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technical article
Handling of radar level gauge failure
2011-8-26 16:48:02

     工艺人员反映乳化沥青液位不准 时,因为 我先 前负责过这套设备上的仪表,对其工艺和仪表现状比较了解 ,所以去检查了雷达液位计 When the technicians reported that the level of the emulsified asphalt was inaccurate , I checked the radar level gauge because I had previously been responsible for the instruments on this equipment and had a better understanding of the process and instrument status .

乳化沥青成品罐,两者距离很近, 并且 底部通过管线联输出到装车泵,因此在正常使用时可以看成是连通器。 Because there are two tanks of emulsified asphalt, the two are very close, and the bottom is connected to the loading pump through a pipeline, so it can be regarded as a connector in normal use. 就安装在 每个沥青罐顶 人孔处开口, 它的 天线是普通的喇叭口,喇叭开度较小。 The Delta radar level gauge is installed in the manhole at the top of each asphalt tank , and its antenna is a common horn, and the opening of the horn is small.

     它的 气相蒸汽压不大,沥青的挥发不强,因此雷达液位计 在使用中比较合适 ,出现故障的几率 较少。 Because the temperature of the emulsified asphalt is not high, its vapor pressure is not large, and the volatilization of the asphalt is not strong. Therefore, the radar level gauge is more suitable in use and has less chance of failure . 一罐 乳化沥青的雷达从2009 年底 时不时 的出现显示不准的故障。 But one of the tanks of emulsified asphalt has shown inaccurate failures from time to time from the end of 2009 . 的师傅们通常采取 的是 雷达液位计 从人 开口处 拆下 来,然后将 天线擦拭一下或 者是 断电重启,这样处理后会正常 显示 My masters usually take the radar level gauge off the manhole opening , then wipe the antenna or restart after power off, so that it will display normally after processing .

     导致 法兰的连接螺栓都没上紧,原先 12 根螺栓只挂上两个,其螺母 没有拧紧 所以在维修雷达液位计时不用带扳手。 Due to frequent disassembly, the flange's connection bolts are not tightened. The original 12 bolts were only hung on two, and the nuts were not tightened . Therefore , no spanner is needed to maintain the radar level timer .

     雷达倒是没出现过故障,也没 拆过,因此碳钢的螺栓上已经锈迹斑斑很难拆卸。 The other radar did not fail and was not disassembled, so the carbon steel bolts were rusty and difficult to remove.

     先前负责过这个设备,所以接完电话, 的反应就是 先前 那台 雷达有出问题了。 Since I was in charge of this device before, after answering the call, my response was that there was something wrong with the previous radar.

Therefore, after wearing the labor protection supplies, he only brought a small flat-blade screwdriver and a rag.

     业务 订单式因此开开停停,前段时间刚刚停车,听说冬季要检修不开了,不知怎么现在有用了。 As the asphalt business is order-based, it starts and stops. It was just stopped some time ago. I heard that it will not be open for maintenance in winter. Somehow it is useful now.

     先出操作室了解情况,在现场看到 操作工正用 设备 进行 吹扫,到了操作室,工艺人员说是倒灌,进行检修。 I first went out of the operation room to understand the situation. I saw the operator was using the equipment to purge at the scene. When I arrived at the operation room, the craftsman said that it was pouring back for maintenance.

     询问为什么不 用准确的那台液位计 ,而要用先前经常出问题的 乳化沥青罐,, 说刚刚清洗完成不用了,其两罐之间的管线也已经关闭。 I asked why the accurate level gauge was not used, but an emulsified asphalt tank that used to have problems before . He said that it had just been cleaned and was not used, and the pipeline between the two tanks had been closed.

     没有询问倒灌的介质,也没有询问怎样倒罐。 I didn't ask about the medium for pouring, nor did I ask how to pour the can.

     另外 加上 没带工具,于是现在控制柜中断电重启看看是否能够恢复正常。 Taking into account the corrosion of the on-site radar level gauge bolts, plus I did not bring tools, so now the control cabinet is powered off and restarted to see if it can return to normal.

     询问工艺人员罐内液位大约是多少, 他说 70 80 公分左右,刚刚进料大约有半个小时 Before the power failure, I asked the craftsman about the liquid level in the tank. He said that it was about 70 or 80 cm, and it had been feeding for about half an hour .

     找到雷达液位计的电源开关( 它的 电源由于使用的24 电源不稳,所有的现场雷达电源重新安装了一台稳压电源调至 28V ,为了方便检修每一路电源都安装了带保险的接线端子)。 I found the power switch of the radar level gauge ( its power supply is unstable due to the 24 power supply used . All the on-site radar power supplies have been re-installed with a regulated power supply to 28V . In order to facilitate maintenance, each power supply is equipped with a fuse. Terminals). Reapply power after a few seconds.

观看电脑中液位 显示, 它的 液位突然变成满程,接着又 大幅度的波动, 30 40 秒后变成了 85cm ,接着 不动了, 和工艺人员说了几句话,准备离开 ,突然液位又变成零了,再也不动 Then watch the display of the liquid level in the computer , its liquid level suddenly becomes full range, and then there is a large fluctuation, it becomes 85cm after 30 or 40 seconds , and then it does not move, I told the craftsman A few words, when I was about to leave , suddenly the liquid level became zero again and never moved again .

      No way but to go to the scene . 里面 介质流动的声音, 而且 声音较大,有一种介质吹动的声音, 并且 罐内介质也是撞击着管壁咚咚响。 Under the emulsified asphalt tank , the sound of medium flowing inside is heard, and the sound is loud. There is a sound of medium blowing, and the medium in the tank also bangs against the pipe wall.

      沿着直梯爬到罐顶,想从雷达接线处断电重启, 无奈 接线盖连接处的密封圈上紧时偏了,怎么也开不开盖。 I climbed up the straight ladder to the top of the tank, and wanted to power off and restart from the radar connection. The seal at the connection cover of the helpless cover was too tight, and I couldn't open the cover. 修的不 好弄 了。 Look at the bolts at the manhole flange .

       取工具吧。 No way to go back and get the tools. 找了瓶子松动剂 Back at the work section, I took a 24 Torx wrench and found a bottle of loosening agent . 现场 先是对着螺栓出一阵猛喷,然后回到操作室和工艺人员聊天,在聊天中 我告诉他 说罐里打的是什么东西很响, 说用空气吹的, 也没在意, 以为是什么新工艺呢。 After arriving at the scene , I first blasted the bolts, then returned to the operating room to chat with the craftsman. During the chat, I told him that what was hit in the tank was very loud, and he said it was blown with air, and I didn't care. I thought it was a new technology.

      我去 现场拆卸法兰, 因为有了 松动剂的作用, 可是 最后一个螺栓 怎么也拧不开 ,拆了半天累死了 After half an hour, I went to the site to disassemble the flange. Because of the action of the loosening agent, the last bolt could not be unscrewed and it was exhausted for a long time . 不敢猛用劲怕站不稳滑下去 最后只好去垃圾堆捡了个80 的废钢管,当做压力杆, 最后 终于拆下来了。 On the top of the tank , I didn't dare to fight hard and I was afraid that the station would not be stable . Finally, I had to go to the garbage dump to pick up a waste steel pipe of 80 , which was finally used as a pressure rod . 累得几乎虚脱 But tired almost collapsed .

    When the manhole flange was moved, some grabbing red mist emerged from the tank . 雷达显示也是 变化的,再看看天线还是没问题。 Remove the radar antenna, there is no problem at first glance, there is no dust or dirt, wipe it with a rag, put it on the top of the tank, look for a fence to see if the radar display changes, and then look at the antenna is still OK .

     Look at the manhole, there is a dirty and grabbing mist. 看看里面介质有多少, 这种状况 根本看不清 雷达液位计根本没办法测量,看到人孔处冒出的雾气越来越多,没办法 只好 又把雷达装上,法兰处只串了两个螺栓固定。 Looking down to see how much media there is, but this situation is not clear at all , the radar level gauge can not measure at all, and seeing more and more fog emerging from the manhole, there is no way but to install the radar again Only two bolts are fixed at the flange.

     不听,给他讲原理 不懂,只是让修好 Go back to the operation room and tell the craftsman that the radar is not accurate in this situation. He doesn't listen, tells him the principle and doesn't understand it, just let it be repaired . 他的 班长,告诉他雷达液位计坏了不能用了。 Really depressed, he went directly to his monitor and told him that the radar level gauge was broken and could not be used. The monitor is good at talking, but let me tell our leaders that the feeding time in the tank takes one day, especially in the evening, and it should be repaired as soon as possible.

     回去和领导反映,领导也没 我们 一块找头,头听完过程,大发牢骚 哪有这样用表的,这么贵的表如此糟蹋,拿起电话找其改性沥青主任 I went back and told the leader that the leader could not do it . We looked for it together, and after hearing the process, we grumbled : how can there be such a watch, such an expensive watch is so bad, pick up the phone to find its modified asphalt director . 进入乳化沥青罐的是别的罐检修吹扫的污油,里面夹杂着铁锈杂质。 It was learned that it entered the emulsified asphalt tank from other tanks which were purged and cleaned, and contained rust impurities. 雷达液位计不能测量,同意不用修了。 The head told him that the radar level gauge could not measure and agreed not to repair it.

     转身准备离开, 无奈 头让我把雷达拆下来, 等到吹扫玩了在装上,怕介质损耗仪表。 I turned to prepare to leave, but helplessly asked me to take off the radar and said that I would wait until the purge was played, and I was afraid of dielectric loss instruments.

     第三次出现场 No way, I appeared for the third time . 现场 前我 又找了个仪表木头箱盖板, 必须 盖住沥青罐的人孔,那挥发出的气体真的受不了。 Before I went to the scene , I found another instrument wooden box cover, which must cover the manhole of the asphalt tank. The volatile gas could not stand it.

      了现场,没进操作室,直接把雷达拽出,放到罐顶上后,去操作室告诉工艺人员,表要拆下 液位不能用了。 I entered the scene, did not enter the operation room, directly pulled the radar out, put it on the tank top, and went to the operation room to tell the craftsman that the level of the meter would be unavailable after removing it .

      画面显示液位93cm I did n’t know the craftsman told me. I did n’t see that the liquid level on the screen was 93cm . It turned out that the radar antenna was facing the guardrail . Go directly to the control cabinet after the power is turned off, and tell the craftsman that the display is false just now.

      雷达液位计 维修, 我去 现场三遍,到后来还不是仪表的事 This time , I went to the scene three times to repair the radar level gauge , but later it was not a matter of instrumentation . 干了一下午 没有 用的活。 Depressed , doing a useless job all afternoon .