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Views: 48 Author: Tuohai Pump Publish Time: 2022-03-24 Origin: www.txtuohai.com
★ Submersible Axial Flow Pump Manufacturing and Assembly Process |
At present, submersible axial flow pumps on the market can be divided into QZB type and QHB type, which can be used for irrigation and drainage of farmland, industrial and mining docks, urban construction, and water supply and drainage of power stations.
QZB series submersible axial flow pump has the characteristics of simple structure, convenient installation, maintenance, etc. It is suitable for low head and large flow occasions.
QHB type submersible mixed-flow pump has high efficiency and good cavitation performance and is suitable for occasions with large changes in water level and high lift requirements.
According to the requirements of users, the QZB series submersible axial flow pump adopts 3D fluid flow field dynamics digital simulation technology in the design of the hydraulic model. The designed hydraulic model has high efficiency and has the ability to pass through particles of a certain diameter so that the pump can operation in harsh environments safely and reliably
The overall structure of the QZB series submersible axial flow pump adopts a mechatronics design, which is compact and easy to use.
The QZB series submersible axial flow pump has various protection functions: water leakage alarm device in the wiring cavity of the unit, used to detect the sealing condition of the wiring cavity, overheat protection device in the stator winding, anti-condensation device for the stator winding, bearing temperature sensor, there is a leakage alarm device in the pump oil chamber.
QZB type and QHB type submersible axial flow pump is a new product that integrates traditional axial flow pump and electric motor, which can be submerged in water for a long time and has many advantages.
● The pump runs submerged in water, which greatly simplifies the engineering of the pump station geotechnical and building structure, reduces the installation steps and the use area of the pump station, and can save 30-40% of the total project cost.
● The water pump and the motor are integrated, no shaft alignment process is required, and the installation is convenient and fast.
● Low noise, no high temperature in the pumping station, which improves the working conditions, and can also build a fully underground pumping station as required to maintain the environment on the ground.
● Easy to operate, no need to lubricate the rubber bearing of the water pump before starting the machine, and it can realize remote control and automatic control.
● It can be used in areas along rivers and lakes where the water level fluctuates greatly and can solve the waterproof problem of pump motors when building pumping stations in these areas.
QZB and QHB submersible electric pumps can be used for irrigation and drainage of farmland, industrial and mining docks, urban construction, and power station water supply and drainage.
Conditions of use: The conveying medium is water or other liquids with similar physical and chemical properties to water. The temperature of the conveyed liquid is 40℃, and the PH should be between 5-9.
QZB submersible axial flow pump is suitable for low head and large flow occasions.
QHB type submersible mixed-flow pump has high efficiency and good cavitation performance and is suitable for occasions with large changes in water level and high lift requirements.
Many advanced technological means are used in the manufacture of submersible axial flow pumps.
The impeller of the submersible axial flow pump adopts an advanced hydraulic model design, and the dynamic balance of the impeller adopts the Shanghai Shenguang balance testing machine to carry out the balance test so that the dynamic balance accuracy reaches G6.
The lead wire of the submersible axial flow pump motor needs special processing. The submersible axial flow pump has been running underwater for a long time, and the working conditions are bad. In addition to other unfavorable factors, the cable will be accidentally damaged and the motor will enter the water.
Our submersible cables are specially vulcanized and sealed to eliminate the hidden danger of damage to the pump due to cable breakage, the pump can run for a long time at 20 meters underwater, which fundamentally eliminates the way for water to enter the motor.
The submersible axial flow pump rotor shaft and bearings are assembled by hot pressing. The main components and key components are processed in the CNC machining center, and the performance test is carried out in the quality inspection center.
The submersible axial flow pump casting uses advanced mold manufacturing technology, with accurate dimensional accuracy, smooth surface of hydraulic components and vane flow channel components, and high hydraulic efficiency, so that the components fully meet the design requirements during the manufacturing process.
The submersible axial flow pumps should can be used to pump media containing a small number of floating objects or impurities and running normally.
The water inlet chamber of the submersible axial flow pump is equipped with a conical water inlet, which is equipped with an anti-vortex flow device, which can ensure that the suction inlet has an ideal inlet flow state.
The submersible axial flow pump can work normally within the specified range and has a stable head and flow. When the pump runs at any point on its characteristic curve, the motor power is not overloaded.
All pressure-bearing parts of the submersible axial flow pump are subjected to an air pressure test, and the test pressure is 1.5 times its design pressure, but not less than 0.4Mpa, which lasts for 5 minutes without leakage.
After the submersible axial flow pump is sealed and assembled, a 0.4MPa air pressure test is carried out, and there is no leakage for 5 minutes.
The surface of the submersible axial flow pump is bright and free of contamination, bumps, cracks, etc. The surface of the components is sprayed with epoxy resin anti-corrosion paint after derusting and degreasing.
The impeller of the submersible axial flow pump adopts a semi-adjustable structure, and the gap between the impeller blade and the hub is uniform.
The static balance test of the impeller is carried out before assembly, and its unbalance is within the allowable range, and the balance accuracy is G6.3.
The submersible axial flow pump consists of a submersible motor and a water pump to form an electromechanical integrated structure. The coaxial structure of the pump and the motor is compact and easy to use. The blades of the pump impeller are semi-adjustable and evenly distributed on the impeller hub.
The fixing method between the impeller and the shaft of the submersible axial flow pump has anti-loose and locking functions, which can be easily disassembled and maintained.
The internal motor of the submersible axial flow pump is equipped with an anti-condensation device to ensure that the insulation of the motor is guaranteed to be above 300MΩ, so that the submersible pump can be started smoothly after a long-term shutdown.
The submersible pump is equipped with a winding temperature sensor, winding water leakage sensor, bearing temperature sensor, mechanical seal with water leakage sensor, etc. All protection functions are protected by special protectors.
The submersible axial flow pump can operate continuously in the medium of ≤40℃, and the operation mode is continuous operation, intermittent operation or recovery operation after long-term stop. The submersible pump adopts a squirrel cage asynchronous motor, and the protection level is IP68. The motor is designed according to the damp heat type, and has the properties of moisture-proof, mildew-proof and salt-fog resistance, and can still maintain excellent moisture resistance, pressure resistance and starting performance after long-term shutdown. Submersible axial flow pumps allow more than 15 starts per hour.
The cooling method of the motor is divided into two ways: inside and outside. The design of the inner air duct, that is, the rotor has its own fan, and there is an axial air duct in the yoke of the stator core, so that the heat generated on the motor rotor and the heat generated at the end of the stator winding can be transmitted through the inner air duct to the inner part of the stator core. The heat generated (including the straight part of the stator winding and the iron core) exchanges heat with the water in the outer cooling water channel by means of the frame wall, thereby cooling the motor. The casing shall not have leakage after 0.4Mpa static pressure test.
The submersible pump is equipped with a control cable and a power cable. In order to prevent the hidden danger of the medium entering the motor due to the failure of the sealing of the cable, the submersible pump adopts the power cable terminal board of the cable inlet box in structure to completely seal the inlet box and the motor. Separated, the external liquid cannot enter the motor, and at the same time, it can facilitate the maintenance of the unit equipment. The cable and wire are sealed with a special vulcanized rubber sealing head, which can be easily replaced and effectively sealed. The cable wire is made of YCW rubber-sheathed cable. The random cable length is 10m, or it can be configured according to user requirements.
In order to ensure the normal and reliable operation of the submersible pump, the pump shaft is equipped with a series-type double-layer independent mechanical seal, and high-quality tungsten carbide mechanical seal is used. The medium used for the mechanical seal is PH5~10, the positive pressure can withstand 1 Mpa, and the negative pressure can withstand 0.5Mpa . The design life of the mechanical seal is more than 12,000 hours. The sealing device operates in the oil chamber, and the sealing contact surface is lubricated by hydraulic action under constant speed conditions.
The lower seal between the pump and the tank has a stationary ring and a forward rotating tungsten carbide ring. The upper sealing device between the oil tank and the motor cavity is equipped with a stationary ring and a forward rotating tungsten carbide ring. The inner interface of the mechanical seal maintains close contact with the spring system by itself. The sealing device automatically compensates for the wear gap, and at the same time facilitates check and replace.
The shaft sealing system of each pump is equipped with an oil chamber. The oil chamber has a certain space to accommodate the expansion of oil caused by temperature changes. The discharge holes and inspection holes are equipped with leak-proof sealing devices and are easy to dredge from the outside.
The insulation grade of the submersible axial flow pump motor winding is F grade and the protection grade is IP68.
The stator adopts F-class insulation, and the maximum temperature rise is 100K in the pumping medium temperature of 40℃.
The motor adopts squirrel-cage induction submersible motor, the protection level is IP68, and the stator adopts F-class insulation.
The vanes of the submersible axial flow pump are made of stainless steel, and the other parts, including the shell, the water inlet, and the guide vane, are made of HT200 cast iron by default. According to customer requirements, stainless steel shell, guide vane, water inlet, and other components can be customized.
The shaft of the submersible axial flow pump is made of stainless steel, and measures are taken to eliminate stress concentration in the structural design, and it is completely separated from the medium.
The mechanical seal of the submersible axial flow pump is designed to operate trouble-free for more than 12,000 hours.
The bearing design life of the submersible axial flow pump can ensure more than 80,000 hours, which can effectively reduce vibration and noise, improve the operational safety and reliability of the submersible axial flow pump, and prolong its service life.
The static seal of the submersible axial flow pump adopts NBR-70 O-ring.
All exposed fasteners are stainless steel.
The submersible axial flow pump must be tested for performance after each is assembled, to ensure that the overall performance of the unit complies with relevant standards and customer requirements.
The test contents include: the flow-head curve, flow-power curve, flow-efficiency curve, and the test report will be provided to the user.
The submersible axial flow pump guarantees a trouble-free running time of not less than 10,000 hours, and the designed service life of the unit is not less than 15 years.
Each submersible axial flow pump has a signal line for control and protection, which is connected to a dedicated control cabinet, which can monitor the pump's overload, phase loss, short circuit, leakage, over-temperature, water immersion, and other faults, and has automatic protection function to ensure the reliable operation of the unit.
Monitoring device:
Motor stator temperature monitoring, with a temperature sensor on the winding coil, and configuration of thermal protection switch, so as to stop when over temperature
The mechanical seal is equipped with functions such as a water leakage alarm.
All of the above functions can be achieved through the protection module.
The installation methods of QZB and QHB submersible axial flow pumps include wellbore type installation, sled type installation, and float type installation.
Wellbore Type Installation
The wellbore installation can be divided into wellbore suspension installation and wellbore floor-standing installation.
The wellbore suspension installation method is mostly used in rainwater pumping stations or sewage pumping stations.
If the pump seat in the middle part of the wellbore cannot bear the load, the wellbore floor-mounted installation method can be selected, and the bottom of the wellbore can bear the weight of the whole device.
Sled Type Installation
The sled installation method is often used in rivers, pools, etc. This installation method directly places the water pump on the bottom of the pool or on the river bank and connects the water outlet pipeline at the end of the water pump outlet. Compared with the wellbore installation method, civil engineering is greatly reduced. cost, reducing the cost of the entire project.
Float-Type Installation
The float-type installation method is mostly used in reservoirs and rivers, etc. If the river embankment is soft and can't use the sled-type installation, the float-type installation method can be used.
In addition, there is an indication of the direction of rotation of the impeller on the outside of the pump, which can be easily operated during installation.
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Tuohai is a leading pump manufacturer in China, provide various submersible pumps in clouding submersible axial flow pump, submersible sewage pump, submersible mixer, mixed flow pump, and other supporting equipments, if there have any needs, please feel free to contact us, we will assure you of our best service at all times.
