5,000 TPD CMIC CEMENT PLANT

PROJECT IN CAMBODIA

LIMESTONE CRUSHING＆STORAGE

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
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

目 录
Catalog
第一章 前 言 ........................................................................................................................... 1
Chapter 1 Introduction..................................................................................................................... 1
第二章 工艺流程和工艺设备........................................................................................................ 2
Chapter 2 Process Flow and Equipment ........................................................................................ 2
一、工艺流程简介 Introduction for process ................................................................... 2
二、工艺设备 Equipment ........................................................................................................ 3
第三章 启动前的准备工作 ........................................................................................................... 4
Chapter 3 Preparation Before Starting .......................................................................................... 4
一、现场设备的检查 Inspection for equipment ...................................................................... 4
二、电控室的准备工作 Preparation for electrical devices ....................................................... 6
第四章 启动与停车操作 ............................................................................................................... 7
Chapter 4 Operation of Startup and Shutdown ................................................................................. 7
一、系统启动操作 Starting operations............................................................................. 7
二、系统正常停车操作 The normal stop operation of the system ......................................... 11
三、设备故障停车和紧急停车的处理 Operations for fault shutdown and emergency stop .. 11
第五章 设备单体试车 ................................................................................................................. 14
Chapter 5 Single-unit test run ..................................................................................................... 14
一、设备试车条件 Conditions for test run ............................................................................ 14
二、试车过程 The process of the trial run. ........................................................................... 14
三、试车要求 Requirements for test run................................................................................ 15
四、单机试车后确认事项 Items to be confirmed after single-unit test run ........................... 17
第六章 试生产阶段注意事项...................................................................................................... 18
Chapter 6 Precautions at Trial Production...................................................................................... 18
一、概述 The overview ......................................................................................................... 18
二、试生产的准备 The preparation for the trial run .............................................................. 19
三、试生产要领及注意事项 The main points and items needing attention in the trial run..... 20
四、 设备使用维护要领 Utilization and maintenance essentials of equipment ................ 21
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第一章 前 言

Chapter 1 Introduction
本操作说明书仅供 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA 的石灰
石破碎、输送及储存系统操作时使用。
This operating manual shall be only applied to the COAL CRUSHING AND STORAGE for
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
本系统是指从石灰石受料斗开始到石灰石黏土预均化堆棚为止。本说明书的内容，仅限
于保证设备的正常运转及工艺操作的基本事项。为了保证顺利生产，提高设备的运转率，本
系统的操作人员必须在掌握本操作说明书内容的基础上，根据各单机设备的说明书以及有关
附图，深入了解该设备的构造、原理和性能，熟练掌握单机设备的操作、维护、检修技术，
以便及时解决生产过程中出现的各类问题。
The system refers to the processing production line from limestonel jaw crusher to Premix
material of Limestone and Clay shed. The manual is only limited to ensure the normal running of
equipment and the basic matter for the processing operation. In order to make sure that production
goes smoothly, and the running rate of equipment is improved, firstly, the operator of the system
must master the content of the manual, and know further about the configuration, principle and
performance of the equipment according to the specification and attached drawing of single
equipment. In this way, master skillfully the operation, maintenance, and overhaul technology of
the single equipment, know the using points of instrument and its control device, to eliminate the
various problems appeared in the production immediately.
编制本操作说明书的基本依据是各类设计文件，同时结合以往生产调试的经验。在实际
生产中，如本操作说明书所述与实际情况、现场到货的设备使用说明书有偏差时，或者对所
述内容有疑问时，请与我院派往现场的调试技术人员进行协商解决，并根据实际情况进行修
改。
The establishment of the operation manual is on the base of the various design technique
documents, moreover, combining with the antecedent experience of the production debugging. In
the actual production, if you find that there is any deviation between the operation manual and the
actual condition, or you have any doubt about the stated content, please get in touch with the
debugging technician sent to the work field by our company to negotiate and solve, and correct it
according to the actual condition. Please read the relevant single equipment's operation manual for
knowing the performance of equipment well.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第二章 工艺流程和工艺设备

Chapter 2 Process Flow and Equipment

一、工艺流程简介 Introduction for process

本系统的工艺流程见流程图。
Process for this department refers to flowsheet.
矿山开采的石灰石由矿用自卸卡车直接卸入石灰石受料坑（211-HP1）内，受料坑采用五
边形形状来确保能够两边卸料，受料坑底石灰石喂料采用重型板式喂料机（211-AC1）和振
动给料机（211-VF1），石灰石破碎机（211-JC1）为颚式破碎机，破碎后的物料经胶带输送
机 (211-BC1)送入振动筛（ 241-VS1&241-VS2）。筛上物料经皮带（ 241-BC1）送入 料 仓
（241-3B1），再经过板式喂料机（241－AF1）送入圆锥破碎机（241-CZ1），破碎后的石灰
石经胶带输送机（241-BC2）返回振动筛（241－VS1 和 241－VS2）。筛下粒度小于 70mm
的成品石灰石经皮带（241-BC3，291-BC1，291-BC2）输送石灰石仓（291-3B1）。
The mined limestone shall be feed into the limestone feed hopper（211-HP1）by dump truck,the
hopper can be used for two 2 trucks at same time. then be fed into jaw crusher（211-JC1）by
heavy-duty apron feeder（211-AC1）and grizzly Feeder（211-VF1）. The crushed limestone
transported to grizzly screen（241-VS1&241-VS2）by belt conveyor(211-BC1). the unqualified
limestone (70 ≤ size ≤ 350mm)transported to (241-3B1) by belt conveyor(241-BC1).then the
unqualified limestone fed into cone crusher by apron conveyor（241－AF1）.the secondary crushed
limestone return to the grizzly screen（241-VS1&241-VS2）by belt conveyor(241-BC2).the
qualified limestone(size≤70mm) which from grizzly screen are transported to bin（291-3B1）by
belt conveyor（241-BC3，291-BC1，291-BC2）.
破碎系统设有破碎机负荷自动调节回路，根据破碎机（211-JC1）的负荷自动控制板喂机
（211-AF1） 的速度。当破碎机超负荷时，板喂机的速度会自动降低，喂料量减少，当破碎
机负荷低于额定值 80%时，板喂机会自动加速，以保证破碎机工作在最佳状态。
The crushing system is provided with crusher load auto-adjusting circuit, which can adjust the
speed of apron feeder（211-AF1）automatically according to the crusher（211-JC1）& （241-CZ1）
load. When the crusher is overloaded, the feeder will be slowed down automatically to decrease the
feed quantity. When the crusher load is less than 80% of the rated value, the feeder will be speeded
up automatically to ensure the best working state of the crusher.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

中间仓中的石灰石经仓底卸料经棒阀（291-NG1) 、链板秤（291－AW1）、胶带输送机
（291-BC3）输送至混合料预均化堆棚。在胶带输送机（291-BC3）上设置有跨皮带分析仪，
用于调节石灰石和粘土的比例。输送至混合料预均化堆棚的石灰石和黏土经侧式悬臂回转堆
料机（291-ST1）在预均化堆棚内往返布料。
After bin（291-3B1）,the limestone are ransported to Premix material of limestone and clay
shed by belt conveyor（291-BC3）. There is a material on-line analyser an quality controlling device
on belt conveyor（291-BC3）.use the analysis result to control the limestone and clay ratio. The
Premix material return distributed by stacker（291-ST1）on pre-homogenization shed.
堆棚内设有四个料堆，其中两个是高品质石灰石料堆，储存能力分别为 3000 吨和 4000
吨；另外两个是石灰石黏土混合料堆，储存能力均为 30000 吨。
There are four stock piles in the shed. Contain two piles of HG limestone(3000T, 4000T),two
piles of Premix material (2x30000T)
在胶带机（241-BC1、291-BC3）上设有除铁器，以去除原料中可能的铁件。在各转运站
设置有袋式除尘器处理粉尘, 处理后粉尘排放浓度小于 30mg/Nm3。
There are magnetic separator on the belt conveyor（241-BC1、291-BC3）to remove metal from
the coal.There is bag filter on all the transport stations to handle the powder and dust.

二、工艺设备 Equipment

本系统所有工艺设备主要技术参数见设备表。
Equipment technical please see the equipment list.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第三章 启动前的准备工作

Chapter 3 Preparation Before Starting

该系统的全部设备，在启动前，都应做认真的检查调整工作，这不仅在试生产时要做，

还必须作为一条制度，在以后的生产中严格执行，保证设备的正常运转。

All the equipment in this system shall be thoroughly inspected and regulated prior to starting up

whatever in commissioning or later putting into production and shall be strictly executed as rules to

ensure best running of the equipment.

一、现场设备的检查 Inspection for equipment

1．润滑设备和润滑油量的检查调整
Inspection and adjustment for lubrication device and lubricating oil volume
设备的润滑对保证设备的长期稳定运转，起着关键性的作用，润滑油量应达到规定的油
标刻度范围，既不能过多，也不能过少。油量过多，会导致设备温度过高；油量过少，设备
会因缺油而损坏。另一方面，要定期检查、补充、更换润滑油。用油的品种、牌号不能错，
而且要保证油中无水无杂质。主要检查项目有以下几点：
The lubrication for the equipment plays a key role on the long-term stable operation, and the
volume of the lubricating oil directly influence the operation of equipment. Overmuch oil will lead
to equipment heating, while too little oil will result in equipment damage. The lubricating oil shall
be inspected and exchanged regularly in strict accordance with the specification of each single
equipment. The kind and grade of oil shall not be wrong and the oil quality shall meet the
requirements. No water or impurity is allowed in the oil.The main chek project has the following
points:
1.1 所有设备的传动装置：包括电动机、减速机、联轴承等润滑点要加好油。
The transmission devices of all the equipment, including gearbox, motor, coupling and so on,
need lubrication at each lubricating point.
1.2 所有设备的各个轴承、活动部件及传动链条等部分加油。
1.2 Each bearing, moving part, transmission chain as well as other parts of all the equipment
shall be oiled.
1.3 所有电动阀门的执行机构加油。
1.3 The actuators of all the electric valve shall be oiled.
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

1.4 检查油质是否变劣，确定换油与否。
1.4 Check if the oil quality turns bad and if the oil needs to be changed.
1.5 检查箱(机)底部所有放油(水)孔，拧紧堵孔螺栓。
1.5 Check all the oil drains at the bottom of tank(machine) and tighten the blockage bolts.
2. 设备内部人孔门、检查门的检查及密封
Check and seal equipment interior, manhole door and inspection door.
在设备启动前，要对设备内部进行全面的检查，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，卡死或打死设备，造成不必要的损失。
Before starting the equipment, fully inspect the interior and remove the foreign matters left
inside during installation and maintenance to prevent the equipment from jamming during operation
so as to avoid the unnecessary losses.
在设备内部检查完后，将所有的人孔门、检查门严格密封，防止生产时漏风、漏料、漏
油等。
Seal all the manhole door and inspection door strictly after checking the equipment interior, in
order to prevent air leakage, material leakage and oil leakage during production.
3. 闸门 gate
各闸门的进口闸板，要全部开到适当的位置，保证物料的畅通。
The inlet damper of each gate shall be opened to the proper position so as to ensure the
unblockedness of material.
所有阀门的开闭方向及开度的确认
Confirmation of the opening and closing direction as well as opening of all the valves
4.1 所有的手动阀门，在设备启动前，都应打到适当的位置。
4.1 All the manual valves shall be operated to the proper position prior to the startup of
equipment.
4.2 所有的电动阀门，首先在现场确认能否灵活开闭，阀轴与连杆是否松动，然后由电
控室遥控操作，确认控制室与现场的开关方向是否一致，开度与指示是否对应，如果阀门带
有上、下限位开关，要与控制室核对限位信号是否返回。
4.2 As for all the electric valves, firstly, the flexible opening and closing shall be confirmed on
site, and check whether the valve shaft and the connecting rod are loosely connected on site, and
then confirm whether the opening and closing direction of control room and site are consistent and
whether the opening corresponds with the indication through the remote operation from electric
control room, if the valve has upper limit switch and lower limit switch, check whether the limit
signal returns with control room.
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

5. 各溜管、收尘风管及输送设备的检查
5. checking of each slide pipe, dust collecting duct and conveying equipment
检查各溜管、收尘风管及输送设备等，确认其畅通，无堵塞，无破损和卡死现象。
Check each slide pipe, dust collecting duct, conveying equipment and other parts, and ensure
that they are unblocked, block-free, damage-free and stuck-ness free.
6. 设备紧固检查
6. checking of tightening of equipment
检查设备的紧固情况，如设备的基础地脚螺栓等，不能出现松动，有的设备的传动的连
杆等易松动部件，都要进行严格的检查。
Check the tightening of equipment, for example, the tightening of anchor bolts for the
foundation of equipment and other parts shall not be loose, as for some components of equipment,
the tightening of which tends to become loose, such as the connecting rod of transmission, therefore,
they shall all be checked strictly.
7. 压缩空气的检查
7. Checking of compressed air
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 whether
the pressure of compressed air at air use points complies with the requirement of air supply, and
inform the relevant personnel to handle it if necessary.

二、电控室的准备工作 Preparation for electrical devices

1. 选择要启动的设备。Choose the device to be started.

2. 检查设备的备妥情况，如果未备妥，应与电气及现场人员联系处理。
2. Check the readiness condition of equipment, if the readiness is not available, let the
electrical and site personnel to handle it by contacting them.
以上各项工作完成后，系统启动前的准备工作即完成，可根据实际情况，启动所有的设
备。
After completing all above work, the preparations before startup have been made, and then
enable all devices one by one in sequence.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第四章 启动与停车操作
Chapter 4 Operation of Startup and Shutdown

一、系统启动操作 Starting operations

本系统 PLC 启动，启动顺序及连锁关系见电气部分。有关 PLC 集中控制的具体操作见

电气说明。在正常启动前，必须做好系统启动前的所有准备工作，确认各主机系统及各辅机

系统能正常运行，确认供水系统工作正常，确认设备润滑正常。另外，在系统启动后，要勤

观察各设备、仪表及系统的运行状况，发现问题及时处理。

This system is started by PLC and the startup sequence and interlocks are shown in the

electrical part. See detailed operations for PLC centralized control in the electrical specification.

Before startup, all preparations must be made to confirm that the host system and the auxiliary

systems can be normally operated, the water supply system is in good condition and the lubrication

for devices is well done. In addition, after startup, the running condition for every device,

instrument and system should be frequently observed and problems (if any) must be solved

immediately.

表 4−1 石灰石二次破碎系统启动操作顺序表
Table 4-1 The startup operation sequence of cone crushing system

序号 操 作 步 骤 operation sequence 检 查 与 调 整 check and adjustment

NO.
1 收尘系统启动。
Dedust system start
2 胶带输送机(291-BC2)启动 (1)滚筒托辊转动灵活，胶带运转平稳。
belt conveyor(291-BC2)start
Ensure that the roller moves flexibly and
3 胶带输送机(291-BC1)启动
the belt runs steadily.
belt conveyor(291-BC1)start
4 胶带输送机(241-BC3)启动 (2)拉紧装置正常工作。

belt conveyor(241-BC3)start The tension device works normally.

5 胶带输送机(241-BC1)启动

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

belt conveyor(241-BC1)start (3)空载运转一定时间(按实际情况

确定)，检查有无跑偏、打滑现

象。

Run without load for certain time

6 振动筛 241-VS1,241-VS2 启动
grizzly screen（241-VS1&241-VS2）
start
(according to the actual conditions) to
check whether it deflects or slips.
检查振动电机运行是否平稳。
检查筛体运行是否平稳。
check whether the motor is running
smoothly and the screen is running

smoothly

7 胶带输送机(241-BC2)启动 (1)滚筒托辊转动灵活，胶带运转平稳。
belt conveyor(241-BC2)start
Ensure that the roller moves flexibly and

the belt runs steadily.

(2)拉紧装置正常工作。

The tension device works normally.

(3) 空 载 运转 一定 时 间( 按 实际 情 况 确

定)，检查有无跑偏、打滑现象。

Run without load for certain time

(according to the actual conditions) to
check whether it deflects or slips.
8 圆锥破碎机(241-CZ1)启动
cone crusher(241-CZ1)start
9 板式喂料机(241-AF1)启动。
Apron feeder(241-AF1) start。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
表 4−2 石灰石颚破系统生产启动操作顺序表
Table 4-2 The startup operation sequence of jaw crushing system
序号 操 作 步 骤
NO. operation sequence
1 确认石灰石二破工段已准备完毕，已
启动相应设备
Confirm limestone cone crushing
system is ready, the corresponding
equipment has been started
2 收尘系统启动
Dedust system start
3 胶带（211-BC1）启动。
belt conveyor(211-BC1)start
4 破碎机(211-JC1)启动。
5 振动给料机（211-VF1）启动。
Start the Grizzly Feeder（211-VF1）
6 板喂机(211-AC1)启动
以低速喂料，逐渐提高至正常速度。
Start the apron feeder(211-AC1)
gradually increases from low-speed
feeding up to normal speed.
9
检 查 与 调 整
check and adjustment
(1)滚筒托辊转动灵活，胶带运转平稳。
Ensure that the roller moves flexibly
and the belt runs steadily.
(2)拉紧装置正常工作。
The tension device works normally.
(3)空载运转一定时间(按实际情况确
定)，检查有无跑偏、打滑现象。
Run without load for certain time
(according to the actual conditions)
to check whether it deflects or
slips.
1.检查驱动装置是否平稳。
1. Check drive unit
2.注意启动电流。
2. Notice starting current
3.注意各点温度。
3. Notice every point temperature
4.达到正常转速后空载运转 5 分钟。
4. Free running 5 minutes after
reaching of normal speed
(1)检查喂料情况。Check the material
condition
(2)注意启动电流。Pay attention to the
starting current
(3)注意轴承温度。Pay attention to the
bearing temperature
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

表 4−3 石灰石中间仓（291-3B1）至混合料预均化堆棚启动操作顺序表
Table 4-3 The startup operation sequence from bin (291-3B1) to Premix material shed

序号 操 作 步 骤 检 查 与 调 整
NO. operation sequence check and adjustment
1 跨皮带分析仪（291-MY1 ）启动
Start the Material on-line Analyser an
quality controlling device
（291-MY1 ）.
除铁器（291-MS1 ）启动
Start the Magnetic Separator
（291-MS1 ）
2 堆料机(291-ST1)启动。 (1)注意启动顺序。
(1)悬臂上的卸料皮带机启动。 (2)注意轴承温度。
(2)液压系统启动。 (3)注意减速器温度。
(3)堆料皮带机启动。 (1)Pay attention to the startup sequence.

(4)电缆卷盘启动。 (2)Pay attention to the temperature of the

bearing.
(5)行走机构启动。
(3)Pay attention to the temperature of the
Start up stacker (L11-ST1)
reducer.
(1)Start up the discharging belt
conveyor on the cantilever.
(2)Start up the hydraulic system.
(3)Start up the stacking belt conveyor.
(4)Start up the cable coiling.
(5)Start up the running mechanism.
3 胶带输送机(291-BC3)启动 (1)滚筒托辊转动灵活，胶带运转平稳。
Start up the belt conveyor(291-BC3)
Ensure that the roller moves flexibly and

the belt runs steadily.

(2)拉紧装置正常工作。

The tension device works normally.

(3) 空 载 运转 一定 时 间( 按 实际 情 况 确

定)，检查有无跑偏、打滑现象。

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

Run without load for certain time

(according to the actual conditions) to
check whether it deflects or slips.
4 离心风机(291-FN3)启动
Start up fan (291-FN3)
5 收尘器(291-BF3) 启动
Start up fan(291-BF3)
6 链板秤(291-AW1)启动 检查各部件运行情况。
Start up Apron Weigh Feeder Check the running condition of each part.
(291-AW1)
注意：当组内有数台大电机时，应分别延时启动，以避免启动电流过大，造成总降跳闸。
Note: when there are several large motors in the group, they should be delayed to start, in order
to avoid the start current is too large, resulting in a total trip down

二、系统正常停车操作 The normal stop operation of the system

把决定要停止的设备所在组的启动开关按流程顺序逐一延时打到“停止”位置，此组内
设备再按停车顺序逐一延时停车。每次停车前，确保输送系统设备正常停车时应卸空设备上
的物料，以便下次正常启动。另外，为了设备安全保护需要，注意各设备的润滑、冷却按各
设备要求进行操作，并勤于检查和维护。在正常情况下，停车顺序为启动顺序的逆顺序。
The starting switch of the group which includes the relative equipments need to stop shall be
put into the "off" position with some time delay sequentially one by one. Then the equipment in the
group shall stop with delay sequentially one by one. Before each stop, confirm that when the
equipment of conveying system stops normally, all the material in the equipment must be
discharged completely for a normal next start. Moreover, in order to guarantee the equipment safety,
pay more attention to the lubrication and cooling of each equipment, operate according to the
relative requirement, and check and maintain regularly. In normal condition, the stop sequence is
the backwardness of the starting sequence.

三、设备故障停车和紧急停车的处理 Operations for fault shutdown and emergency

stop

3.1 在系统运行过程中，由于设备发生故障、电机过载跳闸、机电保护跳闸及其事故，
现场的部分或全部设备会联锁停车。在某种紧急情况下，为了保证设备及人身安全，还会采

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

用紧急停车按钮使系统紧急停车，为了保证能够顺利地再次启动，故障停车或紧急停车后必
须进行处理操作。
3.1 During the system operation, because of the device faults, the trip by motor overload and
by local protection and the relevant accidents, some or all devices will be stopped by interlocking.
In certain emergency circumstances, the emergency button is applied to emergency stop for safety
of device ad personnel. To guarantee the successful restart, operations must be done after the fault
stop or the emergency stop.
3.1.1 设备突然停车的基本处理方法
The basic methods to handle the hard shutdown
3.1.1.1 马上停止向已停车设备供料的相关设备。
Immediately stop the relevant equipment which provides materials to the halted device.
3.1.1.2 尽快查清原因，判断能否在短时间（30 分钟）内处理完，以
决定再次启动时间，并进行相应的操作。
Find out reason as soon as possible and judge if it is handled within a short time (in 30min),
and then determine the restart time and the follow-up procedures.
3.1.2 本系统设备常见故障及处理方法如下：
（1）皮带机

故 障 可能的原因 处 理

皮带跑偏 头、尾滚筒不平行 调整头尾轮

皮带打滑 进料口物料卡死 清除进料口的物料
皮带未张紧 调正皮带张紧力
皮带撕裂或折断 有钢件卡在皮带上 更换新皮带
皮带张得过紧，或胶接不好 用皮带扣连接
油冷式电动滚筒烧坏 缺油 更换油冷式滚筒电机
进料口物料堆积而过载
（1）belt conveyor
Possible cause Treatment
The belt is off tracking Both ends of the roller are not Adjust the head and tail
The belt slips. parallel. wheels.
The material in feeding inlet is Clear out the material in
locked feeding inlet.
Belt is not tensioned Adjust the tension of the belt.
The belt is tore or broken. Steel pieces are locked on the belt. Replace with a new belt.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

The belt is over tense, or is not Connect with a belt buckle.

glued well.
Oil cooling motorized Lack of oil. Replace the oil cooling roller
roller is burnt out. The material in feeding inlet is motor.
accumulated to result in overload.
（2）堆、取料机

故 障 可能的原因 处 理

a. 皮带跑偏 张紧不够 调节尾轮

b. 下料口堵 下料过大，原料夹土过多或含水偏高 清堵
c. 滚筒轴承坏 轴承缺润滑油，进灰尘 更换
d. 皮带断裂 张紧过大，磨损 重接皮带

（2）stacker and reclaimer

Malfunction Possible cause Treatment
a. The belt is off tracking. Tension is not enough. Adjust the tail wheel.
b. Discharging outlet is The discharging is too large, clay Clear the block.
blocked. or water content mixed in the raw
material is over high.
c. The bearing of the roller The bearing lacks in lubricating Replace it.
is broken. oil, and dust enter the bearing.
d. Belt is broken. The belt is over tense, and is Reconnect the belt.
damaged.

3.2 紧急停车操作 operations for emergency stop

当出现紧急情况时，需要全部停车，按紧急停车键，设备急停后，应对设定值、阀门等
进行调整。如润滑设备没有问题，立即启动，并尽快处理，恢复系统运行。
When the emergency happens, it must stop all devices. Press the emergency button to stop the
device, and adjust the set value and valves after the devices stops. If there is no fault on the
lubrication device, start the device immediately, solve problems and reoperate the system.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第五章 设备单体试车

Chapter 5 Single-unit test run

一、设备试车条件 Conditions for test run

1.1 设备安装完成
Finish the installation of the devices
1.2 电器安装完成
Finish the installation of the electric appliance
1.3 减速机内按照设备要求加注润滑油
Add lubricating oil to the devices inside the reducer in accordance with requirements
1.4 所有润滑点按照要求加注润滑油或润滑脂
Add lubricating oil or grease to the point according to requirements
1.5 本系统每台设备应逐个进行单机试运转，并根据相应设备的说明书及验收标准进行。
Every equipment of this system should make trail run one by one, according to the
corresponding instruction and checking and acceptance standard for the equipment.

二、试车过程 The process of the trial run.

2.1 首先把转换开关放在现场位置，点动开关，确认电机旋转方向。
Put the switch on site, open it and confirm the rotation direction.
2.2 确认电机旋转方向正确后，对设备带电进行试运转，观察设备的运行情况，并对电
机电流进行测量。如果电流正常，设备运行情况正常，在无负荷情况下运转 4 小时，在这个
过程中观察各润滑点，确认减速机、轴承不发热，即可以完成无负荷试车。
After confirming the right direction, have test run on the equipment with power on, observe
the equipment running condition and measure the motor current. If the current and the equipment is
in normal condition, run it without load for 4h and observe every lubricating point to confirm the
reducer and the bearing don’t generate heat before start the no-load test run.
无负荷试车结束后，在条件允许的情况下，进行负荷试车。
Start the loaded test run in a allowable condition after finishing the no-load test run.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

三、试车要求 Requirements for test run

3.1 板式喂料机 The apron feeder：

3.1.1 低速启动空载运转，检查正常无误后，逐渐达到正常运转速度，运转若干小时（详见单
机操作说明书）。
Start the no-load test run in a low speed, check it and then gradually run it in a normal speed
for hours (see the single-unit operation specification for details).
3.1.2 所有紧固件应连接牢固，无松动现象。特别是注意检查链板的联接螺栓有无松动现
象。保持链条松紧适当，如发现跑偏应通过拉紧装置进行调整。
Make sure that all fasteners are tightened, especially the connecting bolts of the chain
conveyor. Keep the chains in a proper degree of tightness; if it deflects, adjust it by the tension
device.
3.1.3 检查是否有其它异常情况，如发现异常，应及时检查发生的原因，并排除故障。
Check whether there is other abnormal conditions; if some fault happens, check and find out
the reason and solve it.
3.2 破碎机 the crusher：
3.2.1 检查并确认破碎机机体内没有金属物品和任何其他异物。所有润滑点按照要求加注润滑
油或润滑脂。
Check and confirm that no metals and other foreign matters inside the crusher; add lubricating
oil or grease to the lubricating points according to requirements.
3.2.2 检查机器各门、视孔盖是否封闭。各门和视孔盖在关闭前应在其外沿四周抹一层较厚的
润滑油脂，以使其关闭后有较好的气密性。
Check whether each door and every inspection plate is closed or not. Apply thick lubricating
grease around every door and each inspection plate to make sure its good air impermeability.
3.2.3 空载连续运转试车时间不少于 4 小时。空载试车必须遵循先点动后连续的原则，待
确认情况正常后再连续运转（详见单机操作说明书）。
The time of the no-load test run should not be less than 4h. Following the principle of “first
start point and then the follow-up”, confirm it is in a normal operation before the continuous work
(see the single-unit specification for details).
3.2.4 各运动部位运转是否良好，不得有异常的振动和噪音，否则应停车检查。
Whether all moving parts run in good conditions, the abnormal vibration and noise are not
permitted, otherwise shut down the equipment to check.
3.2.5 检测轴承温升，不应超过规定值。
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

Check that the temperature rise of bearing should not be higher than the limited temperature.
3.2.6 所有紧固件应连接牢靠，无松动现象，如发现异常及时排除。
Make sure that all fasteners are tightened, check whether there is some other abnormal
conditions; if any, dispose it.
3.3 带式输送机：要求皮带运转平稳，无跑偏，拉线开关及跑偏开关动作灵活。
Belt conveyor: it’s required that the belt should be running smoothly and steadily without
deflection; the pull switch and the deflection switch are in good condition.
3.4 收尘器：要求各室能够按照程序进行喷吹清灰，阀门动作灵活。
Dust collector: it is required that every chamber can be cleaned according to the procedures
and the valves are in good condition.
3.5 堆、取料机 Stacker and reclaimer

3.5.1 各传动部位应无异常振动、异常声音、温度应不大于 40℃；

3.5.1 No vibrations or abnormal sounds for all drive parts and the temperature is not over
40℃;
3.5.2 刮板装置中的刮板体表面的耐磨板磨损情况，当磨损到危及刮板体时，应予以及时
更换；
3.5.2 Inspect the wear on the wear-resistance plate of the solid blade face in the scraper
assembly. Replacement in time if the solid blade is endangered by a wear;
3.5.3 刮板装置中的中间导轮螺栓是否有松动现象，如有应及时紧固；
3.5.3 Inspect if the bolt on the intermediate guide wheel in the scraper assembly is
loosening. Please tighten if any;
3.5.4 检查导槽衬板磨损情况，当其磨损到危及导槽本体时应及时更换衬板；
3.5.4 Inspect the wear on the liner in the guide chute. And the liner is replaced in time if the
solid guide chute is endangered;
3.5.5 刮板运行中是否有偏斜现象，若偏斜可调整链轮尾部螺旋张紧装置中的螺杆、螺母，
以使支撑刮板的两链条张力一致；
3.5.5 Inspect if the scraper is skewed in the operation. You can regulate the screw rod and the
nut in the screw tensioning device at the end of the sprocket wheel in order to make two chains
supporting scraper in the same tension if any;
3.5.6 料耙沿支撑轨道运行及换向是否平行，有无异常声音；如有应及时调整；
3.5.6 Inspect if the rake is moves parallelly when it is operated along the support rail or the
direction is changed and if there is an abnormal sound. Please adjust in time if any;

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

3.5.7 要求做到端梁行走机构运行平稳，调节换向可靠，开式齿轮啮合情况良好；
3.5.7 It is required that the walking mechanism of the end beam is operated stably and the can
be regulated and inversed reliably. The open gear engages well;
3.5.8 各部液压系统不得有漏油，油箱油温不得大于 40℃，泵站运行噪音不得大于 80 分
贝。
3.5.8 There is no oil leakage in the hydraulic system of all parts. The temperature of the oil in
the tank is not over 40℃ and the noise level is below 80dB in the operation of the pump station.

四、单机试车后确认事项 Items to be confirmed after single-unit test run

4.1 确认设备空载运转达到说明书要求，记录设备空载启动负荷变化特性及振动噪音、
轴承温升等技术参数。
Confirm the device idle motion is up to the requirements in the specification, record the load
change features of the device running without load, and write down technical parameters such as
vibration sound and bearing temperature rise.
4.2 确认设备旋转方向正确无误。
Confirm that the device is in a right rotating direction.
4.3 确认润滑系统工作正常，冷却水路通畅。各点油压、油温、水压正常。
Confirm that the lubrication system is in a normal operation and the cooling water pipe is not
jammed; the oil pressure, oil temperature and water pressure is normal.
4.4 机旁控制准确无误，阀门动作与仪表指示一致，且开启灵活。
Confirm that the control beside the machine is accurate, the valve motion is in line with that
indicated by the instrument, and it is easily opened.
4.5 检查、确认设备内外无损坏、异常部位。
Check and confirm that there is no damage inside and outside the devices and no abnormal
part.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第六章 试生产阶段注意事项

Chapter 6 Precautions at Trial Production

一、概述 The overview

1.1 系统内所有设备安装完毕，各台单机均按产品说明书要求检查调整并确认合格后，
进行单机空载试运转。单机无故障、空载连续运转时间满足要求后，方可进行空载联动试运
转。联动试运转后应对所有设备再次进行全面检查，确认系统没有问题，再进行荷载联动试
运转。堆料机必须在破碎系统启动前率先开启。根据设备厂家提供的操作的具体要求和说明
进行合理堆料，以确保预均化效果。取料机将根据各配料库的料位开启或停止。
All the equipments in the system have been installed, check and adjust each single equipment
according to the product specification. After everything is confirmed to be qualified, take the
unloading trial run of single equipment. Only after the single equipment has no malfunction and the
time of continuous unloading run meets the requirement, the unloading linkage trial run can start.
After the linkage trial run, recheck all the equipments, and confirm that the system works well, then
take the loading linkage trial run. The stacker should start before the crushing system. Stack the
material properly according to the detailed requirements and instructions supplied by the equipment
factory, to ensure the effect of pre-homogenization. The stacker can start or stop according to
material level of the batch bin.
1.2 本系统的荷载试运转分为部分负荷试车与满负荷试车两种工况进行。应先进行不少
于 12h 的部分负荷试车。部分负荷试车时应逐步增加负荷，最终达到满负荷程度，部分负荷
试车没有问题后才可进行满负荷试车。
The loading trial run of the system is divided into two working conditions: partial loading trail
run and full loading trail run. Partial loading trail run which can be finished in not less than 12
hours should be done first, then increase the loading gradually until it finally reaches the degree of
full loading, the full loading trail run can be done if there is no wrong with the partial loading trail
run.
1.3 满负荷试运转过程中，按各单机设备技术特性所规定的数据进行检验考核，经检验
合格后方可正式投产使用。
During the process of the full loading trial run, inspect and assess according to the
technological characteristic of each single equipment. Only after the qualified evaluation, it can be
put into the formal production.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

二、试生产的准备 The preparation for the trial run

2.1 本系统必须在空载试运转合格后，方能投料进行荷载试运转和试生产。空载试车必
须达到下列要求：
The loading trial run and the trial production can not be taken until the unloading trial run is
qualified for the evaluation in the system. The unloading trial run must meet the following
requirements:
(1) 设备运转平稳正常，回转部位灵活，无卡死和擦碰现象。
The equipment runs stably and normally, the rotating part works flexibly, and there is not
the condition of locking and friction or touch.
(2) 运转中无金属撞击声。
No any metal impact sound in the run.
(3) 主电动机电流平稳。
The current of main motor is steady
(4) 各润滑部位的密封处、结合面无渗油、漏油现象。
No any condition of oil seeping and leakage in the sealed place and connecting surface of
each lubricating part.
(5) 轴承最高温度不超过规定值，温升满足要求。
The maximum temperature of bearing can not beyond the limited value and the
temperature rise must meet the requirement.
(6) 停机后，应检查运转中各部分螺栓和联结销、紧固件有无松动现象，并拧紧松动的螺
栓和紧固件。
After the stop of equipment, check whether the bolts, coupling pins, and the fastening
pieces at each running part are loose or not. Then tighten all the loose bolts and fastening
pieces.
(7) 符合行业规范及设备说明书对空载试运转的各项要求。
Accord with each requirement of the unloading trial run in the equipment manual and the
professional specification.
2.2 系统首次投料之前，应对设备进行检查和调整，重点是：
Check and adjust the equipment before the first feeding to the system. The main points are as
follows:
(1) 检查和调整设备各运动部件。
Check and adjust each moving part of the equipment.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

(2) 检查电机、减速器及各润滑系统的润滑点，确认已加入足够的润滑油。
Check the lubricating points of the motor、speed reducer and each lubricating system,
confirm that adequate lubricating oil has been injected into them.
(3) 检查确认电气信号和仪表正常无误。
Check and confirm that the electrical signal and the instrument are normal and correct.
(4) 确认电动机转动方向正确。
Confirm that the rotating direction of motor is correct.
(5) 检查各润滑部位密封处、结合面有无渗油、漏油现象。
Check whether there is any oil leakage in the sealed place and connecting surface of each
lubricating part.

三、试生产要领及注意事项 The main points and items needing attention in the trial

run

3.1 确认所有设备正常运行，供电系统、通讯设施备妥。
Confirm that all the equipments run normally, the power supply system and the
communication facility are prepared well.
3.2 确认所有设备所需供水、供气的管路通畅，压力满足设计和运行要求。
Confirm that the water and gas supply pipes which are needed by all the equipments are
smooth, the pressure meets the needing of design and run.
3.3 确认本系统中每台设备完好无损，旋转方向正确无误，无异常故障；各种阀门动作灵
活准确，调节控制量与实际操作要求相符，各种仪器仪表指示和信号联络有效无误。
Confirm that each equipment of this system is in good order and condition, the rotating
direction is right, no abnormal malfunction; every kind of valves work freely and accurately, adjust
control variable to make it accord with the actual operation requirement, the indication and signal
communication of each instrument are effective and correct.
3.4 确认集中控制完全满足工艺开停与联锁要求，各操作岗位和生产车间通讯联络畅通。
Confirm that the centralized control completely meets the needing of start and stop for the
processing and interlocking, every operation post and production workshop communicates freely.
3.5 与中控室、相关电气室联系，确认所有设备已经做好供电的准备，随时可以按操作
要求投入运行。
Contact the centralized control room and related electrical room, confirm that all the
equipments are ready for power supply, and they can be put into operation according to the

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requirements at any time.

3.6 系统产量按额定产量 30%、60%、100%的比例逐步提高，直至正常产量。
The output of the system should be gradually increased to 30%, 60% and 100% of the rated
output until normal production.

四、设备使用维护要领 Utilization and maintenance essentials of equipment

设备的使用维护要领参见各设备的使用说明书，在此不再赘述。
The utilization and maintenance essentials of equipment can be referred to the operating manual of each
equipment, it will not be elaborated repeatedly here.

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