Over the past twenty years, we've specialized in maintaining, performing rapid repairs, and conducting major overhauls on horizontal screw centrifuges. Our primary repair services focus on a wide range of brands, including imported models like Flewis, Alfa Laval, Anderitz, Beares, Vesfaria, and Ishikawashima, as well as domestically produced options such as Ruiwei, Haishen, Shangli, Qingtian, and Lushui. This expertise helps address the common maintenance challenges faced by domestic users working with horizontal screw centrifuges. To assist everyone in understanding how to analyze and handle typical centrifuge issues, let’s break down some of the most frequent problems and their solutions:
1. **Oil Pressure Failures**: This issue typically presents as no oil pressure, excessively low pressure, or overly high pressure. Here's how to address these scenarios:
- **No Oil Pressure**: Verify that the oil filter isn’t clogged, inspect the pressure gauge for damage, ensure all oil lines and connections are secure, and confirm there are no leaks or cracks. Also, make sure the oil lines remain unobstructed.
- **Low Oil Pressure**: Normally, the outlet oil pressure for centrifuges in coal preparation plants should be around 3.0-3.5 bar. If the pressure is too low, check the oil line from the pump to the tank for blockages, inspect for leaks in the oil circuit, examine the coupling between the motor and pump shaft for damage, and replace the coupling or oil pump if necessary.
- **High Oil Pressure**: If the oil pressure is too high, confirm that the correct type of mechanical oil has been added as per the equipment manual, and check for any blocked pipelines. If a blockage exists, use compressed air to clear the debris.
2. **Excessive Vibration**: Excessive vibration during centrifuge operation often stems from improper installation, a blocked or deformed screen basket, obstructed coal channels between the screen basket and scraper, or loose bolts. Solutions involve checking the screen basket for blockages, wear, or deformation, examining the exciter springs for signs of aging, looking for fine coal accumulation on one side of the screen basket, verifying the condition of the wedge-shaped screen basket, ensuring the ground corner bolts are secure and free from rust, and inspecting the bearings. If a bearing is damaged, replace it. After installing a new vibrating motor, verify that it matches the load of the other motor and ensure both motors are installed identically.
3. **Abnormal Noise Issues**: Unusual noises are commonly caused by a small gap between the screen basket and scraper, foreign objects entering the equipment, or damaged bearings. Address these by checking the gap between the screen basket and scraper, ensuring the oil circuit is functioning properly, searching for foreign objects inside the machine, inspecting belts for damage or dislodgement, and examining the condition of the bearings.
4. **Motor Failures**:
- **Start-Up or Shutdown Issues**: Ensure the power supply voltage is stable and that the starter is operating correctly. Check for incorrect grounding, verify there is no phase breakage, and ensure there are no short circuits. Also, check for motor overload, either electrical or mechanical.
- **Overcurrent or Overheating Faults**: Inspect the motor’s mounting bolts for tightness and check the end cover for damage to prevent flipping. Look for partial bearing seizure or excess grease. Verify the feeding volume is not excessive; if it is, reduce it. Check for accumulation of discharge material at the bottom and clean the area if necessary.
5. **Feeding and Discharge Failures**: Feeding and discharge issues are often due to worn screen baskets, excessive coal volume, or high moisture content in the coal-water mixture. Solutions include checking for abrasive leakage in the screen basket and replacing it if needed. If the cutting performance decreases, process volume reduces, or materials become blocked, assess changes in coal quality or excess coal sludge, and enhance coal feed control. If the moisture level in the mixture is too high, regulate the moisture and fine coal content. Additionally, inspect the screen basket for blockages, check the gap between the scraper and screen basket, and look for wear on the chute.
These are just five of the many common centrifuge maintenance issues and their solutions. By addressing these problems effectively, you can significantly improve the operational reliability of your centrifuges.
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