Diaphragm pump repair, diaphragm pump maintenance and repair procedures

1 diaphragm pump maintenance General 1.1 Scope This specification applies to chemical enterprises 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-regulated 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 / H4MPa Plunger reciprocating plunger stroke 10 ~ 104 times / min 44mm Inlet and outlet diameter Working temperature 15mm≤100 ℃ 2 Diaphragm pump maintenance and repair standards 2.1 Zero, parts 2.1.1 Lord 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 running 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 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, the foundation, the base and the environment clean; no water, oil plug, etc., so that "ditch to see the end of the shaft to see the light." 2.4.2 Valves, pipelines, fittings, flanges and shaft seals all meet the leak-free standard. 3 diaphragm pump equipment maintenance 3.1 Routine Maintenance 3.1.1 open and stop the pump strictly enforce the safe operating procedures. 3.1.2 often keep the body and the surrounding clean. 3.1.3 Implementation of "five", "three must filter" lubrication system. 3.2 Periodic inspection 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 abnormal phenomenon or leakage. 3.3 Common Troubleshooting Methods Common troubleshooting methods are shown in Table 2. Table 2 Symptoms Causes of the problem Elimination method Phenomenon Causes of the problem Elimination method Insufficient or elevated pressure 1. The pressure regulator valve is not adjusted 2. The pressure regulator valve failure 3. The pressure gauge failure 1. Regulate the pressure valve to the required pressure 2. Overhaul the pressure regulator 3. Check or replace the pressure gauge pressure drop 4. Diaphragm pump reservoir tank oil is too low 5. Diaphragm pump body leaks or diaphragm damage 4. Fill the new oil 5. Check the replacement gasket or diaphragm flow less than 1. Exhaust valve leakage 2. Diaphragm damage 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 of the pressure drop 1. Charge valve less than 2 . Inadequate feed or feed valve leakage 3. Leakage to the plug seal 1. Check the fill valve 2. Check the feed situation and feed valve 3. Overhaul the sealing part of the oil seal, ring damage or too loose adjustment or Replacing seals, seals 3.4 Emergency Parking 3.4.1 Sudden overpressure. 3.4.2 control part of failure. 3.4.5 abnormal sound, vibration. 4 Maintenance cycle and maintenance content 4.1 Maintenance cycle When the unit status monitoring tools have been carried out to predict the conditions for maintenance, after the approval by the competent authority of the unit, may not subject to the above restrictions. 4.2 Maintenance 4.2.1 repair 4.2.1.1 Check the fastening bolts of the ministries. 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 disassembly, cleaning of the 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 seat and valve head anastomosis width of 0.25-2.00mm, and anastomosis should not have rust, pitting and other defects. 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 Valves 5.2.1 Regulating 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 Portion 5.3.1 Plunger 5.3.1.1 Fitted with Guide Sleeve Dimension Tolerance, roundness 0.02mm, straightness 0.022mm, surface roughness, surface hardness HRC45-55.5.3.1.2 Shaft diameter Coaxial with the positioning axis diameter 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 diameter and outer diameter of male 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, 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 0.04.5.4.2 Diameter of the shell 5.4.2.1 There is no strain on the mating surface with the bearing bush, and the surface roughness. 5.4.2.2 with the bush with the guide hole perpendicularity of 0.02mm. 5.4.2.3 After the two bearing shell combination, both ends of the guide hole coaxiality 0.02mm. 5.4.3 Bearing 5.4.3.1