DG型中英文安装使用说明.doc

湖南湘电长泵（长沙水泵厂）长一制泵有限公司ChangYi Pump Manufacturing Co.,Ltd. Of XiangDian ChangSha Pump Works DG型工业锅炉给水泵 Type DG Industrial Boiler Feed Pump安装使用说明书Instruction On Installation And Operation湖南湘电长泵（长沙水泵厂）长一制泵有限公司ChangYi Pump Manufacturing Co.,Ltd. Of XiangDian ChangSha Pump Works一、概 述DG型泵系单吸、多级、节段式离心清水泵，适用于中、低压及次高压锅炉给水、工厂、城市高扬程输水。供输送清水或物理化学性质似于清水的液体，输送介质温度：-20150（DG85-80、200DG43除外、此两种泵输送介质温度为-20150）。泵进口压力不得超过0.59MPa（6kgf/cm2）。参数范围：流量Q 6346m3/h扬程H 1021056m型 号 说 明 本型泵的型号有三种表示方法，举例分述如下：1）例 40DG1406型号中：40泵吸入口直径为40毫米 DG1多级，节段式锅炉给水泵 40单级扬程为40米 6级数为6级此种型号表示的泵有：40DG140 2）例 DG25505 型号中：DG多级，节段式锅炉给水泵 25流量为25米3/时 50单级扬程为50米 5级数为5级此种型号表示的泵有：DG25-50 DG46-50 DG85-67 DG155-673）例 DG80304 型号中：DG多级，节段式锅炉给水泵 80吸入口直径为80米 30单级扬程为30米 4级数为4级此种型号表示的泵有：DG80-30.GeneralType DG pump is single-suction, multi-stage, segmental centrifugal pump. It is used for feeding water of low-middle pressure boiler as well as pumping high lift water of factory and city. It is provided for delivering clear water or other liquid which is physically similar to clear water. The temperature of the liquid for type DG85-80 and 200DG43 pump is -20150，the temperature of liquid for the others usually is -20105. The maximum inlet pressure is not allowed more than 0.59MPa(6kgf/cm2).Performance rangeCapacity Q:6346m3/hHead H:1021056mDescription of pump typeExample 1 40DG140640-Inlet diameter of pump(mm).DG1-Single-suction, multi-stage, boiler feed water pump.40-Single-stage head of pump(m).6-Pump stage numberSuch as type 40DG140.Example 2 DG25-505DG-Single-suction, multi-stage, boiler feed water pump.25-Pump capacity(m3/h).50-Single-stage head of pump(m).5-Pump stage number.Such as type DG25-50 、DG46-50、DG85-67、DG155-67.Example 3 DG80-304DG-Single-suction, multi-stage, boiler feed water pump.80-Inlet diameter of pump(mm).30-Single-stage head of pump(m).4-Pump stage number.Such as type DG80-30.二、结构说明本型泵主要由壳体部分，转子部分，平衡机构，轴承部分及密封部件组成。1 壳体部分壳体部分主要由前段、中段、导叶、轴承体等用螺栓联接而成。泵吸入口和吐出口均垂直向上。2 转子部分转子部分主要由轴及装在轴上的叶轮、轴套、平衡盘等零件组成。轴上零件采用平键和轴套螺母紧固使之成为一体，整个转子由两端轴承支承在泵壳体中。转子部件中叶轮数是根据泵级数而定。3 平衡机构平衡机构由平衡环、平衡套、平衡管路等组成。4 轴承部分轴承部分主要由轴承体和轴承组成。本型泵轴承有滑动轴承和滚动轴承两种。轴承均不承受轴向力，泵在运行中，转子部分在泵壳体中应能自由地轴向游动，不能采用向心球轴承，各型泵采用的轴承见表。泵 型 号轴 承润滑方式冷却方式名 称型 号每台泵用数量DG25-50单列向心短园柱滚子轴承23082付脂润滑DG46-5023082付40DG14023062付DG80-3023072付DG85-67滑动轴承巴氏合金2付稀 油水冷DG155-672付DG85-802付DG155-1002付5 泵的密封泵一般采用填料密封和机械密封6 泵的旋转方向从吸入侧驱动端看泵为顺时针方向旋转。根据用户要求，泵的驱动端也可移到吐出侧，此时从驱动端看泵为逆时针方向旋转。.Construction The constructions of the type DG pumps are described in figure 1.1. Casing element: The casing element is composed of inlet section, middle section, diffuser vane, outlet section, and end cover, connected by studs. The inlet and outlet of the pump are both vertical.2. Rotor element: The rotor element mainly consists of shaft, impeller, shaft sleeve, bearing bush and balance disk, the parts that are assembled on the shaft are fixed with key and sleeve nuts. 3. Balance mechanism for axial thrust: This part consist of balance sleeve, balance plate, balance disk and balance water pipe.4. Bearing element: The bearing element is composed of bearing body and bearing. The rotating or sliding bearing is adopted according to the different type of the pumps in the following table:Type of pumpbearingMethods oflubricatingMethodsof coolingModelTypeNumber in a pumpDG25-50Short column roll bearing23082LubricatinggreaseDG46-5023082Lubricatinggrease40DG14023062LubricatinggreaseDG80-3023072LubricatinggreaseDG85-67Sliding bearing2LubricatingoilWater coolingDG155-672LubricatingoilWater coolingDG85-802LubricatingoilWater coolingDG155-1002LubricatingoilWater cooling5. Stuffing box and sealing elements: The shaft seal uses packing seal or mechanical seal.6. The rotation of the pump：The rotation of the pump is in clockwise direction, looking from the end of the motor. The driving end may be moved to another one according to customers requirements, meantime, the rotation of the pump is counter clockwise looking from motor to pump.- 21 - 湖南湘电长泵（长沙水泵厂）长一制泵有限公司ChangYi Pump Manufacturing Co.,Ltd. Of XiangDian ChangSha Pump WorksDG型泵结构图一（滚动轴承油脂润滑）Sectional Arrangement Fig 1 for Type DG Pump (with Roller Bearing)泵主要零件 Main Parts of pumpDG型泵结构图二（滚动轴承稀油润滑）Sectional Arrangement Fig 2 for Type DG Pump (with Roller Bearing)泵主要零件 Main Parts of pumpDG型泵结构图三（滑动轴承稀油润滑）Sectional Arrangement Fig 3 for Type DG Pump (with Sliding Bearing)泵主要零件 Main Parts of pumpDG型泵结构图四（中心支撑）Sectional Arrangement Fig 4 for Type DG Pump (with Sliding Bearing)泵主要零件 Main Parts of pump 湖南湘电长泵（长沙水泵厂）长一制泵有限公司ChangYi Pump Manufacturing Co.,Ltd. Of XiangDian ChangSha Pump Works三、泵的安装使用说明泵的装配 本型泵装配质量的好坏直接影响泵能否正常工作，影响泵的使用寿命和性能，影响机组的振动和噪音。装配中应注意以下几点：a 、固定部分各零件组装后的同心度靠零件制造精度和装配质量来保证，应保护好零件的加工精度和表面粗糙度，不允许碰、划伤，作密封剂用的二硫化钼应干净，紧固用的螺钉、螺栓应受力均匀。b、 叶轮出口流道的对中性是依各零件轴向尺寸保证，流道的对中性的好坏，直接影响泵性能，故泵的尺寸不能随意调整。c、 泵装配完毕，在未装填料前，用手转动泵转子，检查转子在泵壳体中旋转是否灵活，轴向窜动量是否达到规定要求。d、 上述检查合格后，在泵两端填料室内压入填料，注意填料环在填料室中的相对位置。泵的拆卸a、泵的拆卸按装配相反的顺序进行，拆卸时应严格保护泵上各零件的制造精度不受损伤。b、拆卸穿杆的同时应将各中段用垫垫起，以免各中段止口的松动下沉将轴压弯。泵的安装本型泵安时除满足一般安装技术条件外，还应注意以下几点：1、电机与水泵组合安装时，应将泵联轴器端轴伸向外拉出，再保证泵和电机两端联轴器之间的轴向间隙值。2、泵与电机两面三刀轴心线应在同一水平直线上。3、泵只能承受自身内力，不能承受任何外力。泵的起动、运行、停车起动：1.泵起动前应先盘动转子，检查转子是否灵活。2.检查电机转向是否与泵转向一致.3.关闭出口闸阀，压力表旋转塞，用输送的液体或真空系统排除吸入管和泵内的空气。4.检查泵与电机联接螺栓的松紧程度和泵周围的安全情况，使泵处于准备起状态。5.起动泵，待泵运转正常后，打开压力表旋转塞，慢慢开启泵出口闸阀，按出口压力表读数控制泵给定的扬程。运行：1.本型泵靠泵内平衡机构平衡轴向力,平衡装置内有平衡液体流出,平衡液由平衡水管接至吸入段.为保证泵正常工作,平衡水管绝对不允许堵塞。2.本型泵滚动轴承均无冷却装置，轴承温升变化反映了泵的装配质量。轴承温升不得高于环境温度35，轴承的最高温度不得高于75。3.本型泵转子在运行中存在一定的轴向游动，应保证电机和泵两联轴器端面间的间隙值。4.泵在运行期间应定期检查叶轮，密封环、导叶套、轴套、平衡盘的磨损情况，磨损过大时应予及时更换。5.泵在使用中根据具体情况，订出详细的操作规程。停车：停车前应先关闭压力表旋塞，慢慢半闭出口闸阀，待出口闸阀关闭完毕后再停电机。.Technical Requirements of Employment1. The installation of the multistage pump must be strictly leveled to avoid producing the un-normal operation of the rotor.2. The running of the rotor should be very free and light, and there should be no frictional phenomenon;3. While working, the pumping machine group should be smooth and steady, and there should not be any vibration, noise and cracks. The max vibration should be less than 0.05 mmat the bearing;4. The permissible axial movement of the pump rotor is 25 mm. The movement should be free, un-pinned and un-caught in operation;5. The water flowing must be free and unblocked in the balance water pipe for securing the pressure nearness between the inlet section and the balance water pipe;6. The temperature of the bearing should not be too high, the permissible temperature of the sliding bearing is65，but the temperature of the rotating bearing is70;7. The cooling chamber of the stuffing box and the bearing should be cooled by the water, of which the temperature is normal and the pressure is 0.51.5 kg. force /cm2;8. The stuffing box should be sealed by the normal temperature water (or pumping cold water) for the water pump. 9. The minimum clearances must secure that the frictions are not produced between impeller and sealing ring, impeller hub and diffuser van sleeve, balance 10. A pressure gauge should be severally located an the inlet and outlet of the pump (a vacuum or vacuum pressure gauge should be setup at the inlet when the pressure is lower than an atm. in it) for inspecting the condition of operation. The reading if the vacuum gauge should not be cover norm on the mark plate or books.Suction vacuum (m. water column) is the reading of vacuum gauge.The equation of the suction head (or net positive suction head) is 10(Pa-Pv) Vs2 h= Hsr 2g Pa-Atmospheric pressure (kg.f/cm2) Pv-Vapor pressure of pumping liquid (kg.f/cm2) Hs-The suction vacuum of the pump in the inlet. Vs-The velocity of the liquid in the inlet of the pump (m/sec) g-Acceleration of gravity (m/sec2) r-Specific gravity for Pumping Viscous Medium四、泵可能发生的故障及其解决方法故 障原 因解决方法1.水泵不出水(1) 转向不对(2) 起动前注入泵内的水不够(当使用真空泵时,则抽真空不够)。(3) 底阀未打开或被堵塞。(4) 泵距水面太高，超过了铭牌规定值。(5) 进水管路漏气。(6) 仪表联接处漏气。(7) 填料函部位漏气。(8) 叶轮流道被堵塞。(9) 泵转速不够。(1) 更换电机接线。(2) 注水至少淹没叶轮，最好充满泵（抽真空时也同）。(3) 检查底阀，清洗检修，甚至更新。(4) 降低泵的安装高度。(5) 检查进水管法兰面，拧紧联接螺栓。(6) 检查仪表接头，封口。(7) 检查轴套，轴套螺母，漏气时，端应加垫。(8) 清洗叶轮。(9) 检查电机，找出转速不够的原因，检修或更新，使同水泵匹配。2水量不足(1) 水流通道被堵塞.(2) 叶轮和密封环之间的间隙漏损太大。(3) 转速未达到规定值。范围。(4) 平衡盘与平衡环摩擦。(1) 从进水口(包括水工建筑)至出水口依次检查流道是否畅通,排除堵塞物。(2) 检修或更新叶轮和密封环，使间隙达到规定值。(3) 检查电压是否过低，检查电机是否损坏，检修电机和调整电压，使其转速达到规定值。(4) 在规定的流量范围内使用水泵。检查平衡盘的端面跳动使之不超过规定值，磨损太大应更新。4水泵响声异常和振动。(1) 发生了汽蚀。(2) 机件松动或脱落。(3) 转子不平衡。(4) 轴弯曲。(5) 泵轴与电机轴不同心。(6) 基础薄弱。(1) 降低水泵安装高度，简化进水管路，减少管路损失。(2) 停车检查，紧固零件。(3) 转子作平衡试验，车削不平衡重量。(4) 调查主轴。(5) 调整机组，使之同心。(6) 加固基础。5轴承过热。(1) 润滑不良。(2) 轴弯曲。(3) 轴承损坏。(4) 泵轴与电机轴不同心。(1) 加油（检查油环，使之旋转）。(2) 调直主轴。(3) 更换轴承。(4) 调整机组，使之同心。.Possible troubles and their remediesTroublesCausesRemedies1. No water comes out of the pump(1)Incorrect direction of the pump rotation.(1)Change driving direction of the motor.(2)Insufficient liquid poured into the pump before operation (insufficient vacuum produced in employing the vacuum pump.)(2)Fill the pump with liquid and have the impellers submerged at least, and for the best fill the pump chamber. ( The same applies to sucking up vacuum)(3)Foot valve is not open or blocked.(3)Check clean or replace foot valve.(4)Suction head is too high, over normal value on the mark plate.Reduce setting location of the pump.(5)Air leaks in the suction pipe.(5)Check the flange face of the suction pipe, tighten the joining bolts.(6)Air leaks in the joint of the meter.(6)Check the joint of the meter, block up the leakage.(7)Air leaks in the pump from the stuffing box.(7)Check the shaft sleeve and sleeve nut. A washer should be put between the faces of the both ends when air leaks in.(8)Impellers blocked up.(8)Clean the impellers.(9)Rotating speed too low.(9)Check the motor, find out the causes, adjust or replace the motor for the pump.2.Insufficient discharge charge capacity(1)Water flow passage blocked up.(1)Check the passage, see whether it is blocked from the inlet to outlet (including the building of the hydraulic engineering) and clean up the passage.(2)Wearing clearance too much between the impellers and sealing rings.(2)Adjust or replace the impellers and sealing rings for normal clearance.(3)Rotating speed too low.(3)Check whether the voltage is too low and the motor has been damaged. If necessary, repair the motor or adjust voltage so as to make the rotating speed up to the mark.3. Power of the pump consumed too much and the current of the motor is over value(1)Stuffing pressure too tight;(1)loosen the nut of the stuffing gland;(2)Friction produced between the rotor and the stator(2)Check friction part on the rotor and thestator, especially the part at the small elear-ance between the impeller and the sealingring(3)Discharge capacity of the pumpexceeds the limitation of its emplo-yment;(3)Employ the pump at the normal flow quantity(4)Friction produced between thebalance disk and ring;(4)Check the pulsation of the end face of the balance disk, The tolerance must not exceed the normal value. Change them when they are over worn-out;(1)Cavitation prouduced in the pump(1)Lower setting position of the pump, simplfy the pipe line and reduce losses in the pipe line;4.During operation strange noise and vibration happen in the pump(2)Machine parts loosened or dropped(2)Stop and repair the pump, tighten the parts;(3)Rotor is unbalanced;(3)Balanced rotor, cut off the unbalanced parts;(4)Shaft bent;(4)Straighten the main shaft;(5)Eccentric alignment of the pump shaft and that of the motor;(5)Adjust the concentricity of the machine group;(6)Weak in base;(6)Strenghten the base;(1)Poor lubricating oil;(1)Oil the bearing, check the oil ring so as to make the bearing rotate;(2)Shaft bent;(2)Straighten the shaft;(3)Bearing damaged;(3)Change the bearing;(4)Eccentric alignment of the pump shaft and that of the motor(4)Adjust the concentricity of the machine group;五、简单计算说明1、泵扬程的计算 泵扬程H等于泵的出口总水头H2与入口总水头H1的代数差。H= H2 -H1 （1）其中 H2=P2/r+Z2+V22/2g H1=P1/r+Z1+V12/2g则（1）式可变为 H（P2P1）/r(Z2-Z1)+ (V22 -V12)/2g （2）通常泵吸入口的压力P1用真空表测得，若P1为真空表读数，则（2）式可写成： H=(P2+P1) /r(Z2-Z1)+ (V22 -V12)/2g （3）式中 P1真空表读数（Kg/m2） P2压力表读数（Kg/m2） Z1、Z2分别为真空表和压力表相对于泵轴心线的安装高度，当真空表和压力表装于泵轴心线之上时Z1、Z2取正值，当真空表和压力表装于泵轴心线之下时Z1、Z2取负值。V2压力表测点处的液体速度(m/s)。V1真空表测点处的液体速度(m/s)。 g重力加速度，g=9.81（m/s）。r所输液体的比重（103/m3）,即所输送液体单位体积重量。 2、泵装置汽蚀余量(NPSH)a 计算(NPSH)a=Po/rPv/rHghw （4）式中 Po吸入池液面上的压力 （/cm2） Pv液体在输送温度下的汽化压力（/cm2） Hg吸入液面到泵中心线的距离（m）。若吸入液面在泵中心线之上，则Hg取负值。 Hw吸入管路系统中的水力损失（m）r所输液体的比重（103/m3）,即所输送液体单位体积重量。装置汽蚀余量的计算值必须大于泵厂规定的泵必需汽蚀余量(NPSH)r，而且(NPSH)r值要取泵流量范围内的最大值作比较。如果装置汽蚀余量(NPSH)a小于必需汽蚀余量(NPSH)r，泵将发生汽蚀，导致叶轮汽蚀破坏，影响泵的正常运行。3、泵必需汽蚀余量(NPSH)r与泵吸上真空高度HS的换算。 (NPSH)r与HS都是衡量一台泵的吸入性能（或汽蚀性能），用户选型时必须慎重考虑的一个重要参数，前者比后者更为严密恰当，所以在泵的有关标准和资料中，一般采用(NPSH)r。 (NPSH)r与HS换算关系如下：(NPSH)rPa/r-Pv/r-HS+VS2/2g （5）(NPSH)r泵必需汽蚀余量HS泵吸上真空高度（m）Pa大气压力（/2）Pv液体的汽化压力（/2）VS泵吸入口的液体速度（m/s）r所输液体的比重（103/m3）,即所输送液体单位体积重量。由于泵厂给出的HS是在常温（20），标准大气压（760mm水银柱）下通过清水试验得出的HS值，所以，（5）式可变为： (NPSH)r10.330.24HS+VS2/2 g (NPSH)r10.09HS+VS2/2 g (6)4、叶轮外径D2切割计算如果发现泵的扬程高于装置所需要的实际扬程，在一定范围内，当车小叶轮外径D2时，可使泵运行更平稳，更经济。 D2切割后的性能换算关系为： Q，=(D2/D2)Q (7) H=(D2/D2)2H (8) Pa=(D2/D2)3 Pa (9)式中Q、 H、 Pa、D2为切割后的流量、扬程、轴功率、叶轮直径。Q、 H、 Pa、D2为切割前的流量、扬程、轴功率、叶轮直径。5、泵改变转速后的性能换算当泵降低转速时，其性能换算如下Q”=(n”/n)Q （10） H”=(n”/n)2H（11）Pa”=(n”/n)3Pa （12）Q” 、H”、Pa”、 n”为降低转速后的性能参数。Q、H、Pa、n为降低转速前的性能参数。.Instruction on operation for decreasing speed or cutt