CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 1
S t: 9

HNG DN
VN HNH L SY FERO
NMLT

Trch nhim

Ngi bin son

Ngi kim tra

Ngi ph duyt

H v tn

Nguyn Vn Cu

Cao Tin Ngc

Nguyn c Duyn

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 2
S t: 9

MC LC
1. GII THIU........................................................................................................................... 3
1.1. Ch tiu kinh t k thut thit k l sy ferro...................................................................3
1.2. Thit b l sy ferro ti nh my......................................................................................3
1.3. Mc ch l sy ferro......................................................................................................3
2. MC CH............................................................................................................................ 4
3. PHM VI P DNG.............................................................................................................4
4. NI DUNG............................................................................................................................ 4
4.1. Hng dn thao tc chun b, kim tra h thng u ca, trc m nu...........................4
4.2. Hng dn thao tc im ha..........................................................................................5
4.3. Hng dn sy l t ng...............................................................................................5
4.3.1. iu kin sy l t ng...........................................................................................5
4.3.2. Hng dn thao tc sy t ng..............................................................................6
4.4. Hng dn vn hnh x liu, duy tr sy l khi s dng l sy ferro...............................6
4.5. Hng dn thao tc ngng t l....................................................................................6
4.6. Hng dn s dng bn iu khin.................................................................................7
4.6.1. H thng iu khin sy l.......................................................................................7
4.6.2. Man hinh hin th.....................................................................................................7
5. CC S C THNG GP, CCH KHC PHC............................................................8
5.1. M t t ngt b tt, khng c ngn la sy................................................................8
5.2. ng kt ferro ti ghi l..................................................................................................9
6. AN TON LAO NG, V SINH CNG NGHIP............................................................9
7. TI LIU THAM KHAO......................................................................................................9

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 3
S t: 9

1. GII THIU
1.1. Ch tiu kinh t k thut thit k l sy ferro
Mc ch s dng

Sy ferro

Nhin liu sy l

Kh than

p lc nhin liu (kh than)

4 - 10KPa

Lng to nhit ca nhin liu

Lng tiu hao nhin liu ln nht

3500KJ
2000Nm3/t

Nhit sy

400

Chiu di ngn la

1m

Lng sy 1 ln

12 t

Chu k np liu thit k

4h

Dung tch l ln nht

4,5 m3

1.2. Thit b l sy ferro ti nh my

- Thit b l sy ferro gm c 4 l sy, mi l dung tch 4,5 m3 c th cha ti a 12 tn
ferro/l.
- Trong h thng kh than v khng kh sy l 2 cm: cm 1 s dng sy l s 1 v l
s 2, cm 2 s dng sy l s 3 v l s 4. V vy s dng 2 l cha SiMn v 1 l cha FeSi
phc v cho sn xut, 1 l d phng.
- H thng sy mi l c 2 tng sy, mi tng sy c 2 m t t i din nhau, pha bn
trong ti mi tng sy l cc ghi l tip nhn la t 2 m t ti 1 tng sy. Pha trn ghi l
phn tip gip vi ferro c cc l tc dng tn nhit t m t.
- Vt liu chu la ca l l vt liu rt c mullite chu nhit cao, chu mi mn. V
vt tui th s dng ca l di hn so vi l nung thng thng. Bung t l l thit b chu
nhit cao, nn thc hin gia nhit lin tc khng gin on cho l. Yu cu nhit khi x
liu l 300 5000C.
1.3. Mc ch l sy ferro

- Thit b sy ferro c tc dng gia nhit cho hp kim, sy kh phn t nc t do trn b

mt hp kim v nc kt tinh bn trong hp kim, nng cao cht lng ferro s dng trong hp
kim ha thp lng, nng cao cht lng sn phm thp.

- Trong qu trnh ra thp l thi, khi cho ferro khng qua sy nng th ferro cn 1 lng
nhit vt l nht nh tan ferro vo thp lng gy ra tnh trng gim nhit ca thp lng

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 4
S t: 9

ti thng thp. Khi lng nhit mt i trong qu trnh ra thp s tng ln. Nn i hi nhit
ra thp ti l thi cao hn. V d i vi 1 m thp m bo cho vic ra thp ti l thi
ln thng c (nhit thp lng t 1580 1640oC) th vi ferro khng qua sy nng s i
hi nhit ra thp l thi rt cao (>1680 oC). V vy m bo nhit ra thp ti l thi th
ferro cn phi c sy nng gim tn hao nhit.
2. MC CH
- Hng dn cng nhn thao tc trc l ph trch sy ferro v hp kim ha thp lng
vn hnh thit b v thao tc cng ngh ti l sy ferro theo trnh t, chnh xc, hiu qu ng
thi m bo an ton cho con ngi v thit b.
3. PHM VI P DNG
- Hng dn ny p dng i vi cng nhn thao tc trc l thi ph trch sy ferro v
hp kim ha thp lng ti l thi 30T.
4. NI DUNG
4.1. Hng dn thao tc chun b, kim tra h thng u ca, trc m nu
- u ca, nm bt tnh hnh sn xut, tnh trng thit b ti l sy ferro ca ca trc, tnh
hnh v sinh khu vc lm vic lc giao ca. Kim tra tnh trng thit b ti l sy ferro xem c
hot ng bnh thng khng. Pht hin cc vn bt thng lc giao ca phi bo ngay cho
T trng, Trng ca gii quyt.
- Kim tra ch sy l ca ca trc l vn hnh t ng hay vn hnh bng tay. Kim
tra tnh trng cc m t, nhit sy l, p lc kh than, h thng iu khin t ng cc l
m bo hot ng bnh thng.
- Kim tra tnh trng cc m t sy tng l c chy bnh thng khng. Trong trng
hp bt thng cn kim tra tnh trng kh than sy l (p lc kh than, h thng van iu tit
kh ng c linh hot khng), qut gi. Tnh trng m t vn chy bnh thng nhng cnh
bo kh than r r th phi iu chnh tng t t lng khng kh vo cc m t.
- Kim tra h thng ng ng kh than, van iu tit kh ng, van tay ng m kh than
c hin tng r kh than khng. m bo kh than khng b r ra ngoi, trnh nguy him.
- Kim tra h thng in iu khin x liu, iu chnh kh than, khng kh hot ng tt
khng. Kim tra h thng n bo, chung bo tnh trng m t, qut gi, kh than, ci t
nhit c chnh xc khng.
- Kim tra h thng x liu tng l xem ng c rung hot ng c bnh thng khng.
H thng cn ferro ti cc l c bnh thng khng. Kim tra h thng in ci t x ferro, xe
ch ferro hot ng bnh thng khng.
- Cng nhn vn hnh cn kim tra nhanh chng tnh trng thit b, bo co ln T trng
t l thi. Tt c cc vn s c pht sinh nghim trng, r r kh than phi bo co ngay cho
Trng ca, cn b ph trch x l kp thi.

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 5
S t: 9

4.2. Hng dn thao tc im ha

- Trc khi im ho phi kim tra cc v tr mt bch lin kt xem c hin tng r kh,
kha m bo bt kn tt. Van kh than v van khng kh ti m t cn im ha phi kha
cht.
- Trnh t m my nh sau: m qut gi, m van in ng iu tit kh than, m van
tng trn ng ng kh than, m van tay qut gi. Kim tra li h thng x liu, p lc kh
than tin hnh im ha.
- Ti v tr m t cn im ha, m ht van gi (khng kh) ti m sy cn im ha
x ht kh than d ti cc v tr im ha. Sau , thanh la chy vo trong l im ho
v m van iu tit kh than th cng ti m t im ho. Sau iu chnh van bm
iu tit khng kh v kh than th cng ny tin hnh iu tit mc to nh ca ngn la,
cho n khi t c ngn la thch hp. Ch quan st ngn la, tch ly kinh nghim, quan
st t l phi trn gia kh than v khng kh hp l.
-

Tng t nh vy ta tin hnh im ha ln lt cc m t cn li.

- Kim tra tn hiu bo ngn la ti bn iu khin v theo di qu trnh tng nhit

trong l.
- Thng xuyn kim tra ngn la cc m sy. Nu khng c ngn la phi tin hnh
ngt kh than ti m t trnh hin tng r r kh than rt nguy him, sau tin hnh im
ha li m t.
- Trong trng hp cc m t bo tn hiu khng c ngn la phi tin hnh kim tra
trc tip cc m t. Ln lt ng van ngt nhanh kh ng, van chn ng kh than, tt
qut gi ti cc m t. Kim tra li h thng liu, kh than tin hnh im ha li.
- T in iu khin c nt dng khn cp, khi gp tnh trng khn cp c th dng khn
cp ton b thit b.
- i vi l sy ferro th lng gia nhit ln u khong 6 tn ferro, thi gian gia nhit
ln u tng i di, khong 30h, ch yu tin hnh sy vt liu chu la bn trong l sy
ferro. Khi nhit l t yu cu th ta c th x liu phc v cho sn xut. Lc ny chu k x
liu mi m ngn nht c th rt li trong 5 pht.
- ng h hin th nhit lun lun hin th nhit hin ti ti thi im , khi nhit
vt qu nhit ci t, n ch th qu nhit s sng. T ta tin hnh iu chnh van
kh than, khng kh m bo nhit yu cu.
4.3. Hng dn sy l t ng
4.3.1. iu kin sy l t ng
-

p lc kh than cn phi n nh P 4 KPa.

- Cng nhn vn hnh l sy ferro c o to vn hnh sy ferro t ng v thnh

tho thao tc th cng. Trong qu trnh hot ng ban u cn c s theo di cht ch ca nhn
vin k thut.

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 6
S t: 9

- Thit b in iu khin t ng, cc n bo, chung cnh bo phi hot ng tt, h

thng can nhit hin th nhit phi chnh xc.
- Khi l sy ferro c im ha cc m t chy n nh, nhit ferro hin th >
3000C th ta mi c php chuyn sang ch t ng.
4.3.2. Hng dn thao tc sy t ng
-

Ci t nhit ti mn hnh nhit ferro yu cu (4000C).

Khi nhit ferro hin th > 3000C th chuyn sang ch iu khin t ng.

- Kim tra t l m van kh than v khng kh khi chuyn sang ch t ng cc m t

c chy bnh thng khng (theo di trong khong 15 pht).
- Khi nhit ca ferro hin th vt nhit yu cu th van in ng s t ng
gim kh than, khng kh gim nhit ca ferro. Nhng do h thng t ng ha cha cao
phng lc ny van in ng tit gim mnh s lm tt cc m sy. V vy cn t mc gii
hn di ca t l m van iu chnh kh than v khng kh m bo nhit ferro ra l.
- Khi nhit ferro ti cc l sy ferro nng ln t mc yu cu th cn kim tra t l
m van in ng kh than (P1) v van in ng khng kh (P2) l bao nhiu. T t cc
mc gii hn di ca phn trm m van in ng kh than v van in ng khng kh ny:
van iu chnh kh than P1d= P1-10%, van iu chnh khng kh P2d = P2 10%.
-

Thng xuyn theo di tnh trng cc m t so snh vi mn hnh hin th.

4.4. Hng dn vn hnh x liu, duy tr sy l khi s dng l sy ferro

- Khi nhit sy l t yu cu (300 5000C) th ta c th tin hnh x ferro phc v
sn xut.
- Do ferro nung nng nhit cao ngoi mi trng s gim nhit rt nhanh v vy
ch c x ferro trc khi s dng (hp kim ha thp lng) ti a l 10 pht.
- Cn c vo mc thp nu luyn, thnh phn ha hc im cui, tnh hnh l cng nhn
vn hnh tnh ton lng hp kim hp kim ha.
- Khi bt u x li u ta a xe vo n v tr x li u, nhn nt reset li cn x ferro tng
ng (v mc 0). Sau nhn nt khi ng ng c rung x ferro, khi lng ferro t n
mc trng lng yu cu th ta nhn nt tt ng c rung, quan st hin th s lng cn trn
bng. Tip tc thc hin thao tc x ferro nh vy cho n khi t trng lng yu cu.
- ng thi vi qu trnh ly ferro sy nng vo s dng th cn thng xuyn np ferro
vo trong l. Chu k np liu khong 4h. Lng liu trong l khi sy khng c di 3 tn.
- Trong qu trnh sy ferro, x ferro s dng th mi ln x ferro cn phi kim tra tnh
trng ferro (nhit , chng loi), tnh trng cc m sy m bo nhit ferro hp kim ha
c n nh.
- Sau mi m nu, cng nhn thao tc ghi chp y s lng ferro, nhit ferro vo
biu mu.
4.5. Hng dn thao tc ngng t l

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 7
S t: 9

Trong trng hp ngng sn xut trong nh my di ngy hoc gii quyt cc s c ca

l sy ferro th phi ngng t l, thc hin cc thao tc theo trnh t sau:
-

ng van ngt nhanh in ng trn ng ng kh than.

ng van chn bng tay trn ng ng kh than.

ng van iu tit khng kh tng, van iu tit kh than tng ca cm l sy.

ng van bm iu tit kh than, van iu tit khng kh ca m t.

ng qut gi, hon tt vic ngng sy.

4.6. Hng dn s dng bn iu khin

- H thng iu chnh kh than, khng kh in ng, ci t nhit , ci t khi lng
x liu ca tng l c lin kt vi h thng iu khin in (PLC, Mn hnh cm ng) ti
phng vn hnh (xem hnh 4).
Bn tri hnh 4 l h thng iu khin sy l s 1, 2.
Bn phi hnh 4 l h thng iu khin sy l s 3, 4.
- Trung tm hnh 4 l mn hnh cm ng hin th h thng n bo, hin th nhit , tnh
trng cc m t sy l.v.v.. ng thi, khi sy t ng th ti y c th ci t c nhit ,
khi lng ferro x t ng i vi tng l theo yu cu.
4.6.1. H thng iu khin sy l
- H thng iu khin sy l bao gm khi ng/ dng qut gi, khi ng/ dng cp
liu, ng m van ngt nhanh u thng qua cc nt trn mt t thao tc. Khi t n gi tr
trng lng ci t, mt t c ting ku bo, 4 nt thao tc th cng dng PLC khng a
ra tin hnh thao tc iu tit i vi van kh than s 1,2 v van khng kh 1,2, trong tnh trng
bnh thng khng cn lm thao tc. Nt dng khn cp dng cho ct ngun in iu khin
trong tnh trng khn cp, dng ton b thit b. Xem hnh 5 biu th cc h thng iu khin
ca l 3, 4.
-

H thng iu khin l s 1,2 tng t nh h thng iu khin l s 3, 4.

4.6.2. Man hinh hin th

a. Giao di n chinh (Trng thihome)

Pha bn tri theo th t t trn xung th hin cc thng s sau:

- 8 im kim tra tnh trng ngn la (4 l, khi m t chy ti tng sy no thi n sng
xanh).
- Trng thi v s c ca qut gi 1 v 2: khi qut gi s 1 chy th n bo NO1.R xanh,
c s c v qut gi th NO2.F bo .
-

Trng thi ca 4 ng c x liu (NO.1NO.4).

- Trng thi ca cm kh than 1 v cm kh than 2 (Valve 1, valve 2). Khi s c n s

sng .

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 8
S t: 9

Pha bn phi theo th t t trn xung th hin cc thng s sau:

-

Gi tr nhit thc t ca tng l 1, 2, 3, 4.

Khi lng trng lng trn 2 cn ca cm l 1 v cm l 2.

Hin th p sut kh than ti cc cm l s 1, cm l s 2.

b. Hin th biu nhit (Trng thi curve)

- Giao din ny hin th th nhit thc t, 4 l khc nhau tng ng vi 4 ng
mu khc nhau, nhit l 1 l ng mu , l 2 l mu cam, l 3 l mu xanh lam, l 4 l
mu xanh lc.
c. Thit l p giao di n cai t nhit va trng lng x liu (Trng thi set)

- Giao din ny c th tin hnh ci t nhit 4 l v trng lng x liu ca 4 l. Khi

dng tay chm vo vng gi tr, s t ng xut hin bn phm, c th nhp gi tr, nhp xong
n Enter l c.
5. CC S C THNG GP, CCH KHC PHC
5.1. M t t ngt b tt, khng c ngn la sy
a. M t s c
- Trong qu trnh ang sy l bnh thng t nhin cc m t b tt, khng duy tr c
ngn la sy l.
b. Nguyn nhn s c
- Trong qu trnh sy bng tay p lc kh than t ngt mt hoc gim xung qu thp m
qut gi vn chy vi cng sut bnh thng lc m t b tt.
- Trong qu trnh sy t ng khng ci t mc gii hn thp nht ca phn trm kh
than v khng kh sy l nn khi nhit vt qu nhit ci t s gy ra gim kh than,
khng kh qu thp dn n tt m sy.
- Qut gi ang hot ng th b hng (hng ng c hoc hng do tc ng bn ngoi)
khin m t b tt.
c. Bin php khc phc

- Cn kim tra li p kh than u vo ti ng ng vo cc l xem c hin tng mt

kh than, gim p lc kh than xung qu thp hay khng. Pht hin mt kh than, kh than t
ngt gim thp th phi bo ln nhn vin iu kim tra li ngun cung cp kh than u
vo, h thng van, ng ng c hin tng r r hay khng.
-

Cn ci t mc thp nht ca gii hn kh than, khng kh khi sy t ng.

- Pht hin qut gi b hng u tin phi tt ton b kh than sy l sau phi bo ngay
nhn vin sa cha kim tra sa cha hoc thay th. Khi qut gi hot ng bnh thng th
mi tin hnh sy li l.
d. Bin php phng nga

CNG TY C PHN THP HA PHT

HNG DN
VN HNH L SY FERO
-

M hiu
: HD.05.07-03
Ln ban hnh : 01
Ln sa i : 00
Ngy hiu lc : 01/08/2011
T s: 9
S t: 9

Thng xuyn kim tra ngn la ti cc m t.

- Cn cung cp kh than sy l n nh (lun P 4 KPa). H thng van kh than, qut gi

cn c kim tra thng xuyn, khi hng hc phi sa cha, thay th ngay.
5.2. ng kt ferro ti ghi l
a. M t s c
-

Pht hin thy ferro ra l vi nhit rt cao mu rc.

Ti v tr trn l thy pht hin c ch ferro chy lm hng th xy l.

b. Nguyn nhn s c
- Qu trnh sy bng tay nhit ln qu cao. V vy ferro chy lng kt dnh vo
nhau khin bc th xy l, r ferro ra ngoi.
-

Ferro c ht qu nh (vn) nn rt d dnh kt khi nhit cao (c bit l FeSi).

c. Bin php khc phc

- Trong qu trnh sy bng tay phi thng xuyn ch v nhi t , khi nhi t t
c th phi gim ngay lng kh than vo l bng cch gim van tay m t. Trnh tnh
trng khng kim tra m nhi t tng qu cao c th gy chy hng ghi l.
-

m bo c ht ca ferro 30 100 mm, khng c qu vn.

6. AN TON LAO NG, V SINH CNG NGHIP

- L sy ferro c sy bng kh than nn khi im ha, ngng sy cc m t phi thao
tc ng trnh t vn hnh ng m kh than v khng kh. Yu cu khi bt u chun b im
ha m t mi c php m van kh than.
- Khi thc hin thao tc im ha hoc kim tra van, ng ng kh than nht thit phi
c 2 ngi c trang b y thit b o kh than, trang b v bo h lao ng.
- Cng nhn vn hnh c trang b y cc trang thit b phc v trong cng vic,
trang thit b bo h lao ng. Chun b tt cc bnh cu ha ti cc v tr thun li cho cng
tc phng chy cha chy. ng thi chp hnh tt ni quy, quy ch ca cng ty, k lut lao
ng v cc quy nh v an ton.
- Khi duy tu sa cha bt buc phi ngt my ct t in iu khin, khng c sa
cha khi vn ang c in, khng c tin hnh sa cha khi cha ng van kh than.
-

Khi cu np ferro phi ch cn thn, trnh va p vo thit b.

- Trong qu trnh vn hnh v s dng, hn ch ferro ri vi ra sn cn, sn thao tc. Dn

v sinh sch s khu vc lm vic trong ca v giao ca.
7. TI LIU THAM KHAO
-

Hng dn s dng thit b sy hp kim Trung Quc.

Gii thi u h thng iu khin thit b sy fero Trung Quc.