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

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（N32summerorN46winteraccordingtotheoillevelofoilgauge.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%（ashandwt.60%（ore.

ⅡPATTERN、STRUCTURALFEATUREOFPUMPSTheTypeofZJseriesslurrypumpisdividedintotwocategories,onetypeisZJ,assingle-stagesingle-suctionhorizontalaxialsuctioncentrifugalslurrypump;AnothertypeisZJL,assingle-stagesingle-suctionverticalaxialinhalationcentrifugalslurrypump.

1.ZJStructuralfeatureandtypeofZJslurrypumps

（1ZJPumpStructureFeature

①PumpHead

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

TheoutsidecasesmadebyHT200orHT500-7,connectingwithbolts.Theinsidecases（volutecase,frontliner,backlinermadebyhigh-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,gland

andshaftsleeve,seefig15b.

②Support

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

ZJtypepumpstructureasshowninfigure1.。

（1ZJtypeModelandMeaning

200ZJ–I–A60

ImpellerDia.,cm

TheNo.ofimpellervane,Ais5、Bis4、Cis3、

Fis6、

Gis7、

His8.

ThePumpStage,Ⅰasfirststage,Ⅱassecondstage;

ZJtypeslurrypump

PumpOutletDia.,mm

2.ZJLPumpStructureCharacteristicsandModel

（1ZJLPumpStructureCharacteristics

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.

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

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

（3Thehorizontalpumpunitswithintermediatespeed-transformation,suchascoupledapparatus,shouldbeliftseparately.

（4Cushionshouldbeaddedbetweenwireropeandbodyofpumptopreventdamagingappearanceofpumpandcuttingoffwirerope.

.

Noted:

WithmechanicalsealofpumpinstalledtheSpacersleevenotexpeller.

2.Installation

（1Examinationbeforeinstallation

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

requirements.

（2Installationandcapturingofpump

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

Weassureaxisofpumpunitsbyadjustingcouplingswhenpumpsaredrovebycouplings.Therearetwomethods.Thefirstmethodistheuseofkniferulerandpluggauge.Weadjustoutsidediameterofcouplingswithkniferulertoguaranteealignmentineverydirectionandthemaxtolerance（δlessthan0.1mm[SeeFigure3,（a].Weexaminetheintervalbetweencouplingtoguaranteethemaxtolerance△（△=δ1-δ2smallerthan0.1mm[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

（3Configurationandrequirementofdischargepipelineandsuctionpipeline

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

Figure5Arrangementofsuctionpipelineanddischargepipeline

①Suctionpipeline

Diameterofsuctionpipeline:

diameterofsuctionpipelineshouldbeequaltopumpinletorlargerthanitsoastoavoidcavitationanddepositionofslurryinpipeline.Gatevalveofsuctionpipeline:

Inordertomaintaineasily,weshouldinstallinletgatevalveswhosediameterisequaltothediameterofsuctionpipeline.Theexpansionpipeshouldbesetupbetweeninletofpumpandsuctionpipelinesoastodisassemblepump.

②Dischargepipe