SGX小流量化工流程泵安装及调试

2012-11-02

SGX小流量化工流程泵安装及调试

拆卸与装配
拆卸
1、拆下泵上管路辅助系统。
2、拆下泵体上的放液管堵和轴承架上的放油管堵，放净泵内液体和轴承支架内的润滑油。
3、拆开泵体与泵盖联接螺栓，将泵盖与轴承支架部件等全部转子部件从泵体中一起取出。
4、拆下叶轮螺钉、取下叶轮和键。
5、将泵盖连同轴套、密封盖和机械密封等部件一起从轴上退出。注意勿使轴套相对于泵盖等发生滑动，然后再拆下密封盖，将机械密封连同轴套一起取下，再将轴套和机械密封拆开。
如果密封采用填料，则可从泵盖中直接拆下轴套，再顺次拆下填料压盖，填料和填料环等。
如果密封采用特殊结构，应注意不同的拆卸方法。
6、拆下泵联轴器和键
7、拆下轴承支架两端的前、后折流盘和轴承的前、后轴承盖，再把轴连同轴承一起从轴承支架中取出。
8、从泵轴上查下轴承。
装配
泵的装配顺序基本上可按照拆卸顺序的反方向进行，但装配时要注意检查各密封面垫片是否完好，并注意切勿漏装垫片和更换不完好的垫片。

Disassembly and assemblage
Disassembly
1、 disassemble the pipe work auxiliary system on the pump.
2、 Disassemble the drain pipe plug on the volute casing and the oil drainage plug on the bearing bracket, drain the liquid inside the pump and the lube inside the bearing bracket.
3、 Disassemble the coupling bolt of the volute casing and casing cover, remove casing cover and the bearing bracket ect all rotor equipment from the volute casing.
4、 Disassemble the impeller screw and remove the impeller and key.
5、 Take down the casing cover together with the shaft sleeve, sealing cover and mechanical seal from the shaft. Please pay attention not to make the shaft sleeve slide with the casing cover, then disassemble the sealing cover. Remove the mechanical seal together with the shaft sleeve and then disassemble the shaft sleeve and mechanical seal. If the seal adopts the packing, disassemble the shaft sleeve directly from the casing cover, then disassemble the packing gland, packing and packing ring in order. If the seal adopts the special structure carry out the different disassembling method.
6、 Disassemble the pump coupling and key
7、 Disassemble the bearing bracket front and back deflector and bearing front and back bearing covers, and then remove the shaft together with the bearing from the bearing bracket.
8、 Disassemble the bearing from the pump shaft
Assemblage:
The assemblage of the pump can be operated as the opposite order of the disassembly of the pump, but when assembling the pump, pay attion to check whether all sealing ring are well and also note to leak the sealing ring and replace the incomplete sealing ring.
安装
1、开箱后检查泵和电机，如果证实没有任何因装、卸和运输过程中造成损坏和紧固连接松动，泵的进出口端盖完好，没有尘土、污物等进入泵内，则可不必重新拆卸清洗和装配，直接送到使用现场去安装。
2、必须保证泵在工作时不超过其允许汽蚀余量。泵的吸上高度（或倒灌高度）必须根据泵的汽蚀余量特性，管路阻力损失特性及高温水的吸入液面压力来确定。
泵吸上使用情况下，应在吸入管路上装上底阀，并在出口管路上设置灌液螺孔或阀门，以供起动前灌泵之用。
泵倒灌使用情况下，应在吸入管路上装上阀门和过滤器，以免杂物进入。
3、吸入和吐出管路应该另有支架，不能用泵作支撑。
4、安装泵的地点，应便于巡回检查和检修。对新安装的吸入和吐出管路，应将其中杂物清理干净后方可与泵连接形成循环管路。
5、安装顺序
A、将机组放在埋有地脚螺栓的基础上，在底座和基础之间放置成对的楔垫作找正之用。
B、松开联轴器。用水平仪放在泵轴或泵联轴器的外圆上，通过调整楔垫，赵正机组的水平后，适当拧紧地脚螺栓，以防走动。
C、用混凝土灌注底座和地脚螺栓孔
D、等混凝土干固后，应拧紧地脚螺栓，并重新检查泵轴的水平度。
E、在接好管路及确定原动机转动方向以后，接上联轴器，再核对一遍轴的同心度，测量联轴器的外圆上下、左右的差异不得超过0.1mm，两联轴器端面间隙，在一周内大小的间隙差不得超过0.3mm。
F、在确认冷却和机封冲洗液供应正常情况下，机组才可运行。在机组实际运行3~4小时后检查，如无不良现象，则认为安装合格。

Installation
1、 First check the pump and motor after opening the packing box to see whether there are any broken or loosened of the fastened connecting parts caused during the transportation, and to check whether the inlet and outlet cover of the pump is OK or not and there is any dust in the volute casing. If it is OK, you can send the pump to the working place to install without disassembling and assembling it again.
2、 It is a must to guarantee that the cavitations allowance can’t exceed the specified amount during the pump working. The suction height of the pump(or the height of converse irrigating) depends on the character of the pump’s cavitations allowance, the character of the pipe resistance loss and the hydraulic pressure of the liquid surface of the high temperature.
When the pump is working to suck the liquid to a higher place, it is must to install bottom valve on the sucking pipe and set up the bolt hole or valve on the exhaling pipe to irrigate the pump before start.
When the pump is working to irrigate in the converse way, it is a must to install valve and filter on the sucking pipe on the sucking pipe to protect it form the sundries in.
3、 The sucking pipe and exhaling pipe should have different bracket, don’t take the pump as the bracket.
4、 The place of installing the pump should be easy for checking and maintenance. To the new sucking pipe, you should clean the pipe.
5、 Installing procedure
A、 The machine group should be placed on the place of burying the foundation bolt, and place the cushion between the seat and the foundation to get the better place.
B、 Loosen the couplings. Put a gardener on the pump shaft or the seat and adjust the cushion to find a level place for the machine group and then fasten the foundation bolt to avoid the movement.
C、 To inject the seat and the foundation bolt with the concrete.
D、 To fasten the foundation bolt until the concrete is dry and check the level of the pump shaft again.
E、 To connect the couplings until connecting all the pipes and confirm the rotation direction of the motor. Then check the concentricity of the shaft and measure the left and right, the up and down of the outer circularity of the couplings should not be yond 0.1mm, and the maxim and least clearance of the two couplings should not exceed 0.3mm during a week.
F、 Under the normal condition of the cooling and mechanical seal flushing liquid, the pump can operate, check after the operation of the pump for 3-4hours, if it works well, the installation is ok.

起动、运行和停止
起动前的准备
1、起动前要把泵和现场清理干净。
2、检查轴承支架内润滑油量是否适量。
3、未接联轴器前检查原动机的转向，与泵的转向箭头一致后，接好联轴器。
4、在装好机械密封或填料和联轴器后用手转动泵轴，应无碰擦现象，并将联轴器的防护罩安装好。
5、泵在吸上情况下使用，起动前应灌泵或抽真空；泵在倒灌情况下使用，起动前应用所输送液体将泵灌满，完全驱除泵中的空气后，将吐出管路的闸阀关闭。当泵内无液体时，严防空转、干磨。
6、起动前检查基础螺栓有无松动。压盖是否歪斜，以及润滑油和冷却水的供应情况。
7、输送易挥发或汽化的液体时，泵体上应装设放空阀，便于排气。
起动
1、关闭进出口压力(或真空)表和出水阀门（如有旁通管，此时也应关闭）。起动电机（先点动、确认泵转向正确后，才开始正式运行）。然后打开进出口压力（或真空）表，当泵达到正常转速，且仪表指出相应压力时，再慢慢打开出水阀门，调节到需要的工况。在吐出管路关闭的情况下，泵连续工作的时间，不能超过3分钟。
2、起动过程中要时时注意原动机的功率读书及泵的振动情况，振动数不应超过0.06毫米，测定部位是轴承座。
3、密封情况，机械密封应无泄漏、发热现象，填料密封应呈连续滴流状态。
4、如输送液体温度较高，启动前要均匀预热，其预热速尔为＜50℃/h为宜。
5、起动前必须确认冷却和机封冲洗液供应正常。
运行
1、经常检查泵和电机的发热情况（轴承的温升不应超过35℃，极限温度不应大于75℃）及油位情况（一般每运行500小时后，要全部更换润滑油一次）。
2、不能用吸入阀来调节流量，避免产品汽蚀。
3、泵不宜在低于30%设计流量下连续运转，如果必须在该条件下连续运转，则应在出口处安装旁通管，排放多余的流量。
4、注意泵运转有无杂音，如发现异常状态时，应及时清除或停车检查。
5、冷却水管阀门的开启度应根据泵正常工作后冷却出水管的温度进行调节。
停止
1、缓慢关闭吐出口管路阀门（如果泵在倒灌情况下使用，还要关闭吸入管路的闸阀）并关闭各种仪表的开关。
2、切断电源。
3、如果密封采用外部引液时，还要关闭外引液阀门。
4、如果环境温度低于液体凝固点时，要放净泵内的液体，以防冻裂。
5、如果长时间停车不用，除将泵内的腐蚀性液体放净外，各零部件应拆卸清洗干净，尤其是密封腔。将泵拆下清洗后重新装好，除涂油防锈处理和封闭泵进、出口外，还应定期检查。
6、切断电源后，再关闭冷却水管阀门和机封冲洗液阀门。
Start operation and stop
Preparation before starting
1、 before starting, clean the pump and spot.
2、 Check whether the lube in the bearing bracket is enough.
3、 Before connecting the couplings, check the motor rotary direction. Its identical with the pump rotary direction arrow. Then connect the coupling.
4、 After installing the mechanical seal or packing and coupling, turn the pump shaft by hand to see. Whether there is any bump and install the protective cover of the couplings.
5、 When the pump is working to suck the liquid to a higher place, it is must to irrigate the pump or make it vacuum before starting. When the pump is working to irrigate in the converse way, it is a must to irrigate the pump full with the conveyed liquid and clear the air of the pump and close the exhaling pipe valve before starting. When there is no liquid in the pump, it is forbidden to run the pump.
6、 Check the foundation bolt loose or not before starting. And check the sealing cover, the supply of the lube and cooling water.
7、 When transfer the volatilization liquid, the pump should has the draining air valve in order to exhaust the air.
Start:
1、 close the pressure(or vacuum) meter of the inlet and outlet and the exhaling water valve(if there is other pipe, it also should be closed). Start the motor (it is better to run and confirm the direction of the pumps running ok, the start the proper operation). Then turn on the pressure (or vacuum) meter of the inlet and outlet. When the speed of the pump reaches to a normal state, and the meter points to the related pressure, the open the exhaling water valve and adjust it to the required state. When the exhaling pipe is closed, the working time of the pump shouldn’t exceed 3 minutes.
2、 During the start, pay close attention to the power readings of the motor and the vibration of the pump, which the vibration should not exceed 0.06mm and the measuring part is the bearing seat.
3、 Check the mechanical seal, the mechanical seal should not have the leakage and the heat, and the packing seal should be the state of continuous dripping.
4、 If transfer the liquid of the high temperature, it is a must to heat up the pump before starting, and the value of the heat-up should less 50℃/h
5、 Confirm the cooling and mechanical seal flushing liquid are supplied enough before starting.
Operation
1、 check the pump and the motor’s heat-up normally(the bearings’ temperature rise should not be higher than 35℃ and the maxim temperature should not exceed 75℃.) And the lube position (it is general to change the lube for every 500 operation hours).
2、 Don’t adjust the flux with the sucking valve in order not to produce the cavitations.
3、 The pump should not operate under the condition of less 30% of the designed flux continuously. And if it is a must to run under this condition, you should install another outlet pipe and drain the surplus flux.
4、 Pay attention to the noise of the pump operation. If there is any abnormal performance, please check in time and stop the operation.
5、 The open degree of the cooling water pipe valve should be adjusted according to the temperature of the cooling outlet water pipe after the pump works normally.
Stop
1、 close the outlet pipeline gate valve slowly(if the use of converse irrigation, close the suction pipeline gate valve),close the switch of all meters.
2、 Turn off the switch.
3、 If the seal adopts the exterior liquid close the exterior liquid valve
4、 If the environmental temperature is lower than the liquid freezing point, discharge the liquid in the pump, avoid the pump body frozen and broken.
5、 If stopping using the pump for long time, exhaust the corrosive liquid in the pump, disassemble pump and clean all the parts, especially the sealing cavity. It is better to disassemble and clean the pump then assemble it again. Except for besmearing the oil for anti-rust and airproof the outlet and inlet of the pump, you should check the pump in a certain time.
6、 Turn off the power and then close the cooling water pipe valve and mechanical seal flushing liquid valve.