Whoever uses RX atmosphere generator might find it difficult to deal with: for the generator might be working for months without any malfunctioning, and suddenly fails and causing major production line shut down, leading to days of busy and messy work and headache maintenance team. Yes the RX atmosphere generator is just like a kid, requesting daily care and correction, to run properly.
Now, with years of experiences operating and maintaining atmosphere generators, we are able to share with you a few specific operation procedures and instructions of daily maintenance and inspections. We hope that these experiences will be of help to you
1. Cooling water supply
The cooling water is supplied to the front and rear gas cooler of gas generator to cool down generated endo gas. In case of malfunctioning of the water supply system, and failing of self-protection system, the gas generator can keep working for only 2 to 5 minutes before the front and rear gas cooler being over burnt, leading to shut down of the whole heat treatment line. Therefore, a stable supply of cooling water is critical for the gas generator.
When the water supply pressure runs low and the cooling water pressure switch senses that the pressure is lower than pre-set standard value, the Gas generator will automatically cut down gas blower to protect itself. At this time the water filtration devices should be checked first, and switch immediately to city water as secondary water supply before checking water supply systems.
2. Electrical Heating system
The heaters at all sides of generator heating chamber provides power that maintains the temperature of the generator, by checking the current of the heaters we can quickly see whether the heating system is in good condition. There are two sets of ammeters monitoring electrical current passing through heaters, mind that the readings from two sets of these ammeters shall be more or less the same, and the ammeter readings are proportional to those of the power meters. Otherwise the heaters might be malfunctioning
3. Supply of Feed Gas Medium
The steady supply of feed gas medium is very important to the dew point control of generator. If the feed gas medium supply is unstable, the dew point of generator will lose control, which will directly affect the quality of heat treatment workpiece. In order to avoid such problems, please check the pressure and flow rate of each medium several times a day within the scope of the process requirements, which need to be adjusted in time. In addition, check every shift whether there is leakage in the medium pipelines and valves. Repair it in time if there is leakage.
4. Reaction tank pressure
The Reaction tank pressure should be between 5 and 15 KPa. If the pressure is beyond this range, It means that the generator is encountering either a filter blockage or carbon, and should be stopped for regenerated. Open the discharge valve for 1 hour, check the filters on the front and back pipes of the reactor tank, replace the blocked filters, and then switch the generator to regeneration mode. Burn off the carbon deposit in the reaction tank.
5. Lambda probe measurement gas
The flow rate of measurement gas is 20ml/min, higher flow will lead to the deviation of dew point detection value. Therefore, it is necessary to check and make sure the rate is in right range.
6. Dew point instrument
Dew point should be maintained within ±1℃ range. High dew point temperature will lead to condensate in the rear cooler, resulting in excessive intergranular oxidation in heat treatment workpieces. While low dew point temperature will lead to accumulation of carbon deposit in the reactor tank, resulting in blockage. Therefore, It is necessary to check due point every day and maintain it to be in the correct range.
7. Exhaust port
In order to ensure enough RX gas to the production line, production must be larger than consumption. Excess gas will be burned and discharged through the exhaust port. Therefore, when the generator is in the gas production state, check daily that gas discharging and burning flame must be seen on the exhaust port.
8. Exhaust spark plug
Spark plug is used to ignite the exhaust gas from the exhaust port, so it should be burning-glare. only in this way, the temperature of the spark plug itself can ignite the exhaust gas. If the generator exhaust gas is not ignited by the spark plug, large amount of hydrogen and carbon monoxide will be discharged into the workshop, becoming dangerous risk of explosion or carbon monoxide poisoning; if these gases deposited in the duct, also will leads to explosion.
In production, a current relay is there to monitor the working current of the spark plug. If the working current is too low, meaning the spark plug has broken down, the current relay will send a alarm message and will stop blower to interrupt the production gas for protection. Therefore, check daily for spark alarm signals.
9. Rear cooling
If the dew point is too high during the gas production, condensate water will be generated in the rear cooler, which needs to be drained daily. Open the gate valve on the ash collecting hopper, drain the water and then close the gate valve on the ash collecting hopper.
10. Signal lamp
Press the "Lamp Test" button, then all the signal lights will be lit. If any one does not light, inform electrician to replace the damaged signal lamp immediately.