The safe operation of pipeline homogenizers must strictly follow the following steps and specifications to ensure the safety of personnel and equipment:
1、 Preparation before operation
1. Equipment inspection
Confirm that the fasteners are not loose, the pressure gauge is reset to zero, and the cooling water and lubrication system are operating normally.
Check the oil level of the power box (HJ40 or HJ50 mechanical oil) to ensure that the pulley rotates correctly (counterclockwise).
Verify the integrity of the sealing device to prevent leakage risks.
2. Material pretreatment
The material needs to be pre filtered (60-100 mesh filter), with hard particle diameter ≤ 0.5mm, and viscous materials need to be diluted to a flowable state.
Immerse the material throughout the feeding port to prevent air from entering and causing vibration or idling.
3. Environment and Protection
Wear protective gloves and face shields; Use explosion-proof equipment (such as explosion-proof type D and increased safety type E) in flammable and explosive environments.
Install leakage protection devices in humid environments.
2、 Running operation process
1. Start up and preheating
Release the vent valve and inject 75-85 ℃ hot water circulation preheating pipeline into the hopper. Wait for the temperature to stabilize before feeding.
Start the motor to run without load and observe the stability of the discharge.
2. Key points of pressure regulation
Gradually increase pressure: Slowly rotate the pressure regulating handle clockwise, and increase the pressure by ≤ 100bar every 10 seconds. Sudden changes in pressure are strictly prohibited.
Pressure limit: The primary and secondary valves need to be adjusted in sections, and the final pressure should be ≤ the nominal value of the equipment (such as 1800bar).
Real time monitoring: Continuously observe the fluctuation of the pressure gauge during operation. If there is any abnormal jumping, check for feed blockage or valve sealing failure.
3. Homogenization process control
The material flow rate needs to match the equipment capacity to avoid overload operation; The temperature difference of high-temperature materials changes by ≤ 5 ℃/minute.
It is strictly prohibited to run without materials: the machine must be immediately depressurized and shut down in the absence of materials.
3、 Shutdown and maintenance
1. Safe shutdown steps
Loosen the pressure regulating handle counterclockwise at a constant speed to relieve pressure. After the pressure returns to zero, turn off the motor and finally cut off the cooling water.
2. Thoroughly clean
Immediately clean the pipeline with hot purified water above 90 ℃, add detergent to oily materials, and treat stubborn residues with 1% caustic soda solution.
Clean up the residue of grinding beads and check the wear of the homogenization valve.
3. Regular maintenance
Check the wear of the electric brush every week (replace if it is less than 6mm) and the lubricating oil pressure (maintain 6.0-7.0bar).
Monthly monitoring of bearing temperature and sealing ring leakage.
4、 Emergency situation handling
1. Equipment abnormal shutdown: Immediately release pressure, investigate overload or cooling failure, and restart after the standby body cools down.
2. Abnormal noise or unstable pressure: Check for wear of the homogenization valve, motor failure, or blockage of the feeding system, and repair professionally if necessary.
3. Material splashing/leakage: Cut off the power, wear protective equipment to clean, and confirm the integrity of the sealing structure.
The iron rule of operation: pressure regulation should be gradual, rotating parts should not be touched during operation, material breakage should be stopped immediately, and parameters should be regularly maintained and recorded.