Recently, the automatic upgrading and transformation project of the third refining workshop 1#2# coal car of the coking plant of Laiwu branch of Shandong Steel Co., Ltd. was successfully completed and put into operation. This project is the first intelligent upgrading project of the coking plant undertaken by the intelligent information department, the first step to improve the intellectualization of the four cars in the coking plant of Laiwu Steel Co., Ltd., and has important guiding significance for realizing the automatic running.

The project includes the transformation of two coal charging cars. In order to ensure the normal production of coke oven, the two cars are distributed. While transforming one car, it must ensure that the other car can meet the production demand; Since the two coal feeders are old equipment, and the production record of one car has never been operated alone for a long time, this puts forward high requirements for the construction progress.

The coking plant requires to complete the transformation of one vehicle within 10 days and meet the service conditions of the whole vehicle. It is necessary to complete the demolition and installation of the distribution room house, the demolition of all old electrical panels and cables, the installation and full welding construction of 7ton steel structure, the installation of 13 electrical automation panels and cabinets and 5000 meter cable construction, on-site piping and transformation construction, vehicle industrial television and lighting construction, vehicle electrical automation commissioning, four vehicle chain commissioning, etc. within 10 days, which puts forward quite high strength requirements for the project construction.

In order to ensure production, the project implements 24-hour construction in two shifts, and the construction time of each shift exceeds 16 hours. Based on the condition of ensuring sufficient construction personnel, the construction tasks shall be decomposed by reasonably arranging the construction plan, the scheduling of each construction task shall be specific to hours, and the construction progress shall be dynamically tracked and adjusted in real time. Maximize the construction efficiency of construction personnel, strictly require the construction quality of construction personnel, and most reliably ensure the construction safety of construction personnel.

In order to shorten the construction period, speed up the progress and ensure the smooth completion of construction nodes, four gas cutting and six welding machines are configured in the working space of only 60 square meters for demolition and installation at the same time. Members of the project department stick to the construction site 24 hours a day to supervise the construction quality and progress and ensure construction safety and environmental protection. Due to the disrepair of the original coal truck and the damage of the seal, the thickness of pulverized coal and dust accumulated in the whole vehicle exceeded 5cm, which caused great difficulties in the demolition and cleaning work. The members of the project department, together with the construction personnel, fully carried forward the spirit of hard-working, and went deep into the front line of the demolition site.

In order to carry out wiring according to the plan, members of the project department and construction personnel lay cables all night. Due to the shortage of cable laying personnel, the members of the project department personally went to the battle for cable laying, and conducted the whole process guidance and coordination for cable laying. After the cable review is completed, the overall hoisting construction of the distribution room will be started immediately. The cable wiring work will start one hour later. In order to rush the work, the wiring work will be carried out simultaneously with the welding and fixing work in the distribution room. The wiring worker will carry out the wiring work in the distribution room full of welding smoke, and the working environment is very bad. Members of the project department shall provide wiring guidance in the whole process of the power distribution room. After continuous fighting and suffering, all personnel of the project department are racing against time. The tight construction progress, high construction intensity and long construction time are overcome one by one in front of the members of the project department.

In order to carry out wiring according to the plan, members of the project department and construction personnel lay cables all night. Due to the shortage of cable laying personnel, the members of the project department personally went to the battle for cable laying, and conducted the whole process guidance and coordination for cable laying. After the cable review is completed, the overall hoisting construction of the distribution room will be started immediately. The cable wiring work will start one hour later. The wiring work will be carried out simultaneously with the welding and fixing work in the distribution room. The wiring worker will carry out the wiring work in the distribution room with full of welding smoke. Members of the project department shall provide wiring guidance in the whole process of the power distribution room. After continuous fighting and suffering, all personnel of the project department are racing against time. The tight construction progress, high construction intensity and long construction time are overcome one by one in front of the members of the project department.

After seven days of continuous struggle, in addition to the commissioning of the electrical and control system of the whole vehicle, the industrial television system, lighting system and the replacement of doors and windows in the cab were also successfully completed. On the seventh night, the test run of the whole vehicle was successfully completed, and the control chain was repeatedly tested. The whole vehicle has the conditions for trial production and operation.

I thought the project would proceed smoothly according to the plan, but in the early morning of the eighth day, another running coal truck failed, the motor was damaged and the spare parts could not be replaced temporarily. In order to ensure production, in a hurry, the leaders of the coking plant immediately decided to start the newly transformed coal feeding truck for production in advance. Members of the project department shall immediately take emergency response, actively cooperate with the production department, track the production in the whole process, guide and train while producing, and provide hand-to-hand operation guidance to operators who are not skilled in operation. After nearly 20 hours of "emergency fire fighting" production and operation, the newly transformed coal truck has withstood the test of practice, and the operation is reliable and stable. It not only realizes the goal of "trial production and operation", but also meet the continuous production requirements of the coking plant and avoids the shutdown of the coke oven.

In addition to improving the functions of automatic coal taking, automatic cover taking and sending, automatic dust removal and so on, the upgraded coal feeder has added a one button coal loading function to realize the full-automatic coal loading of the coal feeder, which greatly improves the automation and intelligence level of the coal feeder and reduces the labor intensity of the operators; The original button operation is replaced by more advanced industrial touch screen operation, which makes the picture more intuitive and the operation more convenient; After the transformation, the sealing effect of the coal truck is better, the occurrence of smoke and fire is completely avoided, and the working environment of the operator and the safety and environmental protection requirements of the whole vehicle are greatly improved.

Comparison of cab before and after

Comparison of distribution room before and after

Comparison of distribution cabinet before and after transformation