锅炉仓泵是锅炉输灰系统的重要组成部分，其直接影响输灰系统的除灰效果。转化果平台推荐的《提高锅炉仓泵仪表稳定运行性研究》，针对仓泵仪表故障频繁问题，从设备、环境等方面对故障现象进行原因分析，制定相应方案对策并逐一进行实施，有效减少了仓泵的检修次数，降低了劳动程度，取得较好经济效益。

　　The boiler compartment pump is an important component of the boiler ash conveying system, which directly affects the ash removal efficiency of the ash conveying system. The "Research on Improving the Stable Operation of Boiler Warehouse Pump Instruments" recommended by the Conversion Fruit Platform analyzes the causes of frequent failures in warehouse pump instruments from equipment, environment, and other aspects. Corresponding solutions and countermeasures are formulated and implemented one by one, effectively reducing the number of maintenance times for warehouse pumps, lowering labor levels, and achieving good economic benefits.

　　一、研究背景

　　1、 Research background

　　锅炉输灰系统专门用于处理锅炉排向大气烟气中的粉尘，经过除尘器、仓泵、灰库储运外运等环节完成对粉尘的处理。仓泵运行状态直接影响输灰系统的除灰效果，故障率高会对环保产生不利，增加运行成本，并影响锅炉的安全运行，因此仓泵的稳定运行尤为重要。 项目研究目标：实现降本增效、节能降耗要求，解决仓泵频繁加压超时的现象，降低仓泵仪表故障次数，提高仓泵运行稳定性，达到安全环保高效运行。

　　The boiler ash conveying system is specifically designed to handle the dust emitted from the boiler into the atmosphere. The dust is processed through processes such as dust collectors, bin pumps, and ash storage and transportation. The operating status of the silo pump directly affects the ash removal efficiency of the ash conveying system. A high failure rate can be detrimental to environmental protection, increase operating costs, and affect the safe operation of the boiler. Therefore, the stable operation of the silo pump is particularly important. Project research objective: To achieve the requirements of cost reduction, efficiency improvement, energy conservation and consumption reduction, solve the phenomenon of frequent pressurization and timeout of warehouse pumps, reduce the number of instrument failures of warehouse pumps, improve the stability of warehouse pump operation, and achieve safe, environmentally friendly and efficient operation.

　　某单位月度锅炉仓泵检修统计表

　　Monthly Boiler Storage Pump Maintenance Statistics Table for a Certain Unit

　　二、研究内容

　　2、 Research content

　　1.要因分析

　　1. To analyze the reasons

　　（1）阀门材质不符合工况要求

　　(1) The valve material does not meet the working condition requirements

　　对1#锅炉1-3月仓泵仪表故障进行调查统计。从故障统计表可以看出，仓泵故障现象中，原因最多的是阀门故障，其占比最多。

　　Conduct investigation and statistics on the instrument failures of the storage pump in boiler 1 from January to March. From the fault statistics table, it can be seen that the most common cause of warehouse pump faults is valve failure, which accounts for the largest proportion.

　　改造之前选用的出料阀阀芯是铸钢材质，易冲蚀，密封性差，寿命短。阀门预期寿命为180天，而实际情况由于阀门动作频繁、物料冲蚀等原因，导致阀门实际使用寿命短，实际与预期工作寿命相差较大，要频繁检修更换阀门。

　　The discharge valve core selected before the renovation is made of cast steel material, which is prone to erosion, has poor sealing performance, and has a short service life. The expected service life of the valve is 180 days, but in reality, due to frequent valve movements, material erosion, and other reasons, the actual service life of the valve is short, and there is a significant difference between the actual and expected working life, requiring frequent maintenance and replacement of the valve.

　　（2）仪表接地、隔离措施不规范

　　(2) Improper grounding and isolation measures for instruments

　　物料在仓泵内流动过程中会产生静电，静电通过仓泵远传压力变送器信号回路传输至PLC控制柜内造成控制柜内电压波动大。由于仪表接地、隔离措施不规范，易损坏PLC控制模块和压力变送器等，致使仓泵频繁加压超时，产生报警，无法正常投运。

　　During the flow of materials in the warehouse pump, static electricity is generated, which is transmitted to the PLC control cabinet through the remote pressure transmitter signal circuit of the warehouse pump, causing large voltage fluctuations in the control cabinet. Due to non-standard grounding and isolation measures for instruments, it is easy to damage PLC control modules and pressure transmitters, resulting in frequent pressurization timeouts of the bin pump, generating alarms and preventing normal operation.

　　（3）压力变送器安装位置不当压力变送器安装于控制柜内，与仓泵相连接的导压管过长容易积灰，致使仓泵压力测量不准，导致仓泵频繁加压超时故障报警。

　　(3) Improper installation position of pressure transmitter. The pressure transmitter is installed in the control cabinet, and the pressure pipe connected to the bin pump is too long, which can easily accumulate dust, resulting in inaccurate pressure measurement of the bin pump and frequent pressure exceeding fault alarms.

　　从人、机、料、法、环五个方面集思广益对故障现象（频繁加压超时）可能发生的原因进行彻底的分析。最终得到了：阀门材质不符合工况要求、压力表安装位置不合理、仪表接地隔离措施不规范的三条主要原因。

　　Thoroughly analyze the possible causes of the fault phenomenon (frequent pressure exceeding the time limit) from five aspects: human, machine, material, method, and environment. Finally, three main reasons were identified: valve material not meeting operating requirements, unreasonable installation position of pressure gauges, and non-standard grounding and isolation measures for instruments.

　　2.制定实施对策（1）阀门重新选型通过查阅资料，选择合适的耐冲蚀的陶瓷材质阀门；安装、配置气源管、调试阀门，确保阀门动作正常。

　　2. Develop implementation strategies: (1) Re select valves by consulting relevant materials and selecting suitable ceramic valves that are resistant to erosion; Install and configure the gas source pipe, debug the valve, and ensure that the valve operates normally.

　　实施效果：

　　Implementation effect:

　　①更换完耐冲蚀陶瓷阀后查看阀门趋势，开关正常且规律；②有效解决了流灰对阀内件的冲蚀，阀门使用周期从20多天增长为200多天，使用寿命大幅提升；确保了阀门良好的密封性，解决仓泵因出料阀密封不严而泄露的问题，保证整个系统连续稳定运行。

　　① After replacing the erosion resistant ceramic valve, check the valve trend and ensure that the opening and closing are normal and regular; ② Effectively solved the erosion of valve internals caused by flowing ash, and the service life of the valve increased from over 20 days to over 200 days, significantly improving its service life; Ensure good sealing of the valve, solve the problem of leakage of the bin pump due to poor sealing of the discharge valve, and ensure the continuous and stable operation of the entire system.

　　（2）仪表回路增加安全栅、现场增加接地

　　(2) Add safety barriers to the instrument circuit and increase grounding on site

　　确认控制柜安全栅供电方式及型号；对选型好的安全栅进行组态、安装、接线、调试；对控制柜及现场仪表增加接地。实施效果：①安全栅可以起到很好的隔离高电压、大电流的作用。增加安全栅，以次消除静电，保护电路和设备；②增加仪表接地，将静电与仪表设备有效隔离，从根本上消除现场静电对控制柜PLC模块的不良影响，避免压力变送器的损坏，消除故障报警。（3）压力变送器重新安装

　　Confirm the power supply mode and model of the control cabinet safety barrier; Configure, install, wire, and debug the selected safety barriers; Add grounding to the control cabinet and on-site instruments. Implementation effect: ① Safety barriers can effectively isolate high voltage and high current. Add safety barriers to eliminate static electricity and protect circuits and equipment; ② Add instrument grounding, effectively isolate static electricity from instrument equipment, fundamentally eliminate the adverse effects of on-site static electricity on the control cabinet PLC module, avoid damage to pressure transmitters, and eliminate fault alarms. (3) Reinstall the pressure transmitter

　　考虑到导压管过长，容易堵塞造成压力表测量不准，将变送器由原来控制柜内移至仓泵取压口上方；安装方式由水平安装改为垂直安装。

　　Considering that the pressure pipe is too long and prone to blockage, causing inaccurate measurement of the pressure gauge, the transmitter was moved from the original control cabinet to above the pressure tap of the bin pump; The installation method has been changed from horizontal installation to vertical installation.

　　实施效果：同比活动前，压力变送器故障次数下降明显，在10月、11月次数为零，从根本上解决了变送器积灰、测量不准及导压管过长堵塞的问题。

　　Implementation effect: Before the year-on-year activity, the number of pressure transmitter failures decreased significantly, reaching zero in October and November, fundamentally solving the problems of transmitter dust accumulation, inaccurate measurement, and long and blocked pressure pipes.

　　三、应用效果

　　3、 Application effect

　　1.改造效果

　　1. Transformation effect

　　根据对改造前后故障现象加压超时频次及仓泵故障次数对比统计，加压超时频次呈逐渐递减趋势，在11月份开始趋于稳定状态。故障现象逐渐减少，仓泵的故障次数也在递减，降低了仓泵仪表故障次数。2.经济效益改造前出料阀每月平均消耗2.3台，每台阀门单价8600元，共累积维修费用约24万元；改造后统计出料阀每月平均消耗0.3台，每台阀门单价12000元，累计维修费用约4万元，每年节约费用约19万元。3.社会效益通过改造，降低了仓泵故障次数，有效减少人员检修频次，降低了伤害的风险，减少了非计划停车，仓泵处于良好的工作状态，避免粉尘泄露问题，有效提高周围环境质量。

　　According to the comparison and statistics of the frequency of pressure exceeding and the number of warehouse pump failures before and after the renovation, the frequency of pressure exceeding gradually decreased and began to stabilize in November. The occurrence of faults is gradually decreasing, and the number of faults in the warehouse pump is also decreasing, reducing the number of instrument faults in the warehouse pump. Before the economic benefit transformation, the average monthly consumption of discharge valves was 2.3 units, with a unit price of 8600 yuan per valve, and the cumulative maintenance cost was about 240000 yuan; After the renovation, the average monthly consumption of discharge valves is 0.3 units, with a unit price of 12000 yuan per valve. The cumulative maintenance cost is about 40000 yuan, and the annual cost savings are about 190000 yuan. 3. Social benefits: Through renovation, the number of pump failures in the warehouse has been reduced, the frequency of personnel maintenance has been effectively reduced, the risk of injury has been lowered, unplanned parking has been reduced, the warehouse pump is in good working condition, dust leakage problems have been avoided, and the surrounding environmental quality has been effectively improved.