CENTRIFUGAL PUMP ZPD6-25*7 OPERATION & MAINTENANCE MANUAL HANGZHOU FLYING TECHNOLOGY CO., LTD.
CONTENTS 1. GENERAL (1) 2. NOMENCLATURE OF THE TYPE (1) 3. MAIN TECHNICAL SPECIFICATIONS RANGE (1) 4. STANDARD (1) 5. OUTSTANDING CHARACTERICS (1) 6. SERIES-DIAGRAM (3) 7. Pump Structure Diagram (4) 8. Pump performance curve and performance table (5) 9. Pump overall installation dimension diagram (6) 10. Assemble and disassemble of pump (7) 11. Installation of pump (8) 12. Pump starting, running and stopping (9-12) 13.Common faults and troubleshooting method of pump (13-14)
GENERAL With the typical structural features : in structure complete cancel traditional for balancing axial thrust balancing system, depend on the symmetrical layout of the impeller balanced axial force automatically, this innovation makes the multistage pumps with energy-saving and efficient, stable and reliable, less wearing parts, high reliability and significantly lower operation cost advantages, it is the best alternative to ordinary multistage centrifugal pump. NOMENCLATURE OF THE TYPE Model of pump: ZPD6-25*7 ZP: Automatic balance D: Horizontal multi-stage centrifugal water 25*7 : Head is 175m MAIN TECHNICAL SPECIFICATIONS RANGE Capacity: 6.3 cubic meters per hour Head: 175m Motor power: 11 kw Speed: 2950r/min Protection grade :IP55 Voltage:480V Standard 1.GB/T5657-95 (Technical specifications for centrifugal pumps-class Ⅲ) 2.JB/T1051-93( Multistage centrifugal pump type and basic parameters) Outstanding characteristics 1. High efficiency and energy saving: Advanced of hydraulic model, independent development, efficient energy saving products. Due to pump rotor without balance disc of wear and axis to pulse, impeller and guide leaves of on neutral are always in best State, not like general multilevel balance disc of wear, rotor parts move forward and appear efficiency clear fell. Besides without leak of balance water, volume loss has reduced. It improves running efficiency of pump in overall. And shaft power has been reduced. Compare with general multilevel pump efficiency, life average much 2%~3%. 2. The new structure: With the symmetric part of the impeller rotor part, symmetrical blade rotor at all levels the forces cancel each other out. Automatic balance of pump TOTAL 14 PAGES1 NO.(1 )
chamber huge axial thrust can be achieved without the balanced structure. It broke through the traditional structure of multistage pump. 3. New structure Unique throttling, pressure-relief devices and odd class balance device, which can also act as a secondary support role. 4. High reliability Symmetric layout of impeller make the axial thrust of the run equilibriumed, therefore, a balancing device that small gaps, high pressure drop, easy to wash, easy to wear is not needed. It makes the axial force on the pump wear and minimize the interference effect on the system to a minimum. 5. Good cavitation performance makes life longer : The optimization of the hydraulic and structure design, precision casting, reliable wear-resisting material, Part of the pump impeller type head with double suction structure. all these make the pump have good resistance and cavitation ability. Besides, depend on this, the machine runs smoothly, with low noise and long service life. 6. Mechanical seal reliability: The rotor part has no axial movement when pump starts and stops and works without axial pulse. It overcomes difficulty of poor sealing reliability which multistage pumps have been plagued by; 7. Wide application: Cancellation of small gaps balance dish makes it suitable for worse media properties than traditional multistage pumps structure. 8. Lower maintenance costs: Use of investment casting reduce the number of delicate parts and maintenance access. Besides, extend product lifes. A series of problems caused by assembling and disassembling are avoided and maintenance costs reduce. TOTAL 14 PAGES2 NO.(2 )
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Assemble and disassemble of pump Assemble of pump The pump assembly and disassembly sequence generally in reverse order. Assembly quality affects the normal operation, the service life and performance parameters of the pump directly. Following points should be paid attention to when assemble: 1) Protect accuracy and surface roughness of the parts well. No bumps and scratches. Keep the sealant clean and fastening nails and bolts force uniform.; 2) Neutral of impeller outlet channel and guide vane inlet channel depends on axial dimensions of every part. As runner on neutral affects performance parameters of the pump directly, don t change the pump size freely. 3) Finished assemble of pump, before packing, hand turn the pump rotor to check the flexibility of rotor; 4) Inspection well, then install the packing. Note when disassembling pump 1) Stop according to order; 2) Liquid in the casing ( cooling water included) should be let out; Lubricating oil should let out if bearing parts with thin oil lubrication. 3) Removed the affiliated pipelines in order to disassemble pump, such as return pipe and so on. 4) Protect accuracy of the parts well, Pad the middle stage with pad while disassembling lever so that shaft won t be bent by middle stage. The disassembling step of the pump 1) After disassembled of the coupling, unscrew the bolt on the bearing gland, conjoined nuts between suction and bearing housing, the front bearing housing. 2) Unscrew the round nut on the shaft, then take off bearing inner ring, bearing gland and retaining collar in order. 3) Pad the middle stage with pad, unscrew the wear lever nut, inlet section and packing gland, packing ring and packing on the inlet section. 4) Disassemble the front stage impeller, flat key, forward guide vane, forward guide impeller, end-level forward guide vane, discharge stage, throttle and pressure relief devices in order. 5) Disassemble the end-level backward guide vane, end-level backward impeller, flat key, backward guide vane, backward impeller, after throttle and pressure relief devices in order. Note:the direction of guide vane and impeller. 6) Unscrew the nut between suction stage and end gland, take off the spindle, end gland and part on rear bearing housing. 7) Unscrew the nut between end gland and bearing housing, unscrew the gland packing, packing ring and packing on the end gland. TOTAL 14 PAGES7 NO.(7 )
8) Unscrew the nut on the bearing gland, disassemble shaft,small round nut, bearing cap in order. 9) The disassembling order of the pump is mainly the same for plain bearings except some difference during bearing parts. The installation of the pump In addition to general requirements, this type pump installation should pay attention to the following several points as well: 1) When installation of pump, foundation surface should be level. Check the baseplate and bolts loose or not after foundation of cement solidification. 2) After assemble motor, pump and the baseplate, pls carefully check the concentricity between the pump shaft and the motor shaft, ensure the two axis on the same horizontal line. 3) When Assembling motor and pump, guarantees the pump and motor coupling axial clearance value is 3 MM, the series pump no axial move. 4) The pump can only withstand the internal force, can not withstand any external force. Therefore, the suction line of the pump and pressure line should have its own bracket to avoid crush. 5) To pump D(P) MD(P) that for Mine industry contains combustible gases,explosion-proof motor with protection and explosion-proof mark should be used. TOTAL 14 PAGES8 NO.(8 )
Pump starting, running and stopping Start 1) before starting, turn the rotor to check its flexibility 2) Check if direction of rotation of motor and pump is same. 3) Open suction valve (if suction valve is available), Close gate valves of the export pipeline and pressure gauges cock to make pump full of liquid. Or use vacuum-system exhaust the air in suction line and pump. 4) Check the safety and tightness of joins bolt between pump and motor to make sure the pump is ready to start. 5) Start motor, after pump normal rotation, Open pressure gauges cock, Slowly open the outlet valve, until the pressure gauge pointer to the setting pressure( according to reading of pressure gauge control head of pump) Run 1) Balance of axial force by pump itself, so no balance pipe. To ensure the pump run normally, prohibit block up return pipe. 2) In the process of starting and running, must observe if instrument reading, heating in the bearings, packing leakage and temperature, vibration and the sound of the pump working correctly. Once Abnormal situation happened, should dealt with immediately. 3) Bearing temperature rise changes reflect quality of the pump assembly, Bearing temperature rise shall not be 35 higher than the ambient temperature and the highest wearing temperature shall not be higher than 75. 4) Worn condition of impeller,seal joint, impeller wear during running, guide vane,shaft sleeve, throttle and pressure relief devices should be regularly inspected, if excessive wear,they should be timely replacement Stop 1) Before stopping, close pressure gauges cock. Slowly close the outlet gate valve, close motor after closed outlet gate valve, close the Suction valve after pump stop (if suction valve is available) 2) If pumps stop for long time, should remove all bolts below suction stage, discharge TOTAL 14 PAGES NO( 9)
stage, secondary inlet section, discharge water and disassemble pump and clean and adding oil, packaging for standby TOTAL 14 PAGES NO( 10)
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1. MOTOR 2. PRESSURE GUAGE 3. OUTLET RODE 4. GATE 5. CHECK VALVE 6. EXPANSION JOINTS 7. WATER SHORT TUBE 8. PUMP 9. PUMP TRANSITION TUBE 10. VACUUM GUAGE 11. WATER PIPELINE 12. FILTER MESH 13. ANCHOR BOLT TOTAL 14 PAGES NO.(12 )
Common faults and troubleshooting method of pump No. DEFECTS PROBABLE CAUSE 1 Pump does not absorb water, pointer of pressure gauges and vacuum gauge vibrate violently, or vacuum gauge displays a high vacuum. 1. Pump filled with water is not enough 2. Leakage of pipes or gauges 3.Bottom valve not open 4. Suction pipe block up. 5. Suction height over RECOMMENDED REMEDIES 1. Pump water and exhaust gas 2. Tighten screw fasteners 3.Repair or replace the bottom valve 4. Cleaning suction pipe 5. Lower suction pipe height 2 Pump outlet water have Pressure, no flow or flows too less 1. Flow channel blockage, or bottom valve partially blocked 2. Pump rotation speed lower than a setting value 3. Total head higher than the pump design head 4. gas in pump 5. rotation direction of pump wrong 6. Parts wear, internal leak too large 1. Cleaning channel, or clear foreign matter on bottom valve 2. improve pump rotation speed 3.Increase pump grade or reduce pipeline loss 4. Inlet parts block up 5. Motor reconnect wiring 6. replace wearing parts 3 Motor current is too high 1. The system total head is much lower than the design of the pump head 2. Pipeline broke and leakage 3. Starts with export gate valves opening 4. Pump shaft and electric not concentric. 5. The rotating parts and fixed abrade 6. Bearing wearing. 7. The rotor imbalance and vibrates 8. Voltage is too low 4 Stuffing box leakage Packing smoke Packing short life 1. Pump shaft and electric not concentric 2. Shaft bends 3. The packing place sleeves damage Or packing installation wrong, packing model is wrong 4. impurity between packing and shaft sleeve 5 Pump vibrate or noise 1. Pump cavitate 2. Flow channel blockage or bottom valve partially blocked. 3. Pipeline rupture running water 4. Starts with export gate valves opening 1. Close gate valve to adjust or reduce pump series 2. Stop pump to clean pipeline 3. Close gate valve to restart. 4. Re-alignment to avoid the system force on the pump 5. Open pump to adjust 6. Replace bearing 7. Remove the rotor, do static and dynamic balance test. 8. Improve voltage 1. Re-alignment 2. Remove and correct shaft 3.Polish or replace sleeves repacking, uniform pressure Or replace packing. 4. Replace packing. 1. Reduce the geometry of the pump installation height, reduce the suction pipe resistance 2. clear channel or foot valve 3. Stop pump to clean pipeline TOTAL 14 PAGES NO.(13)
5.Pump shaft and electric not concentric, or shaft bends 6. Insufficient basis rigid 7. The rotating parts and fixed abrade. 8. Impeller defect 9. Too much or too little grease in bearing 10. Bearing wear or dirt there. 6 Bearing heating 1.Pump shaft and electric not concentric, or shaft bends 2. The rotating parts and fixed abrade. 3. Bearing wear or dirt or water there 4. Too much or too little grease in bearing. 7 The place such as the middle with surface leakage 1. The poles to bolts force not enough or force not balanced 2. The manufacturing precision of part(rough degree, beating or vertical degree) is not up to the design requirements, or residual force makes part deformation 3.Joint surface not clean or damage 4. Close gate valve to restart. 5. Re-alignment or repair or replace shaft 6. Reinforce foundation 7. Open pump to adjust 8. Replace impeller 9. Add moderate grease 10.Replace or clear bearing, pay attention to seal bearing 1.Re-alignment or repair or replace shaft. 2.Open pump to adjust 3. Add moderate grease 4.Replace or clear bearing, pay attention to seal bearing 1. To tighten the poles 2. Open pump to check 3. Repair joint surface TOTAL 14 PAGES NO.(14)