Special Notice

1. It is necessary to ensure that the direction of rotation of the pump shaft is consistent with the direction indicated by the arrow on the volute. During the trial run of the motor, it must be completely disconnected from the pump. It is strictly prohibited for the motor to drive the pump shaft to rotate in the opposite direction, as this may cause damage to the pump components.

2. Pumps using water injection type mechanical seals must ensure the supply of shaft seal water. It is strictly prohibited to operate without water, otherwise the mechanical seal will burn out.

3. Pumps using oil injected mechanical seals must ensure that the oil is injected to the specified level. It is strictly prohibited to operate in an oil-free or low oil state, otherwise the mechanical seal will burn out.

4. Pumps lubricated with thin oil should be refueled or refilled with oil according to the oil level line on the oil gauge before driving. It is strictly prohibited to operate in a state where the oil level is below 2mm below the oil level line, otherwise the bearing will burn out.

5. When installing the pump coupling or pump pulley, in order to protect the mechanical seal from damage due to impact force, the pump coupling or pump pulley must be inserted first before installing the mechanical seal. Otherwise, the hammering force may cause the mechanical seal dynamic and static rings to break.

6. Customers install the motor pulley on site. When the shaft diameter is ≥ 65mm, the shaft end machining drawing and accessories provided by our factory should be used for drilling, threading, and installing the shaft end retaining ring to ensure the safe operation of the pulley.

7. Before installation and use, please read this manual carefully.

The purpose and scope of application of the pump

The DT series desulfurization pumps developed by our factory are divided into two structures: horizontal (DT) and vertical (TL). For axial suction, single suction, cantilever centrifugal structure. This series of pumps comprehensively applies the advantages of similar products at home and abroad and innovates in hydraulic design, structural design, and materials used for castings. It has the characteristics of high efficiency, energy saving, corrosion and wear resistance, low vibration, low noise, reliable operation, long service life, and easy maintenance. The comprehensive performance of the pump is at the leading level in China. It can be widely used in desulfurization systems for industries such as thermal power plants, aluminum refineries, and oil refineries to transport limestone or gypsum slurry. The allowable chloride ion concentration in the slurry is 60000ppm, and the pH value of the slurry is allowed to be between 2.5-13.

Types and structural characteristics of pumps

There are two main types of DT series desulfurization pumps. One is the DT type, which is a horizontal, axial suction, single-stage, single suction, centrifugal desulfurization pump; The other type is TL type, which is a vertical, axial suction, single-stage, single suction, centrifugal desulfurization pump.

1. Structural characteristics and models of DT type horizontal desulfurization pump

(1) Structural characteristics of DT type horizontal desulfurization pump

The pump head of DT type horizontal desulfurization pump includes impeller, volute shell, rear guard plate, packing box, liner plate, and shaft seal device. The pump head of DT type desulfurization pump is a single-layer shell structure. The overcurrent components are made of corrosion-resistant and wear-resistant cast alloys (including blades, volutes, rear guard plates, and liners). The impeller and shaft are connected by threads.

The bracket is lubricated with thin oil. It mainly consists of parts such as bracket body, bracket cover, shaft, bearing box, bearing, bearing cover, sleeve, nut, oil seal, water blocking plate, etc. The detailed structure of DT type desulfurization pump is shown in Figure 1.

(2) The significance of the DT type horizontal desulfurization pump model

200 DT1-A60(58)B

200--Pump outlet diameter 200cm

DT--Horizontal desulfurization pump

1--Material of overcurrent components. 1 is C1; 2 is C2; 3 is C3, GLH-5 is not labeled

A--The diameter of one blade was cut from 60cin by the prototype pump to 58cm by the number of impeller blades. A has 5 pieces, B has 6 pieces, C has 3 pieces, D has 2 pieces, E has 1 piece, F has 6 pieces, and G has 7 pieces.

60(58)--The diameter of one blade was cut from 60cin by the prototype pump to 58cm by the number of impeller blades.

B--Special structure code. B represents a semi open impeller. Normal structure does not represent

1. Impeller 2. Spiral shell 3. Rear guard plate 4. Inlet short pipe 5. Export short pipe 6, packing box 7, lining plate 8, mechanical seal 9. Bracket 10, Coupling 11, Base

3、 DT series desulfurization pump direct drive clean water performance table

DT series desulfurization pump direct drive clean water performance table 1

model	Speed nr/min r/min	Clear water performance					Supporting motor
		Flow rate Q ㎡/h	Head Hm	Shaft power Pakw	Maximum efficiency n%	Cavitation allowance m	model	Power/voltage kw/v
800DT-A90	592	6200	28.7	553.2	87.6	2.7	Y560-10	710/6000
		8800	26.1	700.4	89.3	3.5	Y560-10	900/6000
		9700	23.5	715.2	86.8	3.9	Y560-10	900/6000
	492	5170	20.0	321.5	87.6	2.0	Y500-12	400/6000
		7338	18.1	405.0	89.3	2.5	Y560-12	500/6000
		8089	16.3	413.7	86.8	2.9	Y630-12	560/6000
700DT-A84	591	4250	24.5	326.3	86.9	2.8	Y500-10	500/6000
		6300	22.3	430.9	88.8	3.5	Y500-10	560/6000
		7360	20.1	467.4	86.2	4.0	Y500-10	630/6000
	493	3545	17.0	188.9	86.9	2.0	Y450-12	250/6000
		5255	15.5	250.0	88.8	2.6	Y500-12	315/6000
		6140	14.0	271.6	86.2	3.0	Y500-12	355/6000
600DT-A82	595	3300	27.8	343.2	72.8	3.0	YKK5601-10	500/6000
		4700	24.7	358.0	88.3	3.7	YKK5601-10	500/6000
		5300	21.7	362.9	86.3	4.0	YKK5601-10	500/6000
		5600	20.4	368.2	84.5	4.0	YKK5601-10	500/6000
	490	2718	18.9	192.2	72.8	2.2	YKK5003-12	280/6000
		3871	16.8	200.6	88.3	2.8	YKK5003-12	280/6000
		4365	14.7	202.5	86.3	3.0	YKK5003-12	280/6000
		4612	13.8	205.1	84.5	3.0	YKK5003-12	280/6000
500DT-A85	591	2040	26.8	204.5	72.8	4.1	Y450-10	250/6000
		3400	24.4	266.7	84.7		Y450-10	355/6000
		4080	22.0	305.2	80.1		Y500-10	400/6000
	493	1702	18.6	118.4	72.8	3.1	Y450-12	220/6000
		2836	17.0	155.0	84.7		Y450-12	220/6000
		3403	15.3	177.0	80.1		Y450-12	220/6000
350DT-A78	740	1332	51.1	289.6	64.0	6.5	Y450-8	355/6000
		2431	44.5	377.7	78.0		Y500-8	500/6000
		2865	39.6	408.7	75.6		Y500-8	500/6000
	590	1062	32.5	146.9	64.0	3.5	Y450-10	185/6000
		1938	28.3	191.5	78.0		Y450-10	250/6000
		2284	25.2	207.3	85.6		Y450-10	280/6000
300DT-A60	989	1170	53.1	235.6	71.8	8.4	Y400-6	315/6000
		1779	47.1	281.4	81.1		Y400-6	355/6000
		2403	36.1	313.3	75.4		Y400-6	400/6000
	742	878	29.9	99.6	71.8	4.3	Y355M1-8	132/380
		1335	26.5	118.8	81.1		Y355M2-8	160/380
		1803	20.3	132.3	75.4		Y355M2-8	160/380
200DT-B45	990	279	31.0	37.4	62.9	3.3	Y280M-6	55/380
		557	26.1	49.0	80.8		Y315S-6	75/380
		645	23.3	52.6	77.8		Y315S-6	75/380
	730	206	16.9	15.1	62.9	2.0	Y225M-8	22/380
		410	14.2	19.9	80.8		Y250M-8	30/380
		475	12.7	21.1	77.8		Y250M-8	30/380

DT series desulfurization pump direct drive Clear water performance table 2

Model	Speed n r/min	Clear water performance					Supporting motor
		Flow rateQ ㎡/h	HeadH m	Maximum efficiencyPa kw	Cavitation allowance 7%	Cavitation allowance m	Model	Power/voltage kw/v
1S0DT-B55	990	280	53.7	64.8	63.2	3.7	Y315M-6	90/380
		517	48.0	88.3	76.5		Y315L1-6	110/380
		630	45.9	100.8	78.1		Y315L2-6	132/380
	740	209	30.0	27.0	63.2	2.3	Y280S-8	37/380
		387	26.8	36.9	76.5		Y315S-8	55/380
		471	25.7	42.2	78.1		Y315S-8	55/380
150DT-A50	980	123	44.6	27.6	54.1	3.5	Y250M-6	37/380
		221	40.1	36.9	65.4		Y280M-6	55/380
		279	37.2	43.4	65.2		Y280M-6	55/380
	730	92	24.7	11.4	54.1	2.1	Y225S-8	18.5/380
		165	22.3	15.3	65.4		Y225M-8	22/380
		208	20.6	17.9	65.2		Y250M-8	30/380
150DT-A40	1490	260	61.2	68.8	63.0	6.5	Y280M-4	90/380
		440	53.8	88.2	73.1		Y315S-4	110/380
		503	50.7	95.4	72.8		Y315M-4	132/380
	980	171	26.5	19.6	63.0	2.6	Y225M-6	30/380
		289	23.3	25.1	73.1		Y250M-6	37/380
		331	21.9	27.1	72.8		Y250M-6	37/380
100DT-A45B	1480	88	76.4	43.6	42.0	6.0	Y250M-4	55/380
		166	65.2	56.9	51.8		Y280S-4	75/380
		219	54.3	66.5	48.7		Y280M-4	90/380
	970	57	32.8	12.1	42.0	2.4	Y200L1-6	18.5/380
		109	28.0	16.0	51.8		Y200L2-6	22/380
		144	23.3	18.8	48.7		Y225M-6	30/380
100DT-B40	1480	129	61.0	38.7	56.9	3.5	Y250M-4	55/380
		219	56.1	48.7	68.7		Y280S-4	75/380
		268	53.6	55.6	70.4		Y280S-4	75/380
	970	85	26.2	10.7	56.9	1.7	Y180L-6	15/380
		144	24.1	13.8	68.7		Y200L2-6	22/380
		176	23.0	15.7	70.4		Y200L2-6	22/380
100DT-B35	1480	163	45.9	33.5	60.9	4.1	Y225M-4	45/380
		278	41.5	43.7	71.9		Y250M-4	55/380
		323	39.2	47.1	73.2		Y280S-4	75/380
	970	107	19.7	9.4	60.9	1.9	Y180L-6	15/380
		182	17.8	12.3	71.9		Y200L1-6	18.5/380
		212	16.8	13.3	73.2		Y200L1-6	18.5/380
80DT-B36	1480	86	47.1	23.3	47.7	3.2	Y200L-4	30/380
		151	42.0	28.5	60.7		Y225S-4	37/380
		167	39.9	29.3	62.0		Y225S-4	37/380
	970	56	20.2	6.5	47.4	1.5	Y160L-6	11/380
		99	18.0	8.0	60.7		Y180L-6	15/380
		109	17.1	8.2	62.0		Y180L-6	15/380
65DT-A40	1480	71	63.2	26.2	46.7	4.5	Y225S-4	37/380
		141	57.5	35.6	62.1		Y225M-4	45/380
		159	54.6	38.1	62.1		Y250M-4	55/380
	970	47	27.1	7.4	46.7	2.1	Y160L-6	11/380
		92	24.7	10.0	62.1		Y180L-6	15/380
		104	23.5	10.7	62.1		Y180L-6	15/380

 

Model	Speed n r/min	Clear water performance					Supporting motor
		Flow rateQ ㎡/h	HeadH m	Maximum efficiencyPa kw	Cavitation allowance n%	Cavitation allowance m	Model	Power/voltage kw/v
65DT-A30	1470	44	35.6	9.1	46.7	4.6	Y160L-4	15/380
		79	32.6	12.8	54.6		Y180M-4	18.5/380
		99	30.7	15.4	53.8		Y180L-4	22/380
	960	29	15.2	2.6	46.7	2.2	Y132M2-6	5.5/380
		51	13.9	3.5	54.6		Y132M2-6	5.5/380
		64	131.1	4.2	53.8		Y160M-6	7.5/380
50DT-D40	1470	33	51.7	13.1	35.4	2.5	Y180M-4	18.5/380
		68	43.4	17.8	45.1		Y200L-4	30/380
		76	40.8	18.9	44.7		Y200L-4	30/380
	970	22	22.5	3.8	35.4	1.2	Y132M2-6	5.5/380
		45	18.9	5.1	42.1		Y160M-6	7.5/380
		50	17.7	5.4	44.7		Y160L-6	11/380
50DT-A30	1460	34	36.3	7.8	43.1	1.6	Y160M-4	11/380
		55	31.9	9.9	48.5		Y160L-4	15/380
		78	26.4	12.4	45.4		Y180M-4	18.5/380
	960	22	15.7	2.2	43.1	0.8	Y132M1-6	4/380
		36	13.8	2.8	48.5		Y132M1-6	4/380
		51	11.4	3.5	45.4		Y132MM2-6	5.5/380
[] 40DT-A25	2950	35.5	88.6	20.7	41.3	-	Y200L1-2	30/380
		58.8	73.5	27.7	42.5		Y200L2-2	37/380
		74.7	60.8	31.2	39.6		Y225M-2	45/380
	1440	17.3	21.1	2.4	41.3	2.6	Y112M-4	4/380
		28.7	17.5	3.2	42.5		Y132S-4	5.5/380
		36.5	14.5	3.6	19.6		Y132S-4	5.5/380
40DT-B20	2930	16.6	57.5	6.4	40.9	3.5	Y160M1-2	11/380
		33.3	49.9	8.5	53.0		Y160M2-2	15/380
		37.1	47.1	9.2	52.0		Y160M2-2	15/380
	1430	8.1	13.7	0.7	40.9	0.9	Y90L-4	1.5/380
		16.3	11.9	1.0	53.0		Y100L1-4	2.2/380
		18.1	11.2	1.1	52.0		Y100L1-4	2,2/380
40DT-A19	2930	16.3	57.1	6.5	30.2	4.9	Y160M1-2	11/380
		30.3	54.9	8.1	55.4		Y160M1-2	15/380
		34.9	53.7	8.7	58.8		Y160M2-2	15/380
	1400	7.8	13.0	0.7	39.2	1.2	Y90L-4	1.5/380
		14.3	12.5	0.9	55.4		Y90L-4	1.5/380
		16.7	12.3	1.0	58.8		Y100L1-4	2.2/380
40DT-A17	2900	9.4	44.6	3.4	33.2	4.5	Y132S1-2	5.5/380
		17.9	42.7	4.2	49.5		Y132S2-2	7.5/380
		23.4	39.3	4.8	52.4		Y132S2-2	7.5/380
	1400	4.6	10.4	0.4	33.2	2.5	Y802-4	0.75/380
		8.6	10.0	0.5	49.5		Y90S-4	1.1/380
		11.3	9.2	0.5	52.4		Y90S-4	1.1/380
25DT-A25	1440	9.6	21.6	1.7	33.2	7.1	Y100L2-4	3/380
		17.8	16.6	2.1	38.0		Y112M-4	4/380
		19.9	13.9	2.2	33.8		Y112M-4	4/380
	910	6.0	8.6	0.4	33.2	3.3	Y90S-6	0.75/380
		11.2	6.6	0.5	38.0		Y90L-6	1.1/380
		12.5	5.5	0.6	33.8		Y90L-6	1.1/380

DT series desulfurization pump direct drive Clear water performance table 4

Model	Speed n r/min	Clear water performance					Supporting motor
		Flow rateQ ㎡/h	HeadH m	Maximum efficiencyPa kw	Cavitation allowance 7%	Cavitation allowance	Model	Power/voltage kw/v
25DT-A15	2900	9.2	34.4	2.6	32.7	5.3	Y132S1-2	5.5/380
		17.1	29.5	3.3	41.8		Y132S1-2	5.5/380
		19.3	27.1	3.5	40.8		Y132S1-2	5.5/380
	1390	4.4	7.9	0.3	32.7	1.3	Y801-4	0.55/380
		8.2	6.8	0.4	41.8		Y802-4	0.75/380
		9.3	6.2	0.4	40.8		Y802-4	0.75/380

Explanation:

1. The above motors are selected based on a slurry density of 1.15. When selecting a motor, the user should calculate the motor power according to the specific working conditions:

[a] represents that the 40DT-A25 pump cannot be used for suction conditions at 2950r/min, and is only selected for reverse port conditions, with a reverse height of ≥ 2m.

 Lifting, installation, adjustment, and trial operation of pumps

1. Lifting

When lifting pumps with packaging boxes, steel wire ropes should be tied according to the lifting position indicated on the packaging box. When lifting, the bottom or side of the box must not be subjected to external impact, the packaging box must not be excessively tilted, the packaging box must not be placed on objects with sharp edges, and it must not be inverted.
Lift pumps without packaging boxes according to the following requirements:
(1) When lifting a horizontal pump without a base or with only a separate base, the lifting center of gravity should be at the square hole on the side of the bracket near the pump head, and the steel wire rope should be connected to the lifting hook vertically upwards through this point. To maintain the balance of the pump, an auxiliary lifting wire rope should be installed between the short pipe and the lifting hook. The lifting ring screws on the bracket cover are designed for disassembling and assembling the bracket cover, and should not be used alone for lifting the overall pump to avoid accidents.
(2) The lifting belt motor and the horizontal pump with a common base have a lifting center of gravity near the coupling in the square hole of the bracket. The steel wire rope passes vertically upward from here and is connected to the lifting hook. To maintain balance, an auxiliary lifting steel wire rope is installed between the inlet short pipe, motor lifting ring screw, and lifting hook.
(3) Horizontal pump units with intermediate variable speed devices such as couplings should be lifted separately.
(4) The part where the steel wire rope comes into contact with the pump body should be protected with soft cushions to prevent damage to the appearance of the pump or cutting of the steel wire rope.
(5) When lifting a vertical pump, it should be lifted at two positions near the volute side of the motor support and pump bracket. Try lifting first, and if the whole machine is unbalanced, adjust the lifting position again.

2. Installation

(1) Pre installation inspection
The pump has been inspected and tested before leaving the factory, and in order to ensure its good working condition, it must be installed correctly. Before installation, the model and parameters of the equipment should be checked according to the packing list to ensure they are correct, the components are complete and intact, and the accompanying technical data and quality certificates are complete. After verifying that there are no errors, one should carefully read the relevant technical materials, especially this user manual, and master the relevant technical requirements and operating essentials before proceeding with installation.
(2) Pump installation alignment
The horizontal pump unit should be installed using the secondary grouting method. After installation, the centerline of the unit should be consistent with the centerline of the foundation; The deviation between the center height of the unit and the design value should not exceed ± 2mm, and the horizontal tolerance of the unit is 0.1/1000.
For pump units that use coupling direct transmission, the coaxiality of the unit is generally ensured by aligning the coupling. There are two methods for aligning the coupling: one is to use a knife edge gauge and a plug gauge to match. Use a knife edge ruler to align the outer circle of the coupling, ensuring that each pair of couplings is level in all directions, and the maximum error δ should not exceed 0.1mm [Figure 3a]. Check the gap between each pair of couplings with a feeler gauge, and the maximum error Δ (Δ=81-52) should not exceed 0.1mm [Figure 3b]. Another method is to use a magnetic dial gauge with a feeler gauge to align the coupling. First, install the magnetic dial gauge and fix it on the outer circle of one side of the coupling, then rotate it. Then place the dial gauge probe on the outer circumference of the coupling and observe that the runout of the dial gauge should not exceed 0.2mm [Figure 3c]. The clearance of the coupling should be measured with a feeler gauge, and the maximum error should not exceed 0.1mm [Figure 3b].

Figure 3 Alignment of Coupling

For belt driven pump units, the parallelism between the pump shaft and the motor shaft should be ensured, usually using a pulley for alignment. For those with a small center distance, a ruler can be used to align with the flat end face of the pulley. When the center distance is large, a pull line can be used to align with the flat belt end face, as shown in Figure 4.
Figure 4
(3) Configuration and requirements of pump inlet and outlet pipe sections
According to the on-site usage situation and the cavitation performance of the pump, there are two types of pump layouts: high-level layout and low-level layout. The pipeline configuration is shown in Figure 5a) and b) respectively.
① Inhalation pipeline
Suction pipe diameter: The suction pipe diameter should be the same as or slightly larger than the pump inlet diameter, in order to avoid cavitation of the pump and prevent sedimentation of the medium in the pipeline.
Suction gate valve: For the convenience of pump maintenance, a suction gate valve with the same diameter as the suction pipe diameter should be installed. An extension joint should be installed between the suction port and suction pipe of the pump for easy disassembly and assembly of the pump.
② Discharge pipeline
Discharge pipe diameter: The discharge pipe diameter is related to the properties of the medium and the settling velocity. In general, the discharge pipe diameter is equal to or slightly larger than the outlet diameter of the pump.
Export gate valve: The export gate valve should have the same diameter as the discharge pipe.
Pressure gauge: located on the straight pipe section between the pump outlet and the first valve.

Figure 5 Pump inlet and outlet pipelines

③ Precautions for pump pipeline configuration

m

The size of the pipe diameter should consider comprehensive factors such as system resistance and critical settling velocity of the medium. The suction pipeline should be as short and straight as possible. At the suction port of the pump, it is best to equip a straight pipe section with the same diameter as the inlet, and its length should not be less than 3 times the inlet diameter. The flow velocity inside the suction pipe is generally 1.5-2.5m/s, depending on the settling flow velocity of the transported medium.

When using a high-level arrangement, the suction pipeline of the pump should avoid forming steam pockets. It is recommended to use a variable diameter pipe with a horizontal upper busbar, as shown in Figure 6.

The busbar in Figure 6 is a horizontal variable diameter tube

④ Installation position of regulating valve

When adjusting the flow rate with a valve, the regulating valve should be located at the pump outlet. It is not allowed to use valves to adjust the population pipeline to avoid cavitation.

(4) Backwash system of desulfurization pump

A backwash system for desulfurization pumps should be installed at the customer's site. Backwash system refers to a flushing system that injects clean water from the pump outlet, flows through the pump chamber and impeller, and is discharged from the pump inlet. After stopping the pump, the pump chamber should be immediately rinsed with clean water to prevent the medium from settling and solidifying, blocking the flow channel, and affecting the next start and operation of the pump. At the same time, it should be ensured that the inlet and outlet valves are reliably closed to avoid the phenomenon of slurry leakage into the pump chamber.

(5) Mechanical seal

The shaft seal of the horizontal desulfurization pump adopts mechanical seal. Mechanical seals have the characteristics of no leakage, long service life, and low power consumption during cleaning.

The mechanical seals used in our factory are manufactured by professional mechanical seal manufacturers and have been installed and debugged before leaving the factory. Customers do not need to debug them anymore. When pumps equipped with water injection and oil injection mechanical seals are not used for a long time, the mechanical seal part should be filled with N46 mechanical oil to prevent rusting of the mechanical seal components.

① Water injection type mechanical seal

Before using the pump with water injection type mechanical seal, the shaft seal water must be connected first, and the pump must be stopped for 3 minutes before the shaft seal water can be turned off. The function of shaft seal water is to block and balance the pressure of the slurry inside the pump, and to cool the mechanical seal components. Recommend customers to use water filled mechanical seals. At present, the water injection type mechanical seal is used as the basic mechanical seal for pumps in our factory. When customers have no special requirements, this type of mechanical seal is always chosen. With the maturity of new mechanical seal products, if customers have no special requirements, water injection type mechanical seals are manufactured with a double end face structure.

The water injection type mechanical seal is equipped with a shaft seal water short pipe and a pressure gauge. Valves should be installed on site to regulate the water pressure of the shaft seal. The pipeline configuration and requirements for shaft seal water are shown in Figure 7, and the pressure of shaft seal water should be calculated according to the following formula.

When the inlet pressure of the pump is Pa=0 (i.e. the inlet pressure is atmospheric pressure). Shaft seal water pressure P=1/2Pm;

When the pump inlet pressure Pa>0, the shaft seal water pressure P=1/2 (Pa+Pa), Pm is the pump outlet pressure.

The mechanical seal part has two exposed pipe joints, with the pressure gauge side as the inlet and the other side as the outlet. The flow rate of the shaft seal water is 0.1-1% of the pump flow rate. When the pump delivery flow rate is high, the smaller value is taken, and when the flow rate is low, the larger value is taken, but the minimum shaft seal water volume is not less than 1 ㎡/h.

Figure 7: Shaft seal water pipe configuration diagram

② Oil filled mechanical seal

Oil filled mechanical seals are suitable for situations where there is no shaft seal water configuration. If the customer has no special requirements, oil filled mechanical seals are manufactured with a double end face structure. Before and during the operation of the pump, check whether the mechanical seal oil chamber and pipeline are unobstructed; Whether the oil level has reached the designated level in the oil cup, otherwise it should be replenished in a timely manner; Check if the oil has deteriorated, and replace it if it has.

③ Waterless mechanical seal

If the customer has no special requirements, waterless mechanical seals are manufactured in a single end structure. Water free mechanical seal refers to a mechanical seal that does not require the injection of oil seal water and lubricating oil during pump operation.

(6) Requirements for filling lubricating oil

The thin oil lubricating oil bracket should be filled with N32 (winter) or N46 (summer) engine oil according to the oil level line before driving. Avoid driving without fuel.

The TL type vertical desulfurization pump should be filled with lithium based lubricating oil No.2 or No.3 into the oil filling cup.

3. Pump adjustment

After the installation and alignment of the pump, it should be checked and adjusted.
(1) The inspection and adjustment of the clearance between the impeller and the front guard plate are described later.
(2) Adjustment of motor direction. The direction of rotation of the motor should ensure that the direction of rotation of the pump is consistent with the specified direction; Do not rotate in reverse, otherwise it may damage other components. When adjusting the direction of the motor, it should be done in a completely disconnected state from the pump (i.e. without coupling pins or belts), and can only be connected to the pump after confirming that the motor direction meets the requirements. Blindly starting the motor is not allowed.
(3) Adjustment of transmission device. For the transmission using elastic sleeve column pin coupling, the column pin and protective cover should be installed properly; For those using belt transmission, the belt should be properly installed, the tension should be adjusted to ensure that each belt has consistent tension, and a protective cover should be installed; If a speed control device is used for transmission, it should be adjusted according to the requirements of the corresponding user manual.
(4) Tighten all fasteners with a wrench.
(5) Clean up the tools and debris placed on the unit to prevent accidents during pump operation.

4. Trial operation of the pump

After installation and adjustment, the pump unit can be put into trial operation. Customers with conditions should first use clean water for trial operation, and then transport the medium after normal operation.
(1) Start up
① Before starting the pump, it must be manually turned according to the regulations and confirmed to rotate flexibly before starting.
② Open the shaft seal water and adjust the pressure to the specified value (for pumps that do not require shaft seal water, this item is omitted). Especially for pumps equipped with water injection type mechanical seals, if there is no dry friction between the shaft seal water dynamic and static rings, the mechanical seal will be instantly burned out. For oil filled mechanical seals, the oil level in the oil cup and the smoothness of the oil circuit should be checked.
③ Fully open the inlet valve.
④ Open the water injection valve to inject water into the pump (the reverse pump does not require water injection).
⑤ Adjust the opening of the outlet valve to 1/4.
⑥ Start the unit. After the speed returns to normal, turn on the outlet pressure gauge. If the pressure is normal and stable, the outlet valve can be slowly opened until it is fully opened or meets the operating requirements.
Attention: Starting the pump with the outlet valve fully open will cause motor overload; Using a small inlet valve to control the flow rate can cause pump cavitation and should be avoided.
(2) Operation
After normal operation, the following should be observed:
① Whether the shaft seal water or lubricating oil supplied to the mechanical seal is normal, and whether the temperature rise of the mechanical seal is ≤ 35 ℃ and the maximum temperature is ≤ 75 ℃.
② Whether the flow rate and head of the pump are stable and meet the process requirements.
③ Is the current stable.
④ Is there any abnormal noise or excessive noise from the crew.
⑤ Is the shaft seal leaking normally (dripping). Mechanical seal specification size>50mm, leakage rate ≤ 3ml/h; Mechanical seal specifications and dimensions are greater than 50mm, with a leakage rate of ≤ 5ml/h. It is recommended to use drip sealing without forming a line.
⑥ Bearing temperature rise ≤ 35 ℃, maximum temperature ≤ 75 ℃.
⑦ The vibration value should be kept within the specified range.
(3) Stop the pump
① Close the pump outlet valve.
② Stop the machine.
③ Activate the backwash system. The flushing time should ensure that the sediment in the slurry inside the pump is thoroughly flushed to prevent it from solidifying and affecting the next start and operation of the pump.
④ Close the shaft seal water.
⑤ Close the inlet valve of the pump.
Attention: Never stop the pump when the outlet valve is fully open, otherwise it may cause water hammer and damage to the pump or fittings.

Common faults and their solutions

The common faults and troubleshooting measures of the pump are shown in Table 1.

Table 1 Common faults and troubleshooting methods

Serial number	Failure mode	Root cause analysis	exclusion method
1	The pump does not produce water, and the pointers of the pressure gauge and vacuum gauge jump violently	The suction pipe is not filled with water	Fill the pump with water
		Blockage of suction pipeline or insufficient opening of valve	Open the inlet valve and clear the blocked parts of the pipeline
		Serious air leakage at the inlet pipeline and instrument of the pump	Block the leaking area
2	The pump is not producing water, and the vacuum gauge shows pressure	The imported valve is not open or has been clogged	Open the valve or clear the sediment
		Excessive resistance or blockage in the suction pipeline	Improve the design of suction pipelines or dredging
		The water absorption height is too high	Reduce installation height
3	The pump is not producing water, and the pressure gauge shows pressure	The resistance of the water outlet pipeline is too high	Check and adjust the water outlet pipeline
		Impeller blockage	Clean the impeller
		Speed is not enough	Increase pump speed
4	The pump is not rotating	The snail shell is silted up by solid sediment	Remove blockages
		The pump outlet valve is not tightly closed, causing slurry to leak into the pump chamber and settle	Repair or replace the outlet valve, remove sediment
5	Insufficient Flow Rate	Impeller or inlet/outlet pipeline blockage	Clean the impeller or pipeline
		Severe impeller wear	Replace the impeller
		Speed below the specified value	Adjust speed
		Unreasonable installation of the pump or leakage at the inlet pipe joint	Reinstall or block the air leakage
		The conveying height is too high, and the resistance loss inside the pipe is too large	Reduce the conveying height or decrease the resistance
		The inlet valve is opened too small	Open the valve appropriately
		Unreasonable pump selection	Re select

continued table

Serial number	Failure mode	Root cause analysis	exclusion method
6	The motor of the pump is overloaded	The pump head is greater than the required head for the operating condition, and the operating condition point is shifted towards a higher flow rate	Turn down the outlet valve, cut the impeller or reduce the speed
		When selecting the motor, the specific gravity of the medium was not taken into account	Re select the motor
7	The internal sound of the pump is abnormal, and the pump does not produce water	Excessive resistance in the suction pipe	Clean the suction pipeline and gate valve
		Suction height too high	Reduce the suction height
		Cavitation occurs	Adjust the water outlet and close it to operate within the specified range
		There is air entering the inhalation port	Block the leakage point
		The temperature of the liquid being pumped is too high	Reduce liquid temperature
8	Pump vibration	Pump cavitation occurs	Pull out the water valve, lower the installation height, and reduce the inlet resistance
		Impeller single blade channel blockage	Clean the impeller
		The pump shaft and motor shaft are not concentric	Find the correct one again
		Loose fasteners or foundation	Tighten the bolts and reinforce the foundation
9	Bearing overheating	Cooling water not turned on	Turn on the cooling water
		Poor lubrication	Adjust the oil level according to the instructions
		Lubricating oil is not clean	Clean the bearings and change the oil
		The direction of the thrust bearing is incorrect	In response to the import pressure situation, the direction of the thrust bearing should be adjusted
		There is a problem with the bearing	replace the bearing
10	Mechanical seal leakage	Friction pair damage	Replace the mechanical seal
11	Pump oil leakage	The oil level is too high	Reduce the oil level
		Adhesive failure	Replace the rubber parts
		Assembly issues	Adjust assembly
12	Pump head leakage	The rubber parts are not pressed properly	Reinstall or tighten

Maintenance and disassembly of pumps

To ensure the safe and reliable operation of the DT series desulfurization pump, and to fully utilize the equipment's efficiency, proper daily maintenance and disassembly methods are crucial. For this purpose, we have taken into account the characteristics of the DT series desulfurization pump. The following maintenance and disassembly requirements are hereby proposed for customers' reference.

1. Maintenance and upkeep

The DT series desulfurization pump has been adjusted before leaving the factory, and customers do not need to disassemble and inspect unused pumps within 6 months after purchasing. Just check whether the rotation is flexible, whether there is rust, and whether there is oil filling.

(1) Keep the equipment clean, dry, free of oil stains, and leak proof.

(2) Check the oil level in the bracket daily to ensure it is appropriate. The correct oil level should be near the oil level line and should not exceed ± 2mm.

(3) Regularly inspect the operation of the pump for any abnormal sounds, vibrations, and leaks, and promptly address any issues found.

(4) It is strictly prohibited to operate the pump in an evacuated state, as it not only vibrates violently but also affects the service life of the pump. Special attention must be paid.

(5) It is strictly prohibited to enter metal objects and large solid objects that exceed the pump's allowed passage inside the pump, and it is also strictly prohibited to enter flexible materials such as rubber, cotton, plastic cloth, etc., in order to avoid damaging the flow components and blocking the impeller channel, which may prevent the pump from working properly.

(6) Regularly check whether the pressure and flow rate of the shaft seal water are appropriate, and whether the oil has reached the specified oil level in the oil cup. Methods such as checking the opening of the shaft seal water pipe valve or detecting the temperature of the mechanical seal can be used. When the temperature is high, it indicates insufficient water supply or inappropriate oil level.

(7) To ensure the high-speed operation of the pump, it is necessary to regularly adjust the clearance between the impeller and the volute (after a period of use, under constant operating conditions, when the current slowly decreases) to maintain it between 0.75-1.00mm. The gap is usually adjusted before leaving the factory. If it is found that the gap does not meet the requirements, it should be adjusted; If problems are found during operation, the machine should also be stopped for adjustment. Adjust the pump according to the following method:

① Loosen the clamp nut of the bracket cover.

② Loosen the adjustment screw of the bearing housing.

③ Uniformly tighten the bearing box compression nut to move the rotor towards the pump head, while tightening and turning until the disc stops moving. Pay attention to the direction of the turning gear, which should be in accordance with the working direction of the pump.

④ Measure the gap δ=a between the bearing box flange and the bracket end face with a feeler gauge. At this point, the gap between the impeller and the front guard plate is 0.

⑤ Loosen the compression nut of the bearing box;

⑥ Uniformly tighten the adjustment screws of the bearing box to move the rotor towards the motor direction. Use a feeler gauge to check the gap δ until δ=a+(0.75-1.00) mm (take the larger value for large pumps), and pay attention to the uniform and consistent gap.

⑦ Tighten the bearing box compression nut and the bracket cover compression nut to completely fix the axial position of the rotor.

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(8) Regularly check that the maximum bearing temperature should not exceed 75 ℃.

(9) After running continuously for 800 hours, the lubricating oil should be completely replaced once.

(10) The standby pump should rotate 1/4 turn per week to evenly distribute static loads and external vibrations on the shaft.

(11) If the shutdown time is long, the sediment in the pump should be flushed with backwash water before starting again.

(12) Regularly check the looseness of the support mechanism of the inlet and outlet water pipeline system to ensure that the support is secure and the pump body is not subjected to support force.

(13) Regularly check the fastening of the pump on the foundation. The connection should be firm and reliable.

(14) Special attention: For newly installed or overhauled pumps, it is necessary to first test the direction of the motor before threading the coupling pin. Drive with a belt, test the direction of the motor before installing the drive belt, and do not reverse the pump driven by the motor. However, it is allowed for the liquid in the pipe to reverse and cause the pump to reverse when the motor is powered off. However, it should be noted that when the height difference is particularly large (≥ 80m), it is also necessary to prevent the backflow of water from causing the pump to suddenly reverse.

(15) Before starting the pump, the shaft seal water should be opened first, and then the pump should be started;; Stop the pump for 3 minutes before closing the shaft seal water.

2. Disassembly and assembly

2. Disassembly and assembly

Before assembly, the pump should undergo a comprehensive inspection of all parts, clean them thoroughly, and check whether the parts meet the requirements for use; If the parts are damaged, they must be repaired and replaced with new parts before assembly can proceed.

Assembly sequence and basic requirements for assembly:

(1) Assembly of rotor components

The lubrication system uses thin oil.

① Precautions for bearing assembly

a、 Bearings that have been verified as qualified must be used.

b、 Check the inner diameter, outer diameter, width, parallelism and surface roughness of the two end faces of the bearing raceway, as well as whether there are defects such as rust and spots, and whether the rotation is flexible.

c、 For angular contact bearings and double row self-aligning bearings, it is necessary to check the bearing clearance separately, find the center of the ball raceway, and determine whether to add pads based on the height of the inner ring relative to the outer ring. After adding pads, the thickness should be determined according to the standard clearance of the bearing. The radial thrust bearing shall not be installed in reverse.

d、 When assembling detachable (inner and outer ring separated) bearings, they must be installed according to the alignment marks on the inner and outer drawings, and must not be installed randomly.

e、 For bearings with adjustable heads, the numbered end should be facing outward during assembly for easy identification.

② Shaft assembly

a、 To avoid biting with the mating surface, a layer of lubricating oil should be applied to the installation surface in advance before assembly to protect the shaft hole from damage.

b、 The bearing installation adopts the hot installation method, which means that the bearing is placed in a heating box containing engine oil and heated to 80-100 ℃ with the oil. The mating surface should be completely immersed in oil, and a thermometer should be placed inside the oil tank to strictly control the temperature adjustment to not exceed 100 ℃. After hot installation, it should

Natural cooling is not allowed, sudden cooling is not allowed to avoid damage or deformation of parts.

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c、 First install the rear bearing, then install the gear sleeve and round nut and tighten the bearing.

d、 Check if the bearing is tightly attached to the shaft shoulder and if it rotates smoothly and flexibly. Then install the bearing box. The assembly of the bearing box adopts the hot installation method, with the same requirements as above.

e、 Finally, install the front bearing with the same requirements as above.

f、 Install the sealing ring on the bearing box.

g、 The other components of the shaft section will be installed in sequence according to the diagram after the main shaft assembly and bracket are installed.

(2) Assembly of the bracket section

① First, clean the dirt in the oil tank of the bracket body and wipe the bearing holes clean.

② After cleaning the joint surface of the bracket cover of the bracket body, the size of the bearing hole should meet the tolerance of the drawing and be allowed to be within ± 0.015mm. The thickness of the added paper pad should be determined (when adjusting the thickness, it should not exceed three layers of pads at most).

③ Install the hexagonal plug and oil gauge in the oil tank, and apply red paint on the oil gauge pan by drawing a horizontal line of -0.2-0.5mm through the center of the circle to indicate the oil gauge.

④ Install oil tank cooler components and water cooling chamber cover (with a 2mm rubber pad underneath the cover). Note: Some pumps do not have this cover.

⑤ Lift the two ends of the spindle and install the spindle components into the matching holes of the bracket. Lift the bracket cover, apply oil resistant sealant on the green shell paper of the bracket joint surface, and then close the bracket cover. Reserve a gap of 3mm between the inner end face of the bearing box flange and the end face of the bracket. Insert the taper pin and pre tighten the bolt.

⑥ Install oil seal on the front axle pressure cover, pad with green shell paper, and connect it to the bracket with screws on the shaft.

⑦ Check the gap size between the bearing cover stop and the bearing box stop. The height of the cover stop can be repaired, or a pad can be added to ensure a tight fit between the cover and the bearing. After processing, the rear axle pressure cover is equipped with an oil seal, padded with green shell paper, installed on the shaft, and connected to the bearing box with bolts.

⑧ Install the water deflector and remove it. When installing and disassembling the ring, a small amount of lubricating oil should be added to the bolt holes, and the disassembly ring should be tightly pressed against the water stop ring.

⑨ Install the adjusting bolts and fastening screws on the bearing box.

⑩ Install a magnetic dial gauge on the shaft to check the coaxiality and perpendicularity of the semi-circular positioning hole and end face connected to the bracket and rear pump housing with the shaft rotation center, which should not exceed 0.25mm.

① Install pump couplings or pump pulleys. To protect the mechanical seal from damage caused by impact force, it is necessary to first insert the pump coupling or belt before installing the mechanical seal. If the installed pump is equipped with a mechanical seal, the pump head and mechanical seal should be removed first, then the pump coupling or pulley should be inserted, and finally the mechanical seal and pump head should be restored. Otherwise, the hammering force may cause the dynamic and static rings of the mechanical seal to break.

(3) Mechanical seal installation

① Check the mechanical seal model according to the drawings or instructions and prepare all relevant accessories.

② Clean the stuffing box shaft seal cavity, stopper, and lining plate thoroughly.

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③ Tighten the O-ring seal between the packing box and the lining plate with hook bolts.

④ Install the mechanical seal knob into the packing box body, install the mechanical seal cover bolt, and do not tighten it.

(4) Installation of stuffing box and rear guard plate

① Install the packing box onto the bracket.

② Install the sealing ring between the packing box and the rear guard plate into the groove.

③ Use lifting tools to lift the rear guard plate, install it on the packing box, and tighten it with hook bolts.

(5) Install impeller and volute shell

① Apply lubricating oil to the T-shaped thread of the impeller, install the impeller on the shaft, tighten it, and compact the clearance sleeve.

② Tighten the mechanical seal gland bolts.

③ Install the rear protective plate sealing ring.

④ Lift the snail shell, assemble it on the rear guard plate, and connect the bolts.

(6) Install short pipes for import and export

Place 3mm thick rubber pads at the inlet and outlet of the snail shell, tighten the bolts, and check if the rubber pads are tightly compressed. If not tightened, the rubber pad should be thickened.

(7) Assembly of other parts

① After aligning the motor and pump, check the direction of rotation of the motor. If there are no errors, then install the coupling pin and pin rubber ring or belt.

② Install the coupling cover or pulley cover.

(8) Trial operation

During the trial operation, attention should be paid to detecting the leakage, vibration, temperature rise, etc. of the pump.