电解槽大修

一、现场安全技术措施
1现场所有工作人员的着装，工器具的使用均应符合安规的要求
2将运行设备与检修设备进行隔离，将整流柜断电。
3.进行检修工作时应每隔二小时，测量检修工作区域内空气中的氢含量。
4在进行除油工作时，应尽量在室外进行，如必须在室内进行，则空气中丙酮量不得超过400mg/m3。
5检修工器具、材料、备品配件摆放整齐，检修现场“三不落地。
二、大修前备品件要求
1极板垫片外部光滑无划痕，无任何杂物附在上面。垫片严整均匀，无裂纹、弯曲现象。
2测量单片垫片厚度尺寸差值不许超过0.20mm，50片累计偏差不能超过0.50mm。
3定位销孔尺寸偏差不能超过0.5mm。

4气液孔道严整无毛刺。　　

5石棉布的密度为每10*10cm2经线为138根，纬线为174根，经纬线纺织均匀，无线头及断裂。
6极框密封线良好，无污物，无穿透横纹，无大面积变形现象。
7极板表面无锈蚀产物，镍层完好无损，密封线无穿透横纹，干净无污物。
8盘形弹簧无变形，金相检查无裂纹。

三、准备和检查

1将电解槽的碱液抽回碱箱，并用大量的除盐水进行冲洗，直至出水澄清透明为止。
2检查制氢系统各阀门开关及渗漏。
3检清洗极柜,极板,主极楹,石棉布等部件
4检查紧固螺栓,螺帽及盘形弹簧

5记录主极板四点间距及蝶形弹簧高度。

6由正极向负极在每个极框上按顺序打出字码号。
7清理电解槽外部积碱并在渗碱处做好标记。
8卸开所有的连接法兰及与电解槽相连的各种管道附件，做9好标记，管口用布包好。
10将双头螺栓均匀依次松开。
11抽出上部一根螺栓并取下盘形弹簧组。
12按序号依次取出极框、极板。
13所有卸下的极框和极板，应放在木板上，不得叠放以防止结合面损伤和零件变形。
四、电解槽检修工艺及检修质量

1. 将极板上的污物用铜丝刷刷净并用除盐水冲洗
2. 检查极板阳极的腐蚀情况及阴极的锈蚀情况
3. 检查并清理密封线,清理时只许用铜丝刷或木制工具

1. 极板与附加板应连接牢固,无松动
4. 极板阳极侧镀镍无严重脱落或起皮现象
5. 极板密封线内无杂物,无穿透性横纹
6. 极板密封面不严度不准超过0.2mm
极框

1.用除盐水冲洗极框及石棉布的污物,并用软毛刷刷洗
2. 检查导气管和碱液孔道
3. 清理极框密封线,清理时只许用铜丝刷或木制工具
4. 检查石棉布情况并做透气实验,如不合格应更换

5. 极框的密封线无污物,无穿透性横纹
6. 极框的开口环到位,垫块牢固,无松动
7. 石棉布经透光实验后无透光点,无裂纹和松动现象
8. 极框导气孔及碱液孔道无污物堵塞
五，电解槽附件

1.清洗拉紧螺栓及螺母的丝扣,除去锈蚀, 拉紧螺栓螺纹良好无乱丝扣

2. 检查盘形弹簧是否变形, 盘型弹簧无变形,无裂纹。并做金相检查
3. 检查胶木绝缘垫圈，应无断裂
4. 检查氢、氧、碱孔道，应无污物

六、石棉布透光试验及安装
透光试验
1将装有石棉布的极板框放在透光圈桶上,圈桶内装有三只60W的灯泡,灯距布距离为400mm。
2进行实验时应在暗室检查。
3当发现有透光点时应先用记号笔做好标记，当石棉布的透光点直径大于0.2mm时,其点数在10点以上时应更换石棉布,小于此标准可进行修补。
更换
1 将极框平放在工作台上,均匀沿极框内径辅放好,开口环辅好放在石棉布上,将石棉布拉紧卡具安装在隔膜框上,并箍住开口环,对称紧固拉紧卡具上的螺栓,测量各拉紧卡具两侧开口环凸出部分的差值不超过0.5mm,则石棉布安装成功。
2沿极框内部修剪石棉布。
3卸下拉紧卡具，用木锤将片轻轻敲入开口环的开口内。
4 用钻头来清除氢、氧、碱孔道的石棉布碎片,保持其畅通。

七、电解槽的组装

1用水平尺检查绝缘垫片的水平情况,其高度不超过±2mm。

组装前将所有的部件用丙铜清洗。将极板沿极向移动80mm。
在主极板上的拉紧螺栓位置安装绝缘套，并装上拉紧螺栓，2调整下面的拉紧螺栓的水平位置，其水平偏差不超过2mm。
3将六个定位销安装在主阴极板上，并在上面挂上极板垫片，然后安装极框 ，安装时将开口环侧对向主阴极板。
4将极框、极板、中间极框按照拆卸时编号全部安装好，安装时不许任何杂物落入电解槽内部 。
将拉紧螺栓穿入并套好螺片。
八、电解槽紧固
电解槽热紧
1从电解槽一端的氢氧沟孔内通入0.1—0.15MPa的蒸汽,由碱液入口管排出进行加热,加热必须连续不断地进行。加热开始每隔2小时均匀拧紧电解槽螺栓，每次紧固螺栓的紧进尺寸差量最大不超过1mm。
2在紧固螺栓的过程中，盘形弹簧的压缩量不能大于4mm，测量两主极板间距四个角差不大于0.1mm。
3加热约经过30—40小时停止，再紧固1—2次螺栓，待电解槽冷却后面紧固一次，但紧固力距不大于4400kgf/m。
4电解紧固后两主极板尺寸应与拆卸之前相等或最后二次紧固尺寸稳定不变时即合格。

冷电解槽紧
1电解槽冷紧可在电解槽冷态下直接拧紧螺栓，但紧固时间与热紧相同。
2电解槽每条螺栓负载达到4400kgf/m时，要对电解槽进行水压试验。
九、电解槽的水压试验
1电解槽冷却后要进行水压试验，先将水充满，逐渐将压力从0.8MPa提到1.2MPa,经过10分钟后,如压力不下降,再将压力降到1.0MPa进行检查,若发现局部渗漏,可再紧一次螺栓,水压试验合格后,如电解槽不启动运行,应向电解槽内充满10%的氢氧化钾溶液以防生锈。
十、电解槽的装配工艺要点

1电解槽的装配采用垂直叠装的方式，电解槽极板数量众多，准确定位是关键，否则不可避免要扭曲。

2校准装配底座，制作定位监视器，保证叠装过程的定位正确。

3采用电动液压技术，同时用多只液位拉伸器，对角进行压紧工作保证各部位受力均匀。

4使用专业的工具，监测各个绝缘密封垫片和极板受力情况。避免出现受力不均匀现象。影响电解槽密封和使用寿命。
5 电解槽采用多条拉紧螺栓紧固，垫片受力更均匀。
6 电解槽经过多道工艺和外观检查后，进行压力和密封检查。

Electrolyzer Overhaul 1, Site Safety Technical Measures 1 all the site staff's clothing, the use of tools should comply with the requirements of safety regulations 2 running equipment and maintenance equipment isolation, rectifier cabinet power cut. 3. The hydrogen content in the air in the maintenance area should be measured every two hours during the maintenance work. 4 when Deoiling, should be done outdoors as far as possible, if it must be done indoors, the amount of acetone in the air should not exceed 400mg / M3. The tools, materials and spare parts for inspection and repair should be kept in good order, maintenance site "three do not fall to the ground. ". Spare parts before major repair requirements 1 plate gasket external smooth without scratches, without any debris attached to the above. Gasket strict and even, no crack, bending phenomenon. 2 The measurement of the thickness of the single gasket shall not exceed 0.20 mm, and the cumulative deviation of 50 pieces shall not exceed 0.50 mm. The dimension deviation of the locating pin hole can not exceed 0.5 mm. The gas-liquid channel is strict and neat without burr. 5 The density of Asbestos cloth is 138 threads per 10 * 10 cm 2,174 threads per 10 * 10 cm 2. 6 Pole frame sealing line is good, no dirt, no through transverse grain, no large area deformation phenomenon. There is no corrosion product on the surface of the electrode plate, the nickel layer is intact, the sealing line does not penetrate through the transverse lines, and there is no dirt and dirt. There is no deformation and no crack in the plate spring. 3. Preparation and Inspection 1. Drain the Lye from the electrolyzer back to the alkaline tank and flush with a large amount of desalted water until the effluent is clear and transparent. Check the valve switch and leakage of hydrogen production system. Check and clean electrode cabinet, electrode plate, main electrode couplet, asbestos cloth and other parts. 4 check the fastening bolt, nut and disc spring. 5 record the four-point distance of main electrode plate and butterfly spring height. 6 from the positive to the negative pole in each pole box in order to type the word number. Clean up the alkaline deposit on the outside of the electrolyzer and mark it at the soakage. Remove all connecting flanges and all pipe accessories connected to the electrolyzer, mark 9 well and cover the pipe mouth with cloth. 10 loosen the Stud Bolt evenly and in turn. 11 remove the upper bolt and remove the disc Spring Assembly. Take out the poles and plates in sequence by serial number. All unloaded Poles and plates shall be placed on board and shall not be stacked to prevent joint damage and deformation of parts. The repair technology and repair quality of ELECTROLYZER. Brush the dirt on the plate with copper wire and rinse with desalting water. 2. Check the corrosion of anode and Cathode. 3. Check and clean the sealing wire. Only use copper wire brush or wooden tools for cleaning. Plate and additional plate should be connected firmly, no loose 4. Nickel plating on anode side of plate has no serious peeling or peeling phenomenon 5. There is no sundry in the sealing line of the plate, and there is no penetrating transverse grain 6. Plate sealing surface shall not exceed 0.2 mm pole frame 1. Rinse the pole frame and asbestos cloth with desalting water and brush with a soft brush 2. Check the airway and Lye duct 3. Clean the sealing wire of the pole box. Only use copper wire brush or wooden tools. Check the condition of asbestos cloth and do ventilation test, if unqualified should be replaced 5. The sealing line of the pole frame is free from dirt and penetrative cross-grain 6. The opening ring of the pole frame is in place, the cushion block is firm, no looseness 7. After the light transmission experiment, asbestos cloth has no light transmission spot, no crack and looseness 8. Pole frame air hole and alkaline liquid hole without dirt plug five, cell accessories 1. Clean and tighten the screw of bolt and nut, remove rust, tighten bolt thread without disorder. 2. Check whether the disc spring deformation, disc spring without deformation, no crack. And do metallographic examination 3. Check bakelite insulation gasket, should not break. Check hydrogen, oxygen, Alkali channels, should be free of dirt six, asbestos cloth through light test and installation through light test 1 will be equipped with asbestos cloth plate frame on the transparency ring barrel, the ring barrel with three 60 w light bulbs, lamp distance from the cloth 400 mm. When the experiment is carried out, it should be examined in the dark room. If the diameter of the transparent point of asbestos cloth is larger than 0.2 mm, the cotton cloth should be replaced when the number of the transparent point is more than 10, less than this standard can be repaired. Replace 1 place the pole frame on the worktable, put the pole frame evenly along the inner diameter of the pole frame, put the opening ring on the Asbestos Cloth, install the asbestos cloth tensioning clamp on the diaphragm frame, and fasten the bolts on the clamp symmetrically, measure the difference of the protruding part of the opening ring of each side of the tensioning clamp is less than 0.5 mm, then the installation of the asbestos cloth is successful. 2. Trim the asbestos cloth along the inside of the pole frame. Remove the tensioning clamp and gently tap the piece into the opening of the opening ring with a wooden hammer. Use a drill to remove fragments of Asbestos cloth from hydrogen, oxygen and Alkali channels and keep them open. 7. Assembly of the ELECTROLYZER 1 check the level of the insulating gasket with a level ruler, the height of which shall not exceed 2mm. Clean all parts with cupronickel before assembly. Move the plate 80 mm along the pole. Install the insulating sleeve at the tension bolt position on the main plate and install the tension bolt. 2 adjust the horizontal position of the tension bolt below, the horizontal deviation is not more than 2 mm. Install the six dowels on the main cathode plate and hang the plate gasket on it, then install the pole frame with the side of the opening ring facing to the main cathode plate. 4 The pole box, plate, intermediate pole box are all installed according to the number when disassembling, no sundries are allowed to fall into the electrolyzer when installing. Insert the tension bolt and set the bolt. 8. The cell fastening the cell heating 1. Steam of 0.1(0.15 MPA) is passed through the hydrogen-oxygen groove at one end of the cell, and is heated by discharge from the LYE inlet pipe. The heating must be continuous. Starting from heating, tighten the electrolytic cell bolts evenly every 2 hours. The screw-in size difference of each fastening bolt should not exceed 1mm. 2 In the course of fastening bolt, the compression quantity of disc spring should not be more than 4mm, and the difference of four angles between two main plates measured should not be more than 0.1 mm. 3 after heating for 30 ~ 40 hours, the bolts were tightened 1 ~ 2 times, and then the cell was cooled once, but the tightening force distance was not more than 4400KGF / m. 4 after electrolytic fastening, the size of the two main plates should be equal to that before disassembly or when the size of the last second fastening is stable. Cold Cell Tight 1 the cell cold tight can be in the cell cold state directly tighten the bolt, but the fastening time is the same as the hot tight. 2 when the load of each bolt reaches 4400kgf / m, the water pressure test should be carried out on the electrolyzer. Water pressure test of the ELECTROLYZER 1 after the electrolyzer is cooled, the electrolyzer shall be subjected to a water pressure test by first filling the water and gradually raising the pressure from 0.8 MPA to 1.2 MPA. After 10 minutes, if the pressure does not decrease, the pressure shall be lowered to 1.0 MPA for inspection. If local leakage is found, the bolts may be tightened again. After the water pressure test is qualified, if the ELECTROLYZER does not start operation, the electrolyzer shall be filled with 10% potassium hydroxide solution to prevent rust. The assembly of Electrolyzer 1 the Assembly of electrolyzer adopts the way of vertical stacking, the number of electrolyzer plates is numerous, accurate positioning is the key, otherwise it is inevitable to be distorted. 2 calibrate the assembling base and make the positioning monitor to ensure the correct positioning of the assembling process. Adopt electrohydraulic technology, at the same time use a number of liquid level tensioner, press on the corners to ensure that all parts of the force uniform. Use a professional tool to monitor the force on each insulating gasket and plate. To avoid the phenomenon of uneven force. Affect the electrolyzer seal and service life. 5 electrolyzer adopts many tension bolts to fasten, gasket bears force more even. After multi-channel process and appearance inspection, the pressure and seal of the electrolyzer are checked.