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1、 INSTALLATION AND OPERATION TECHNICAL MANUAL FOR CRYOGENIC-LIQUID PUMPHangzhou Tailian Gas Equipment Co., Ltd.Address: No. 186, Fangjiatang, Moganshan Road, Gongshu, Hangzhou, Zhejiang, ChinaTel: (0571) 88190806Fax: (0571) 88192468ContentsI. Description2II. General3III. Technical parameters3IV. Conf
2、iguration and components3V. Installation4VI. Starting8VII. Stopping pump9VIII. Maintenance9IX. Fault analysis14X. Commitment and responsibilities15XI. Product technical specification16XII. Packing list17XIII. Flow chart and foundation drawing18XIV. Assembly drawing of transmission box19XV. Part list
3、 of transmission box20XVI. Assembly drawing of pump head21XVII. Part list of pump head22XVIII. Electric control chart23XIX. Cryogenic-liquid pump inspection report24XX. Cryogenic-liquid pump delivery inspection report25XXI. Product certificate25AdviceElectrical wiring project should be carried out a
4、ccording to the electrical equipment technical standards or rules. Wrong wiring and the operation by non-professional personnel might cause electric shock and fire.While there is no safety measures or any other type of liquid is used to this system, fire, explosion, fatal injury or suffocate might p
5、ossibly caused. As for any cryogenic liquid or gas under high pressure, if the safety regulations are not obeyed, serious injury or death might be possibly caused.I. Description1. We express sincere gratitude for your purchasing our products. For ensuring you shall use the pump freely, we have carri
6、ed out elaborate design and manufacturing; however, some certain unexpected accident may also occur due to improper installation and operation. Thus, the instructions in this manual shall be noticed before its installation and operation for your safely and effectively operating this pump. In additio
7、n, this manual shall be carefully kept.2. This manual shows safety matters to ensure you shall operate the pump safely and correctly to prevent any injury to you and others or damage in advance. Once a wrong manipulation method is implemented, its consequences may be divided into two parts, namely “
8、warning” and “notice”; either of them is related to safety. Anyone should abide by the rules.3. The strict degreasing and drying treatment shall be carried out to all parts in the pump head cold end during the maintenance and repair processes because all materials the cold end of this pump are appli
9、cable for the operating conditions of oxygen medium and cryogenic media.4. If the pump is not immediately installed for application, it must be kept at a dry place to prevent the erosion of oil contamination, moisture and dust.5. While a pump is delivered and the strict degreasing and drying treatme
10、nt shall be carried out to all parts in the pump head cold end, users do not need to clean it before installation. However, if the adhesive bands in the vapor inlet and return ports and the liquid discharge port in the cold end of the pump head have been damaged, the degreasing and drying treatment
11、shall be carried out again.Note: adhesive bands in the liquid inlet and vapor return port of the cold end of the pump head may only be removed while the system is installed; thus, the oil contamination or dust and moisture may be prevented to result in erosion to any part inside the pump.II. General
12、This type of reciprocating cryogenic-liquid pumps is applicable for the pressurization filling bottle system and the pipeline gas supply system, whose operation is to fill pressurized and vaporized vapor of cryogenic liquid from the storage tank into bottles. Its performance is stable; the operation
13、 is easy and the maintenance is convenient. Under the good installation conditions, the pump start-up time is about 5 10 minutes. The pump head can be removed independently, which may be assembled after maintenance. Such operation process may be carried out within 2-4 hours.III. Technical parameters
14、Conveying media: Liquid oxygen, liquid nitrogen, liquid argonType: Horizontal, single cylinder, piston pumpFlow rate: 300600L/hMaximum outlet pressure: 16.5MPaMinimum inlet pressure: 0.02MPaInput power: 380V, 3-phase, 50HzMotor operating speed: 125-1250rpmMotor power: 7.5KW(Pumps with special flow r
15、ate and pressure requirements can be customized according to users needs.)IV. Configuration and componentsThe pump consists of a motor, the pulleys, a transmission box and a pump head, which are assembled in a public base.The pump driven end is to transform the rotation movement of the motor into re
16、ciprocating motion and speed reduction and transfer the output power of the motor to the compression end of the pump head. The power conversion and reduction of speed may be carried out through the parts of the motor, such as a pulley, a drive shaft, an eccentric wheel, a connecting rod and a crossh
17、ead. The shaft, the eccentric wheel and the bearing structure in the transmission system are the splashing immersion oil type so that the life of the power system may be greatly extended. The lubricating oil inside the transmission box is N46 machine oil, which has been adjusted well before delivery
18、. When the environment temperature is below -10C, the lubricating oil may be replaced with oil with a low freezing point by users. In general, the lubricating oil shall be replaced once each year. The lubricating oil level shall be appropriately at two-thirds of the oil level mirror. Its structure a
19、nd components are shown in Figure 3. Stepless speed regulation is completed by an electromagnetic control motor.The compression end of the pump head is made up of a cylinder liner, a pump body, a piston component, a sealing device, a liquid inlet valve and liquid outlet valve. This pump is equipped
20、with a piston ring and a guide ring made of good wear resistance material; thus, its operating life is long. The sealing device is made up of sealing elements with good sealing performance to ensure that the pump shall be in reliable and free-fault operation mode under the normal operating pressure.
21、 The pump head is equipped with a vacuum jacket for thermal insulation. The clearance between the piston and the pump end cover is 1.5mm. The details are shown in Figure 4.V. InstallationInstallation rules here is only suitable for being a regular operation norm; therefore, there are only some key i
22、ntroductions in all kinds of different conditions. Such installation norm is only related to some equipments, pipelines and valves in any pump installation system; on the other hand, installation rules are different for the needs of the various users. As shown in the installation figure, the install
23、ation project shall be correctly designed according to the specific situations of the system and the users operating conditions by the installation department to ensure the safety and reliable operation of the entire system. The flow process system recommended by us is shown in Figure 1.1. Pump inst
24、allation conditionsThe pump installation foundation should above the ground by 50mm, and one canopy shall be built. The installation dimensions are shown in Figure 2. The operation space shall be provided around the pump.2. Storage tankThe joint for liquid drainage from the storage tank to the pump
25、shall be at the bottom of storage tank; moreover, the distance between the pump and storage tank shall be short as can as possible. No siphon shall be used; otherwise, vapor or gas in such pipeline might form gas resistance so that the pump might not be put into operation. The diameter of the liquid
26、 drainage joint of the storage tank shall meet the flow rate requirement; however, it shall not be less than the diameter of the pump suction joint.3. Pipeline layoutPipeline layout shall be designed elaborately so as to prevent any stress or external force being transferred to the operating pump. T
27、he shrinkage or expansion due to the temperature difference effect shall also be taken into account. Therefore, the compensation of the pipelines shall be taken into account for installation, as shown in Figure 1.Warning: All the pipeline parts which may be cut off with valves shall be equipped with
28、 relief valves to prevent any additional overpressure due to accumulated cryogenic liquid vaporization or misoperation.4. Suction pipelineThe suction pipeline between the liquid outlet and inlet in the storage tank shall be short as can as possible (in general, 0.5m); on the other hand, the opening
29、diameter shall be large as can as possible to lower the loss of vaporization and pipeline pressure loss or cooling power loss. Pipelines shall be maintained to be continuously downwards inclined (from the storage tank to the pump) so that the vapor formed within the pipelines may return the storage
30、tank. With taking the loss of vaporization into account, the volume of a valve or joint shall not be too large; otherwise, the additional heat might be introduced.Because liquid delivered through the pump is in saturated state in most cases, some liquid may be vaporized to form vapor cavity due to p
31、ressure loss while liquid is transferred from the storage tank to the pump. Thus, the correct installation of the suction pipeline of a pump shall be extremely important. As shown based on our survey results, the cause for improper operation of most cryogenic pumps is incorrect installation of their
32、 suction pipelines, namely one enough positive pressure head (NPSP) may not be maintained or the storage tank situations may not be known.The net positive suction head (NPSP) is a energy head; the cavitation in any pump may be prevented only when such value is more than the flowing medium steam pres
33、sure; moreover, some possible means for increasing RMS of NPSP are listed as follows:A.To increase the level difference between the storage tank and the suction port;B.To lower liquid temperature (the vapor phase inside the storage tank may be vented to lower the hot vapor quantity);C.To increase th
34、e original pressure of the storage tank (such case is only applicable for increasing pressure under the liquid-vapor balance conditions); D.Good thermal insulation wrapping shall be carried out to the liquid inlet pipeline and the vapor return pipelines;E.Under the same external conditions, a good p
35、ump structure results in less loss of pressure; andF.To decrease the number of elbows in the pipelines and use the larger corner radius as can as possible.5. Vapor return pipelineThe pipeline between the storage tank vapor return port and the pump vapor return port shall be short as can as possible;
36、 moreover, the opening diameter of the vapor return joint of the storage tank shall be more than that of the vapor return joint of the pump. The tapered shrinkage transitional connection may be used. There shall be no siphon phenomenon between the vapor return pipelines of the storage tank. The pipe
37、line shall be maintained to be continuously downward inclined (from the pump to the storage tank) to prevent any gas resistance phenomenon. With taking the cold loss due to the vaporization inside the pipelines, the suction pipeline and the vapor return pipeline between the storage tank and the pump
38、 shall be bandaged with good thermal insulation material. A vent valve shall be equipped in the vapor return pipeline to check the operation state of the pump, which shall be installed in the relatively high location in the vapor return pipeline as can as possible. The number of elbows in the vapor
39、return pipeline shall be lowered as can as possible and the relatively large radius shall be taken. In addition, they shall be insulated.6. Discharge pipelineThe diameter of the pipeline to the manifold shall be the same at least as that of the liquid discharge joint of the pump, which is generally
40、more and whose length is 3 meters at least. There shall be one vent valve in the liquid discharge pipeline so that some vapor may be vented properly according to the pre-cooling situation to accelerate the starting of the pump. For ensuring the safety of the system, one pressure switch had better be
41、 equipped in the discharge pipeline. While the operating pressure is more than the setting pressure, the pressure switch can automatically cut off power supply and interlock the motor for stopping the pump. Thus, your system shall be more safety.7. Control and safetyThis manual suggests some protect
42、ion devices shall be used to ensure the safety of the system.A. A high pressure check valve and a pressure gauge shall be equipped at the pump outlet. Any abnormal pressure may be found early and the correct direction of the check valve (as shown by the arrow in the check valve) may be found. The ch
43、eck valve may effectively prevent moisture and air ingression into the system filling bottles and ensure the gas purity. B. Besides the relief valve preventing too high pressure, the system also is equipped with a pressure sensor and a pressure switch. When the pressure is too high, the pressure swi
44、tch will shut off the motor power to stop the pump automatically.C. A temperature indication interlocking control motor device is equipped after the vaporizer to prevent cryogenic vapor flowing into gas bottles and ensure the safety of gas bottles. Especially, the safety can be ensured in north and
45、lower ambient temperature areas.D. The speed controller is used to realize the remote control to the pump output for easy management.E. A emergency manual cut off switch is equipped in the filling bottle to cut off the power source of the pump or a pressure interlocking switch may cut off power supp
46、ly automatically. Thus, your system shall be more safety.Warning: because this pump is a positive flow rate pump and if the pressure pipeline is closed, the pressure more than 20MPa may be built so that the system might be extremely possibly damaged. Thus, the pressure pipeline shall be equipped wit
47、h a relief valve.8. FoundationThe installation dimensions for anchor screws are shown in Figure 2.9. Inspection before starting the pumpAll pipelines, accessories, bolts and electrical joints shall be checked to ensure they shall be ready. All pipeline joints shall be checked to ensure their sealing situations shall meet the requirements.Rotation direction: The pump can be in two-direction operation mode. For ensuring longer life of the crosshead, the sliding sleeve and the connecting r
