ZJ系列安装使用说明书.docx

ZJ系列安装使用说明书.docx

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ZJ系列安装使用说明书

ZJ系列安装使用说明书

CONTENTS

ⅠUSESANDSCOPEOFAPPLICATION……………………………………1

ⅡPATTERN、STRUCTURALFEATUREOFPUMPS……………………1

ⅢSLING、INSTALLATION、ADJUSTMENTANDTESTRUNOFPUMPS………6

ⅣCOMMONFAILUREANDHANDINGMEASURE……………………22

ⅤMAINTENANCEANDDISMOUNTINGOFPUMPS………………………28

ⅥLISTOFQUICK-WEARPARTS……………………………………………36

VIILISTOFSPECIALTOOLS………………………………………………38

ATTENTION

1.ThedirectionofmotormustkeepconsistentwitharrowontheFrontcasing.Beforetestingrunningthemotor,themotormustbeseparatedfrompump.TheshaftsofMotorandpumparestrictlyforbiddentorotatereversely;otherwisesomepartswillbedamaged.

2.Beforeoperatingthepump,thepackingmustbeinstalled.

3.Adoptmechanicalsealofpump,mustensurethattheshaftsealwatersupplies,itisstrictlyprohibitedwithoutrunningwater,ormechanicalsealwillbedamaged.

4.Beforeoperationwemustaddoil（N32summerorN46winter）accordingtotheoillevelofoilgauge.Pumpisstrictlyforbiddentooperatewithoutlube;otherwisebearingswillbeburnedout.

5.WhenInstallthecouplingorpulley,mustfirstintothepumpcouplingorpulleyandthenloadthemechanicalsealtoprotectthemechanicalsealfromtheimpactdamage,

6.Whenequippingthebeltwheelofmotor,theshaftofmotorshouldmanufacturedinaccordingtodrawingsiftheshaftdiameterishigherthan65mmsothatthebeltwheeloperatingsafely.

7.Pleasereadthistechnicalmanualcarefullybeforeinstallationandoperation.

ⅠUSESANDSCOPEOFAPPLICATION

TypeZJseriesSlurryPumpisanewenergy-savingcentrifugalpump.Theyareinnovativeinhydraulicdesigns,structuraldesignsandmaterialsofcastingsafterintegratingcon-genericproductsthroughouttheworld.Theyhavemanyfeatures:

highefficiency,reasonabledesign,reliableoperation,longinservicetime,easymaintenance,andlowrunningcostsandsoon.TheZJseriespump’sleadtheirdomesticcounterpartsinvarioustechnicalperformances,withmostofthemapproachingtheadvancedworldlevel,andwidelyusedforhandlingabrasiveorcorrosiveslurriesinpower,metallurgical,mining,coal,aswellaschemicalindustries.Forexample,flushingashinpowerplantsandpumpingcoalslurryincoalpreparationplants.Theyaresuitableforhandlingabrasiveandcorrosivesolids-bearingslurrywithmaximumconcentrationsofwt.45%（ash）andwt.60%（ore）.

ⅡPATTERN、STRUCTURALFEATUREOFPUMPS

TheTypeofZJseriesslurrypumpisdividedintotwocategories,onetypeisZJ,assingle-stagesingle-suctionhorizontalaxialsuctioncentrifugalslurrypump;AnothertypeisZJL,assingle-stagesingle-suctionverticalaxialinhalationcentrifugalslurrypump.

1．ZJStructuralfeatureandtypeofZJslurrypumps

（1）ZJPumpStructureFeature

①PumpHead

Itisahorizontalcantileveredslurrydouble-casespump.Thepumpheadincludescases,impeller,andshaftseal.Double-casespumpcentrallysplitverticalsplitdirection.Dischargeportcanbepositionedat8differentpositionatanintervalof45°.

TheoutsidecasesmadebyHT200orHT500-7,connectingwithbolts.Theinsidecases（volutecase,frontliner,backliner）madebyhigh-chromealloyorrubbermaterials.

Impellerfrontandbackcoverplateswithbackvanestoreduceleakageandincreaseoperatinglife,impellerandshaftisfirmlyconnectedbyladder-shapedwithdisassemblyring,”O”rubberringisusedbetweenlinerandvolutecasinganditisveryconvenientandreliable.

Therearethreekindsofshaftsealtype,expellershaftseal,packingshaftsealandmechanicalseal,seefig.1

Expellershaftsealismadeofstuffingbox,expeller,lanternring,packing,packingglandandshaftsleeve,seefig.15

Packingshaftsealismadeofstuffingbox,spacersleeves,lanternring,packing,packingglandandshaftsleeve,seefig.15a。

Mechanicalsealismadeofstuffingbox,spacersleeves,mechanicalseal,glandandshaftsleeve,seefig15b.

②Support

Thehorizontalsplit-casehasoillubricationandgreaselubrication.Oillubricationismainlycomposedofthebracketbody,thebracketcover,shaft,bearingbox,bearing,bearinggland,spacersleeve,nuts,oilseal,waterretainingplate,strippingringparts,seefig1.Themaindifferencebetweengreaselubricationbracketandoillubricationbracketisthatincreasedtheembeddedthroughcoverandoilcup,removethewatercoolingdevice,seefigure116a.

ZJtypepumpstructureasshowninfigure1.。

（1）ZJtypeModelandMeaning

200ZJ–I–A60

ImpellerDia.，cm

TheNo.ofimpellervane，Ais5、Bis4、Cis3、

Fis6、Gis7、His8.

ThePumpStage，Ⅰasfirststage，Ⅱassecondstage；

ZJtypeslurrypump

PumpOutletDia.，mm

2．ZJLPumpStructureCharacteristicsandModel

（1）ZJLPumpStructureCharacteristics

ZJLtypeslurrypumpismainlycomposedoftheimpellerandvolute,backplate,shaftsleeve,support,supportplate,shaft,bearing,bearingbodyparts,etc.Thematerialoftheimpellervoluteandbackplateishighchromealloy.Theimpellerandshaftconnectedbyscrewthread,thevoluteandsupport,bearingconnectedbybolted.Pumpshaftandmotoradoptcouplingtodirectdriveorbeltdrive.ThebearingsZJLpumpadoptgreaselubrication.Thisseriesofpumpisnoshaftseal.

ZJLtypepumpstructureasshowninfigure2.

ZJLtypeModelandMeaning

80ZJL–36

ImpellerDia.，cm；

ZJL,VerticalSlurryPump

PumpOutletDia.，mm

ⅢSLING、INSTALLATION、ADJUSTMENTANDTESTRUNOFPUMPS

1.Sling

Whenslingingapackedpump,weoperateinaccordancewithmarksonthepackingcase.Thepackingcaseshallavoidvibratingviolently,over-inclining,landingonthebodywithpointedendsandbeingplacedupsidedown.

Whenslinginganunpackedpump,weoperateaccordingasthefollowingrequirement.

（1）Whenliftingthehorizontalpumpwithoutbaseorwithsinglybase,theliftgravityisonthesideofsupportsquareholethatnearthepumphead.Wireropepassthroughthisplacetojoinwithlifthook.Inordertokeepthebalanceofpump,theauxiliarywireropeshouldbeaddedbetweeninletpipelineandliftingscrew.Theliftingscrewsonsupportcoverandcasingsareassembledtodismountsupportcoverandcasings.Theycannotbeusedwhenliftthewholepumpincaseofaccident.

（2）Whenslingingthehorizontalpumpwithmotorandcommonbase,theliftgravityisonthesideofsupportsquareholethatnearcouplings.Wireropepassthroughthisplacetojoinwithlifthook.Inordertokeepthebalanceofpump,theauxiliarywireropeshouldbeinstalledamonginletpipeline,liftingscrewsonmotorandlifthook.

（3）Thehorizontalpumpunitswithintermediatespeed-transformation,suchascoupledapparatus,shouldbeliftseparately.

（4）Cushionshouldbeaddedbetweenwireropeandbodyofpumptopreventdamagingappearanceofpumpandcuttingoffwirerope.

.

Noted:

WithmechanicalsealofpumpinstalledtheSpacersleevenotexpeller.

2.Installation

（1）Examinationbeforeinstallation

Thepumpshavebeeninspectedandtestedbeforeex-factory.Pumpsshouldbesetupcorrectlyinordertopossessgoodoperatingmode.Wemustcheckuptypesofpumps、parametersofpumpsandcomponentsandpartsinaccordancewithPackingListbeforeinstallation.Weensurethattechnicaldataandqualitycertificateofpumpiscomplete.Pumpcanbeinstalledafterreadingcorrelationtechnicaldatacarefully,especiallysuchasTHEINSTRUCTIONSOFINSTALLATIONANDAPPLICATIONFORTYPEZJSLURRYPUMPSandmasteringrelatedtechnicalrequirements.

（2）Installationandcapturingofpump

Thehorizontalpumpunitsshouldbeequippedbymakinguseoftwicegrouting.Thecentrallineofpumpsisconsistentwiththecentrallineoffoundation.Thedeviationbetweencenter-heightofpumpanddesignvalueissmallerthan±2mmverticallyand0.1/1000horizontally.

Weassureaxisofpumpunitsbyadjustingcouplingswhenpumpsaredrovebycouplings.Therearetwomethods.Thefirstmethodistheuseofkniferulerandpluggauge.Weadjustoutsidediameterofcouplingswithkniferulertoguaranteealignmentineverydirectionandthemaxtolerance（δ）lessthan0.1mm[SeeFigure3,（a）].Weexaminetheintervalbetweencouplingtoguaranteethemaxtolerance△（△=δ1-δ2）smallerthan0.1mm[SeeFigure3,（b）].Theothermethodistheuseofpluggaugeandmagneticcentigradescale.Wefixmagneticcentigradescaleonoutsidediameterofonecouplingandputmeasuringheadonoutsidediameteroftheothercoupling.Thepulsationofcentigradescaleshouldbesmallerthan0.15mm[SeeFigure3,（c）]whenturnrotor.Wecheckupthespacebetweencouplingswithpluggaugetoensurethemaxtolerancelessthan0.1mm[SeeFigure3,（b）]

Theshaftofpumpandthemotorshouldassuredtheparallelismwhenpumpsaredrovebybelts,soweadjustdirectiononthebasisofpulley.Whencentraldistanceissmall,wecanalignendfacesofpulleywithruler;whencentraldistanceisbig,andwecanadjustthembyaligningendfacesthroughspanwiresystem[SeeFigure,（4）].

（a）（b）（c）　

Figure3Capturingofcoupling

Figure4Capturingofbeltwheels

（3）Configurationandrequirementofdischargepipelineandsuctionpipeline

Accordingtotheappliedconditionandthecavitationperformanceofpump,thearrangementofpumpcanbeclassifiedintoexaltedsetting[SeeFigure5,（a）]andlowsetting[SeeFigure5,（b）].

Figure5Arrangementofsuctionpipelineanddischargepipeline

①Suctionpipeline

Diameterofsuctionpipeline:

diameterofsuctionpipelineshouldbeequaltopumpinletorlargerthanitsoastoavoidcavitationanddepositionofslurryinpipeline.

Gatevalveofsuctionpipeline:

Inordertomaintaineasily,weshouldinstallinlet