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Article(id=1199810030284403104, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, articleNumber=1009-5438(2022)06-0076-05, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1666281600000, receivedDateStr=2022-10-21, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1763986602611, onlineDateStr=2025-11-24, pubDate=1671897600000, pubDateStr=2022-12-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763986602611, onlineIssueDateStr=2025-11-24, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763986602611, creator=13701087609, updateTime=1763986602611, updator=13701087609, issue=Issue{id=1199810028623458694, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='6', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763986602216, creator=13701087609, updateTime=1764034375076, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200010402584163079, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200010402584163080, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=76, endPage=80, ext={EN=ArticleExt(id=1199810030645113262, articleId=1199810030284403104, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Analysis and Equipment Improvement of High Pressure Water Descaling System for Heavy Plate Mill, columnId=1187100786392711543, journalTitle=Science & Technology of Baotou Steel, columnName=Equipment and Automation, runingTitle=null, highlight=null, articleAbstract=

In the paper, the design, main components and features of high pressure water descaling system in the production line of heavy plate of Baotou Steel are introduced and analyzed. Moreover, the system equipment is improved based on the experiences of on-site maintenance and fault handling for high pressure water system in the production line, which is with greater reference significances for the design, maintenance, fault diagnosis and optimization of high pressure water descaling system in the production line of heavy plate.

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文章对包钢宽厚板生产线高压水除鳞系统的系统设计、系统主要组成、系统特点等进行了介绍和分析,同时根据生产线高压水系统现场维护和故障处理经验,对系统设备进行改进,对宽厚板生产线高压水除鳞系统的设计、维护、故障诊断、系统优化等有较大的参考意义。

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陈国庆(1969-),男,江苏省泰兴市人,硕士,高级工程师,现从事设备工程技术及管理工作。

, authorsList=陈国庆, 杨文海)}, authors=[Author(id=1200024815865262223, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, orderNo=0, firstName=null, middleName=null, lastName=null, nameCn=null, orcid=null, stid=null, country=null, authorPic=null, dead=0, email=null, emailSecond=null, emailThird=null, correspondingAuthor=0, authorType=1, ext={EN=AuthorExt(id=1200024815986897052, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, authorId=1200024815865262223, language=EN, stringName=Guo-qing Chen, firstName=Guo-qing, middleName=null, lastName=Chen, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=1, address=1 Engineering Service Co. of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China, bio=null, bioImg=null, bioContent=null, aboutCorrespAuthor=null), CN=AuthorExt(id=1200024816074977446, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, authorId=1200024815865262223, language=CN, stringName=陈国庆, firstName=null, middleName=null, lastName=null, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=1, address=1 内蒙古包钢钢联股份有限公司工程服务公司, 内蒙古 包头 014010, bio={"content":"

陈国庆(1969-),男,江苏省泰兴市人,硕士,高级工程师,现从事设备工程技术及管理工作。

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陈国庆(1969-),男,江苏省泰兴市人,硕士,高级工程师,现从事设备工程技术及管理工作。

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journalId=1185652524569653253, articleId=1199810030284403104, language=CN, label=图1, caption=宽厚板生产线高压水除鳞系统图, figureFileSmall=UHtALjKxJWcdTRPOnerfuw==, figureFileBig=d3vEZghGoPQGcCadqhWy+w==, tableContent=null), ArticleFig(id=1200024818507673883, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, language=EN, label=null, caption=null, figureFileSmall=2SHcoYnACLWFVAdZVGISxA==, figureFileBig=8TXFd2YczJ0TB9yJ4O/1/w==, tableContent=null), ArticleFig(id=1200024818637697313, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, language=CN, label=图2, caption=自平衡式滑阀结构图

1-入口法兰;2-阀体;3-滑阀活塞式阀芯

4-气缸;5-密封泄露监测孔;6-出口法兰;7-阀座

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主要设备 数量 主要技术参数
除鳞泵 4 流量:280 m3/h,扬程:230 m,额定转速:2 988 r/min
电机功率:2 800 kW,转速:700-2 988 r/min
蓄能器 5 容积:8 m3,设计压力:28 MPa,安全阀起跳压力:27 MPa
类别:两个气水罐,三个气罐
反冲洗过滤器 2 流量:1 000~1 300 m3/h,过滤精度:100 μm,反冲洗设定压差值:0.05 MPa
低压水罐 1 公称容积:10 m3,设计压力:1.0 MPa,安全阀起跳压力:0.8 MPa
除鳞喷射阀 10 DN150 PN320
), ArticleFig(id=1200024822009917744, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, language=CN, label=表1, caption=

包钢宽厚板轧机高压水除鳞系统主要设备技术参数表

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主要设备 数量 主要技术参数
除鳞泵 4 流量:280 m3/h,扬程:230 m,额定转速:2 988 r/min
电机功率:2 800 kW,转速:700-2 988 r/min
蓄能器 5 容积:8 m3,设计压力:28 MPa,安全阀起跳压力:27 MPa
类别:两个气水罐,三个气罐
反冲洗过滤器 2 流量:1 000~1 300 m3/h,过滤精度:100 μm,反冲洗设定压差值:0.05 MPa
低压水罐 1 公称容积:10 m3,设计压力:1.0 MPa,安全阀起跳压力:0.8 MPa
除鳞喷射阀 10 DN150 PN320
), ArticleFig(id=1200024822093803826, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
项目 高压水除鳞系统年均导致
产线停线事故时间		 高压水除鳞系统年均非导致
产线停线的故障时间		 高压水除鳞系统年均
检修维护时间
改进前 19.8 30.1 264
改进后 3.5 13.3 196
降低幅度 16.3 16.8 68
), ArticleFig(id=1200024822160912693, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810030284403104, language=CN, label=表2, caption=

高压水除鳞系统设备改进前后实际运行情况对比表 h

, figureFileSmall=null, figureFileBig=null, tableContent=
项目 高压水除鳞系统年均导致
产线停线事故时间		 高压水除鳞系统年均非导致
产线停线的故障时间		 高压水除鳞系统年均
检修维护时间
改进前 19.8 30.1 264
改进后 3.5 13.3 196
降低幅度 16.3 16.8 68
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宽厚板高压水除鳞系统分析及设备改进
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陈国庆 1 , 杨文海 2
包钢科技 | 设备与自动化 2022,48(6): 76-80
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包钢科技 | 设备与自动化 2022, 48(6): 76-80
宽厚板高压水除鳞系统分析及设备改进
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陈国庆1, 杨文海2
作者信息
  • 1 内蒙古包钢钢联股份有限公司工程服务公司, 内蒙古 包头 014010
  • 2 内蒙古包钢钢联股份有限公司薄板坯连铸连轧厂, 内蒙古 包头 014010

    • 陈国庆(1969-),男,江苏省泰兴市人,硕士,高级工程师,现从事设备工程技术及管理工作。

Analysis and Equipment Improvement of High Pressure Water Descaling System for Heavy Plate Mill
Guo-qing Chen1, Wen-hai Yang2
Affiliations
  • 1 Engineering Service Co. of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
  • 2 CSP Plant of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
出版时间: 2022-12-25
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摘要
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文章对包钢宽厚板生产线高压水除鳞系统的系统设计、系统主要组成、系统特点等进行了介绍和分析,同时根据生产线高压水系统现场维护和故障处理经验,对系统设备进行改进,对宽厚板生产线高压水除鳞系统的设计、维护、故障诊断、系统优化等有较大的参考意义。

宽厚板生产线  /  高压水除鳞系统  /  系统特点  /  系统分析  /  设备改进

In the paper, the design, main components and features of high pressure water descaling system in the production line of heavy plate of Baotou Steel are introduced and analyzed. Moreover, the system equipment is improved based on the experiences of on-site maintenance and fault handling for high pressure water system in the production line, which is with greater reference significances for the design, maintenance, fault diagnosis and optimization of high pressure water descaling system in the production line of heavy plate.

production line of heavy plate  /  high pressure water descaling system  /  system features  /  system analysis  /  equipment improvement
陈国庆, 杨文海. 宽厚板高压水除鳞系统分析及设备改进. 包钢科技, 2022 , 48 (6) : 76 -80 .
Guo-qing Chen, Wen-hai Yang. Analysis and Equipment Improvement of High Pressure Water Descaling System for Heavy Plate Mill[J]. Science & Technology of Baotou Steel, 2022 , 48 (6) : 76 -80 .
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除鳞是将在加热时生成的初生氧化铁皮和轧制过程中生成的次生氧化铁皮去除干净,以免压入钢板表面形成表面缺陷[1]。初生氧化铁皮要在轧制开始阶段去除,这时氧化铁皮高压水除鳞系统在宽厚板生产中对钢板的表面质量起着决定性的作用,其原理是通过除鳞泵将除鳞介质(水)加压转换储存为液压势能,通过释放液压势能转换的动能来清除钢板表面的氧化铁皮,从而达到提高钢板表面质量的作用[2]。
包钢宽厚板生产线高压水除鳞系统由德国SMS公司进行基本设计。通过对高压水除鳞系统在宽厚板生产线的实际生产应用中的特点及对其系统设备使用、维护、故障分析处理、设备改进等方面进行分析总结,可以深入地理解其系统设计原理和特点,对于宽厚板生产线高压水除鳞系统设计、维护、故障判断处理、系统优化改进等有较大的参考意义。
1 高压水除鳞系统设备组成及参数
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包钢宽厚板轧机高压水除鳞系统如图1所示,高压水除鳞系统用水来自于宽厚板车间的浊环水系统,浊环水系统经反冲洗过滤器过滤后,供给除鳞泵组使用。除鳞泵组由四台离心泵组成,依据产线轧制节奏的不同可为三用一备或两用两备,其驱动电机调速方式为变频调速。除鳞泵和变频电机采用集中稀油润滑方式进行润滑,变频泵组的高速和低速运行之间的切换由蓄能器组的压力控制。轧制钢板除鳞时,蓄能器组中的高压水从除鳞喷梁喷出,蓄能器组中的压力下降,压力下降至除鳞泵升速压力19 MPa时,变频电机由低转速700 r/min升速至额定转速2 988 r/min,蓄能器组压力上升,当蓄能器组中压力上升达到除鳞泵降速压力21.5 MPa时,除鳞泵降速至低转速运行,完成一个工作循环。
除鳞系统供至各除鳞喷梁的低压水主要作用为向高压管路及喷梁提供低压预充水,防止高压管路及除鳞喷梁“空腔”时高压水进入而引起除鳞管路喷梁的剧烈冲击振动。
包钢宽厚板轧机高压水除鳞系统主要设备技术参数见表1。
2 高压水系统主要特点分析
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(1)高压水系统设计采用除鳞泵电机变频调速配备蓄能罐的总体配置方案,与宽厚板生产线间断性除鳞用水的工况特点相适应,具有除鳞系统高压水水压稳定,水压波动冲击小,高压水供水量充足,且运行能耗低等多重优点。
除鳞泵驱动电机的变频泵组的高速和低速运行之间的切换受蓄能器压力控制,当蓄能器压力达到除鳞泵的降速压力时,变频电机降速至低速运行转速700 r/min,此时最小流量阀处于“关”位,其开关只受泵体温度传感器信号控制;当蓄能器压力降低到除鳞泵的升速压力时,变频电机升速至额定转速,直到蓄能器压力达到鳞泵的降速压力为止,完成一个工作循环。该工作机制除鳞泵在大部分工作时间内为低速运行状态,大幅节约运行能耗,此外变频调速除鳞泵升降速过程平稳,整个高压水系统压力稳定,系统对泵、阀、管路等组件冲击压力小,对于系统组件的稳定运行起到了至关重要的作用。
(2)系统设计运行保障功能及自动联锁保护功能完善。高压水除鳞系统设置蓄能罐最低液面关断阀,除鳞泵出口设置事故切断阀、最小流量阀,蓄能罐中的气水罐设置压力传感器和多重液位检测开关,除鳞泵泵体设置入水压力、出水压力传感器、泵体轴瓦温度传感器、振动传感器、润滑油压力传感器,泵出口事故切断阀、最小流量阀、系统各喷射阀均设置开闭状态显示接近开关,通过这些检测元件的设置,实现了系统运行关键参数的实时监测、自动运行时序设置、系统和设备状态报警和关键设备联锁保护,保障了系统的稳定运行。
(3)系统的主要部件高压水喷射阀采用自平衡式滑阀结构,开闭平稳。
系统除鳞喷射阀、泵出口最小流量阀、泵出口截止阀均采用自平衡式滑阀结构,其显著特点为活塞式阀芯自平衡结构的设计,阀体内部的活塞式阀芯上设置有通水孔,将高压水引入活塞上方,从而使活塞受到的向下的和向上的高压水水压作用力相平衡,极大地减小高压水阀开闭所需的驱动力,使其通过车间内压缩空气作为动力源驱动高压水阀体顶部气缸就可实现开闭动作,同时具有开闭平稳,管路无冲击振动的特点,大幅提高了除鳞阀的运行平稳性。自平衡式滑阀结构如图2所示。
3 高压水除鳞系统设备改进
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高压水系统投入运行后,系统总体运行稳定,但长时间运行后,也出现了一些运行缺陷,主要包括高压除鳞泵止推瓦出现烧损故障、填料密封常渗漏故障;除鳞喷射阀高压管路有时出现剧烈振动等,针对这些运行缺陷,厂部决定成立攻关组来解决上述问题。
原设计中高压水除鳞系统除鳞泵为普通多级高压离心泵,叶轮依次排列,高压水除鳞泵在输送高压水时,转子部件产生的巨大轴向力由止推瓦承担,叶轮依次排列增压的泵体结构型式导致止推瓦承受的轴向力非常大,且高压水除鳞泵在变频调速工况下止推瓦承受的轴向力频繁变化,这些因素导致除鳞泵止推瓦经常出现烧损故障。原设计中高压水除鳞系统除鳞泵轴封采用填料密封,长时间使用后填料密封易出现渗漏,破坏现场工作环境。同时,随着产线产量的不断增加,填料密封组件愈发暴露出密封可靠性欠佳、维护维修工作量大、易损件更换频繁等缺陷。
针对该缺陷,经过对同类生产线进行考察后,攻关组对高压水除鳞泵进行了选型改进,选择轴向自平衡式高压除鳞泵,轴向自平衡式高压除鳞泵出水口位于泵体中部,其叶轮相对于泵体出水口呈对称布置,其结构设计为运转中将入口侧一侧各叶轮加压后的高压水引至泵体另一侧各叶轮处进行加压,这样在运转过程中泵腔内巨大的轴向力能够自动平衡,大大降低了止推瓦承受的轴向推力,有效地避免了普通多级离心泵止推瓦烧损的事故,且轴向自平衡式高压除鳞泵轴封采用迷宫螺旋非接触式密封型式,杜绝了渗漏故障。选型改进后的高压水除鳞泵运行稳定,大幅降低了故障率。
改进前及改进后除鳞泵结构型式如图3所示。
除鳞喷射阀高压管路有时出现剧烈振动的原因为喷射阀开启时高压管路内没有充满低压预充水,喷射阀开启时高压水进入空的高压管路造成管路剧烈振动,将预充水阀解体,找到低压预充水无法将高压管路充满的原因是长时间运行后低压预充水阀因管路内杂质影响卡阻没有打开、预充水未进入高压管路,清理预充水阀内的杂质后,高压管路剧烈振动消除。攻关组注意到对于位于系统低压预充水路末端的除鳞喷射阀,长时间运行后易出现高压管路剧烈振动现象,分析因其位于管路末端,预充水水系统中的杂质等易淤积,后来攻关组在管路末端加装了排污阀,定期进行管路排污,高压管路剧烈振动的异常现象得到了完全消除。
通过对除鳞系统的设备改进,除鳞系统运行稳定性得到了大幅提高,设备故障停机时间大幅降低,高压水除鳞系统设备改进前、后实际运行情况对比见表2。
高压水除鳞系统经改造后,因系统稳定运行引起产线停产的事故停机时间、系统故障时间、年均检修维护时间显著减少,以及系统稳定运行带来的备件消耗等维护费用大幅降低,产生的经济效益约310万元/年。
4 结束语
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通过对包钢宽厚板生产线高压水除鳞系统的系统设计、系统主要组件及其参数进行介绍,对其系统设计及组件选型等特点进行分析,可进一步加深对高压水系统的理解。在此基础上结合系统实际运行情况,对高压水除鳞系统设备进行了改进。在高压水系统等设备的维护工作中,应不断总结思考,熟练掌握系统特性,对于科学合理地对系统进行维护、系统出现故障时能够较准确地做出故障原因判断、对系统进行优化改进等方面具有较大意义。
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参考文献 引证文献
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[1]
王生朝. 中厚板生产实用技术[M]. 北京: 冶金工业出版社, 2009.
[2]
赵双涛, 伍詟, 刘勇豪. 中厚板2800精轧机高压水除鳞系统的改造[J]. 冶金设备管理与维修, 2014, 32(6):21-23.
2022年第48卷第6期
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  • 接收时间：2022-10-21
  • 首发时间：2025-11-24
  • 出版时间：2022-12-25
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    1 内蒙古包钢钢联股份有限公司工程服务公司, 内蒙古 包头 014010
    2 内蒙古包钢钢联股份有限公司薄板坯连铸连轧厂, 内蒙古 包头 014010
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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