特罗蒙德降温设备使用说明书.pdf

Toromont Industries Ltd. 使用说明书使用说明书 OPERATION MANUAL 煤矿井下用制冷装置煤矿井下用制冷装置 REFRIGERATION AND AIR- COOLING SYSTEM 特罗蒙德工业有限公司特罗蒙德工业有限公司 TOROMONT INDUSTRIES LTD. OPERATION MANUAL 使用说明书 Page 2 of 48 Toromont Industries Ltd. CIMCO Ref. A1190016 Rev. No. 2 Date 17/01/08 使用说明书使用说明书 OPERATION MANUAL 产品名称 煤矿井下用制冷装置 Product REFRIGERATION AND AIR- COOLING SYSTEM 产品型号 CCS- 400WS Model CCS- 400WS 制冷量 400 kW Cooling Capacity 400 kW 生产商 特罗蒙德工业有限公司 Manufacturer TOROMONT INDUSTRIES LTD. 电话Tel 1 416 465- 7581 传真Fax 1 416 465- 8815 地址Address 65 Villier Street, Toronto, Ontario Canada M5A 3S1 网页web - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 版版权权声明声明 - COPYRIGHT 本说明书中的所有技术资料以及相关图纸本说明书中的所有技术资料以及相关图纸和和附件均附件均属属特罗蒙德工业有限公司特罗蒙德工业有限公司所有所有。。 未经未经特罗蒙德特罗蒙德工业有限公司工业有限公司许可许可，，本说明书不得本说明书不得被复制被复制、、修改修改、、发送发送给任何第三方给任何第三方。。 本说明书本说明书文件整体和任何部分内容文件整体和任何部分内容均均不得被第三方不得被第三方使用使用于任何用途于任何用途。。 Copyright of this document and all attached data and drawings belongs exclusively to TOROMONT INDUSTRIES LTD. Without the permission of TOROMONT INDUSTRIES LTD., this document is NOT allowed to be copied and/or modified and/or forwarded to any third party, and is NOT allowed to be used as a whole or in parts, by any third party in any purpose. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - OPERATION MANUAL 使用说明书 Page 3 of 48 Toromont Industries Ltd. 重要声明重要声明 – IMPORTANT NOTICE 本使用说明书含有重要信息，其中包含预防事故、避免设备受损的事项及说明，是安全无故障操作的 指南。在安装和运行设备之前，请仔细阅读本使用说明书，并且严格遵照执行。 This OPERATION MANUAL contains important ination, which includes clauses and explanations that to prevent accidents, to avoid damaging equipment. It is the instruction for safety and faultless operation. Please carefully read this OPERATION MANUAL before install and operate the equipment. Please strictly comply with the instructions during the operation. 特罗蒙德工业有限公司保留对设计图纸、产品构造进行随时更改的权利。特罗蒙德工业有限公司无任 何义务使其已销售的产品适应此更改。 TOROMONT INDUSTRIES LTD. reserves the right to revise, modify or change design drawing and product configurations at any time. TOROMONT INDUSTRIES LTD. has no obligation for adapting these revise, modify or change to its sold products. 本使用说明书含有在设备安装、操作和维护过程中所需注意的基本提示。在设备安装和投入使用之 前，本使用说明书必须被使用者或安装人员认真阅读，并且必须保证它在设备使用地点的长期可用。 This OPERATION MANUAL contains basic tips during equipment installation, operation, and maintenance. Before installation and start- up, This OPERATION MANUAL has to be read carefully by users or installation operators. This OPERATION MANUAL has to be stored safely on jobsite to ensure its long term availability. OPERATION MANUAL 使用说明书 Page 4 of 48 Toromont Industries Ltd. 免责免责声明声明 – MPTION OF LIMITED WARRANTY 特罗蒙德工业有限公司所遵守的质量保证，仅限于我方同意的范围之内。下列情况的发生不在质量保 证范围之内，且我方提供的质量保证立即失效。 TOROMONT INDUSTRIES LTD. provides product warranty which is limited to its agreed terms and conditions. Any happens to the following situations are mpted from product warranty, and will cause this limited warranty null and void immediately. 维护或操作没有按照说明进行； Failure to carry out maintenance or operation according to the instructions; 没有按照说明进行安装和投入使用； Failure to carry out installation and start- up according to the instructions; 没有由我公司人员或我公司书面授权的人员进行必要的维修； Carry out repair works without TOROMONT employee or without qualified person who is authorized by TOROMONT; 用户在无我公司书面同意的情况下更改设备； Any modifications on equipment without TOROMONT approval in a written ; 使用其它公司配件来代替我公司原装配件； Replace equipment accessories other than those provided by TORONMONT; 使用其它介质来代替本使用说明书规定的介质； Replace its working mediums other than OPERATION MANUAL stated hereinafter; 以其它使用目的替换本使用说明书规定的使用目的； Replace its working purpose other than OPERATION MANUAL stated hereinafter; 没有认真正确地使用、或疏忽地使用了本设备； Incorrect and/or improper operate equipment; 磨损部件不属于质量保证范围。 Wearing parts are excluded from product warranty. OPERATION MANUAL 使用说明书 Page 5 of 48 Toromont Industries Ltd. Table of Contents 目目 录录 1 设备描述设备描述 - EQUIPMENT DESCRIPTION.................................................................................................7 1.1 制冷机组- REFRIGERATION PACKAGE.....................................................................................................8 1.1.1 设备铭牌和机组型号的代表意义 – Nameplate and explanation of model number........................8 1.1.2 技术参数 – Specification...............................................................................................................9 1.1.3 设备描述 - Description...............................................................................................................10 1.2 空冷机 - AIR- COOLER..........................................................................................................................11 1.2.1 技术参数 – Specification.............................................................................................................11 1.2.2 设备描述 - Description...............................................................................................................12 1.3 回冷机 - RE- COOLER............................................................................................................................13 1.3.1 设备和机组型号的代表意义 – Nameplate and explanation of model number.............................. 13 1.3.2 技术参数 – Specification.............................................................................................................14 1.3.3 设备描述 - Description...............................................................................................................15 1.4 图纸 – DRAWINGS................................................................................................................................ 16 1.4.1 制冷机组流程图 - CHILLER PACKAGE FLOW DIAGRAM........................................................16 1.4.2 制冷机组布局图 - CHILLER PACKAGE LAYOUT .....................................................................16 1.4.3 降温系统图 - System Scheme ......................................................................................................16 1.4.4 电气原理图 - Description............................................................................................................16 1.4.5 空冷机现场安装图 - AIR- COOLER SITE INSTALLATION .........................................................16 1.4.6 回冷机现场安装图 - RE- COOLER SITE INSTALLATION...........................................................16 1.5 机组配套件技术参数表 - ASSOCIATED EQUIPMENT SPECIFICATIONS....................................................17 2 操作描述操作描述 - OPERATING DESCRIPTION................................................................................................ 18 2.1 功能描述 - FUNCTION DESCRIPTION.....................................................................................................18 2.2 故障模式 - FAILURE MODES.................................................................................................................21 3 制冷安全建议制冷安全建议 - SUGGESTION FOR REFRIGERATION SAFETY.......................................................24 3.1 概述 - GENERAL................................................................................................................................ 24 3.2 制冷剂 - REFRIGERANTS..................................................................................................................24 3.3 制冷系统 - REFRIGERATION SYSTEM....................................................................................................25 3.4 安全性 - SAFETY ............................................................................................................................... 26 3.4.1 培训 - Training............................................................................................................................26 3.4.2 设备 - Equipment ........................................................................................................................27 3.4.3 操作及维修 - Operation And Repairs..........................................................................................28 3.4.4 维护 - Maintenance.....................................................................................................................29 3.4.5 制冷剂罐 - Handling Refrigerant Cylinders.................................................................................31 3.5 处理泄露 - IN THE EVENT OF A LEAK OR SPILL....................................................................................34 3.6 安全资料 - SAFETY INATION AVAILABLE.....................................................................................35 OPERATION MANUAL 使用说明书 Page 6 of 48 Toromont Industries Ltd. 4 测试测试、、充装及初始启动充装及初始启动 - TESTING, CHARGING AND INITIAL START- UP......................................36 5 停机停机 - SHUT- DOWN.................................................................................................................................40 5.1 维护检查 - MAINTENANCE CHECKS......................................................................................................40 6 启动启动（（长时间停机后再次启长时间停机后再次启动动）） - START- UP RESTART AFTER PROLONGED SHUT- DOWN....42 7 系统运行与维修系统运行与维修 - SYSTEM OPERATION AND MAINTENANCE........................................................44 8 故障排除故障排除 - TROUBLE SHOOTING..........................................................................................................47 OPERATION MANUAL 使用说明书 Page 7 of 48 Toromont Industries Ltd. 1 设备描述设备描述 - Equipment Description 煤矿井下用制冷装置是专门用于煤矿井下掘进工作面和采煤工作面降温用的制冷设备。 This REFRIGERATION AND AIR- COOLING SYSTEM is exclusively use for coal mine air cooling application on tunnelling surface and coal surface. 煤矿井下用制冷装置主要由以下相互连接的部分组成 This REFRIGERATION AND AIR- COOLING SYSTEM is composed of the following equipment 制冷机组（Refrigeration Package） 空冷机（Air- Cooler） 回冷机（Re- Cooler） OPERATION MANUAL 使用说明书 Page 8 of 48 Toromont Industries Ltd. 1.1 制冷机组制冷机组- Refrigeration Package 1.1.1 设备铭牌设备铭牌和机组型号的代表意义和机组型号的代表意义 – Nameplate and explanation of model number OPERATION MANUAL 使用说明书 Page 9 of 48 Toromont Industries Ltd. 1.1.2 技术参数技术参数 – Specification 型号规格 CCS- 400WS 外形尺寸 mm 长宽高 414014372238 机组重量 4,990 kg 制冷剂型号 R407c 噪声（声功率级）dBA 90 供电 3x660/220V,50Hz 型号规格 OSK7461- K 2台 制冷量 406 kW 吸/排气温度 10 / 80 OC 吸/排气压力 5.47 / 23.73 bar 蒸发温度 5.5 OC 冷凝温度 53 OC 压 缩 机 耗电量 122.8 kW 出水温度 10 OC 回水温度 15 OC 阻力损失 95 kPa 蒸 发 器 冷冻水流量 62,500 kg/h 出水温度 47.97OC 回水温度 42 OC 阻力损失 88 kPa 冷 凝 器 冷却水流量 75,060 kg/h OPERATION MANUAL 使用说明书 Page 10 of 48 Toromont Industries Ltd. 1.1.3 设备设备描述描述 - Description 设备安装了配备有自动控制系统的两台单极螺杆压缩机，设计蒸发温度为 2OC，冷凝温度 最高为 53OC。制冷剂为 R- 407c。 The unit is built up as an automatically regulated plant with two single stage screw compressors, designed for an evaporating temperature of 2OC and a condensing temperature of up to 53OC. The refrigerant used is R- 407c. 压缩机的制冷量由 PLC 控制系统通过安装在冷冻水入口处的温度传感器与安装在制冷剂 管路控制阀一起协同控制。 The water chilling capacity of the compressors is controlled by a purpose built PLC controller via a temperature transmitter mounted in the chilled water inlet to the evaporator in combination with control valves incorporated in the refrigerant piping. 在制冷剂侧，设备为直接膨胀系统。 At the refrigerant side, the plant works as a Direct Expansion system. 液态制冷剂自冷凝器通过两个电子调节阀门（即膨胀阀）变为汽态进入一个水冷式热交换 器（即蒸发器），其蒸发时吸收了来自二次循环水侧的热量，然后变为过热汽态返回压缩 机。制冷蒸发为两个独立的回路，每个回路配有一个膨胀阀。 The water chilling heat exchanger evaporator is supplied with liquid refrigerant from the condenser via two electronic modulating valves expansion valves, one for each of the two separate and independent refrigerant circuits, where it evaporates while absorbing heat from the water circulating through the secondary side before it returns as superheated vapour gas to the compressors. 汽态制冷剂及润滑油的混合体经由压缩机被压缩成高压高温后进入油分离器，润滑油随即 被分离出来进入储油箱，然后再回到压缩机进行往复循环。过热的汽态制冷剂则从油分离 器进入冷凝器，在 40 至 53OC 的范围内冷凝成液态，其冷凝时所释放的热量则被冷凝器 冷却循环水带走。 In the compressors the vapour is compressed and consequently the pressure and temperature is raised. The superheated gas is discharged to the oil separator, where the oil swept along by the discharge gas is separated and accumulated in the oil reservoir before it is returned to the compressor. From the oil separator the superheated gas is led to the condenser where it is cooled and condensed to a liquid at a temperature between 40 and 53OC. Heat removal at the condenser is accomplished by recirculation of water. 液态制冷剂由主冷凝器经过液体/吸入热交换器被冷却至 5 to 10O。从这里液态制冷剂再次 通过膨胀阀进入冷凝器，形成一个封闭的制冷循环。 From the main condenser, the liquid refrigerant flows through a liquid/suction heat exchanger where it is cooled by 5 to 10O. From there the liquid flows through the expansion valve to the evaporator - and this refrigeration circuit is closed. OPERATION MANUAL 使用说明书 Page 11 of 48 Toromont Industries Ltd. 1.2 空冷机空冷机 - Air- Cooler 1.2.1 技术参数技术参数 – Specification 型号规格 WGC- 36- 03- 08- 120 外形尺寸 mm 长宽高 370814671730 重量 1,049 kg 总换热量 400 kW 进口干/湿球温度 32.2 / 31.4 OC 出口干/湿球温度 22.9 / 22.7 OC 风量 496 m3/min 空气侧 参数 阻力损失 72.2 Pa 进水温度 10 OC 出水温度 15 OC 冷冻水流量 62,500 kg/h 水侧 参数 阻力损失 34.5 kPa 进水口管径 100 mm 接口 管路 出水口管径 100 mm OPERATION MANUAL 使用说明书 Page 12 of 48 Toromont Industries Ltd. 1.2.2 设备设备描述描述 - Description 空冷机为由带翅片的空气/水热交换盘管构成的闭式冷水循环系统。空气在经过翅片盘管 时被冷却及除湿后被送往工作面。经过与空气热交换后的循环水温度升高再次进入制冷机 组的蒸发器被冷却成低温水从而进行往复循环。冷冻水循环系统工作压力保持在 1 至 3 bar 之间，当系统压力低于 1 bar 时则通过压力调节阀向系统内补水，当大于 3 bar 时则通 过安全阀将水释放出来。系统内的气体则通过安装在缓冲水箱上的手动/自动排气阀放 出。 \At the water side, the plant works as a closed circuit water cooled air cooling system. Air is drawn over a finned coil heat exchanger where it is cooled and moisture is removed before it is discharged toward the coal face. Cooling effect is accomplished by water which is cooled in the chiller unit and circulated through tubes in the heat exchanger where it increases in temperature as it removes heat and moisture from the air. This warmed water then returns to the chiller unit where it is cooled thus completing the circuit. The circulating water circuit is maintained at a pressure of between 1 and 3 bar by a combination of an outlet pressure regulator which admits water into the circuit whenever press