1 General
1.1 Scope This procedure applies to the chemical industry 2WMF-250/40-type diaphragm macro maintenance and overhaul.
1.2 Structure Description Diaphragm pump is a horizontal symmetrical two cylinder reciprocating type, which consists of the main components of the fuselage, crankshaft, shaft, plunger, diaphragm set, control valve, etc. The drive unit consists of electromagnetic speed regulation asynchronous motor through cycloid reducer drive.
1.3 Equipment Performance Equipment performance in Table 1.
Table 1
Item Index Item Index Item Index Maximum flow Maximum pressure 250L / H
4MPa plunger reciprocating plunger stroke 10 ~ 104 times / min
44mm inlet and outlet diameter working temperature 15mm
≤100 ℃
2 good standard
2.1 zero, parts
2.1.1 main and auxiliary zero, complete components, quality to meet the requirements.
2.1.2 control devices, pressure gauges, pressure regulating device complete, sensitive and reliable.
2.1.3 Basis, solid and solid base, anchor bolts and all parts of the bolt tight due to complete specifications uniform, threaded 1-3 deduction, in line with technical requirements.
2.1.4 pipelines, fittings, valves, brackets and other reasonable and solid installation of a complete, clear signs, in line with the requirements.
2.2 operating performance
2.2.1 equipment lubrication is good, the implementation of "five, three filter."
2.2.2 no abnormal vibration, loose, noise and other phenomena.
2.2.3 pressure, flow should meet the requirements.
2.2.4 equipment production capacity should reach the nameplate output or capacity.
2.3 technical information
2.3.1 equipment resume card, maintenance and inspection records are complete.
2.5.2 equipment operation must have a running record.
2.3.3 equipment assembly drawings and wearing parts drawings are complete.
2.3.4 equipment operating procedures, equipment maintenance and repair procedures complete.
2.4 Equipment and Environment
2.4.1 Equipment clean, dust-free shell, no grease, no debris, foundation, base and the environment clean; no water, oil plug, etc., so that "ditch bottom view, shaft see light."
2.4.2 Valves, pipelines, fittings, flanges and shaft seals all meet the leak-free standard.
3 equipment maintenance
3.1 routine maintenance
3.1.1 open and stop the pump strictly enforce the safety rules.
3.1.2 often keep the body and the surrounding clean.
3.1.3 Implementation of "five", "three must filter" lubrication system.
3.2 regular inspection of the content
3.2.1 regularly check the current, speed, temperature, flow, pressure meets the requirements.
3.2.2 Regularly check whether all parts of equipment operate normally, whether there is any abnormal phenomenon or leakage.
3.3 Common Troubleshooting Methods Common troubleshooting methods are shown in Table 2.
Table 2
Phenomenon Causes of the problem Elimination method Phenomenon Causes of the problem Elimination method Insufficient pressure or increase 1. Pressure regulating valve is adjusted
2. pressure regulator failure
3. Pressure Gauge Failure 1. Adjust the pressure valve to the desired pressure
2. Overhaul pressure regulator
3. Check or replace the pressure gauge pressure drop 4. Storage tank oil level is too low
5. Pump leakage or diaphragm damage 4. Fill new oil
5. Check the replacement of gaskets or diaphragm flow less than 1. Leak into the discharge valve
2. The diaphragm is damaged
3 speed is too slow, adjusting failure 1. Overhaul or replacement into the discharge valve
2. Replace the diaphragm
3. Overhaul the control device, adjust the speed
Pressure drop 1. Charge valve insufficient oil
Inadequate feed or feed valve leakage
3. To plug the oil seal 1. Check the oil valve
2. Check the feed situation and feed valve
3. Maintenance seal part
Oil seal, damaged or too loose ring Adjust or replace the seal,
Sealing ring
3.4 Emergency Parking
3.4.1 sudden overpressure.
3.4.2 control part of failure.
3.4.5 abnormal sound, vibration.
4 inspection cycle and maintenance content
4.1 Maintenance cycle When the unit status monitoring means have been carried out to predict the conditions for maintenance, after the unit approved by the competent authority, may not be subject to the above restrictions.
4.2 maintenance content
4.2.1 repair
4.2.1.1 Check the fastening bolts of each department.
4.2.1.2 cleaning access intake valve group and pipeline.
4.2.1.3 clean the orifice plate, check the diaphragm usage.
4.2.1.4 Check and adjust the plunger seal.
4.2.1.5 cleaning pressure control valve storage tank.
4.2.1.6 overhaul pressure regulating valve, fill valve.
4.2.1.7 inspection, replacement of lubricating oil and control oil.
4.2.2 Overhaul
4.2.2.1 including the repair content.
4.2.2.2 Complete disintegration, cleaning of various parts.
4.2.2.3 inspection, repair or replacement of crankshaft, bearing bush, shaft shell, sleeve wear and with the gap.
4.2.2.4 inspection, inspection change the shaft and bearing wear and tear and with the gap.
4.2.2.5 Check and repair plunger and guide body.
4.2.2.6 inspection and repair of electrical and mechanical devices.
4.2.2.7 Exterior painting rust.
5 maintenance methods and quality standards
5.1 pump head part, into the discharge valve group
5.1.1 The width of the anastomosis between valve seat and valve head is 0.25-2.00mm, and there should be no rust, pitting and other defects on the anastomosis line. Does not match the standard, can be machined and centering percussion method combined repair. Severe rust, should replace the seat.
5.1.2 diaphragm should be smooth, no scratches, flexibility to meet the requirements.
5.2 control valve
5.2.1 Adjust the pressure valve spool and valve seat closely, five minutes of leak test kerosene, leakage does not exceed one drop. According to wear and tear, can be taken accordingly, machining centering or grinding method of repair. Can not be repaired, then replaced.
5.2.2 fill valve quality standards, maintenance methods and pressure valve the same.
5.3 Pump section
5.3.1 Plunger
5.3.1.1 with the guide sleeve size tolerance for the sauce, roundness of 0.02mm, straightness of 0.022mm, surface roughness, surface hardness HRC45-55.
5.3.1.2 with the shaft diameter and positioning shaft coaxiality 0.02mm.
5.3.1.3 The maximum grinding amount 0.01D (D is the diameter).
5.3.2 Guide sleeve
5.3.2.1 with the plunger size tolerance for the surface roughness
5.3.2.2 The inner diameter and outer diameter of coaxial 0.02mm.
5.3.3 seal should be good elasticity, aging phenomenon of aging cracks, and no scratches the surface with the plunger injury.
5.4 crankshaft, the shaft part
5.4.1 crankshaft
5.4.1.1 The main journal, crank neck and bush with dimensional tolerance, roundness 0.02mm, straightness Φ0.02mm, surface roughness.
5.4.1.2 main journal and crank neck parallelism 0.03mm.
5.4.1.3 The maximum grinding amount of the main journal and crank neck is 0.04 of the diameter.
5.4.2 bearing shell
5.4.2.1 with the bearing surface without pulling lint, surface roughness.
5.4.2.2 with the bush with the guide hole perpendicularity of 0.02mm.
5.4.2.3 After the combination of two bearing shell, both ends of the guide hole coaxiality 0.02mm.
5.4.3 Bearing
5.4.3.1 Tolerances with bushings Tolerances shall be such that, in conjunction with the crankshaft, the dimensional tolerances shall be in accordance with the surface roughness
5.4.3.2 bush keyway and positioning keys with the size tolerance.
5.4.4 crankshaft sleeve
5.4.4.1 With the main uranium neck size tolerances, the surface roughness is.
5.4.4.2 The inner diameter and outer diameter of coaxiality is Φ0.02mm.
5.4.5 axis
5.4.5.1 with the sleeve with dimensional tolerances, roundness of 0.02mm, straightness 0.02mm, surface roughness, quenched and tempered.
5.4.5.2 with the shaft diameter and positioning shaft diameter coaxiality Φ0.01mm.
5.4.5.3 The maximum grinding amount is 0.04 of the diameter.
5.4.6 sleeve
5.4.6.1 Surface roughness.
5.4.6.2 inner diameter and outer radial axis Φ0.02mm.
6 test and acceptance
6.1 test preparation before
6.1.1 clear all around the pump seat and debris.
6.1.2 Check all the connecting bolts are tightened.
6.1.3 check the seal tightness.
6.1.4 Check the crankcase, hydraulic chamber, control valve tank oil is sufficient.
6.1.5 crank two weeks, pay attention to whether there is no noise in the pump, crank light is.
6.1.6 Check the electrical parts and control devices without exception.
6.1.7 Remove the coupling pin and verify that the motor is steered correctly.
6.1.8 Install the coupling pin, press the safety cover, ready to test.
6.2 test
6.2.1 Before driving the pump head must be filled with water or feed solution.
6.2.2 Turn on the power, according to operating procedures to start the device.
6.2.3 Remove the control valve cover, at a lower speed, hand-push the upper end of the charge valve, the hydraulic chamber discharge air until no air bubbles.
6.2.4 adjust the safety valve to the desired pressure, pressure on both sides should be equal.
6.2.5 According to need, adjust the motor speed, to achieve the required flow, normal operation.
6.2.6 test must meet the following requirements:
a. Equipment lubrication is good;
b. ministries run, run, drip, leak;
c. control valve is working properly;
d. pressure gauge and control device is sensitive and reliable;
e. No abnormal noise during operation
f. continuous operation test time 2-4 hours;
g. The performance of the design ability to meet or meet production requirements
6.3 The quality of inspection and acceptance to meet the standards of this procedure; test to meet the requirements; maintenance test records complete and accurate; can be required to handle the acceptance procedures, handed over to production use.
7 Maintenance Inspection safety precautions
7.1 Maintenance Safety Precautions
7.1.1 must strictly enforce the rules and safety regulations.
7.1.2 to keep the ground wire safe and reliable.
7.2 maintenance safety precautions
7.2.1 Paiqiu before pumping liquid drain, do a good job of appearance and on-site cleaning work, according to the provisions of the equipment transferred to the maintenance department.
7.2.2 maintenance personnel should strictly abide by the safety inspection requirements.
7.2.3 Before dismantling the equipment, it is necessary to cut off the power supply and hang up the "forbidden card" sign at the power supply before starting the overhaul.
7.2.4 disassembly equipment to civilized construction.
7.3 test safety precautions
7.3.1 There should be someone responsible for the safety inspection during the test.
7.3.2 Check each part of the safety device is reliable and effective.
7.3.3 To prepare for the test before the start, by holding the post "safety operation certificate" is responsible for the operation of personnel, in strict accordance with the requirements of the test steps.
7.3.4 Found that unsafe hidden dangers should be ruled out in time.
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