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Nantong automatic A / O integrated machine common fault analysis
1 Preparation for pipeline welding
Before the welding of the pipeline, the qualification of the welding procedure and the qualification of the welder must be performed. Those projects that have not been assessed by the welding procedure shall be organized to participate in the construction welders and technical personnel in accordance with the specifications, and to work together with the technical department to perform the welding procedure assessment. Welders who have participated in the construction of the project but do not have a welding project certificate should organize training and must obtain the certificate after passing the examination before welding.
Welding materials: Welding wire electrodes used for pipe welding must have a quality assurance certificate or quality certificate before use, and within the warranty period. For welding materials with unclear identification, unclear delivery date, and other quality, it is forbidden to use it during construction. Before use, the electrode should be dried according to regulations and kept dry during use; the surface of the electrode should be cleaned of oil, rust, etc. before use.
2 welding process
1) In principle, the steel pipeline shall be constructed in accordance with the requirements of GB50238-98. The specific requirements shall meet the design drawings.
2) In principle, argon-arc welding is used for pipeline welding with pipe diameter less than DN50 or wall thickness less than 3mm in process piping; manual arc welding is used for other pipe welding. The argon arc welding of stainless steel pipelines also needs argon protection.
3) The weldment group should be cleaned of oil stains, rust, burrs, etc. in the range of not less than 10mm on the groove and its inner and outer surfaces beforehand, and there must be no defects such as cracks or interlayers.
4) When the weld group is correct, the inner wall should be flush with the same wall thickness of the tubes and fittings. The amount of misalignment in the inner wall is not less than 10% of the wall thickness, and no more than 2mm; for pipes and fittings with different wall thicknesses , before the group to deal with thick-walled finishing before finishing the group welding.
5) During pipeline welding, no current is allowed on the surface of the weldment, and the arc is prevented from being scratched by the base metal. In order to reduce the welding distortion and welding stress, a reasonable welding sequence should be selected during the welding; arc starting and closing should be ensured during the welding process. The quality of the arc should be filled with arc pits at the time of arc closure. The interlayer joints of multilayer welding should be staggered.
6) In addition to the special requirements of the process or inspection, each weld should be welded consecutively once. When the welding is interrupted for any reason, measures should be taken to prevent cracking, such as slow cooling or post-heating, according to the process requirements. Before welding again, Check the surface of the welding layer and confirm that there are no cracks before proceeding with the welding according to the original process requirements.
3 stainless steel pipe welding
1) When welding stainless steel pipes, suitable welding materials and welding methods should be selected.
2) Welding method: Manual tungsten-arc welding is adopted for pipes with DN ≤ 50, and argon-welded welding method is used for pipes with DN> 50.
3) When transporting and stacking stainless steel pipes, they should be separated from ordinary carbon steel to avoid rust and other pollution.
4) In order to ensure the stability of the weld composition, the stability of welding process parameters should be ensured to reduce the thermal sensitivity of the weld. Strictly controlling harmful impurities and minimizing weld overheating are very effective in preventing solidification cracks in welds.
5) The tube should be filled with argon gas during welding.
6) After welding, the weld joint needs to be pickled and passivated. After acid washing, the surface residue should be rinsed with clean water.
Nantong automatic A / O integrated machine common failure analysis of the preparation and addition of raw materials
(1) Preparation of Naclo3 solution, mixing Naclo3 with water in a mass ratio of 1:2, and stirring until completely dissolved to obtain Naclo3 solution.
(2) Adding Naclo3 solution and acid solution, under the normal working conditions of the water ejector, insert the feeding pipe into the bucket, open the suction pipe valve, close the inlet pipe valve, and the solution is automatically sucked into the storage tank. According to the storage tank liquid pipe, after reaching a certain amount, the intake pipe valve is opened first, the suction pipe is pulled out of the bucket, and then the feed pipe valve is closed.
Preparation before starting up
(1) To the Naclo3 storage tank, fill the acid storage tank with raw materials.
(2) Fill the heating tank with water from the water inlet.
(3) Observe the height of the liquid in the reaction chamber. If the liquid level is lower than the normal level, open the outlet valve and inhale a certain amount of clean water from the air inlet to the host.
(4) Check if other valve components are sealed.
Power on: Turn on the power box switch, open the power water valve, increase the pressure as much as possible, but not more than 0.3Mpa, so that the water ejector works normally. Open the ball valve A, B, adjust the upper burette adjustment valve, observe the flow of the burette, the device can run normally.
Adjustment of flow: The flow rate is determined based on the amount of residual chlorine in the treated water. The method is: using the upper regulating valve of the burette to adjust the titration speed, when the titration speed is faster, the gas production increases, and vice versa. Note: Try not to make the number of drops into a stream.
Shutdown: Turn off the ball valves A and B. The equipment stops feeding. The water injector will continue to work for 1 to 2 hours before turning off the power water.
Equipment cleaning: The equipment is cleaned every 2 to 3 months. When cleaning, turn off the power supply of the temperature control box and the ball valves A and B. The rest is the same as the power-on condition. A certain amount of clean water is sucked from the air inlet, and then the power source is turned off and the sewage valve is opened. Repeat this cycle several times until it is clean.
Nantong automatic A / O integrated machine common fault analysis equipment operating procedures and application classification
1, check before starting:
1) Check that all valves are in normal operation.
2) Check that the tank level is in normal working condition.
3) Check that the electrical equipment is in a normal working condition.
2, boot steps
1) Equipped with adding flocculant, with good medicine, start stirring system.
2) Start the air compressor, open the intake valve, and adjust the intake pressure to 0.2 MPa.
3) Turn on the water pump of the container and fill the water in the container tank. Adjust the water level of the container tank to about 1/3 of the level gauge of the container tank. At this time, the pressure of the container tank should reach 0.4 MPa. After the container feed pump works normally for 3-10 minutes, Only start the air float pump.
4) Adjust the dosing amount, influent amount, and container volume to ensure the quality of the effluent according to changes in effluent quality.
5) According to the generation of scum, control the sluice gate, adjust the level of the scum to the slag discharge requirements, and start the slag scraper to scrape.
6) After starting the machine, check the air-floating water and drainage system to achieve the balance of water in and out and ensure that the air-float works normally.
3, shutdown steps
1) Turn off the slag scraper.
2) Close the air float pump.
3) Close the container water pump.
4) Close the air compressor.
5) Check all valves to normal shutdown.
4, matters needing attention
1) The tank level should be maintained after adjustment and should not be adjusted frequently.
2) According to the quality of effluent water, timely adjust the dosage, water intake, and container water volume.
3) Regularly grease the bearings, chains, sprockets, gears, racks, and slides (about ten days), and perform a three-month inspection.
Common fault analysis of equipment
1, the device inlet no negative pressure:
1) Dynamic water pressure does not meet the set requirements.
2) The ejector is damaged.
3) The check valve is blocked.
4) The safety plug opens.
5) Crystal blockage at the inlet of the device.
6) The outside of the equipment inlet pipe is partially blocked.
7) There is damage to the internal head of the device.
2, the device controller has a heating display but the temperature does not rise:
1) The heating tube is damaged.
2) The solid state relay is damaged.
3) Heater power cord is not connected. Check whether there is voltage output at both ends of the heating pipe of the equipment. If the voltage is normal but the water temperature does not rise, measure the resistance value of the heating pipe is normal (3KW is about 16.1Ω, 5KW is about 9.7Ω), if the resistance is not normal, it is the heating pipe malfunction. If there is no voltage across the heating tube, it may be a controller solid state relay failure. Check the internal status relay of the controller. When the signal is output, the small light on the solid state relay is on and the output is on. If it is not the above fault, replace the controller.
3, controller display over temperature:
1) The solid state relay is damaged.
2) The temperature sensor is damaged.
4, after the controller shows over-temperature but the temperature continues to rise
1) The solid state relay is damaged.
2) controller failure.
5, the metering pump has a power display but does not work:
1) The controller has no output.
2) The metering pump is not adjusted to the automatic page.
3) The metering pump frequency line is reversed.
4) Damage to Light Europe.
6, measurement work but not material:
1) The raw material tank outlet or pipe feeder is blocked.
2) The metering pump inlet is blocked.
3) Aging or damage to the diaphragm of the metering pump.
4) The pressure valve is blocked.
7, the equipment gas production is insufficient or not gas:
1) Equipment has clogged places
2) Clogged or damaged ejector Cleaning, replacement
3) The aging or damage of the pressure valve leads to unbalanced charge. Correction, cleaning, replacement
4) The raw materials do not meet the requirements Replace the raw materials that meet the requirements
5) Ingredients do not meet the requirements (low concentration) Replace raw materials that meet the requirements
6) Raw material suction hose is not smooth or has air plugging phenomenon. Cleaning, replacement, exhaust
7) Blockage of raw material tank filter
8) The metering pump is not feeding, or the feed is not balanced Check the metering pump, wash the pump head, replace the diaphragm
9) Safety port opens Place safety plug back into safety port
10) Low temperature Check equipment heating system
8, explosion-proof plug open
1) The power water pressure is low until the power water pressure is normal before turning on the equipment
2) Wrong valve switch at the injection point Check system exclusion
3) The jet ejector does not eliminate the blockage and air resistance phenomenon
4) The pipeline is far away and there are too many pipes behind the ejector. Change the installation pipeline again
5) The back pressure valve generates a DC phenomenon, and the raw material enters the reaction chamber. Observe the troubleshooting of the raw material tank and the metering pump.
9. After the power is turned on and the main power switch is closed, there is no display on the man-machine interface.
It may be that the power switch is not powered, check with a test pencil or measure the power supply with a multimeter. Check whether the PLC is running. If the PLC is running normally, check the power supply voltage of the human-machine interface (normally 24V DC). If the display is still not displayed, the human-machine interface is damaged.
10. The temperature of the human-machine interface is displayed at 0°C, and the input of the temperature signal is ≤ 4MA. Check whether the temperature-measuring thermal resistance on the device has been connected. If the fault is still connected, check the thermal resistance. The method is as follows: Disconnect the two ends of the thermal resistor, and use a multimeter to measure the resistance at both ends. When the resistance is normal, the resistance is between 100Ω and 138.5Ω. If the resistance is abnormal, replace the thermal resistance. If the voltage at both ends of the normal measurement temperature transmitter is normal (24vdc), if it is normal, measure the temperature signal in the temperature measurement loop with the multimeter MA, and if the current signal is normal, if it is abnormal, the temperature transmitter is damaged or the related signal line is faulty; Normal, the plc analog input port is damaged.
Note: The standard current signal size at the current temperature = 4 + (current temperature / 100) * 16 MA
11. The fault page shows water shortage faults.
Check the heating water jacket of the equipment for lack of water. If there is water shortage, add water to the heating water jacket. If the water is still full and there is a lack of water, the water level electrode may be damaged and the water level electrode needs to be replaced.
12. The fault page has undervoltage fault display.
It may be that the water pressure of the ejector is insufficient. Check whether the pressure displayed on the pressure gauge on the power water pipe reaches the specified low limit. If it is because the pressure of the power water is insufficient, the power pump must be turned on to increase the pressure of the power water. . Or the contact of the electric contact pressure gauge is damaged, replace the electric contact pressure gauge.
13. The fault page displays the missing material fault.
Insufficient raw material tank storage, please feed the raw material tank.