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Baldor产品提高了大河能源公司煤炭干燥系统的可靠性
2020-03-19

Baldor产品提高了大河能源公司煤炭干燥系统的可靠性


Baldor Products Improve Reliability of Critical Fuel Enhancement System at Great River Energys Coal Creek Station

Baldor产品提高了大河能源公司煤炭干燥系统的可靠性


Great River Energy is owned by 28 electric distribution cooperatives throughout Minnesota, making it the second largest power producer in the state.
大河能源公司由明尼苏达州的28个配电合作社合资所有,它是该州第二大电力生产商。

Coal burns; water doesn’t. That is the founding principle behind DryFining™, an innovative technology developed by Great River Energy and partners to reduce the moisture and refine lignite coal. Lignite, a softer coal that naturally contains more water, is transformed through this unique process into a product with increased energy density that burns cleaner and improves overall power plant efficiency.
燃煤; 无水。 这就是DryFining™的创立原则,DryFining™是大河能源公司及其合作伙伴开发的一项创新技术,旨在减少水分和提炼褐煤。 褐煤(一种较软的煤炭,自然含有更多的水分)通过这种独特的过程转化为具有更高能量密度的产品,可燃烧更清洁并提高整个发电厂的效率。

In 2009, after years of research and development, Great River Energy installed the DryFining system at its Coal Creek Station power plant, located in Underwood, North Dakota. Today, 7.5 million tons of lignite per year is DryFined at Coal Creek Station, yielding more energy with less emissions.
经过多年的研发,2009年,大河能源公司在北达科他州Underwood的Coal Creek Station电厂安装了DryFining系统。 如今,每年在煤溪站对750万吨褐煤进行DryFined处理,产生的能源更多,排放更少。

But from the beginning, issues with failing gearboxes on coal conveyors in the new facility threatened the reliability of the system, a situation that needed to be remedied to ensure maximum uptime. Damian Meier, maintenance mechanic and coal drying specialist at Coal Creek Station, says there were two different problems he and the rest of the team had to deal with.
但是从一开始,新工厂的煤炭输送机上齿轮箱故障的问题就威胁了系统的可靠性,这种情况必须加以纠正,以确保最大的正常运行时间。 Coal Creek站的维修技工和煤炭干燥专家Damian Meier说,他和团队的其他成员必须解决两个不同的问题。

“Initially we were having temperature problems with the gearboxes,” explains Meier. “The duty cycle on this box was rated for the load they were carrying, but they were overheating. Another problem we had to deal with was twisting and breaking shafts.”
“起初,我们在变速箱方面遇到温度问题,” Meier解释说。 “这个减速箱上的工作周期是根据他们所承受的负载而定的,但是它们过热了。 我们还必须处理的另一个问题是轴的扭曲和折断。”

First, the maintenance team tried installing a larger size of the same gearbox, in essence over-sizing the gearbox to ensure it could more than handle the load. But that didn’t solve all of the problems. And while failing gearboxes never prevented the plant from drying coal, Meier says they could have, and he and the rest of the maintenance team worried about it all of the time.
开始,维护团队尝试安装更大尺寸的同一系列的变速箱,实质上是加大变速箱的尺寸,以确保变速箱可以胜任更久的工作。 但这并不能解决所有问题。 齿轮箱故障仍然存在,虽然永远不会阻止工厂干燥煤炭,但迈耶说他们本来可以做到的,而他和其他维护团队始终对此感到担忧。

“This was a constant concern because it’s our responsibility to keep the coal flowing,” says Meier. “We understand that we need to always be up and running – that we can’t afford to be shut down. We were under pressure to solve the problem and get this right.”
迈耶说:“这一直是一个令人担忧的问题,因为保持煤炭输送是我们的责任。” “我们了解到,我们需要始终保持运行状态–我们无法承受关机的后果。 我们面临着解决问题并实现这一目标的压力。”

Local Motion Industries Branch Manager Craig Taylor and Baldor’s Dodge Mechanical Sales Engineer, Jeff Schall, both frequent visitors to the plant, were asked to come up with a solution. Les Dockter, the plant’s welder mechanic and coal drying specialist, says these two went through everything on the conveyors to figure out what was needed.
经常来工厂参观的Local Motion Industries分公司经理Craig Taylor和Baldor的Dodge机械销售工程师Jeff Schall被要求提出解决方案。 工厂的焊工和煤炭干燥专家莱斯·多克特(Les Dockter)说,这两个人仔细检查了传送带上的所有内容,以找出需要的东西。

“We get exceptional service from Craig and Jeff, and they have always been very helpful,” says Dockter. “We’re also familiar with Baldor’s Dodge® brand of gearing, so when they proposed installing Dodge Quantis® gear reducers, we were open to the suggestion. They were both convinced that this was the solution, so we decided to install them.”
“我们从克雷格和杰夫那里得到了出色的服务,他们一直非常有帮助,”多克特说。 “我们还熟悉Baldor的Dodge®品牌的齿轮,因此,当他们建议安装DodgeQuantis®齿轮减速器时,我们坦然接受。 他们俩都确信这是解决方案,因此我们决定安装它们。”

Initially, four Quantis reducers were installed on coal conveyors feeding dried coal into the furnace, with each unit pulling 250 feet of conveyor. The next unit was installed on a 325-foot conveyor that feeds wet coal into two dryers. Since their installation in 2009, Meier says, they have not had one moment of concern.
最初,在煤炭输送机上安装了四个Quantis减速机,将干燥的煤供入炉中,每个装置拉动250英尺的输送机。 下一个单元安装在325英尺的输送机上,该输送机将湿煤输送到两个干燥机中。 Meier说,自2009年安装以来,他们就再也没有发生故障。

“Since we installed these Quantis units, we have not had one problem – not one issue,” says Meier. “They are easy to take care of, and really all we do is our regular preventive maintenance, like sampling oil and taking vibrations tests. We just don’t have to do much with them.”
“自从我们安装了这些Quantis设备以来,我们就没有出过一个问题,一个也没有,” Meier说。 “它们很容易保养,实际上我们所做的只是定期的预防性维护,例如取样机油和进行振动检测。 我们不再像以前一样做过多的事情。”

Dockter calls the gear reducer exceptional and bases his opinion on the way the reducer performs in one of the hottest locations in the plant, close to where coal is delivered to the dryers. He says this area can be as hot as 100 degrees in the winter and can reach 120 degrees in the summer.
Dockter称齿轮减速器运行环境超恶劣,减速器在工厂中最热的位置之一(靠近煤炭输送至干燥机的位置)的运行方式提出意见。 他说,这个区域在冬天可能高达100度,在夏天可能达到120度。

“In the past, the competitor’s gearbox ran so hot that it was just not pulling the belt the way it should,” explains Dockter. “We just knew that we would really burn through reducers in this location. However, despite the heat, the Quantis unit maintains a constant operating temperature – it just runs great with no issues.”
“过去,竞争对手的变速箱非常热,以至于没有按照原设计的方式拉动皮带,”多克特解释说。 “我们只是知道我们真的会烧掉这个位置的减速器。 但是,尽管一样超高温,Quantis装置仍保持恒定的工作温度–它运行得很好,没有任何问题。”

Based on the success with Quantis reducers, when the plant ordered a new transfer hopper, Dockter and Meier specified Baldor products on the equipment. The transfer hopper drops wet coal on the feed belts leading to the dryers. Meier says they changed systems so they could better control the flow of coal.
基于Quantis减速机的成功经验,当工厂订购了新的输送漏斗时,Dockter和Meier在设备上指定了Baldor产品。 转移料斗将湿煤滴落到通向干燥机的进料带上。 Meier说,他们改变了系统,以便更好地控制煤的输送量。

“We ordered this piece about a year after we installed the Quantis units,” explains Meier. “We told the OEM that since the Dodge reducers were working so well for us, we would like a similar Dodge gearbox on these feeders. The equipment was delivered with four 100K MagnaGear™ reducers coupled with  20 HP Baldor•Reliance® motors.”
“在安装Quantis装置大约一年后,我们订购了这件产品,” Meier解释说。 “我们告诉原始设备制造商,由于道奇减速机对我们来说运转良好,因此我们希望在这些斗轮上安装类似的道奇变速箱。 该设备随附了四个100K MagnaGear™减速器以及20HP Baldor•Reliance®电动机。”

Both Meier and Dockter report that since replacing problem reducers with Dodge gearing, they no longer worry about conveyors. Neither of them miss the stress involved in scrambling to repair gearboxes to keep coal flowing. Dockter says maximizing uptime is even more critical now, as additional plants will soon be relying on Coal Creek Station to supply them dry coal.
Meier和Dockter均报告说,由于用Dodge齿轮装置代替了原来的问题减速机,因此他们不再担心传送带。 他们俩都没有了担心错过争夺修理变速箱以保持煤炭流通的压力。 Dockter说,现在,最大化正常运行时间成为工厂最关键的问题,因为更多的工厂不久将依靠Coal Creek Station向他们提供干煤。


(Customer Testimonials 客户见证:)
“Installing the Dodge gearboxes has taken the pressure off of us,” says Dockter. “These products are giving us the reliability that we need; plus, they don’t require a lot of attention. We really appreciate the great service we get from Craig and Jeff in helping us be successful.”
“安装道奇变速箱减轻了我们的压力,”多克特说。 “这些产品为我们提供了所需的可靠性; 另外,他们不需要太多关注。 我们非常感谢Craig和Jeff在帮助我们取得成功方面所提供的出色服务。”


(Customer Testimonials 客户见证:)
“Since we installed these Quantis units, we have not had one problem – not one issue.”  Damian Meier,  maintenance mechanic  and coal drying specialist,  Coal Creek Station
“自从我们安装了这些Quantis单元以来,我们就没有一个问题-也不是一个问题。” 达米安·迈尔(Damian Meier),煤溪站维修技工和煤炭干燥专家

(Picture meaning 图片说明:)
Failing gearboxes on conveyors feeding dried coal into the furnace threatened the reliability of the system. In 2009, the plant’s maintenance team installed size 168 Baldor•Dodge® Quantis® right-angle helical bevel gear drives. The team reports these units have performed without fail and only require regularly scheduled maintenance.
将干煤送入炉内的传送带上的变速箱故障,威胁到系统的可靠性。 2009年,该工厂的维护团队安装了168型Baldor•Dodge®Quantis®直角斜齿轮锥齿轮传动装置。 该团队报告说,这些设备的性能没有出现故障,只需要定期维护即可。

(Picture meaning 图片说明:)
Designed for greater torque density in a compact housing, the Quantis RHB product features a helicalbevel-helical gear train that offers cost-effective, high- and low-speed solutions. Replacing failing gearboxes with the size 168 Quantis units has meant no unplanned downtime at the plant. The maintenance team responsible for keeping coal running reports that since installing the units, it has not had one moment of concern because the units run great with no issues.
Quantis RHB产品旨在在紧凑的外壳中提供更高的扭矩密度,其斜齿轮-斜齿轮-斜齿轮-斜齿轮传动机构提供了经济高效的高,低速解决方案。 用168个Quantis单元更换故障的变速箱意味着在工厂内不会发生计划外的停机时间。 负责使煤保持运转的维护团队报告说,自从安装单元以来,就没有一刻值得关注,因为这些单元运行良好,没有任何问题。

(Picture meaning 图片说明:)
Based on the success with Quantis reducers, plant officials specified Baldor equipment on a new coal transfer hopper. The OEM chose Baldor’s Dodge MagnaGear reducer, a power-dense, heavy duty reducer well suited for a variety of high torque applications.
基于Quantis减速器的成功经验,工厂官员在新的煤炭输送漏斗上指定了Baldor设备。 OEM选择了Baldor的Dodge MagnaGear减速器,这是一种功率密集的重型减速器,非常适合各种高扭矩应用。

(Picture meaning 图片说明:)
A total of four MagnaGear reducers coupled with Baldor•Reliance motors power the transfer hopper that drops wet coal on the feed belts leading to the dryers. Maintenance team members say the new system allows them to better control the flow of the coal.
总共有四个MagnaGear减速器与Baldor•Reliance电机配合使用,为输送漏斗提供动力,该漏斗将湿煤掉落到通向干燥机的进料皮带上。 维护团队成员说,新系统使他们能够更好地控制煤的流量。

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