1 General
1.1 The scope of application
This code applies to chemical plant PN-type mud pump maintenance and overhaul.
1.2 Structure Description
The pump from the disaster body, bracket, shaft, impeller, back cover and bearings and other components.
1.3 equipment performance
PN and PNL single-stage mud pump series of technical performance:
Head: 12-92m
Flow: 7.2-1290m 2 / h
Inhalation pipe diameter: 50-300mm
Speed: 980r / min or 1450r / min
2 good standard
2.1 zero, parts
2.1.1 pump body zero, complete components.
2.1.2 various parts of the connection bolts; complete nut tightening, thread exposed 2-3 phase.
2.1.3 motor and attachment zero, complete components.
2.1.4 security guards are complete and stable.
2.1.5 pressure gauge, ammeter and other sensitive and regularly calibrated.
2.1.6 inlet and outlet valves and lubrication, cooling system piping installed tidy, obvious signs, do not plug does not leak; oil standard, oil cups and other complete easy to use.
2.1.7 The foundation, base and anchor bolts are firm.
2.2 operating performance
2.2.1 good lubrication, smooth flow of oil, the implementation of "five", "three filter."
2.2. 2 operating pressure, steady flow, temperature, current stability.
2.2.3 smooth operation, no abnormal vibration, noise and other abnormal phenomena.
2.2.4 can reach the nameplate output or capacity.
2.3 technical information
2.3.1 assembly drawings, the main parts map, vulnerable parts map.
2.3.2 there are instructions.
2.3.3 operating procedures, maintenance procedures, maintenance procedures complete.
2.3.4 complete equipment files, data accuracy, including;
a. product certification or quality certificate;
b. equipment history card;
c. Operating time record and cumulative operating time record;
d. All previous maintenance and acceptance records.
2.4 Equipment and Environment
2.4.1 pump, pump seat and ancillary fittings paint a complete, no bubble off phenomenon.
2.4.2 pump clean bright, no dust, grease.
2.4.3 clean and tidy, no water and debris on the surface and around, neat and clean environment.
2.4.4 import and export valves, pipe flanges, the various sections of the pump, the cover seal and other joints at the junction and the balance of water pipes, cooling pipe joints have reached the standard leak-free.
3 equipment maintenance
3.1 Regular maintenance
3.1.1 in strict accordance with the rules of the pump start, run and stop, and make a record.
3.1.2 keep the surface of a dedicated equipment clean, no grease, no water on the ground.
3.1.3 keep the packing easy to use, drip leakage within the specified range.
3.1.4 Check the pump at any time in the presence of abnormal sound and abnormal vibration, rolling bearing temperature does not exceed 70 ℃, sliding bearing temperature does not exceed 65 ℃.
3.1.5 Each class check the lubricating oil surface, so that it often remains in place. Bearings that use grease should be refueled on time to maintain good lubrication.
3.1.6 pump long-term deactivation, should be swept clean, and regular crank.
3.2 regular inspection
Periodic inspection content in Table 1.
Table 1
Check item | Cycle | Check the content | Judgment criteria | Recommended Use instrument | ||
instrument | Feel the hand | instrument | Feel the hand | |||
Monitor scrolling Bearings shipped Turn the situation | 2 ~ 15 day | Every class A lot In two Times | Measurement roll Bearing vibration move | When dbN <20 indicates a good condition, measured next by cycle When 20 <dbN <30 should pay attention, the bearing has appeared early damage, must Measure again in a shorter period of time Bearing obvious damage when dbN> 35, must be measured in a shorter period When dbN> 50, replace the bearing immediately | Deserted hand bearing outside Shell feel smooth Feel more vibration Move, we must step up picking up Set Feel vibration, we should always pay attention to the operation Shell has a strong vibration feel | Impact pulse CMJ-â…¡ type and Swiss Code SPM-3A type |
3.3 common troubleshooting approach
See Table 2 for the treatment of common faults.
3.4 Emergency Parking
Emergency stop in case of one of the following conditions:
sudden abnormal vibration, loud noise;
b. current does not fall over the rated value.
table 3
|
4.1 overhaul period
Maintenance cycle in Table 3.
4.2 maintenance content
4.2.1 minor repair
4.2.1.1 Check, replace the impeller, pump shaft, roller bearings and shaft protection sleeve.
4.2.1.2 Check and replace the coupling bolt and elastic ring.
4.2.1.3 to eliminate defects and leakage occurred in operation. Tighten all parts of the bolt.
4.2.1.4 inspection, trimming security guards.
4.2.2 Overhaul
4.2.2.1 include minor repairs.
4.2.2.2 repair, replacement pump body, shaft seal body, shield, coupling.
4.2.2.3 repair, replacement of bearings.
4.2.2.4 measure and correct the level of the pump body.
4.2.2.5 rust pump and ancillary pipeline corrosion.
Table 2
5 maintenance methods and quality standards
5.1 main parts maintenance methods
5.1.1 shaft wear shaft, plating method can be used, spraying method for repair, processing qualified.
5.1.2 bearing housing bearing hole wear set repair.
5.1.3 shaft sealing body packing room can be set after wear and adhesive repair.
5.1.4 cooling snake tube leakage can be repaired by welding repair method.
5.2 maintenance quality standards
5.2.1 Spindle
5.2.1.1 Spindle roundness and cylindricity deviation value is not more than half the diameter tolerance.
5.2.1.2 Bearings at the two bearings as a fulcrum with a dial indicator check impeller, bushings, couplings and other journal, radial runout is 0.05mm.
5.2.1.3 key and keyway on both sides should be closely matched, not allowed to add gaskets. Keys can be used with.
5.2.2 parts with the main parts of the processing surface roughness:
a. And rolling bearings and sliding bearings with the parts;
b. And the impeller, deputy impeller, bushings, couplings, pulley with the journal;
c. impeller, vice impeller, bushings, couplings, pulleys and shaft with the hole;
d. The outer surface of the uranium sheath rubbing against the packing is.
5.2.3 Rotor, the outer circle of the sleeve on the axis of rotation rounding value in Table 4.
5.2.4 shell and base
5.2.4.1 shell should be free of cracks and other casting defects.
5.2.4.2 The installation of the whole pump should be based on the level of the flange of the outlet for leveling, horizontal: 0.05mm / m in length and 0.10mm / m in width.
5.2.5 Impeller
5.2.5.1 Impeller surface and liquid flow path should be smooth, can not have sticky sand, burrs, cracks and other defects.
5.2.5.2 Shafts and impellers with the hole between the impeller should be closely with the firm, are not allowed to loose.
Table 5 mm
|
Table 4 mm
Bushing nominal diameter | ≤50 | 51 ~ 120 | 121 ~ 250 | 251 ~ 500 |
Round beating | 0.09 | 0.12 | 0.14 | 0.16 |
From the back of the impeller to heavy, cutting to the thickness of not more than 1/3 of the original wall thickness, cutting edge should be flat transition.
5.2.6 Rotor
5.2.6.1 The rotor impeller end face and the housing and the back cover on both sides of the gap should be equal, if not equal with the bearing housing and back cover gasket adjustment.
5.2.6.2 Rotor total axial channeling amount should be in the range of 0.025-0.10mm.
5.2.7 bearing box
5.2.7.1 Bearing box bearing hole coaxiality Φ0.02 mm, roughness, with the recommendation.
5.2.7.2 cooling pipe should be cleaned regularly to prevent blockage.
5.2.7.3 oil mask on the bearing box should be transparent, no leakage.
5.2.8 uranium device
5.2.8.1 Elastic cylindrical pin coupling:
a. Coupling and shaft with the selection;
b. The coupling halves of the coupling halves are Φ0.10mm and the end face runout of the coupling halves is 0.9mm. See Table 6 for the axial clearance.
5.2.8.2 Claw couplings:
a. The difference between the three claws should meet the requirements of the drawings;
b. The outer surface of the hole round hole tolerance of 0.06mm;
c. Large diameter end face of the radial hole diameter circle bore tolerance of 0.06mm.
5.2.8.3 Semi-Uranium devices mounted on the shaft, the radial runout and face beat shall not exceed Table 7 requirements.
5.2.9 Rolling bearings
5.2.9.1 bearings should be used to remove special tools, the installation can not be directly struck with a hammer bearings, you need to pad when you need to soft metal.
5.2.9.2 When assembling the bearing. Should first check the bearing quality, with the size deviation, etc. are in line with the requirements.
5.2.9.3 bearing the end of the figure should be close to the shoulder.
5.2.9.4 bearing neck heating; heating oil bath can be used, the oil temperature does not exceed 100-120 ℃, bearing oil bath time 10-15 minutes; no direct flame heating flame roller bearings.
6 test and acceptance
6.1 Preparation before test
6.1.1 Check the tightness of the bolts on equipment and pipelines.
6.1.2 Check the safety device is fully solid.
6.1.3 Check whether sufficient grease. Oil level is within the specified range.
6.1.4 crank two weeks, to ease and ease, no jam as the phenomenon.
6.1.5 Remove the coupling pin and check that the motor is steered correctly.
6.2 no-load test
6.2.1 according to the rules to start the pump.
6.2.2 Check the transmission parts with no abnormal sound and contact phenomenon.
6.3 load test drive
6.3.1 Operators first open the pump inlet valve and then start the motor, slowly open the pump outlet valve when the pressure gauge indicates a gradual increase close to the rated pressure, this time to observe the smooth operation of the pump.
6.3.2 Check the rolling bearing, packing gland temperature is sharply increased, such as temperature rise too fast to stop the pump to find out the cause, remove the fault before driving.
6.3.3 Check the joints of the pipeline for leaks.
6.3.4 smooth operation without noise, cooling water system is working properly.
6.3.5 Measurement of bearing vibration, when the speed is 3000r / min, the amplitude of not more than 0.06mm, speed of 1500r / min, the amplitude is not greater than 0.09mm.
6.4 Acceptance
Equipment load test run, continuous operation for 24 hours, in good condition, confirmed that the intact standard. According to the prescribed procedures for the transfer of production and delivery procedures.
7 Maintenance Inspection safety precautions
In addition to the implementation of the relevant state departments of the safety regulations and the type of safety technical specifications, the special provisions to comply with the following:
7.1 Maintenance Safety Precautions
7.1.1 No illegal opening, parking or illegal operation.
7.1.2 It is forbidden to use unqualified or deteriorated lubricating oil.
7.1.3 temporary maintenance troubleshooting, you must apply for safety inspection mission, take reliable safety measures, and in accordance with the provisions of the approval.
7.1.4 It is strictly forbidden to loosen the pressure and tighten the bolts.
7.1.5 Do not touch the rotating parts during equipment operation.
7.1.6 lifting heavy objects shall not stay on the running equipment.
7.1.7 The site shall not store items unrelated to the operation of the equipment, hijacking the road at the scene smooth.
7.2 maintenance safety precautions
7.2.1 Before maintenance, it is necessary to handle the task book of safety inspection, adopt reliable safety measures, and approve and approve them in large, medium and small size.
7.2.2 cut off the power of electrical equipment and hang "someone overhaul, forbidden closing" logo.
7.2.3 add the corresponding parts of the blind plus plate; overhaul after inspection.
7.2.4 lifting tools for maintenance, machinery, rigorous inspection, lifting heavy parts, there must be someone to command.
7.2.5 open the equipment holes and pipe holes, plugging in time or separated by a fence to prevent personnel from falling and falling into debris.
7.2.6 Disassembly parts must be carried out in order, neatly placed around the fence.
7.2.7 thoroughly clean the site, remove the fence.
7.2.8 After maintenance, the need to close the site for a detailed inspection to prevent tools, sundries and other equipment left in the.
7.3 test safety precautions
7.3.1 open, stop operation by hand, the operator should hold the post "safety operation certificate."
7.3.2 commissioning work should be assigned a unified command.
Check item
Cycle
Check the content
Judgment criteria
Recommended Use
instrument
instrument
Feel the hand
instrument
Feel the hand
Monitor scrolling
Bearings shipped
Turn the situation
2 ~ 15
day
Every class
A lot
In two
Times
Measurement roll
Bearing vibration
move
When dbN <20 indicates a good condition, measured next by cycle
When 20 <dbN <30 should pay attention, the bearing has appeared early damage, must
Measure again in a shorter period of time
Bearing obvious damage when dbN> 35, must be measured in a shorter period
When dbN> 50, replace the bearing immediately
Deserted hand bearing outside
Shell feel smooth
Feel more vibration
Move, we must step up picking up
Set
Feel vibration, we should always pay attention to the operation
Shell has a strong vibration feel
Impact pulse
CMJ-â…¡ type and Swiss
Code SPM-3A type
table 3
Maintenance category | Minor repair | Overhaul |
Maintenance cycle, month | 1 ~ 3 | 12 ~ 24 |
Maintenance category
Minor repair
Overhaul
Maintenance cycle, month
1 ~ 3
12 ~ 24
Table 5 mm
Impeller diameter, mm | 201 ~ 300 | 30l ~ 400 | 401 ~ 500 |
Allow uneven weight, g | 5 | 8 | 10 |
Impeller diameter, mm
201 ~ 300
30l ~ 400
401 ~ 500
Allow uneven weight, g
5
8
10
Bushing nominal diameter
≤50
51 ~ 120
121 ~ 250
251 ~ 500
Round beating
0.09
0.12
0.14
0.16
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