First, the diaphragm pump operation and preparation
1. Prepare the pump for operation a. Check that the bolted connections at the joints are tight and do not allow any looseness.
b. The new pump should be cleaned before pumping anti-corrosion grease on the pump or the dirt on the pump, scrub when using kerosene scrub, can not use a knife scraping.
c. Inject the appropriate amount of synthetic lubricating oil to the oil level oil line according to the ambient temperature.
d. The oil chamber of the diaphragm pump cylinder must be filled with transformer oil. The gas in the oil chamber should be drained. An appropriate amount of defoamer can be added. The safe automatic charge valve should inject a proper amount of transformer oil to about 10mm from the overflow surface. Regardless of the type of hydraulic diaphragm pump, the transformer oil should be filled in the bracket between the pump head and the gearbox, and the oil level should be filled to the flooded column. The plug can be plugged, the plunger pump is not refueled here.
e. Rotate the coupling to move the plunger back and forth several times. It should be flexible and must not be stuck. If there is an abnormal phenomenon, it is necessary to remove the fault in time before driving.
f. Check the power voltage condition and the motor circuit. The pump should be rotated in the specified direction of rotation.
g. start the motor, the pump is put into operation under no load, and then the zero point of the pump corresponds to the zero point of the adjustment table to eliminate the drift caused by the inertial self-rotation of the dial indicator during transportation.
h. The high-temperature plunger metering diaphragm pump conveying easy-solidifying medium should be passed through the insulating medium for 1~2h first, so that the temperature of the pump head can reach the operation requirement and then feed operation.
2, with load operation a. According to the needs of the process, reference to the flow of the calibration curve provided in the certificate or check the actual operating conditions of multiple flow calibration curve, draw the corresponding percentage of the value of the trip, the transfer meter pointer to the specified Scale. When rotating the meter, care should be taken not to go too fast or too fast. It should be adjusted according to the direction from small flow to large flow. If the flow needs to be adjusted from a large flow to a small flow, the dial should be rotated a few squares and then turned to a larger one. The direction of flow is rotated to the desired scale. After adjustment, the adjustment dial must be locked to prevent loosening.
The stroke adjustment of the pump can be performed during parking or running. After the stroke adjustment, the flow of the pump takes about 1~2 min to stabilize. The longer the stroke length change, the longer the time required for the flow to stabilize, especially the diaphragm pump.
b. Check for leakage loss at the plunger packing seal and temperature rise in the movement.
When the leakage loss exceeds 15 drops per minute, tighten the packing gland bolts in appropriate amounts.
When the temperature rises rapidly, it shall be stopped in an emergency and the packing gland shall be loosened to check the cause. Whether it is caused by over-tightening of the packing or scratches on the surface of the plunger and the metal parts, and then put it into operation after being eliminated.
c. After the pump is started, the operation should be steady and there should be no abnormal noise. Otherwise, it should be stopped to check the cause, and after eliminating the root cause of noise, it should be put into operation.
3, parking a. cut off the power, the motor stops rotating.
b. Close the inlet pipe valve, but pay attention to open before driving.
Second, the diaphragm pump membrane filling operation
1. Operation of automatic replenishment valve In the oil chamber of the diaphragm pump, the transformer oil has been filled during the factory test, and the user does not need to disassemble and refill the oil. However, when there is no oil in the cylinder, proceed as follows.
a. Open the safety fuel valve storage cover first, push the charge valve stem by hand and fill the film chamber with oil. At the same time, rotate the coupling to make the diaphragm agitate the gas in the film chamber until the bubble no longer goes up. .
b. When driving, loosen the safety valve adjusting screw gradually, make the safety valve discharge the gas in the film chamber during the pump discharge movement, it should be started several times, then tighten the adjusting screw to the original position and make the safety valve The starting pressure is about 1.1 times that of the pipeline. At the same time when the safety valve starts to bleed and exhaust, during the suction process of the plunger, the stem is pressed lightly by hand to make a short-term manual replenishment. If there is excessive quantity, vibration and shock will occur. When the plunger is in the discharge stroke, lightly pressurize the charge valve rod to discharge excess oil until the pump runs smoothly.
2. The operation of the limit charge valve will completely remove the safety valve on the upper part of the liquid cylinder and inject the transformer oil into the cylinder from the hole. At the same time, the coupling is driven to move the diaphragm to agitate the gas in the film chamber until the air bubbles no longer exist. Take up and reinstall the safety valve in the reverse order. When driving, loosen the safety valve adjusting screw gradually, so that the safety valve discharges the gas in the film chamber during the discharge movement of the pump until the oil nozzle discharges the oil outward several times. Then tighten the adjusting screw to the original position and make The starting pressure of the safety valve is about 1.1 times the pipeline pressure.
Third, on the diaphragm pump small flow adjustment method
Diaphragm pump in accordance with the national standard GB/T7782-2008 "metering pump", for the measurement accuracy of the assessment requirements: "The pump under rated conditions and the maximum relative stroke length of the flowmeter accuracy should not be less than ± 1%." When the user When the process requires the pump to be used under 20% of the rated flow rate, it must be equipped with an AC variable speed governor to reduce the motor speed, and double stroke function of stroke and pump speed should be used to meet the requirements. Tests have shown that, after double adjustment, the relative stroke Sre of the pump is
Type S-pump stroke length;
F—frequency of frequency conversion display, Hz.
In addition, when the pump is used, the relative stroke value of the pump is limited to S ≥ 25%, and the frequency value is limited to F ≥ 15 Hz. In the optional frequency converter, its capacity must not be less than the motor capacity. Because the metering pump is a single pulsating load, it is better to select one gear larger than the motor capacity.
Fourth, the routine maintenance of the diaphragm pump
1. In the oil tank and safety valve group of the transmission case, diaphragm cylinder oil chamber and pump bracket, the specified oil level should be observed regularly, not too much or too little, the lubricant should be clean without impurities, and pay attention to timely change For oil and oil change intervals, refer to Table 1.
Table 1 Oil change intervals
2. The amount of leakage at the packing seal should not exceed 8 to 15 drops per minute. If the leakage exceeds the amount, tighten the packing gland bolts properly, but do not allow the temperature at the packing to rise too high, causing the shaft to stick or burn out. Plunger and seal packing.
When self-made packing is used, it should be pressed on the press as shown in Fig. 1 before use. The total pressure is selected according to the following formula.
P=Ap(N)
In the formula p-press packing pressure, generally take p=20~25MPa;
A—filler axial area, m2,
B—Plunger diameter, m;
C—packing box inner diameter, m.
Figure 1 Filling Mould Pressing on the Press The temperature of the main parts of the pump during operation is specified as follows: The maximum allowable temperature of the motor is 70°C, the temperature of the lubricating oil in the transmission case must not exceed 65°C, and the temperature of the stuffing box must not exceed 70°C.
3. After the new pump is operated for 5000 hours, the internal parts shall be disassembled for inspection and cleaning, and the easy-to-wear components such as connecting rod sleeves shall be replaced according to the wear conditions to eliminate the impact noise generated by the excessive clearance.
4. If the pump is decommissioned for a long period of time, the medium in the pump cylinder should be drained cleanly, and the inner surface should be cleaned. It is best to remove the plunger from the stuffing box to prevent the surface from being corroded locally. The exposed processing surface is coated with anti-rust oil. During the storage period, the pump should be placed in a ventilated and dry place, covered with a cover.
V. Common Faults of Diaphragm Pumps and Their Treatments
Diaphragm pump common faults, causes of failure and treatment methods are shown in Table 2.
Table 2 Common Faults, Causes and Treatments of Diaphragm Pumps
1. Prepare the pump for operation a. Check that the bolted connections at the joints are tight and do not allow any looseness.
b. The new pump should be cleaned before pumping anti-corrosion grease on the pump or the dirt on the pump, scrub when using kerosene scrub, can not use a knife scraping.
c. Inject the appropriate amount of synthetic lubricating oil to the oil level oil line according to the ambient temperature.
d. The oil chamber of the diaphragm pump cylinder must be filled with transformer oil. The gas in the oil chamber should be drained. An appropriate amount of defoamer can be added. The safe automatic charge valve should inject a proper amount of transformer oil to about 10mm from the overflow surface. Regardless of the type of hydraulic diaphragm pump, the transformer oil should be filled in the bracket between the pump head and the gearbox, and the oil level should be filled to the flooded column. The plug can be plugged, the plunger pump is not refueled here.
e. Rotate the coupling to move the plunger back and forth several times. It should be flexible and must not be stuck. If there is an abnormal phenomenon, it is necessary to remove the fault in time before driving.
f. Check the power voltage condition and the motor circuit. The pump should be rotated in the specified direction of rotation.
g. start the motor, the pump is put into operation under no load, and then the zero point of the pump corresponds to the zero point of the adjustment table to eliminate the drift caused by the inertial self-rotation of the dial indicator during transportation.
h. The high-temperature plunger metering diaphragm pump conveying easy-solidifying medium should be passed through the insulating medium for 1~2h first, so that the temperature of the pump head can reach the operation requirement and then feed operation.
2, with load operation a. According to the needs of the process, reference to the flow of the calibration curve provided in the certificate or check the actual operating conditions of multiple flow calibration curve, draw the corresponding percentage of the value of the trip, the transfer meter pointer to the specified Scale. When rotating the meter, care should be taken not to go too fast or too fast. It should be adjusted according to the direction from small flow to large flow. If the flow needs to be adjusted from a large flow to a small flow, the dial should be rotated a few squares and then turned to a larger one. The direction of flow is rotated to the desired scale. After adjustment, the adjustment dial must be locked to prevent loosening.
The stroke adjustment of the pump can be performed during parking or running. After the stroke adjustment, the flow of the pump takes about 1~2 min to stabilize. The longer the stroke length change, the longer the time required for the flow to stabilize, especially the diaphragm pump.
b. Check for leakage loss at the plunger packing seal and temperature rise in the movement.
When the leakage loss exceeds 15 drops per minute, tighten the packing gland bolts in appropriate amounts.
When the temperature rises rapidly, it shall be stopped in an emergency and the packing gland shall be loosened to check the cause. Whether it is caused by over-tightening of the packing or scratches on the surface of the plunger and the metal parts, and then put it into operation after being eliminated.
c. After the pump is started, the operation should be steady and there should be no abnormal noise. Otherwise, it should be stopped to check the cause, and after eliminating the root cause of noise, it should be put into operation.
3, parking a. cut off the power, the motor stops rotating.
b. Close the inlet pipe valve, but pay attention to open before driving.
Second, the diaphragm pump membrane filling operation
1. Operation of automatic replenishment valve In the oil chamber of the diaphragm pump, the transformer oil has been filled during the factory test, and the user does not need to disassemble and refill the oil. However, when there is no oil in the cylinder, proceed as follows.
a. Open the safety fuel valve storage cover first, push the charge valve stem by hand and fill the film chamber with oil. At the same time, rotate the coupling to make the diaphragm agitate the gas in the film chamber until the bubble no longer goes up. .
b. When driving, loosen the safety valve adjusting screw gradually, make the safety valve discharge the gas in the film chamber during the pump discharge movement, it should be started several times, then tighten the adjusting screw to the original position and make the safety valve The starting pressure is about 1.1 times that of the pipeline. At the same time when the safety valve starts to bleed and exhaust, during the suction process of the plunger, the stem is pressed lightly by hand to make a short-term manual replenishment. If there is excessive quantity, vibration and shock will occur. When the plunger is in the discharge stroke, lightly pressurize the charge valve rod to discharge excess oil until the pump runs smoothly.
2. The operation of the limit charge valve will completely remove the safety valve on the upper part of the liquid cylinder and inject the transformer oil into the cylinder from the hole. At the same time, the coupling is driven to move the diaphragm to agitate the gas in the film chamber until the air bubbles no longer exist. Take up and reinstall the safety valve in the reverse order. When driving, loosen the safety valve adjusting screw gradually, so that the safety valve discharges the gas in the film chamber during the discharge movement of the pump until the oil nozzle discharges the oil outward several times. Then tighten the adjusting screw to the original position and make The starting pressure of the safety valve is about 1.1 times the pipeline pressure.
Third, on the diaphragm pump small flow adjustment method
Diaphragm pump in accordance with the national standard GB/T7782-2008 "metering pump", for the measurement accuracy of the assessment requirements: "The pump under rated conditions and the maximum relative stroke length of the flowmeter accuracy should not be less than ± 1%." When the user When the process requires the pump to be used under 20% of the rated flow rate, it must be equipped with an AC variable speed governor to reduce the motor speed, and double stroke function of stroke and pump speed should be used to meet the requirements. Tests have shown that, after double adjustment, the relative stroke Sre of the pump is
F—frequency of frequency conversion display, Hz.
In addition, when the pump is used, the relative stroke value of the pump is limited to S ≥ 25%, and the frequency value is limited to F ≥ 15 Hz. In the optional frequency converter, its capacity must not be less than the motor capacity. Because the metering pump is a single pulsating load, it is better to select one gear larger than the motor capacity.
Fourth, the routine maintenance of the diaphragm pump
1. In the oil tank and safety valve group of the transmission case, diaphragm cylinder oil chamber and pump bracket, the specified oil level should be observed regularly, not too much or too little, the lubricant should be clean without impurities, and pay attention to timely change For oil and oil change intervals, refer to Table 1.
Table 1 Oil change intervals
Use deadline
Oil change conditions
Start within 1 month
After 6 months
Replace 1 time
6~10 months replacement 1 time
2. The amount of leakage at the packing seal should not exceed 8 to 15 drops per minute. If the leakage exceeds the amount, tighten the packing gland bolts properly, but do not allow the temperature at the packing to rise too high, causing the shaft to stick or burn out. Plunger and seal packing.
When self-made packing is used, it should be pressed on the press as shown in Fig. 1 before use. The total pressure is selected according to the following formula.
P=Ap(N)
In the formula p-press packing pressure, generally take p=20~25MPa;
A—filler axial area, m2,
B—Plunger diameter, m;
C—packing box inner diameter, m.
Figure 1 Filling Mould Pressing on the Press The temperature of the main parts of the pump during operation is specified as follows: The maximum allowable temperature of the motor is 70°C, the temperature of the lubricating oil in the transmission case must not exceed 65°C, and the temperature of the stuffing box must not exceed 70°C.
3. After the new pump is operated for 5000 hours, the internal parts shall be disassembled for inspection and cleaning, and the easy-to-wear components such as connecting rod sleeves shall be replaced according to the wear conditions to eliminate the impact noise generated by the excessive clearance.
4. If the pump is decommissioned for a long period of time, the medium in the pump cylinder should be drained cleanly, and the inner surface should be cleaned. It is best to remove the plunger from the stuffing box to prevent the surface from being corroded locally. The exposed processing surface is coated with anti-rust oil. During the storage period, the pump should be placed in a ventilated and dry place, covered with a cover.
V. Common Faults of Diaphragm Pumps and Their Treatments
Diaphragm pump common faults, causes of failure and treatment methods are shown in Table 2.
Table 2 Common Faults, Causes and Treatments of Diaphragm Pumps
Fault phenomenon
the reason
Approach
Motor cannot start
1 no power supply
2 power supply with one or two phases off
1Check the power supply
2 check the fuse contact point is good
Not drained or drained
1 Suction tube block or suction line valve not open
2 suction pipe is too long, sharp turn too much
3 Leakage in suction line
4 suction valve or discharge valve sealing surface is damaged
5 There is residual air in the diaphragm
6 Leakage, oil leakage in the replenishing valve group or diaphragm chamber
7The safety valve and compensation valve do not operate normally
8 plunger leakage serious
9 motor speed is not enough or unstable
10 suction liquid level is too low
1 Check suction tube and filter, open valve
2 Bold suction pipe to reduce sharp turn
3 seal the leak
4 check the valve's tightness, replace the valve if necessary
5 refill the oil, discharge the air
6 Find out and eliminate leaks
7 Readjustment
8 Adjust packing gland or update packing
9 Stable motor speed
10 Adjust the suction level
The pressure of the pump reaches
No performance parameters
1 inhalation, discharge valve damage
2 plunger leakage serious
3 The diaphragm or discharge pipe joints are not tightly sealed
1 update valve
2 adjust the packing gland or replace the new packing
3 Find out the leak and eliminate it
Reduced accuracy of measurement
1 Same as 4 to 10 in "Not drained or drained"
2 Plunger zero offset
1 Same as 4 to 10 in "Not drained or drained"
2 Readjust the plunger zero
Parts are overheated
1 Transmission mechanism The fuel tank is too much or too little, and the oil contains impurities
2 The lubrication of each pair of sports is poor
3 packing pressure too tight
1 Replace new oil and make proper amount of oil
2 check the cleaning of the oil hole
3 adjust the packing gland
There is a shock in the pump
1 The wear of each pair of sports is serious
2 valve lift too high
1 Adjust or replace parts
2 adjust lift height to avoid valve lag
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