查，确认没有问题之后，方可进行水泥配料系统的试生产。
When all the equipment is installed, and solo test run and no load linkage test are
completed, and each equipment is inspected comprehensively to confirm that there is
no problem before the trial-production of cement proportioning system.
试生产各阶段的运转时间以现场到货设备使用说明书为准。
The running time of each stage of the trial production shall be based on the
instruction manual of the arrived equipment.
本系统试生产阶段即为自投料试车开始，至合同工厂性能试验结束为止。
The trial production stage of the system is from the start of commissioning and
test run, until the end of factory performance test in contract.
二、试生产的准备 Preparation for trial production
本系统的设备经空载试运转合格后，经过全面和认真细致地检查和调整，确
认没有问题之后，就可进行投料试运转。在首次投料之前进行如下准备工作。
After the equipment of the system pass the trial test without loading, after a
comprehensive and careful inspection and adjustment to confirm that there is no
problem, the feeding and trial-run can be carried out. Prepare the following before the
first commissioning test run.
2.1 润滑油的注入 Lubricant injection
对于设备需要润滑的部位，也必须按照各自的要求，注入相应的润滑油(注
意注油的位置、油的品种及注油量要正确)。
The parts needs to be lubricated must in accordance with their own requirements
and inject corresponding lubricants (pay attention to the location of injection, oil
varieties and oil volume).
2.2 物料的准备 material preparation
在磨机投料之前，应保证配料仓内有足够的熟料、石仓、石灰石、窑灰等物

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

料，并保证物料供应的连续性。试生产过程中要经常测量库内料位的变化，及时
仓料。
Before the test run of mill, should ensure that there is enough clinker, gypsum,
limestone, kiln dust and other materials, and ensure the continuity of material supply.
During the trial production, measure the changes in the material level in regular, and
feed material timely.
2.3 人员准备及试生产组织 Personnel preparation and trial production organization
试生产前要组织好本系统的调试人员。各岗位都要安排有操作人员，操作人
员必须坚守岗位，注意机械设备的运转情况及倾听机械设备的转动声音，以便及
时发现问题，及时解决问题，不得擅离职守，随便走动。
Try to organize the commissioning staff of the system before the commissioning.
All positions should be arranged the operator, and the operator must adhere to the post
and pay attention to the operation of equipment and listen to the working sound of
mechanical equipment in order to detect problems in time and solve the problem, and
it is not allowed to leave their duties and casually walking.
本系统投料运转前，相关生产系统如供电、供水、供气、通讯、控制室、质
量控制、化验和消防等设施都要备妥。
Before the commissioning test run of the system, the relevant production systems
such as power supply, water supply, gas supply, communication, control room, quality
control, laboratory and fire facilities should be prepared.
三、试生产要领及注意事项 Precautions of trial production
水泥配料系统的试生产，必须按照时间要求，慎重实施。水泥配料系统试生
产期间运转的好坏，将直接影响整条生产线能否尽快投入正常生产。因此，必须
认真对待。
The trial production of cement proportioning system must be carefully
implemented in accordance with the time requirements. During the trial production,
the operation situation of cement proportioning system will directly affect the speed
that who quick the entire production line can be put into normal production. Therefore,
must be taken seriously.

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

3.1 单点试车 solo test run

单点试车，就是对每台设备进行与控制室联系的检查(可不带设备)。首先，
将现场转换开关打到集中控制位置，由控制室强制驱动，并在机旁停车。在此过
程中要核对以下几点：
Solo test run, that is, contact each device with the control room to inspect
(without equipment is allowed). First, place the site switch to the centralized control
position, and driven by the control room, and stopped near machine. Verify the
following in the process:
（1）备妥信号 ready signal
（2）驱动是否正确 Whether the drive is correct
（3）应答信号 answering signal
（4）故障报警 failure alarm
（5）电机指示的对应 Correspondence of motor indication
3.2 联动试车 Linkage test run
当单点试车完成后，即可进行联动试车。由控制室进行遥控操作，并进行必
要的试验。
After the solo test run is completed, the linkage test run can be carried out. The
remote control operation and the necessary tests is carried out by the control room.
（1） 对每台设备都要进行模拟故障试验，检查程序连锁是否正确无误。
Simulated fault test should be carried out on each device, and check whether the
program interlock is correct.
（2） 模拟压力、温度、仓料位开关等设备保护接点的连锁试验。
Linkage test for equipment protection contact of analog pressure, temperature,
warehouse level switch and others.
（3） 检查正常开车、停车的顺序及延时设定。
Check the normal order of starting, stopping and delay settings.
（4） 检查紧急停车的操作。
Check the operation for emergency stop .
3.3 空载试车 No load test-run

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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

3.3.1 检查脉冲袋除尘器各个运动部位，以振动小、噪音低和运转平稳为正
常。
Check every moving parts of pulse bag dust collector, and regards the gentle
vibration, low noise and smooth operation as normal.
检查除尘器进出风管的压力差是否正常。
Check whether the pressure difference between the inlet and outlet of the dust
collector is normal.
检查清灰时间程序控制器是否按定值进行动作，脉冲喷吹是否正常，观察滤
袋抖动情况是否正常。
Check whether the program controller of cleaning time act according to the
specified value, and whether pulse injection is normal, and observe whether the filter
bag jitter is normal.
空负荷运转至少 24 小时后，停机检查各部件。若有故障，要及时处理。
After at least 24 hours of operation without load, stop and check each part. If
there is a problem, deal with that in time.
3.4 荷载试运转 Load test run
3.5 试生产中的注意事项 Precautions in trial production
3.5.1 关于物料供应 About material supply
在运转过程中，要保证物料供应的连续性，定时检测各配料仓料位的变化，
及时进仓。物料性质应满足化验室的要求。
In the operation, ensure the continuity of the material supply, check material
level change in the material proportioning bin regularly, and feeding in time. The
property of the material should meet the requirements in laboratory.
3.5.2 关于轴承温度 About bearing temperature
在所有运转部件中，最重要的是轴承；而最容易损坏的部件之一，也是轴承。
为了避免重大事故的发生，必须认真检查轴承的温度、润滑油的温度、油量和油
压等。
Among all running parts, the most important is the bearing; and one of the most
vulnerable parts is also bearing. In order to avoid the occurrence of major accidents,
must carefully check the bearing temperature, lubricating oil temperature, oil amount
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 5000 TPD CEMENT PLANT PROJECT IN CAMBODIA

and oil pressure.

主要轴承有：The main bearings are:
定量给料机轴承；belt weigh feeder bearings;
螺旋输送机轴承; screw conveyor bearing;
胶带输送机轴承；belt conveyor bearings;
风机轴承;Fan bearing.
试运转结束后应复查以下工作内容：
After the trial operation, review the following work:
（1）运转中不易检查到的设备部位的温升情况。
Temperature increasing situation of part equipment that is not easy to be checked
during operation.
（2）润滑油的油质有无变化，油中是否有金属铁屑和污物，滤油器的滤油
网有无污物。
If there is any change in quality of Lubricant oil, whether there are metal iron
and dirt in lubricant, and whether there is dirt on oil cleaner screen of oil filter .
（3）地脚螺栓、紧固螺栓、连接螺栓及键销等固定件有无松动及损坏。
Whether anchor bolts, fastening bolts, connecting bolts and key pins and other
fixed parts are loose and damaged.
（4）冷冻季节，必须排净设备及管道内所有的存水。
During the freezing season, all the water in the equipment and pipelines must be
drained.
（5）检查齿轮传动和啮合情况及运转部件的接触情况。
Check the gear transmission and engagement and the contact of the operating
parts.
（6）检查各开关、各电气仪表指针是否复位。
Check whether the switch, the electrical instrument pointer is reset.

22