Ash Handling System Operetaion and Maintenance Instruction

POWER PLANT
ASH HANDLING SYSTEM
FUNCTIONAL DESIGN SPECIFICATION
CLYDE BERGEMANN HUATONG MATERIALS HANDLING CO.,LTD.
克莱德贝尔格曼华通物料输送有限公司
August 2007
CONTENTS
1. INTRODUCTION
2. ESP FIELD 1 or 2 MD PUMP OPERATION
3. ESP FIELD 1 AND AIR HEATER MIXED GRITS OPERATION
4. ESP FIELD 3 ASH vessel OPERATION
5. ESP FIELD 4&5 ASH vessel OPERATION

INTRODUCTION
The timer values and conveying pressure set point limits given in this description may need
changing during the tests and ideally the HMI should be set up to allow this to be done via the
CRT.
ESP FIELD 1 or 2 MD PUMP OPERATION
OVERVIEW
During normal operation of the boiler fly ash will accumulate in the outlet from the electrostatic
precipitators. The fly ash will be discharged by gravity into the MD-Pumps mounted beneath each outlet
and will then be pneumatically conveyed to the reception silos.
The MD-Pumps located beneath the outlets from filed 1 or 2 will be connected to a common pipeline.
The inlet Dome Valves of the MD-Pumps will open and ash will fall under gravity into the vessels.
During filling the vent Dome Valves will be opened to allow the displaced air to be released from the
vessels. When either or both of the level probes in the MD-Pump vessels indicates that the vessel has
filled. After a short timed delay to allow the vessel to completely fill the inlet and vent Dome Valves will
be closed. When all of the inlet and vent Dome Valves have closed and sealed there will be a further
short delay before air is introduced into the MD-Pumps. The ash will then be discharged from all of the
vessels into the conveying pipeline and will be conveyed to the reception silo. When the material has
been discharged into the reception silo, signalled by a drop in conveying pressure, the conveying air
valves will be closed and the cycle is complete.
The material will be routed to one of 2 reception silos by means of a switch valve. A high level switch in
each reception silo will signal when the silo is full and the control system will change the route to
another silo if possible, or will inhibit further operation of the ash system.
The conveying air from the reception silo will be vented to atmosphere via a reverse jet filter. It is
important that the filter cleaning is operated continuously while the ash system is in operation. The
exhaust from the filter must be unobstructed and open to atmosphere at all times, even when the ash
system is not in operation. This is to permit any compressed air leakage into the system, or expansion of
the air due to an increase in temperature, to be safely vented.
SYSTEM AT REST
When the ash system is stopped and at rest the status of the valves will be as follows:
Control air off Control air on Control air on

Electrical power off Electrical power off Electrical power on
PLC mode off PLC mode off PLC mode run
Master MD-Pumps last position* closed closed
inlet Dome Valve
Slave MD-Pumps last position* closed closed

inlet Dome Valve
Main conveying air closed closed closed

valve
(PV02)
The MD-Pumps should be empty and at zero pressure.
 Note: The Dome Valve incorporates an inflating seal. In the event of the loss of control air
pressure the valve will not be sealed.
MD-PUMP OPERATING SEQUENCE
At the start of a conveying cycle the control system will check that the following cycle start interlock
conditions are fulfilled:
The start/stop/purge switch on the main electrical controls screen is set to “START” or “PURGE”.
The Remote/Local switch on the pneumatic control panel is set to “Remote”.
Conveying pressure is < 0.03MPa (PT02).
Conveying air supply pressure is > 0. 55MPa (client signal).
Master MD-Pump inlet and vent Dome Valves are closed and sealed (PS01/PS05).
Slave MD-Pump inlet and vent Dome Valves are closed and sealed (PS01/PS05).
Minimum cycle period timer expired.
Route confirmed available (As defined in the section titled Conveying Route Control)
Space is available in the target reception silo (As defined in the section titled Conveying Route Control).
Providing the above conditions are true a conveying cycle will be initiated and will proceed as follows:
Step 1
All the inlet and vent Dome Valves will be opened by energising solenoids (EV01). Simultaneously, the
short fill timer (900 seconds), cycle watchdog timer (1060 seconds), and minimum cycle period timer
(10 seconds), will be started. Material will fall under gravity into the MD-Pumps.
Note: If one or more of the MD-Pump high level probes (LSH01) is covered at the start of the cycle,
or if “PURGE” has been selected on the display screen, the inlet and vent Dome Valves will
not be opened and the cycle will continue from the step 5.
Step 2
When one or more of the MD-Pump high level probes (LSH02) has been covered, or when the short fill
timer has expired, the overfill timer (0.1 seconds) is started.
Step 3
When the overfill timer has expired, all the inlet and vent Dome Valves are closed by
de-energising solenoids (EV01).
Step 4
When all of the inlet and vent Dome Valves (PS01/PS05) have closed and sealed, the conveying air
valve open delay timer (2 seconds) will be started.
Step 5
When the conveying air valve open delay timer has expired, the conveying air valve (PV02) is opened
by energising solenoid (EV02). Simultaneously, all the MD-Pump fluidising air valves (PV15) will be
opened by energising solenoids (EV15). Air will enter the MD-Pumps and the conveying pressure will
begin to rise. The material will be discharged into the conveying pipeline. The convey secure timer (20
seconds) will be started.
Note: If the conveying pressure rises to greater than 0.35MPa (PT02), the conveying air valve (PV02) and the MD-Pump fluidising air
valves (PV15) will be closed. When the pressure has fallen below 0.15MPa the valves will be re-opened.
Step 6
The material will be conveyed through the pipeline to the target reception silo. When the convey secure
timer has expired, and the pressure in the conveying pipeline has fallen to < 0.03MPa (PT02), signalling
that the material transfer is complete, the conveying air valve (PV02) and the MD-Pump fluidising air
valves (PV15) will closed by de-energising solenoids (EV02) and (EV15) respectively. The cycle reset
timer (3 seconds) will be started.
Step 7
When the cycle reset timer has expired the conveying cycle is complete.
Note: If during the cycle any start interlocks become untrue, then that cycle will be permitted to
continue and end. The system will then stop until all of the start interlock conditions once
again become true. For example, at the start of the cycle the high level probe will be
uncovered. If this level probe becomes covered during the cycle, this will be ignored and will
not cause the cycle to stop or reset. To achieve this the PLC program will latch the cycle start.
Similarly, where an event has to occur to permit the cycle to proceed to the next step, then the progress
of the cycle will be halted until that interlock condition has become true. The cycle will then proceed to
the next step. The progress of the cycle to the next step will be latched for the remainder of the cycle, so
that in the event of the interlock condition subsequently becoming untrue, the cycle will not stop or
regress. The latches are released at the end of the cycle during the cycle reset timer.
CONVEYING ROUTE CONTROL
The material will be routed to one of 2 reception silos by means of a switch valve.
To permit the route to be changed the ash system cycle must be complete and the system must be at rest.
To ensure this the route change delay timer (see previous section) must be timed out.
A 2 position switch for each reception silo will enable the operators to select that silo for filling. The two
positions will be labelled “off” and “auto”. When the switch is in the “auto” position then that silo will
be filled until the high level switch is covered. When the silo has been filled and the high level switch is
covered, or if the “off/auto” switch is set to the “off” position then a current cycle will be permitted to
continue and end. The control system will then change the routing to another silo which is set to “auto”
and whose high level switch is uncovered. If no other hopper is available the control system will inhibit
further operation of the system.
Prior to a ash system operating cycle the control system will check the position of the routing valves to
ensure that the route is correctly set. In the event of a route valve fault the control system will inhibit
the operation of the system until the fault has been rectified. This is referred to as the “conveying route
confirmed” requirement in the cycle start interlocks.
Prior to a ash system operating cycle the control system will check the status of the high level switch in
the target reception silo to ensure that there is sufficient space available for a charge of material. In the
event that the high level switch in the current target silo is covered then the control systems will change
the routing to another available silo, or inhibit the operation of the system.
SWITCH VALVE
GENERAL
The Switch Valve is located on the top of a reception silo. It comprises a Y shaped junction with an
Isolating Valve mounted on each of the branches. The material is routed through the appropriate branch
by opening the Isolating Valve on that branch and closing the Isolating Valve on the other branch.
A position switch (ZS50A/ZS51A) provides confirmation that a Isolating Valve has fully opened. A
position switch (ZS50B/ZS51B) provides confirmation that a Isolating Valve has fully closed.
The position of the Isolating Valves may only be changed when the conveying cycle has been completed
and the system is at rest.
CHANGING THE SWITCH VALVE POSITION
At the start of the conveying cycle reset timer the route change delay timer (10 seconds) will
be started.
When the route change delay timer has expired the Isolating Valve open and closed solenoids
(EV50A/B and EV51A/B) will be energised/de-energised to open and close the
appropriate valves for the selected route.
When the close position switch (ZS50B or ZS51B) indicates that the appropriate valve has
closed and sealed, and when the open position switch (ZS50A or ZS51A) indicates
that the other valve has fully opened, the Switch Valve position is confirmed as
correct.
In the event that the solenoids are energised/de-energised for more than 5 seconds
and the appropriate valve positions are not confirmed then the intended target silo
“selected” indication lamp will flash to alert the operators of a route valve fault.
TIMER DEFINITIONS AND VALUES
Timer name Purpose of timer Timer setting Timer range
Short fill timer The short fill timer allows the 900 seconds 0 – 3600 seconds
conveying cycle to continue after a
delay even if the DensePhase
MD-Pumps high level probes (LSH02)
are not covered.
Cycle watchdog The cycle watchdog timer provides a 1060 seconds 0 – 3600
timer conveying cycle fault alarm if the seconds
conveying cycle is not completed
within the pre-set time period.
Minimum cycle This regulates the maximum 10 seconds 0 – 3600
period timer conveying cycle frequency. seconds
Overfill timer The inlet Dome Valve opening is 0.1 seconds 0 – 60 seconds
extended by the overfill timer after the
vessel level probe has been covered.
This is to allow the vessel to
completely fill.
Conveying air valve This timer allows a delay for the 2 seconds 0 – 60 seconds
open delay timer in-line Dome Valve to be fully opened
before the material is conveyed.
Convey secure The convey secure timer is to allow 20 seconds 0 – 120
timer time for the conveying pressure to rise seconds
before the line pressure switch (PT02)
is interrogated.
Cycle reset timer The cycle reset timer provides time 3 seconds 0 – 20 seconds
for the pressure in the vessel and
conveying pipework to be completely
released before the start of another
conveying cycle.
Dome Valve fault This allows a delay for the Dome 5 seconds 0 – 20 seconds
timer Valve to open / close before initiating
a Dome Valve fault alarm.
OPERATOR CONTROLS AND INDICATIONS
PNEUMATIC CONTROL PANEL
A pneumatic control panel is provided at each of the MD-Pumps which houses the solenoid valves and
pressure switches associated with that vessel. The pneumatic control panel on the master MD-Pumps
also provides the following local controls and indications:
Remote/Local switch. For the MD-Pumps to run both this switch must be set to “Remote” and the
start/stop switch on the main electrical panel must be set to “start”.
A pressure gauge mounted on the air inlet manifold of the master vessel provides an
indication of the pressure in the conveying pipe. Note: a valve is provided to prevent the
entry of dust into the gauge during normal operation of the system. The valve should be
kept closed when not using the gauge.
ELECTRICAL CONTROL PANEL
The MD-Pumps will be controlled by a PLC located in the main electrical control panel. The operator
interface (HMI) will be via a CRT and keypad and includes the following operator controls, indications
and alarms.
MD-Pump main start/stop/purge switch. This will permit the operators to start and stop the line of
MD-Pumps. When the switch is set to the “START” position the MD-Pumps will run normally. When
the switch is set to the “PURGE” position the MD-Pumps will cycle without the inlet Dome Valves
being opened. This is intended for use in maintenance, or when clearing residual material from the
system.
MD-Pump high level probe uncovered indication lamp. The lamp will be “on” when the high level probe
(LSH02) in the MD-Pump is uncovered.
Inlet and vent Dome Valve open / fault indication lamp. The lamp will be “on” when the inlet Dome
Valve open solenoid (EV01) is energised and both the inlet and vent Dome Valve seal pressure switches
(PS01) and (PS05) are not made. The lamp will flash in the event of the inlet and/or vent Dome Valve
failing to open or failing to close and seal. See summary of alarm conditions.
Conveying in progress lamp. The lamp will be “on” when the conveying air valves are open.
Conveying cycle fault lamp. This is a lamp to indicate that there is a conveying cycle fault. The lamp
will be illuminated when any of the following occur:
The cycle watchdog timer has expired and a conveying cycle is still in progress.
Conveying pressure is > 0.03MPa (PT02) and a conveying cycle is not in progress.
Conveying air pressure low lamp. The lamp will be “on” if the conveying air pressure is less than
0.5MPa (client signal).
Reception silo high level probe covered indication lamps. This will be illuminated when the reception
silo high level probe is covered.
SUMMARY OF ALARM CONDITIONS
INLET AND VENT DOME VALVE NOT OPEN ALARM
Definition:
Inlet Dome Valve open solenoid (EV01) energised for more than 5 seconds and one or more seal
pressure > 0.5MPa (PS01) and (PS05).
Control Action:
Visual alarm only.
INLET AND VENT DOME VALVE NOT CLOSED AND SEALED ALARM
Definition:
Inlet Dome Valve open solenoid (EV01) de-energised for more than 5 seconds and one or more seal
pressure < 0.5MPa (PS01) and (PS05).
Control Action:
Visual alarm and conveying cycle start/progress inhibited.
CONVEYING CYCLE FAULT ALARM
Definition:
or:
Control Action:
Visual alarm only and conveying cycle start inhibited if (PT02) > 0.03MPa.
CONVEYING AIR PRESSURE LOW ALARM
Definition:
The conveying air supply pressure < 0.55MPa (client signal).
Control Action:
Visual alarm, conveying cycle start inhibited until pressure is >0.65MPa (see start interlocks).
ISOLATING VALVE FAULT ALARM
Definition:
Isolating valve “Open” solenoid (EV50A/51A) energised for more than 5 seconds and “Opened”
position switch (ZS50A/51A) not made.
or:
Isolating Valve “Close” solenoid (EV50B/51B) energised for more than 5 seconds and “Closed” position
switch (ZS50B/51B) not made.
Control Action:
Visual alarm (Silo selected indication lamp flashes) and conveying cycle start inhibited.
ESP FIELD 1 AND AIR HEATER MIXED GRITS OPERATION
OVERVIEW
The ESP field 1 system comprises 2 MD-Pump and the Air Heater system comprises 2 Ash Vessel. The 2
systems are routed to the reception silo via a common pipe. The 2 systems will be capable of
simultaneous operation in mixed grits mode. ESP filed 1 MD PUMP systems will be capable of
independent operation mode. Before independent operation can be started blanking plates will need to be
fitted in the conveying pipework to prevent material from being conveyed into the other system.
important that the filter cleaning is operated continuously while the ash system is in operation. The
exhaust from the filter must be unobstructed and open to atmosphere at all times, even when the ash
system is not in operation. This is to permit any compressed air leakage into the system, or expansion of
the air due to an increase in temperature, to be safely vented.
SYSTEM AT REST
When the system is stopped and at rest the status of the valves will be as follows:
Ash Vessel system

Ash vessel Inlet last position* closed closed
Dome Valves
Supplementary air closed closed closed

valve (PV10)
Conveying air valve closed closed closed

(PV02)
Bypass air valve closed closed closed

(PV08)
Density stabiliser closed closed closed

valve PV09)
MD-Pump system

MD-Pump Inlet last position closed closed
Dome Valves
MD-Pump Vent last position closed closed

Valves
Conveying air valve closed closed closed

(PV02)
The MD-Pumps and Ash Vessel should be empty and at zero pressure.
MIXED GRITS OPERATION ------ ASH VESSEL OPERATION
The start mixed grits conveying/stop/purge switch on the main electrical control panel is set to “START
MIXED GRITS CONVEYING” or “PURGE”.
The Start/Stop switch on the pneumatic control panel is set to “START”.
Client interlock is healthy.
Conveying air supply pressure > 0.55MPa.
Master vessel inlet Dome Valve is closed and sealed (PS01).
Slave vessel inlet Dome Valves are closed and sealed (PS01).
All MD-pump inlet Dome Valves and vent Dome Valve are closed and sealed (PS01/PS05).
Space is available in the target reception silo (As defined in the section titled Conveying Route Control)
If the start mixed grits conveying /stop/purge switch is set to “PURGE” and the MD PUMP system is
not conveying, the inlet Dome Valves will not be opened and the cycle will continue from the Step 4.
If the conveying air pressure is greater than 0.03MPa (PT02), the cycle will continue from the Step 5
Step 1
The master vessel inlet Dome Valve will be opened by energising solenoid (EV01). The
master vessel inlet Dome Valve open timer (10 seconds), master/outlet inlet Dome Valve
open delay timer (1 second), cycle watchdog timer (120 seconds), minimum cycle period
timer (204 seconds), and maximum cycle period timer (204 seconds),will be started.
Material will fall under gravity into the master ash vessel.
Step 2
When the master/outlet inlet Dome Valve open delay timer has expired the outlet vessel
inlet Dome Valve will be opened by energising the solenoid (EV01) and the outlet vessel
inlet Dome Valve open timer (10 seconds) will be started. Material will fall under gravity
into the outlet ash vessel.
Step 3
As each of the inlet Dome Valve open timers expires the appropriate inlet Dome Valve will
be closed by de-energising solenoid (EV01).
Step 4
When all of the inlet Dome Valves have closed and sealed (PS01), the conveying air valve open delay
Step 5
When the “start ash vessel system conveying” signal has been initiated (see MD-Pump
section) and providing the ash vessel system inlet Dome Valves are all closed (PS01), the
bypass air valve (PV08) and density stabiliser air valve (PV09) will both be opened by
energising solenoids (EV08) and (EV09) respectively. Simultaneously, the bypass air
changeover timer (15 seconds) will be started. A bypass cycle will be started.
When the bypass air changeover timer (15 seconds) expires, the conveying air valve (PV02) and
supplementary air valve (PV10) will both be opened by energising solenoids (EV02) and (EV10)
respectively, the bypass air valve (PV08) will be closed by de-energising solenoid (EV08), the density
stabiliser air valve (PV09) will be opened by energising solenoids (EV09).and the convey secure timer
(20 seconds) will be started. Conveying air will enter the system and material will be discharged into the
conveying pipe. Simultaneously, the conveying air changeover timer (5 seconds) will be started. A
conveying cycle will be started.
When the conveying air changeover timer (5 seconds) expires, the conveying air valve
(PV02) and supplementary air valve (PV10) will both be closed by de-energising solenoids
(EV02) and (EV10) respectively and the bypass air valve (PV08) will be opened by
energising solenoid (EV08).
This changeover sequence will be repeated for the duration of this sequence step.
When conveying air is introduced, the system will become pressurised and material will be conveyed to
the silo. During this part of the cycle the controls will monitor the conveying air pressure (PT02) and
take steps to prevent it exceeding pre-set limits.
First conveying air pressure limit.
If the conveying air pressure becomes greater than 0.25MPa (PT02), the conveying air changeover
sequence will be stopped and the conveying air valves will be set to the following positions:-
 The main conveying air valve (PV02) will be closed by de-energising solenoid (EV02).
 The supplementary air valve (PV10) will be open by energising solenoid (EV10).
 The bypass valve (PV08) will be opened by energising solenoid (EV08).
 The density stabiliser air valve (PV09) will be open by energising solenoid (EV09).
When the conveying air pressure becomes less than 0.2MPa Ash vessel system solids flow (FT08). The
ash vessel system solids flow will be displayed in the range 0 – 100%.
, the conveying air changeover sequence will be re-started from the beginning and the conveying air
valves will be set to the following positions:-
 The main conveying air valve (PV02) will be opened by energising solenoid (EV02).
 The bypass valve (PV08) will be closed by de-energising solenoid (EV08).
 The density stabiliser air valve (PV09 will be open by energising solenoid (EV09).
Second conveying air pressure limit.
If the conveying air pressure becomes greater than 0.35MPa (PT02), the conveying air changeover
sequence will be stopped and the conveying air valves will be set to the following positions:-
 The supplementary air valve (PV10) will be closed by de-energising solenoid (EV10).
When the conveying air pressure becomes less than 0.3MPa, the conveying air valves will be set to the
following positions:-
 The bypass valve (PV08) will be opened by energising solenoid (EV08).
If during this step the MD-Pump system reaches its first conveying air pressure limit, then the conveying
air changeover sequence will be stopped and the conveying air valves will be set to the following
positions:
 The supplementary air valve (PV10) will be closed by de-energising solenoid (EV10).
 The bypass valve (PV08) will be open by energising solenoid (EV08).
When the MD-Pump system becomes re-set from its first conveying air pressure limit, the conveying air
changeover sequence will be re-started from the beginning and the conveying air valves will be set to the
following positions:
 The main conveying air valve (PV02) will be opened by energising solenoid (EV02).
Step 6
The material will be conveyed through the pipeline to the reception silo.
When the ash vessel system convey secure timer has expired and the conveying pressure
has fallen to less than 0.03MPa (PT02), or the MD-Pump system convey secure timer has
expired and the MD-Pump system conveying pressure has fallen to less than 0.03 MPa
(PT02) or the MD-Pump system convey secure timer has expired and the MD-Pump
system conveying pressure has fallen to less than 0.175MPa and the differential pressure
between MD-Pump system and ash vessel system conveying pressure is less than 0.03MPa
(PT25), signalling that the transfer is complete, then the ash vessel system material transfer
will be stopped, the main conveying air valve (PV02), supplementary air valve (PV10),
density stabiliser air valve (PV09) and bypass valve (PV08) will all be closed by
de-energising solenoids (EV02), (EV10), (EV09) and (EV08) respectively. Simultaneously,
the cycle reset timer (3 seconds) will be started.
Step 7
When the cycle reset timer has expired the conveying cycle is complete and the system will
be at rest.
Note:
If during the cycle any start interlocks become untrue, then that cycle will be permitted to
again become true. For example, at the start of the cycle the low level switch will be
covered. If this level probe becomes uncovered during the cycle, this will be ignored and
will not cause the cycle to stop or reset. To achieve this the PLC program will latch the
cycle start.
ASH VESSEL SYSTEM TIMER DEFINITIONS AND VALUES
Inlet Dome Valve During filling of the ash vessels the 10 seconds 0 - 60
open timer inlet Dome Valve will be opened for seconds
the duration of the inlet Dome Valve
open timer.
Inlet Dome Valve The opening of the inlet Dome Valves 1 seconds 0 - 60
open delay timer is staggered to allow the vessel to fill seconds
uniformly. The stagger is set by the
inlet Dome Valve open delay timer.
Cycle watchdog The cycle watchdog timer provides a 90 seconds 0 - 600
Minimum cycle This regulates the maximum 120 seconds 0 - 600
Convey secure The convey secure timer is to allow 20 seconds 0 - 120
before the vessel low pressure switch
(PT02) is interrogated.
Cycle reset timer The cycle reset timer provides time for 3 seconds 0 - 20
the pressure in the vessel and seconds
conveying cycle.
Dome Valve fault This allows a delay for the Dome 5 seconds 0 - 20
timer Valve to open/closed before initiating a seconds
Dome Valve fault alarm.
Conveying air This timer regulates the frequency at 5 seconds 0 - 600
changeover timer which conveying air is routed to either (conveying) seconds
the ash vessels or the bypass. 10 seconds
(bypass) 0 – 600
seconds
MIXED GRITS OPERATION ------ MD-PUMP OPERATION
The start independent conveying / start mixed grits conveying / stop /purge switch on the main electrical
controls screen is set to “start independent conveying” or “start mixed grits conveying ” or “PURGE”.
Conveying air supply pressure is > 0.55MPa (client signal).
Master MD-Pump inlet and vent Dome Valves are closed and sealed (PS01/PS05).
Slave MD-Pump inlet and vent Dome Valves are closed and sealed (PS01/PS05).
ALL Ash Vessel inlet Dome Valves are closed and sealed (PS01).
Space is available in the target reception silo (As defined in the section titled Conveying Route Control).
Step 1
All the inlet and vent Dome Valves will be opened by energising solenoids (EV01). Simultaneously, the
short fill timer (900 seconds), cycle watchdog timer (1060 seconds), and minimum cycle period timer
(10 seconds), will be started. Material will fall under gravity into the MD-Pumps.
Step 2
When one or more of the MD-Pump high level probes (LSH02) has been covered, or when the short fill
timer has expired, the overfill timer (0.1 seconds) is started.
Step 3
When the overfill timer has expired, all the inlet and vent Dome Valves are closed by
de-energising solenoids (EV01).
Step 4
When all the MD-Pump inlet and vent Dome Valves (PS01/PS05) have closed and sealed, and providing
all the Ash Vessel inlet Dome Valve are closed and sealed (PS01), the conveying air valve open delay
Note: If one or more of the MD-Pump high level probes (LSH01) is covered at the start of the cycle,
or if “PURGE” has been selected on the display screen, the inlet and vent Dome Valves will
not be opened and the cycle will continue from the next step.
Step 5
When the conveying air valve open delay timer has expired, the conveying air valve (PV02) will be
opened by energising solenoid (EV02). Air will enter the MD-Pumps and the conveying pressure will
begin to rise. The material will be discharged into the conveying pipeline. The convey secure timer (20
seconds) will be started.
Simultaneously, the “start ash vessel system conveying” delay timer (40 seconds) will also be started.
Note: If the conveying pressure rises to greater than 0.35MPa (PT02), the conveying air valve (PV02)
will be closed. When the pressure has fallen below 0.15MPa the valves will be re-opened.
Step 6
The material will be conveyed through the pipeline to the target reception silo. When the convey secure
timer has expired, and the pressure in the conveying pipeline has fallen to < 0.03MPa (PT02), the
convey secure timer (20 seconds) will be started. When the convey secure timer has expired, the
signalling that the material transfer is complete, the conveying air valve (PV02) will closed by
de-energising solenoids (EV02). The cycle reset timer (3 seconds) will be started.
Step 7
When the cycle reset timer has expired the conveying cycle is complete.
Note: If during the cycle any start interlocks become untrue, then that cycle will be permitted to
again become true. For example, at the start of the cycle the high level probe will be
uncovered. If this level probe becomes covered during the cycle, this will be ignored and will
not cause the cycle to stop or reset. To achieve this the PLC program will latch the cycle start.
MD-PUMP SYSTEM TIMER DEFINITIONS AND VALUES
Conveying air This timer allows a delay for the in-line 2 seconds 0 – 60
valve open delay Dome Valve to be fully opened before seconds
timer the material is conveyed.
Cycle watchdog The cycle watchdog timer provides a 90 seconds 0 – 600
Minimum cycle This regulates the maximum conveying 10 seconds 0 – 3600
period timer cycle frequency. seconds
Convey secure The convey secure timer is to allow 20 seconds 0 – 120
before the line pressure switch (PT02)
is interrogated.
Cycle reset timer The cycle reset timer provides time for 3 seconds 0 – 20
conveying pipe work to be completely
conveying cycle.
Dome Valve fault This allows a delay for the Dome Valve 5 seconds 0 – 20
timer to open / close before initiating a Dome seconds
Valve fault alarm.
Start ash vessel The timer allows ESP ash transfer to 40 seconds 0 - 60
system conveying become established before the ash seconds
delay timer vessel system starts to convey.
A pneumatic control panel is provided at each of the MD-Pumps (Ash Vessel) which houses the solenoid
valves and pressure switches associated with that vessel. The pneumatic control panel on the master
MD-Pumps (Ash Vessel) also provides the following local controls and indications:
Remote/Local switch. For the MD-Pumps (Ash Vessel) to run both this switch must be set to “Remote”
and the start/stop switch on the main electrical panel must be set to “start”.
indication of the pressure in the conveying pipe. Note: a valve is provided to prevent the
entry of dust into the gauge during normal operation of the system. The valve should be
kept closed when not using the gauge.
The MD-Pumps and Ash Vessel will be controlled by a PLC located in the main electrical control panel.
The operator interface (HMI) will be via a CRT and keypad and includes the following operator controls,
indications and alarms.
Ash Vessel system
Inlet Dome Valve open / fault indication lamp. The lamp will be “on” when the inlet Dome Valve open
solenoid (EV01) is energised and the inlet Dome Valve seal pressure switch (PS01) is not made. The
lamp will flash in the event of the inlet Dome Valve failing to open or failing to close and seal. See
summary of alarm conditions.
Conveying pressure (PT02). The conveying air pressure will be displayed in the range 0 – 1.0MPa.
MD-Pump system
START MD-Pump system conveying. This command allows the operators to initiate a conveying cycle
which will proceed providing there are no relevant alarm conditions.
Inlet Dome Valve open / fault indication lamp. The lamp will be “on” when the inlet Dome Valve open
solenoid (EV01) is energised and the inlet Dome Valve seal pressure switch (PS01) is not made. The
lamp will flash in the event of the inlet Dome Valve failing to open or failing to close and seal. See
Conveying pressure (PT02). The conveying air pressure will be displayed in the range 0 – 1.0MPa.
Common Equipment
START mixed grit conveying. This command allows the operators to initiate a mixed grit conveying
cycle which will proceed providing there are no relevant alarm conditions. The control system will
automatically control the conveying sequences for both the ash vessel and MD-Pump systems.
Conveying in progress lamp. The lamp will be “on” when the conveying air valves are open.
Conveying cycle fault lamp. This is a lamp to indicate that there is a conveying cycle fault. The lamp
will be illuminated when any of the following occur:
Conveying air pressure low lamp. The lamp will be “on” if the conveying air pressure is less than 5.0
barg (client signal).
Reception silo high level probe covered indication lamps. This will be illuminated when the reception
silo high level probe is covered.
INLET DOME VALVE NOT OPEN ALARM
Definition:
Inlet Dome Valve open solenoid (EV01) energised and seal pressure > 0.5MPa (PS01) for more than 5
seconds.
Control Action:
Visual alarm only.
INLET DOME VALVES NOT CLOSED AND SEALED ALARM
Definition:
Inlet Dome Valve open solenoid (EV01) de-energised and seal pressure < 0.5MPa (PS01) for more than
5 seconds.
Control Action:
Visual alarm and conveying cycle start inhibited.
ESP FIELD 3 ASH VESSEL OPERATION
OVERVIEW
precipitator. The fly ash will be discharged by gravity into an ash vessel mounted beneath each
outlet and will then be pneumatically conveyed to the reception silo.
The ash vessels located beneath the outlets from filed 3 will be connected to a common pipeline.
The two pipelines from each row will be connected via a Pipeline Switch Valve and will share a
common conveying pipe to the reception silo. Since only one system may convey at a time the
operation of the two rows of vessels will be sequenced.
A level switch located in each precipitator outlet will signal the presence of material and will
initiate a conveying cycle for that line of ash vessels. The inlet Dome Valves of that line of ash
vessels will then open and ash will gravity discharge into the vessels. After a timed delay the inlet
Dome Valves will be closed. The Pipeline Switch Valve from the system on the other field will
also be closed. When all of the inlet Dome Valves have closed and sealed there will be a further
short delay before air is introduced into the master ash vessel. The ash will then be discharge
from all of the vessels into the conveying pipeline and will be conveyed to the reception silo.
Conveying air will also be introduced into the conveying pipe after each slave vessel. When the
ash has been discharged into the reception silo, signalled by a drop in conveying pressure, the
conveying air valves will be closed and the cycle is complete.
The material will be routed to one of 2 reception silos by means of a silo top switch valve. A high
level switch in each reception silo will signal when a silo is full and the control system will
change the route to another silo if possible, or will inhibit further operation of the ash system.
important that the filter cleaning is operated continuously while the ash system is in operation.
The exhaust from the filter must be unobstructed and open to atmosphere at all times, even when
the ash system is not in operation. This is to permit any compressed air leakage into the system,
or expansion of the air due to an increase in temperature, to be safely vented.
SYSTEM AT REST

Master vessel inlet last position* closed closed
Dome Valve
Slave vessel inlet last position* closed closed

Dome Valve
Pipeline Switch Valve last position* open open

valve
(PV02)
Secondary conveying closed closed closed
air valve
(PV10)
The ash vessels should be empty and at zero pressure.
* Note: The Dome Valve incorporates an inflating seal. In the event of the loss of control air
ASH VESSEL OPERATING SEQUENCE
At the start of a conveying cycle the control system will check that the following cycle start
interlock conditions are fulfilled:
The start/stop/purge switch on the main electrical control panel is set to “START” or
“PURGE”.
The other system which uses the shared conveying pipeline is not currently in a conveying
cycle.
Conveying air supply pressure > 0.55MPa.
All slave vessel inlet Dome Valves are closed and sealed (PS01).
Space is available in the target reception silo (As defined in the section titled Conveying
Route Control)
Precipitator outlet level switch is covered (LS01) and minimum cycle period timer
expired.
Providing the above conditions are true a conveying cycle will be initiated and will proceed as
follows:
Step 1
The master vessel inlet Dome Valve will be opened by energising solenoid (EV01).
The master vessel inlet Dome Valve open timer (10 seconds), master/slave 1 inlet
Dome Valve open delay timer (1 second), cycle watchdog timer (90 seconds), and
minimum cycle period timer (120 seconds), will be started. Material will fall under
gravity into the master ash vessel.
Note: If the start/stop/purge switch is set to “PURGE” the inlet Dome Valves will
not be opened and the cycle will continue from the Step 5.
The operation of the system on the other line will be inhibited until the current
conveying cycle is complete.
Step 2
When the master/slave 1 inlet Dome Valve open delay timer has expired the slave
vessel 1 inlet Dome Valve will be opened by energising the solenoid (EV01) and the
slave 1 vessel inlet Dome Valve open timer (10 seconds) and the Pipeline Switch
Valve close delay timer (1 second) will be started.
As each of the inlet Dome Valve open timers expires the appropriate inlet Dome
Valve will be closed by de-energising solenoid (EV01).
Step 3
When the Pipeline Switch Valve close delay timer has expired, the Pipeline Switch
Valve will be closed by energising solenoid (EV50B/51B).
Step 4
When all of the inlet Dome Valve open timers have expired the Pipeline Switch
Valve of this line will be opened by de-energising the appropriate close solenoid
(EV50B/EV51B) and energising the open solenoid (EV50A/EV51A).
Step 5
When all of the inlet Dome Valves (PS01) have closed and sealed the conveying air
Step 6
When the conveying air valve open delay timer has expired the main conveying air
valve (PV02) and secondary conveying air valve will be opened by energising the
solenoid (EV02) and the convey secure timer (20 seconds) will be started. Air will
enter the system and the material will be discharged into the conveying pipe.
Note:
If the conveying pressure rises above 0.35MPa (PT02) the conveying air valves will
be closed. The valves will remain closed until the pressure has fallen below 0.15MPa
and will then be re-opened.
Step 7
The material will be conveyed through the pipeline to the reception silo. When the
convey secure timer has expired and the pressure in the conveying pipeline has fallen
to less than 0.3 barg, signalling that the transfer is complete, the main conveying air
valve (PV02) and secondary conveying air valve (PV10) will be closed by
de-energising solenoid (EV02). The cycle reset timer (3 seconds) and route change
delay timer (10 seconds) will be started.
Step 8
When the cycle reset timer has expired the conveying cycle is complete. The Pipeline
Switch Valve from the other system will be opened by energising the appropriate
open solenoid (EV50A/EV51A) and de-energising the close solenoid
(EV50B/EV51B).
Note:
If during the cycle any start interlocks become untrue, then that cycle will be
permitted to continue and end. The system will then stop until all of the start
interlock conditions once again become true. For example, at the start of the cycle
the low level switch will be covered. If this level probe becomes uncovered during
the cycle, this will be ignored and will not cause the cycle to stop or reset. To achieve
this the PLC program will latch the cycle start.
Similarly, where an event has to occur to permit the cycle to proceed to the next step, then the
progress of the cycle will be halted until that interlock condition has become true. The cycle will
then proceed to the next step. The progress of the cycle to the next step will be latched for the
remainder of the cycle, so that in the event of the interlock condition subsequently becoming
untrue, the cycle will not stop or regress. The latches are released at the end of the cycle during
the cycle reset timer.
The material will be routed to one of 2 reception silos by means of a silo top switch valve.
To permit the route to be changed the ash system cycle must be complete and the system must be
at rest. To ensure this the route change delay timer (see previous section) must be timed out.
A 2 position switch for each reception silo will enable the operators to select that silo for filling.
The two positions will be labelled “off” and “auto”. When the switch is in the “auto” position
then that silo will be filled until the high level switch is covered. When the silo has been filled
and the high level switch is covered, or if the “off/auto” switch is set to the “off” position then a
current cycle will be permitted to continue and end. The control system will then change the
routing to another silo which is set to “auto” and whose high level switch is uncovered. If no
other hopper is available the control system will inhibit further operation of the system.
Prior to a ash system operating cycle the control system will check the position of the routing
valves to ensure that the route is correctly set. In the event of a route valve fault the control
system will inhibit the operation of the system until the fault has been rectified. This is referred to
as the “conveying route confirmed” requirement in the cycle start interlocks.
Prior to a ash system operating cycle the control system will check the status of the high level
switch in the target reception silo to ensure that there is sufficient space available for a charge of
material. In the event that the high level switch in the current target silo is covered then the
control systems will change the routing to another available silo, or inhibit the operation of the
system.
SILO TOP SWITCH VALVE
GENERAL
The Silo Top Switch Valve is located on the top of a reception silo. It comprises a Y shaped
junction with an Isolating Valve mounted on each of the branches. The material is routed through
the appropriate branch by opening the Isolating Valve on that branch and closing the Isolating
Valve on the other branch.
A position switch (ZS50A/ZS51A) provides confirmation that a Isolating Valve has fully opened.
A position switch (ZS50B/ZS51B) provides confirmation that a Isolating Valve has fully closed.
The position of the Isolating Valves may only be changed when the conveying cycle has been
completed and the system is at rest.
CHANGING THE SILO TOP SWITCH VALVE POSITION
be started.
that the other valve has fully opened, the Silo Top Switch Valve position is
confirmed as correct.
In the event that the solenoids are energised/de-energised for more than 5 seconds and the
appropriate valve positions are not confirmed then the intended target silo “selected” indication
lamp will flash to alert the operators of a route valve fault.
open timer inlet Dome Valve will be opened for the seconds
duration of the inlet Dome Valve open
timer.
Conveying air This timer allows a delay for the in-line 2 seconds 0 - 60
valve open delay Dome Valve to be fully opened before seconds
timer the material is conveyed.
Minimum cycle This regulates the maximum conveying 120 seconds 0 - 600
period timer cycle frequency. seconds
conveying cycle.
Dome Valve fault This allows a delay for the Dome Valve 5 seconds 0 - 20
timer to open/closed before initiating a Dome seconds
Valve fault alarm.
A pneumatic control panel is provided at each of the ash vessels which houses the solenoid
valves and pressure switches associated with that vessel. The pneumatic control panel on the
master ash vessel also provides the following local controls and indications:
Remote/Local switch. For the Ash Vessel to run both this switch must be set to
“Remote” and the start/stop switch on the main electrical panel must be set to “start”.
indication of the pressure in the conveying pipe. Note: a valve is provided to prevent
the entry of dust into the gauge during normal operation of the system. The valve
should be kept closed when not using the gauge.
The ash vessels will be controlled by a PLC located in the main electrical control panel. The
operator interface (HMI) will be via a CRT and keypad and includes the following operator
controls, indications and alarms.
Ash vessel main start/stop/purge switch. This will permit the operators to start and stop
the system. When the switch is set to the “START” position the ash system will run
normally. When the switch is set to the “PURGE” position the ash vessels will cycle
without the inlet Dome Valve being opened. This is intended for use during
maintenance, or when clearing residual material from the system.
Precipitator outlet level probe uncovered indication lamp. The lamp will be “on” when
the level probe (LS01) is uncovered.
Inlet Dome Valve open/fault indication lamp. The lamp will be “on” when the inlet
Dome Valve open solenoid (EV01) is energised and the seal pressure is < 0.5MPa
(PS01). The lamp will flash in the event of the inlet Dome Valve failing to open or
failing to close and seal. See summary of alarm conditions.
Pipeline Switch Valve open/fault indication lamp. The lamp will be “on” when the inlet
Dome Valve open solenoid (EV50A/EV51A) is energised and the seal pressure is <
0.5MPa (PS01). The lamp will flash in the event of the inlet Dome Valve failing to
open or failing to close and seal. See summary of alarm conditions.
Conveying in progress lamp. The lamp will be “on” when the conveying air valves are
open or the conveying pressure > 0.03MPa (PT02).
Conveying cycle fault lamp. This is a lamp to indicate that there is a conveying cycle
fault. The lamp will be illuminated when any of the following occur:
The conveying pressure > 0.03MPa (PT02) and a conveying cycle is not in
progress.
Reception silo “off/auto” switch. The silo will be filled if the switch is set to the “auto”
position until the high level switch is covered. When the high level switch is covered,
or if the switch is set to “off” then a current conveying cycle will be permit to continue
and end. The control system will then change the routing to another available hopper,
or inhibit further operation of the system.
Reception silo selected indication lamp. This lamp will be on when a reception silo is
set as the target silo. The lamp will flash when a silo is selected by the control system
as the intended target silo and the route valves are not confirmed in their appropriate
positions.
Reception silo full indication lamp. The lamp will be on when the reception silo high
level switch is covered. Where a reception silo is used by more than one system there
will be only one silo full indication lamp
Definition:
Inlet Dome Valve open solenoid (EV01) energised for more than 5 seconds and seal pressure >
0.5MPa (PS01).
Control Action:
Visual alarm only.
INLET DOME VALVE NOT CLOSED AND SEALED ALARM
Definition:
Inlet Dome Valve open solenoid (EV01) de-energised for more than 5 seconds and seal pressure
< 0.5MPa (PS01).
Control Action:
PIPELINE SWITCH VALVE NOT OPEN ALARM
Definition:
Pipeline Switch Valve open solenoid (EV01) energised for more than 5 seconds and seal
pressure > 0.5MPa (PS01).
Control Action:
Visual alarm only.
PIPELINE SWITCH VALVE NOT CLOSED AND SEALED ALARM
Definition:
Pipeline Switch Valve open solenoid (EV01) de-energised for more than 5 seconds and seal
pressure < 0.5MPa (PS01).
Control Action:
Definition:
or:
The conveying pressure > 0.03MPa (PT02) and a conveying cycle is not in progress.
Control Action:
Visual alarm and conveying cycle start inhibited if PT02 > 0.03MPa.
Definition:
or:
Isolating Valve “Close” solenoid (EV50B/51B) energised for more than 5 seconds and “Closed”
position switch (ZS50B/51B) not made.
Control Action:
ESP FIELD 4&5 ASH VESSEL OPERATION
OVERVIEW
precipitator. The fly ash will be discharged by gravity into an ash vessel mounted beneath each
outlet and will then be pneumatically conveyed to the reception silo.
The ash vessels located beneath the outlets from filed 3 will be connected to a common pipeline.
The two pipelines from each row will be connected via a Pipeline Switch Valve and will share a
common conveying pipe to the reception silo. Since only one system may convey at a time the
operation of the two rows of vessels will be sequenced.
When the minimum cycle period timer expired the PLC will initiate a conveying cycle for that
line of ash vessels. The inlet Dome Valves of that line of ash vessels will then open and ash will
gravity discharge into the vessels. After a timed delay the inlet Dome Valves will be closed. The
Pipeline Switch Valve from the system on the other field will also be closed. When all of the inlet
Dome Valves have closed and sealed there will be a further short delay before air is introduced
into the master ash vessel. The ash will then be discharge from all of the vessels into the
conveying pipeline and will be conveyed to the reception silo. Conveying air will also be
introduced into the conveying pipe after each slave vessel. When the ash has been discharged into
the reception silo, signalled by a drop in conveying pressure, the conveying air valves will be
closed and the cycle is complete.
The material will be routed to one of 2 reception silos by means of a silo top switch valve. A high
level switch in each reception silo will signal when a silo is full and the control system will
change the route to another silo if possible, or will inhibit further operation of the ash system.
important that the filter cleaning is operated continuously while the ash system is in operation.
The exhaust from the filter must be unobstructed and open to atmosphere at all times, even when
the ash system is not in operation. This is to permit any compressed air leakage into the system,
or expansion of the air due to an increase in temperature, to be safely vented.
SYSTEM AT REST

Master vessel inlet last position* closed closed
Dome Valve
Slave vessel inlet last position* closed closed

Dome Valve
Pipeline Switch Valve last position* open open

valve
(PV02)
Secondary conveying closed closed closed
air valve
(PV10)
The ash vessels should be empty and at zero pressure.
ASH VESSEL OPERATING SEQUENCE
The start/stop/purge switch on the main electrical control panel is set to “START” or
“PURGE”.
The other system which uses the shared conveying pipeline is not currently in a conveying
cycle.
Conveying air supply pressure > 0.55MPa barg.
All slave vessel inlet Dome Valves are closed and sealed (PS01).
Space is available in the target reception silo (As defined in the section titled Conveying
Route Control)
follows:
Step 1
The master vessel inlet Dome Valve will be opened by energising solenoid (EV01).
The master vessel inlet Dome Valve open timer (10 seconds), master/slave 1 inlet
Dome Valve open delay timer (1 second), cycle watchdog timer (90 seconds), and
minimum cycle period timer (120 seconds), will be started. Material will fall under
gravity into the master ash vessel.
Note: If the start/stop/purge switch is set to “PURGE” the inlet Dome Valves will
not be opened and the cycle will continue from the Step 6.
The operation of the system on the other line will be inhibited until the current
conveying cycle is complete.
Step 2
When the master/slave 1 inlet Dome Valve open delay timer has expired the slave
slave 1 vessel inlet Dome Valve open timer (10 seconds) and the slave 1/slave 2 inlet
Dome Valve open delay timer (1 second) will be started.
Step 3
When the slave 1/slave 2 inlet Dome Valve open delay timer has expired the slave
slave 2 vessel inlet Dome Valve open timer (10 seconds) and the slave 2/slave 3 inlet
Dome Valve open delay timer (1 second) will be started.
Step 4
When the slave 2/slave 3 inlet Dome Valve open delay timer has expired the slave
slave 3 vessel inlet Dome Valve open timer (10 seconds) and the Pipeline Switch
Valve close delay timer (1 second) will be started.
As each of the inlet Dome Valve open timers expires the appropriate inlet Dome
Valve will be closed by de-energising solenoid (EV01).
Step 5
When the Pipeline Switch Valve close delay timer has expired, the Pipeline Switch
Valve will be closed by energising solenoid (EV50B/51B).
Step 6
When all of the inlet Dome Valve open timers have expired the Pipeline Switch
Valve of this line will be opened by de-energising the appropriate close solenoid
(EV50B/EV51B) and energising the open solenoid (EV50A/EV51A).
Step 7
When all of the inlet Dome Valves (PS01) have closed and sealed the conveying air
Step 8
When the conveying air valve open delay timer has expired the main conveying air
valve (PV02) and secondary conveying air valve will be opened by energising the
solenoid (EV02) and the convey secure timer (20 seconds) will be started. Air will
enter the system and the material will be discharged into the conveying pipe.
Note:
If the conveying pressure rises above 0.35MPa (PT02) the conveying air valves will
be closed. The valves will remain closed until the pressure has fallen below 0.15MPa
and will then be re-opened.
Step 9
The material will be conveyed through the pipeline to the reception silo. When the
convey secure timer has expired and the pressure in the conveying pipeline has fallen
to less than 0.3 barg, signalling that the transfer is complete, the main conveying air
valve (PV02) and secondary conveying air valve (PV10) will be closed by
de-energising solenoid (EV02). The cycle reset timer (3 seconds) and route change
delay timer (10 seconds) will be started.
Step 10
When the cycle reset timer has expired the conveying cycle is complete. The Pipeline
Switch Valve from the other system will be opened by energising the appropriate
open solenoid (EV50A/EV51A) and de-energising the close solenoid
(EV50B/EV51B).
Note:
If during the cycle any start interlocks become untrue, then that cycle will be
permitted to continue and end. The system will then stop until all of the start
interlock conditions once again become true. For example, at the start of the cycle
the low level switch will be covered. If this level probe becomes uncovered during
the cycle, this will be ignored and will not cause the cycle to stop or reset. To achieve
this the PLC program will latch the cycle start.
Similarly, where an event has to occur to permit the cycle to proceed to the next step, then the
progress of the cycle will be halted until that interlock condition has become true. The cycle will
then proceed to the next step. The progress of the cycle to the next step will be latched for the
remainder of the cycle, so that in the event of the interlock condition subsequently becoming
untrue, the cycle will not stop or regress. The latches are released at the end of the cycle during
the cycle reset timer.
The material will be routed to one of 2 reception silos by means of a silo top switch valve.
To permit the route to be changed the ash system cycle must be complete and the system must be
at rest. To ensure this the route change delay timer (see previous section) must be timed out.
A 2 position switch for each reception silo will enable the operators to select that silo for filling.
The two positions will be labelled “off” and “auto”. When the switch is in the “auto” position
then that silo will be filled until the high level switch is covered. When the silo has been filled
and the high level switch is covered, or if the “off/auto” switch is set to the “off” position then a
current cycle will be permitted to continue and end. The control system will then change the
routing to another silo which is set to “auto” and whose high level switch is uncovered. If no
other hopper is available the control system will inhibit further operation of the system.
Prior to a ash system operating cycle the control system will check the position of the routing
valves to ensure that the route is correctly set. In the event of a route valve fault the control
system will inhibit the operation of the system until the fault has been rectified. This is referred to
as the “conveying route confirmed” requirement in the cycle start interlocks.
Prior to a ash system operating cycle the control system will check the status of the high level
switch in the target reception silo to ensure that there is sufficient space available for a charge of
material. In the event that the high level switch in the current target silo is covered then the
control systems will change the routing to another available silo, or inhibit the operation of the
system.
SILO TOP SWITCH VALVE
GENERAL
The Silo Top Switch Valve is located on the top of a reception silo. It comprises a Y shaped
junction with an Isolating Valve mounted on each of the branches. The material is routed through
the appropriate branch by opening the Isolating Valve on that branch and closing the Isolating
Valve on the other branch.
A position switch (ZS50A/ZS51A) provides confirmation that a Isolating Valve has fully opened.
A position switch (ZS50B/ZS51B) provides confirmation that a Isolating Valve has fully closed.
The position of the Isolating Valves may only be changed when the conveying cycle has been
completed and the system is at rest.
CHANGING THE SILO TOP SWITCH VALVE POSITION
be started.
that the other valve has fully opened, the Silo Top Switch Valve position is
confirmed as correct.
In the event that the solenoids are energised/de-energised for more than 5 seconds and the
appropriate valve positions are not confirmed then the intended target silo “selected” indication
lamp will flash to alert the operators of a route valve fault.
open timer inlet Dome Valve will be opened for seconds
the duration of the inlet Dome Valve
open timer.
Conveying air valve This timer allows a delay for the 2 seconds 0 - 60
open delay timer in-line Dome Valve to be fully opened seconds
before the material is conveyed.
Minimum cycle This regulates the maximum 120 seconds 0 - 600
conveying cycle.
Dome Valve fault This allows a delay for the Dome 5 seconds 0 - 20
timer Valve to open/closed before initiating a seconds
Dome Valve fault alarm.
A pneumatic control panel is provided at each of the ash vessels which houses the solenoid
valves and pressure switches associated with that vessel. The pneumatic control panel on the
master ash vessel also provides the following local controls and indications:
Remote/Local switch. For the Ash Vessel to run both this switch must be set to
“Remote” and the start/stop switch on the main electrical panel must be set to “start”.
indication of the pressure in the conveying pipe. Note: a valve is provided to prevent
the entry of dust into the gauge during normal operation of the system. The valve
should be kept closed when not using the gauge.
The ash vessels will be controlled by a PLC located in the main electrical control panel. The
operator interface (HMI) will be via a CRT and keypad and includes the following operator
Ash vessel main start/stop/purge switch. This will permit the operators to start and stop
the system. When the switch is set to the “START” position the ash system will run
normally. When the switch is set to the “PURGE” position the ash vessels will cycle
without the inlet Dome Valve being opened. This is intended for use during
maintenance, or when clearing residual material from the system.
Precipitator outlet level probe uncovered indication lamp. The lamp will be “on” when
the level probe (LS01) is uncovered.
Conveying in progress lamp. The lamp will be “on” when the conveying air valves are
open or the conveying pressure > 0.03MPa (PT02).
The conveying pressure > 0.03MPa (PT02) and a conveying cycle is not in
progress.
Reception silo “off/auto” switch. The silo will be filled if the switch is set to the “auto”
position until the high level switch is covered. When the high level switch is covered,
or if the switch is set to “off” then a current conveying cycle will be permit to continue
and end. The control system will then change the routing to another available hopper,
or inhibit further operation of the system.
Reception silo selected indication lamp. This lamp will be on when a reception silo is
set as the target silo. The lamp will flash when a silo is selected by the control system
as the intended target silo and the route valves are not confirmed in their appropriate
positions.
Reception silo full indication lamp. The lamp will be on when the reception silo high
level switch is covered. Where a reception silo is used by more than one system there
will be only one silo full indication lamp
Definition:
0.5MPa (PS01).
Control Action:
Visual alarm only.
Definition:
< 0.5MPa (PS01).
Control Action:
PIPELINE SWITCH VALVE NOT OPEN ALARM
Definition:
Pipeline Switch Valve open solenoid (EV01) energised for more than 5 seconds and seal
Control Action:
Visual alarm only.
PIPELINE SWITCH VALVE NOT CLOSED AND SEALED ALARM
Definition:
Pipeline Switch Valve open solenoid (EV01) de-energised for more than 5 seconds and seal
Control Action:
Definition:
or:
The conveying pressure > 0.03MPa (PT02) and a conveying cycle is not in progress.
Control Action:
Visual alarm and conveying cycle start inhibited if PT02 > 0.03MPa.
Definition:
or:
Isolating Valve “Close” solenoid (EV50B/51B) energised for more than 5 seconds and “Closed”
position switch (ZS50B/51B) not made.
Control Action:
电厂
床料输送系统运行说明书

二 OO 七年八月北京
审核：
校核：
编写：
目录
1. 绪论
2. D 泵输送系统
1. 绪论
其中定时器设定值，计数器设定值以及其它设定参数值为系统典型值。在实际调试过程中可以更改，
请在编写程序过程中考虑此点。
2.1. 概述
系统由运行人员启动。D 泵的入口圆顶阀打开，物料靠重力作用落进 D 泵。在物料填充的过程中排
气阀将打开使空气从泵内排出。当 D 泵中高料位计被覆盖，主输送空气阀将打开建立输送气流。经
过一个短延迟，使泵已完全充满，入口圆顶阀和排气圆顶阀关闭。
当入口及排气圆顶阀关闭并密封后，平衡阀及流化进气阀打开。经过一个短延时，使泵内压力与输
送管道压力一致，然后出口圆顶阀打开至设定的位置，物料进入输送管道中，由气流带动进入锅炉。
无论何时输送管道压力太高，出口圆顶阀将关闭，当管路压力回到正常压力时，出口圆顶阀重新打
开。
当输送压力降低显示泵内已经排空，经一个短延时使泵内物料彻底排净，然后关闭出口阀、平衡阀
和流化进气阀。当出口阀、平衡阀都关闭、密封后，排气阀打开释放泵内剩余压力。当泵内压力下
降到小于 0.3bar，循环结束。
主输送进气阀保持打开状态并维持一设定时间。如果下一循环在设定时间内没有开始，输送进气阀
将关闭。
系统继续按这种方式运行，直到操作员停止系统，或一个或多个启动联锁条件不满足。
正常循环时，系统压力将周期性的从 D 泵内排放至床料库中。因此保证缓冲斗内压力释放出去是非
常重要的。
2.2. 系统初始状态
当系统停止及处于待料状态时各阀门启闭情况见下：
控制空气关闭控制空气提供控制空气提供
电源关闭电源关闭电源提供
PLC 模式关闭 PLC 模式关闭 PLC 模式运行
入口圆顶阀原来位置* 关闭关闭
排气阀原来位置* 关闭开启
出口圆顶阀原来位置* 关闭关闭
平衡阀原来位置* 开启关闭
流化进气阀关闭关闭关闭
主输送空气阀关闭关闭关闭
D 泵应是空的并且处于零压力状态。
注意：圆顶阀采用充气密封方式。在控制空气压力不能满足要求时，圆顶阀将不能密封。
2.3. 浓相 D 泵运行顺序
当启动一次输送循环时，控制系统将检查下列循环启动联锁条件是否完全满足：
D 泵气控箱上的就地程控/停止开关置于“程控”位置；
CRT 屏幕上的启动/停止/吹扫开关置于“启动”或者“吹扫”位置；
其他联锁条件正确；
D 泵压力小于 0.03 Mpa；
入口圆顶阀关闭并且密封；
出口圆顶阀关闭并且密封；
平衡圆顶阀关闭并且密封；
管道压力小于 0.1MPa；
输送供气压力大于 0.55MPa；
当上述条件均为真值时，将触发输送循环并且按照以下步骤运行：
步骤 1
入口圆顶阀通过相应的电磁阀(EV01)得电开启。启动物料填充定时器（10m)、循环监视定时器
（20m）。物料将在重力作用下落入 D 泵中。
步骤 2
当泵中的高料位计已被覆盖，或者物料充填定时器已完成时，启动过量充填定时器（0.1s）。
同时，如果主输送进气阀没有打开，将通过相应电磁阀得电开启。
步骤 3
当过量充填定时器已到时，入口圆顶阀通过相应的电磁阀(EV01)失电关闭。
同时，排气圆顶阀通过相应的电磁阀(EV05)失电关闭，循环监视定时器将开启。
步骤 4
当入口(PS01)和排气圆顶阀(PS05)关闭且密封，平衡阀将通过相应电磁阀(EV04)失电开启，流化进
气阀将通过相应电磁阀(EV15)得电打开。出口圆顶阀开启延时定时器(10s)启动，使 D 泵泵内压力与
输送管道内压力平衡。
注：如果平衡阀在 3 秒钟内未能开启，流化进气阀将通过相应的电磁阀失电关闭直到平衡阀开启时
再打开。
步骤 6
当出口圆顶阀开启延时定时器到时，出口圆顶阀开启至设定位置。出口圆顶阀的开启控制将在后面
介绍。物料将从 D 泵进入输送管道然后随气流进入锅炉。
同时，最大排放定时器将启动。
如果管道压力高于 0.15MPa，出口圆顶阀将关闭。直到管道压力下降至低于 0.13MPa 后，出口圆顶

阀再重新开启。
D 泵的就地设有手动按钮，可手动操作使出口圆顶阀全开以清除大块物料。
步骤 7
当最大排放定时器到时，或输送压力下降至 0.06MPa，显示泵内已经排空，出口圆顶阀关闭延时定
时器（10s）启动。
步骤 8
当出口圆顶阀关闭延时定时器到时，出口圆顶阀关闭。
同时，平衡阀将通过相应的电磁阀得电关闭，流化进气阀将通过相应的电磁阀失电关闭。主输送进
气阀关闭延时定时器将开启。
注意：主输送进气阀将保持开启状态，如果主输送进气阀关闭延时定时器到时，下一次循环仍未开
始，主输送进气阀将通过相应的电磁阀关闭。
步骤 9
当出口圆顶阀和平衡阀关闭并密封，D 泵排气阀将通过相应的电磁阀得电开启。
步骤 10
当泵内压力降至低于 0.03MPa，循环复位定时器将启动。
步骤 11
当循环复位定时器已到时，则输送循环完成。管路切换延时定时器启动。
注意：如果在循环过程中，任何一个启动联锁条件变为非真值，则本次循环将允许继续进行直到完
成，然后系统将停止，直到所有的启动联锁条件重新变为真值。例如，系统启动时渣（灰）库的高
料位计是不被覆盖的，如果在循环过程中，此料位计被覆盖，这个条件将被忽略而不会使循环停止
或复位。这将通过 PLC 程序锁定循环启动指令来实现。
同样的，当发生一个故障，将允许循环执行到下一步骤，然后循环进程将被挂起，直到联锁条件恢
复为真值后，循环将继续执行下一步。下一步骤进程的信息将被锁定，因此在联锁条件变为非真值
时，循环不会停止或者倒退。循环结束，循环复位定时器定时期间，将释放这个锁存内容。
1. 出口圆顶阀控制
出口圆顶阀将控制物料下落至管道内的速度。在输送过程中，出口圆顶阀将打开至设定位置，用以
控制物料准确排放量。设定的位置将在调试期间确定。
D 泵就地设有设定按钮，允许操作员手动全开出口圆顶阀来清除存积在阀门上的大块物料和残片。
当按压下按钮，阀门全开并保持一设定时间（2 秒），然后全关一设定时间（2 秒），再打开至中间设
定位置。注：只有泵在输送灰时按下此按钮，阀门才全开。
当阀门关闭，密封电磁阀将失电密封，没有信号进入阀门开度控制器接口端。
2.3.1. 打开出口圆顶阀至设定位置
步骤 1
密封电磁阀将得电。
步骤 2
当密封泄气后，出口圆顶阀打开延时定时器将开启。
步骤 3
当出口圆顶阀开启延时定时器到时，出口圆顶阀将通过提供给阀门开度控制器接口端 A 信号而打开。
2.3.2. 从设定位置打开出口圆顶阀至全开位置
通过除去开度控制器接口端 A 信号，给信号到接口端 B 和 C 使阀门全开。
2.3.3. 关闭阀门
除去开度控制器接口信号并使密封电磁阀失电，关闭阀门。
2.4. 定时器定义和取值
定时器名称定时器设定定时器范围

物料充填延时定时器 30 秒 0 –120 秒
过量填充定时器 0.1 秒 0 – 60 秒
出口圆顶阀开延时定时器 3秒 0－60 秒
循环监视定时器 5 分钟 0－60 分钟
最大排放定时器 8 分钟 0－60 分钟
出口圆顶阀关闭延时定时器 10 秒 0－60 秒
圆顶阀故障定时器 5秒 0－20 秒
循环复位定时器 3秒 0 – 20 秒
主输送空气阀关闭延时定时器 30 秒 0 – 600 秒
2.5. 操作员控制与指示
1) 气控盘
每个 D 泵配有就地控制盘，盘内装有与 D 泵有关的电磁阀、压力开关，就地控制盘提供以下控制和
指示：
(1) 程控/就地开关。当 D 泵开始运行前，就地气控盘上的程控/就地开关应设定为程控。
(2) 出口圆顶阀打开手动旁路按钮。这个按钮允许操作员全开出口圆顶阀以便清除大块物料。
(3) 安装在 D 泵输送空气配气管路入口的压力表将指示输送管道的压力。安装在 D 泵上的压力表将

指示 D 泵的压力。
2）CRT 画面
D 泵由位于主电控盘的 PLC 控制。操作员界面包括以下控制、指示和报警信息：

(1) D 泵主启动/停止/吹扫开关。允许操作员启动或者停止 D 泵。
(2) 缓冲斗满指示。当缓冲斗高料位计覆盖时指示灯点亮。
(3) 入口圆顶阀开启/故障指示。这个灯将在入口圆顶阀开启电磁阀得电，同时圆顶阀密封压力
<0.5MPa 时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(4) 出口圆顶阀开启/故障指示。这个灯将在出口圆顶阀电磁阀得电，同时圆顶阀密封压力<0.5MPa
时点亮。这个灯将在发生出口圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(5) 平衡阀开启/故障指示。这个灯将在平衡阀关闭电磁阀失电，同时圆顶阀密封压力<0.5MPa 时
点亮。这个灯将在发生平衡阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(6) 排气圆顶阀开启/故障指示。这个灯将在排气圆顶阀开启电磁阀得电，同时圆顶阀密封压力
<0.5MPa 时点亮。这个灯将在发生排气圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(7) 泵内高料位计状态指示。当泵内高料位计被覆盖时点亮。
(8) 输送循环失败指示。这个灯指示一个输送循环失败。这个灯将在以下任何一种情况发生时点亮：
循环监视定时器已经完成，但是一次输送循环仍在进行中
泵内压力大于 0.03MPa 但没有输送循环在运行过程中
D 泵高料位计在循环结束时被覆盖。
(9) 渣(灰)库高高/高料位覆盖指示。当渣库高高/高料位开关被覆盖时灯点亮。
2.6. 报警条件一览
1) 入口圆顶阀未开启报警
定义：
入口圆顶阀开启电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。
控制方式：
只进行可视报警。
2) 入口圆顶阀未关闭和未密封报警
定义：
入口圆顶阀开启电磁阀失电时间超过 5 秒，但是密封压力仍然小于 0.5MPa。
控制方式：
可视报警并且输送循环的启动/进程被禁止。
3) 排气圆顶阀未开启报警
定义：
排气圆顶阀开启电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。
控制方式：
4) 排气圆顶阀未关闭和未密封报警
定义：
排气圆顶阀开启电磁阀失电时间超过 5 秒，但是密封压力仍然小于 0.5MPa。
控制方式：
5) 出口圆顶阀未开启报警
定义：
密封泄气电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。
控制方式：
6) 出口圆顶阀未关闭和未密封报警
定义：
没有信号应用到出口圆顶阀位置器且密封泄气电磁阀失电时间超过 5 秒同时密封压力<0.5MPa。
控制方式：
可视报警并且输送循环进程被禁止。
7) 平衡阀未开启报警
定义：
平衡阀关闭电磁阀失电时间超过 5 秒，但密封压力仍然>0.5Mpa。
控制方式：
可视报警并且循环进程被禁止。
8) 平衡阀未关闭和未密封报警
定义：
平衡阀关闭电磁阀得电时间超过 5 秒，但密封压力仍然小于 0.5Mpa。
控制方式：
9) 输送循环失败报警
定义：循环监视定时器已经完成，但是一次输送循环仍在进行中。或者：泵内压力>0.03MPa 并且
没有输送循环在运行过程中。或者：泵内高料位计在循环结束时被覆盖。
控制方式：
可视报警并且如果大于 0.03MPa 时输送循环启动被禁止
10) 缓冲斗料满报警
定义：缓冲斗高料位计（LSH01）被覆盖超过 2 分钟。
控制方式：可视报警。
POWER PLANT
BED ASH HANDLING SYSTEM
August 2007
CONTENTS
6. INTRODUCTION
7. D-PUMP OPERATION
INTRODUCTION
CRT.
D-PUMP OPERATION
OVERVIEW
The system will be started by the operators. The inlet Dome Valve of the D-Pump will be opened.
Material will be discharged into the D-Pump vessel. When the vessel high level switch has been
covered the main conveying air valve will be opened. After a short delay the inlet Dome Valve
and vent valve will be closed. When the inlet Dome Valve and vent valve have both closed and
sealed the balance valve will be opened and air will enter the vessel to pressurise the vessel to the
same pressure as that in the conveying pipeline. The outlet Dome Valve will then be opened to a
set position and bed ash will be discharged into the conveying pipeline and will be entrained in
the conveying airflow. The material will be pneumatically conveyed to the boiler.
When the pressure in the conveying pipeline has fallen to < 0.06MPa (PT02), the outlet Dome
Valve, balance valve and fluidising air valve will be closed. When the outlet Dome Valve and
balance valve are both closed and sealed the vent valve will be opened to release the pressure
from the D-Pump vessel. When the vessel pressure is less than 0.03MPa (PS02) the cycle is
complete. After a timed delay to allow the conveying pipe to be cleared of material the main
conveying air valve will be closed.
The system will continue to operate in this way until the system is stopped by the operators, or
until one or more of the cycle start interlock conditions become unhealthy.
As part of the operation of the D-pump pressure is periodically vented from the vessel. The vent
will be routed back into the bed ash silo.
SYSTEM AT REST

Inlet Dome Valve last position* closed closed
PV01
Balance valve PV02 last position* closed closed
Outlet Dome Valve last position* closed closed

PV03
Fluidising air valve closed closed closed

PV04
Vessel vent valve last position* open open

PV05

valve PV12
The D-Pumps should be empty and at zero pressure.
D-PUMP OPERATING SEQUENCE
The start/stop switch on the main electrical control panel is set to “START”.
Vessel pressure has been < 0.03MPa (PS02) for 5 seconds.
Inlet Dome Valve is closed and sealed (PS01).
Outlet Dome Valve is closed and sealed (PS03).
Balance Dome Valve is closed and sealed (PS04).
Conveying pressure < 0.1Mpa (PS06)
Conveying air supply pressure is > 0. 55MPa (client signal).
follows:
The inlet Dome Valve on the D-pump will be opened by energising solenoid (EV01). The
short fill timer (10 minutes) and cycle watchdog timer (20 minutes), will be started.
Material will fall under gravity into the D-pump.
When the vessel high level switch (LS02) has been covered, or when the short fill timer has
expired, the main conveying air valve (PV02) will be opened by energising the
solenoid (EV02). The overfill timer (0.1 second) will be started.
When the overfill timer has expired the inlet Dome Valve and vent valve will be closed by
de-energising solenoid (EV01、EV05), respectively.
When the inlet Dome Valve (PS01) and vent valve (PS05) have both closed and sealed the
balance valve will be opened by energising the solenoid (EV04), the fluidising air
valve (PV15) will be opened by energising the solenoids (EV15), and the outlet
Dome Valve open delay timer (10 seconds) will be started.
When the outlet Dome Valve open delay timer has expired, and providing the balance valve is
open (PS04), the outlet Dome Valve will be opened to the set position. The control of
the outlet Dome Valve is detailed in a later section. Bed ash will be discharged from
the D-pump into the conveying pipe and will be entrained in the airflow. It will be
conveyed to the boiler.
Simultaneously, the maximum discharge timer (8 minutes) will be started.
Note:
If the conveying pressure should rise above 0.15MPa (PT02) the outlet Dome Valve will be
closed to stop the flow of further material into the pipeline until the pressure has fallen below
0.13MPa.
A push-button will be provided local to the D-pump to enable the operators to fully open the
outlet Dome Valve manually to clear any over-sized material should the need arise.
When the conveying pressure has fallen to < 0.06MPa (PT02), or the maximum discharge
timer has expired, the outlet Dome Valve close delay timer (10 seconds) will be
started.
When the outlet Dome Valve close delay timer has expired the outlet Dome Valve will be
closed.
Simultaneously, the balance valve and fluidising air valve (PV15) will be closed by de-energising
the solenoids (EV04) and (EV15), respectively. The main conveying air valve close delay timer
(2 minutes) will be started.
Note:
If the main conveying air valve close delay timer expires before the main conveying air valve
(PV02) is opened for a subsequent cycle then the main conveying air valve will be closed by
de-energising the solenoid (EV12).
When the outlet Dome Valve (PS03) and balance valve (PS04) have both closed and sealed
the vessel vent valve will be opened by de-energising the solenoid (EV05).
When the pressure within the vessel has fallen to less than 0.03MPa (PS02) the cycle is
complete.
This cycle of operation will be repeated until one, or more of the start interlock conditions
becomes false.
OUTLET DOME VALVE CONTROL
The outlet Dome Valve will be used to control the discharge of bed ash into the conveying
pipeline. During conveying the outlet Dome Valve will be opened to a set position which will
allow the ash to discharge at the correct rate. The set position will be established during
commissioning.
A push-button mounted local to the D-pump will allow the operators to fully open the outlet
Dome Valve manual to clear any oversized material or debris that collects above the valve. When
the push-button is pressed the valve will fully open. When the push-button is released the outlet
Valve will return to the set position.
The position of the outlet Dome Valve is controlled by two solenoid valves (EV03A) and
(EV03B). When both solenoid valves are de-energised the outlet Dome Valve will fully close.
When both solenoid valves are energised the outlet Dome Valve will open. When solenoid valve
(EV03A) is energised, and (EV03B) is de-energised the valve will stay in its current position.
To determine the valve position a limit switch will be provided. When the outlet Dome Valve is
open less than the set position the switch contacts will be closed. When the outlet Dome Valve is
at the set position, or is open further than the set position, the switch contacts will be open.
To open the outlet Dome Valve to the set position, energise solenoid valve (EV03A) and
(EV03B). When the position switch signals that the valve is in the correct position the valve will
be held in its current position by de-energising solenoid (EV03B).
If the manual override push-button is pressed the outlet Dome Valve will be fully opened by
energising both solenoid valves (EV03A) and (EV03B). When the push-button is released the
outlet Dome Valve will be closed by de-energising both solenoid valves (EV03A) and (EV03B).
When the position indicates that the set position has been reached the outlet Dome Valve will be
held in its current position by energising solenoid valve (EV03A). The manual override
push-button will have no effect if the outlet Dome Valve is closed when the button is pressed.
To closed the outlet valve both solenoid valves (EV03A) and (EV03B) will be de-energised.
Short fill timer The short fill timer allows the conveying 10 minutes 0 - 60 minutes
cycle to continue after a delay even if the
D-pump vessel high level switch is not
covered.
Overfill timer The filling time is extended by the overfill 0.1 seconds 0 - 20 seconds
timer to ensure that the vessel has
completely filled.
Outlet Dome Valve This timer allows the conveying airflow to 10 seconds 0 - 60 seconds
open delay timer become established before the outlet Dome
Valve is opened and material is discharged
into the conveying pipe. It also allows time
for the pressure in the vessel to equalise
with that in the conveying pipe.
Cycle watchdog The cycle watchdog timer provides a 15 minutes 0 - 60 minutes
timer conveying cycle fault alarm if the
conveying cycle is not completed within the
pre-set time period.
Maximum This timer allows the cycle to continue after 8 minutes 0 - 60 minutes
discharge timer a timed delay even if the vessel low level
switch (LS03) is not uncovered.
Outlet Dome Valve This provides a timed delay after the vessel 10 seconds 0 - 60 seconds
closed delay timer low level switch has uncovered for the
vessel to completely empty before the outlet
Dome Valve is closed.
Dome Valve fault This allows a delay for the Dome Valve to 5 seconds 0 - 20 seconds
timer open/closed before initiating a Dome Valve
fault alarm.
A pneumatic control panel is provided at each of the D-pump which house the solenoid valves and
pressure switches associated with that vessel. The pneumatic control panel also provides the following
local controls and indications:
Outlet Dome Valve open manual override push-button. This push-button allows the operators to
fully open the outlet Dome Valve so that oversized material can be cleared if the need arises.
Remote/Local switch. For the D-pump to run both this switch must be set to “Remote” and the
start/stop switch on the main electrical panel must be set to “start”.
Vessel pressure gauge. This provides an indication of the pressure in the D-pump vessel.
The D-pump will be controlled by a PLC located in the main electrical control panel. The operator
interface is by means of a mimic diagram and includes the following operator controls, indications and
alarms.
D-pump main start/stop switch. This will permit the operators to start and stop the D-pump.
Inlet Dome Valve open/fault indication lamp. The lamp will be “on” when the inlet Dome Valve
open solenoid (EV01) is energised and the seal pressure is < 0.5MPa (PS01). The lamp will
flash in the event of the inlet Dome Valve failing to open or failing to close and seal. See
Outlet Dome Valve open/fault indication lamp. The lamp will be “on” when the outlet Dome
Valve is open. The lamp will flash in the event of the outlet Dome Valve failing to open or
Balance valve open/fault indication lamp. The lamp will be “on” when the balance valve open
solenoid (EV04) is energised and the seal pressure is < 0.5MPa (PS04). The lamp will flash in
the event of the balance valve failing to open or failing to close and seal. See summary of alarm
conditions.
Vent valve open/fault indication lamp. The lamp will be “on” when the vent valve close
solenoid (EV05) is de-energised and the seal pressure is < 0.5MPa (PS05). The lamp will flash
in the event of the vent valve failing to open or failing to close and seal. See summary of alarm
conditions.
Main conveying air valve open indication lamp. The lamp will be “on” when the main
conveying air valve open solenoid (EV12) is energised.
Fluidising air valve open indication lamp. The lamp will be “on” when the fluidising air valve
open solenoid (EV02) is energised.
Vessel high level switch status indication lamp. The lamp will be on when the vessel high level
switch (LS02) is covered.
Vessel low level switch status indication lamp. The lamp will be on when the vessel low level
switch (LS03) is covered.
Conveying cycle fault lamp. This is a lamp to indicate that there is a conveying cycle fault. The
lamp will be illuminated when any of the following occur:
Short fill timer expired and vessel high level switch (LS02) uncovered.
Maximum discharge timer expired and vessel low level switch (LS03) covered.
The conveying pressure exceeds 0.1MPa (PS06).
The indications and controls associated with the reception silos are described in the section on
conveying route control.
Definition:
0.5MPa (PS01).
Control Action:
Visual alarm only.
Definition:
< 0.5MPa (PS01).
Control Action:
OUTLET DOME VALVE NOT OPEN ALARM
Definition:
Outlet Dome Valve open solenoid (EV03B) energised for more than 5 seconds and seal
Control Action:
Visual alarm only.
OUTLET DOME VALVE NOT CLOSED AND SEALED ALARM
Definition:
Outlet Dome Valve open solenoid (EV03B) de-energised for more than 5 seconds and seal
Control Action:
Visual alarm and cycle progress inhibited.
BALANCE VALVE NOT OPEN ALARM
Definition:
Balance valve open solenoid (EV04) energised for more than 5 seconds and seal pressure >
0.5MPa (PS04).
Control Action:
BALANCE VALVE NOT CLOSED AND SEALED ALARM
Definition:
Balance valve open solenoid (EV04) de-energised for more than 5 seconds and seal pressure <
0.5MPa (PS04).
Control Action:
VENT VALVE NOT OPEN ALARM
Definition:
Vent valve close solenoid (EV05) de-energised for more than 5 seconds and seal pressure >
0.5MPa (PS05).
Control Action:
Visual alarm only.
VENT VALVE NOT CLOSED AND SEALED ALARM
Definition:
Vent valve close solenoid (EV05) energised for more than 5 seconds and seal pressure < 0.5MPa
(PS05).
Control Action:
Visual alarm and conveying cycle progress inhibited.
Definition:
or:
or:
or:
The conveying pressure is > 0.1MPa (PS06)
Control Action:
Watchdog timer expired: Visual alarm only.
High level switch not covered: Visual alarm only.
Low level switch covered: Visual alarm only.
Conveying pressure > 0.1MPa: Visual alarm and outlet Dome Valve closed.
电厂
石灰石粉输送系统运行说明书

二 OO 七年八月北京
审核：
校核：
编写：
目录
3. 绪论
5. ROTOFEED 石灰石给料系统
3. 绪论
其中定时器设定值，计数器设定值以及其它设定参数值为系统典型值。在实际调试过程中可以更改，
请在编写程序过程中考虑此点。
4.1. 概述
系统由运行人员启动。D 泵的入口圆顶阀打开，物料靠重力作用落进 D 泵。在物料填充的过程中排
气阀将打开使空气从泵内排出。当 D 泵中高料位计被覆盖，主输送空气阀将打开建立输送气流。经
过一个短延迟，使泵已完全充满，入口圆顶阀和排气圆顶阀关闭。
当入口及排气圆顶阀关闭并密封后，平衡阀及流化进气阀打开。经过一个短延时，使泵内压力与输
送管道压力一致，然后出口圆顶阀打开至设定的位置，物料进入输送管道中，由气流带动进入石灰
石粉库。
无论何时输送管道压力太高，出口圆顶阀将关闭，当管路压力回到正常压力时，出口圆顶阀重新打
开。
当输送压力降低显示泵内已经排空，经一个短延时使泵内物料彻底排净，然后关闭出口阀、平衡阀
和流化进气阀。当出口阀、平衡阀都关闭、密封后，排气阀打开释放泵内剩余压力。当泵内压力下
降到小于 0.3bar，循环结束。
主输送进气阀保持打开状态并维持一设定时间。如果下一循环在设定时间内没有开始，输送进气阀
将关闭。
系统继续按这种方式运行，直到操作员停止系统，或一个或多个启动联锁条件不满足。
正常循环时，系统压力将周期性的从 D 泵内排放至石灰石粉库中。因此保证缓冲斗内压力释放出去
是非常重要的。
入口圆顶阀原来位置* 关闭关闭
排气阀原来位置* 关闭开启
出口圆顶阀原来位置* 关闭关闭
平衡阀原来位置* 开启关闭
流化进气阀关闭关闭关闭
主输送空气阀关闭关闭关闭
4.3. 浓相 D 泵运行顺序
当启动一次输送循环时，控制系统将检查下列循环启动联锁条件是否完全满足：
D 泵气控箱上的就地程控/停止开关置于“程控”位置；
CRT 屏幕上的启动/停止/吹扫开关置于“启动”或者“吹扫”位置；
其他联锁条件正确；
D 泵压力小于 0.03 Mpa；
入口圆顶阀关闭并且密封；
出口圆顶阀关闭并且密封；
平衡圆顶阀关闭并且密封；
管道压力小于 0.1MPa；
输送供气压力大于 0.55MPa；
当上述条件均为真值时，将触发输送循环并且按照以下步骤运行：
步骤 1
入口圆顶阀通过相应的电磁阀(EV01)得电开启。启动物料填充定时器（10m)、循环监视定时器（20m）。
物料将在重力作用下落入 D 泵中。
步骤 2
当泵中的高料位计已被覆盖，或者物料充填定时器已完成时，启动过量充填定时器（0.1s）。
同时，如果主输送进气阀没有打开，将通过相应电磁阀得电开启。
步骤 3
当过量充填定时器已到时，入口圆顶阀通过相应的电磁阀(EV01)失电关闭。
同时，排气圆顶阀通过相应的电磁阀(EV05)失电关闭，循环监视定时器将开启。
步骤 4
当入口(PS01)和排气圆顶阀(PS05)关闭且密封，平衡阀将通过相应电磁阀(EV04)失电开启，流化进气
阀将通过相应电磁阀(EV15)得电打开。出口圆顶阀开启延时定时器(10s)启动，使 D 泵泵内压力与输
送管道内压力平衡。
注：如果平衡阀在 3 秒钟内未能开启，流化进气阀将通过相应的电磁阀失电关闭直到平衡阀开启时
再打开。
步骤 6
当出口圆顶阀开启延时定时器到时，出口圆顶阀开启至设定位置。出口圆顶阀的开启控制将在后面
介绍。物料将从 D 泵进入输送管道然后随气流进入石灰石粉库。
同时，最大排放定时器将启动。
如果管道压力高于 0.15MPa，出口圆顶阀将关闭。直到管道压力下降至低于 0.13MPa 后，出口圆顶

阀再重新开启。
D 泵的就地设有手动按钮，可手动操作使出口圆顶阀全开以清除大块物料。
步骤 7
当最大排放定时器到时，或输送压力下降至 0.06MPa，显示泵内已经排空，出口圆顶阀关闭延时定
时器（10s）启动。
步骤 8
当出口圆顶阀关闭延时定时器到时，出口圆顶阀关闭。
同时，平衡阀将通过相应的电磁阀得电关闭，流化进气阀将通过相应的电磁阀失电关闭。主输送进
气阀关闭延时定时器将开启。
注意：主输送进气阀将保持开启状态，如果主输送进气阀关闭延时定时器到时，下一次循环仍未开
始，主输送进气阀将通过相应的电磁阀关闭。
步骤 9
当出口圆顶阀和平衡阀关闭并密封，D 泵排气阀将通过相应的电磁阀得电开启。
步骤 10
当泵内压力降至低于 0.03MPa，循环复位定时器将启动。
步骤 11
当循环复位定时器已到时，则输送循环完成。管路切换延时定时器启动。
注意：如果在循环过程中，任何一个启动联锁条件变为非真值，则本次循环将允许继续进行直到完
成，然后系统将停止，直到所有的启动联锁条件重新变为真值。例如，系统启动时渣（灰）库的高
料位计是不被覆盖的，如果在循环过程中，此料位计被覆盖，这个条件将被忽略而不会使循环停止
或复位。这将通过 PLC 程序锁定循环启动指令来实现。
同样的，当发生一个故障，将允许循环执行到下一步骤，然后循环进程将被挂起，直到联锁条件恢
复为真值后，循环将继续执行下一步。下一步骤进程的信息将被锁定，因此在联锁条件变为非真值
时，循环不会停止或者倒退。循环结束，循环复位定时器定时期间，将释放这个锁存内容。
A. 出口圆顶阀控制
出口圆顶阀将控制物料下落至管道内的速度。在输送过程中，出口圆顶阀将打开至设定位置，用以
控制物料准确排放量。设定的位置将在调试期间确定。
D 泵就地设有设定按钮，允许操作员手动全开出口圆顶阀来清除存积在阀门上的大块物料和残片。
当按压下按钮，阀门全开并保持一设定时间（2 秒），然后全关一设定时间（2 秒），再打开至中间设
定位置。注：只有泵在输送灰时按下此按钮，阀门才全开。
当阀门关闭，密封电磁阀将失电密封，没有信号进入阀门开度控制器接口端。
4.3.1. 打开出口圆顶阀至设定位置
步骤 1
密封电磁阀将得电。
步骤 2
当密封泄气后，出口圆顶阀打开延时定时器将开启。
步骤 3
当出口圆顶阀开启延时定时器到时，
出口圆顶阀将通过提供给阀门开度控制器接口端 A 信号而打开。
4.3.2. 从设定位置打开出口圆顶阀至全开位置
通过除去开度控制器接口端 A 信号，给信号到接口端 B 和 C 使阀门全开。
4.3.3. 关闭阀门
除去开度控制器接口信号并使密封电磁阀失电，关闭阀门。
4.4. 定时器定义和取值
定时器名称定时器设定定时器范围

物料充填延时定时器 30 秒 0 –120 秒
过量填充定时器 0.1 秒 0 – 60 秒
出口圆顶阀开延时定时器 3秒 0－60 秒
循环监视定时器 5 分钟 0－60 分钟
最大排放定时器 8 分钟 0－60 分钟
出口圆顶阀关闭延时定时器 10 秒 0－60 秒
圆顶阀故障定时器 5秒 0－20 秒
循环复位定时器 3秒 0 – 20 秒
主输送空气阀关闭延时定时器 30 秒 0 – 600 秒
4.5. 操作员控制与指示
1) 气控盘
每个 D 泵配有就地控制盘，盘内装有与 D 泵有关的电磁阀、压力开关，就地控制盘提供以下控制和
指示：
(1) 程控/就地开关。当 D 泵开始运行前，就地气控盘上的程控/就地开关应设定为程控。
(2) 出口圆顶阀打开手动旁路按钮。这个按钮允许操作员全开出口圆顶阀以便清除大块物料。
(3) 安装在 D 泵输送空气配气管路入口的压力表将指示输送管道的压力。安装在 D 泵上的压力表将

指示 D 泵的压力。
2）CRT 画面
D 泵由位于主电控盘的 PLC 控制。操作员界面包括以下控制、指示和报警信息：

(1) D 泵主启动/停止/吹扫开关。允许操作员启动或者停止 D 泵。
(2) 缓冲斗满指示。当缓冲斗高料位计覆盖时指示灯点亮。
(3) 入口圆顶阀开启/故障指示。这个灯将在入口圆顶阀开启电磁阀得电，同时圆顶阀密封压力
<0.5MPa 时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(4) 出口圆顶阀开启/故障指示。这个灯将在出口圆顶阀电磁阀得电，同时圆顶阀密封压力<0.5MPa
时点亮。这个灯将在发生出口圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(5) 平衡阀开启/故障指示。这个灯将在平衡阀关闭电磁阀失电，同时圆顶阀密封压力<0.5MPa 时点
亮。这个灯将在发生平衡阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(6) 排气圆顶阀开启/故障指示。这个灯将在排气圆顶阀开启电磁阀得电，同时圆顶阀密封压力
<0.5MPa 时点亮。这个灯将在发生排气圆顶阀开启或关闭密封失败故障时闪烁。见报警条件一览。
(7) 泵内高料位计状态指示。当泵内高料位计被覆盖时点亮。
(8) 输送循环失败指示。这个灯指示一个输送循环失败。这个灯将在以下任何一种情况发生时点亮：
循环监视定时器已经完成，但是一次输送循环仍在进行中
泵内压力大于 0.03MPa 但没有输送循环在运行过程中
或
D 泵高料位计在循环结束时被覆盖。
(9) 渣(灰)库高高/高料位覆盖指示。当渣库高高/高料位开关被覆盖时灯点亮。
1) 入口圆顶阀未开启报警
定义：
入口圆顶阀开启电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。
控制方式：
2) 入口圆顶阀未关闭和未密封报警
定义：
入口圆顶阀开启电磁阀失电时间超过 5 秒，但是密封压力仍然小于 0.5MPa。
控制方式：
3) 排气圆顶阀未开启报警
定义：
排气圆顶阀开启电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。
控制方式：
4) 排气圆顶阀未关闭和未密封报警
定义：
排气圆顶阀开启电磁阀失电时间超过 5 秒，但是密封压力仍然小于 0.5MPa。
控制方式：
5) 出口圆顶阀未开启报警
定义：
密封泄气电磁阀得电时间超过 5 秒，但是密封压力仍然大于 0.5Mpa。

控制方式：
6) 出口圆顶阀未关闭和未密封报警
定义：
没有信号应用到出口圆顶阀位置器且密封泄气电磁阀失电时间超过 5 秒同时密封压力<0.5MPa。
控制方式：
可视报警并且输送循环进程被禁止。
7) 平衡阀未开启报警
定义：
平衡阀关闭电磁阀失电时间超过 5 秒，但密封压力仍然>0.5Mpa。
控制方式：
可视报警并且循环进程被禁止。
8) 平衡阀未关闭和未密封报警
定义：
平衡阀关闭电磁阀得电时间超过 5 秒，但密封压力仍然小于 0.5Mpa。
控制方式：
9) 输送循环失败报警
定义：循环监视定时器已经完成，但是一次输送循环仍在进行中。或者：泵内压力>0.03MPa 并且没
有输送循环在运行过程中。或者：泵内高料位计在循环结束时被覆盖。
控制方式：
可视报警并且如果大于 0.03MPa 时输送循环启动被禁止
10) 缓冲斗料满报警
定义：缓冲斗高料位计（LSH01）被覆盖超过 2 分钟。
控制方式：可视报警。
5. ROTOFEED 石灰石给料系统
5.1. 概述
在锅炉正常运行过程中，ROTOFEED 系统用来将石灰石灰斗中的物料通过管线输送至锅炉附近，然后
再分为 4 路进入锅炉内部。
ROTOFEED 系统由两个压力仓泵，给料器组件和压缩空气主进气组件组成。给料器通过一台标准的感
应电动机带动的变速箱而驱动。由变频器为供电，控制 ROTOFEED 给料器的旋转速度，控制给料器的
给料量。通过测量 ROTOFEED 给料器的转速来计算系统输送的物料量。在给料器转子安装有热电耦，
在过载的情况下，转子温度超过正常值，系统会给出提示，通过变频电机保护系统，会停止给料器
工作。
ROTOFEED 泵体采取垂直布置方式，收料泵位于给料泵上方。泵的入口由带密封圈的入口圆顶阀控制
落料。给料泵为给料器提供持续稳定的物料量。在给料过程中，给料泵内加压保持一定的压力。收
料泵通过和给料泵以及石灰石灰斗中的交替压力平衡，从而实现为给料泵周期性的补充物料的功能。
通过这种方式，可以实现持续稳定的给料过程。
其它时间，圆顶阀关闭，收料泵为空的状态。当给料泵内低料位计未覆盖而触发时，给料过程按照
如下方式开始。
排气圆顶阀开启，收料泵内余压气体由此排出。收料泵内压力开关监测泵内压力。余压排放完毕，
收料泵入口圆顶阀打开，物料依靠重力由石灰石灰斗落入收料泵内。在收料泵收料过程中，收料泵
进气角阀打开进气，压缩空气进入收料泵底部，保证下落物料不堆积板结。
当收料泵高料位触发显示泵内已满，收料泵入口圆顶阀关闭，排气圆顶阀关闭。收料泵内进气压力
开始上升，当压差开关显示收料泵内压力等于给料泵内压力时，收料泵进气角阀关闭。
随即落料泵入口圆顶阀打开，物料依靠重力从收料泵落入给料泵。为了更好的落料，此时开启收料
泵底部进气角阀，同时，平衡圆顶阀打开，给料泵上部空气通过平衡阀返回收料泵。经过一段预先
设定的时间之后，视物料由收料泵落入给料泵的过程结束，收料泵的进气角阀，给料泵的入口圆顶
阀和平衡圆顶阀关闭。
当圆顶阀关闭并密封，落料过程完成，当给料泵低料位计重新触发后进行下一个循环。
输送空气随着物料一起进入锅炉，且随着其它气体排出。灰斗必须设置排气口或者布袋除尘器，已
保证其中气体安全排放。
控制系统监控预先设定好的落料时间，如果超出设定值，则报警。同时系统会监控输送压力，超出
正常值，系统报警。
收料泵入口圆顶阀最终位置* 关闭关闭
排气圆顶阀最终位置* 关闭关闭
给料泵入口圆顶阀最终位置* 关闭关闭
平衡圆顶阀最终位置* 关闭关闭
主输送空气阀 (PV11) 开启开启开启
收料泵气控角阀 (PV13) 关闭关闭关闭
5.3. ROTOFEED 泵落料循环

当启动一次落料循环时，控制系统将检查下列循环启动联锁条件是否完全满足：
紧急停止按钮未按下*
其它外部联锁条件正确*
收料泵入口圆顶阀关闭且密封（参见报警条件）*
落料泵入口圆顶阀关闭且密封（参见报警条件）*
排气圆顶阀关闭且密封（参见报警条件）*
平衡圆顶阀关闭且密封警（参见报警条件）*
输送压力未超高报警（参见报警条件）*
输送压力传感器（PT25）未异常报警（参见报警条件）*
变频电机工作正常，给料器转子未过载
以上条件为真值时且
控制台（HS02A）落料循环按钮“启动”按下,落料循环可以启动
如果落料循环启动但上述条件中有条件不能满足或者控制台（HS02A）落料循环按钮“启动”
未按下，则落料循环不能启动
当 ROTOFEED 落料循环启动时，步骤如下：
5.3.1. 给料泵低料位计（LSL25）触发，排气圆顶阀通过相应得电磁阀（EV05）得电开
启。同时，排气时间（10S）和落料循环时间定时器（140S）启动。收料泵内压
力开始下降。
5.3.2. 当收料泵内压力低于 0.2 barg（PS02）且排气时间到，收料泵入口圆顶阀通过

相应的电磁阀（EV01）得电开启，同时，收料泵进气气控角阀通过相应的电磁阀
（PV13）得电开启同时短填充定时器（30S）开启。物料由石灰石灰斗落入收料
泵。
5.3.3. 当收料泵高料位计触发，或者短填充定时器完成，收料泵入口圆顶阀和排气圆
顶阀通过相应的电磁阀（EV01）（EV05）失电关闭，收料泵内压力开始上升。
5.3.4. 当压差开关（DPS08）显示收料泵内压力等于给料泵内压力时，收料泵进气气控
角阀通过相应的电磁阀（EV13）失电关闭，给料泵入口圆顶阀通过相应的电磁阀
得电开启（EV27），同时，给料泵的入口圆顶阀的开启定时器启动（30S）。物
料从收料泵落入给料泵中。
5.3.5. 给料泵入口圆顶阀（PS27）打开，收料泵进气气控角阀和平衡圆顶阀通过相应
的电磁阀（EV13）（EV16）得电分别打开。
5.3.6. 当给料泵圆顶阀打开时间定时器到，收料泵进气气控角阀，给料泵入口圆顶阀
和平衡圆顶阀通过相应的电磁阀（EV13）（EV27）（EV16）失电分别关闭。
5.3.7. 当给料泵入口圆顶阀和平衡圆顶阀分别关闭且密封（PS27）（PS16），启动循
环复位定时器（3S）。
5.3.8. 当循环复位定时器已完成，则落料循环完成。
注意：
如果装料循环过程中，任何一个标记为“*”的启动联锁条件变为非真值，则装料循环过程立即停止，
阀门回复到初始状态（参见 2）。
如果装料循环过程中，未标记为“*”的联锁条件变为非真值或者此时输入“结束”命令，则本次循
环将允许继续进行直到结束，然后阀门回复到初始状态（参见 2）。
在装料循环过程中，当发生一个故障，将允许循环执行到下一步骤，然后循环进程将被挂起，直到
联锁条件恢复为真值后，循环将继续执行下一步。下一步骤循环进程的循环信息将被锁定，因此在
联锁条件变为非真值时，循环不会停止或者倒退。闭锁在循环末的循环复位定时器运行过程中解除。
5.4. 给料过程
5.4.1. 给料器启动
当启动给料过程时，控制系统将检查下列循环启动联锁条件是否完全满足：
紧急停止按钮未按下
其它外部联锁条件正确
收料泵入口圆顶阀关闭且密封（参见报警条件）
落料泵入口圆顶阀关闭且密封（参见报警条件）
排气圆顶阀关闭且密封（参见报警条件）
平衡圆顶阀关闭且密封（参见报警条件）
输送压力未超高报警（参见报警条件）
输送压力传感器（PT25）未异常报警（参见报警条件）
变频电机工作正常，未过载
给料泵落料故障报警未出现
以上条件满足，给料过程可以正常工作。
如果给料起始条件满足，而且主控台给料“开始”按钮按下（HS17A）
，给料器通过相应的变频电机
得电驱动而开始工作。
给料器旋转工作过程中，石灰石会被拨动而落入输送空气气流，一起输送进入锅炉。
如果给料器运行过程中，以上联锁条件中有不满足或者在主控制台（HS17B）按下“停止”按钮，给
料器通过相应的变频电机失电而停止工作。
注意：当给料器因为以上某个条件不满足而停止工作后，即使条件再次全部满足，给料器仍然不会
开始工作，直到重新按下主控制台上（HS17A）
“开始”按钮。
5.4.2. 系统出力的控制
当给料系统运行过程中，系统出力可以就地或者远程控制调整。PLC 利用系统出力设置值（M）来计
算所需给料器速度（N）
，由此，控制系统按照以下方式计算出电机频率（HZ）：
1.1.1.1 给料器旋转速度计算（转数/每分钟，范围为 4.08RPM～21.5RPM）
1.1.1.2 给料器转子转动频率计算（HZ，变动范围为 14HZ~73HZ）
1.1.1.3 实际出力（吨/小时，变动范围 6.49~29 吨/小时）
5.5. 输送空气阀
利用压缩空气可以将石灰石物料输送进入锅炉。主进气通过 ROTOFEED 主进气管路组件上气控角阀
（PV11）控制。
系统运行过程中，主输送压力会随着系统出力进行变化。如果系统发生堵管，则主输送压力（PT25）
将会升高到一个非正常值，产生一个输送压力超高报警。
输送空气阀按照以下步骤工作：
5.5.1. 步骤 1
当给料泵压力大于 1.5barg（PT25），输送压力超高报警，则输送空气阀关闭延时启动（10S）。
5.5.2. 步骤 2
当输送空气阀关闭延时时间到，且输送空气压力仍然大于 1.5barg（PT25），则输送空气阀通过相应
的电磁阀得电关闭（EV11）。
5.5.3. 步骤 3
当给料泵压力小于 1.5barg（PT25），则输送空气阀开启延时启动（10S）。
5.5.4. 步骤 4
当输送空气阀开启延时时间到，且输送空气压力仍然小于 1.5barg（PT25），则输送空气阀通过相应
的电磁阀失电关闭（EV11）。
5.6. 定时器定义及取值
定时器名称定时器目的定时器设定定时范围

10 秒 0 –60 秒
排气定时器保证足够的时间使收料泵泄压
140 秒 0 – 600 秒
循环监视定时器如果输送循环在预设定的时间周期
内没有完成，则循环监视定时器提
供一个输送循环失败的报警信息
30 秒 0 – 60 秒
物料短填充定时器即使收料泵的低料位计（LS02）没
被覆盖，物料短填充定时器也允许
输送循环经过一个延迟后继续。
30 秒 0 – 120 秒
给料泵圆顶阀开启定当平衡圆顶阀打开时，保证收料泵
时器内物料可以完全的落入给料泵
3秒 0 – 20 秒
循环复位定时器循环复位定时器提供在另一个输送
循环启动前，泵和输送管道中的压
力完全释放的时间
10 秒 0 – 30 秒
输送空气阀延时关闭定时器留出一个延迟使得在给料器
定时器停止运行后继续将物料吹扫干净
10 秒 0 – 30 秒
输送空气阀延时开启定时器留出一个延迟使得在主输送
定时器空气重新被建立之前可以自然的下
降到正常值范围内
5秒 0 – 20 秒
圆顶阀故障定时器在发出故障报警之前，允许有一个
延时使圆顶阀开启/关闭。
5.7. 操作员控制及指示
1）气控盘
每个 ROTOFEED 泵都配有就地控制盘，盘内装有与本泵有关的电磁阀、压力开关，气控盘提供以下就
地控制和指示：
压力监测装置显示收料泵压力值；
压力监测装置显示给料泵压力值。
2）电控盘
ROTOFEED 的控制放置在别的系统控制柜内，主控界面可以是组态仿真界面，控制面板或者通过视频
键盘控制的方式，应该包括以下控制、指示和报警信息。
以下控制和显示信息对于 ROTOFEED 的控制和操作是必须的。如果为控制面板或者视频控制方式的人

机界面，以下相关项必须在控制界面上显示和列出。
落料允许按钮：该按钮允许 ROTOFEED 可以开始落料循环。落料循环条件满足时，如果给料泵低料位

计触发，则自动开始由收料泵为给料泵开始落料循环。
落料禁止按钮：该按钮允许操作人员停止落料循环，当该按钮按下时，当前循环继续完成后落料过
程停止。
落料可行指示灯：当落料过程条件满足，落料可行指示灯点亮；
落料过程进行指示灯：在落料过程中，落料过程进行指示灯点亮。
落料过程错误指示灯：当落料循环监视定时器设定时间到，但落料循环仍然在进行过程中或者给料
泵落料错误报警触发，则落料过程错误指示灯点亮，参见报警条件。
给料开始按钮：按下此按钮，且给料起始联锁条件满足时，变频电机相应的“停止/开始”按钮得电
启动，带动给料器转子。
给料停止按钮：按下此按钮，变频电机相应的“停止/开始”按钮失电停止，给料器转子停止。
给料过程错误指示灯：在因为电动机过载或者变频器出错而造成条件不满足时，给料过程停止，指
示灯点亮，参见报警条件。
系统出力设定点：单位为 T/H，吨/小时。
系统实际出力：通过控制系统的计算而显示实际的出力，单位为 T/H，吨/小时。
灰斗低料位计指示灯：灰斗低料位计（LSL01）触发时，该指示灯点亮。
主输送压力超高指示灯：当主输送压力（PT25）超高时，该指示灯点亮。
主输送压力传感器失效指示灯：主输送压力传感器失效时，该指示灯点亮，参见报警条件。
在 ROTOFEED 系统故障检修过程，需要以下参数和报警显示。
如果利用控制面板和视频系统，以下指示必须设置单独的控制页面显示。
收料泵高料位开关覆盖指示灯：当收料泵高料位开关被覆盖时该指示灯点亮。
收料泵入口圆顶阀开启/故障指示灯：这个灯将在收料泵入口圆顶阀开启电磁阀（EV01）得电，同时
入口圆顶阀密封压力小于 5.0 barg（PS01）时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失
败故障时闪烁。见报警条件一览。
排气圆顶阀开启/故障指示灯：这个灯将在排气圆顶阀开启电磁阀（EV05）得电，同时排气圆顶阀密
封压力小于 5.0 barg（PS01）时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失败故障时闪烁。
见报警条件一览。
给料泵入口圆顶阀开启/故障指示灯：这个灯将在给料泵入口圆顶阀开启电磁阀（EV27）得电，同时
入口圆顶阀密封压力小于 5.0 barg（PS01）时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失
败故障时闪烁。见报警条件一览。
平衡圆顶阀开启/故障指示灯：这个灯将在平衡圆顶阀开启电磁阀（EV16）得电，同时入口圆顶阀密
封压力小于 5.0 barg（PS01）时点亮。这个灯将在发生入口圆顶阀开启或关闭密封失败故障时闪烁。
见报警条件一览。
主输送空气阀打开指示灯：当主输送空气阀相应的电磁阀（EV02）失电时点亮。
给料泵低料位开关覆盖指示灯：当给料泵低料位计（LSL25）未被覆盖时该指示灯亮。
主输送压力显示：主输送压力在界面显示（barg）。
紧急停止按钮触发指示灯：当设备紧急停止按钮按下时，此指示灯点亮。
1）收料泵入口圆顶阀未开启报警
定义：
入口圆顶阀开启电磁阀（EV01）得电且密封圈压力大于 0.5MPa (PS01)时间超过 5 秒。
控制方式：
2）收料泵入口圆顶阀未关闭和未密封报警
定义：
入口圆顶阀开启电磁阀（EV01）失电且密封圈压力小于 0.5MPa (PS01)时间超过 5 秒。

控制方式：
可视报警并且输送循环的启动/进程被禁止，给料器停止。
3）排气圆顶阀未开启报警
定义：
排气圆顶阀开启电磁阀（EV05）得电且密封圈压力大于 0.5MPa (PS05)时间超过 5 秒。
控制方式：
4）排气圆顶阀未关闭和未密封报警
定义：
排气圆顶阀开启电磁阀（EV05）失电且密封圈压力小于 0.5MPa (PS05)时间超过 5 秒。
控制方式：
5）给料泵入口圆顶阀未开启报警
定义：
给料泵入口圆顶阀开启电磁阀（EV27）得电且密封圈压力大于 0.5MPa (PS27)时间超过 5 秒。
控制方式：
可视报警且进料循环过程被禁止。
6）给料泵入口圆顶阀未关闭和未密封报警
定义：
给料泵入口圆顶阀开启电磁阀（EV27）失电且密封圈压力小于 0.5MPa (PS27)时间超过 5 秒。
控制方式：
7）平衡圆顶阀未开启报警
定义：
平衡圆顶阀开启电磁阀（EV16）得电且密封圈压力大于 0.5MPa (PS16)时间超过 5 秒。
控制方式：
8）平衡圆顶阀未关闭和未密封报警
定义：
平衡圆顶阀开启电磁阀（EV16）失电且密封圈压力小于 0.5MPa (PS16)时间超过 5 秒。
控制方式：
9）输送空气压力过高报警
定义：
输送空气压力高于 0.15MPa（PS25）。
控制方式：
10）输送空气压力传感器故障报警
定义：
输送压力信号低于 3.5mA 或者高于 20.5mA（PT25）。
控制方式：
11）给料器故障失效报警
定义：
给料器转子超温导致继电器跳闸或者变频电机跳闸。
控制方式：
可视报警并且给料器停止，进料循环的启动进程被禁止。
12）给料泵进料故障报警
定义：
进料循环起始条件满足，给料泵高料位计未覆盖（LSL25）且给料器旋转超过 60 转。
注意：给料器旋转的转数通过给料器速度信号（UT17）计算得出。
控制方式：
可视报警并且给料器停止。
13）进料故障报警
定义：
进料循环监视时间到但是进料循环仍然在进行。
控制方式：
可视报警。
14）紧急停止按钮报警
定义：
客户紧急停止按钮被按下。
控制方式：
POWER PLANT
LIMESTONE HANDLING SYSTEM
August 2007
CONTENTS
8. INTRODUCTION
9. d-PUMP OPERATION
10. rootfeed LIMESTONE INJECTION SYSTEM

INTRODUCTION
CRT.
D-PUMP OPERATION
OVERVIEW
The system will be started by the operators. The inlet Dome Valve of the D-Pump will be opened.
Material will be discharged into the D-Pump vessel. When the vessel high level switch has been
covered the main conveying air valve will be opened. After a short delay the inlet Dome Valve
and vent valve will be closed. When the inlet Dome Valve and vent valve have both closed and
sealed the balance valve will be opened and air will enter the vessel to pressurise the vessel to the
same pressure as that in the conveying pipeline. The outlet Dome Valve will then be opened to a
set position and limestone will be discharged into the conveying pipeline and will be entrained in
the conveying airflow. The material will be pneumatically conveyed to the limestone silo.
When the pressure in the conveying pipeline has fallen to < 0.06MPa (PT02), the outlet Dome
Valve, balance valve and fluidising air valve will be closed. When the outlet Dome Valve and
balance valve are both closed and sealed the vent valve will be opened to release the pressure
from the D-Pump vessel. When the vessel pressure is less than 0.03MPa (PS02) the cycle is
complete. After a timed delay to allow the conveying pipe to be cleared of material the main
conveying air valve will be closed.
The system will continue to operate in this way until the system is stopped by the operators, or
until one or more of the cycle start interlock conditions become unhealthy.
As part of the operation of the D-pump pressure is periodically vented from the vessel. The vent
will be routed back into the limestone silo.
SYSTEM AT REST

Inlet Dome Valve last position* closed closed
PV01
Balance valve PV02 last position* closed closed
Outlet Dome Valve last position* closed closed

PV03
Fluidising air valve closed closed closed

PV04
Vessel vent valve last position* open open

PV05

valve PV12
The D-Pumps should be empty and at zero pressure.
D-PUMP OPERATING SEQUENCE
The start/stop switch on the main electrical control panel is set to “START”.
Vessel pressure has been < 0.03MPa (PS02) for 5 seconds.
Inlet Dome Valve is closed and sealed (PS01).
Outlet Dome Valve is closed and sealed (PS03).
Balance Dome Valve is closed and sealed (PS04).
Conveying pressure < 0.1Mpa (PS06)
follows:
The inlet Dome Valve on the D-pump will be opened by energising solenoid (EV01). The
short fill timer (10 minutes) and cycle watchdog timer (20 minutes), will be started.
Material will fall under gravity into the D-pump.
When the vessel high level switch (LS02) has been covered, or when the short fill timer has
expired, the main conveying air valve (PV02) will be opened by energising the
solenoid (EV02). The overfill timer (0.1 second) will be started.
When the overfill timer has expired the inlet Dome Valve and vent valve will be closed by
de-energising solenoid (EV01、EV05) respectively.
When the inlet Dome Valve (PS01) and vent valve (PS05) have both closed and sealed the
balance valve will be opened by energising the solenoid (EV04), the fluidising air
valve (PV15) will be opened by energising the solenoids (EV15), and the outlet
Dome Valve open delay timer (10 seconds) will be started.
When the outlet Dome Valve open delay timer has expired, and providing the balance valve is
open (PS04), the outlet Dome Valve will be opened to the set position. The control of
the outlet Dome Valve is detailed in a later section. limestone will be discharged
from the D-pump into the conveying pipe and will be entrained in the airflow. It will
be conveyed to the boiler.
Simultaneously, the maximum discharge timer (8 minutes) will be started.
Note:
If the conveying pressure should rise above 0.15MPa (PT02) the outlet Dome Valve will be
closed to stop the flow of further material into the pipeline until the pressure has fallen below
0.13MPa.
A push-button will be provided local to the D-pump to enable the operators to fully open the
outlet Dome Valve manually to clear any over-sized material should the need arise.
When the conveying pressure has fallen to < 0.06MPa (PT02), or the maximum discharge
timer has expired, the outlet Dome Valve close delay timer (10 seconds) will be
started.
When the outlet Dome Valve close delay timer has expired the outlet Dome Valve will be
closed.
Simultaneously, the balance valve and fluidising air valve (PV15) will be closed by de-energising
the solenoids (EV04) and (EV15), respectively. The main conveying air valve close delay timer
(2 minutes) will be started.
Note:
If the main conveying air valve close delay timer expires before the main conveying air valve
(PV02) is opened for a subsequent cycle then the main conveying air valve will be closed by
de-energising the solenoid (EV12).
When the outlet Dome Valve (PS03) and balance valve (PS04) have both closed and sealed
the vessel vent valve will be opened by de-energising the solenoid (EV05).
When the pressure within the vessel has fallen to less than 0.03MPa (PS02) the cycle is
complete.
This cycle of operation will be repeated until one, or more of the start interlock conditions
becomes false.
OUTLET DOME VALVE CONTROL
The outlet Dome Valve will be used to control the discharge of limestone into the conveying
pipeline. During conveying the outlet Dome Valve will be opened to a set position which will
allow the limestone to discharge at the correct rate. The set position will be established during
commissioning.
A push-button mounted local to the D-pump will allow the operators to fully open the outlet
Dome Valve manual to clear any oversized material or debris that collects above the valve. When
the push-button is pressed the valve will fully open. When the push-button is released the outlet
Valve will return to the set position.
The position of the outlet Dome Valve is controlled by two solenoid valves (EV03A) and
(EV03B). When both solenoid valves are de-energised the outlet Dome Valve will fully close.
When both solenoid valves are energised the outlet Dome Valve will open. When solenoid valve
(EV03A) is energised, and (EV03B) is de-energised the valve will stay in its current position.
To determine the valve position a limit switch will be provided. When the outlet Dome Valve is
open less than the set position the switch contacts will be closed. When the outlet Dome Valve is
at the set position, or is open further than the set position, the switch contacts will be open.
To open the outlet Dome Valve to the set position, energise solenoid valve (EV03A) and
(EV03B). When the position switch signals that the valve is in the correct position the valve will
be held in its current position by de-energising solenoid (EV03B).
If the manual override push-button is pressed the outlet Dome Valve will be fully opened by
energising both solenoid valves (EV03A) and (EV03B). When the push-button is released the
outlet Dome Valve will be closed by de-energising both solenoid valves (EV03A) and (EV03B).
When the position indicates that the set position has been reached the outlet Dome Valve will be
held in its current position by energising solenoid valve (EV03A). The manual override
push-button will have no effect if the outlet Dome Valve is closed when the button is pressed.
To closed the outlet valve both solenoid valves (EV03A) and (EV03B) will be de-energised.
Short fill timer The short fill timer allows the conveying 10 minutes 0 - 60 minutes
cycle to continue after a delay even if the
D-pump vessel high level switch is not
covered.
Overfill timer The filling time is extended by the overfill 0.1 seconds 0 - 20 seconds
timer to ensure that the vessel has
completely filled.
Outlet Dome Valve This timer allows the conveying airflow to 10 seconds 0 - 60 seconds
open delay timer become established before the outlet Dome
Valve is opened and material is discharged
into the conveying pipe. It also allows time
for the pressure in the vessel to equalise
with that in the conveying pipe.
Cycle watchdog The cycle watchdog timer provides a 15 minutes 0 - 60 minutes
timer conveying cycle fault alarm if the
conveying cycle is not completed within the
pre-set time period.
Maximum This timer allows the cycle to continue after 8 minutes 0 - 60 minutes
discharge timer a timed delay even if the vessel low level
switch (LS03) is not uncovered.
Outlet Dome Valve This provides a timed delay after the vessel 10 seconds 0 - 60 seconds
closed delay timer low level switch has uncovered for the
vessel to completely empty before the outlet
Dome Valve is closed.
Dome Valve fault This allows a delay for the Dome Valve to 5 seconds 0 - 20 seconds
timer open/closed before initiating a Dome Valve
fault alarm.
A pneumatic control panel is provided at each of the D-pump which house the solenoid valves
and pressure switches associated with that vessel. The pneumatic control panel also provides the
following local controls and indications:
Outlet Dome Valve open manual override push-button. This push-button allows the
operators to fully open the outlet Dome Valve so that oversized material can be cleared
if the need arises.
Remote/Local switch. For the D-pump to run both this switch must be set to “Remote”
and the start/stop switch on the main electrical panel must be set to “start”.
Vessel pressure gauge. This provides an indication of the pressure in the D-pump
vessel.
The D-pump will be controlled by a PLC located in the main electrical control panel. The
operator interface is by means of a mimic diagram and includes the following operator controls,
indications and alarms.
D-pump main start/stop switch. This will permit the operators to start and stop the
D-pump.
Outlet Dome Valve open/fault indication lamp. The lamp will be “on” when the outlet
Dome Valve is open. The lamp will flash in the event of the outlet Dome Valve failing
to open or failing to close and seal. See summary of alarm conditions.
Balance valve open/fault indication lamp. The lamp will be “on” when the balance
valve open solenoid (EV04) is energised and the seal pressure is < 0.5MPa (PS04). The
lamp will flash in the event of the balance valve failing to open or failing to close and
seal. See summary of alarm conditions.
Vent valve open/fault indication lamp. The lamp will be “on” when the vent valve close
solenoid (EV05) is de-energised and the seal pressure is < 0.5MPa (PS05). The lamp
will flash in the event of the vent valve failing to open or failing to close and seal. See
Main conveying air valve open indication lamp. The lamp will be “on” when the main
conveying air valve open solenoid (EV12) is energised.
Fluidising air valve open indication lamp. The lamp will be “on” when the fluidising
air valve open solenoid (EV02) is energised.
Vessel high level switch status indication lamp. The lamp will be on when the vessel
high level switch (LS02) is covered.
Vessel low level switch status indication lamp. The lamp will be on when the vessel
low level switch (LS03) is covered.
The conveying pressure exceeds 0.1MPa (PS06).
The indications and controls associated with the reception silos are described in the
section on conveying route control.
Definition:
Inlet Dome Valve open solenoid (EV01) energised for more than 5 seconds and seal
Control Action:
Visual alarm only.
Definition:
Inlet Dome Valve open solenoid (EV01) de-energised for more than 5 seconds and seal
Control Action:
OUTLET DOME VALVE NOT OPEN ALARM
Definition:
Outlet Dome Valve open solenoid (EV03B) energised for more than 5 seconds and seal
Control Action:
Visual alarm only.
OUTLET DOME VALVE NOT CLOSED AND SEALED ALARM
Definition:
Outlet Dome Valve open solenoid (EV03B) de-energised for more than 5 seconds and seal
Control Action:
Definition:
Balance valve open solenoid (EV04) energised for more than 5 seconds and seal pressure >
0.5MPa (PS04).
Control Action:
Definition:
Balance valve open solenoid (EV04) de-energised for more than 5 seconds and seal pressure
< 0.5MPa (PS04).
Control Action:
Definition:
Vent valve close solenoid (EV05) de-energised for more than 5 seconds and seal pressure >
0.5MPa (PS05).
Control Action:
Visual alarm only.
VENT VALVE NOT CLOSED AND SEALED ALARM
Definition:
Vent valve close solenoid (EV05) energised for more than 5 seconds and seal pressure <
0.5MPa (PS05).
Control Action:
Visual alarm and conveying cycle progress inhibited.
Definition:
or:
or:
or:
The conveying pressure is > 0.1MPa (PS06)
Control Action:
Watchdog timer expired: Visual alarm only.
High level switch not covered: Visual alarm only.
Low level switch covered: Visual alarm only.
Conveying pressure > 0.1MPa: Visual alarm and outlet Dome Valve closed.
LIMESTONE INJECTION SYSTEM
OVERVIEW
The Rotofeed system is fed from a limestone silo and dispenses limestone through
conveying pipework to the boiler unit via a 2-way static splitter.
The Rotofeed machine consists of two pressure vessels, a volumetric feeder and
a compressed air distribution manifold. The volumetric feeder will be driven
through a gearbox by a standard induction motor. The electrical supply to the
motor will be from a variable frequency / voltage inverter drive (VFD), which
will enable the Rotofeed feeder speed and hence material output of the Rotofeed
to be controlled. The Rotofeed feeder speed is measured and used to calculate
material output. Thermistors incorporated into the feeder motor will provide an
indication of motor overheating and protection within the VFD will stop the
motor in the event of an overload.
The pressure vessels are arranged vertically with the dispensing vessel located beneath the
lock vessel. The inlet to each vessel is provided with Dome Valve. The dispensing vessel is
used to provide a constant supply of material to the volumetric feeder. When material is
being injected, the dispensing vessel will be pressurised. The lock vessel is used to
periodically replenish the dispensing vessel with material by providing a pressure lock
between the high pressure environment of the dispensing vessel and the limestone silo. In
this way, injection of material to the process can be continually maintained.
At rest the Dome Valves will be closed and the lock vessel will be empty. When the low
level switch in the dispensing vessel becomes uncovered, a filling cycle will be initiated and
will proceed as follows. The vent valve will open and allow residual pressure in the lock
vessel to be vented. A pressure switch will detect the pressure in the lock vessel. Providing it
has subsided at the end of the venting period the lock vessel inlet Dome Valve will be
opened and material will be gravity fed from the feed silo into the lock vessel. During lock
vessel filling, the lock vessel equalisation valve will be opened introducing air into the base
of the lock vessel to prevent consolidation of the material.
A level switch fitted to the lock vessel will signal that the lock vessel has filled. When this
occurs, the lock vessel inlet Dome Valve and the vent valve will be closed. The pressure in
the lock vessel will begin to increase. When the lock vessel pressure becomes equal to the
dispensing vessel pressure as indicated by the differential pressure switch, the lock vessel
pressure equalisation valve will be closed.
The dispensing vessel inlet Dome Valve will then be opened and material will
flow under gravity from the lock vessel into the dispensing vessel. To assist the
discharge, air will be introduced into the lock vessel through the pressure
equalisation valve. During this period the balance valve will be open to allow
displaced air from the dispensing vessel to be routed back into the lock vessel.
After a pre-set time material transfer from the lock vessel to the dispensing
vessel will be deemed to be complete and the lock vessel pressure equalisation
valve, dispensing vessel inlet Dome Valve and balance valve will all be closed.
When the pressure switch connected to the Dome Valve seals indicates that the valves have
closed and sealed the filling cycle will be complete and will be repeated when the
dispensing vessel level switch once again becomes uncovered.
The conveying air will enter the boiler unit along with the limestone material
and will leave the boiler along with the other process gases. It is important that
the feed hopper is fitted with a vent or filter to allow the air released during
venting to be safely vented.
The controls will monitor the time taken for the fill cycle and an alarm will be raised if the
time taken is significantly longer than a pre-set norm. The controls will also monitor the
conveying air pressure and will activate an alarm if it goes abnormally high.
SYSTEM AT REST
When the Rotofeed is stopped and at rest the status of the valves will be as follows:

Lock vessel inlet last position* closed closed
Dome Valve
Vent valve last position* closed closed
Dispensing vessel last position* closed closed

inlet Dome Valve
Balance valve last position* closed closed
Conveying air valve open open open

(PV11)
Lock vessel pressure closed closed closed

equalisation valve
(PV13)
INJECTOR FILLING ENABLE/DISABLE AND SEQUENCE
The control system will check that the following interlock conditions are fulfilled before the
Rotofeed filling cycle is enabled:
Plant emergency stop button (from client) not pressed. *
External critical interlocks (from client) are healthy. *
Lock vessel inlet Dome Valve not closed and sealed alarm is off. (see summary of
alarms) *
Dispensing vessel inlet Dome Valve not closed and sealed alarm is off. (see
summary of alarms) *
Vent valve not closed and sealed alarm is off. (see summary of alarms). *
Balance valve not closed and sealed alarm is off. (see summary of alarms). *
Conveying pressure high alarm is off. (see summary of alarms). *
Conveying pressure transmitter (PT25) has not failed. (see summary of alarms).
*
Variable frequency drive is healthy / motor not overheated.
Providing all the above conditions are true

AND
The filling cycle “ENABLE” command has been entered by the operator (HS02A)
THEN
The filling cycle will be ENABLED.
IF the filling cycle is enabled

AND any of the above conditions becomes false
OR
The filling cycle “DISABLE” command has been entered by the operator
(HS02B)
THEN
The filling cycle will be DISABLED.
When the Rotofeed filling cycle is enabled, filling cycles will proceed as
follows:
Step 1
When the dispensing vessel low level switch becomes uncovered (LSL25), the
vent valve will be opened by energising solenoid (EV05). Simultaneously, the
vent timer (10 seconds) and filling cycle watchdog timer (140 seconds) will be
started. The residual pressure in the lock vessel will begin to fall.
Step 2
When the pressure in the lock vessel has fallen below 0.02MPa (PS02) and the
vent timer has expired, the lock vessel inlet Dome Valve will be opened by
energising solenoid (EV01). Simultaneously, the lock vessel pressure
equalisation valve (PV13) will be opened by energising solenoid (EV13) and the
short fill timer (30 seconds) will be started. Material will fall from the limestone
silo into the lock vessel.
Step 3
When the lock vessel level switch becomes covered, or when the short fill timer
has expired, the lock vessel inlet Dome Valve and vent valve will be closed by
de-energising solenoids (EV01) and (EV05) respectively. The pressure in the
lock vessel will start to increase.
Step 4
When the pressure in the lock vessel and the dispensing vessel are equal,
indicated by the differential pressure switch (dPS08), the lock vessel pressure
equalisation valve will be closed by de-energising solenoid (EV13), the
dispensing vessel inlet Dome Valve will be opened by energising solenoid
(EV27) and the dispensing vessel Dome Valve open timer (30 seconds) will be
started. Material will fall from the lock vessel into the dispensing vessel.
Step 5
When the dispensing vessel inlet Dome Valve has opened (PS27), the lock
vessel pressure equalisation valve and balance valve will both be opened by
energising solenoids (EV13) and (EV16) respectively.
Step 6
When the dispensing vessel Dome Valve open timer has expired, the lock vessel
pressure equalisation valve, dispensing vessel inlet Dome Valve and balance
valve will all be closed by de-energising solenoids (EV13), (EV27) and (EV16)
respectively.
Step 7
When the dispensing vessel inlet Dome Valve and balance valve have closed
and sealed, (PS27) and (PS16) respectively, the cycle reset timer (3 seconds)
will be started.
Step 8
When the cycle reset timer has expired, the filling cycle will be complete.
Note:
If a filling cycle is in progress and becomes disabled as a result of any enable interlock
marked * becoming false then the filling cycle will be immediately terminated and the
valves will be returned to the at rest position. (see section 3.2).
If a filling is in progress and becomes disabled as a result of any enable
interlock not marked * becoming false, or if the disable command is entered,
then the filling cycle will be allowed to continue and end before the valves are
returned to the at rest position. (see section 3.2)
When a filling cycle is in progress and an event has to occur to permit the cycle
to proceed to the next step, then the progress of the cycle will be halted until that
interlock condition has become true. The cycle will then proceed to the next step.
The progress of the cycle to the next step will be latched for the remainder of the
cycle, so that in the event of the interlock condition subsequently becoming
untrue, the cycle will not stop or regress. The latches will be released at the end
of the cycle during the cycle re-set timer.
FEEDER OPERATION
Running the Feeder
The control system will check that the following interlock conditions are fulfilled before
starting the feeder:
Plant emergency stop button is not pressed.
External critical interlocks (from client) healthy.
Lock vessel inlet Dome Valve not closed and sealed alarm is off. (see
summary of alarms).
Dispensing vessel inlet Dome Valve not closed and sealed alarm is off. (see
summary of alarms).
Vent valve not closed and sealed alarm is off. (see summary of alarms).
Balance valve not closed and sealed alarm is off. (see summary of alarms).
Variable frequency drive is healthy / motor not overheated.
Conveying pressure high alarm is off. (see summary of alarms).
Conveying pressure transmitter (PT25) has not failed. (see summary of

alarms).
Dispensing vessel filling fault alarm is off. (see summary of alarms).
Providing all of the above conditions are true then the feeder will be
AVAILABLE to run.
If the feeder is available

AND the feeder “START” command has been entered by the operator (HS17A)
THEN the feeder will be started by energising the feeder stop/start contact at the
variable frequency drive.
When the feeder is running, limestone will be dispensed into the conveying air
and transferred to the boiler unit.
If the feeder is running

AND any of the above conditions become false
OR
If the feeder “STOP” command is entered by the operator (HS17B)
THEN the feeder will be stopped by de-energising the stop/start contact at the
variable frequency drive.
Note: When the feeder is stopped due to one of the above conditions becoming
false, the feeder will not re-start when the condition becomes true but can only
be re-started when all the conditions are true and the feeder “START” command
has been entered by the operator (HS17A).
Feeder conveying rate control

When the system is operational, the conveying rate may be altered by the
operator or by a remote signal. The PLC will use this set point (M) to calculate
the feeder speed (N), and from this the controls will calculate the feeder motor
frequency signal (HZ) to the variable frequency drive as follows:-
Feeder speed set point (N). Units – RPM. Range – 4.08 to 21.15
Feeder motor frequency set point (HZ). Units – Hz. Range – 14 to 73
Actual feed rate (Ma). Units – Tonnes/hour. Range – 6.49 to 29
CONVEYING AIR VALVE

Limestone will be conveyed to the boiler unit by compressed air. This will be introduced
into the system by the conveying air valve (PV11) at the Rotofeed manifold.
When the system is operational the conveying pressure will vary according to the limestone
feed rate. If a blockage occurs within the system, the conveying pressure (PT25) will rise to
an abnormal level and this will generate the conveying pressure high alarm.
The conveying air valve will operate as follows:-
Step 1
When the conveying pressure high alarm is initiated by the dispensing vessel pressure > 1.5
barg (PT25), the conveying air valve close delay timer (10 seconds) will be started.
Step 2
When the conveying air valve close delay timer has expired, and providing the conveying
air pressure > 1.5 barg (PT25), the conveying air valve will be closed by energising solenoid
(EV11).
Step 3
When the dispensing vessel pressure < 1.5 barg (PT25), the conveying air valve open delay timer (10 seconds) will be started.
Step 4
When the conveying air valve open delay timer has expired, and providing the conveying air
pressure < 1.5 barg (PT25), the conveying air valve will be opened by de-energising
solenoid (EV11).
Vent timer This allows sufficient time for the lock 10 seconds 0 – 60 seconds
vessel to depressurise.
Filling cycle The filling cycle watchdog timer provides a 140 seconds 0 – 600
watchdog timer filling fault alarm if the filling cycle is not seconds
completed within the pre-set time period.
Short fill timer The short fill timer allows the filling cycle 30 seconds 0 – 60 seconds
to continue after a delay even if the lock
vessel level switch (LS02) is not covered.
Dispensing vessel This sets the time period for the lock vessel 30 seconds 0 – 120
Dome Valve open contents to fully discharge into the seconds
timer dispensing vessel, when the balance valve
is opened.
Cycle reset timer The cycle reset timer provides time for the 3 seconds 0 – 20 seconds
system to settle and the latches to be
released before the vent valve is opened at
the start of the next cycle.
Conveying air This timer allows the conveying air to 10 seconds 0 – 30 seconds
valve close delay continue after the feeder stops in order to
timer blow material clear.
Conveying air This timer allows time for a high conveying 10 seconds 0 – 30 seconds
valve open delay pressure to reduce before re-instating
timer conveying air.
Dome Valve fault This allows a delay for the Dome Valve to 5 seconds 0 – 20 seconds
timer open / close before initiating a Dome Valve
fault alarm.
A pneumatic control panel at the Rotofeed houses the solenoid valves and pressure switches.
and provides the following local indications:
A pressure gauge showing the lock vessel pressure is mounted on the pneumatic
panel door.
A pressure gauge showing the dispensing vessel pressure is mounted on the

pneumatic panel door.
The Rotofeed controls will be supplied by others. The operator interface can be by means of
a mimic, panel view or by VDU and keypad and will typically include the following
The following controls and indications are essential to operate the Rotofeed system.
If a panel view or VDU is employed as the MMI the following should be
incorporated on the control page.
Filling enable pushbutton. This will permit the operators to enable the Rotofeed
filling cycle. When the filling cycle is enabled a filling cycle will start
automatically whenever the dispensing vessel level switch becomes
uncovered.
Filling disable pushbutton. This will permit the operators to disable the filling
cycle. When this pushbutton is pressed, a current filling cycle will be permitted to
continue and end.
Filling enabled indication. The indication will be “on” when filling is enabled.
Filling in progress indication. The indication will be “on” when a filling cycle is
in progress.
Filling fault alarm indication. This indication will be “on” when the filling cycle
watchdog timer has expired and a filling cycle is still in progress, or
when the dispensing vessel filling fault alarm is on. See summary of
alarm conditions.
Feeder start pushbutton. When this button is pressed and the feeder start
interlock conditions are healthy, the feeder motor will be started by
energising the stop/start contact at the variable frequency drive.
Feeder stop pushbutton. When this button is pressed, the feeder motor
will be stopped by de-energising the stop/start contact at the variable
frequency drive.
Feeder fault indication. The indication will be “on” when the feeder is stopped in
an abnormal condition, because either the motor is overheated or the VFD is
tripped. See summary of alarm conditions.
Feed rate set point. This will be displayed in Tonnes per hour.
Feed rate. The actual feed rate calculated by the controls will be displayed in
Tonnes per hour.
Silo low level indication. The indication will be “on” when the limestone silo low
level switch is uncovered. (LSL01).
Conveying pressure high alarm indication. The indication will be “on” when the
conveying pressure is high (PT25). See summary of alarm conditions.
Conveying pressure transmitter failed (PT25) indication. The indication will

be “on” when the conveying transmitter has failed. See summary of
alarms conditions.
The following status and alarm indications are useful for troubleshooting the
Rotofeed system.
If a panel view or VDU is employed as the HMI the following should be
incorporated on a separate page to the control functions.
Lock vessel high level indication. The indication will be “on” when the lock
vessel high level switch is covered (LSH02).
Lock vessel inlet Dome Valve open/fault indication. The indication will be “on”
when the lock vessel inlet Dome Valve open solenoid (EV01) is energised and the
seal pressure is < 5.0 barg (PS01). The indication will flash in the event of the
lock vessel inlet Dome Valve failing to open or failing to close and seal. See
Vent valve open/fault indication. The indication will be “on” when the vent valve
open solenoid (EV05) is energised and the seal pressure is < 5.0 barg (PS05). The
indication will flash in the event of the vent valve failing to open or failing to
close and seal. See summary of alarm conditions.
Dispensing vessel inlet Dome Valve open/fault indication. The indication will be
“on” when the dispensing vessel inlet Dome Valve open solenoid (EV27) is
energised and the seal pressure is < 5.0 barg (PS01). The indication will flash in
the event of the dispensing vessel inlet Dome Valve failing to open or failing to
close and seal. See summary of alarm conditions.
Balance valve open/fault indication. The indication will be “on” when the balance
valve open solenoid (EV16) is energised and the seal pressure is < 5.0 barg
(PS01). The indication will flash in the event of the balance valve failing to open
or failing to close and seal. See summary of alarm conditions.
Conveying air valve open indication. The indication will be “on” when the
conveying air valve close solenoid (EV02) is de-energised.
Lock vessel pressure equalisation air valve open indication. The indication will be
“on” when the lock vessel pressure equalisation air valve open solenoid (EV13) is
energised.
Dispensing vessel low level indication. The indication will be “on” when the
dispensing vessel low level switch is uncovered (LSL25)
Conveying pressure indication. The conveying pressure (PT25) will be

displayed in barg.
Plant emergency stop button pressed indication. This indication will be “on” when
the plant emergency stop button is pressed.
LOCK VESSEL INLET DOME VALVE NOT OPEN ALARM

Definition:
Lock vessel inlet Dome Valve open solenoid (EV01) energised and seal pressure > 5.0 barg
(PS01) for more than 5 seconds.
Control Action:
Visual alarm.
LOCK VESSEL INLET DOME VALVE NOT CLOSED AND SEALED ALARM
Definition:
Lock vessel inlet Dome Valve open solenoid (EV01) de-energised and seal pressure < 5.0
barg (PS01) for more than 5 seconds.
Control Action:
Visual alarm and filling cycle start inhibited / progress terminated and feeder stopped.
Definition:
Vent valve open solenoid (EV05) energised and seal pressure > 5.0 barg (PS05) for more
than 5 seconds.
Control Action:
Visual alarm.
3.3.1 VENT VALVE NOT CLOSED AND SEALED ALARM
Definition:
Vent valve open solenoid (EV05) de-energised and seal pressure < 5.0 barg
(PS05) for more than 5 seconds.
Control Action:
DISPENSING VESSEL INLET DOME VALVE NOT OPEN ALARM
Definition:
Dispensing vessel inlet Dome Valve open solenoid (EV27) energised and seal pressure > 5.0
barg (PS27) for more than 5 seconds.
Control Action:
Visual alarm and filling cycle progress inhibited.
DISPENSING VESSEL INLET DOME VALVE NOT CLOSED AND SEALED

ALARM
Definition:
Dispensing vessel inlet Dome Valve open solenoid (EV27) de-energised and seal pressure <
5.0 barg (PS27) for more than 5 seconds.
Control Action:
Definition:
Balance valve open solenoid (EV16) energised and seal pressure > 5.0 barg (PS16) for more
than 5 seconds.
Control Action:
Visual alarm.
Definition:
Balance valve open solenoid (EV16) de-energised and seal pressure < 5.0 barg (PS16) for
more than 5 seconds.
Control Action:
CONVEYING PRESSURE HIGH ALARM
Definition:
Pressure in dispensing vessel > 1.5 barg (PT25).
Control Action:
CONVEYING PRESSURE TRANSMITTER FAILED ALARM
Definition:
Conveying line pressure transmitter signal less than 3.5 mA or greater than 20.5
mA (PT25).
Control Action:
FEEDER FAULT ALARM
Definition:
Rotofeed feeder motor over-temperature relay tripped (TS17).
or
Variable frequency drive tripped.
Control Action:
Visual alarm and Rotofeed feeder stopped / filling cycle start inhibited.
DISPENSING VESSEL FILLING FAULT ALARM
Definition:
The Rotofeed filling cycle is enabled.
AND
The dispensing vessel level probe is uncovered (LSL25)
AND
The feeder has completed more than 145 revolutions.
Note: The number of revolutions completed by the feeder will be calculated from the feeder
speed signal UT17.
Control Action:
Visual alarm and Rotofeed feeder stopped.
FILLING FAULT ALARM
Definition:
The filling cycle watchdog timer has expired and a filling cycle is still in
progress.
Control Action:
Visual alarm.
3.3.2 EMERGENCY STOP BUTTON PRESSED ALARM
Definition:
Clients emergency stop button has been pressed.
Control Action:
Visual alarm and filling cycle disabled / progress terminated and feeder stopped.
气力输送系统
运行维护手册
目录
一、系统运行维护
二、常见问题和处理方法
三、圆顶阀维修手册
附录：
输送系统设备用油牌号、规格
一：系统运行维护
正确的操作和有效的维护是保证输灰系统正常运行的前提，系统投运前运行和
检修人员应仔细阅读此说明书。
运行人员应按以下规范来操作运行输灰系统：
（一）准备工作：
在锅炉初次启动，除灰系统首次投入运行时需要做好如下准备工作：
1、检查并清除灰斗内及上部相关部分杂物。
2、打开闸板阀。
3、将空压机、干燥机、冷却水、灰斗气化风机、电加热器和灰库灰斗气化风机、
电加热器、布袋除尘器投入运行。
（二）锅炉初次启动及锅炉低负荷投油运行时
１、锅炉投油阶段：
锅炉初次启动或停炉后重新启动时，会投油燃烧，此时产生的油灰应采用少量多送的
原则进行输送。由于油灰的特性完全不同于干灰，输送耗气量大，应启动备用空压机。
A、静电除尘器第一次投运时，缩短所有仓泵入口圆顶阀装料时间，循环间隔时间设为
零，达到少量多送的目的，直至锅炉正常投粉运行。
（推荐初期２～５秒装灰运行，观
察输送压力控制在１Bar 以内；锅炉停燃油运行３～４个小时后，输送系统逐渐增加装
料时间，现场敲击泵体，半泵或大半泵运行。）
B、如果不是第一次投粉运行，每次在投静电除尘器前几个小时，要求提前开动静电除
尘器振打装置，将上次静电除尘器内的余灰清理干净，确保油灰不与余灰混合，否则
将造成落灰更加困难。此时输灰系统可以设较短的装灰时间进行运行，直至锅炉投粉。
２、锅炉低负荷运行时：
锅炉投油结束、并且投粉运行开始后，电除尘器的投运将收集下较大量的飞灰，此时
灰系统需要改变输送状态，适当延长泵的装料时间，使泵内料位从较低料位运行逐渐
过渡到较高料位运行。然后在条件允许时，通过增加循环间隔时间，使仓泵带上较大
负荷输送，为高负荷运行奠定基础。
３、输灰系统正常运行时：
低负荷运行一段时间后，飞灰的状态趋于稳定，随着锅炉负荷的增加，灰量也逐渐的
增加，此时应延长仓泵的落料时间尽量达到满泵运行。当锅炉负荷低时可以延长循环
间隔时间，以减少输送次数；当锅炉负荷高时应缩短循环间隔时间，以满足大灰量的
输送要求。
４、锅炉停炉时输灰系统的运行方法：
锅炉和静电除尘器停止运行后，静电除尘器的振打装置仍需运行 3 个小时以上。此时
灰温逐渐降低，需要降低泵的装灰量，输灰系统持续运行，直至确认灰斗清空为止，
并应打开静电除尘器侧门检查。
（三）输灰系统排堵操作
在输灰系统运行过程中有可能发生堵管；需要排通。
排堵方法：
A：在 CRT 操作画面上将“运行”停止，进行“吹扫”

。在较高的管道压力时，关
闭输送管道上的手动进气阀，将手动排堵阀打开，将灰通过排堵管排到灰斗内。
并反复进行“加气—压力升高后关进气阀—开排堵阀—压力降低后关排堵阀”，
直到吹扫后最高压力达到空吹压力时停止，最后进行两次吹扫。
B：在方法 A 无法排除堵管时，可以将主泵（或其他泵）上的手动排气阀在有较高
压力的情况下打开；通过此方法可以将管道内的灰抽回到泵内。
除灰系统运行期间，要对输送情况进行监测。除了观察 CRT 输送画面外，还要

定时到现场巡视。
现场巡视内容：
１、巡测各个电场的灰斗出口短节（方圆节或大小头）的温度。
正常时，各电场灰斗出口短节的温度如下：
一电场 90—100℃，
二电场 50—70℃，
三~五电场 30—50℃。
检测此处温度，用来检查落灰情况和灰斗存灰情况。
如果同一电场灰斗出口短节温度差异较大，就有可能存在各个灰斗落灰不均匀
或某个灰斗落灰较差的现象。需要调整烟道、静电除尘器的负荷分配、调整灰斗气
化风的气量或对落灰时间、循环间隔时间做相应调整，使落灰正常，保证运行处于
良性循环。
要求现场在每次运行开始阶段（约 1 周时间内）
，对所有的短节温度进行监测。
２、泵的落灰情况
设备在落灰—输送—输送完成的过程中，泵内物料的落入和送出的状态，可以通过
敲击泵的声音辨别或打开泵上的手动排气阀看排出灰尘的浓度。特别是在输送刚刚
开始、没有在满泵输送的情况下，要进行此项工作，以便了解输送的基本状态。
３、排气管道和排堵管道的状态
在 MD 泵上设有排气管道和阀门，在 MD 泵入口圆顶阀打开装灰的同时，排气圆
顶阀同时打开排气。正常情况下，10～20 秒时间内灰可以落满泵，落灰管温度上升，
排气管排气正常。如果在静电除尘器灰斗内有足够灰的情况下，较长时间仍然不能
落满泵，排气管道可能排气不足、工作不正常。此时，可以用以下方法处理。
A：在排气阀打开时，敲打排气管；在排气阀关闭后，停止敲打，并重复进行多
次，可以将故障排除。
B：通过排气管上的堵丝，将管道内的积灰清理。
C：将出口管道密封，将入口阀上的闸板门关闭，在泵内和管道内冲气到 1-2
公斤后，敲打管道后，将排气阀打开。并可重复多次。
排堵管道在对正常状态的灰进行排堵时，有明显的物体流动的声音，并有温度
上升的现象。
４、泵的流化空气管道的工作情况
在输送时，泵的流化空气阀打开，流化管道内应有气流通过声音并拌有振动。
气量大，振动大；气量小，振动小。如果没有声音和振动，则孔板与逆止阀有被灰
和杂质堵住的可能。需要对孔板和逆止阀进行清理，并将该管路进行吹扫清理。
５、输送空气
输送空气应避免含有较多的水量。在空气干燥的情况下，储气罐应 2 小时排水
一次；在空气潮湿及阴雨天，则需要适当增加排水次数。
二、气力输送系统运行常见问题和处理方法
警告! 对系统寻找故障前, 检查供气、供电，并作好相应保护。
处理故障时，请在 CRT 画面上将系统置于“停止”或“吹扫”状态
症状可能原因补救措施
1：系统不启动 1 “程控/就地”开关的位置将主泵气控箱上的“程控/就地”开

不对—在“就地”位置。关置于“程控”位置。
2 输送空气母管压力低启动其他输送空压机、打开相应阀门
并检查储气罐就地压力表和压力开
关、压力变送器。
3 圆顶阀密封压力信号不对照圆顶阀初始状态表检查所有圆
对，控制气源故障. 顶阀的状态。有差异时检查控制气源
及气控箱进气阀，检查、调整错误的
密封压力反馈信号的相关条件。详见
第 8 项。
4 路径选择不对—目标灰库正确选择路径。有高料位报警信号的
有高料位报警信号灰库无法继续送灰。
5 管道输送压力开关反馈信对压力开关重新整定并检查接线。
号不对。
6 CRT 画面上的运行按键没将其他命令停止，按下运行命令。
有按下。
2：泵启动，泵 1 圆顶阀密封压力信号不对检查、调整错误的密封压力反馈信号
内装料完成，或限位开关不动作的相关条件。
圆顶阀关闭，按照维修手册调整，若有故障则更换
但不输送。限位开关。
2 圆顶阀未关严，外物卡住切断气路和电路，从底部弯头拆出管
圆顶阀或轴子做清理，清理容器。
拆去汽缸，手动操作，检查限位开关
的动作。
3 输送空气进气阀不动作在控制气源正常的情况下：
就地动作电磁阀，如进气阀动作正
常，则检查或更换电磁阀线圈
如进气阀不动作，则修理或更换进气
阀
4 输送空气管道的手动阀门打开输送空气管道的手动阀门
关闭
3：系统开始输 1 输送管道堵塞并不能自行人工就地排堵。

送，然后停止疏通。检查供气和供电。确认各阀门的工作
状态。
从管路的最远点开始，轻敲管子确定
堵管位置，切断供气和供电，允许空
气减少。拆除阻塞段管子，调查原因，
吹扫干净。
2 泵出口物料起拱检查泵出口物料是否颗粒过大或潮
湿。
4：输送时入口 1 密封空气压力下降至接近检查供气管路。
圆顶阀或排气输送压力
圆顶阀空气泄 2 圆顶阀密封开裂更换密封圈，按维修手册检查球顶和
漏密封圈之间的间隙。
(注: 某些系
统有小泄露是 3 过滤器堵塞拆除并清理。
正常的)
5：通过电磁阀 1 电磁阀不能全行程工作拆除并清理。

连续排气 2 圆顶阀汽缸密封泄漏安装新密封。
6：落灰不正常 1 与正常情况对比灰量小，确认除尘器、电加热板等设备在工作
输送压力大大低于正常输状态，并确认灰斗内确实有灰。
送压力敲打灰斗振打铁和钢质短节。
调整气化风量。
检查设备的排气管的工作状态。排除
故障。
利用设备上的排气阀增加排气，促进
落灰。
7：管道/弯头 1 孔板设置不当，物料流动调整孔板气量
磨损严重太快
2 输送部分负荷小检查容器充满时间、排气阀、振动器
设置；提高落入泵内灰量。
3 管道弯头安装不当检查位置
8：圆顶阀密封 1 气源压力低于设计要求检查储气罐的就地气源压力。

压力信号反馈
2 反馈气路不通畅。检查就地控制箱内压力表的显示。
不对
低于反馈压力时，进行下列工作 3、
4、5。
3 限位开关没有被接通就地检查限位开关和控制气路连接。
4 调整螺栓需要调整调整调整螺栓的长度。
5 气路连接错位检查密封气路连接情况、气源压力。
6 压力开关整定值高检查压力开关的整定值，并进行适当
调整。
7 断子排接线松动检查就地气控箱的电源和 PLC 柜内
的接线。
8 异物阻挡关闭动作检查是否有杂物影响关闭到位。
三、圆顶阀维修手册
1. 圆顶阀拆卸步骤
1.2 入口圆顶阀
1. 手动插板门全关，输送泵继续运行直至排空。
2. 关断并隔离系统。
3. 切断并标识连接汽缸和限位开关的尼龙供气管道，及到顶板/球顶的供水管
道（仅用于高温圆顶阀）
。
4. 去掉圆顶阀顶板和手动插板门之间的螺栓。
5. 去掉圆顶阀下法兰和泵壳体之间的螺栓。
6. 利用壳体支腿的顶起螺栓降低壳体。
7. 使用起吊设备将圆顶阀从侧面卸出。
1.2 出口圆顶阀
。
4. 确保出口圆顶阀的连接管可靠支撑，除去圆顶阀连接法兰的螺栓。
5. 使用起吊设备将圆顶阀从侧面卸出。
1.3 排气圆顶阀
4. 拆除顶部连接法兰与管路法兰连接的螺栓，滑出孔板（如果有的话）和垫
片。
5. 拆除底部连接法兰与容器短管法兰连接的螺栓。
6. 如果可能，使用起吊设备取出排气圆顶阀。
2. 圆顶阀阀顶密封圈的更换和检查
1. 拆除顶板/接头的螺栓，吊出由顶板/接头、密封圈、嵌入环和接头箍圈等
组成的密封组件。
2. 记下接头箍圈下的垫片的数量和厚度。使用 0.4mm、0.8mm 和 1.5mm 厚度
的垫片，得到要求的密封间隙（密封圈和圆顶之间）
。
3. 从嵌入环上拆下密封圈，检查磨损和损坏的情况。必要时马上更换。
4. 用手转动圆顶，检查轴承状况。如果轴承卡住或需要更换，按照‘圆顶阀
轴承拆除/更换’部分处理。
5. 重新组装阀门时，确保顶板/接头下侧没有腐蚀。所有表面应清洁，保证密
封的严密。
6. 将垫片装入阀体，随后装接头箍圈和嵌入环/密封圈。
7. 顶板/接头就位，注意不要压住密封圈，拧紧螺栓。
3. 圆顶阀轴承拆卸与更换
直行程气缸型。
1. 拆除气缸防护罩头部盖板。
2. 拆除气缸防护罩外侧盖板。
3. 拆除气缸与摇臂连接。
4. 拆出汽缸。
5. 拆除销轴润滑脂注入油嘴。
6. 敲出固定圆顶阀与销轴的弹簧销，必要时拆除气缸摇臂。
7. 拆除气缸防护罩内侧板。
8. 取出销轴，吊出球顶。注意：销轴上是否有薄垫片，应注意垫片的安装位
置，回装时在原位置应装入这些垫片。
9. 现在把轴承和密封推向阀门中心，拆除。注意密封件的安装顺序和方向。
10. 彻底清洗并检查所有机加工面。检查球顶和销轴的表面是否平整，必要时更
换。去除边缘的毛刺，防止重新安装时损坏更换的密封和轴承。
11. 仔细地把更换的密封装入座圈，密封唇朝向座圈的倒角边。
12. 座圈平直压入孔内。轴承导向边朝向孔，轴承孔与阀体 1/8“NPT 孔中心对
准。平直压入直到轴承位于孔表面下约 3mm. 另一侧重复相同过程。
13. 密封之间的空间填满 Shell Malleus JB 或相当的润滑脂，轴承也使用这种润滑
脂。
14. 重新装入薄垫片（如果有）
，新 O 型圈沿着销轴滑入轴套。
15. 销轴滑过轴承直到它与第一个密封接触。另一侧重复同样的过程。
16. 保持球顶靠近孔，用塑料/皮锤敲打销轴穿过密封和球顶。重新安装注润滑
脂嘴。
17. 转动销轴，直到轴孔和球顶对中。装入弹簧销定位。
18. 阀门转动 180 度。
19. 按照步骤 2-7 的相反顺序重新安装汽缸组件，缸套固定就位。
20. 重新安装气缸防护罩头部盖板。
21. 调整限位开关，拧松气缸摇臂上的锁定螺母。圆顶阀全关时，拧出螺钉，直
到六角头与限位开关上的撞杆接触。螺钉拧紧 4mm(3.25 转)，压下撞杆。
注意：
1）圆顶阀维修前，确保阀体已降下来。
2）拆除轴承前，关断冷却水源（对水冷圆顶阀）。
4. 圆顶阀轴承拆卸与更换
扇形气缸型。
1. 拆除密封头组件。
2. 转动球顶到一个阀门开关的中间位置。
3. 拧出连接汽缸和阀体的螺栓。
4. 拆除润滑脂注入嘴。
5. 阀门转过 180 度。
6. 敲出固定圆顶阀与销轴的弹簧销。
7. 取出销轴，吊出球顶。注意：销轴上是否有薄垫片，应注意垫片的安装位
置，回装时在原位置应装入这些垫片。
8. 把轴承和密封推向阀门中心，拆除。注意密封件的安装顺序和方向。
9. 彻底清洗并检查所有机加工面。
10. 检查球顶和销轴的表面是否平整，必要时更换。去除边缘的毛刺，防止重
新安装时损坏更换的密封和轴承。
11. 仔细地把更换的密封装入座圈，密封唇朝向座圈的倒角边。
12. 座圈平直压入孔内。轴承导向边朝向孔，轴承孔与阀体 1/8“NPT 孔中心
对准。平直压入直到轴承位于孔表面下约 3mm. 另一侧重复相同过程。
13. 密封之间的空间填满 Shell Malleus JB 或相当的润滑脂，轴承也使用这种润
滑脂。
14. 重新装入薄垫片（如果有）
，新 O 型圈沿着销轴滑入轴套。
15. 销轴滑过轴承直到它与第一个密封接触。另一侧也重复同样的过程。
16. 保持球顶靠近孔，用塑料/皮锤敲打销轴穿过密封和球顶。
17. 转动销轴，直到轴孔和球顶对中。装入弹簧销定位。
18. 阀门转动 180 度。
19. 装上注润滑脂嘴和执行机构。
20. 重新安装密封头组件。
21. 调整限位开关，拧松气缸摇臂上的锁定螺母。圆顶阀全关时，拧出螺钉，
直到六角头与限位开关上的撞杆接触。螺钉拧紧 4mm(3.25 转)，压下撞杆。
注意：
1) 顶阀维修前，确保阀体已降下来。
2) 拆除轴承前，关断冷却水源（对水冷圆顶阀）。
5. 日常维护
注意：开始日常维护前，请确认系统的供气和供电已切断，余压已排空，冷却水切
断，圆顶阀充分冷却。
每周
设备巡检，观察运行状况。
每月
给圆顶阀轴和轴承填加润滑脂，润滑脂注入口在圆顶阀阀体上，润滑脂采用 Shell
公司 Malleus JB1 或 Mobil 公司 SHC1500
检查气控箱外侧的过滤/润滑组件。监视过滤器的状态，及时清理（通常每年一次）
可选油料：
Shell 公司 Tellus 37 等级 37
Moibl 公司 DTE Oil.Light 等级 32
BP 公司 HLP32 等级 32
注意：如果需要清理或更换过滤器，必须切断气控箱的供气。
每年
1．检查圆顶阀的限位开关
2．气控箱：检查排气消音器，需要时更换。需要时清理过滤器。
3．手动插板门：清理轴上的集灰，给轴加润滑脂，检查阀动作灵活。
4．从配气组件上的过滤器上拆下滤芯，清理干净，更换。检查系统中的球阀。
5．检查料位计的连接情况。
两年
注意：关闭泵上方的手动插板门，运行系统直到系统全部排空。卸掉手动插板门下
方的柔性接头。采用合适的起吊装置卸下圆顶阀。
1．卸下圆顶阀，检查圆顶和密封圈的磨损情况。
2．检查圆顶阀轴的磨损情况，更换轴承和密封圈。
3．气控箱：检查电气和气动设备的状况和连接。
4．圆顶阀及气缸：检查气缸筒的划痕、点蚀、锈迹等。这些会使气缸的密封很快失
效。
附录１
输送系统设备用油牌号、规格*
1：圆顶阀轴承(润滑脂)
可选油料： Shell 公司 Malleus JB1 或 Mobil 公司 SHC1500
2: 气缸和阀门（润滑油）
可选油料：
Shell 公司 Tellus 37 等级 37
Moibl 公司 DTE Oil.Light 等级 32
3：高速装置和轴
SHELL 公司 Tellus 32 等级 32
Moibl 公司 Velocite No 6 等级 10
4: 推荐圆顶阀注油黄油枪：
油枪品牌：SATA（世达）
油枪型号：97202#黄油枪、97203#黄油枪
厂家：丹纳赫工具（上海）有限公司—（美国丹纳赫工具集团子公司）
联系电话：021—63612012 传真：021—64216308
备注：该油枪另配 1/8NPT 的高压油管后，可以保证加油更便利。
5： 97202#、97203#、1/8NPT 高压油管使用注意事项：
a) 在油枪油嘴含入一端的油嘴前，可以将油枪油嘴与油管之间的螺纹连接先松
动，含入后，将所有的螺纹连接处紧固。在油脂挤入后，按倒序操作。
b) 油枪油嘴内有一个由弹簧、钢珠组成的逆止组件，该组件保证油脂在高压下
注入设备油嘴中，此组件不可缺少。每次工作前，请检查此组件。
c) 其他操作见 SATA（世达） 97202#、97203#产品说明书。
Pneumatic conveying System Operation & Maintenance
Instructions
Table of Content
PART I System Operation & Maintenance .........................................................
PART II Fault Diagnosis and Managing Methods ...............................................
PART III DOME VALVE MAITENANCE INSTRUCTIONS ..........................
APPENDIX 1: CONVEYING SYSTEM LUBRICANT SPECIFICATION ...

1. System Operation & Maintenance
Ensure the normal ash handling system operation on the base of the correct
manipulating and effective maintenance, this manual must be ready by personnel
before operating the equipment or carrying out maintenance work.
Personnel should carry out the handling system according to the following
rules.
1. Preparation
The following rules should be carried out before the ash system firstly being
commissioned and when the boiler system first start-up.
4、Clear the hopper and remove the sundries.
5、Open the isolated valve.
6、Place the compressor, drier, cooling water, hopper aeration fan, electric heater and
silo aeration fan, electric heater and bag filter in operation.
2. When The Boiler System First Start-up and Boiler Ignition Oil in Low load
Operation
1) Boiler Ignition Oil Period:
When the boiler system first start-up or restarting after the halt, the puffy should be
conveyed using a method with “little amount, more times”, because of the great difference
between the character of the dry ash and that of puffy, it is necessary to start the stand-by
compressor to supply more conveying air.
A、On the first time of ESP operation, shorten all the pump inlet dome valve ash filling time,
circle interval time is set to be zero, with “little amount, more times”, until the boiler runs
normally.（Suggest: at the first ２～５seconds of ash conveying operation, keep the
conveying pressure within １Bar；３～４hours after the boiler stops oil burning, increase
the ash feeding time gradually, knock the pump body, and operate with half pump or more
than half pump of ash.）
B、During the normal start-up of boiler, several hours before ash piling in the ESP, turn on
the rapping hammer of ESP in advance, clear the remaining ash in ESP hopper，ensure that
the putty will not be mixed with the ash, which will result difficulties in ash falling. Then the
ash filling time can be set to be shorter until the pulverized coal is combusted.
2) Boiler low load operation:
After the boiler ignition oil being complete and pulverized coal being combusted, the great
quantity ash should be accumulated in the ESP hopper, and the ash system should change the
putty conveying status, prolong the pump ash filling time properly, and let the ash in pump
more and more. If permitted, increase the circle interval time to make the pump conveying
with higher load, which can establish the conditions of the high load operation.
3) Normal operation of ash handling system:
After a period of low load ash handling system operation, the ash status tends to be stable.
With the increasing of boiler load, the ash quantity should be increased, then prolong the
circle interval time to carry out full pump operation. When boiler being in low load operation,
prolong the circle interval time to shorten the circle times; and when boiler being in high
load operation, shorten the circle interval time to meet the requirement of the great quantity
conveying.
4) Ash conveying system operation method when boiler being shutdown：
After the boiler and ESP halts, the ESP rapping system should keep operating more than 3
hours. Then the ash temperature starts to fall, it’s necessary to decrease the pump ash
containing and keep the ash conveying system running continuously, until ensure that the
hopper is cleaned up, then open the ESP man-hole for checking.
a) System operation to remove blockage
It is necessary to remove blockage when pipe blockage occurs in the conveying as
follows:
Blockage removing method：
A: Stop “run”, start “blow” on the CRT operation menu. When the pipe pressure is high,
shut off the air manual valve on the pipeline, open the manual blockage relief valve，
discharge ash into the ash hopper by the blockage relief pipe. And carry on
“pressured—shut off the air valve after pressure increasing—open the blockage relief
valve —shut off the blockage relief valve after pressure starting to fall”，stop the
operation until the highest pressure reaches the blowing pressure, then purging system
twice finally.
B: If the blockage can not be handled with method A, open the manual vent valve of
master pump (or other pumps) at higher pressure, with this method, take out the ash from
the pipe to the pump.
Need to closely observe the conveying system condition during the ash
conveying. The regular system walk-down will be required while keep monitoring
the CRT.
Spot walk-down Content：
1) Review the temperature on the adaptors above inlet dome valve of vessels.
Normally, for the first field , the joint temperature is 90—100℃，for the second
field temperature , that is 50—70℃，and for the third to the fifth field ,that is
30—50℃.
Review the temperature of this point to check the status of ash falling and ash
accumulating in ash hopper.
If the joints temperature in the same field has great difference, it is possible
that the ash falling will be uneven or bad ash falling occurs in some hoppers. It is
necessary to adjust the load distribution of the flue and ESP, adjust hopper aeration
gas quantity and ash feeding time, adjust the circle interval time, make the ash falling
normal and ensure good operation circle.
Review all the joint temperature after a period (about a week) of each operation
starting.
2) Ash Falling
During the period of the “falling –conveying –conveying over”, know the ash falling
and conveying status by knocking the pump body, or check the ash thickness by
opening the manual vent valve. This job must be carried out to know the basic ash
conveying status especially at the beginning of the conveying and the pump being still
not full.
3) Vent-Pipe And Blockage Relief Pipe Status
Setting vent-pipe and valves in the MD pump, the vent valve is opened to
exhaust when the MD pump inlet dome valve is opened for ash falling by gravity. At
the normal condition, it takes 10～20 seconds to full the pump, and the ash falling
pipe temperature increases and vent-pipe works normally. If there is enough ash in the
ESP hopper, but it is still hard to fill the pump, maybe the vent-pipe acts abnormally
without enough venting. Here, the following methods can be used:
A：Knock the vent-pipe before opening the vent valve; after turning off the vent valve,
stop knocking, and repeat the above to remove handicap.

B：Clear the accumulated ash in the pipe through the vent-pipe plug.
C：Seal the outlet pipe and shut off the isolated valve above the inlet valve, pressurize
the pump and pipeline to 1~2bar, open the vent valve after knocking pipe. And
repeat the above.
When the blockage removing goes along well in the blockage relief pipe, obvious
sound of material flowing can be heard with the temperature rising.
4) The Working Status of the Pump Fluidizing Air Pipe

When ash conveying, the pump fluidizing air valve is open, the air flow sound
in the fluidizing air pipe can be heard with the libration. The greater gas dosage is, the
greater quiver is; the smaller gas dosage is, the lighter quiver is. If there being no the
sound and vibration, it is possible that blockage occurs in the plate and isolated valve
caused by impurity. It is necessary to clear the orifice plate and isolated valve and blow
the pipe.
5) Conveying Air
Avoid more water content in the conveying air. In the dry day, make drainage in
air receiver once 2hours, in the wet day, increase the drainage times.
Part II Fault Diagnosis And Managing Methods Of Ash Conveying System
Warning: Prior to system fault diagnosis, check air & electrical supplies and carry
out the protection.
When carrying out fault diagnosis, the switch on the CRT menu is set to “stop”
or “purge”.
symptom Possible cause Remedial measure
1. Incorrect switch position Put the switch of control panel is set to

“remote/local----In the “remote” position
“local” position
2 low conveying main pipe

pressure Initiate other compressors, open
the valve and check the pressure
gauge, pressure switch and pressure
transmitter of the air receiver
3. Incorrect dome valve seal Check all the dome valve status
1 ： circle not pressure signal，control gas comparing with the dome valve
starting malfunction initial status list. If the difference
occurs, check the control gas and
pneumatic panel gas inlet valve,
check and adjust the wrong signal
feedback conditions.
4 Incorrect path----high level Select the correct path. Once the high
probe alarm of silo level probe alarm occurs, the ash silo
can not convey.
5 Incorrect pipe conveying Readjust the pressure switch and
pressure switch signal check the connection
feedback
6 No pressing the CRT menu Stop other orders and press the
circulate key operation key
2 ： pump 1. Incorrect dome valve seal

start-up, pressure signal or limit Check and adjust the wrong seal
accomplish switch fails to work. pressure single feedback
ash accompanying conditions. according
falling ,dome to the maintenance manual, exchange
valve is the limit switch if failure occurs.
closed, no ash
conveying 2. Dome valve not closed
completely, and the dome or Isolate electrically and pneumatically,
shaft are blocked. remove the pipe from bottom bend,
clear vessel. Remove the actuator
and operate manually, check the limit
switch operation
3. Blowing valve not working Under the condition of normal

controlling air:
Turn on local solenoid, if the blowing
valve acts normally, check or change
the solenoid, if the blowing valve can
not work, repair and change the
blowing valve.
4. The manual valve of Open the manual valve
conveying pipeline shut off
1. Pipeline is blocked and isn’t Manual local blockage relief valve.

unobstructed.
Check the gas supply and power
supply. Affirm all the valve working
status.
3：conveying From the farmost point of the

system starts, pipeline, knock the pipe slightly and
then stops ensure the position， isolate the gas
supply and power supply, reduce
the gas quantity. Remove the pipe
where the blockage occurs, investigate
the reason and blow the pipe.
2. Arch occurs in the outlet Check bulk and humidity of the pump
materiel. outlet material
4：inlet dome 1. Seal pressure decreases to Check the gas supply pipeline
valve or vent conveying pressure
dome valve 2. Crazing in the dome valve
leakage Replace the seal ,check the clearance
(note : some between the manual and seal
little leakage 3. Blockage in the strainer Remove and clear
in the sytem
is normal
1. Solenoid is not working full Remove and clear

travel.
5 ： air 2. dome valve actuator seal Fit new seals
venting leaks
continuously
through
opening/closi
ng solenoid
6： 1 If the ash quantity than the Ensure the filter and electric heater
Abnormal normal condition, the plate working condition and ensure
ash falling conveying pressure is much the ash in the hopper。
lower than the normal
conveying pressure Knock the ash hopper vibrator and
rigid joints
Adjust aeration gas quantity
Check the vent-pipe condition and
eliminate fault
Increasing exhausting with the vent
valve, accelerate ash falling
1. Improper orifice plate Adjust the orifice plate gas quantity

7 ： bad setting， too fast material
abrasion of flowing
pipe /bend 2. Low conveying load Check the vessel filling time, vent
valve and vibrator setting, increase the
falling ash quantity in the pump
3. Improper pipe bend Locate the position
installation
8： incorrect 1 The gas source pressure is Check the air receiver local gas source
feedback lower than the design pressure.
requirement
signal of 2 Feedback gas pipeline is
dome valve obstructed. Check pressure gauge display of the
seal pressure local pneumatic panel.
When the pressure is lower than
the feedback pressure, transact as the
following 3,4,5 items.。
3 Limit switch Check connection of the local limit
non-connection switch and controlling gas pipeline.
4 the adjusting bolt need to Adjust the adjusting bolt length
adjust
5 Gas pipeline connection Check the connection of seal gas
malposition pipeline and gas source pressure
6 high pressure gauge setting Check and adjust the pressure gauge
value setting value properly
7 Group terminal block Check the local pneumatic panel
connection becoming power supply and the connection PLC
loosing cabinet
8 Switch can not be closed Check if there being something
Part III Dome Valve Maintenance Instructions
PROCEDURE FOR REMOVAL OF DOME VALVE
Inlet Dome Valve
1. Fully close isolating valve and run the Ash Vessel until empty.
2. Shut down and isolate system.
3. Disconnect and mark nylon pneumatic pipework to the cylinder/actuator and limit
switch, and water pipework to the top plate/dome (high temperature models only).
4. Remove set screws securing isolating valve to adaptor if fitted to Dome Valve top
plate.
5. Remove set screws from Dome Valve bottom flange to vessel.
6. Lower vessel by means of the jacking bolts on the feet of the vessel (25mm).
7. Remove Dome Valve by sliding sideways using lifting equipment if possible.
Outlet Dome Valve
3. Disconnect and mark nylon pneumatic pipework to the actuator and limit switch, and
water pipework to the top adaptor/dome (high temperature models only).
4. Ensure pipework local to valve is supported and remove bolting from both Dome
Valve adaptor flanges.
5. Remove Dome Valve by lowering and sliding sideways using lifting equipment if
possible.
Exhaust Dome Valve

3. Disconnect and mark nylon pneumatic pipework to the actuator and limit switch, and
water pipework to the top adaptor/dome (high temperature models only).
4. Remove bolting from both Dome Valve adaptor flanges, and remove the plate orifice
and gasket.
5. Detach the bolt between bottom flange and vessel flange.
6. Remove Dome Valve using lifting equipment if possible.

DOME VALVE MAINTENANCE INSTRUCTIONS
Replacement/Inspection of Dome Valve Insert Seal
1. Remove set screws from top plate/adaptor, lift out the sealing head assembly
consisting of top plate/adaptor, insert seal , insert ring and spigot ring .
2. Note the number and thickness of gaskets under the spigot ring. Combinations of
0.4mm, 0.8mm and 1.5mm thickness gaskets are fitted to achieve the required seal gap
(between the seal and the dome).
3. Separate the seal from the insert ring and inspect for wear or damage. Replace
immediately if necessary.
4. Rotate the dome by hand to check the condition of the bearings . If the bearings are
seized or due for replacement proceed to 'Removal/Replacement of DomeValve
Bearings'.
5. When re-assembling the valve ensure that the underside of the top plate/adaptor is
free from corrosion. All surfaces should be clean in order to form an air tight seal.
6. Lower the gaskets onto the valve body followed by the spigot ring and insert
seal/ring .
7. Lower the top plate/adaptor into position taking care not to trap the seal, and tighten
down.
REMOVAL/REPLACEMENT OF DOME VALVE BEARINGS
Centre Mounted Cylinder Version
1. Remove the sealing head assembly.
2. Remove cylinder guard front cover
3. Remove the nearside circlip on the front clevis assembly and lightly tap the pin out.
4. The cylinder can now be removed.
5. Turn the valve through 180°, remove grease nipples.
6. Punch out the two inner spring pins securing the dome to the shafts and remove
torque arm if necessary.
7. Remove rear guard.
8. Withdraw the shafts and lift out the dome . Note if there are any shims present on
the shafts. The shims are occasionally fitted at the factory for centralising the dome and
should therefore be refitted on subsequent overhauls.
9. Bearings and seals can now be removed by driving them towards the centre of the
valve.
10. All machined surfaces should be thoroughly cleaned/degreased and inspected.

Check for surface irregularities in the dome and shafts and replace if
necessary. Also de-burr the edges to prevent damage to the replacement
seals and bearings on re-assembly.
11. Carefully fit the replacement seal into the locating ring so that the lip on the seal
faces the chamfered leading edge of the locating ring.
12. Press the locating rings squarely into the bore. Offer the leading edge of the bearing
up to the bore, align the hole in the bearing of the 1/8" NPT hole in the body. Press in
squarely until the bearing sits approximately 3mm below the face of the bore. Repeat for
the other side.
13. Liberally pack the space between the seals and coat the bearings with Shell Malleus
JB or equivalent.
14. Re-fit the shim(s) (if applicable) and slide a new 'O' ring over the shafts up to the
boss.
15. Slide the shaft through the bearing until it touches the first seal. Repeat for the other
side.
16. Hold the dome adjacent to the bores and drive the shaft through the seals and the
dome using a plastic/hide mallet. Re-fit the grease nipples .
17. Rotate the shafts until the holes in the shaft and dome align. Grease the spring pins
and drive in.
18. Turn the valve through 180°.
19. Re-fit the cylinder assembly steps 2 to 7 in reverse order. Secure the guard in
position.
20. Re-fit the sealing head assembly.
21. Setting of Limit Switch Loosen the lock nut on the striker arm and wind up the set
screw. With the dome
Fully closed wind out the screw until the hex head touches the plunger on the
limit switch. Turn the screw a further 4mm (3.25 turns) to depress the plunger.
REMOVAL/REPLACEMENT OF DOME VALVE BEARINGS
Vane Type Actuator Version
1. Remove the sealing head assembly.

2. Rotate the dome until it resets in a position halfway between open and closed.
3. Remove the set screws which attach the actuator mounting to the valve body and
withdraw.
4. Remove the grease nipples.
6. Punch out the two inner spring pins securing the dome to the shafts.
7. Withdraw the shafts and lift out the dome . Note if there are any shims present on the
shafts. The shims are occasionally fitted at the factory for centralising the dome and
should therefore be refitted on subsequent overhauls.
8. The bearings and seals can now be removed by driving them towards the centre of
the valve.
9. All machined surfaces should now be thoroughly cleaned/degreased and inspected.
10. Check for surface irregularities in the dome and shafts and replace if necessary. Also
de-burr the edges of the two holes and the leading edge of each drive shaft to prevent
damage to the replacement seals/bearings on re-assembly.
11. Carefully fit the replacement seal into the locating ring so that the lip on the seal
faces the chamfered leading edge of the locating ring.
12. Press the locating rings squarely into the bore. Offer the leading edge of the bearing
up to the bore, align the hole in the bearing to the 1/8" NPT hole in the body. Press in
squarely until the bearing sits approximately 3mm below the face of the bore. Repeat for
the other side.
13. Liberally pack the space between the seals and coat the bearings with Shell Malleus
JB or equivalent.
14.Re-fit the shim(s) if applicable to the correct side of the valve, slide a new 'O' ring (7)
over the shafts up to the boss.
15. Slide the shaft through the bearing until it reaches the first seal in the bore.
16. Hold the dome adjacent to the bores and drive the shafts through the seals and the
dome using a plastic/hide mallet.
17. Rotate the shafts until the holes in the shaft and the dome align. Grease the spring
pins and drive in.
19. Fit the grease nipples and the actuator.
20. Re-fit the sealing head assembly.
21. Limit Switch Setting Loosen the lock nut on the striker arm and wind up the set
screw. With the dome fully closed wind out the screw until the hexagon head touches
the plunger on the limit switch. Turn the screw a further 3.25 turns to depress the plunger.
Warning :
1) Before carrying out any Dome Valve Maintenance ensure

that the temperature has cooled sufficiently.
2) Before removing top plate and removing bearing isolate cooling water
supply.
ROUTINE MAINTENANCE
Before starting any routine maintenance ensure the system is fully both electrically and
pneumatically isolated. The remaining pressure is given off. The cool water is shut off, and the
dome is fully cooled.
Weekly
Have polling and look into the operating condition.
Monthly
Grease Dome Valve shafts and bearings (hydraulic type grease

nipples). Use Shell Malleus JB.
Check the filtrate/grease subassembly. Watch the filtrate subassembly condition, and
clean it (once a year).
use:
Shell Tellus 37 degree 37

Moibl DTE Oil.Light degree32
BP HLP32 degree 32
Annually
1. check the dome valve limit Switch.
2. pneumatic panel: check up the silencer, and change it timely. And clean filtrate
subassembly if necessary.
3.HM isolate valve : clean the dirty of the daft, and grease the shaft, check the valve
work flexible.
4.detach the filtrate core from the air injection assembly ,clean and change it. Check
the globe valve .
5.check the level probe connecting condition.
Every two year
Note: shut off the HM isolate valve, run system to the circle end. Remove the fexible
joint . Remove Dome Valve using lifting equipment.
1) Remove Dome Valve and check dome and head for seal wear.
2) Check Dome Valve shafts for wear and replace bearings and seal if necessary.
3) Pneumatic panel: check connecting condition electrically and pneumatically.
4) Dome valve and actuator: check the nick, pitting ,rust of the actuator inner
wall ,which can make the actuator seal invalid quickly.
电厂工程气力除灰、石灰石输送及床料添加系统操作维护手册
SILOPI 1X135MW Asphaltite Fired Power Plant OPERATING & MAINTENANCE INSTRUCTIONS
(PART ONE)
Appendix 1: Conveying System Lubricant Specification
1：Dome valve bearing (lubricating grease)

Choice grease： Shell Malleus JB1 or Mobil SHC1500
2: Actuator and valve （lubricating grease）
Choice grease：
Shell Tellus 37 degree 37
Moibl DTE Oil.Light degree 32
BP HLP32 degree 32
3：High-speed equipment and shaft
SHELL Tellus 32 degree32
Moibl Velocite No 6 degree10
BP HLP22 degree 22
4: Recommend the grease gun for dome valve greasing：
grease gun brand：SATA
grease gun model：97202#grease gun、97203#grease gun
manufacturer：Danaher Tool group(shanghai)—（Danaher Corporation branch
company）
Tel：021—63612012 Fax：021—64216308
Remark：If the gun is equipped with a 1/8NPT high-pressure vitta, it is
more convenient for greasing.
5： Notice of 97202#、97203#、1/8NPT high-pressure vitta usage：

d) Before the gun keeps the oil nipple in mouth, loosen the bolts between the nipple
and vitta. After this, fasten all the screwing connection. After the grease is
injected, operate it by reverse order.
电厂工程气力除灰、石灰石输送及床料添加系统操作维护手册
SILOPI 1X135MW Asphaltite Fired Power Plant OPERATING & MAINTENANCE INSTRUCTIONS
(PART ONE)
e) There is reversing subassembly inside the gun nipple made of spring, steel
ball， which can ensure the grease be injected into the nipple under the high
pressure，this subassembly is absolutely necessary . Check this before work
begins.
f) Other operation is referred to the SATA 97202#、97203# manufacturer's
specification.

Ash Handling System Operetaion and Maintenance Instruction

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Ash Handling System Operetaion and Maintenance Instruction

Caricato da

Copyright:

Formati disponibili

POWER PLANT

ASH HANDLING SYSTEM

FUNCTIONAL DESIGN SPECIFICATION

CLYDE BERGEMANN HUATONG MATERIALS HANDLING CO.,LTD.

2. ESP FIELD 1 or 2 MD PUMP OPERATION

3. ESP FIELD 1 AND AIR HEATER MIXED GRITS OPERATION

4. ESP FIELD 3 ASH vessel OPERATION

5. ESP FIELD 4&5 ASH vessel OPERATION

Control air off Control air on Control air on

Slave MD-Pumps last position* closed closed

Main conveying air closed closed closed

The MD-Pumps should be empty and at zero pressure.

The Remote/Local switch on the pneumatic control panel is set to “Remote”.

Conveying pressure is < 0.03MPa (PT02).

Conveying air supply pressure is > 0. 55MPa (client signal).

Minimum cycle period timer expired.

CHANGING THE SWITCH VALVE POSITION

Timer name Purpose of timer Timer setting Timer range

PNEUMATIC CONTROL PANEL

ELECTRICAL CONTROL PANEL

INLET AND VENT DOME VALVE NOT OPEN ALARM

CONVEYING CYCLE FAULT ALARM

CONVEYING AIR PRESSURE LOW ALARM

ISOLATING VALVE FAULT ALARM

Ash Vessel system

Control air off Control air on Control air on

Supplementary air closed closed closed

Conveying air valve closed closed closed

Bypass air valve closed closed closed

Density stabiliser closed closed closed

Control air off Control air on Control air on

MD-Pump Vent last position closed closed

Conveying air valve closed closed closed

The Start/Stop switch on the pneumatic control panel is set to “START”.

Client interlock is healthy.

Conveying pressure is < 0.03MPa (PT02).

Conveying air supply pressure > 0.55MPa.

Master vessel inlet Dome Valve is closed and sealed (PS01).

Minimum cycle period timer expired.

First conveying air pressure limit.

Second conveying air pressure limit.

Timer name Purpose of timer Timer setting Timer range

The Remote/Local switch on the pneumatic control panel is set to “Remote”.

Conveying pressure is < 0.03MPa (PT02).

Conveying air supply pressure is > 0.55MPa (client signal).

Minimum cycle period timer expired.

Timer name Purpose of timer Timer setting Timer range

PNEUMATIC CONTROL PANEL

ELECTRICAL CONTROL PANEL

Ash Vessel system

INLET DOME VALVE NOT OPEN ALARM

INLET DOME VALVES NOT CLOSED AND SEALED ALARM

Control air off Control air on Control air on

Slave vessel inlet last position* closed closed

Pipeline Switch Valve last position* open open

Main conveying air closed closed closed

The ash vessels should be empty and at zero pressure.

The Remote/Local switch on the pneumatic control panel is set to “Remote”.

Client interlock is healthy.

Conveying pressure is < 0.03MPa (PT02).

Conveying air supply pressure > 0.55MPa.

Master vessel inlet Dome Valve is closed and sealed (PS01).

CHANGING THE SILO TOP SWITCH VALVE POSITION

Timer name Purpose of timer Timer setting Timer range

定时器名称定时器设定定时器范围