fuyangby@126.com
86 15188770013
fuyangby@126.com
86 15188770013
I. Purpose and Applicable Scope of the Pump
Type-ZGM slurry pumps are new-type effective energy-saving anti-ablation pumps designed and developed by Our company and Tsinghua University jointly.The pumps have comprehensively absorbed advantages of similar products at home and abroad and are innovated in terms of hydraulic design , strtucture designand wearproof materials used, which have the characters of high efficiency, energy saving,icw noise , steadyoperation, long service life and convenient maintenance , etc.The comprehensive performances of the pump takethe lead in the domestic market and the efficiency index of most pumps reaches the international advanced levei.They can be widely applied to transport slurry with solid particles for such industries as electricity, metallurgy,coal and building materials, for example, for hydraulic removal of ashes in thermal power stations, mine slurrydelivery in metallurgy concentrating mill and delivery of coal slurry and heavy media in coal separation plants.The allowable maximum slurry weight concentration,Cw, for delivery is: 45% for grout(cinder slurry) and coalslurry,60%for mine slurry and heavy media.
II. Model, Structure Feature and Type of the Pump
Type-BGMslurry pumps can be classified into two models: one is TypeZAM, horizontal axial absorptioncentrifugal slurry pump with single stage and single absorption; the other is Type TAM ,vertical axial absorptioncentrifugal slurry pump with single stage and single absorption.
1.Structural features and type ofZGMslurry pump
(1)Structural feature of Type-ZGMslurry pumpPump head
The pump head of Type-&KMslurry pump includes: pump body, impeller and shaft seal unit.The pump head andtray shall be connected with bolts.According to requirements, the outlet position of the pump can be installed anduscd at eight different directions in the intervals of 45°
The pump body of Type-IMslurry pump is the double-shell structure. The outer shell is metal(front pump body,rear pump body), and its material is generally HT200 or QT500--7; the inner shell may be made of high chromealloy cast iron (including volute, front guard plate, rear guard plate)or of rubbers (including front volute,rear volute).
The impeller is composed of front cover sheet , rear cover sheet, blades and rear blades.The blades is twistedblades and the number is generally 3-6.The rear blades are located at the outside of front cover sheet and rear coversheet and the number is generally 8.The impeller is made of high-chrome-alloy cast iron, which is connected withshaft by screw.
The shaft seal unit has three types: combined seal of associate impeller and packing, packing seal andmechanical seal.See Figure 1.
The combined seal of associate impeller and packing is composed of packing box, associate impeller, waterseal ring, packing, packing gland and shaft sleeve.See 5 in Figure 1.
The packing sealis composed of packing box, distance sleeve, water seal ring, packing, packing gland andshaft sleeve.See 5a in Figure 1.
The mechanical seal is composed of packing box, distance sleeve, mechanical seal, gland and shaftsleeve.See 5b in Figure 1.
2 Tray
The tray has two types: horizontal middlc-open type and solid bowl type.
The middle-open tray has two types: thin oil lubrication and grease lubrication. The thin oil lubricationtray is mainly composed of tray body, tray cap, shaft, bearing box, bearing, bearing gland, shield sleeve, nut,oil seal, water shield pan, stripping ring and other spare parts. See figure 1.Type ZM and above various pumpsare also equipped with water cooling unit.The main differences between grease lubrication tray and thin oillubrication tray are: the imbed unclosed -face cover and grease cup are added to the grease lubrication tray,and the water cooling device is removed.See 16a in Figure 1(continued).
The solid-bowl tray adopts the grease lubrication and is mainly composed of tray body, bearing body,shaft, bearing,bearing support sleeve, bearing gland, oil seal, grease cup, water shield pan, stripping ring andother spare parts. See 16b in Figure 1(continued).The solid bowltype frame is only applicable to pumps withlow power ofType 200ZMand below; at present, there are only three types of specifications:T200ZGM-1一A70,T200ZGM一I一A60 and T1507GM一I一A60.
(1)Model and meanings of Type-ZMslurry pump
2.Structural features and model of Type-ZGMLslurry pump
(1)Structural features of Type-ZMLslurry pump
Type-ZML slurry pump is mainly composed of impeller，volute,rear guard plate,shaft sleeve,supporter,supporting sheet, shaft, bearing, bearing body and other spare parts.Materials of impeller, volute and rear guardplate are high chrome alloy cast iron.The screw-thread connections are used for connecting impeller and shaft,and the bolt connections for volute, supporter and bearing body. The pump shaft and electric motor can use thecoupling for the purpose of direct driving or belt driving.The bearing of Type-TKMslurry pump adopts the greaselubrication, which belongs to the pump without shaft seal.
The structure of Type-ZGMI.pumps is in chart 2.
(2)Model and significances of Type-ZGML,slurry pump
III.Lifting, Installation,Adjusting and Trial Operation of the Pump
1.Lifting
For lifting of pumps with package case, the wire rope shall be tied according to signalsmarked on the case .In the process of lifting, the bottom or sides of the case shall not beimpacted or be vibrated violently.The package case shall not be inclined excessively andplaced at the object with cusped edge, nor shall it be placed in reverse.
III.Lifting, Installation,Adjusting and Trial Operation of the Pump1 .Lifting
For lifting of pumps with package case, the wire rope shall be tied according to signalsmarked on the case.In the process oflifting, the bottom or sides of the case shall not beimpacted or be vibrated violently.The package case shall not be inclined excessively andplaced at the object with cusped edge, nor shall it be placed in reverse.
Figure 1 Constructional drawing of Type-ZGMPump
1 .coupling 2.shaft 3.bearing box 4. disassembly ring 5.shaft seal 6.service impeller(interval sleeve)7. rear guard plate 8.volute 9.impeller 10.front guard plate 11. front pump body 12.rear pump body13.packing box 14.water seal ring 15.pedestal 16.tray 17.adjustment screw
Note: the interval sleeve should be installed in multi-stage pump or mechanical-seal pump, no assistant impeller.
(16a）tray with grease lubrication
(16b) tray with solid bowl
1 Figure i Continued
For lifting of pumps without package case, the following requirements shall beimplemented.
(1)For lifting horizontal pump without pedestals or with only one pedestal, the liftingcenter of gravity should be near the pump head and at the side square hole of the tray, andthe wire rope shall pass through it and then vertically up to connect the crampon.In orderto maintain the balance of the pump, the supporting lifting wire rope shall be set betweenhanging ring screw of the pump body and crampon.Hanging ring screw on the tray coverand the pump body are set for the assembly and disassembly of tray cover or the pump body,and shall not be separately used for lifting of the whole pump so as to avoid accidents.
Figure 2 Constructional drawing of Type-ZGMLpump
1 .volute
2.impeller
3.rear guard plate
4. seal ring
5.oil seal
6.bearing
7.oil cup
(2)For lifting horizontal pump with electric motor and joint pedestal, the lifting center of gravity should benear coupling at the square hole of frame, and the wire rope shall pass through the part and then vertically up toconnect the crampon.In order to maintain the balance of the pump, the supporting lifting wire rope shall be setamong hanging ring screw of pump body and crampon, hanging screw of electric motor and crampon.
(3) The horizontal pump with middle variable speed gear such as coupling etc. shall adopt the method oflifting in segments.
(4)The soft cushion shall be placed between the wire rope and the connection part of the pump so as to avoiddamage to the exterior design of the pump or to the wire rope.
2.Installation
(1) Inspection before installation
The pump has been inspected and tested before the ex-works. In order to guarantee the good operating state,the pump must be installed correctly.Before the installation, the model and parameters ofthe equipment shall befirstly inspected based on the Packing Lift to find whether the spare parts are intact and whether technical data andquality certification together with the equipment are complete.After the inspection is accepted, relevant technicaldata shall be read carefully, especially the Operation Manual on Type-MSlurry Pump.The installation can only beconducted after relevant technical and operational requirements are grasped, and the unplanned operation shall beavoided.
(2) Installation and alignment of the pump
The horizontal pump set should be installed by adopting the back grouting method.After the installation, thecenter line of the set should be consistent with that of the foundation.The deviation of center height of the set withthe design value shall not be more than ±2mm, and the allowable horizontal error is 0.1/1000.
As for the pump set with coupling direct driving, the axiality of the set is generally guaranteed by the couplingalignment.There are generally two methods of coupling alignment:
One method is to combine knife edge ruler and clearance gauge.The knife edge ruler should be used for alignmentof outer circle of coupling to ensure that each pair of coupling is accordant horizontally, and the maximum error 8shall not be more than 0.1l0 mm [ Figure 3，( a ) ].The clearance gauge should be used to inspect the clearancebetween each pair of coupling,and the maximum error △(A=8182) shall not be more than 0.10mm ( Figure3，(b)) .
Another method is to use magnetic dial indicator with clearance gauge to align with the coupling . Themagnetic dial indicator should be fixed at the outer circle of one side of coupling and turned; the feeler pin of thedial indicator is placed at the outer circle of opposite coupling and the jumping of the dial indicator shall not bemore than 0.15mm [Figure 3,(c)]. The clearance of coupling is measured with the clearance gauge,and themaximum crror is generally not more than 0.10mm [Figure 3,(b)].
As for the pump set with belt driving, the parallelism for pump shaft and electric motor shaft shall beguaranteed; generally, the belt wheel is used for alignment. When the center distance is small, the ruler can beused on the flat belt pulley end face for alignment; when the center distance is large, the anchor line can be used onthe flat belt pulley end face for alignment.See Figure 4.
(3 )Deployments and requirements for suction and discharge tube of the pumpsuction tube
Suction tube diameter: the suction tube diameter shall be the same as the suction diameter of the pump or slightly
longer than it. The principle is that cavitations shall not be caused in the pump and slurry shall not be turned intosediments in the tube.
For conveniences of pump maintenance, the gate valve of suction inlet shall be set, and its diameter shall be thesame as that of suction tube diameter.The expansion joint shal be set between the suction inlet and suction tube forconveniences of asscmbly and disassembly of the pump.
Discharge tube
Discharge tube diameter:the discharge tube diameter is related to the slurry nature and subsidence flow.Generally, the discharge tube diameter shall be the same as the suction tube diameter of the pump or slightly longerthan it.
Discharge gate valve: the diameter of discharge gate valve shall be the same as the discharge pipe diameter.Pressure gauge: positioned at the straight tube section between the discharege of pump and the first valve.③Precautions concerning deployment of pump pipelinc
See Figure 5 for pipeline deployment:
Figure 5 suction and discharge tubes of the pump
The size of pipe diameter shall take comprehensive factors into considerations, such as system resistance andcritical subsidence flow of slurry etc.The suction pipe shall be as short and straight as possible.At the suction inletof the pump, a straight pipe with the same diameter of the inlet had better be equipped, and the length shall be notless than three times of the inlet diameter.The flow velocity in the suction pipe is generally 1.5~3.0 m/s,whichdepends on the subsidence flow of the delivered slurry.
When the high position deployment is adopted, the vapor cavity shall not be formed in the suction pipeline ofthe pump, and the tapering pipeline with the level upper line is recommended for use.SeeFigure 6.
Figure 6 Tapering pipeline with level upper line
When the valve is used for adjustment, the adjust valve shall be set at the outlet of the pump. The valve adjustmentshall not be used in the suction pipeline so as to avoid the formation of cavitations erosion.
(4)Deployments and requirements for pipelines of shaft seal water and cooling water
The pipelines of shaft seal water and cooling water shall be deployed in accordance with Figure 7. The coolingwater shall not be added for grease lubrication frame; and the shaftseal water shall not be added for grease lubricationpacking.
Figure 7 Deployment of shaft seal water and cooling water
The pressure and flow of shaft seal water are shown in Table 1.
Table 1 Pressure and Flow of Shaft Seal Water
Notes:P-Discharge pressure of single stage pump; i一the stage number of pumps in series; Pi-Shaft seal waterpressure of i-stage pump.
The pressure ofcooling water is 0.05~0.2MPa, and the flow of cooling water is 1~3m3/h.Interface dimensions of shaft seal water and cooling water in Figure 2
(5)Adding requirements for packing
①Material quality and selection of packing
Under the normal condition, when the working pressure of pump is under 0.5MPa, the cotton thread soaked inbeen tallow or amaranthine soaked in oil can be used for packing; when the working pressure of pump is above0.5MPa, the polytetrafluoro ethylene or carbon fiber soaked in polytetrafluoro ethylene can be used for packing.
②See Tablc 2 for specifications of packing.
③Adding requirements for packing
Specifications of packing shall meet requirements in size of packing box, and the interface of adjacent two ringsof packing shall be overlapped with an angle of 120° .
(6) Mechanical seal
The mechanical seal is a kind of end surface sealing characterized by no leakage and low consumed power etc.When the mechanical seal is used to the slurry pump, the following matters shall be specially noticed:
①The mechanical seal adopted by our factory is generally a kind of special mechanical scal of balanced typewith double end surface, and the cooling water nozzle stub and pressure gauge are equipped.
②The mechanical seal adopted by our factory is manufactured by a professional mechanical sealing elementplant and has been debugged before the ex-works.The user need not conduct the debugging.
③Two external pipe joints in the mechanical seal are the inlet and outlet of shaft seal water respectively, ofwhich the pump opening at the same side is the water outlet and at the other side is the water inlet.
④Before utilization of the pump with mechanical seal, the shaft seal water shall be connected first.The shaftseal water can only be stopped after the pump is halted at least for three minutes.
⑤When the spare parts of the mechanical seal are provided to users, the manufacturer will generally put themechanical seal in the packing box and supply it as set parts.
⑥When the pump with the mechanical seal and the spare parts of the mechanical seal are not utilized for along time, the mechanical seal part shall be filled with No.46 mechanical oil so as to avoid rustiness of parts of themechanical scal and failure of internal rubbers.
(7)Requirements for adding lubrication oil
No.32(winter) or No.46 (summer) machine oil shall be added to the thin oil lubrication tray in accordancewith the oil level line of the oil scale before starting.
The starting of the equipment without machine oil is strictly forbidden!!
No.2 or No. 3 lithium lubricating grease shall be added to the tray with grease lubrication.
3. Pump adjustment
The pump shall be inspected and adjusted after the installation and alignment.
(1)See Chapter Five for inspection and adjustment of clearance between the impeller and the front guard plate.(2)Adjustment of turning of the electric motor.
The turning of the electric motor shall ensure that the turning of the pump is consistent with the stipulateddirection, and the reverse turning shall be prohibited; otherwise the drop-out of impeller or damage of other partswill be caused.
The turning adjustment of the electric motor shall be conducted under the condition that the pump is completelyrelieved (i.e.the coupling pin or belt shall not be installed). The connection with the pump can only be operatedwhen the turning of the electric motor is confirmed to meet the requirements.The electric motor shall not be startedwithout plan.
(3 )Adjustment of the driving unit
lf the elastic pin coupling drive is used, thc pin and the protective cover shall be properly installed.
lf the belt drive is used, the belt shall be installed and the tensile force shall be adjusted to make each beltconsistent in terms of tensile force.The protective cover shall be properly installed.
(4) If the speed-adjusting gear drive is used, it shall be properly adjusted in accordance with requirements inthe relevant instructions.
(5)Adjustment of fastening
All fastenings shall be fastened once more with the wrench.
(6)The tools and sundries put on the machine set shall be cleaned up so as to avoid occurring accidents in therunning of the pump.
4.Trial operation of the pump
The trial operation can be conducted after the pump set is installed and adjusted.If possible, the user shal first usethe clean water to conduct the trial operation, then the slurry can be utilized after the operation is proved to be normal.
(1)Starting of single-stage pump
①Open the shaft seal water and cooling water, then adjust the pressure to the stipulated value;
②Open the suction valve completely:
③Open the water injecting valve, and then inject water into the pump (it need not be used for reverse flow pump);
④Adjust the discharge valve to the level of 1/4;
⑤Start the machine set.A fter the rotating speed becomes normal, the pressure gauge of discharge should beopened.If the pressure is normal and steady, the discharge valve can be opened slowly until it is opened completelyor reaches the requirements under the working conditions.
Note: If the discharge valve is opened completed.starting the pump may result in the overload of electric motor;if the suction valve is turned down to control the flow.the cavitations erosion ofthe pump may be caused, which shallbe avoided!
(2)Starting the pumps in series
The transport pipeline for pumps in series is generally long, and the pipeline head is calculated under thepresumption that all pipelines are fully filled with slurry. In fact, when the pump is started, all pipelines are not fullyfilled with slurry , if the valve is opened completely, the pipeline head is lower and the instantaneous delivery of thepump tends to be large to result in such faults as the overload of electrical motor or cavitations erosion vibration ofthe pump. Therefore, the following steps shall be used for the startup:
①Close the discharge valve and complctely suction the inlet valve;
②Open the shaft seal water and cooling water, then adjust the pressure to the stipulated value;
③Open the water injecting valve and inject the water into the pump(the suction valve shall be opened forreverse flow pump);
④Start the I stage pump and gradually open the discharge valve to 1/i(iis the number of stage in series).
⑤Estimate that the 1/i pipeline is fully filled with slurry, start the second state pump and gradually open theoutlet valve to 2/i.
⑥Estimate that the 2/i pipeline is fully filled with slurry, start the third state pump and gradually open the outletvalve to 3/i.
⑦ By analogy, all pipelines shall be fully filled with slurry and the operation is normal.
(3) Precautions for starting the pump:
① Due to severe compaction of packing, when the pump is rotated, the packing can generate heat and smoke;therefore, the packing gland nut shall be loosed to leak the shaft seal water, then the screw-down shall be conductedslowly until the drop leakage is appeared.
②After the normal operation, the following items shall be observed:
Whether the flow head of the pump (pressures of discharge and suction) is stable and meets the processrequirements;
Whether the electric current is stable;
Whether the machine set has abnormal noise and the noise vibration is abnormal;Whether the shaft seal leakage is normal(drop leakage);
The bearing temperature will be 35℃, the highest temperature shall not be more than 75℃.
(4) Pump stopping
① Stir clean water for 30 minutes before the pump stopping to clean up slurry in the pump and pipe.
②Close the discharge valve of the final-stage pump.
③Stop the pumps from the final-stage pump to the first-stage pump in order, and close corresponding shaftseal water and cooling water.
④Close the suction valve of the first-stage pump.
Note: under the condition that the discharge valve is fully opened.the pumps at each stage shall not be stopped.at the same time; otherwise the water hammering can be formed easily which candamagethe pump or pipe fittings.
IV. Common Faults and Handling Measures
See Table 2 for common faults and handling measures of the pump.
Table 2 Common Faults and Handling Measures
V. Maintenance, Servicing, Disassembly and Assembly of the Pump
In order to ensure the safe and reliable operation of Type-ZGMslurry pump and make the equipment into fullyplay, it is very important to adopt the correct repair, assembly and disassembly methods in the daily maintenanceand serving.Therefore, according to the features ofType-ZMof the slurry pumps, we put forward the followingrequirements in maintenance, serving and repairing for the user's reference.
(Ⅰ) Maintenance and Serving
The complete set of Type-&aMslurry pumps has been debugged bcfore the ex-works, so the user does not needdismounting and inspecting the unused pump within six months after the purchase. The user only needs to examineits flexibility，corrosion and oiling,etc.The packing must be added before the usc.
1.Maintain the equipment clean and dry, and ensure that there is no oil stain and leakage.
2.Check daily whether the oil evel in the tray is appropriate; the right oil level is near the oil levelline andthe error shall be controlled within the scope of 士2mm
3.Pay attention to the sound of pump operation, vibration and leakage etc.In case of any problem, settle it intime.
4.The pump shall not be operated when it is empty, because in such state the vibration is intense, and the life-span of the pump is also affected.Thereforc, pay more attcntion to it.
5.Metal objects and bulk solids not allowed by the pump shall not be put into the pump, nor such flexible objectsas rubber,cotton and plastic cloth etc.are put into the pump, which can avoid damaging flowing parts and blockingflow passage of the impeller to ensure the normal operation of the pump.
6.Often examine whether the pressure and flow of shaft seal water and cooling water are appropriate. Themethod we adopt is to check the opening of pipe valve of shaft scal water or to test the temperature of packing box.A high temperature indicates that the water supply is insufficient.As for the pump with lubrication grease packing,the oil shall be added 1-2 times each day regularly to ensure that the packing is in a good lubrication state.
7.Examine the leakage of shaft seal water regularly. When it increases, the bolt of packing gland shall be adjusted;the replacement of packing requires to be conducted in time.
8. Ilt is suggested to take carbon fiber soaked in polytetrafluoro ethylene or cotton thread soaked in beef tallowas packing.When the working pressure is lower than 0.5 MPa, the amianthine can be used for packing.The fillingand pressing methods for packing shall be performed strictly in accordance with the following requirements:
(1)The packing length shal be determined according to the length of the circumference of the shaft sleeve.Forfilling and pressing each ring, the insection shall be overlapped in the angle of 120°
(2)After completion of filling and pressing, the trial run with water shall be conducted; in the process of running,the gland bolt can be adjusted carefully into the best state of leaking in drops not a line.The filling and pressing ofpacking is very important, because it affects not only the sealing condition but also the performance of pump.Moreattentions shall be paid to this.
9.In order to ensure the high-efficient operation of the pump, the clearance between the impeller and frontguard plate shall be adjusted regularly(when the current decreases slowly under the steady operation conditionsafter a period of utilization) to keep within the scope of0.75—一1.00 mm. The adjustment steps are as follows:
(1)As for the pump with middle open-type tray
The clearance between the impeller and the front guard plate shall be 0.75—1.00 mm; in general, it has beenadjusted properly before the ex-works.If such clearance is not consistent with requirements, the adjustment shall beconducted; the adjustment shall also be performed after the pump is stopped in case of any problems in the operatingprocess.The pump with middle open-type tray shall be adjusted according to the following steps:
①Loosen the tray cap compression nut;
②Looscn the bearing box adjustment screw;
③Screw up the bearing box compression nut evenly to make the rotor assembly move towards the directionof pump head, screwing up while turning until the pan can not be turned any more.Pay attention to the directionof turning that shall be consistent with working direction of the pump.
④Usc the clearance gauge to measure thc ciearance 8=a between the bearing box flange and thc tray end face;at this time, the clearance between the impeller and the front guard plate is 0.
⑤Loosen the bearing box compression nut;
⑥Screw up the bearing box adjustment screw evenly to make the rotor assembly move towards the directionof electric motor.The clearance gauge is used to inspect the clearance until 8=a+(0.75一1.00)mm (the large pumpshall adopt the big value). Notice that all clearances shall be even and coincident;
⑦Screw up the bearing box and compress nut tightly to ensure the axial position of rotor is completely fixed.
(2)As for pump with solid-bowl tray [See 16b in Figure1 (Continued)]
The clearance between the impeller and the front guard plate shall be 0.75一1.00 mm, it is generally adjustedproperly before the ex-works.lIf such clearance is not consistent with requirements, the adjustment shall be adjustedaccording to the following steps:
①Looscn the nuts on tray pressure plate;
②Adjust the rod screw to make the rotor move forward.Adjust while turning until the pan can not be turnedany more. Notice that the direction of turning shall be consistent with working direction of the pump.
③Mark a straight line as signal with a scriber at the intersection of tray and pony roll;
④Adjust the rod nut to make the rotor move backward 0.75—1.00mm(the large pump shall adopt the big value).Screw up the Adjusting nut to cnsure the axial position of rotor is fixed.
⑤Screw up the nut on the tray pressure plate.
10.Check the temperature of bearing frequently to ensure that the highest one is not more than 75℃.
11.The lubrication oil of the pump shall be replaced thoroughly after a continuous operation of 800 hours.
12.The stand-by pump shall rotate 1/4 circle each week to make the shaft bear static load and external vibrationevenly.
13.If the stop time is long, the backwash water shall be used to wash sediments in the pump before the pumpstarts up again.
14.Check the supporting status of the suction and discharge pipe system frequently to ensure the supporting issteady and supporting force is imposed on the pump body.
15.Check the fastening condition of the pump on the foundation frequently to ensure that the connection issteady and reliable.
16.Special notes: As for newly-installed and repaired pumps, the turning direction of clectric motor shall bedebugged firstly, then the coupling pin can be installed.The belt is used for driving, i.e . after completion ofdebugging of turning direction, the driving belt can be installed,and it is strictly forbidden that the electric motoris used to drives the pump to rotate reversely.However,under the circumstance of power-off of the electric motor,the liquid in the pipe is allowed to make the pump to rotate reversely; when the elevation difference is excessivelyhigh (≥80m), the backwater counter flow shall also be avoided to control the sudden reverse turn of the pump.
17.Open the shaft seal water and cooling water firstly before staring the pump, then start the pump; after stoppingthe pump, the shaft seal water and cooling water can only be closed 15 minutes later.
(Ⅱ) Overhaul and Assembly
Before assembly, a complete examination and cleaning of all spare parts shall be conducted to determine whetherspare parts meet the requirements of use; in case of any damage, spare parts shall be repaired or replaced by newones, then the assembly can be proceeded.
Sequences and basic requirements of assembly:
1.Assembly of rotor groupware
The bearing of the slurry pump is generally made in China.The thin oil is used for lubrication system(exceptfor 200ZGM-70,200ZGM-60and150ZGM-60 pumps which have two kinds of lubrication:oil and grease). If usershave special requirements, they can select one according to such requirements.
(1) Precautions of bearing assembly
①Adopt qualified bearing.
②Examine the inner diameter, externaldiameter and width of bearing,parallel of two end faces of the raceand surface roughness and check whether there are such defects as corrosion and stain and whether the rotation isflexible;
③As for angular-contact bearing and double-row self-aligning bearing, the bearing clearances shall be examinedrespectively to find the center of the bal and race.Based on the height ofinternalring against the external ring,determine whether the cushion is added and the thickness of the cushion.The thickness of cushion shall be determinedon the basis of the standard bearing clearance.
④As for the assembly of detachable bearing(detachable internal-external ring ) , the installation shall beconducted in accordance with the paraposition mark of internal-external ring, and try to avoid confusing.
⑤As for direction-changeable buildup bearing, the end with serial No.shall be installed at the outside foridentification.
(2)Assembly of shaft
①In order to avoid seizing the fitting surface,one film of lubrication oil shall be coated on the installationsurface before the assembly to prevent the axle hole from damage.
②The bearing installation shall adopt the hot metal process,i.e.the bearing shall be put into the heating cabinetwith machine oil and heated to 80~100℃ along with the oil; its fitting surface shall be immersed into the oilcompletely and a thermometer shall be equipped with the oil tank to control the temperature within 100℃.After theheating process of the metal, the natural cooling shall be followed; the shock cooling shall be prohibited to avoiddamage or distortion of the spare parts.
a. Firstly install the rear bearing, then the gear sleeve and circle nut, ncxt press the bearing tightly.
b.Examine whether the bearing is close to the shaft shoulder, and the rotation shall be flexible and stable, theninstall the bearing box.The assembly of bearing box shall also adopt the hot metal process,and the requirementsare the same as above.
c. Next install the front bearing, and the requirements are the same as above.d. Install the seal ring on the bearing box.
c.As for the other parts of the shaft, after the principal shaft groupware and the tray are installed, they shall beinstalled in order according to the assembly drawing.
2.Assembly of tray
The tray cap and tray body oil bath shall be cleaned up first, then the bearing hole shall be wiped up.
(1)After cleaning up the jointing surface between the tray body and the tray cap, the position of bearing holeshall be guaranteed to meet the requirements of tolerance in the drawing which shall be controlled within the scopeof ±0.015 mm.The thickness of paper gasket shall be determined (when adjusting the thickness, three layers ofpaper gasket is the most).Paint the gasket cement on the jointing surface of tray body evenly, then put the papergasket on the tray body, and next screw up the stud bolt.
(2)As for the oil loading bath，M16× 1.5 hexagonal plug screw and oil scale, a 0.2~0.5mm horizontallinepassing through the center of circle shall be marked with red paint on the oil scale pan to indicate the oillevel.
(3)Cooler parts of the oil loading bath and water way cap(2mm cushion shall be made under the cap.Notes:some pumps have no such cap).
(4) Asscmbly of the shaft groupware and the tray
Lift the two ends of the principal shaft, put the principal shaft groupware into the mating holes of the tray, thenlift up the tray cap.Next, coat the oil-proof gasket cement on the fish paper on the tray jointing surface. Finally,close the tray cap.The clearance of 3mm shall be reserved between the bearing box flange end face and the tray endface.The taper pin shall be knocked in and the bolt shall be screwed up in advance.
(5)The front bearing gland shall utilize the oil seal with the fish paper; which shall be installed on the shaftand connected with tray through the bolt.
(6)Examine the clearance size between the rabbets of the rear bearing gland and the bearing box.The methodsof the garage gland rabbet or the cushion addition may be adopted to ensure that there are 0.05~0.10 clearancebetween the gland and the bearing.After completion of these handling,the rear bearing gland shall utilize the oilseal with the fish paper; which shall be installed on the shaft and connected with the bearing box through the bolt.
(7)Install the water shield pan and the stripping ring.For installation of the stripping ring, some lubricationgrease shall be added to the bolt holes, and the stripping ring shall be pressed tightly on the water shield pan.
(8) Install the adjustable bolt and the holding screw of the bearing box.
(9)Install the magnetic dialindicator on the shaft to examine the semicircle locating hole which is on the jointof the tray and the rear pump body, and examine the axiality and verticality of the centre of gyration of the shaft,which shall not be more than 0.25mm.
3.Installation of the rear pump body and the rear guard plate part
(1)Install the rearguard plate on the tray ( Notes: it is suggested that the rear pump body should not bedisassembled from the tray in the process of overhaul.)
(2)Install the gasket cement ring on the shaftsleeve and the shaft, then install the packing gland and the waterscal ring on the shaft sleeve.
(3) Install the packing box, then the seal ring within the slot; install the seal ring of the associate impeller andthen install the associate impeller.
(4) Firstly install the rear guard plate stud bolt, use the lifting device to lift the rear guard plate which shall beplaced at the rear pump body, then screw up the bolt.Measure whether the clearance between the rear guard platehole and the wheel hub of associate impeller is even and observe whether there is some friction through the turning.
4.Installation of the impeller and the volute
(1)Coat the lubrication grease on the“T”screw thread of the impeller, and install it on the shaft, then screwup and compact the associate impeller.
(2)Install the sealring of the rear guard plate.
(3)Use the volute lifting device to lift the volute which shall be placed at the rear guard plate; adjust properlythe pump body connection bolt and strap clamp，and adjust the distance of 5mm between the volute water outlettop face and the effluent water top face ofthe rcar pump body properly then to lock the volute.
5.Installation of the front pump body and the front guard plate part
(1)Underlay the front pump body on the horizontal ground, set the stud bolt in the front guard plate, then usethe lifting device to move the guard plate within the front pump body and fasten with the front pump body.
(2) Install the seal ring of the front guard plate and the hanging ring screw of the front pump body.
(3)Lift the front pump body and the front guard plate part, push the cone excircle of the front guard plate intothe volute tapered bore of inner ring; adjust properly the distance of 5mm between the top surface of the volute wateroutlet and the top surface of the anterior pump body water outlet, then screw up all bolts of the pump body.
(4)Adjust properly the clearance of0.75-1.00mm between the impeller and the front guard plate; the adjustingmethods are the same as above.
6. Installation of the suction and discharge tube part
(1) Fill up the rubber pad with 3-mm thickness at suction and discharge of the pump body respectively andthen screw up the bolt and check whether the cushion is tight. If it is not tight, the thick rubber pad shall be added.The clearance between the suction and discharge flange and the suction and discharge plane of pump body shallnot be less than 1mm.
(2)The expansion joint shall be installed before the suction tube for disassembly.
(3)Conduct the turning manually; before the packing of the pump is compacted, the rotation shall be smoothand cven and there are no phenomena of tightness and unsmooth.
7.Assembly of other spare parts
(1) Install the coupling or the belt wheel.
(2)After the alignment of the electric motor and the pump, test the rotatory direction of the electric motor,and then install the coupling pin and the pin rubber ring or set the belt after such direction is verified.
(3)Install the coupling cap or the pulley shell.
(4) Fill the packing based on the packing requirements.
8.Trial operation
In the process oftrial operation, the leakage, vibration and temperature rise etc.of the pump shall be examined;and the elasticity of the packing shall be adjusted in time to reach an appropriate extent.
VI. Detailed Lift of Wearing Parts
Table 4 Detailed lift of wearing parts
VII. Detailed List of Special Tools
Type-XMslurry pump has special tools, which specifications is corresponding with the type of the pump.Userscan order the special tools according to the pumps they adopt.The items of these special tools are in Table 5.
Table 5 Detailed list of special tools
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