列管式油冷却器使用说明书常州华立教学教材.doc

Good is good, but better carries it.精益求精，善益求善。列管式油冷却器使用说明书常州华立-列管式油冷却器TubularOilCooler使用说明书OperationInstruction常州市华立液压润滑设备有限公司ChangZhouHualiHydraraulicLubricationEquipmentCo.Ltd列管式油冷却器使用说明书一、 概述1.用途：本产品按JB/T7356-2005或用户要求设计和制造，油侧工作压力1.6MPa，工作温度90，水侧工作压力1.0MPa，工作温度50。介质为粘度等级N10N460的工业润滑油，适用于稀油润滑系统和液压系统中作冷却油液之用。广泛适用于化工、电力、冶金、矿山、轻工等行业的各种液压设备的冷却，是一种较为理想的冷却装置。2.特点：(1)为2流程或4流程列管式冷却器。(2)安装形式有卧式和立式。(3)油、水接口法兰标准：正常供货时，按PN1.0MPa机标JB/T81-94；也可根据用户要求选配国标、化工、石化、欧标、美标、船标法兰。(4)换热器的材质：根据使用场所、水系统条件进行选配。水室、壳体、三通阀可选碳钢或全不锈钢；换热管材质可选紫铜、普通黄铜、耐海水黄铜HSn70-1或HAl77-2、白铜B10或B30、不锈钢管等。(5)外形尺寸符合本公司样本或订货合同规定。二、 使用要求1.启用油冷却器的步骤和注意事项：(1)检查所有附件与仪表、并察看各连接处是否紧密可靠。(2)拧下处于冷却器壳体上部的排气螺塞，再缓缓开启进油阀，当油溢出时，关闭进油阀，拧紧排气螺塞。(3)拧下冷却器水路中排气阀,然后缓缓开启进水阀，当水溢出时，关闭进水阀，拧紧排气螺塞。此时水和油均为静止状态，经热交换后，温度差逐渐减小。(4)当水温升高5-10后，打开冷却水的排出阀，再逐渐打开冷却水的进入阀,使冷却水处于流动状态，再逐渐打开油的进入阀，使油也处于流动状态，然后调整冷却水的流量,使出油温度保持在正常工作状态之中。(5)在启用油冷却器时，切忌快速打开进水阀门，因冷却水大量渡过油冷却器时，会使换热管表面形成一层导热性能极差的“过冷层”，以后即使大量和水进入油冷却器，结果还是起不到良好的冷却效果。(6)油冷却器的油侧压力要大于水侧压力。(7)如果在水侧发生电化作用的腐蚀，可以在水侧位置自行安装锌棒。2.油冷却器使用中的管理与故障消除方法：(1)经常观察油的出口温度，借调节冷却水进入阀的开启量来保证油液的冷却要求。(2)冷却水通常采用净化的淡水，使用江河水时在进水口须配置滤水器。(3)为提高热交换性能，防止水垢形成，冷却水温度应尽可能低一些，水流量尽可能大一些。(4)在寒冷季节，为防止油冷却器换热管冻裂，在停止使用前必须放尽油冷却器内的剩油和剩水。(5)清洗周期：根据水质及油质情况，一般每510个月即应进行一次内部的检查及清洗。(6)故障及消除方法：故障及产生原因消除方法换热性能下降冷却水量不足(1) 开大进水阀(2) 检查管路、阀门、滤网、换热管是否被阻塞，如有应排除。换热管内或管间积气拧下螺塞排气换热管内积垢，流阻增大清理换热管内、外表面污垢在回水盖放水时，发现有水和油的混合物(1) 浮动管板式，有3种可能:a) 密封件失效b) 换热管破裂c) 换热管与管板连接处泄漏(2) 固定管板式，有2种可能:a) 换热管破裂b) 换热管与管板连接处泄漏回水盖、后盖螺钉连接处发生泄漏(1) 拧紧两盖上紧固件或更换密封垫(2) 换热器拆卸后，应尽可能使用新的密封垫固定管板和浮动管板以及换热管被严重腐蚀，油冷却器失去密封性(1) 浮动管板式，更换管簇；(2) 固定管板式，换新。3.油冷却器停止工作的步骤：(1)关闭油液进入阀。(2)关闭冷却水进入阀。(3)关闭油液排出阀。(4)关闭冷却水排出阀。(5)拧下排水、排油接口上的螺塞，疏尽积于油冷却器内的冷却水和油。4.清洗：油冷却器长期工作后，管壁表面逐渐积垢，换热性能下降，以至不能保证换热要求，此时必须停用清洗。清洗方法如下：(1)水侧清洗：用软管引洁净水高速冲洗回水盖、后盖内壁和油冷却器内表面，同时用清洗通条进行洗刷，最后用压缩空气吹干。(2)油侧清洗：A、用三氯乙烯溶液进行冲洗，使清洗液在换热管内循环流动，溶液压力不大于1.6MPa；溶液的流向最好与油冷却器油流方向相反。清洗时间视污垢情况而定。B、用煤油清洗，直到流出的煤油清洁为止。C、放尽清洗煤油。(3)清洗后进行液压试验或气压试验，合格后装到系统上使用。三、 油冷却器的拆卸和再装配1关闭进出油口和水口的阀门，放尽油冷却器内的剩油和剩水，然后从系统中拆卸。2.浮动管板式油冷却器拆卸顺序如下：(1)从后盖开始，依次拆除螺栓，取下后盖，同时小心取下密封圈。(2)再折前盖，依次拆除螺栓，取下前盖，同时小心取下密封圈。(3)将管束从壳体中抽出。3.固定管板式油冷却器不能拆卸管束清洗。4.油冷却器装配顺序与拆卸顺序相反。四、 长期停用时的保养1.封存时要做的工作：(1)疏尽油冷却器内的介质。(2)拆除与油冷却器连接的全部管路，清洗后吹干冷却器零部件。(3)油冷却器外露工作表面应涂上防锈油脂，进出口须用聚氯乙烯盖盖严。(4)定期检查油封（6个月）必要时重新调换，并积极改善存放条件。2.启封备用时要做的工作：(1)取下聚氯乙烯盖，除去外露加工表面上的油脂。(2)进行气压密封性试验。(3)装妥外连接管路。(4)按使用要领使油冷却器处于备用状态。五、 标志、包装及运输1.油冷却器出厂时附有合格证，压力试验报告，使用说明书。2.在油冷却器壳体的明显部位固定有一标牌，标牌上注明有以下内容：-(1)产品名称、商标(2)型号(3)编号(4)工作温度(5)工作压力(6)冷却面积(7)重量(8)制造厂名六、 售后服务1.公司售后服务电话：0519-88675056；0519-88675060传真：0519-886703432.公司地址：江苏省常州市北门外三河口3.公司名称：常州市华立液压润滑设备有限公司OperationInstructionsForTubularOilCooler1.Outline1.1Usage:ThisproductismadeaccordingtostandardJB/T7356-2005ortheuserrequirements,designandmanufactureofoilpressureofwork1.6MPa,worktemperature90,watersidepressureofwork1.0MPa,workemperature50t.MediumviscositylevelforN10N460industriallubricants,applicabletothinoillubricationsystemandhydraulicsystemforcoolingtheuseofoil.Widelyusedinchemicalindustry,electricpower,metallurgy,mining,lightindustryofhydraulicequipmentcooling,isamoreidealcoolingdevice1.2Characteristics:1.2.1For2processesor4processtubetypecooler.1.2.2Installedahorizontalandverticalform.1.2.3Oil,waterinterfaceflangestandards:normalsupply,accordingtoPN1.0MPamachinestandardJB/T81-94;Accordingtousernationalstandard,thechemicalindustry,thepetrifaction,thestandard,Americanstandard,theshipstandardflange.1.2.4Theheatexchangermaterial:accordingtouseplace,watersystemconditionsareoptional.Waterroom,shell,the3-wayvalve(posoptionalcarbonsteelorstainlesssteel;Heatexchangetubematerialoptionalcopper,brass,ordinaryresistanttosaltwaterbrassHSn70-1orHAl77-2,cupronickelB10orB30,stainlesssteelpipe,etc.1.2.5Shapedimensioninaccordancewiththecompanysampleororderofthecontract.2.Operationrequirements2.1Enableoilcoolerstepsandnote:2.1.1Checkallaccessoriesandinstruments,andseewhetherthejointcloselyandreliable.2.1.2Backoffinacoolershellandtheupperpartoftheventscrew,againslowlyopenJinYouvalve,whentheoilspills,closeJinYouvalve,tightenventscrew.2.1.3Backoffwatercooler,thenslowlyopenrankedairvalveinletvalveandwhenthewateroverflow,shutintowatervalve,tightenventscrew.Atthistimethewaterandoilarestationary,aftertheheatexchanger,decreasingthetemperaturedifference.2.1.4Whenincreasedwatertemperatures5-10,openthecoolingwaterdischargevalve,thengraduallyopenthecoolingwaterintothevalve,coolingwaterinflowstate,thengraduallyopentheoilintothevalve,alsowasintheoilflowstate,andthenadjustcoolingwaterflow,useoiltemperatureismaintainedatastateofthenormalwork.2.1.5Intheopeningoilcooler,avoidbyallmeansisquicklyopentheinletwatervalve,becausealotofcoolingwaterthroughoilcooler,willmaketheheatexchangetubesurfacetoformalayerofheatconductionperformanceverybad"cold",evenifalotofafterwaterintotheoilcooler,andtheresultwasnotagoodcoolingeffect.2.1.6Oilcoolerthanthelateralpressureoilwatersidepressure.(7)Ifthewatersideeffectofelectrochemicalcorrosionoccurred,canbeinwatersidepositiontoinstallzincbar.2.2Themanagementanduseoilcoolerfaulteliminatemethods:2.2.1Oftenobservedtheexportofoiltemperature,adjustcoolingwaterintothevalvethroughopenamounttoensuretheoilcoolingrequirements.2.2.2Thepurificationoffreshwatercoolingwaterusually,useJiangHeShuiinletmustbeinconfigurationwaterfilter.2.2.3Inordertoimprovetheheattransferperformance,topreventscaleformation,coolingwatertemperatureshouldbeaslowaspossiblesome,theflowofwaterasfaraspossiblebigsome.2.2.4Inthecoldseason,topreventoilcoolerheatexchangeinDongLie,stopbeforeusehavetoputalloilcoolerShengYouandleftinthewater.2.2.5Thecleaningcycle:accordingtothewaterqualityandoily,generalevery510monthsnamelyshouldconductainternalinspectionandcleaning.2.2.6Faultandeliminatemethods:FailurecausesEliminatingmethodsTheheatexchangeperformancedropCoolingwaterinsufficient(1)Adjustthewatersuckingvalvetoincreasethewatervolume(2)Checkthetube,valve,filter,heatexchangetubesischoked,suchaswhethershouldberuledout.AccumulatedairinsideorbetweentubesofexchangerLoosenthebolttoexhaustairAccumulatedwateroroildirtinsidethebubesoftheoilcoolerCleaninginsideandoutsidesurfacedirtMixtureofwaterandoilappearswhendrainingthewaterinthewaterbackcover(1) Floattubeplateheatexchanger,oil-watermixhavethreepossible:a) Sealfailureb) Heatexchangetuberupturec) Heatexchangetubeandtubeplatejointleakage(2) Fixedtubeplateheatexchanger,oil-watermixhavetwopossibilities:a) Heatexchangetuberuptureb) HeatexchangetubeandtubeplatejointleakageBackwatercover,backcoverscrewconnectiontotheleak(1) Twocovertotightenfastenersorreplacethesealgasket(2) AfterremovalofheatexchangershouldasfaraspossibletousenewgasketFixedtubeplateandfloattubeplateandheatexchangetubewasseriouscorrosion,oilcoolerlosetightness(1) Floattubeplate,replacingthecluster；(2) Fixedtubeplate,changenew。2.3Oilcoolerstopworksteps:2.3.1Shutofftheoilintothevalve.2.3.2Closecoolingwaterintothevalve.2.3.3Shutofftheoildischargevalve.2.3.4Closecoolingwaterdischargevalve.2.3.5Backoffdrainage,farontheinterfacescrew,thindoproductinoilcoolerinthecoolingwaterandoil.2.4Cleaning:Oilcoolerlong-termwork,wallsurfacefoulingheatexchangeperformance,graduallydeclinethatcan'tguaranteeheattransferrequest,thenitshouldbediscontinuedcleaning.Cleaningthemethodisasfollows:2.4.1Watersidewithhoseclean:ledcleanwaterhigh-speedflushcover,thewaterbackwallandoilcoolerinsidesurface,atthesametimeusethecleaningbrush,finallytoramrodwithcompressedairisblowndry.2.4.2Oilsidecleaning:2.4.2.1Withthreevinylchloridesolutiontowash,makecleaninginheatexchangecirculatingwithin,thesolutionisnomorethan1.6MPapressure;Thebestsolutiontooilandoilcoolerinoppositedirections.Cleaningtimedependingonthedirttocircumstances.2.4.2.2Kerosenecleaning,untilthekerosenecleanoutsofar.2.4.2.3Putdocleaningkerosene.2.4.3Aftercleaninghydraulictestedorairpressuretest,afterpassingonthesystemwithuse.3.Oilcoolerremovalandassemblyagain3.1Closeinandoutofthemouthofthevalveoutletandoil,putalloilcoolerShengYouandleftinthewater,andthenremovefromthesystem.3.2Floattubeplateoilcoolerdisassemblysequenceisasfollows:3.2.1Fromthebackcoverbegantodismantlebolt,inturn,tookbackcover,andbecarefultakesealingring.3.2.2Tofoldthefrontcover,inturn,demolition,removethefrontcoverbolts,andbecarefultakesealingring.3.2.3Willbundleoutfromshell.3.3Fixedtubeplateoilcoolercannotberemovedovercleaning.3.4Oilcoolerassemblysequenceanddisassemblysequenceinstead.4.Long-termdiscontinuationofmaintenance4.1Sealstorageofworktodo:4.1.1Alloilcooleroutinthemedia.4.1.2Removedandoilcoolerconnectionofallthelines,blowdrycoolerpartsaftercleaning.4.1.3Oilcoolerexposedworksurfaceshouldbecoatedwithoil,mustusetheimportandexportofrustPVCcovercovertightly.4.1.4Regularinspectionoilseal(6months)whennecessarytoexchange,andactivelyimprovestorageconditions.4.2Whenopenedspareofworktodo:4.2.1TakePVCcover,removeexposedunderthemachinedsurfaceofoil.4.2.2Thesealingpressuretest.4.2.3Theinstallsedimentconnectionline.4.2.4Accordingtobringmakeoilcoolerinstandbymode.5Marks,PackagingandShipping5.1Oilcoolerwhenthefactorywithcertificateofapproval,thepressuretestreport,specifications.5.2.Theobviousinoilcoolershellpartsasign,fixedsignsindicatehasthefollowingcontents:5.2.1Theproductname,Trademark5.2.2Type5.2.3No.5.2.4Operatingtemperature5.2.5Operatingpressure5.2.6Coolingarea5.2.7Weight5.2.8NameofManufacturer6.After-salesservice6.1Thecompanyafter-salesservicetelephone:0519-88675056;0519-88675060Fax:0519-886703436.2Thecompanyaddress:ThreeEstuary,NorthDoorOutside,Changzhou,Jiangsuprovince,ThePeople'sRepublicofChina6.3CompanyName:ChangzhouHualiHydraulicLubricationEquipmentCo.,LTD