A bundle extractor is a device used for the automatic extraction and packaging of tube bundle products, widely applied in industries such as petrochemicals, power generation, and metallurgy. To ensure the safety of operators and the normal operation of the equipment, systematic safety training for operators is crucial. Below are the detailed contents regarding the safety training for bundle extractor operators:

Overview and Working Principle of the Equipment

·The bundle extractor mainly consists of a welded steel structure main frame, lead screws, electrical control cabinet, cycloid pinwheel reducer, motor, load trolley, etc. Its working principle utilizes the planetary cycloid pinwheel reducer as the power source, driving through a trapezoidal lead screw to achieve smooth extraction of the tube bundle.

·Operators should be familiar with the structure and working principle of the equipment, understanding the functions and roles of each component, to correctly judge and handle various situations during operation.

Preparations Before Operation

·Check the power supply of the equipment to ensure it is connected to power and working normally.

·Inspect the area around the equipment for any debris or obstacles, ensuring the operating area is clean and tidy.

·Prepare the required tube bundle products and packaging materials, ensuring their quantity and quality meet requirements.

·Wear personal protective equipment such as helmets, gloves, work clothes, etc.

·Check the lubrication status at all lubrication points, ensuring components like the lead screw and trolley are intact and perform an idle test run.

Operation Steps and Precautions

·When starting the machine, insert the battery into the remote control, turn on the remote switch, and twist out the "press-in/twist-out" button.

·Lift the bundle extractor and position it near the tube bundle.

·Press the clamping loosening button to extend the clamping cylinder to an appropriate position, ensuring its extension exceeds the thickness of the heat exchanger shell flange.

·Press the left and right descending buttons, retracting both cylinder pistons and tightening the cables. Adjust jointly with the crane to align the extractor jaws with the outer flange of the heat exchanger, making sure the height of the extractor is suitable and its axis aligns with the heat exchanger.

·Press the clamping button to tightly press the bundle extractor against the outer flange of the heat exchanger, then drive the crane to reach the frontmost position.

·Assemble the initial pull beam and connect it to the rear part of the tube bundle with the primary pull cable.

·Press the crane retract button, allowing the crane to drag out the tube bundle through the initial pull beam as far as possible.

·Remove the primary pull beam cable and use the secondary pull cable to bundle the tube bundle flange.

·Press the crane retract button again; the tube bundle is dragged out until the crane's hanging plate can be placed under the tube bundle flange. Remove the secondary pull cable and move the crane forward to hang onto the tube bundle flange.

·Press the hanging plate raise button; the hanging plate rises to a height where it does not touch the tube bundle.

·Press the crane retract button again; the tube bundle continues to be dragged out until about 150mm remains unextracted. Stop the dragging at this point and relax the clamping cylinder.

·Adjust the height of the extractor grip by using the left and right balance cylinders, making it roughly level with or slightly lower than the lower end of the tube bundle shell. Then place the second trolley behind the grip, adjusting its height to be level with or slightly lower than the upper surface of the grip.

·Press the clamping button to clamp onto the heat exchanger shell.

·Press the crane retract button again; the tube bundle is completely dragged out of the heat exchanger and falls onto the second trolley through the grip, which, together with the first trolley, drags it to a balanced position and stops.

·Press the clamping release button to disengage the bundle extractor from the heat exchanger shell flange. Press the left and right descending buttons to relax the cables, then remove the cables, making the bundle extractor separate from the heat exchanger.

·Cut off the power supply to the bundle extractor, dismantle it along with the tube bundle, concluding the tube bundle operation.

Common Fault Handling

·Slow action of hydraulic cylinders: May be due to a blocked oil filter at the inlet; clean the oil filter.

·One-way action normal for a single hydraulic cylinder, but not working in reverse: Could be due to a damaged seal ring on one side of the cylinder piston; replace the seal ring.

·Side pulling cylinder lacks strength after loading: Could be due to low pressure adjustment of the relief valve or a faulty relief valve; adjust or replace the relief valve accordingly.

·Clamping cylinder automatically releases when extracting the tube bundle: May be due to internal leakage in the clamping solenoid valve; replace the clamping solenoid valve.

Safety Regulations and Emergency Measures

·Operators must undergo professional training and be familiar with the equipment's operating procedures and safety regulations.

·Overloading operations are strictly prohibited, non-operators are forbidden from using the equipment.

·During field operations, always pay attention to the trolley's walking position; do not allow it to walk to either end of the lead screw bearing seat to avoid damaging the lead screw and reducer.

·If abnormal operation or unusual noises are detected, stop immediately for inspection. If repairs are needed, notify maintenance personnel immediately; do not operate with faults.

·In emergency situations, operators should quickly press the emergency stop button to halt the equipment's operation.

Maintenance

·Regularly check all parts of especially vulnerable components like lead screws, trolleys, and steel cables.

·Regularly replace hydraulic oil and bearing grease.

·Keep the equipment clean and dry to prevent corrosion and rust.