To ensure the long-term stable and efficient operation of vertical cuttings dryer, routine maintenance is essential. Scientific and reasonable routine maintenance can timely find and solve the potential problems of the equipment, prolong the service life of the equipment, reduce the operating cost, and guarantee the smooth development of the rock chip processing work. This article will elaborate the daily maintenance of vertical cuttings dryer.
一.Equipment cleaning and maintenance
1.External cleaning
vertical cuttings dryer’s external in the operation process, easy to adsorb dust, oil and rock chip particles and other impurities. Every day after the equipment is shut down, the operator should use a clean rag or soft brush to wipe and clean the shell of the equipment, the operation panel and the exposed parts of the transmission parts. For stubborn stains, neutral detergent can be used with a damp cloth for cleaning, but be careful to avoid detergent penetration into the equipment. Cleaning process, also need to check whether the shell has broken, deformation and other conditions, if found problems should be promptly recorded and reported for processing. Regular cleaning of the outside of the equipment, not only to maintain the appearance of the equipment is clean, but also to prevent dust and other impurities into the equipment, affecting the normal operation of the equipment.
2Internal Cleaning
Feeding and Discharging Ports: The feeding and discharging ports are the channels for rock chips to enter and exit the equipment, and are prone to residual rock chip accumulation. After each operation of the equipment, special tools (such as long-handled brushes, shovels, etc.) should be used to clean the feeding and discharging ports to remove residual rock chips and prevent them from blocking the channels and affecting the efficiency of feeding and discharging. At the same time, check whether the sealing devices of the feeding and discharging ports are intact, if there is wear or damage, the seals need to be replaced in time to ensure the sealing of the equipment, to avoid hot gas leakage and dust outward. Inside the drying chamber: Open the access door of the drying chamber on a regular basis (once a week is recommended) and clean the inside thoroughly. Use hoover or high-pressure air gun to clean the rock chips and dust attached to the inner wall of the drying chamber, stirring paddle, surface of the heating element and other parts. During the cleaning process, pay special attention to check whether there is any damage, deformation or accumulation of dirt on the heating element. If you find that there is accumulation of dirt on the surface of the heating element, you can use special cleaning agent to clean it, but make sure that the cleaning agent is thoroughly rinsed out, so as not to affect the service life of the heating element and the heating effect. In addition, check whether the blades of the stirring paddle are worn and deformed, and whether the gap between the stirring paddle and the inner wall of the drying chamber is normal, if there is any problem, it should be adjusted or repaired in time. Dust Removal System: The dust removal system of vertical cuttings dryer is an important part to ensure the clean environment of equipment operation and reduce dust pollution. Regularly (according to the running time of the equipment and the amount of dust, generally every 1 – 2 days) clean the dust collection box of the dust collector and discharge the collected dust in time. At the same time, check whether the filter element or bag of the dust collector is clogged, if it is found that the resistance of the filter element or bag increases and the air permeability decreases, it should be cleaned or replaced in time. For the dust collector adopting pulse cleaning method, check whether the pulse blowing system is working normally and whether the blowing pressure meets the requirements, so as to ensure that the filter element or filter bag can be effectively cleaned and maintain the efficient operation of the dust collection system.
二.Lubrication and sealing maintenance
1.Lubrication maintenance
Lubrication point inspection: the main lubrication points of vertical cuttings dryer include transmission bearing, gear box, chain, coupling and other parts. Operators should be familiar with the location and lubrication requirements of each lubrication point of the equipment, and check the lubrication point every day to see the oil level and oil quality of the lubricant. For the oil level is too low for the lubrication point, should be timely replenishment of lubricating grease; if found that the lubricating grease colour becomes darker, emulsification or contains impurities and other conditions, it means that the lubricating grease has been deteriorated, and need to be replaced by new lubricating grease in a timely manner. Lubrication cycle management: different lubrication points have different lubrication cycles, should be strictly in accordance with the lubrication cycle specified in the equipment instruction manual. Generally speaking, the transmission bearings should be replenished with lubricating grease once every 500-800 hours of operation, the gear box should be replaced with lubricating oil once every 3-6 months, and the chain should be lubricated once every 100-200 hours of operation. In the lubrication operation, make sure that the type and specification of the lubricating grease matches with the requirements of the equipment, avoiding the use of mismatched lubricating grease to affect the lubrication effect of the equipment. At the same time, pay attention to the old lubricating grease clean up, and then add new lubricating grease to ensure the quality of lubrication.
2.Seal maintenance
Seal inspection: The seals of vertical cuttings dryer are mainly used to prevent hot gas leakage, dust outward and lubricant leakage, etc. The seals of vertical cuttings dryer are mainly used to prevent hot gas leakage, dust outward and lubricant leakage. Regularly (at least once a week) check the seals of each sealing part of the equipment, such as feed port seal, discharge port seal, access door seal, transmission parts seal, etc., to see if the seals are aging, worn, deformed, etc. If any problem is found, the seals should be replaced with new ones in time. If the seal is found to have problems, it should be replaced with new seals in time to ensure good sealing performance. Seal Pressure Adjustment: For the parts with mechanical seal or packing seal, the seal pressure should be adjusted at the right time according to the operation of the equipment and sealing requirements. Seal pressure is too large, will increase the wear and tear of seals, reduce the service life of seals; sealing pressure is too small, it may lead to poor sealing, leakage phenomenon. The operator should strictly follow the requirements of the equipment instruction manual, use special tools for sealing pressure adjustment, and after adjustment, carry out trial operation to check whether the sealing effect meets the requirements.
三.The electrical system maintenance
1.Electrical components check
control cabinet check: check the appearance of the control cabinet every day to see whether the cabinet door is closed tightly, whether the cabinet is damaged, deformation and so on. Open the control cabinet, check whether the connection of the internal electrical components is firm, whether the terminals are loose, oxidation, whether the fuse is blown and so on. For loose terminals, should use the appropriate tools for fastening; for oxidation of the terminals, to be cleaned; if the fuse is blown, need to find out why, replace the fuse with the same specification. At the same time, check whether the contacts of the relays, contactors and other electrical components in the control cabinet are ablated and worn out; if the contacts are seriously damaged, the corresponding electrical components should be replaced in time. Sensor check: the vertical cuttings dryer is equipped with a variety of sensors, such as temperature sensors, pressure sensors, liquid level sensors, etc., which are used to monitor the operating parameters of the equipment. Regularly (once a week) check whether the appearance of the sensors is intact, whether the installation is firm, whether the connecting cable is broken, aging and so on. Use professional testing instruments to calibrate and test the sensors to ensure that the measurement data of the sensors are accurate and reliable. If the sensor is found to be faulty or the measurement error is large, it should be repaired or replaced in time. Motor inspection: the motor is the power source of the vertical cuttings dryer, and it is vital to conduct regular inspections on it. Check the appearance of the motor every day to see whether the motor shell is overheated, deformed, broken, etc., and whether the cooling fan of the motor is operating normally. Use an infrared thermometer to measure the temperature of the motor winding to ensure that the motor operating temperature is within the specified range. At the same time, check the bearing lubrication of the motor, if the bearing is out of oil, the lubricating grease should be replenished in time; if the motor is found to be running with excessive vibration or abnormal noise, it should be shut down for checking, analysing the reasons and processing, such as checking the alignment of the motor with the load and whether the bearing is damaged.
2.Maintenance of chain drive
Chain inspection: Check the appearance of the chain every day to see whether there is any wear, elongation or breakage of the chain. Measure the pitch of the chain, if the chain pitch elongation exceeds the specified value (generally 2% – 3%), it means that the chain has been seriously worn and needs to be replaced in time. At the same time, check the lubrication of the chain, if the surface of the chain is dry and without lubricating grease, it should be lubricated in time. Sprocket wheel inspection: check whether the teeth of the sprocket wheel are intact, whether there is wear and broken teeth, etc. If the sprocket wheel is seriously worn, it will cause the sprocket wheel to be worn out. If the sprocket is seriously worn, it will lead to poor meshing between the chain and sprocket, and there will be phenomena such as jumping teeth and chain removal, so the sprocket should be replaced in time. At the same time, check whether the installation of the sprocket is firm, and whether the fit with the shaft is tight, if the sprocket is loosely installed, it should be tightened. Chain Adjustment: With the wear of the chain, the chain will gradually elongate, so it is necessary to adjust the chain regularly to ensure the chain tension is appropriate. When adjusting the chain tension, it can be adjusted by adjusting the position of the sprocket or using the tensioning device. After adjustment, check the meshing of chain and sprocket to make sure that the chain can run normally without any phenomenon such as stagnation and tooth jumping.
Routine maintenance of vertical cuttings dryer is the key to ensure its efficient and stable operation, and each maintenance point is just like the parts in a precision instrument, which are interrelated and indispensable. Through scientific and standardised routine maintenance, it can not only effectively reduce the equipment failure rate and prolong its service life, but also improve the efficiency and quality of rock chip processing, reduce the risk of environmental pollution, and provide strong support for the sustainable development of oil and gas exploration and development.
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