KKK-AP风机的运行维护手册(中英文对照)86p.doc

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Operating and Maintenance Manual
for Fans Type KK&K

KK&K风机的运行和维护手册

Type: 类型：
CKPF-Job-No.: 工作号：
Machine-No.: 设备号：
Application: 应用：
Year of design: 设计年份：
Client No.: 客户号
Plant: 厂家：
Plant Location: 厂家地址：

Chengdu KK&K Power Fan Co. Ltd. 成都KK&K电站风机有限公司
610041 Changyi Road 12 610041 长益路 12
Wuhou District Chengdu City 成都市武侯区
Sichuan Province 四川省
Tel. +86 …
Fax +86 …

This instruction is exclusive property of Chengdu KK&K Power Fan Co. Ltd.
Availability is limited to supervisors or service personnel. Surrender to or access by third persons, as well as duplication of the plant in its entirety or in parts is prohibited. We reserve the right to claim for full reimbursement of all damages resulting form non-compliance.
We must point out that these operating instructions cannot always cover every eventuality completely. Accordingly they do not free the operator from the usual responsibility when operating technical equipment also in respects of health, safety and environmental protection. It is assumed that the operation personnel has been instructed and knows how to run the plant.
No claims of any kind may be derived from these operating & maintenance instructions.
该说明书版权为成都KK&K所有。
仅限管理和服务人员使用。不允许第三方使用、完全或部分拷贝该说明书。我方保留索赔权。我们需要指出这些运行操作说明书不能包括所有的不可预测的情况。因此在操作时，还应警示个人健康，安全，以及对环境的保护等。本说明书供组装、运行、维护人员认真阅读，严格遵循，风机的组装和维护工作必须由专业人员承担。操作人员需要掌握如何操作这些设备。
目 录
1. OPERATING DATA运行参数 6
1.1. PRESSURE INDICATIONS压力指示 6
1.2. OPERATING CONDITIONS 运行条件 6
1.3. LIMITATIONS TO OPERATING DATA 运行参数限制 6
1.4. PERFORMANCE GRAPH 性能曲线 7
1.5. STARTING TORQUES AND MASS MOMENT OF INERTIA 启动力矩和转动惯量 8
1.6. ACOUSTICS声学 8
2. DESCRIPTIONS简介 9
2.1. FLUIDIC EFFECT (1-STAGE)工作原理（单级） 9
2.2. FLUIDIC EFFECT (2-STAGE)工作原理（双级） 9
2.3. DESCRIPTION OF THE FAN风机（部件）简介 9
2.3.1. STATOR COMPONENTS静止件 10
2.3.2. ROTOR (1-STAGE) 转子（单级） 11
2.3.3. ROTOR (2-STAGE) 转子（双级） 11
2.3.4. IMPELLER (1-STAGE, WITH COUNTERWEIGHTS) 叶轮（单级，带平衡锤） 11
2.3.5. IMPELLER (2-STAGE, WITH COUNTERWEIGHTS) 叶轮（双级，带平衡锤） 11
2.3.6. IMPELLER (1-STAGE, WITHOUT COUNTERWEIGHTS)叶轮（单级，不带平衡锤） 11
2.3.7. IMPELLER (2-STAGE, WITHOUT COUNTERWEIGHTS)叶轮（双级，不带平衡锤） 12
2.3.8. BLADE ADJUSTMENT叶片调节 12
2.3.9. BLADE BEARINGS 叶片轴承 13
2.3.10. SHAFT (1-STAGE) 主轴（单级） 13
2.3.11. SHAFT (2-STAGE) 主轴（双级） 13
2.3.12. SERVOMOTOR (1-STAGE)伺服马达（单级） 13
2.3.13. SERVOMOTOR (2-STAGE)伺服马达（双级） 13
2.3.14. CONTROL HEAD控制头 13
2.3.15. ADJUSTING PISTON油缸 13
2.3.16. ADJUSTING DISC (1-STAGE) 调节盘（单级） 14
2.3.17. ADJUSTING DISC 2-STAGE)调节盘（双级） 14
2.3.18. ROTOR BEARINGS (ANTIFRICTION BEARING) 主轴承（滚动轴承） 14
2.3.19. ROTOR BEARINGS (SLEEVE BEARING) 主轴承（滑动轴承） 14
2.3.20. ACCESSORIES附件 15
3. OPERATION/运行 16
3.1. TECHNICAL PLANT REQUIREMENTS技术设备要求 16
3.1.1. OPERATING RANGE工作运行区域 16
3.1.2. SECURITY安全 17
3.1.3. ADJUSTMENT调节 19
3.2. PRIOR TO TEST RUN/ COMMISSIONING/ OVERHAULS试运转前期/试运转/检查 21
3.3. TEST RUN试运行 22
3.4. STARTING UP启动 23
3.5. SHUTTING DOWN关机 24
3.6. MONITORING DURING OPERATION运行监控 24
4. MAINTENANCE 维护 26
4.1. DURING OPERATION风机运行期间 26
4.2. OIL MAINTENANCE油系统维护 26
4.3. MAINTENANCE INTERVALS & SCOPE计划停机（检修）维护 27
4.3.1. FAN壳体 27
4.3.2. IMPELLER 叶轮 28
4.3.3. SERVOMOTOR伺服马达 29
4.3.4. MAIN BEARINGS主轴承 29
4.3.5. ADJUSTMENT DEVICE调节装置 30
4.4. UNSCHEDULED STOPPAGE 非计划停机维护 30
4.5. WEAR DATA (ID/ FGD FAN ONLY)磨损数据（仅适用于引风机/增压风机） 31
5. ASSEMBLY组装 32
5.1. FAN风机 34
5.1.1. PREPARATION 准备 34
5.1.2. CHECKS 检查 34
5.1.3. ASSEMBLY 组装 34
5.1.4. CONNECTIONS 连接 35
5.1.5. FUNCTION TESTS 功能测试 35
5.2. SEALS, PARTS SUBJECT TO WEAR密封件和易损件的拆装 36
5.3. ROTOR转子 36
5.3.1. LIFTING OFF THE HOUSING COMPONENTS 机壳部分的起吊 36
5.3.2. DISCONNECTION 拆卸 37
5.3.3. REMOVING ROTOR BLADES 拆卸动叶片 38
5.3.4. ROTOR REMOVAL 转子的拆卸 38
5.3.5. FITTING THE ROTOR 组装转子 38
5.3.6. FITTING ROTOR BLADES动叶片组装 38
5.3.7. SECURING THE CONNECTIONS 连接保护 38
5.3.8. FITTING THE HOUSING COMPONENTS 壳体部件的组装 39
5.4. IMPELLER叶轮 40
5.4.1. REMOVAL OF ROTOR 转子拆卸 40
5.4.2. BLADE-BEARING REMOVAL 叶片轴承的拆卸 40
5.4.3. DISASSEMBLY OF THE ADJUSTING LEVER 曲柄的拆卸 41
5.4.4. ASSEMBLY OF ADJUSTING LEVER 曲柄的组装 41
5.4.5. ASSEMBLY OF BLADE BEARING 叶片轴承的组装 42
5.5. ROTOR BLADES动叶片 45
5.5.1. REMOVAL 拆卸 45
5.5.2. FITTING 组装 45
5.6. SERVOMOTOR伺服马达 48
5.6.1. REMOVAL FROM THE IMPELLER 从叶轮上拆卸 48
5.6.2. FITTING TO THE IMPELLER 组装到叶轮上 49
5.7. ADJUSTING DISC (1-STAGE) 调节盘（单级） 49
5.7.1. DISASSEMBLY 拆卸 49
5.7.2. ASSEMBLY 组装 49
5.8. ADJUSTING DISC (2-STAGE) 调节盘（双级） 49
5.8.1. DISASSEMBLY拆卸 49
5.8.2. ASSEMBLY组装 51
5.9. MAIN BEARINGS (ANTIFRICTION BEARING) 主轴承（滚动轴承） 51
5.9.1. DISASSEMBLY拆卸 51
5.9.2. ASSEMBLY组装 52
5.10. MAIN BEARING (SLEEVE BEARING) 主轴承（滑动轴承） 55
5.10.1. DISASSEMBLY拆卸 55
5.10.2. ASSEMBLY组装 56
5.11. SHAFT SEALS轴封： 57
5.11.1. DISASSEMBLY拆卸 57
5.11.2. ASSEMBLY组装 57
5.12. NOTES ON THE COUPLING联轴器提示 59
5.13. HYDRAULIC ASSEMBLY SHAFT/ IMPELLER液压组装主轴与叶轮 59
5.13.1. METHOD OF OPERATION操作方法 59
5.13.2. INSTALLATION DEVICES组装设备 59
5.13.3. DISASSEMBLY拆卸 60
5.13.4. ASSEMBLY组装 61
5.14. COOLING/SEALING AIR SYSTEM (ID FAN ONLY) 冷却/密封空气系统（仅用于引风机） 64
5.14.1. SEALING AIR密封空气 64
5.14.2. COOLING AIR冷却空气 65
5.15. CONNECTION OF THE PIPES管道连接 65
6. TRANSPORTATION运输 67
7. LUBRICATION润滑 68
7.1. GENERAL概述 68
7.2. MAIN BEARING AND SERVOMOTOR主轴承和伺服马达用油 68
7.2.1. REQUIRED PROPERTIES要求特性 68
7.2.2. OIL CARE润滑油警示事项 69
7.2.3. OIL SYSTEM油系统 70
7.2.4. OIL FILLING注油 70
7.2.5. CHANGING THE OIL换油 71
7.2.6. DOCUMENTATION OF LUBRICATION润滑油记录文档 72
7.3. BLADE BEARINGS叶片轴承用油 72
7.3.1 REQUIRED PROPERTIES要求特性 72
8. SPARE PARTS备件 74
8.1. STOCKS库存 74
8.1.1. AVAILABILITY建议存储的备件 74
8.1.2. WEAR, MALFUNCTIONS磨损、故障 74
8.2. ORDERING订货 76
8.3. STORAGE贮存 76
9. PRESERVATION保存 78
9.1. NOTE说明 78
9.2. INTERRUPTION OF INSTALLATION组装间歇期的防护 78
9.3. STANDSTILL停机时的防护 79
9.4. PRIOR TO COMMISSIONING试运行之前 81
10. MALFUNCTION ANALYSIS故障分析 82
10.1. VIBRATION振动 82
10.2. BEARING TEMPERATURE轴承温度 82
10.3. OIL TEMPERATURE油温 83
10.4. OIL PRESSURE油压 83
10.5. OIL CONDITION油况 84
10.6. OIL LEVEL油位 84
10.7. BEARING LEAKING轴承泄漏 84
10.8. BEARING CONDITION轴承状态 85
10.9. WEAR磨损 85
10.10. POWER CONTROL动力控制 86
10.11. BLADE BEARING BLOCKED叶片轴承卡滞 86

1. Operating data运行参数
1.1. Pressure indications 单位说明

Pressures indicated in bar and/or mbar are gauge pressures. Pressures indicated in “abs” are absolute pressures.
单位为bar或mbar的压力为表压力，单位为abs的压力值为绝对压力。
1.2. Operating conditions 运行条件

Description描述

Customers machine no.用户设备编号

CKPF machine no. CKPF设备编号

Fan type风机型号
Axial fan with adjustable blades
动叶可调轴流风机
Fan Size风机尺寸

Dimension
尺寸

Fluid介质

Ambient air当地大气压
Load负荷

Design设计
Volume at 0°C and 1,013 bar
标态流量
Nm3/min

Volume at fan inlet实际入口流量
m3/s

Temperature at inlet fan入口温度
°C

Structural design temperature
设计温度
°C

Pressure at fan inlet入口压力
mbar abs

Density at fan inlet入口密度
kg/m3

Total pressure rise风机全压
mbar

Fan speed风机转速
1/min

Motor speed电机转速
1/min

Absorbed power at motor coupling
电机输出功率
kW

Installed nominal motor power
电机额定功率
kW

Performance graph性能曲线
no.
PG …
Acoustic data声学数据
no.
AC …
Starting torques启动扭矩
no.
ST …
Mass moment of inertia转动惯量
Kgm2

1.3. Limitations to operating data 运行参数限制

DANGER !警示
The fan or parts and all parts of the fan are specifically designed based on information supplied by the customer.If in the course of time any changes to this information take place or are planned, these should be checked with CKPF to ensure that they are permissible.
风机及配件是按用户提供的参数资料进行专门选型设计的，若参数改变，应由CKPF检验校核以确认其可行性。

Motor speed Fluctuations in the power-supply frequency must not cause the speed of the drive motor to exceed the rpm figure specified in the operating data by more than 2%.
电机转速 电源频率的波动导致转速的波动不能超过运行数据规定的2%。

Motor power The permissible motor power may exceed the power required at the fan shaft indicated in the operating data by max. 15%.
电机功率 电动机安全的功率余量应至少大于风机运行工况下轴功率的15%。

Gas temperature The admissible gas temperature measured at the fan intake
气流温度 风机入口气流温度

must not exceed a maximum of …°C permanently
最大不能长时间超过（ ）℃

may be at a maximum of ... °C for a short time for max. .... minutes.
或（ ）℃时最长不得超过（ ）分钟。

IMPORTANT !重要
In case of exceeding these limits please
若超过上述限制要求

check the fan for damage
检查风机的损害

and contact CKPF
并联系CKPF

Operating points The fan may only be operated for brief periods with an insufficient volume flow. The limit is mentioned in the attached performance graph.
运行点 风机尽量避免在不稳定区运行。此区域在特性曲线图上可以查到。

IMPORTANT !重要
Low volume operation over a longer period can cause overheat of the fan. This should be avoided
风机若长时间在低流量运行会导致过热，应避免。

IMPORTANT !重要
The fan must not be operated above the surge limit. The limit is mentioned in the attached performance graph.
不允许风机在失速喘振区域运行，此区域在特性曲线图上可以查到。

IMPORTANT !重要
The operation of the fan above the surge limit strains blades, other fan parts, plant components extremely. Impacts and vibration can cause heavy damage to all parts of the fan and the plant. This should be avoided.
若风机在失速喘振区域运行会导致动叶和其它机件重大损坏、撞击和振动导致更大的系统设备事故，应避免。

1.4. Performance graph 性能曲线

(to be inserted here)（由此插入）

1.5. Starting torques and mass moment of inertia 启动扭矩和转动惯量

(to be inserted here)（此处插入）

1.6. Acoustics声学特性
(to be inserted here)（此处插入）

2. Descriptions简介
2.1. Fluidic effect (1-stage)工作原理（单级）

On entering the direction of the flow is altered in the suction bend, accelerated by a nozzle and directed into the impeller.
气流由系统管道流入风机进气箱后改变方向，经集流器收敛加速后流向叶轮。

In the impeller the axially-directed flow becomes circumferential and is accelerated. The pitch angle of the rotor blades is infinitely variable during operation. The adjustment has the effect of changing the volume flow.
电动机带动叶轮对气流作功，动叶的工作角度与叶栅距可无级调节，由此改变风量、风压满足工况变化需求。

After the impeller the guide vanes (outlet guide-vane unit) redirect the flow in an axial direction, thus increasing the pressure (reaction-type fan).
气流由轴向运动经叶轮作功后变为螺旋运动，流出的气流经后导叶导向转为轴向流动。

In the diffusor the kinetic energy is then converted into static pressure.
再经扩压器，将部分动能转换成静压能，流至系统满足运行要求。
2.2. Fluidic effect (2-stage)工作原理（双级）

On entering the direction of the flow is altered in the suction bend, accelerated by a nozzle and directed into the impeller.
气流由系统管道流入风机进气箱后改变方向，经集流器收敛加速后流向叶轮。

In the impeller the axially-directed flow becomes circumferential and is accelerated. The pitch angle of the rotor blades is infinitely variable during operation. The adjustment has the effect of changing the volume flow.
电动机带动叶轮对气流作功，动叶的工作角度与叶栅距可无级调节，由此可改变风量、风压满足工况变化需求。

After the impeller the guide vanes (outlet guide-vane unit) redirect the flow in an axial direction, thus increasing the pressure (reaction-type fan).
气流由轴向运动经叶轮作功后变为螺旋运动，流出的气流经后导叶转为轴向流动。

In the second stage pressure is further increased.
在第二级叶轮处压力进一步增加。

The pitch angle of the rotor blades in both stages is adjusted synchronously.
两级叶轮的叶片角度同时调整。

In the diffusor the kinetic energy is then converted into static pressure.
再经扩压器，将部分动能转换成静压能，流至系统满足运行要求。

2.3. Description of the fan风机（部件）简介

Seen in the direction of the flow the 1-stage fan consists of the following components …
· Suction bend with shaft protection tube
· Fan housing with flow hub
· Guide vane housing
· Rotor with bearing (in the flow hub)
· Diffuser
从气流方向看，单级风机由以下部件组成…
带护轴管的进气箱
带整流罩的机壳装配
后导叶装配
主轴承装配（在整流罩中）
扩压器

Seen in the direction of the flow the 2-stage fan consists of the following components …
· Suction bend with shaft protection tube and flow hub
· Fan housing
· Rotor with bearing (in core of fan housing)
· Guide vane housing
· Diffuser
从气流方向看，双级风机由以下部件组成…
带护轴管和整流罩的进气箱
机壳装配
主轴承装配（在整流罩中）
后导叶装配
扩压器

The structure is made clear by the accompanying sectional drawing.
结构详见附图。
2.3.1. Stator components定子部件

Stator components are suction bend, fan housing, guide vane housing and diffusor.
定子部件分为进气箱，机壳装配，后导叶装配和扩压器。

General The stator components are welded structures made of even rolled sheeting reinforced with ribs and flanges. The process of welding them together is not completed until the stage of on-site assembly.
概述 定子部件由焊接了加强筋板和法兰的壳体铆焊件构成，到组装时再将其焊接或组合在一起。

Suction bend The suction bend has a rectangular inlet cross-section.
It has an access door on the front. The base fastenings are sliding supports, when the fan expands on heating they can move on the foundation.
进气箱 进气箱入口截面为矩形，在前端面带人孔门，当风机热胀冷缩时，基础可适量滑动，抵消热膨胀量。

Fan housing 1-stage: The fan housing is horizontally split.
机壳装配 单级：中分剖分。

2-stage: The fan housing is horizontally split. The guide vanes
of the first impeller stage are welded in.
双级：中分剖分。第一级叶轮的后导叶焊接。

Guide vane housing 1-stage: The guide vane housing is horizontally split. The guide
后导叶装配 vanes are welded in place.
单级：中分剖分，后导叶焊接。
2-stage: The stator housing is horizontally split. The guide
vanes of the second impeller stage are welded in.
双级：定子壳体中分剖分，2级后导叶焊接。

Diffuser There is a door in the diffusor core permitting access from the discharge pipe.
扩压器 芯筒带人孔门，允许人从出口管路进入其中。
2.3.2. Rotor (1-stage) 转子（单级）

The rotor consists of the impeller, the shaft and the servomotor. The shaft has a pin to engage with the coupling hub.
单级风机的转子包括叶轮、主轴、伺服马达。主轴通过键与联轴器轮毂联接。
2.3.3. Rotor (2-stage) 转子（双级）

The rotor consists of the impeller, the shaft, the servomotor and the adjusting rod with adjusting disc. The first-stage impeller has a drive disc for the coupling hub.
双级风机的转子包括叶轮、主轴、伺服马达、带调节盘的芯轴。第一级叶轮由驱动盘（中介环）和联轴器连接。
2.3.4. Impeller (1-stage, with counterweights) 叶轮（单级，带平衡锤）

The impeller is overhung. The impeller hub is a welded structure. The forged body accommodates the blade bearings. It is connected to the shaft with a hub disc. The hub disc is attached to the shaft with a taper press fit.
叶轮为悬臂式、焊接件。叶片轴承组装在叶轮毂体内，叶轮毂通过毂盘与主轴联接，毂盘由圆锥面过盈配合联接固定到主轴上。

The restoring moments of the blades are generated by the rotating mass of the blading and the air forces. For a partial compensation of the restoring moments compensating weights are attached to the blade shaft which generates a moment reacting to the restoring moment of the blades.
叶片回复力矩由叶片的旋转质量和气体压力产生。作为回复力矩的部分补偿，组装在叶片轴上的平衡锤能产生一个力矩来抵消叶片产生的回复力矩。

2.3.5. Impeller (2-stage, with counterweights) 叶轮（双级，带平衡锤）

The imp