VD使用维护手册3.docx

VD使用维护手册3.docx

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VD使用维护手册3

3.1MAINTENANCEOPERATIONSPERIODICALLYRECOMMENDED推荐的定期维护操作

3.2MAINTENANCEOFTHEVACUUMPUMPAREA真空泵站的维护

3.3MAINTENANCESCHEDULES维护时间表

3.3.1Centralandhydrauliccomponents中心液压组件

3.3.2Waterandgasfluidinstallation水和介质气体安装

3.3.3Metalstructureandworkingplatform钢结构和工作平台

3.3.4Electricalcomponentsandswitchboard电气组件和配电盘

3.1-MAINTENANCEOPERATIONSPERIODICALLYRECOMMENDED

推荐的定期维护操作

Beforeanymaintenanceoperations,wehavetodisconnectallelectrical,pneumatic,oilpressureandfluidfeedingstoavoidanyaccidentalmovementofmachinery.在任何维护操作前，我们必须断开电气、气动、油压和介质，以防止运动设备造成的意外

Toavoidanyaccidentalmovement,itisadvisabletoputoncontrolboardawarningsignwithfollowingnotice:

“Attention,closingformaintenanceoperations”.

为了防止意外发生，在控制操作面板上挂警示牌，并注明“注意！

维护操作结束！

”

Inparticular,maintenanceoperationsofeachcomponentareherebelowdescribed:

每个组件的维护细节作如下描述

Recommendedmaintenanceoperations推荐的维护操作

DAILY每天

-Visuallycheckcorrectfunctioningofeachcomponent.目测检查各部件的功能正确

-Checkcorrectfunctioningofallworkingphasestryingtopreventallpossibleruptureordangersituation.检查各工作阶段设备的功能，设法防止运行中断或危险情形的发生

-Makesurethatnosteelorslagsquirthasdamagedworkingcomponents.

确认没有钢水或钢渣喷溅而伤害到工作部件

-Oftencheckgasketsintegrityanditsperfecttightallowingagoodvacuumtightontankwhilecovergoesdownonladle.Thisisanessentialconditionforthevacuumgeneration.

经常性的检查密封件的完整，并且当罐盖下降时有一个很好的真空密封。

这也是真空过程需要满足的一个基本条件

-Makesuregasketisnotdamagedorburnt.Ifnecessary,repairorreplaceit.

确认密封没有损坏或燃烧。

如果需要必须维护或更换。

-Checkthatcoolingwatercorrectlycirculatesinallcircuits.

检查所有回路的冷却水能正确循环

-Makesureofgoodconditionsofmovementelementssuchasmovingcar,coverlifting,valvesanddoorscontrol,etc.确认各个运动部件具备良好的运行条件，例如罐盖车、盖提升、阀门控制等等；

-Makesuretherearenofluidlossesoncircuits（water,oil,argon,oxygen,etc.）

确认循环回路中没有介质泄露（水、油、氩气、氧气等等）

-Checkthatalldataoncontrolinstrumentationareinconformitytonormalexercisedata.检查所有控制仪表的值，与正常运行值相一致。

-Makesureofprotectionintegrityandthattheyhavenotbeendamaged.

确认安全保护未损坏

WEEKLY周检

-Acarefulcleaning,inparticularonworkingareasandonmorecriticalpoints.

小心清洁，特别是在工作区域和超出临界点时；

-Blowwithcompressedairandcleanthemostfacedelements.

用压缩空气吹扫和清洁大部分元件的表面

-Checkintegrityofmaincomponentsexposedtoimpactsandsteelsquirts.

检查主要部件的完整，外围的撞击和钢水的喷溅

-Checkfunctionalityofallmaincomponents,makingsuretheyarenotdamaged.

检查主要部件的功能，确认没有受到损坏

-Checkthatprotectiondevicesforthetightgasketprotection（cylinders,deflectors,joints,etc）properlywork.

检查保护装置，真空密封件的保护（气缸、活动板、连接轴等）能很好的工作；

-Checkand,ifnecessary,cleansupportflangeonvacuumtank.

检查，如果必要，清洁真空罐上的支撑法兰

-Checkconditionandintegrityofallflexibleelements（checkthatargonflexiblepipesarenotdamagedandhavenoloss）.检查软连接元件完好（检查氩气软管没有受到损坏和缺失）

-Checkand,ifnecessary,cleancarrails.

检查，如果必要，清洁车子的轨道

-Checkand,ifnecessary,cleancarslidingguidance

检查，如果必要，清洁车子的滑导承

-Checkefficiencyofallcarcomponents,especiallytransferlimitswitches.

检查所有车子部件的效率，特别是移动限位开关；

-Checkfunctionalityofallcomponentsrelatedtotransfercarblock.

检查所有与车子移动挡块相关的部件功能

-Checkandeventuallyregistertransmissionchainstightening.

检查和最终记录传输链条的紧固

-Checkthatvacuumcoverheatshieldisnotdamaged.

检查真空罐盖的热防护盖未损坏

-Checkintegrityandgoodconditionofallrefractorycovering.

检查耐材完好；

-Checkcorrectfunctioningofallcomponentsinstalledoncoverholes（TV,shuttersandscreens）andtheirwatertightintegrity（ifneeded,replacegaskets）.

检查罐盖上各空安装的设备功能正确，（监视器，活动板、屏幕），水封完好（如果需要更换密封件）；

-Verifygoodconditionsofprotectionsandreplacethem,iftheyaredamaged.

检验保护装置的完好，如果损坏就更换；

-Checkgoodcentralfunctioningandoilpressurecomponents.

检查中心液压站和压力部件完好，

-Checkcorrectmovementofpneumaticandhydrauliccylinderandhydraulicmotor.

检查气缸、液压缸和液压马达正确运行

-Checkthereisnolossondifferentfluidfeedingcircuits.

检查各种介质循环回路没有损失

-Verifycorrectworkingcycleofalllimitswitches.

确认各个限位开关正确的循环工作

-Verifygoodconditionsofvalvesandinstrumentsonsite.

确认现场的阀门和仪器完好

MONTHLY月度

-Checkhydrauliccomponents,theirfunctionandtightening.

-Operativeconditionsandgasketstighteningonshaftside,ofalloilpressureandpneumaticcylinders.

-Checkoperativeconditionsofmotors,reducers,encoder,jointsanddifferenttransmissionelements.

-Operativeconditionsandeventualusuryoftransmissionchainsandpinions.

-Checkandregisterplayoncenteringdevicessuchaswheelsandguides.

-Generalcheckonmainmovingoperativecomponents（motors,reducers,joints,supports,etc）

-Checkconditionsandadjustableofchainssupportingcables.

-Checkingofhydraulicunit,withinspectiononvalves,electricaldistributorsandoilpressurecomponentsonsite）.

-Checkofflexiblepipes,theirtighteningandtheirconnections.

-Checkcorrecttightofboltsandscrews.

-Makeacleaninginordertoeliminateincrustations,slagandaccumulateddusts.Lubricatefollowingindicationsonlubricationtable.

ANNUALLY

-Emptyvacuumtankfrommaterial.

-Checkand,ifnecessary,repairinternalrefractoryfromvacuumtank.

-Checkthatbeamssupportingladleinsidethetank,arenotdamaged.

-Checkgoodconditionsandintegrityofmainandmoststressedcomponentstousury,asgaskets,flexiblepipes,bearings,etc

-Checkgoodconditionsoftheswivelring

-Makeageneralcheckonconditionsoftightgasketsandproceedwithreplacementsifnecessary.

-Makeageneralcheckofmaincomponentssuchascar,cover,valves,piping,connections,tightening,etc.

-Makeageneralcheckandeventuallyarevisionofmovementelementssuchasbearings,motors,reducers,joints,etc.

-Checkmoststressedwelding.

-Checkoilsinreducersandoilpressuresunits.

3.2-MAINTENANCEOFTHEVACUUMPUMPAREA

Therearetwokindsofmaintenanceforthevacuumpumpstation（includingsuctionlineanddustseparator）:

a）Thenormalmechanicalmaintenanceofcomponents.

b）Thecleaningofdustproducedbypollutionduetodustsuction.

A）MECHANICALMAINTENANCE

Itincludesthenormalmaintenanceofthevalves,instrumentationandthecompressedairsystemwithsolenoids,filtersandlubricationsprayers.

Itisimportanttokeepvacuumvalvesairtightasregardstotheatmosphere.

Ifoneofthesehassomeairlossesinthesystem,suctionpumpcapacitywillreduce.Biglossescanalsopreventacorrectdegassing.

Italsoincludesthesealringchanger（O-ring）forthedoorsandalltheotherclosingsurfaces,ifnecessary.

Recommendedmaintenanceoperations

Daily

-Checkonthegraphicscreenofcontrolconsole,thecorrectfunctioningoflockoutvalves.

-Makeacheckofdifferentoperativephasesinordertopreventrupturesordangeroussituations.

-Checkthatwatercorrectlyfloatsinthecoolingcircuits,inthefirstpartofcooledpipingandheatexchanger.

-Makesureofgoodconditionsofallmovingelementssuchastransfercars,commandforvalvesanddoors,etc.

-Makesuretherearenofluidlossesinthecircuits（water,argon,etc）

Weekly

-Checkandifnecessarycleanrailsoftransfercar.

-Checkefficiencyofallcarcomponents,inparticulartransferlimitswitches.

-Checkgoodconditionsandintegrityofrefractorycovering.

-Checkintegrityandgoodconditionsofadjustmentbellowsonsuctionpipenexttothecover.

-Checkconditionsofprotectionsand,ifrequired,replacethem.

-Checkcorrectmovingofallpneumaticcylindersinstalled.

-Checktherearenolossesinthefeedingfluidscircuits.

-Checkcorrectworkingcycleofalllimitswitches.

-Checkgoodconditionsofvalvesandinstrumentsonsite.

-Blowwithcompressedairandcleanmostexposedoperativeelements.

-Makeageneralcleaningonoperativeareas.

Monthly

-Checkoperativeconditionsofmotorreducers,jointsanddifferenttransmissionelements.

-Makeageneralcheckofmainoperativecomponents,inparticularvalves.

-Checkefficiencyandgoodconditionsofdustcollector.Cleandustdeposits.

-Checkflexiblepipesconditions,theirtighteningandconnections.

-Checkcorrecttighteningofmostlystressedboltsandscrews.

-Cleanincrustations,slagandaccumulateddust.

-Lubricatefollowingindicationsoflubricationtable.

Annually

-Makeageneralcheckofdustcollectorconditions.

-Checkgoodconditionsandintegrityofmainandmoststressedcomponentstousury,asbellows,gaskets,bearings,motors,cylinders,etc

-Makeageneralcheckonconditionsoftightgasketsandproceedwithreplacementsifnecessary.

-Checkgoodconditionsofmostlystressedcomponentstousury.

-Generalcheckondustcollectorconditions.

-Checkmostlystressedwelding.

B）CLEANINGOFTHEDUSTSTORAGE

Dustisproducedbymeltedsteelexpositiontothevacuum,duringdegassingphase.

Partofthisdust,togetherwithmetalsplashesandslag,depositasedimentonthevacuumtankbottom.Mainpartofthedustissuckedbysuctionlineandconveyedtodustseparatorandfilter.Inthisarea,almostallthedustgeneratedbyvacuumtreatmentiscapturedinthedustseparatorandbagfiltersituatedonthesuctionline,betweenvacuumtankandvacuumpump.

Wecansaythatgasarrivingtosuctionvacuumpumpshasnodust.

Measurestofollow

-Emptydustseparatorevery30-40castingsatleast.Anemptyseparatorhasabiggerefficiency.

-Checkcorrectfiltrationcycleonfiltrationhose.

-Regularlydischargeandevacuatecollecteddustsunderfilters.Oneayearcleansuctionline.

Cleaningprogram

Thebestandeasiestwaytocleaninginternalpipesanddustcollectoristousehighpressurewaterinstrumentation.

-Waterpressure:

500–600bar.

-Waterflux:

about25l/min.