Chemical Maintenance Manual Qn1 Sec g 04 Tp 011(104)

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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW

CHEMICAL SYSTEM MAINTENANCE MANUAL

Date: 2008-10-20 No.:QN1-SEC-G-04-TP-011 Rev. : A

QUANG NINH THERMAL POWER JOINT STOCK COMPANY

2 × 300 MW – Anthracite Coal Fired Power Station

Chemical System

Maintenance Manual

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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-011 - 1 - Rev. : A

INDEX

1 OVERVIEW OF CHEMICAL EQUIPMENT AND SYSTEMS ............................................................- 1 -

1.1 FUNCTION OF BOILER FEED-WATER TREATMENT SYSTEM ........................................................................ - 1 -

1.2 OVERVIEW OF BOILER FEED-WATER SYSTEM ........................................................................................... - 1 -

2 MAINTENANCE OF PUMP .....................................................................................................................- 1 -

2.1TECHNICAL SPECIFICATION AND STRUCTURE OF EQUIPMENT ................................................................... - 1 -

2.1.1TECHNICAL SPECIFICATION OF PUMP..................................................................................................... - 1 -

2.1.2 OVERVIEW OF PUMP STRUCTURE AND WORKING PRINCIPLE ................................................................. - 2 -

2.1.3 PUMP CATEGORY ................................................................................................................................. - 8 -

2.1.4 MAINTENANCE PROCESS AND QUALITY STANDARDS OF PUMP.............................................................. - 9 -

2.2 COMMON FAULTS AND TROUBLE SHOOTING OF PUMP ......................................................................... - 18 -

2.3 SPECIAL TOOLS AND SPARE PARTS FOR PUMP MAINTENANCE................................................................. - 21 -

3 MAINTENANCE OF WATER PURIFICATION SYSTEM EQUIPMENT .......................................- 23 -

3.1 TECHNICAL SPECIFICATION AND STRUCTURE OF EQUIPMENT ................................................................ - 23 -

3.1.1TECHNICAL SPECIFICATION OF EQUIPMENT......................................................................................... - 23 -

3.1.2 OVERVIEW OF THE STRUCTURE OF WATER PURIFICATION SYSTEM EQUIPMENT ................................... - 23 -

3.1.3 MAINTENANCE OF WATER PURIFICATION SYSTEM EQUIPMENT ........................................................... - 27 -

3.2 COMMON FAULTS AND TROUBLE SHOOTING OF WATER PURIFICATION SYSTEM ...................................... - 33 -

3.3 SPECIAL TOOLS AND SPARE PARTS FOR MAINTENANCE OF WATER PURIFICATION SYSTEM ...................... - 33 -

3.3.1 AGITATOR OF THE CLARIFICATION TANK AND SPARE PARTS OF MUD SCRAPER: ................................... - 33 -

3.3.2 AIR SCRUB FILTER CHAMBER AND SPARE PARTS AND SPECIAL TOOLS OF ANCILLARY EQUIPMENT: ...... - 33 -

4 MAINTENANCE OF FEED-WATER TREATMENT SYSTEM EQUIPMENT ...............................- 34 -



4.1.2 OVERVIEW THE STRUCTURE OF FEED-WATER SYSTEM EQUIPMENT ..................................................... - 35 -

4.1.3 MAINTENANCE OF FEED-WATER SYSTEM EQUIPMENT ........................................................................ - 40 -

4.2 COMMON FAULTS AND TROUBLE SHOOTING OF FEED-WATER SYSTEM EQUIPMENT ................................ - 45 -

4.3 SPECIAL TOOLS AND SPARE PARTS FOR MAINTENANCE OF FEED-WATER SYSTEM EQUIPMENT ................ - 45 -

4.3.1 LIST OF ESSENTIAL SPARE PARTS (GUARANTEE THREE-YEAR OPERATION PERIOD).............................. - 45 -

4.3.2 LIST OF SPECIAL TOOLS ...................................................................................................................... - 45 -

4.3.3 MANDATORY SPARE PARTS ................................................................................................................. - 45 -

5 MAINTENANCE OF BLOWER.............................................................................................................- 46 -

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5.1TECHNICAL SPECIFICATION AND STRUCTURE OF EQUIPMENT ................................................................. - 46 -

5.1.1 TECHNICAL SPECIFICATION OF EQUIPMENT ........................................................................................ - 46 -

5.1.2 OVERVIEW OF THE STRUCTURE OF BLOWER....................................................................................... - 46 -

5.1.3 MAINTENANCE OF BLOWER............................................................................................................... - 47 -

5.2 COMMON FAULTS AND TROUBLE SHOOTING OF BLOWER ....................................................................... - 52 -

5.3 SPECIAL TOOLS AND SPARE PARTS FOR BLOWER MAINTENANCE............................................................ - 54 -

5.3.1 LIST OF SRD TYPE SPARE PARTS（4 SETS）....................................................................................... - 54 -

6 MAINTENANCE OF HYDROGEN PRODUCTION SYSTEM EQUIPMENT ................................ - 54 -



6.1.2 OVERVIEW OF HYDROGEN PRODUCTION SYSTEM EQUIPMENT STRUCTURE......................................... - 57 -

6.1.3 MAINTENANCE OF THE HYDROGEN PRODUCTION SYSTEM EQUIPMENT .............................................. - 58 -

6.2 COMMON FAULTS AND TROUBLE SHOOTING OF HYDROGEN PRODUCTION SYSTEM EQUIPMENT ............. - 63 -

6.2.1 UNQUALIFID HYDROGEN AND OXYGEN PURITY.................................................................................. - 63 -

6.2.2 ELECTROLYZER LEAKS ALKALI AND GAS SERIOUSLY.......................................................................... - 63 -

6.2.3 THE HYDROGEN PRODUCTION SYSTEM............................................................................................... - 64 -

6.2.4 COMMON FAULTS AND TROUBLE SHOOTING OF DIAPHRAGM COMPRESSOR ........................................ - 64 -

6.3 SPECIAL TOOLS AND SPARE PARTS FOR HYDROGEN PRODUCTION SYSTEM MAINTENANCE ..................... - 66 -

6.3.1 SPECIAL TOOLS .................................................................................................................................. - 66 -

6.3.2 MANDATORY SPARE PARTS ................................................................................................................. - 66 -

6.4 PARTICULAR ATTENTIONS TO HYDROGEN PRODUCTION SYSTEM: .......................................................... - 66 -

7 VALVE MAINTENANCE........................................................................................................................- 68 -

7.1 BASIC PARAMETERS AND MODEL OF THE VALVE .................................................................................... - 68 -

7.1.1 NOMINAL DIAMETER OF THE VALVE ................................................................................................... - 68 -

7.1.2 NOMINAL PRESSURE OF THE VALVE.................................................................................................... - 68 -

7.1.3 APPLICABLE MEDIA OF THE VALVE ..................................................................................................... - 68 -

7.1.4 APPLICABLE TEMPERATURE OF THE VALVE......................................................................................... - 68 -

7.1.5 EXPRESSION METHOD OF VALVE MODEL............................................................................................. - 68 -

7.2 OVERVIEW OF STRUCTURE OF GENERAL VALVE IN WATER TREATMENT PIPELINE SYSTEM ...................... - 72 -

7.2.1 GATE VALVE (Z) ................................................................................................................................. - 72 -

7.2.2 STOP VALVE <J>................................................................................................................................. - 74 -

7.2.3 BUTTERFLY VALVE (D)....................................................................................................................... - 75 -

7.2.4 DIAPHRAGM VALVE............................................................................................................................ - 76 -

7.2.5 BALL VALVE (Q)................................................................................................................................. - 79 -

7.2.6 PRESSURE REDUCING VALVE.............................................................................................................. - 80 -

7.3 MAINTENANCE OF VALVE...................................................................................................................... - 81 -

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7.3.1 MAINTENANCE OF GATE VALVE.......................................................................................................... - 81 -

7.3.2 MAINTENANCE OF STOP VALVE .......................................................................................................... - 83 -

7.3.3 MAINTENANCE OF BUTTERFLY VALVE ................................................................................................ - 85 -

7.3.4 MAINTENANCE OF CHECK VALVE ....................................................................................................... - 87 -

7.4 COMMON FAULTS AND TROUBLE SHOOTING OF VALVES......................................................................... - 88 -

8 CHEMICAL DOSING SYSTEM ............................................................................................................- 88 -

8.1 TECHNICAL SPECIFICATION OF EQUIPMENT ........................................................................................... - 88 -

8.2MATTERS NEEDING ATTENTION DURING MAINTENANCE......................................................................... - 89 -

8.3 DAILY SERVICING PROGRAMMER .......................................................................................................... - 90 -

8.4PRECAUTIONARY SERVICING PROGRAMMER .......................................................................................... - 90 -

8.5MAINTENANCE OF MACHINES ................................................................................................................ - 90 -

8.6 FREQUENT FAILURE AND TROUBLESHOOTING ....................................................................................... - 91 -

9 HLORINE FEEDING SYSTEM OF CIRCULATING WATER...........................................................- 92 -

9.1 TECHNICAL SPECIFICATION OF EQUIPMENT ........................................................................................... - 92 -

9.2 SAFETY MAINTENANCE OF EQUIPMENT................................................................................................ - 94 -

9.3 DISMANTLING AND MAINTENANCE OF EQUIPMENT .............................................................................. - 94 -

9.4 REGULARLY MAINTENANCE OF EQUIPMENT......................................................................................... - 95 -

9.5 COMMON FAULTS AND TROUBLE SHOOTING OF GAS DOSING SYSTEMS................................................. - 97 -

10 WASTE WATER TREATMENT SYSTEM..........................................................................................- 97 -

10.1 TECHNICAL SPECIFICATION FOR EQUIPMENT: ...................................................................................... - 97 -

10.2 INSTALLATION SEQUENCE OF AGITATOR AND SLUDGE SCRAPER OF MECHANICAL ACCELERATING

CLARIFIER................................................................................................................................................... - 98 -

10.3 MAINTENANCE OF INTEGRATED EQUIPMENT....................................................................................... - 99 -

10.4 CAUTIONS FOR OPERATION OF INTEGRATED EQUIPMENT..................................................................... - 99 -

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1 Overview of Chemical equipment and systems

Purification station system is designed in accordance with the capacity of 4 × 300MW

planning generating units, the equipment will be installed in different phases, the treatment

water capacity of 4 × 300MW generating units is about 350 m3/h, and the water treatment

capacity of the current 2 × 300MW project is about 200 m3/h. The mechanical acceleration

clarification tank of the purification station is planned and laid in accordance with the capacity of

4 × 300MW generating units, the current 2 × 300MW project is provided with two mechanical

acceleration clarification tanks and filter chambers with 200% treatement capacity, couplecd

with coagulant dosing system, coagulant aid dosing system and sodium hypochlorite dosing

system

1.1 Function of boiler feed-water treatment system

1.1.1 Demineralized water is provided to the boiler;

1.1.2 Demineralized water is provided to the laboratory, sample analysis system and closed

cycle cooling system and so on;

1.1.3 Demineralized water is provided when the boiler and steam turbine system are cleaned

and washed and the generating units start.

1.2 Overview of boiler feed-water system

1.2.1 According to the quality of water source and form of generating units, the boiler feed-water

treatemtn system is set by two-stage desalination system.

1.2.2 System process: self supply water and professional inflow → activated carbon filter →

cation bed →decarbonizer → middle water pump→ middle water tank → anion bed → mixed

bed → resin catcher→desalination water tank→desalination pump→ (main building).

2 Maintenance of pump

2.1Technical specification and structure of equipment

2.1.1Technical specification of pump

Equipment name Mode or major technical parameter Unit Qty Remark

Raw water booster pump

Q=200m3/h,H=15m

N=15KW, V=400V Set 2

One is in operation and the other is for standby

General service pump

Q=180m3/h, H=65m



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Clear water booster pump

Q=200m3/h,H=35m



Filtered water booster pump

Q=190m3/h, H=35m



Electric fire-fighting pump

Q=600m3/h, H=110m

N=315KW, V=6.60KV Set 1

Fire-fighting pump driven by

diesel fuel

Q=600m3/h, H=110m

N=315KW Set 1


Industrial water pump

Q=110m3/h, H=60m



Living water pump

Q=130m3/h, H=45m



Active carbon filter

backwashing pump

Q=300m3/h, H=30m



Coagulant metering pump

Q=0-85l/h, H=70m

N=0.25KW, V=400V Set 2


Coagulant aid metering pump

Q=0-400l/h, H=50m

N=0.37KW, V=400V Set 2


Filter chamber backwashing

pump

Q=350m3/h, H=35m



2.1.2 Overview of pump structure and working principle

2.1.2.1 Pump is equipment for transportation of liquid and is widely used in water treatment

systems of chemical plant, such as desalination water pump, chemical water pump, industrial

water pump and other clear water centrifugal pumps in the water treatment system, all types of

dosing pumps and metering pumps in the dosing system, various anti-corrosive pumps for the

acid-base system, as well as mud pump and fuel pump and others of the waste liquid system.

There are many types of pumps, and this section focuses on introduction to the most common

three categories of chemical centrifugal pumps, chemical dosing pumps and metering pumps

used in the chemical water treatment system.

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2.1.2.2 Working principle of centrifugal pump: after the pump and the entire absorption

pipeline are full of fluid, when the impeller is rapidly rotating, the liquid between blades is also

rotating, and the rotating fluid in the role of centrifugal force moves outward along the blade

runner from the impeller center, is spun off the end of the blade, and enters into the

spiral-shaped worm room and diffusion pipe (or guide wheel) in the pump shell; when the fluid

flows to the diffusion pipe, as the liquid area gradually expands, the flow rate slows down, some

kinetic energy can be converted into pressure energy, the pressure rises and the liquid is

pressed out of the discharge pipe finally. At the same time, because the liquid is spun off the

impeller centre, a vacuum is generated, and the liquid in the role of pressure difference inside

the low-open inlet pipe is sucked into the pump constantly from the inlet pipe. The liquid is

sucked by the centrifugal pump constantly while it is continuously drained, and is evenly

transmitted to the place where it is more needed.

2.1.2.3 IS type centrifugal clear-water pump The back of the impeller is divided into the pump body and pump cover of IS type

centrifugal clear-water pump, that is, the structural form of opening the door at the back. Its

advantage is easy maintenance, that is, the pump body \suction pipeline\discharge pipeline do

not move to carry out maintenance. It is mainly composed of pump body, pump cover, impeller,

shaft, seal ring, sleeve and suspension, bearing and other parts, as shown in Figure (1-1).

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Fig. 1-1

2.1.2.4 S-type centrifugal pump

S-type centrifugal pump is a single-stage, dual-suction and level middle-open centrifugal

pump, as shown in the figure1-2. It is mainly fixed by the pump body, pump cover, impeller,

shaft, dual-suction seal ring, bushing and bushing nuts on both sides. The axial displacement of

the shaft can be adjusted by the bushing nut so that the shaft with the pump body is protected

from being worn with the middle-shaft sleeve filling. During maintenance the impeller shall not

be installed reversely. The seal ring is a semi-circle ring which outer edge is convex, and is

embedded in the groove of the pump shell to fix the axial displacement. Filling of shaft seal

device is assembled by the pump body together with the pump cover, and the soft filling is

pinched by the filling as the sealed role. As the shaft seal of the dual-suction pump is arranged

at the low pressure part of the liquid, the role of the shaft seal is to prevent the air out of the

pump from being sucked under the normal circumstances.

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Fig.1-2

2.1.2.5 IH chemical centrifugal pump

IH-pump for single-stage cantilevered structure, the basic structure and IS-type pumps

similar, but their material flow components for ZG1Cr18Ni9Ti, seal a mechanical seal structure.

Can be used to transport temperature of -20 ℃ ~ 105 ℃ the corrosive liquid water or chemical

properties similar to the medium, IH-pump from the body, covered pumps, impeller shaft, seal

ring, bushings, impeller nut, the middle frame, Axis and suspension components. China is now

using the IH-use mechanical pump seals, shaft and the motor shaft coupling connected by

lengthening.

2.1.2.6 Multi-stage centrifugal pump

For a multi-stage centrifugal pump, the shaft is equipped with two or more impellers, and a

certain amount of energy is increased after liquid flows through each impeller. The pump body

comprises a front section, and middle section and rear section, and is fastened with the shaft,

and the front and rear filler or end cover is connected with bolts and the pump body. Multi-stage

pump is provided with multiple impellers, which are mostly toward one direction, so there is

axial thrust to the impeller suction side and a balance tray is set to balance the axial thrust.

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Fig 3 Multi-stage centrifugal pump

2.1.2.7 Reciprocating metering pump

Reciprocating metering pump is classified into piston metering pump and diaphragm

metering pump, and its structure is shown in the Figure (1-4) and it mainly consists of a gearbox

and liquid cylinder head two parts. Gearbox parts are composed of crank linkage mechanism

and stroke adjustment mechanism, and a worm and gear are used for the transmission

mechanism to slow down, (a planet-cycloid slowdown structure is also used). A high-accuracy

N-axis structure is adopted for the stroke adjustment mechanism, N-axis is used to change

directly the rotating partiality and thus to change the stroke. The cylinder parts are composed of

suction valve, discharge valve, plunger piston and filling seal. The diaphragm pump still has

diaphragm and limit board, and the cylinder is equipped with safety filling oil valve box.

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Structure of the metering pump

1. Motor 2. Coupling 3. Worm 4. Worm wheel 5. Lower sleeve 6. Partial block

7. N-axis 8. Partial filling sleeve 9. Connecting bar 10. Crosshead 11. Bracket

12. Plunger 13. Suction valve 14. Discharge valve 15. Diaphragm 16. Cylinder body

17. Automatic safety water inlet valve box 18. Adjustment dial 19. Small helical gear

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20. Big helical gear 21. Adjustment screw 22. Adjustment nut 23. Adjustment box body

24. Gearbox body 25. Filling nut 26. Sealing components 27. Valve seat

28. Tennis 29. Pipe 30. Flange

Technical requirements:

1. The technical requirements of the gearbox parts should meet the provisions of

technical conditions of JB2918-81 metering pump.

2. The tightness degree of the indication location “A” is adjusted with the gasket at the “B”

and it is required that the string quantity of shaftless valve is adjusted flexibly.

3. After the gearbox parts are assembled, the stroke convection zone must be adjusted

and its convection zone tolerance should not exceed 0.3 mm.

2.1.3 Pump Category

2.1.3.1 By lift:

① Low-pressure pump (lift <10 m)

② Middle-pressure pump (lift = 10 - 60 m)

③ High-pressure pump (lift > 60 m)

The pumping out height of pump itself is called the lift of pump, which is in general

indicated in meter and also in pressure (MPa or Pa).

2.1.3.2 By number of impeller:

① Single-stage pump: there is only one shaft impeller on the pump shaft.

② Multi-stage pump: there are two or more impellers on the pump shaft.

2.1.3.3 By water absorbing mode of impeller:

① Single-sided absorbing pump

② Double-sided absorbing pump

2.1.3.4 By layout mode of pump shaft:

① Horizontal pump (level layout)

② Vertical pump (vertical layout)

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2.1.4 Maintenance process and quality standards of pump

2.1.4.1 Maintenance of centrifugal pump

Name Maintenance of centrifugal pump Type Type of pump

Maintenance item Process sequence Quality standard

Preparation for maintenance

Disassemble

2.1 Disassemble the coupling

2.1.1 Disassemble the coupling shield

2.1.2 Check whether there is a mark on two coupling interface, and make a mark if not.

2.1.3 Disassemble the coupling screws and place them correspondingly.

2.1.4 Loosen the motor anchor bolts and move the motor away.

2.2 Disassemble the impeller tank and inspect. 2.2.1 Disassemble the water inlet joints of the

pressure gauges and the short inlet and outlet pipes of the pump

2.2.2 Disassemble the connection screws between the pump cover and the pump body.

2.2.3 Fasten the stop head screw (22) to separate the pump covered from the pump body, take down the pump cover and paper pad, and then check the impeller.

2.2.4 Unscrew the impeller nut (18), pay attention to the forward and reverse direction (left wire) of thread, remove the stop retreat ring and check the impeller (3) (whether there is crack or other damage).

2.3 Check, repair and replace the shaft and bearing.

2.3.1 Disassemble the coupling and keys.

2.3.2 Let off lubricant in the oil tank.

2.3.3 Unscrew the screws of the bearing end cover (11) (loosen two bearing end covers).

2.3.4 Unscrew the screws of the filling gland (7) and retreat from the filling gland.

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Assemble

2.3.5 Hook out all the filling in the filling room with a dedicated hook.

2.3.6 Expulse the shaft out of one end of the impeller with a copper rod.

2.3.7 Clean the shaft and bearing.

2.3.8 Check the gap of bearings on both sides, and them must be replaced if the gap exceeds the standard. At the same time, check whether there is defect that can not be eliminated.

2.3.9 When necessary, remove the bearing and bushing and check the bending of the shaft on the ingot iron.

2.4 Pump assembly.

2.4.1 Put the oil baffle ring (13) first on the shaft, install the bearing (12) and positioning sleeve (16) as well as another bearing on the shaft, and then put on the oil baffle ring, baffle sleeve, paper pad and bearing end cover, load the coupling and finally fix these parts on the shaft with the stop withdrawal ring (14) and nut (15).

2.4.2 Install the loaded shaft inside the shaft bracket (crush with copper rod), then install the second bearing end cover and the paper pad, and keep the gap between the bearing and the end cover (make adjustment with the thickness of the gasket); the tightening force on all of the screws of the end cover shall be the same.

2.4.3 Cover the water deflector (10), filling gland and filling ring on the shaft, install the impeller and fix them with the stop withdrawal ring and impeller nut, the impeller should rotate flexibly, without friction.

2.4.4 Cover the paper pad on the pump cover and then fix the pump cover on the pump body.

No cracks, corrosion or spot.

The bending of the shaft is not more than 0.05mm.

No loosening. The gap between the bearing and the inner ring of the bearing is no more than 0.03mm and the tightening force of the rolling bearing is not more than 0.02mm.

1. Impeller should be clean and have no damage or crack; the end surface of the impeller and bushing should be vertical to the axis and keep close contact; the seal ring should be clean and be not deformed and have no crack and the ovality of its inside and outside circle is not more than 0.03 to 0.04mm; the new impeller must be corrected about the static equilibrium, the axial and radial sloshing at the impeller entrance is not more than 0.08 to 0.14mm, the impeller out of the center line must align the pump body out of the center line of the water room.

2. Seal ring is positioned

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2.4.5 Fill the filling into the filling ring (room) and press the filling ring not tightly.

2.4.6 Inject lubricant into the fuel tank until the normal oil level.

2.4.7 Correct the coupling and fasten the motor anchor bolt.

2.4.8 Install the short inlet and outlet pipe and connect the pressure gauge joints.

slightly lower than the level combination face of the pump shell by 0.05mm, the radial gap between the seal ring and the impeller is not more than 0.5mm, and the axial gap between the seal ring and the impeller is not more than 3mm.

The screws should be tightened and the tightening degree should be the same.

The tightening degree should be appropriate, and the filling gland and the gap are uniform but do not abrade with the shaft. The oil position is generally controlled around ±5mm at the center line of the shaft.

1° coupling head face distance is 2 to 4mm and the central deviation is no more than 0.06mm, 2 ° when the rotating speed is 300r/min, the vibration is less than 0.05mm; when the rotating speed is 200r/min, the vibration is less than 0.08mm No leakage

2.1.4.2 Maintenance process of S type pump

Name Maintenance process of S type pump Type Type of pump


1. Disassemble the pump cover Loosen the filling gland screws on both sides of the pump body, open the two sides the filling gland, then loosen all the connecting screws between the pump cover and the pump body, take down the positioning pin and uncover the pump cover (take care not to damage the paper pad ).

2. Disassemble the coupling

Unscrew the connecting screws between the coupling and the motor coupling, then disassemble the bearing glands on two ends of the pump shaft and pull out the entire pump

Do not damage the pump shaft.

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shaft.

3. Disassemble the rotor

3.1 Pull the coupling out of the pump shaft with Rama slowly.

3.2 Disassemble the bearing assembly caps at both ends of the pump shaft, pay attention to the positive and negative direction, and then pull the bearing out of the pump shaft with Rama slowly.

3.3 Disassemble the bearing nuts separately (note: the positive and negative direction, it is the positive thread near the coupling and it is the negative thread on the other end); take down the water seal ring, filling sleeve, filling and dual-suction seal ring separately.

3.4 Place the impeller levelly and pad it well and know the pump shaft with a wood hammer (or rubber hammer) gently.

4. Assemble the rotor part

4.1 Place keys in the middle keyway of the pump shaft, install the impeller, respectively, load the dual-suction seal ring, filling sleeve, water seal ring, filling sleeve, water seal ring, bushing nut and bearing on both sides of the impeller respectively, and assemble the bearing with assembly caps and install the coupling.

5. Load the rotor part

5.1 Begin to assemble the pump cover after confirming the parts of the rotor assembled correctly, load the renovated rotor into the pump seat, align the location, and align the dual-suction seal ring of the impeller to the embedded pump body slot, place the bearing body on the stop mouth of the stent at both ends of the pump body, cover the inner cover of the bearing body, and cover the spring gasket and tighten the nuts.

6. Load the pump cover

6.1 Place the sealed paper pad levelly onto the pump body, align the pump cover onto the position, load the fixed pin and tighten the nuts symmetrically.

6.2 Install the filling gland finally, and its tightening degree is appropriate and it can be slowly adjusted in work generally.

Check whether all parts of the renovated rotor are assembled correctly or omitted carefully.

Adjust the impeller position with the bushing nut to align the centre of the impeller to the centre of the pump body, and tighten the bushing nut with a hook wrench after adjustment, and align the water seal ring to the position of the water seal pipe and fill the filling into both ends of the water seal ring respectively.

The vibration of the water pump should be below 0.05mm after it is adjusted, the distance between the two end surfaces of the coupling is 2 to 4mm and the center deviation is less than 0.06mm

2.1.4.3 IH type chemical pump (including HZ type chemical pump)

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Name IH type chemical pump Type Type of pump


Disassemble

Assemble

1. Unscrew the drain pipe plug of the pump body and the hoisting body and drain liquid in the pump body and oil in the oil storage room of the hoisting body. If there is outside liquid pipeline, it should not be disassembled.

2. Disassemble the middle connecting part of the lengthened coupling, open the connecting bolts between the pump body and the middle stent, and take the middle stent, suspension parts, sealing parts, and all rotor parts out of the pump body.

3. Loosen the impeller nuts and take out the impeller and keys.

4. Take down the pump cover with the bushing, mechanical seal end cover and mechanical seal and other components from the shaft, when the bushing shall not relatively slide with the pump cover and others, and then take out the mechanical seal together with the bushing, and then disassemble the bushing and mechanical seal. If the sealing material is soft, take down the bushing first from the pump cover, and disassemble the filling gland, filling, filling ring and others in sequence. It is necessary to pay attention to using different methods to disassemble the mechanical seal with a special structure.

5. Disassemble the middle bracket and the hoisting bracket from the hoisting stent part.

6. Disassemble the pump coupling and take out the keys.

7. Disassemble dust-proof tray on the both ends of the hoisting stent and the front and rear cover of the bearing, and then take the shaft together with the bearings out of the hoisting bracket.

8. Disassemble and check the bearing. 9. The assembly sequence is basically in accordance with the disassemble sequence to the contrary.

1. The deviation and shaking degree of the wheel meet the design requirements, and the impeller has no serious wear and corrosion.

2. The wheel, shaft, coupling and bearing should meet the technical assembly requirements.

3. The keys matching with the slot should meet the relevant technical requirements.

4. The imbalance metal in the static equilibrium test of wheel is no more than 5g.

5. The abrasion clearance of inlet and outlet of the wheel is 0.30 to 0.60 mm

6. The bending of the shaft is no more than 0.05mm.

7. The playing is 0.10 to 0.15mm

8. The distance between the wheel and the centrifugal pump room is less than 1.0mm and the tightening force of the pump cover bearing is 0.00 to 0.02 mm.

9. The internal and external trajectory of the bearing have no serious wear or crack, the cartridge clip is integral and rotates flexibly but is not loose, without noise.

10. The bearing

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temperature does not exceed 35 to 45℃ of the room temperature and is not more than 80 ℃ at most.

11. The drop leak of mutually staggered material laps at 180° and 12° packing is moderate, not warming.

13. There is right amount of grease lubricant for the bearing.

14. The gap between back gears is 2 to 4mm.

15. The circumference of the axis center on the deviation plane is no more than 0.05mm.

16. The mechanical seal does not drip and warm. No collision, friction or abnormal sound occurs in operation.

17. Pump vibration is no more than 0.05 mm.

18. The mouth pressure and flow meet the nameplate output

2.1.4.4 Maintenance process of plunger (diaphragm) metering pump

Name Plunger (diaphragm) metering pump Type Type of pump


1. Preparation for maintenance

2. Disassemble

1.1 Handle the maintenance work sheet and take the appropriate security measures.

1.2 Prepare the necessary spare parts, materials and maintenance tools.

2.1 Disassemble the cylinder head of the plunger metering pump

a) Move the plunger to the front dead point and disassemble the plunger from the cross head; disassemble the connecting bolts between the pump and the inlet and

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outlet pipe, as well as the connecting nuts between the gearbox body and the liquid cylinder and cylinder head, and disassemble the overall cylinder head.

b) Pull out the plunger, disassemble the filling gland and take out the seal filling, water seal ring and piston sleeve.

c) Disassemble the suction pipe flange, and then take down the valve sleeve, spacing slice, valve ball, valve seat or spring and valve in series.

2.2 Disassemble the cylinder head of the diaphragm metering pump

2.2.1 Move the plunger to the front dead point and spin the plunger out of the cross head; disassemble the plunger from the cross head; disassemble the connecting bolts between the pump and the inlet and outlet pipe, as well as the connecting nuts between the gearbox body and the liquid cylinder head, and disassemble the overall cylinder head.

2.2.2 Disassemble the safety fill oil valve, pull out the plunger, disassemble the filling gland and take out the seal filling, caulking ring and piston sleeve.

2.2.3 Disassemble the suction and racking pipe flange, and then take down the valve sleeve, spacing slice, valve ball, valve seat or spring and valve in series.

2.2.4 Disassemble the cylinder head, and take down the limit board and diaphragm.

2.3 Disassemble the gearbox

2.3.1 Place oily screw plug on the gearbox, drain the lubricant and disassemble the end cover at the back of the gearbox.

2.3.2 Disassemble the motor, take out the coupling, unscrew the pinched nut on the bearing cover, and take the bearing cover, bearing, worm and oil extractor out of the gearbox body as shown by the general assembly.

2.3.3 Open the adjusting box cover, disassemble the pinched adjusting nut, rotate the adjustment dial, take down the adjusting box from the sleeve, and

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then disassemble the upper sleeve from the gearbox.

2.3.4 Disassemble the pinched bracket nut, take the bracket out of the gearbox, open the upper cover of the gearbox and take the crosshead pin and cross head out of the upper gearbox.

2.3.5. Take N axis and the partial block, connecting rod, upper ring of the partial block and others on the N axis together out of the gearbox.

2.3.6 Disassemble the adjusting nut and round nut, as well as the lower partial ring, bearing and pad from the N axis.

2.3.7 Pull out the partial block sleeve on the partial block and take out the rolling needle and partial block.

2.3.8 Disassemble the lower bearing cover of the gearbox and take the worm, lower sleeve, bushing and others out of the gearbox at the same time to remove the bearing, worm and lower sleeve and so on.

3.Clear parts

4.Check parts

3.1 Clear parts (including the box body): use kerosene to clean and dry them for rust prevention. 3.2 Wash the parts of the cylinder head part with clean water. Pay attention to preventing injuries to the body in the cleaning process when the water with acid and alkali, and other corrosive media is output to flow parts of the pump. 4.1 Check the gearbox part g) Check whether the meshing surface of the

worm wheel and worm is worn. h) Check whether the N-type shaft surface is

scratched and worn. i) Check whether all the matching surfaces of

the cross head and the crosshead pin and connecting rod are worn and whether the lubricant hole is unobstructed.

j) Check the meshing status of spiral gears with different size in the adjustment mechanism and whether the adjustment screw and nut can normally rotate.

k) Check all the bearings, and they must be replaced if they are loosening and have corrosion and other defects.

l) Check other parts.

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5.Assembly

3.2 Check the cylinder head part f) Check whether the plunger is corroded and

worn; the seriously corroded plunger or those with deep axial wear track must be replaced.

g) Check water seal and piston ring sleeve, to wear or severe deformation to replace.

h) Check the valve seat and ball of the suction valve and release valve; the defect valve seat and the corroded and cracked valve ball must be replaced.

i) Check whether there is a worn and corroded cylinder and whether the anti-corrosion coating on the overflow part is intact, and repair or replace the coating damaged.

j) Check whether the diaphragm metering pump is aged and check the flexible conditions and rupture status, and replace it if necessary. Check the performance of the safety feed-oil valve of the diaphragm metering pump and check whether the oil through-hole of the cylinder body is open.

5.1 Assembly of transmission box Install the transmission box according to the

reverse disassembly sequence and turn and check the coupling, which should rotate freely and have no jam phenomenon. And the rotate and adjust the dial and turn the motor coupling, and adjust the stroke to zero position, install the adjusting quantity meter and then turn the adjusting dial, adjust the stroke to the maximum provided stroke position and move the crosshead the front dead point.

5.2 Assembly of the cylinder head Install it on the transmission box in accordance with the reverse disassembly sequence, adjust the tightness of the filling gland, and turn the coupling, which should rotate freely and have no jam phenomenon.

1. Pay attention to the rolling needle not to be lost when the rolling needle bearing at the partial block is assembled.

2. Check the meshing situation of the worm wheel and worm in the assembly with the painting method to ensure the uniformly distributed meshing impress, and the area should account for 50 to 60% of the full length and total height; adjust the position of the worn wheel through the pad of the bearing cover at the bottom.

3. When assembling the suction and discharge valve, pay attention to the position of the valve seat is correct and it is not reversely installed, so as not to affect the suction and discharge effect of the pump.

4. When the diaphragm of the diaphragm metering pump is placed into the cylinder body and the cylinder cover is fastened, tighten the

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bolts uniformly symmetrically to ensure that part of the diaphragm around is closed, to prevent liquid in the oil chamber and the medium cavity from stringing each other and impact the normal working of water pump

6.Trial run

6.1 After the equipment assembly is correct, proper N32 or N46 machine oil should be injected into the transmission box, and the diaphragm metering pump should also provide the safety oil valve with the transformer oil and the surplus air in the oil chamber should be managed to be drained.

6.2 Turn the coupling for several times, and contact the operator on duty to operate the trial run if all parts have no card Yin phenomenon.

1. All moving parts move freely and the adjusting mechanism is flexible, without card Yin phenomenon.

2. The leakage of the plunger filling seal part is less than 15 drops per minute, and there is no abnormal temperature rise and the other parts have no oil leakage.

3. The temperature rise of all moving parts should be less than 65℃, without unusual noise in operation.

4. Pump works properly; flow, pressure and other parameters can be up to the rating values

2.2 Common faults and trouble shooting of pump

S/N Symptom Possible factors Elimination methods

1 Liquid can not be transported from pump

1. There is air inside the pump or suction pipe.

2. The suction pipe is too small or there is debris in it.

3. The lift is too high or the perfusion height is not enough.

4. The suction pipe provides inadequate depth of immersion or leaks air.

5. Rotation speed is too high or low. 6. The rotation direction of the pump is

wrong. 7. The pipeline or pump is blocked by

debris. 8. The bottom valve can not be closed

1. R-irrigate the pump and exclude the air.

2. Increase the diameter of the suction pipe and remove blockage.

3. Lower the pump position and increase the pressure on the entrance.

4. Increase the immersion depth or repair the pipeline.

5. Check the rotation speed of motor in accordance with the regulated requirement.

6. Adjust the direction of the motor.

7. Remove the debris.

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but can be opened. 9. The bottom valve is blocked by

debris.

8. Repair the bottom valve.

2 Inadequate flow and lift

1. There is air in the suction pipe.


3. The suction lift is too high or the perfusion height is not enough.

4. The suction pipe provides inadequate depth of immersion or leaks air.

5. Rotation speed is too high or low.

6. The rotation direction of the pump is wrong.

7. The seal ring is worn too much.

8. The pipeline or pump is blocked by debris.

9. The bottom valve is blocked by debris.

1. R-irrigate water and exclude the air in the pump.


Lower the pump position and increase the pressure on the entrance.

4. Increase the immersion depth or repair the pipeline.

Check the rotation speed of motor in accordance with the regulated requirement.

5. Adjust the direction of the motor.

6. Replace the seal ring.

7. Remove the debris

3 Excessive power consumption

1. The rotation speed is too high or low.

2. The total lift is inconsistent with the pump lift.

3. The medium weight and viscosity do not match with the pump requirements.

4. The seal ring is worn too much.

5. The valve sleeve, filling or dynamic and stationary ring is worn.

6. The selected filling (or mechanical seal) or installation is improper.

7. Oil amount in the fuel room is too much (or oil is too dirty).

1. Check the rotation speed of the motor in accordance with the regulated requirement.

2. Reduce the system resistance or height.

3. Conversion should be done.

4. Replace the seal ring.

5. Replace the worn parts.

6. Make a correct choice or installation.

7. Maintain normal oil level (or replace new oil).

4 Abnormal vibration and noise

1. There is air inside the pump or suction pipe.


3. The suction lift is too high or height is not enough.

4. The restriction export flow is too

1. Re-irrigate the pump and exclude the air.


3. Lower the pump position and increase the pressure on

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small.

5. The pump and motor axis are inconsistent or bend.

6. The dynamic and static parts have friction.

7. The bearing is worn seriously or damaged.

8. The rotation part is imbalance.

9. The oil in the oil room is too much (or the oil is too dirty).

10. The pipeline or pump is blocked by debris.

11. The oil room lacks of oil.

12. The anchor bolt is loose.

13. The pump base is loose.

the entrance.

4. Increase the flow or set a pass cycle pipe.

5. Correct

6. Maintain

7. Replace the bearing

8. Check the reason and try to eliminate.

9. Maintain the normal oil level (or replace new oil).

10. Remove debris.

11. Make appropriate adjustment.

12. Screw the nut tightly.

13. Treat the base

5 Too much leakage at the sealed part

1. The restriction export flow is too small.

2. The bearing sleeve, filling or dynamic and stationary ring is worn.



5. The seal hydraulic pressure is improper.

6. The filling gland is too tight or loose.

1. Increase the flow or set a bypass cycle pipe.


3. Make correct choice or installation


5. Make adjustment according to the requirement

6. Make appropriate adjustment.

6 Bearing seal (including filling) overheats

1. The pump and motor axis are inconsistent or bend.


3. The valve sleeve, filling or dynamic and stationary ring is worn.



6. The seal hydraulic pressure is improper.

1. Correct



4. Make correct choice or installation


6. Make adjustment according to the requirement

7. Make appropriate adjustment

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7. The filling gland is too tight or loose.

7 The bearing overheats and does not work

1 The export flow is too small.

2. The pump and motor axis are inconsistent.


4. The bearing is seriously worn or damaged.

5. The bearing sleeve, filling or the dynamic and static ring is worn.




2. Make correct choice or increase flow

3. Set a bypass cycle pipe.

4. Correct 5. Maintain



8 The bearing heats

1. The export flow is too small.

2. The pump and motor axis are inconsistent.




6. The oil amount in the oil room is too much (or the oil is too dirty).

7. The oil room lacks of oil.

1. Increase the flow or set a bypass cycle pipe.

2. Correct

3. Maintain


5. Check the reasons and try to eliminate.

6. Maintain the normal oil level (or replace new oil)

Make appropriate adjustment

2.3 Special tools and spare parts for pump maintenance

2.3.1 Mandatory spare parts of water pump of water treatment system: One (1) set of bearing,

seals, rings, wear parts and gasket for each type pump; each type of water pump has one set of

bearing, seal, seal ring and seal gasket respectively, without special tools.

S/N Equipment name Name of spare parts Unit Qty Manufacturer

Flexible cushion rubber Set 1 Shanghai Rubber Plant

bearing NSK of Japan

pump seal Burgmann Shanghai 1

Backwashing water pump

HG200-315（IA）

Oil seal

Set

1

NAK Company of Taiwan

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Flexible cushion rubber

Set 1 Shanghai Rubber Plant


pump seal Burgmann Shanghai 2 Middle wanter pump

HZ100-400

Oil seal

Set

1





pump seal Burgmann Shanghai 3 Demineralized water

pump HZ100-400B

Oil seal

Set

1





pump seal Burgmann Shanghai 4 Demineralized water

pump HZ125-400

Oil seal

Set

1





pump seal Burgmann Shanghai 5

Self demineralized water pump HZ100-400C

Oil seal

Set

1


6

Feed-water neutralizing tank

wasterwater pump80HLB-B

Seal gasket

Set

1 Jiangsu Huadian

7 Generating unit drain

tank wasterwater pump 150HLB-B

Seal gasket Set

1 Jiangsu Huadian




pump seal Burgmann Shanghai 8 Alkali transfer pump

HZ50-250

Oil seal

Set

1



Set 1 Shanghai Rubber Plant 9

Delivery pump of hydrochloric acid

50FSB-20L Oil seal Set 1 NAK Company of Taiwan

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2.3.2 Mandatory spare parts of diaphragm speed change metering pump: One (1) set of bearing,

seals, rings, wear parts and gasket for each type pump, bearing, one set of mechanical seal

and gasket and wearing part (one set of each type of pump), without special tools

3 Maintenance of water purification system equipment

3.1 Technical specification and structure of equipment

3.1.1Technical specification of equipment

Equipment name Major technical parameter Unit Qty Remark

Mechanical acceleration

clarification tank

Q=200m3/h, inlet silt content ≤5Kg/m3

Effluent turbidity: ≤20PPM Set 2

One is in operation and the other is for

standby

Filter chamber Q=200m3/h, inflow turbidity:

≤20PPM

Effluent turbidity: ≤3PPM

Set 2


standby

Fire-fighting pressure stabilizer Q=21m3/h, H=110m

Set 1


standby

Living frequency conversion feed

water device

Total feed water volume Q=0~160m3/h, H=70m

Set

1

Two are in operation and one is for standby, each pump has Q=80m3/h, H=70m, N=30KW, V=400V.

Living water chlorination equipment

Effective chlorination amount：9.5g/h

Set 1

Cleaning station chlorination equipment

Effective chlorination amount：700g/h

Set 1

3.1.2 Overview of the structure of water purification system equipment

3.1.2.1 Mechanical acceleration clarification tank

The mechanical acceleration clarification tank is characterized that a mechanical agitator

impeller is upgraded to complete the reflow and contact reaction of mud residue. The raw water

dosed and mixed enters into the first reaction room and reacts with reflow mud residue water

which is several times (five times at maximum) the raw water under the stirrup of the blade, and

then it is elevated by the impeller to the second reaction room to continue to react, coagulating

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into large flocs, and then it enters into the separation room through a diversion room to

complete the precipitation and separation.

The structure of the mechanical acceleration clarification tank is shown in Figure (2-1)

below, and it is a reinforced concrete structure. Water processes in the clarification tank are as

follows: the raw water enters into a ring-shaped distribution channel 2 which vertical section is

triangle through the water inlet pipe 1 and flows into the mixture room (also known as the first

reaction room) 3 through the water outlet hole below the distribution channel 2 evenly; a certain

negative pressure forms in the mixture room due to the rotating agitator impeller so that the inlet

water and reflow mud residue are mixed evenly and are elevated to the second reaction room 4

by the impeller; the sediment reaction and flocculation growth of water and agent are basically

completed in the second room, and they are rectified, then after turbulence and rotation of water

are eliminated in the diversion room 5 at the upper part further, water enters into the separation

room 6. In the separation room, because of large cross-sectional area and very small water flow

rate, coupled with pipe chute device, mud residue and water are separated. The separated

water flows evenly into the ring-shaped header tank 7 at the upper part of the clarification tank,

and flows into the clean water tank or gravity filter chamber through the outlet pipe to filter; the

separated mud residue sinks to the tank bottom, and most of it returns to the mixture room and

a small portion of the quality through the regular water blowdown pipe (discharge pipe) at the

bottom of the tank is discharged away. In the settlement process of mud residue, there is still a

considerable amount of mud residue to enter into the bucket 8, and such mud residue is

excluded in the continuous or periodic manner, maintaining the balance of mud residue.

Fig. 2-1

3.1.2.2 Agitator and mud scraper

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In the mechanical acceleration clarification tank, the agitator plays a role in mixing and

stirring and upgrading water; the mud scraper is used to scrape and collect mud at the bottom

of the tank to facilitate the centralized discharge.

The transmission mechanism in an agitator comprises a speed regulating motor, belt pulley

and worm reducer, the vertical axis in the agitator and the worm in the reducer are connected

with keys, and the lower end of the vertical axis is connected with the impeller through key and

ring.

The mud scraper is driven by a motor and planetary-cycloid reducer, sprocket pair and

worm and worm wheel to a spindle, which extends into the tank bottom from the tank centre

through the hollow shaft of the agitator to drive a rake to move in the rotary manner.

Diagram of agitator and mud scraper

3.1.2.3 Air cleaning filter chamber

Air cleaning filter chamber is a new filter chamber combined with the air scrub function of

valveless filter chamber and mechanical filter. The equipment operates normally in accordance

with the mode of valveless filter chamber, (when the water inlet valve and water outlet valve are

open and all other valves are closed), the raw water through the inlet pipe flows into the baffle

water sump of the filter chamber evenly, passes through the filter material layer and water hap

to the catchment room with the perforated plate bottom, and is filtered by gravity from up to

down; the filtered clean water through a connecting pipe enters into a backwashing water tank

from the lower sump to the upper sump and is sent to the clean pool of the water purification

system through the water outlet pipe.

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After the filter chamber operates normally for a period of time, when the filter layer

resistance increases and the turbidity of output water rises, it is necessary to backwash the filter

layer from up to down. The equipment body is provided with a backwashing water tank and the

backwashing water is from the clean water inside a backwashing water tank. When

backwashing, the sand layer is scrubbed in the air first with a Roots blower, and then is

backwashed with water so that the backwashing is more thorough to ensure the effluent quality.

The equipment has a glass peep hole, through which the status of the filter layer can be

observed in the operation process of the filter chamber.

Chinese English 图 2 Fig 2 反洗水槽 Backwashing tank 水 Water 水槽 Tank 进 Inlet 出水 Effluent 进水装置 Inlet device 无烟煤 Anthracite 滤层 Filtering layer 砂 Sand 压缩空气 Compressed air 水帽 Water hat

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集水室 Catchment chamber 进水阀 Inlet valve 反洗出口阀 Backwashing outlet valve 排放阀 Drain valve 底排阀 Bottom outlet valve 反洗进口阀 Backwashing inlet valve 出水阀 Outlet valve

3.1.3 Maintenance of water purification system equipment

3.1.3.1 Agitator and mud scraper

Name Agitator and mud scraper Type


1.Preparation for maintenance

2.Disassemble

1.1 Check first whether the inlet and drainage valve of the mechanical acceleration clarification tank are reliably opened and closed, and any problem found should be dealt with first.

1.2 Prepare the necessary lifting appliances, which must have adequate safety margin.

1.3 Prepare repair tools and spare parts.

1.4 Handle the maintenance work sheet and implement safety measures.

2.1 Drain the surplus oil inside the worm reduction gearbox of the mud scraper and agitator. Pay attention not to placing the oil tray into the clarification tank.

2.2 Disassemble the transmission chain of the mud scraper and the sprocket of the worm shaft.

2.3 Disassemble the end cover of the worm shaft of the mud scraper and the upper cover of the worm reduction gearbox as well as the worm and bearing; hoist the mud scraper shaft slightly, take down the key block of the driving wheel, and then slow the mud scraper shaft down and take out the worm and bearing.

2.4Disassemble the connecting seat between the worm reduction gearbox of the mud scraper and the reduction gearbox.

2.5 Take down the drive belt of the agitator and the belt pulley of the worm shaft.

2.6 Disassemble the end cover of the worm

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shaft of the agitator and the upper cover of the worm gearbox as well as the worm and bearing; hoist the mud scraper shaft slightly, take down the key block of the worm gear, and then place 2 pieces of φ57 above steel pipes below the impeller of the Ⅱ reaction tank to support the agitator impeller which is put down slowly, so the agitator worm wheel can be taken out.

3.Maintenance and measurement

3.1 All parts including the reduction gearbox must be cleared to facilitate the inspection.

3.2 Check bearings of all parts and replace them if there are wear and tear, corrosion, loosening status and other defects.

3.3 Check whether the working face of the worm wheel and worm is worn or scratched, and replace the seriously worn ones.

3.4 Check the chain transmission and belt drive parts, and replace the deformed or worn transmission belt or chain.

4.Assembly

5. Maintenance of the agitator impeller and mud scraper rake

4.1 Carry out assembly according to the reverse order of the disassembly.

5.1 Check the corrosion status of the agitator impeller and check whether the mixing blades at the lower part fall off.

5.2 Check whether the mud scraper rake and various parts are corroded and the paint falls off.

5.3 Check whether the sliding bearing at the bottom of the tank is worn.

5.4 Check whether the connecting parts are corroded and the connectivity is reliable.

5.5 The underwater parts corroded, worn and seriously deformed must be replaced, and they should be timely painted after each inspection and repair. Clear the rust scale product on the surface before painting and then paint the vinyl chloride paint.

6.1 Before trial run, each reduction gearbox should be filled with proper N68 machine oil, and the remaining bearings and other lubricating parts in accordance with the regulations, are filled with grease lubricant (ZG-3).

6.2 Open the cooling water door of the sliding

Check that the meshing situation of the worm wheel and worm should meet the regulated requirements.

3. Agitator

The deviation of the output shaft of the worm reducer and the tank centre: 5 mm

The deviation of the two wide centre surfaces of the belt pulley: 1 mm.

The nonparallelism of two axles of the belt pulley: 0.5mm/m

Runout of the end surface of the agitator impeller: 5mm

The radial runout of the agitator impeller: 5mm.

4. Mud scraper

The central axis of the worm reducer should be the same center as the hollow shaft of the agitator.

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6.Trial run and acceptance

bearing at the lower part of the mud scraper and ensure adequate pressure and flow.

6.3 Trial run with idle load at the rated speed for two hours.

6.4 After the trial run is normal and the person responsible for maintenance work and the personnel on duty co-recognize, the necessary acceptance procedures are handled

The level deviation of planetary reducer skateboard: 0.05mm.

The thickness deviation of the center line of two sprocket teeth: 1mm.

The deviation of nonparallelism of two chain shafts: 0.5 mm.

The side sag of chain driven pulley: 9 to 13mm The length deviation of mud scraper rake: 6 mm.

The warping deviation of the rake rack in the length direction: 4 mm.

The distance between the mud scraper bottom and the tank bottom: 20 ± 10mm

Current should be no abnormal fluctuation, and the reducer should have no unusual noise, large vibration or oil leakage phenomenon. All functioning parts shall not have interference phenomenon, abnormal sound and beat.

3.1.3.2 Mechanical acceleration clarification tank

Name Mechanical acceleration clarification tank Type


1. Preparation

for maintenance

1.1 Check first whether the inlet and drainage valve of the mechanical acceleration clarification tank are reliably opened and closed, and any problem found should be dealt with first.

1.2 Open the sludge bucket valve first, drain the mud residue inside the mud bucket, open the emptying valve at the bottom of the clarification tank, and drain all the

1. The inside and outside of the mechanical acceleration clarification tank should be complete and be not injured, and the tank full of water under the static pressure test is not leaked. The platform, railing and escalator are integral.

2. All metal parts are integral and solid and the paint is intact.

3. Concrete structures are integral

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2. Maintenance

sequence

3.Trial run

surplus water and mud residue in the tank into the sludge sedimentation tank.

1.3 Prepare the necessary lifting appliances, which must have adequate safety margin.

1.4 Prepare repair tools and spare parts.

1.5 Handle the maintenance work sheet and implement safety measures.

2.1 Start with the tank roof and rinse the pipe chute and the upper tank wall from up to down.

2.2 Disassemble and overhaul the agitator and mud scraper.

2.3 Check and clear the ring-shaped header tank and sloping plate.

2.4 Check and repair the guide plate of the second reaction room to make it solid and reliable.

2.5 Check and clear the sewage bucket and plug-in board device in the separation room

2.6 Check and clear the holes of the ring-shaped header tank and the radiation tank.

2.7 Check and clear the dosing pipe and sampling pipe.

2.8 Check and clear the air separator.

2.9 Check and repair the sewage valve, emptying valve and other valve pipelines.

3.3 The agitator and mud scraper pass separately the trial run.

3.4 The body and inner facilities pass the acceptance.

3.3 The inlet water and dosing trial run and output water quality are up to the standard.

3.4 After the trial run is qualified, handle the end procedures the work sheet.

and have no crack and are installed firmly.

4. Catchment handle is levelly good, the small water outlet is clean, the running water is smooth and the level error is no more than 2mm.

5. Sampling pipe is smooth and the sampling points provide correct locations.

6. The pipeline of the smooth system is dosing, the output of the dosing pump is normal and there is no abnormality when the machine rotates

7. Valve switch is flexible and the packing is not leaked and the sealing performance is good.

8. Sludge bucket wall is integral, the erosion resistant coating is good, and the movable plug-in board acts flexibly and is tight but is not leaked.

9. The deviation error of the spindle center line of the mechanical mixing device and the center line of the second reaction room should not be more than 0.5% of the diameter of the second reaction room.

10. The distance between the mud scraper and the tank bottom shall be not less than 5mm and the error is +4mm.

3.1.3.3 Air scrub filter chamber

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Name Maintenance of air scrub filter chamber Type Type of tank


1 Preparation for maintenance

1.1 understand the operation status and existing problems of the equipment.

1.2 Prepare adequate filter sand

1.3 Prepare tools for screening filtering layer

1.4 Backwash once thoroughly before decommissioning

2 Check the unloaded filter materials out of the filtering layer

3. Clean and check the grille and so on inside.

4 Paint the anti-corrosion paint and fill the filter material

2.1 Contact with the operator, backwash the filter chamber required for maintenance and withdraw from operation, and prepare for maintenance.

2.2 Open the outlet valve of the drain pipe and drain all the water in the filter chamber.

2.3 Open the access door

2.4 Observe the levelness of the filter chamber and the present pit subsidence.

2.5 Measure the height of the filtering layer.

2.6 Check whether there is agglomeration phenomenon for the filtering materials with different depths and make records aobut all the inspection work.

2.7 Unload filter sand first, and then unload the cushion coat in different layers and stack them separately.

2.8 Clean and screen respectively

3.1 Rinse the inside of the filter chamber with pressure water.

3.2 Repair the cracks of the shell with the bad oxygen glass.

3.3 Take out the grille, wash and check it block by block, repair or replace the damage piece.

3.4 Fix the grille stent firmly and replace the bent or corroded or damaged support parts.

4.1 Do painting after all the maintenance work is completed.

4.2 After drying the paint film, reassemble the

Be careful not to mix. Anti-corrosion inside and outside is intact and the filter chamber has no leakage.

1. Cushion coat and filter layer are quartz sand without other debris mixed, and the sizes of their seeds should meet the specifications.

2. The level error of the grille installed is less than 3mm.

3. The filter layer and cushion coat filled should be level and the level error is less than 3mm.

4. The backwashing system is normal, without leakage

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grille, install padding in different layers levelly (inspected with the level gauge), and assemble the filter material.

phenomenon after siphon.

5. The effluent transparency meets the water quality standard.

6. The filter chamber has no leakage.

7. The equipment and environment are clean.

3.1.3.4 Tank related to water purification system（taking chemical water tank as example）

Name Chemical water tank Type Type of tank


1. Stop the last pump (Prevent the pump from fanning the air) when the the water level reduces to the minimum limit.

2. Install another temporary drainage pump (or submersible pump) to basically drain the water in the tank.

3. Wash the bottom with water and clean the debris in the catchpit.

4. Clean and check the inlet screen and the bottom valve of the pump.

5. Do anti-corrosion treatment on metal parts.

6. Check comprehensively whether there are cracks and abnormal situations in the concrete pool, and treat them timely.

7. Re-check the bottom and add drugs after the there are surely no debris in the catchpit

1. The inlet screen of the pump is intact and is not blocked and the check valve is flexible.

2. There are no debris on the bottom of the tank.

3. The concrete structure has no cracks

4. Paint anti-corrosion paint on metal part for three times

3.1.3.5 Coagulant dissolving tank

Name Coagulant dissolving tank Type Type of tank


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1. Drain the surplus water and wash the precipitation drugs in the tank

2. Check the outlet screen and update depending on the actual condition

3. Check concrete erosion resistant coating and paint a layer of epoxy glass depending on the actual condition

4. Repair the valve according to the maintenance regulation of the valve.

5. Clear dire in the inner wall of related pipeline.

1° Tank is clean without debris

2° Erosion resistant coating is intact, without leakage.

3° The valve is opened flexibly, without leakage.

3.2 Common faults and trouble shooting of water purification system

(No, gradual improvement after the equipment operation and maintenance)

3.3 Special tools and spare parts for maintenance of water purification system

3.3.1 Agitator of the clarification tank and spare parts of mud scraper:

one set of agitator motor, one set of slowdown motor, three transmission belts, a chain, as well

as two indicator ights and two switches of electric control cabinet.

3.3.2 Air scrub filter chamber and spare parts and special tools of ancillary equipment:

S/N Name Specification & model Qty Production

Place Manufacturer Remark

1 bearing Supporting blower 2 sets Jiangsu Jiangsu

B-Tohin

2 Mechanical seal Supporting blower 2 sets Jiangsu Jiangsu

B-Tohin

3 Gasket Supporting blower 2 sets Jiangsu Jiangsu

B-Tohin

a. List of spare parts in operation for three years

S/N Name Specification & model Qty Production

Place Manufacturer Remark

1 Stainless steel water hap 1Cr18Ni9Ti 10 pcs Jiangsu Jiangsu

Binpeng

2 Roots blower belt Supporting blower 1 set Jiangsu Jiangsu

B-Tohin

b. Special tools

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S/N Name Specification & model

Qty Production Place

Manufacturer Remark

1 Special wrench of water hap 1Cr18Ni9Ti 3 sets Jiangsu Jiangsu Binpeng

4 Maintenance of feed-water treatment system equipment



Equipment output Filling

S/N

Equipment name

Qty

Nomial diameter Norma

l Maximum Model Height

Grain diameter

mm

1 Activated carbon filter 4 DN2800 60 73 2.0m 0.8~1.6

2 Strong acid cation exchanger

2 DN2500 120 145 001X7 1.6m 0.315-1.25

3 Decarbonizerand blower 2 DN1600 120 Multi-plane

ball H=1600mm

4 Middle water tank 2 V=10

m3

5 Strong acid anion exchanger 2 DN2500 120 145 D202II 2.5m 0.315-1.2

5

6 Mixed bed 2 DN2000 120 150 MB001X7

MB201X7

Cation =500mm

Anion =1000mm

0.7-1.25

0.7-1.25

7 Hydrochloric acid storage tank

2 V=25 m3

8 Alkali storage tank 2 V=25

m3

9 hydrochloric acid metering tank（cation）

1 V=1.6m3

10 Hydrochloric acid metering 1 V=1.0m

3

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Equipment output Filling

S/N

Equipment name

Qty

Nomial diameter Norma

l Maximum Model Height

Grain diameter

mm

tank（mixed）

11 Alkali metering pump（anion） 1 V=1.6m

3

12 Alkali metering pump（mixed） 1 V=1.0m

3

13 Acid mist absorber （ with filling）

2 DN500

14 Hydrochloric acid metering pump（cation）

1 Cation bed 2.6t/h(0.4mpa)

15 Hydrochloric acid metering pump（mixed）

1 Mixed bed 1.0t/h(0.4mpa)

16 Alkali metering pump（cation） 1 Anion

bed 2.0t/h(0.4mpa)

17 Alkali metering pump（mixed） 1 Mixed

bed 1.0t/h(0.4mpa)

18 Resin catcher 2 Mixed bed

19 Safety shower 2 Pedal type, 1Cr18Ni9Ti material (including eye bath, spray-head, wash basin and accessories, etc.)

20 Compressed air tank 2 V=8.0m3 Material: 16MnR design, safety valve is

DN80PN1.6MPa

4.1.2 Overview the structure of feed-water system equipment

4.1.2.1 Cation exchanger The internal structure of cation exchanger is shown in Figure 3-1. The inner diameter of the

exchanger is 2500mm and the total height of the equipment is 7342mm. Two-layer line with

rubber is used for preservation of the inner surface of the cylinder and the seal head, and a

layer of 3mm thick accessory and receiving pipe line with rubber is positioned in the cylinder

body. There are a water inlet device, drainage, device, distribution device of renewable liquid

and middle discharge device in the cylinder body. The external pipeline interface of the

exchanger is shown in Figure 3-2.

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Fig.3-1 Fig.3-2

Water inlet device:

The water inlet device is used to distribute the inflow water on the wetted cross-section of

the exchanger uniformly, so it is also said water distribution device, and it is also used to collect

backwashing drainage uniformly. The material of the water inlet device is the concave pore

plate of carbon steel line with rubber.

Drainage device:

The drainage device is used to collect the processed water uniformly and distribute

backwashing water uniformly, so it is also known as water distribution device. The drainage

device of the cation exchanger is quaquaversal porous plate quartz sand layer type, as shown

in Figure 3-2. The gradation of quartz sand is shown in the following table 3-1.

Table 3-1 Quartz sand gradation

Level（down to up）

1 2 3 4 5

Thickness（mm）

250 150 100 150 200

Grain diameter（mm）

32～16 16～8 8～4 4～2 2～1

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Middle liquid drainage device:

The middle liquid drainage device is primarily used to enable the renewable liquid and

cleaning water flowing upward to be discharged from the device evenly, so as not to disturb the

resin layer because the liquid flow strings upward; secondly the device also serves as small

backwashing water and small positive washing and drainage. Its structure is the mother tube

branch type, and it is made of 316L and the trapezoid wire water hap is used in its branch to

communicate with the liquid channel and prevent the loss of resin, as shown in Figure 3-3.

Fig. 3-3

Renewable liquid distribution device:

Renewable liquid distribution device is used to distribute renewable liquid into the resin

layer uniformly, and the renewable liquid distribution device of the cation exchanger is also used

as a drainage device. That is, the renewable liquid enters into the quaquaversal perforated plate

in the opposite direction along the outlet pipe and then into the resin layer through the quartz

sand cushion coat.

Resin layer and compacted layer:

Cation exchanger is equipped with resin layer and compacted layer, and there is

backwashing room in its upper part. Resin layer is used as the exchange agent to exchange the

ion in water. 001 × 7 strong acid cation exchange resin is installed inside and the height of the

resin layer is 1800mm, and the volume is about 8.83m3. Pressure lipid layer is used to filter the

suspending impurities in the water to prevent resin from being polluted; at the same time when

it is renewable, the top pressure air through the pressure lipid layer evenly acts on the whole

surface of the resin layer, to prevent the resin layer from moving upward or loosening. The

material of the pressure lipid layer is of the same type of resin and the thickness is 200mm.

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Backwashing room is used for the resin layer to expand when the resin is backwashed, and its

height is equivalent to 100% of the height of the resin layer.

4.1.2.2 Anion exchanger: The inner diameter of the anion exchanger is 2500mm, the height of the resin layer is

1800mm, the resin is 201 × 7 strong base anion resin and OH bed operates. Its structure and

pipeline connection are the same as the cation exchanger.

4.1.2.3 Decarbonizer: When the decarbonizer works, water goes into it from the upper part and pours down

through the water distribution device, and is discharged into the water tank from the lower part

through the filling layer. The air for removing CO2 enters from the blower into the decarbonizer

bottom and is discharged from the top through the filling layer. The decarbonizer body is a

cylindrical container that does not bear pressure, the inner diameter of the decarbonizer is

1600mm and the height is 4428mm, the height of the wind room at the lower part is 850mm,

two layers of lines with rubber positioned on the inner wall of the decarbonizer are used for

preservation, the thickness of each layer is 3mm, and the thickness of lines with rubber of the

receiving pipe and other accessories is 3mm. The filling of the decarbonizer isφ38 plastic

multi-faceted hollow ball, the height of the filling layer is 2500mm, the water distribution device

at the upper part is the mother tube type, and the blower of the decarbonizer is CJQ-22

high-efficiency centrifugal type, the wind capacity is 3000m3/h, and the wind pressure is 1265Pa

and it is equipped with DQ-22 type φ230 silencer. The decarbonizer and the middle water tank

are connected into a whole through flange and the total height is 7572mm. The structure is

shown in Figure 3-4.

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Fig. 3-4

4.1.2.4 Activated carbon filter Activated carbon filter has the filter material of activated carbon, which is a full porous

material with great surface area and provides organic matter with strong absorption. After water

passes through the activated carbon filter, the organic matter in water is absorbed and its

content declines. While removing the organic matter, the active nitrogen, oil colloidal silicon,

iron and suspended materials in water are also removed, thereby preventing the cation resin

from being oxidized and degraded, delaying the pollution to organic matter and colloidal silicon

of anion resin and extending the life of resin. The structure includes a water inlet device, water

outlet device (composed of perforated plate and ABS long handle water cap) and filling

(coconut capsomere activated carbon).

4.1.2.5 Mixed bed ion exchanger Mixed bed ion exchanger is regarded as a multi-stage mixed bed composed of a lot of

anion and cation resins that are staggered and arranged because anion exchange resins and

cation exchange resins are placed in the same container and first generate into OH type and

H-type, and then are mixed evenly before the mixed bed ion exchanger operates. Its body is a

cylindrical pressure container, including internal device and external pipeline system. Its inner

diameter is 2000 mm, the height of resin layer is 1500 mm, the total height of the equipment is

5429 mm, and the anti-corrosion measures are the same as the cation exchanger. Its water

inlet device and middle draining device are the same as the cation exchanger, the difference is

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that the draining device at the lower part is the perforated plate water hap type, acid and

compressed air are also input into the draining device and the middle draining device is

installed at the interface of the anion and cation resin. The alkali input device at the upper part

is the line branch pipe type. The structure is shown in Figure 2-4-21.

Fig. 2-4-20 Fig. 2-4-21

4.1.3 Maintenance of feed-water system equipment

4.1.3.1 Maintenance process of cation bed and anion bed

Type Maintenance of cation bed and anion bed Type Type of bed body


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Check 1. Check the resin layer

1.1 First of all backwash the ion exchanger large (by the operator), and then drain the surplus water inside the container.

1.2 Open the upper manhole door, check the height and levelness of the exchange resin layer and whether the surface is level, as well as the broken or polluted exchange resin, and inform the laboratory staff to take the ion exchange resin samples.

2 Exchange resin recovery

2.1 Determine the recovery methods according to the pollution condition of ion exchange resins.

3 Dumping cushion coat

3.1 Open the manhole door, and unload the remaining exchange resin (take care not to touch the quartz sand cushion coat) first.

3.2 Check whether the cushion coat is level and there is mixed layer.

3.3 Unload the filling in different layers, clean, dry and screen them and then store them separately.

1° The quartz sand cushion coat should be levelly filled and the error is not more than 2mm; those with a large grain diameter are installed on the lower layer. The rain diameter is 16 to 25mm thick; 8 to 16mm, 100mm thick filling, 4 to 8mm, 100mm thick filling; 3 to 4mm, 100mm thick filling; 2 to 3mm, 200mm thick filling.

2° The grain size of exchange resin should be more than 50 packages, and there shall be no mixed debris; the installation height 200mm above the middle distribution pipe.

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4 Maintenance of the upper and middle water distribution devices

4.1 Remove the nylon cloth packed on the distribution pipe.

4.2 Check the corrosion and damage to the distribution pipe and stent, and replace the damaged parts.

4.3 Check the levelness of the upper and middle distribution pipes, which need be leveled if the level error is not more than 3mm.

4.4 Check whether the nylon cloth is damaged, and replace the damaged nylon cloth.

5 Check erosion resistant coating

5.1 Check the internal erosion resistant coating of the ion exchanger (whether the paint or lining is intact). Carry out the electric spark test when necessary.

5.2 If the erosion resistant coating is only partially damaged and the area of the damaged part is not large, the damaged part can be eradicated and plastic or lining epoxy glass is re-filled.

6 Maintenance of the subsidiary pipe valve

6.1 Replace or repair the valve that is not close.

6.2 Replace the valve gaskets that are not close.

6.3 Replace the corroded and damaged pipe section.

7 Ion exchanger recovery

According to the inverse order of disassembly, the following several points shall be paid special attention to:

(1) Begin to install cushion coat and ion exchange resins only if the internal erosion resistant coating is completely solidified and stabilized.

(2) The method for packing the nylon cloth on the distribution pipe is:

Seam the nylon cloth in accordance with the size of the distribution pipe into the pouched shape (dual seams seamed), and then cover it on the distribution pipe, and tie it with nylon rope generally every 100mm once.

(3) Fill the cushion coat in different layers, fill each layer levelly and check the levelness of the cushion coat with the irrigation method

1° The upper and middle distribution pipes should be level and the error is not more than 10mm.

1° 0.58 Mpa water pressure test done meets the requirement after maintenance.

Level error is less than 2mm.

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4.1.3.2 Maintenance process of fine sand filter(multi-media filter)

Type Mechanical filter Type Type of bed body


1. Close the inlet and outlet water valve and open the drainage door to drain the surplus water in the bed.

2. Open the manhole door at the upper part.

3. Unload the quartz sand, anthracite filter material.

4. Check the water inlet device and re-tighten all the screws.

5. Disassemble the draining device to clean and check it, and pay attention to debris falling into the water outlet hole.

6. Check the epoxy resin paint and clean debris in the bed.

7. Check and rub the pore plate.

8. Recover the water outlet device after all the maintenance work in the bed is ended and it is confirmed there is no debris.

9. Load anthracite, quartz sand filter material.

10. Close the manhole door to do hydrostatic testing.

11. Check and repair the valve according to the maintenance requirements of the valve.

1° The channel of the water inlet device is open and unhindered.

2° Antirust paint inside the bed is intact.

3°Antirust paint outside the bed is intact.

4° Clean the pore plate as bright.

5° The grain size of quartz sand is 0.5 to 1.2mm, the grain size of anthracite is 0.5 to 1.2mm, and the height of filter material filled follows the original one.

6° Quartz sand is paved levelly.

7° Various decay resistance rubbers and washers are replaced by new ones.

8 ° No leakage happens under the 0.8Mpa hydraulic test.

9° All the valves are opened flexibly, without leakage

4.1.3.3 Maintenance process of mixed bed

Name Mixed bed Type Type of bed body


1. It is confirmed that water in the bed has been drained; disassemble the grease hole blind and install 100mm ball line, and use PVC strengthening pipe and unload resin.

2. Open the upper and lower big holes, and open the manhole at the bottom as appropriate.

1° The screws of the water inlet device are fastened and intact.

2° The middle draining pipe is not bent and deformed significantly

Branch PVC network is

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3. Check the water inlet device and re-tighten screws.

4. Disassemble the outlet exhaust branch and mother tube, check, clean, correct and update two cylinder liners.

5. Check and update the water outlet hap

6. Check and repair internal line with rubber. Conduct an electric spark test if the conditional is allowed.

7. Process and clean with sight glass.

8. Recover the middle racking pipe.

9. Close the first pressurised water of the manhole door after no internal debris is confirmed.

10. Open the manhole resin and close pressurised water of the manhole door.

11. All valves are checked and repaired according to the maintenance requirements.

covered with φ43 × 20 meshes, terylene network is covered with φ44 × 60 meshes, belting is packed each 200 mm and there is no hole exposed at both ends of the branch. U screw is fixed, 1mm thick rubber is padded above and below, a full pad bed is used for the flange, and after the screws are fastened, they are checked with 0.20 filler gauge.

4° The sight glass is intact and bright.

5° The height of anion resin with the model 732 is 500mm, and that of cation resin with the model 717 is 1000mm.

6° The internal line with rubber should have no strike bag, shelling, cracking phenomenon

7° The middle draining pipe does not leak grease.

8° All the valves are checked and repaired according to the maintenance quality standard.

9° No leakage happens in the 1.0Mp water pressure

4.1.3.4 Maintenance process of decarbonizer

Name Decarbonizer Type Type of bed body


1. Shut off power supply of the decarbonization fan, and move away the upper cover of the decarbonizer.

2. Disassemble the branch of the main water inlet pipe.

3. Open the lower manhole door and unload

1° The height of multi-faceted hollow ball loaded is 3000mm and it is integral.

2° The lower angle of the water inlet pipe φ6 hole surface is 90°.

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the multi-faceted air ball.

4. Check whether the lower scaleboard (P, V, C) is intact, and hoist the upper shell as appropriate.

5. Check and repair the internal line with rubber and carry out the electric spark test if the condition is allowed.

6. Clean, check and clear the small hole φ6 of the water inlet branch pipe, recover the water inlet device and close the manhole door.

7. Add φ50 multi-faceted hollow ball, to prevent debris from entering.

8. Recover the upper cover and connect the escape pipe.

9. The efficiency of removing CO2 is up to the design requirements no less than 95%.

3° No strike bag, shelling or crack phenomenon of the line with rubber in the inner wall of the cylinder should exist.

4° No Yaohua phenomenon exists in PVC pipe.

5° The material of all screws is 1Cr8NigTi and other materials are prohibited

4.2 Common faults and trouble shooting of feed-water system equipment

(No, gradual improvement after the equipment operation and maintenance)

4.3 Special tools and spare parts for maintenance of feed-water system equipment

4.3.1 List of essential spare parts (guarantee three-year operation period)

S/N Name and specification Qty

1 DN150 sampling ring 3 pcs

2 DN500 manholegasket 5 pcs

3 DN150 rubber gasket 5 pcs

4 316L water hat（1t/h） 5 pcs

4.3.2 List of special tools


1 Special wrench of water hap 2

4.3.3 Mandatory spare parts


1 strong acid cation exchange resin 001×7 1.9m3

2 Strong alkali anion exchange resin 202Ⅱ 2.8m3

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3 MB001×7 0.4m3

4 MB201×7 0.7m3

5 Sampling valve DN15 10 个

6 Each metering pump is equipped with a set of seal ring and bearing

5 Maintenance of Blower

5.1Technical specification and structure of equipment

5.1.1 Technical specification of equipment

S/N Name Model Flow Pressure Qty

1 Roots blower of feed-water neutralizing tank

SRD-100 8.86m3/min 0.098MPa 2

2 Roots blower of generating unit drain tank

SRD-100 8.86m3/min 0.098MPa 2

3 Decarbonization blower CQ20-J 3600Nm3/h 1.5KPa 2

5.1.2 Overview of the structure of Blower

5.1.2.1 Roots blower

Roots blower is a volume type blower, its transmitted air volume is in proportion to the

number of rotation, and two impellers suck and exhaust for three times every three-blade type

impeller rotates . Compared with the two-blade type, its gas pulsation is small, vibration is also

small and noise is low. A slight gap has always maintained between the impellers of 2 shafts of

the blower and the inner hole surface of the oval-shaped shell, between the impeller end

surface and the front and back end surface of the blower and between the impellers of the

blower, and air is transmitted to the discharge side along the inner wall of the shell from the inlet

of the blower driven by the synchronized gear. Intracavity of the blower does not need lubricant,

its structure is simple and it operates smoothly with stable performance.

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5.1.3 Maintenance of Blower

5.1.3.1 Maintenance of decarbonization blower

Name Decarbonization blower Type Type of bed body


Disassembly and

1. Disassemble the air intake trumpet of the blower.

1° Static balance blower is no more than 5g

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assembly 2. Disassemble the insurance, locknut and impeller.

3. Check the blower scroll casing, which should have no rust, and the combination surface bolt of it with the decarbonizer is intact and has no rust.

4. Conduct the static balance test of the impeller.

5. Clean and check all the parts.

Install the imported horn trumpet and the hand tray blade has no sticking point.

2° Impeller flutter is no more than 0.05mm.

3° The gap between the impeller and the shaft is 0.01 to 0.03mm.

4° The axle head should limit and loosen the locked nuts.

5° The hand tray has no sticking point.

6° Serious noise does not occur in the operation and vibration is good.

7° The impeller is D rotation type.

8° There should be rhombus strainer at the inlet side and the specification is 10 × 10mm.

5.1.3.2 Maintenance of Roots blower


1. Preparation for maintenance 2. Disassembly

1.1 Prepare the necessary maintenance tools, materials and spare parts.

1.2 Handle the maintenance work sheet and conscientiously implement all safety measures and provisions.

2.1 Disassemble the safety shield of the belt pulley, take down the dynamic belt, disassemble the belt pulley of the Roots blower spindle with Rama, and take down the transmission belt and the key block.

2.2 Take down the muffler at the inlet and the bolts connected with the muffler at the outlet side of the Roots blower. (Disassemble the blower anchor bolt if the whole is disassembled for maintenance)

2.3 Close the water inlet door of the cooling pipe of the gearbox and loosen the external connector of the cooling pipe with the gearbox.

2.4 Drain the lubricant in the blower gearbox and auxiliary tank (received by oil disc), and disassemble the gearbox and auxiliary tank.

2.5 Make marks on the corresponding position of the gearing mesh (the

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3. Check parts and measure sizes

supporting gear transmission machine is not damaged), screw off the locknut, check washer and gear pressure ring of the gear, and disassemble the gear with Rama.

2.6 Screw off the locknuts and check washers of the inner rings of all bearings and disassemble the outer ring compression rings of the bearings.

2.7 Loosen the fastening screws of the bearing seats, screw in the lid lift screw symmetrically gradually with the lid lift screw hole, withdraw from the bearing seat, and take down the bearing seat together with the bearing from the shaft. Note the bearing seat is a cast iron, with poor intensity, and it should be prevented from being damaged when being disassembled.

2.8 When disassembling the wallboard and lateral plate at both ends of the shell, disassemble the impeller and shaft.

3.1 Check parts which must be cleaned or cleared, have no rust scale, dust, and oil stain and others.

3.2 Check whether the shell, lateral plate, belt pulley, wallboard and others are cracked or damaged, and the defects found should be repaired or the corresponding parts should be replaced.

3.3 Check whether there are collision and traces between the impellers and whether there is a devil phenomenon between the impeller and the shell.

3.4 Check whether there are cracked and damaged bearing seats, which chamber groove should be intact, and the oil return hole is smooth. The O-ring rubber of the bearing seat can not be soaked in kerosene, and the damaged should be replaced.

3.5 Measure the sizes of the matching surface between the bearing seat

The high-speed gaskets between the bearing and the wallboard should be placed respectively.

The adjustment gaskets between the disassembled bearing seat and wallboard should be placed respectively.

When disassembling the bearing seat and the bearing, the impeller shaft should be supported and padded to prevent bending and damage.

No crack or damage

The bearing with corrosion, wear and loosening and other defects should be replaced.

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and the outer ring of the bearing, and the sizes should meet the required values.

4.Assembly

3.6 Do not take apart the gear ring and wheel spider if they match reliably and closely, and check whether the tooth surface is worn.

3.7 Verify the matching condition of the skeleton oiltight and the shaft at the shaft run-through place, and the oiltight which spring has lost flexibility or sealing surface is worn should be replaced.

3.8 The damaged nuts and gear gaskets for locking the bearings and gears on the shaft when being taken apart should be replaced.

3.9 The impeller should work closely with the shaft without loosening phenomenon, and the damaged Maze groove and thread, key slot and others should be repaired and those that are unable to be repaired or changed should be replaced.

3.10 Dredge the cooling pipe and the connecting fastener is intact.

3.11 Remove the dust adsorbed inside and outside the inlet and outlet (filter) muffler, and blow and clean it with compressed gas, to ensure the smooth airway. Check whether its internal and external are damaged.

3.12 The occlusometer is sent to the heat engineering branch for inspection.

4.1 Assembly follows the reverse sequence of the disassembly.

4.2 The shell should be clean, without debris.

4.3 To prevent “interference” phenomenon from happening due to the collision between the impeller and the shell, lateral plate and the impeller with the gear in the functioning process, a certain gap

4.1 The gap δ1 between the bearing and the shell has been guaranteed within the provided scope in manufacturing at the factory and need in general be adjusted.

4.2 Measure the thickness of the original gasket between the reference wallboard and the shell, and the thickness of the gasket is appropriately adjusted in accordance with the installation requirements, so that the total gap

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must be maintained in the installation process between the impeller and the shell, between the impeller and the front and rear board and between the impeller and impeller and meet the required value. The regulated backlash must be maintained between the gears.

4.4 The locking nuts of the bearing and gear should be fastened with crescent wrench.

4.5 When the belt is assembled, the hand hammer is prohibited to directly strike the wheel edge and the axle hole and other weaknesses.

4.6 Install the cooling water pipe connector of the gearbox and check that the waterway must be smooth without leakage phenomenon.

4.7 After assembly of all parts has been completed, add the appropriate machine oil to both ends of the fuel tank (N68 machine oil for summer and N32 machine oil for winter).

4.8 Turn the belt pulley, and inform the staff on duty to trial run if it rotates flexibly and there is no devil collision phenomenon.

between the impeller end surface and the lateral plate is 0045 to 0.65mm. Then, the adjustment gasket between the rear wallboard and the bearing seat is used to adjust the gap δ3 and δ4 of both end surfaces of the impeller and the front and back lateral plate. In the process of adjustment, 5 to 10kg force should be imposed on the shaft, and measurement is conducted along the thrust direction of the bearing.δ3 and δ4 are separately adjusted to 0.25 to 0.35 and 0.20 to 0.30.

4.3 The impellers run relatively at various locations and the gap δ2 between them should be maintained at 0.20 to 0.35. It is detected by the location as shown in the figure, and if the gap has varying size and the size exceeds the required value, the fastening bolts of two gear wheels of the transmission gear may be slightly loosened and two impellers are rotated to the mesh surface with small gap; make a mark first, then move the meshing machine with small gap upward, or beat the mark on the impeller with a mallet or copper rod slightly so that relatively small displacement between the gear wheel ring and wheel spider occurs; adjust the gap between the impellers to meet the required value, and then lock the fastening bolts of the gear wheel.

5. Trial run and acceptance

5.1 Trial run and acceptance shall be carried out by persons responsible for maintenance, operators on duty and other relevant staff commonly participating.

5.2 Check whether there is friction, collision or other unusual situations of Roots blower in operation, and the unusual situations must be promptly eliminated and the blower with idle load runs for 20 to 30 minutes.

4.4 The gap of the gearing side should be ensured at 0.05 to 0.08 mm.

4.5 After the belt pulley is installed, it should be adjusted so that the belt and the end surface on the belt pulley of the motor are on the same plane, and the error should be controlled below 1.18 mm, and the nonparallelism of two pulley axes should be less than 0.6mm.

4.6 The belt tension should be

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5.3 After it with idle load trial runs normally stably, it can be gradually re-loaded to the provided pressure in operation, and it is not allowed to exceed the rated pressure and also stop suddenly when being fully loaded, so as to avoid damage to the equipment.

5.4 After the equipment trial runs normally, the maintenance and operation personnel both sides handle the procedures for acceptance.

adjusted to meet the requirements of the figure.

5.2 Common faults and trouble shooting of blower

S/N Fault Possible reasons Eliminating methods

1

Friction between impellers

(1) There are pollution impurities on the impeller, resulting in too small gap;

(2) The gear wheel is worn, resulting in big backlash;

(3) The gear wheel is not fixed strongly, and the impeller can not remain synchronous;

(4) The bearing worn results in the clearance increased.

(1) Remove dirt and check whether the inner part is damaged;

(2) Adjust the gear gap, and replace the gear if the gear backlash is more than the average value by 30 to 50%;

(3) Re-assemble the gear, and maintain the taper and the contact area up to 75%;

(4) Replace the bearing;

2 Impeller and wallboard, impeller top and shell

(1) The installation gap is not correct;

(2) Operation pressure is too high and is beyond the specific value;

(3) The operating temperature is too high;

(4) The shell or seat is deformed and the blower positioning fails;

(5) The axial positioning of the bearing is poor.

(1) Re-adjust the gap;

(2) Identify the reasons for overloading, and reduce the pressure to the specified value;

(3) Check the accuracy of installation and reduce the pipeline pull;

(4) Check and repair the bearing and ensure the clearance.

3 Too high temperature

(1) The oil in the oil tank is too much, thick and dirty;

(2) The filter or muffler is blocked;

(3) The pressure exceeds the

(1) Lower oil level or hold between oil;

(2) Remove blockage;

(3) Reduce the pressure difference through the

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specified value;

(4) The impeller is excessively worn and the gap is big;

(5) The ventilation is bad and indoor temperature is high, resulting in high temperature at the entrance;

(6) The operating speed is too low and the belt skids.

blower;

(4) Repair the gap;

(5) Opened the vent and lower the room temperature;

(6) Increase the rotation speed and prevent the belt from skidding.

4 Inadequate flow

(1) The inlet filter is blocked;

(2) The impeller is worn and the gap is increased too much;

(3) The belt skids;

(4) The loss of inlet pressure is large;

(5) The ventilation leakage is caused by pipeline.

(1) Remove the dust and blockage of the filter;

(2) Repair the gap;

(3) Tighten the belt and increase the number;

(4) Adjust the inlet pressure to the required value;

(5) Check and repair the pipeline.

5 Leak oil or leak out oil to the shell

(1) The oil level of the oil tank is too high and oil is leaked out of the oil discharge outlet;

(2) Oil seal is worn, causing oil leakage at the shaft;

(3) The pressure is higher than the specific value;

(4) The vent of wallboard and oil tank is blocked, causing oil to leak into the shell.

(1) Lower the oil level;

(2) Replace the oil seal;

(3) Dredge the vent, install a cock with 2 mm aperture in the middle chamber and open the cock under the wallboard;

6

Stop once abnormal vibration an noise

(1) The clearance of the rolling bearing exceeds the specific value or the bearing is worn;

(2) The gear backlash is too large and is not centralized or fixed tightly;

(3) The impeller impacts another impeller and shell caused by the external substance and dust;

(4) The impeller collision is caused by the overload and the deformed shaft;

(5) The friction on the entrance to

(1) Replace the bearing or bearing seat;

(2) Re-load the gear and ensure the backlash;

(3) Clean the blower and check whether the shell is damaged;

(4) Check back-pressure, check whether the impeller is aligned, and adjust the gap;

(5) Check the filter and back-pressure, and increase the gap between the impeller

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the impeller and shell is caused by the overheating;

(6) Due to fouling or foreign body, the impeller is out of balance;

(7) Anchor bolts and other fasteners are loose.

and shell inlet;

(6) Clean the impeller and shell and ensure the working space of the impeller;

(7) Tighten the anchor bolt and level the base.

7 Motor over load

(1) The pressure difference is big compared with the provided pressure, that is, back-pressure or inlet pressure is too high;

(2) The blower flow is too big compared with the flow required by the equipment, thus increasing the pressure;

(3) The inlet filter is blocked, and the outlet pipeline is hampered or blocked;

(4) The rotation parts collide and rub (blocked);

(5) The oil level is too high;

(6) Narrow V-shaped belt overheats, vibration is too large and the belt pulley is too small.

(1) Reduce the pressure to the provided value;

(2) Put surplus air into the atmosphere or reduce the blower speed;

(3) Remove the obstacles;

(4) Shut down immediately and check the reasons;

(5) Transfer the oil level to the correct location;

(6) Check the belt tension, and change into a large-diameter pulley.

5.3 Special tools and spare parts for blower maintenance

5.3.1 List of SRD type spare parts（4 sets）

S/N Name of spare parts Model/specification Qty

1 Skeleton oil seal(GB9877.1-88) 55×78×12 8

2 Stopping gasket (GB858-88) φ45 8

3 Stopping gasket(GB858-88) φ60 8

4 O type seal ring (GB1236-76) 55*3.1 8

5 V type seal ring T80.1-RD 90×70×9 8

6 Narrow V belt 8

6 Maintenance of hydrogen production system equipment

SEC






S/N Item Unit Data

1 Hydrogen making machine

Hydrogen treatment volume Nm3／h 8．4

Working pressure MPa 0.7

Purity of outlet hydrogen ％ 99. 8

Purity of outlet oxygen ％ 99.5

Humidity of outlet hydrogen mg/m3 ≤0.049gH2O/N.Cu.m3

Temperature of outlet hydrogen ℃ 35

Requirement of cooling water

Cooling discharge of stream m3／h 2.64

PH valve ≈7

Dissolve solid content ppm 1

Hardness （ take CaCO3 as example） ppm 1

2 Cylinder manifold


Qty Set 1

Manufacturer Beijing CEC

3 Pure water tank

Volume m3 0.219

Outside diameter mm 2700*1800*2270

Qty Set 1

Manufacturer Beijing CEC

4 Hydrogen compressor

Hydrogen yield Nm3／h 0.8～20

Inlet pressure Mpa 1.0

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S/N Item Unit Data

Outlet pressure Mpa 5．0 -15.0

Working temperature ℃ -36—50

Working voltage V(DC) 380

Dimension mm 550×300×700

Qty Set 6

Manufacturer Beijing Tiangao

5 Storage tank

Type Vertical type

Design pressure MPa 15.5


Design temperature ℃ 50

Working temperature ℃ -36~50

Volume m3 0.51

Diameter mm 457

Wall thickness mm 22

Total height mm 3810

Material 16MnR

Qty Set 27

Manufacturer Kaiyuan Chemical Engineering & Machinery

6 Demineralized water cooling device

Model CLZ-100

Closed cooling water flow: T/h 10

Industrial cooling water flow: T/h 25

Closed cooling water pressure MPa 0.2-0.6

Volume of reflow water tank: m3 1.4

Power： KW 8

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S/N Item Unit Data

Qty Set 1

6.1.2 Overview of hydrogen production system equipment structure

6.1.2.1 Electrolyzer

The heart of HM hydrogen production system is electrolyzer. The structure of HM

electrolyzer provides tight tolerance, and special equipment and tools are necessary for

handling it. Electrolyzer compriss a row of single in tank rooms on which respective electrode

surface hydrogen and oxygen are produced. Each tank room contains a hydrogen electrode,

fluid network, one diaphragm, n oxygen electrode and fluid network. The electrodes in each

tank room are separated by a porous paper diaphragm with the soaked electrolyte. The humid

paper diaphragm material is made into a gas-tight membrane, thereby preventing the produced

gas from re-combining. The thin tank rooms in the electrolyzer aare connected in series with

bipolar plates. All tank rooms are pressed between two pressure plates by 16 screws distributed

evenly around the pressure plate. This structure is often referred to as bipolar or pressure filter

structure and eventually becomes a compact and efficient electrolyzer.

The electrolyte flows through each tank room circulatorily, as required for electrolyzer

assembly. The electrolyte flows only circulatorily through half of each tank room at the cathode

(oxygen). The simple wetting process is achieved through the pressure of oxygen slightly higher

than the pressure of hydrogen produced. The pressure difference can enable the paper

diaphragm to maintain the electrolyte to be moist, thus preventing electrolyte from overflowing

from half of each tank room at the cathode (hydrogen).

6.1.2.2 Diaphragm compressor

A crankcase, crankshaft connecting bar operating mechanism, cylinder body part,

transmission part and some accessories form mainly into Z structure. The cylinder body part

includes cylinder cover, cylinder body and valve and other parts. A curved surface with a special

shape is separately positioned on the cylinder cover and cylinder body, and a group of metal

membranes are clamped in the middle, forming respectively two cavities, of which the cavity at

the side of the cylinder cover is a cylinder and the cavity which is positioned on the side of the

cylinder body and is communicated with the space below the cylinder body through many small

holes in the cylinder body is a fuel tank. The fuel tank piston is connected with the connecting

bar through a crosshead, the inlet and outlet valves of the compressor are positioned in the

valve hole of the cylinder cover, and the crankcase is equipped with a compensation pump

driven by the partial sleeve at the crankshaft end. The compressor also has oil and gas display

meters. The compressor power is transmitted by the motor through triangular belt to the host.

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Working principle: taking the piston positioned on the upper stop point as a starting point,

when the crankshaft rotates, the piston begins to move downward, and the membrane restores

to the balance position with the sinking oil and its own elasticity, when the cylinder volume

Increases gradually, the gas in the clearance first expands and then gas is sucked from the

suction valve of the cylinder; when the piston moves to the lower stop point abd the membrane

reaches the lower limit position, the suction process of the cylinder is complete. Then, the piston

begin to move upward and drive oil, and many small holes in the cylinder body act evenly on

the membrane, pushing the membrane to deform upward, when the gas in the cylinders begins

to be compressed; when the pressure is higher than the gas pressure in the exhaust pipeline,

the exhaust valve is automatically opened, the gas is pressed out and oil pressure continues to

rise, forcing the membrane to keep close to the curved surface of the cylinder cover, draining

the gas, so the exhaust process ends. The piston in reciprocating movement drives oil, causing

the membrane to vibrate back and forth, every the membrane vibrates for a cycle under the

cooperation of the suction and exhaust valve, a circulating process including expansion, suction,

compression and exhaust is completed in the cylinder, thereby increasing the pressure of gas

transportation.

Part of oil in the fuel tank leaks to the crankcase through the clearance between the piston

and the ring tank, in order to enable the membrane to keep close to the curved surface of the

cylinder cover and drain the compression medium when the compression stroke ends, so a

compensation oil pump is installed; the compensation oil pump in the suction stroke will inject

oil into the oil cavity, the oil amount is slightly more than leakage amount, and the surplus oil at

the end of the stroke flows back to the crankcase by controlling the pressure regulating valve of

the oil pressure.

As the cylinder and the fuel tank are completely separated by the membrane and the

membrane itself is in reciprocating vibration, playing the role in a piston, it is not necessary to

increase any lubricating substance into the cylinder, the compression medium only contacts with

the metal mebrane, so it can not be strained by traces of oil, thus ensuring the purity of the

compression medium; the cylinder comprises the curved surface of the cylinder cover and the

membrane and is a closed cavity, so it has a very good sealing performance.

6.1.3 Maintenance of the hydrogen production system equipment

6.1.3.1 Electrolyzer maintenance

Name Electrolyzer Type Hydrogen production

station

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Disassembly

Reassembly

1. Disassemble the wire, pipeline, flange and bolt connected with the electrolyzer, and ensure that it is separated from other parts.

2. Lift the electrolyzer with a bottle gourd, hold up the tank, place the pressure plate at the left end downward and the pressure plate the right end upward onto the platform, loosen the clamped bolt and hang and open the pressure plate.

3. Check the corrosion status and sundries of the disassembled parts, the damaged electric arc, eindruck and diaphragm, and the damaged gasket and sealing surface of the polar plate and so on.

4. Take down the nuts and saucer-shaped spring board in series when disassmeblign the tank, lift the pressure plate at the right end with the bottle gourd, and take down the polar plates and fluorine plastic cotton cloth gasket and others block by block.

5. Make signs on the plates at all levels in order and direction (in the positive direction) when disassembling the cylinder, so as to avoid the wrong bag.

6. Disassemble small chambers of the cylinder sequentially, and take down the middle polar plate when disassembling the last polar plate, and then take down the anion polar plate, fluoride plastic diaphragm, asbestos gasket, caiton polar net and left plate block by block, followed by disassembling the cylinder.

7. Reassemble the system in the reverse sequence.

1. Pay strict attention to the general sequence and positive and negative face in the process of disassembly, and do not mix the left and right poles.

2. Disassemble the anion polar net and immerse it in the NaOH solution (10%) immediately, pay attention to the positive and negative face, and flush it until there is no dirt on the surface.

3. If a large area of nickelage on the surface drops off after cleaning the left and right polar plates, nickel on the nickelage must be fully removed or spare parts must be replaced.

4. When replacing an anion polar net, it should be immersed in 10% NaOH solution for 24 hours, and an activation layer forms on the anion ploar net.

5. Replace the disassembled fluoride plastic diaphragm cotton cloth gasket, wash the new gasket with tap water when installing the tank and then wash it with distilled water and meanwhile brush asbestos powder on the surface with nylon.

6. When assemblying the left and right polar plates, small pressure slices may not fall off.

7. When assemblying the anion polar net, the surface of the activation layer must be close to the diaphragm asbestos cloth.

8. When assembling, the nipples of the polar plates on both sides of the small room are opposite.

9. Check the 3.2Mpa gas-tight of the tank, which shall not leak.

10. After assembly, check also whether there is a short-circuit

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phenomenon of the adjacent polar plates of the tank body with 12-volt light bulb, and it is qualified if there is no short-circuit phenomenon.

6.1.3.2 Maintenance of membrane compressor

6.1.3.2.1 Methods and steps of disassembling cylinder body parts:

Disassemble the inlet and exhaust pipeline; disassemble the cooling water pipeline

connected with the cylinder cover, and the oil return pipe below the pressure regulating valve.

Take out the suction and exhaust valve with valve tools; disassemble all the nuts on the cylinder

cover; prepare two M12 bolts and screw them into two M12 screw holes outside the cylinder

cover as the suspension point of the sling, hang the cylinder cover and take out the membrane

group;

Note: before disassembling, mark the relative position between the cylinder cover and

cylinder body, so as to avoid mistakes; in the process of assembly, do not damage thread on

the bolt, so as to avoid difficulties in the assembly; pay special attention to the protection for the

curved surface of the cylinder cover and body and the surface of the membrane, as may not be

damaged, scratched or abraded.

6.1.3.2.2 Cleaning

Cleaning agent should be trichloroethylene. Clean the connectors of the inlet and exhaust

pipe, cylinder cover, suction and exhaust valve and the seal oil of the membrane with the

cleaning agent, brush them first lightly with a brush, and then rub up with clean mircofabric,

blow the surface with dry nitrogen finally, and rub and clean the piston top and the wall surface

of the fuel tank.

6.1.3.2.3 Assembly steps:

Insert metal membrane group. Note: when installing the membrane,pay attention to the

assembly sequence, there are three pieces of membrane: gas-side mebrane, middle membrane

and oil-side membrane; there are two positioning holes in the oil side and middle membrane

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near the edge, there is a small hole in the middle of the two positioning holes in the oil-side

membrane, there is a gas tank in the middle membrane between the two positioning holes, and

the positioning holes of the mebrane should be covered onto the two positioning pins of the

cylinder body. Installation sequence: install the oil-side mebrane first, and then install the middle

mebrane, followed by the gas-side membrane; before installing the gas-side membrane, check

whether the alarm channel is open. Lift the cylinder cover, identify the correct position, insert

into the stud, and then slid toward the cylinder body slowly, place down the cylinder cover

slowly, so that it contacts with the cylinder body, and then check and guarantee the cylinder

cover keeps close to the mebrane along the circumference. Install all the nuts and tighten them

while increasing the torque value evenly symmetrically in at least three steps, the first is 25% of

the torque value, the second is 60% of it and the third is 100%. Install the inlet and exhaust

valve, inlet and exhaust pipeline and cooling water pipes with valve tools.

Install the oil return pipe and oil taking pipeline of the pressure regulating valve.

6.1.3.2.4 Oiling

a. The crankcase is oiled and the oiling method is: turn the crank on the crankshaft to the

lowest point first, and then inject lubricant to the crankcase, and suspend oiling when the oil

surface rises to the minimum place of the balance iron. The oiling amount is 10 liters for the first

time, but it can not be all injected once. Lubricant quality: L-HM32 advanced anti-wear hydraulic

oil is used in the machine. High-viscosity lubricants, such as L-HM46 and L-HM68 should be

replaced in summer or the high temperature environment.

b. Oil to the fuel tank: open the inlet and exhaust pipe valve of the laminator, and make it

communicate with the atmosphere, turn the flywheel mannualy for several times and activate

the laminator and oil to the fuel tank with the slippage pump on the machine;

Regular check and overhaul cycle

Accumulated running time h Inspection contents

1000 2000 4000 6000

SEC




Regular check cycle

Suction and exhaust valve of the laminator

Membrane in the working cylinder

Curved surface of cylinder cover cavity membrane Valve seat plane of thepressure regulating valve Inlet and exhaust valve and oil filter of the slippage pump Oil inlet check valve of the cylinder

Lubricant quality

Gear pump

Δ

Δ

Δ

Δ

Δ

Δ

Δ

Δ

Cycle of overhaul items

Clearance between the connecting gap block and the crank neck

Clearance between the crosshead pin and the small head copper sleeve of connecting bar

Clearance between the crosshead outer wall and crosshead sleeve

Clearance between the working cylinder plunger and the plunger sleeve

Clearance between the slippage pump plunger and plunger sleeve

Clean the crankcase oil tank and oil channel

Δ

Δ

Δ

Δ

Δ

Δ

Safety inspection

Check whether all the parts and pipelines are loose

Safety valve and pressure gauge

Check the broken alarm valve of the mebrane

At any time

Δ ＊Δ

Note: * indicates that it can also be calibrated according to the regular cycle of

measuremenet department.

Replacement cycle of wearing parts Accumulated running time h S/N Inspection contents

1000 2000 4000

1 Mebrane of working cylinder Δ

2 Pressure regulating valve seat Δ

3 Suction and exhaust valve Δ

Note: the replacement cycle varies with different using environments and conditions.

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6.1.3.3 Maintenance of lye tank

Name Lye tank Type Hydrogen production

station


1. Close the inlet stop valve and inlet and outlet lye valve of the lye tank, and open the sewage stop valve.

2. Open the inlet stop valve and then close after washing the lye sewage.

3. Open the box cover and check the inside, clean up dirt inside the box, and check the corrosion status and welding situation of the inner wall.

4. Clean the cartridge.

5. Check protective lacquer.

6. Check and repair the valve according to the maintenance process of the valve

1° The box is clean without debris, and the inner wall is intact without leakage.

2° Anti-corrosion paint is intact.

3° All the pipelines are smooth.

4 ° The liquid level of the glass tube is clear without leakage

6.2 Common faults and trouble shooting of hydrogen production system equipment

6.2.1 Unqualifid hydrogen and oxygen purity

Reason Treatment

The diaphragm is broken

The serious electrization corrosion results in polar plates corroded and perforated

Electrolyzer is required to be overhauled due to beyond the overhaul period.

The water level difference of hydrogen and oxygen pressure regulator is big

Adjust the hydrogen discharging door or oxygen discharging door, so that the water level is normal

The electrolyte in the electrolyzer is too dirty or electrolyte concentration is too low

Re-prepare electrolyte

There are sediments in the electrolyzer Electrolyzer stops backwashing

6.2.2 Electrolyzer leaks alkali and gas seriously

Reason Treatment

Frequent startup, uneven expansion and contraction

Strengthen the supervision in operation, to prevent the lye from emitting and wounding

Electrolyzer has been running for a long period of time, and the tightness is damaged

Reduce the number of startup and reduce the load slowly

The surface on polar plates or diaphragm framework is corroded The insulation pads are damaged

When stopping for overhaul, replace the insulation pads, polar plates, diaphragm framework and disc-type spring and so on

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Disc-type spring is fractured

6.2.3 The hydrogen production system

The hydrogen production system can not retain pressure and the hydrogen cooler lets out

sound Reason Treatment

Check whether the sewage discharge of the pollution discharge door at the bottom of the hydrogen cooler is beyond the normal range Observe whether there is a bubble in industrial water flowing out from the cooling water peep hole of the cooler Listen to whether there is sound in the cooler with ears

Stop the electrolyzer immediately if the phenomena are found, and release the pressure of the system to 0.02Mpa, and replace H2 system with N2

Hydrogen cooler is corroded seriously and perforated due to long-term immersion in the industrial water

Disassemble the hydrogen cooler for overhaul, and replace a snake tube

6.2.4 Common faults and trouble shooting of diaphragm compressor

S/N Fault Requirements Fault analysis Eliminating methods

1 No oil pressure after startup

a. Oil amount in the fuel tank is in shortage ( some oil leaks into the crankcase due to long-time shutdown)

b. Slippage pump is not normal

c. The pressure regulating valve does not work properly

d. The gear pump does not work properly

a. The oil amount can be supplemented automatically after operating for a few minutes

b. See Table S/N5 for details

c. See Table S/N6 for details

See Table S/N4 for details

2 Low or instable oil pressure

a. The pressure regulating valve does not work properly

b. The oil drain pressure of the slippage pump is small

c. The valve port of the inlet stop valve of the fuel tank valve is not closed

d. The valve port of the instrument valve under the oil pressure meter is not closed

e. The seal in the working cylinder plunger (or piston) sleeve (or piston ring) is worn too much

f. The gear pump does not work

a. See Table S/N6for details

b. See Table S/N5 for details

c. Disassemble and check the stop valve

d. Disassemble and check the instrument valve

e. Replace the seal (or piston ring)

e. See Table S/N4 for details

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properly

3 Small air displacement

The valve ports of suction and exhaust valve are not closed

The pipeline leaks air (such as loose joints and deflected pressure pipe of valve)

The oil pressure of is not higher than 10% to 20% od the exhaust pressure.

The pressure oil has air

The pretightening force of the cylinder cover bolt is too large, the mebrane is warpped and deformed

See Table S/N6 for valve maintenance

Check leakage with soap bubble and repair symptomatically

See Table S/N4 for details

Clean the oil-filter screen; check that the crankcase oil level may not be too high or low

Release the cylinder cover bolts and re-fasten according to Article 7.1.2.2

4 Low oil pressure on the gear pump

The oil level in the crankcase is low

The threshold pressure on the overflow oil valve is lower

The oil-absorbing filter screen is blocked

The meshing clearance of gear is too large

Inject appropriate oil

Adjust the overflow oil valve

Clean the filter screen

Maintain the gear pump

5 Low oil pressure on the slippage pump

a. The oil-absorbing filter screen is blocked

b. The valve port of the inlet and discharge oil valve is not closed or the steel ball stroke is too big

c. Lubricant is too thin or the temperature is too high

a. Clean the oil filter

b. See Article 11.4 for maintenance methods

c. Or change the heavy oil to reduce the oil temperature

6 The pressure regulating valve is abnormal

The oil channel is blocked

The valve port plane of valve seat is damaged

Clear the oil channel

Grind the plane or replace

7 Valve is abnormal

The valve port is not closed

The valve plate or valve slide is blocked

Spring is damaged or deformed

a. Clean and restore

b. Repair or replace

c. Replace the spring

8 Cylinder body leaks

The pretightening force of cylinder cover bolt preload is too small or

a. Re-fasten according to Article 7.1.2.2

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uneven

The sealing surface is defective or O-ring is damaged

The pipeline joint is not sealed

b. Repair or replace the O-ring

c. Replance the pad

6.3 Special tools and spare parts for hydrogen production system maintenance

6.3.1 Special tools

S/N Name Drawing No. Qty Manufacturer Price

1 Dedicated torque

wrench of Electrolyzer

10164 1 American Teledyne

2 Two-inch open wrench

5414A37 1 American Teledyne

3 Deep 3/8-inch sleeveBD-622 1 American Teledyne

Free

6.3.2 Mandatory spare parts

Spare Parts List for China Supplying equipments

1 Compressor parts 2+1 Sets

2 Electric-magnatic valve 2+1 sets

3 Safety gate 2+1 sets

4 Regulating valve H2 N2 2 set

5 Safty Valve 1 Sets

6 Ball valve 2+1 Sets

7 Bearing, bushing, wearing rings, gaskets for pump 1 Sets

6.4 Particular attentions to hydrogen production system:

1) The relevant devices and meters in the hydrogen stations must be regularly checked and

maintained to ensure their normal operation, in order to ensure that the purity and humidity

of hydrogen can meet the requirements.

2) Smoke and fire must be prohibited in the hydrogen station and near other equipment filled

with hydrogen, flammable and explosive materials are prohibited to be placed, “No

smoking” signs should be set up, there should be fences around the hydrogen storage tank

(within 10m) and there should be equipped with necessary fire-fighting equipment in the

hydrogen station.

3) Personnel unrelated to the work are prohibited to enter the hydrogen station.

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4) Operations with fire or the work with sparks produced are prohibited in the hydrogen station.

Staffs are not allowed to wear the shoes with nails, and the hydrogen amount should be

determined ahead of time if they need weld or work with fire in the hydrogen station, and

they can not work until it is confirmed that the hydrogen content in the air is less than one

percent in the working area and they are approved by the leadership (CE) in charge of

production. When the pipeline valves or other equipment in the hydrogen station are frozen,

they are unfrozen with steam or hot water but fire is prohibited. To check whether there is

hydrogen to be leaked in all connecting pipes, instruments or soapy water can be used in

inspection but fire is prohibited.

5) Before the hydrogen storage devices (including the pipeline system) and generator

hydrogen-cooled system are maintained, repair parts and connection parts must be cut off

and strict blocking plates are installed, and hydrogen is replaced by air.

6) When hydrogen with pressure is discharged or the hydrogen is inverted, the valve on the

equipment should be uniformly slowly opened so that the air is slowly released and fast

discharge is prohibited, to prevent friction from generating spontaneous combustion.

7) Air cylinder should be uprightly fixed on a rack and is not directly heated and is avoided

from direct sunlight exposure, the storage tank should be coated with white, and the

security doors of the hydrogen storage tank should be regularly checked to ensure good

action.

8) When the hydrogen station is on fire, the electrical equipment should immediately stop

operating, the power supply is shut off and the the system pressure is removed and carbon

dioxide fire extinguishers are used for extinguishment. When fire is caught due to hydrogen

leakage, carbon dioxide is used for extinguishment, asbestos cloth is used to seal the

hydrogen leakage parts so as to avoid hydrogen from escaping, or gas sources are cut off

with other methods.

9) When the hydrogen system is maintained and operated, the tools with sparks that may be

generated are prohibited to be used and copper tools should be used.

10) The hydrogen station should be equipped with explosion-proof type electrical installations.

11) There may be explosion danger if hydrogen and oxygen are mixed, the upper limit is 96%

hydrogen and 4% oxygen, and the lower limit is 5% hydrogen and oxygen 95%.

12) When the equipment in the hydrogen station is in operation, any maintenance work shall

not be conducted, and the equipment need stop operation and then repair is conducted in

accordance with the relevant provisions if repair is needed.

13) Operators should not wear synthetic fiber and wollen overalls.

14) The fresh personnel in the plant should also master the operations of the hydrogen station

and can independently work only after passing the examination.

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15) The gate of the hydrogen station should always keep closed, the kindling before entering

the hydrogen station should be submitted and registeration is necessary.

7 Valve Maintenance

7.1 Basic parameters and model of the valve

7.1.1 Nominal diameter of the valve

The diameter of the valve inlet and outlet channel is called the nominal diameter of the

valve, expressed as Dn, in unit of mm, and it means the specification size of the valve.

7.1.2 Nominal pressure of the valve

Nominal pressure of the valve is the maximum working pressure of the valve which is

allowed to bear in the baseline temperature, that is, the nominal pressure of the valve,

expressed as Pn.

The actual pressure-proof capacity of the pressure is much more than the nominal

pressure due to the safety factor considered in the design. When strength pressure-proof test is

done for the valve, it is allowed to be more than the nominal pressure in accordance with the

regulations but it is prohibited under the working state to be more than the nominal pressure,

and it is in general controlled to be less than the nominal pressure value.

7.1.3 Applicable media of the valve

There are a lot of working media of the valve, some media are highly corrosive and some

media have a very high temperature. These different media have different requirements for the

valve materials. Thus the media applicable to various types of products should be considered in

the process of design and selection of the valve.

7.1.4 Applicable temperature of the valve

Different valve bodies, sealing materials and filling are selected in accordance with different

uses when manufacturing valves. Different valves have different applicable temperatures. For

the same valve, the allowable maximum working pressures are also different in different

temperatures. Therefore, the applicable temperature must be taken into account when selecting

valves.

7.1.5 Expression method of valve model

7.1.5.1 Preparation method of valve model is shown as follows

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1 765432

Symbol of valve body material

Symbol of seal surface or lining material of valve seat

Symbol of structure form

Symbol of connection method

Symbol of transmission mode

Symbol of type

Value of nominal pressure

7.1.5.2 Symbol of type is expressed by pinyin letter

Type Symbol Type Model

Brake valve

Stop valve

Plug valve

Ball valve

Butterfly valve

Diaphragm valve

Z

J

X

Q

D

G

Check valve

Throttle

Safety valve

Reducing valve

Steam trap

H

L

A

Y

S

7.1.5.3 Symbol of transmission mode is expressed by Arabic numerals

Transmission mode Symbol transmission mode Symbol

Electromagnetic

Electromagnetic

— hydraulic

Electric — hydraulic

Worm wheel

Positive gear

0

1

2

3

4

Umbrella gear

Pneumatic

Hydraulic

Gas— hydraulic

Electromotion

5

6

7

8

9

Note:

1). The symbol is omitted for hand wheel, handle and wrench drive as well as safety valve,

reducing valve and steam trap.

2). For the pneumatic or hydraulic: open type is expressed as 6K and 7K, the pneumatic with

manual is expressed as 6S and the explosion-proof electrical is expressed as 9B.

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7.1.5.4 Symbol of connecting method is expressed by Arabic numerals

Connecting worm Symbol Connection method Symbol

Inner worm 1 Butt clamp 7

Outer worm 2 Clamp 8

Flange 4 Sleeve chuck 9

Welding 6

7.1.5.5 Symbol of structure form is expressed by Arabic numerals

Structure form of brake valve Symbol

Flexible disc 0

Single disc 1 Wedged type

Double disc 2

Single disc 3

Rising stem

Parallel Double disc 4

Single disc 5 Non-rising stem wedge type

Rigidity

Double disc 6

Structure form of stop valve and throttle valve Symbol

Straight-through type 1

Angle type 4

Direct flow type 5

Straight-through type 6 Balance

Angle type 7

Structure form of ball valve Symbol


Upper shape

Floating

Lower shape

Three-pass type

4

5

Fixed Straight-through type 7

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Structure form of check valve and bottom valve Symbol


Lifting Vertical 2

Single-lobe type 4

Multi-lobe type 5

Open Double-lobe type 6

Structure form of butterfly valve Symbol

Lever type 0

Vertical plate type 1

Sloping plate type 3

Structure form of safety valve Symbol

With thermal sink Full open 0

Low lift 1

Full open 2

Full open 4

Closed

Dual-spring low lift 3

Low lift 7

Full open 8

With wrench

Low lift 5

Spring

Open With control mechanism

Full open 6

Pulse 9

Structure form of steam trap Symbol

Floating ball 1

Inverted bucket 5

Pulse 8

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Dynamic 9

7.1.5.6 Symbol of the sealing surface of the valve seat or lining material is expressed as Pinyin letter

Sealing surface of the valve seat or lining material

Symbol Sealing surface of the valve seat or lining material

Symbol

Copper alloy

Rubber

Nylon plastic

Fluorine plastic

Sikkim bearing alloy（Babbitt metal）

Alloy steel

T

X

N

F

B

H

Nitriding steel

Hard alloy

Line with rub

Line with lead

Enamel

Boron steel

D

Y

J

Q

C

P

7.1.5.7 Symbol of the valve body material is expressed as Pinyin letter

Valve body material Symbol Valve body material Symbol

Gray cast iron

Mollealle iron

Ductile cast iron

Copper alloy

Carbon cast steel

Z

K

Q

T

C

Cr5Mo

1Cr18Ni9Ti

1Cr18Ni12Mo2Ti

12Cr1MoV

I

P

R

V

7.2 Overview of structure of general valve in water treatment pipeline system

7.2.1 Gate valve (Z)

Disc driven by the stem moves relatively along the sealing surface of the valve seat until

opening the valve, such is called gate valve.

7.2.1.1 Characteristics and uses of gate valve

Gate valve is provided with features of good sealing performance, small flow resistance,

labor-saving switch, double-flow, wide applicable range and small erosion of the sealing surface

caused by medium in the full open state. At the same time there are also some shortcomings,

for example, some space is needed for opening (due to tall structure), long-time opening and

closing process, easy erosion and abrasion of the sealing surface in the process of opening and

closing, and difficulties in processing and maintenance of two sealing surfaces.

Gate valve applies to water, gas, oil and other media (not including the softened water with

high salt content) with the working temperature less than or equal to 120℃. The specifications

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of gate valves commonly used in the water treatment equipment and pipelines are Dn15 to

Dn400mm. Gates valves are mainly used to cut off the media of pipelines and are not used for

throttle.

7.2.1.2 Structure of gate valve

Gate valve has several structure forms, such as rising stem, nonrising stem, mode and

parallel, and its structure is shown in Figure 6-2-1. It is mainly composed of the following parts.

Valve body: it is the main body of gate valve and is an important part where the valve cover

is installed, the valve seat is placed and the pipeline is connected.

The valve cover and valve body form a pressure-proof cavity, on which a filling box (case)

is positioned, and the cavity is also connected with the stent and gland.

Stent: it is a part supporting the valve body and transmission mechanism. Some gate valve

stents and valve covers form a whole, but some have no stent.

Stem: it is directly connected with the stem nut or transmission mechanism, and its middle

and filling form a sealing pair, transferring torque and playing the role in opening and closing the

disc. The stem includes rising stem and nonrising stem two types.

Stem nut: it forms a thread pair with the stem and is also a part transferring torque.

Hand wheel: it is a part in the transmission device.

Filling and gland: it is a seal device.

Gasket: it is a material for sealing the static sealing surface.

Valve seat: it is a part which a seal ring is fixed with inlay and other processes on the valve

body and forms a seal pair with the disc. Some seal rings are directly processed by resurfacing

welding or valve body itself.

Disc: it is a part with two seal surfaces which can open the gate channel and is also known

as a closed part. It has mode and parallel type, single-disc and double-disc.

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。

Figure 6-2-1

7.2.2 Stop valve <J>

A valve clack driven by the stem moves from up to down along the axis of the sealing

surface of the valve seat until opening and closing the aim switch, such is called the stop valve,

also called the shut-off valve, stop door and so on.

7.2.2.1 Characteristics and uses of the stop valve

Compared with the stop valve and gate valve, the stop valve has a small opening height,

short opening and closing time, small structure height, relatively simple structure (there is only

one sealing surface for manufacturing and maintenance>, and small friction between sealing

surfaces but poor sealing performance and long structure, and its opening height is not easier

grasped than the rising stem. The stop valve can be used to regulate flow roughly and is mainly

used to cut off the medium of the pipeline.

7.2.2.2 Structure of stop valve

The structure of the common stop valve is shown in Figure 6-2-2. The shape of its part is

different from the gate valve, but their roles are the same.

The valve clack of the stop valve has plane and conical surface two sealing forms. The

plane sealing surface (shown in Figure 6-2-2) is little scratched and is vulnerable to be ground,

but its switching force is large, and it is mostly used in the stop valve with a large diameter. The

conical sealing surface has abrasion phenomenon, and is ground with a special grinding tool,

but provides a compact structure and small switching force and is normally used in the stop

valve with a small diameter, as shown in Figure 6-2-3.

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Figure 6-2-2 Figure 6-2-3

7.2.2.3 Type of stop valve

The form of the stop valve body has straight-through, direct flow and angle type generally.

The straight-through means the form of valve body which inlet and outlet are on the same axis

or parallel each other (as shown in Figure 6-2-2), and the stop valve is installed in a straight-line

pipeline, is easily operated but has big fluid resistance. Direct flow indicates the form of valve

body which inlet and outlet channel are a straight line, and the stem and valve body channel

axis form into an acute angle, that is, the stem is positioned at the tilted positioned, with small

fluid resistance but inconvenient operation. The angle type is the form of valve body which inlet

and outlet channel are mutually vertical, and it is mainly used in the small-diameter

high-pressure pipeline.

The form of stop valve stem has the rising stem and nonrising rod (referring to stem thread).

The nonrising thread stem is usually used for the small-diameter step valve because of its small

size, as shown in Figure 6-2-3. The rising thread stem is generally used for the large-diameter

stop valve, and the advantage is that it is not subject to media corrosion and is easy for

lubrication and inspection..

7.2.3 Butterfly valve (D)

The valve with the butterfly plate which rotates around a fixed axis in the valve body to

realize opening and closing or regulating is called butterfly valve.

7.2.3.1 Characteristics and uses of butterfly valve

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Butterfly valve is provided with small body, lightweight, easy accessibility and maintenance,

simple and compact structure, rapid opening and closing in 90。Rotation, small operating torque

and labor saving, and its flow characteristics tend to a straight line and adjusting performance is

good. Therefore, the butterfly valve serves as the valve with various calibres, and is used for

cutoff and throttle in water, air and other media and is in general not used in the

high-temperature and high pressure places.

7.2.3.2 Structure of butterfly valve

Butterfly valve mainly comprises a valve body, rotating shaft, cone pin, butterfly plate, valve

seat, lubricating bushing, gear worm and actuator pneumatic device or electrical device and

other components, as shown in Figure 6-2-4. Butterfly valve has manual, pneumatic and electric

three transmission modes. The butterfly valves commonly used in chemical water treatment are

D371J-10-(worm wheel transmission), D671J-10 type (pneumatic) and D97J-10 type.

Figure 6-2-4

7.2.4 Diaphragm valve

Stem is isolated from medium valve and the valve clack driven by the stem moves from up

to down along the stem axis to open and close the valve (rubber diaphragm driven by the valve

clack), as is called diaphragm valve.

Diaphragm valve is classified into manual rubber lined diaphragm, electric rubber lined

diaphragm and pneumatic rubber lined diaphragm according to its transmission methods.

7.2.4.1 Structure and working principle of the diaphragm valve

The diagram of the manual rubber lined diaphragm is shown in Figure 6-2-5. The valve

consists of a valve cover, stem, valve clack, diaphragm, valve body and hand wheel and other

major parts. The diaphragm is made of natural rubber, neoprene, fluorine rubber and poly

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fluoronated ethylene propylene plastic and others. The diaphragm plays the role in sealing the

valve clack and the sealing surface of the valve body.

Figure 6-2-5

7.2.4.2 Pneumatic piston diaphragm valve

7.2.4.2.1 Reciprocating: its structure is shown in Figure 6-2-6. It consists of valve body, valve

cover, valve clack, diaphragm, cylinder, cylinder cover, piston, piston rod, rubber piston ring and

manual devices and other parts, including pneumatic operation and manual operation. Its

working principle is: after the compressed air from the cylinder enters the cylinder, the

compressed air pushes the piston, so that the piston drives the valve clack and diaphragm to

move upward, thus opening the diaphragm valve; on the contrary when the compressed air

from the air intake of the cylinder cover enters, the valve is closed. The pneumatic diaphragm

valve with a manual operation device can not only regulate flow and but also be manually

operated in the case of shutting off gas source so as to open and close the valve.

7.2.4.2.2 The normal open type structure is shown in Figure 6-2-7 (a). Its working principle is:

when the air intake in the cylinder is not smooth, due to the spring tension, the piston drives the

piston rod and the valve clack and diaphragm are in the open position; when the cylinder is

smooth, as the pressure on the upper part of the piston is more than the spring tension, the

spring is compressed when the piston moves downward, and meanwhile the piston rod, valve

clack and diaphragm are driven to move downward, and the valve is closed. Once the cylinder

exhausts, because of the spring tension, the valve will be automatically opened. The pneumatic

diaphragm valve with a manual operation device can not only regulate flow and but also be

manually operated when the air supply fails, so as to open and close the valve.

7.2.4.2.3Normal close type. its structure is shown in Figure 6-2-7 <b>, it is basically similar to

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the normal open type, and the difference is that the valve is in the closed position when the

valve is not smooth. Once ventilation, the valve is opened. Similarly, the manual device at the

upper part of the valve can also regulate the flow and open the valve

Figure 6-2-6

Figure 6-2-7 （a） Figure 6-2-7（b）

7.2.4.3 Film type pneumatic diaphragm valve

7.2.4.3.1 Reciprocating: its structure is shown in Figure 6-2-8 (a). It consists of a valve body,

valve cover, valve clack, diaphragm, upper film room, lower film room, stem, film, gland and

other parts. Its working principle is similar to (reciprocating) of the pneumatic piston diaphragm

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valve. When air enters into the cylinder and air hole, because the thrust of compressed air, the

pressure head and film move upward, driving the stem, valve clack and diaphragm to move

upward so as to open the valve; on the contrary, when air enters into the cylinder cover, the

valve is closed.

Figure 6-2-8

7.2.4.3.2 The structure forms of normal open and close type are shown in Figure 6-2-8 (b) and

(c). In addition to parts of the reciprocating film valve, it has hand wheel, spring, spring seat and

guided rod and others. The working principle of the normal open and close film pneumatic valve

is basically similar to the pneumatic piston valve, so it is no longer presented here.

The pneumatic diaphragm valve is developed from the cylinder piston to the current

cylinder film type, and is in a leading position in the latter of the pneumatic valve. Compared

with the pneumatic piston diaphragm valve, it has the following characteristics:

(1) Reasonable design structure;

(2) Long service life and low operating pressure;

(3) Light weight, small opening torque when the pneumatic valve is manually operated;

(4) Adapt to the needs for water treatment and sewage treatment systems in large-scale

power plant units

(5) According to the size of media pressure, different models of actuators can be chosen.

7.2.5 Ball valve (Q)

The valve with a ball body which rotates around the axis vertical to the channel to open and

close the channel is called ball valve.

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7.2.5.1 Structure of ball valve:

An ordinary floating ball valve is shown in Figure 6-2-9, and is composed of a wrench, stem,

pressing sleeve nut, filling pressure sleeve, sleeve, valve seat, ball body, seal gasket, valve

body and other parts. The sealing surface of the valve seat is made of polyfluortetraethylene

and other plastics, with good corrosion resistance, small friction and good temperature

resistance, and some sealing surfaces are made of rubber or metal.

Ball valve with pneumatic, electric actuators is mostly applied in resin pipelines of the plant,

creating good conditions for achieving remote control and programmed control.

Figure 6-2-9

7.2.6 Pressure Reducing valve

The throttle through the valve clack reduces the pressure on the media and regulates the

opening degree of the valve clack relying on the pressure after the valve so that the pressure

after the valve can be maintained within the scope, such is the reducing valve.

7.2.6.1 Working principle of reducing valve

When the reducing valve spring is under the free state, the valve clack is off. Tighten the

adjusting screw and open the valve clack, and the medium enters into the valve through the

valve seat and then flows out. At this time when the pressure after the valve is more than the

spring, film, piston mechanism, leverage mechanism and bellows mechanism and other sensing

pieces, some force of the media before the valve to the valve clack is offset, the opening degree

of the valve clack is reduced and the pressure after the valve declines. As the pressure after the

valve declines, the pressure on the sensing piece declines, so that the opening degree of the

valve is again increased, resulting in the pressure after the valve to automatically always

maintain in a certain fluctuation range.

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7.2.6.2 Structure of reducing valve

Reducing valve is classified into piston, film and bellows type, and their structures are

complicated and a piston reducing valve is shown in Figure 6-2-10. It is composed of a main

valve seat, main valve clack, main valve spring, piston, pulse valve seat, pulse valve clack,

pulse valve spring, metal diaphragm, spring, adjusting screws and other parts. The structure of

the film and bellows type reducing valve is mainly different from the piston type: film and bellows

are instead of piston in the former.

Figure 6-2-10

7.3 Maintenance of valve

7.3.1 Maintenance of gate valve


（1）

Disassembly

1. Valve is opened manually to the middle;

2. Contact the heat worker to disassemble the electric power plug;

3. Disassemble the electric head bolt and hoist the electric hoist heat away;

4. Mark on the head and neck flange and disassemble the head and neck flange bolts;

5. Hoist the head and neck and place them on the designated locations;

Note: mark on the inlet and outlet of the valve core and do not damage the sealing surface of

1. When replacing a valve, its nominal diameter and pressure or working pressure must meet requirements.

2. The combination surface of the valve body and the valve cover should have no cracks, sand hole and other defects and should be level, the concave surface and convex surface are not injured and the radial clearance should meet the requirements (0.2 to 0.5 mm).

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the valve core

6. If necessary, disassemble the inlet and outlet flange of the valve.

7. Disassemble the valve core, stem and transmission mechanism.

（2）

Cleaning, inspection

and measurement

1. Check the sealing surface of the valve seat and valve core;

2. Check the stem bending;

3. Clear the inside of the valve;

4. Clear the filling box and replacing filling;

5. Clean the transmission mechanism and replace oil.

1. The sealing surface of the valve seat and valve core should have no groove, corrosion, flanging, napping, and so on;

2. The stem bending is not more than 0.10 to 0.25mm (stem bending of important valve is not more than 0.05mm), surface rust and wear depth are not more than 0.1 to 0.2 mm, and stem thread should be intact and match with thread sleeve flexibly.

（3）

Replacement

Prior to assembly, press the sealing surface with red lead to determine its sealing;

Assembly sequence is opposite to the disassembly one;

After the assembly, do hydrostatic testing.

1. The gap between the filling gland and box and the stem should be appropriate (0.1 to 0.2mm).

2. The filling section is square at best and the front joints to be pressed into the filling box should be cut into 45° oblique or the whole circle of filling is directly used.

3. Filling should be pressed in different layers, and a little graphite or ceruse is added between each layer, and the joints per layer should be staggered at 120 ° to 180°.

4. When tightening the filling gland, it should not be skewed, and the depth of the filling gland pressed to the filling box is 20mm for the valve of Dg <100mm and is 30 to 40 mm for the valve of Dg> 100mm.

5. Thread of all bolts and nuts is intact, and matches flexible.

6. Balls and raceways of plane bearings should have no pitting, corrosion, peeling and other defects.

7. Gear acts flexibly and the clearance is proper.

8. Hand wheel should be intact.

9. Generally high-pressure valve or the

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valves at the important places should be hydrostatically tested in a hydrostatic table; the air in the valve before hydraulic test should be drained, the pressure gradually increases until 1.25 times the working pressure, maintaining five minutes, and it is qualified if there is no leakage; after the medium-low-pressure valve is repaired, the valve entrance is placed upward, water or kerosene is injected into its entrance, and it is qualified after a few hours if there is water or oil seepage.

7.3.2 Maintenance of stop valve


（1）

Disassembly

1. Valve is opened manually to the middle;

2. Contact the heat worker to disassemble the electric power plug;

3. Disassemble the electric head bolt and hoist the electric hoist heat away;



Note: Do not damage the sealing surface of the valve core


7. Disassemble the valve core, stem and transmission mechanism.

1. When replacing a valve, its nominal diameter and pressure or working pressure must meet requirements.

2. The combination surface of the valve body and the valve cover should have no cracks, sand hole and other defects and should be level, the concave surface and convex surface are not injured and the radial clearance should meet the requirements (0.2 to 0.5 mm).

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（2）


and measurement

Check the sealing surface of the valve seat and valve core;

Check the stem bending;

Clear the inside of the valve;

Clear the filling box and replacing filling;

Clean the transmission mechanism and re replace oil.

The sealing surface of the valve seat and valve core should have no groove, corrosion, flanging, napping, and so on;

The stem bending is not more than 0.10 to 0. 25mm (stem bending of important valve is not more than 0.05mm), surface rust and wear depth are not more than 0.1 to 0.2 mm, and stem thread should be intact and match with thread sleeve flexibly.

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（3）

Reassembly

Prior to assembly, press the sealing surface with red lead to determine its sealing;

Assembly sequence is opposite to the disassembly one;

After the assembly, do hydrostatic testing.

The gap between the filling gland and box and the stem should be appropriate (0.1 to 0.2mm). The filling section is square at best and the front joints to be pressed into the filling box should be cut into 45° oblique or the whole circle of filling is directly used.

Filling should be pressed in different layers, and a little graphite or ceruse is added between each layer, and the joints per layer should be staggered at 120 ° to 180°.

When tightening the filling gland, it should not be skewed, and the depth of the filling gland pressed to the filling box is 20mm for the valve of Dg <100mm and is 30 to 40 mm for the valve of Dg> 100mm.

Thread of all bolts and nuts is intact, and matches flexible.

Balls and raceways of plane bearings should have no pitting, corrosion, peeling and other defects.

Gear acts flexibly and the clearance is proper.

Hand wheel should be intact.

Generally high-pressure valve or the valves at the important places should be hydrostatically tested in a hydrostatic table; the air in the valve before hydraulic test should be drained, the pressure gradually increases until 1.25 times the working pressure, maintaining five minutes, and it is qualified if there is no leakage; after the medium-low-pressure valve is repaired, the valve entrance is placed upward, water or kerosene is injected into its entrance, and it is qualified after a few hours if there is water or oil seepage.

7.3.3 Maintenance of butterfly valve


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（1）

Disassembly

Disassemble the transmission device of the butterfly valve ;

Disassemble the filling seal ring at the shaft of the butterfly valve and press the bolts, gland and filling seal ring.

（2）


and measurement

1. Check the connection state of the butterfly valve and the transmission device;

2. Check whether the filling seal ring of the butterfly valve is damaged;

3. Clear the filling seal ring gland of the butterfly valve ring, the butterfly valve shaft and filling box;

4. Check the sealing surface of the butterfly valve;

5. Check whether the centre of the butterfly valve and the valve seat is consistent, and adjust the upper and lower deviation by adjusting the gaskets on the lower shaft;

(1) If the sealing surface is worn and leaks, it can in general be solved by means of pressing the screws on the seal ring pressure plate and increasing the pressure amount of the rubber seal ring; three adjustment screws are generally a group, the middle one is the lock screw for fixing the sealed pressure plate and the other two are the pressure screws, and the pressure amount of rubber can be increased or decreased by adjusting the two screws;

(2) If there is large leakage, the seal ring pressure plate can be removed and the rubber secret ring is replaced.

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（3）

Replacement

1. Assembly sequence is opposite to the disassembly sequence.

1. After maintenance of the butterfly valve has been completed, the manual switch is not flexible;

2. Valve body has no crack and damage; the valve sealing surface matches with the rubber ring seal well and no leakage exists under the water pressure;

3. There is no water seepage under the water pressure at the filling gland of the butterfly valve;

4. The connection part of the butterfly valve with the transmission device is intact

7.3.4 Maintenance of check valve


（1）

Disassembly



Note: do not damage the sealing surface of the valve core


4. Disassemble the valve core, connecting bar and core bar.

（2）


and measurement

Check the sealing surface of the valve seat and valve core

Check the connecting bar and core bar.

Clear the inside of the valve

The sealing surface of the valve seat and valve core should have no groove, corrosion, flanging, napping and other defects.

The connecting bar and core bar are not worn or cracked, etc.

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（3）

Replacement 1. Assembly sequence is opposite to

disassembly sequence.

7.4 Common faults and trouble shooting of valves

Symptom Possible factors Elimination methods

Seal ring leaks 1. The valve seat and valve body do not match well

2. Close the valve, use the auxiliary tool improperly and close too tight

1. Repair the seal ring

2.Close the valve with appropriate force and do not open or close the valve with a lever

The seal surface has

scratch, concave trace

and other defects

1. There is dirt in the valve body

2. Welding slag and rust impurities enter into the valve body

3. Due to improper operation, the valve is opened excessively

1. Disassembly and clean

2. Grind the seal surface

3. Take proper operation

Flange seal surface leaks

1. The gasket is injured

2. The flange seal surface is damaged

1. Replace the gasket

2. Grind the seal surface

The filling leaks 1. The filling added does not meet the requirement

2. The stem is injured

3. The filling is inappropriately selected or is not clean

1. The filling is fed in different sections

2. The stem is ground smoothly

3. The oily filling is replaced

The stem does not move from up to down flexibly

1. The stem and bushing material

are inappropriately selected

2. Lubrication is poor

3. Thread is worn and the stem is skewed

1. Change the materials meeting the requirements, such as: bronze

2. Enhance lubrication

3. Replace the stem and bushing

8 Chemical Dosing System

8.1 Technical specification of equipment

No. Description Model/specification Qty Remarks 1 Ammonia dosing equipment 1 a Ammonia solution tank V=1M3 2 b Ammonia mixer 910rpm 1.1kw 2 c Level gauge UZ，L=1300mm 2

d Feed water ammonia metering pump

RA 58L/h 20Bar 316SS 3 Milton Roy

e Feed condensing water ammonia RB 22L/h 67Bar 3

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metering pump 316SS Milton Royf Pulsation damper NXQ 6 g Relief valve A21W 6 h Y-type strainer GLT-15 6 i Ball valve DN15\DN20\DN25 1 j Pressure gauge YA-100 6 k Control panel 600x600x1800mm 1

2 Hydrazine dosing equipment 1 a Hydrazine solution tank V=1.5M3 2 b Hydrazine mixer 910 rpm 1.1 kw 2

c Level gauge

UZ，L=1300mm 0mm the low-low level 50mm 1250mm

2

d Hydrazine metering tank V=20L φ250mm 2

e Feed water hydrazine pump RA 58L/h 20Bar 316SS 3 Milton Roy

f Closed cooling water hydrazine pump

RA 36L/h 20Bar 316SS 2

Milton Royg Pulsation damper NXQ-L/A 5 h Relief valve A21W 5 i Y-type strainer GLT-15 5 j Ball valve DN15\DN20\DN25 1 k Pressure gauge YA-100 5 l Suction pump WB-3 1

m Control panel 600x600x1800mm 1

3 Phosphate dosing equipment a Phosphate solution tank V=1M3 2 b Phosphate mixer 910 rpm 1.1 kw 2 c Level gauge 2

d Phosphate metering pump MBH 35L/h 250Bar 316SS 3 Milton Roy

e Pulsation damper NXQ 3 f Relief valve R5252T1-3MP-3 3 Circle sealg Y-type strainer GLT-15 3 h Ball valve DN15\DN20\DN25 1 i Globe Valve DN15 9 j Pressure gauge Y-150 3 l Control panel 600x600x1800mm 1

4 ladder & platform 1 Common use

8.2Matters needing attention during maintenance

8.2.1 Only the qualified electric engineer can maintain the electrical installation.

8.2.2 At first, the operator must check up the equipment safe condition and the working area

carefully. Remove the unsafe factor promptly.

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8.2.3 Use proper tools, protective clothing and goggles when working.

8.2.4 The operator should cut the power and turn off the machine before remove the safe

facilities for adjusting or repairing the machine. Resume the safe facilities after finishing

immediately.

8.2.5 Do not repair the motor, wiring, and pumps under power supply condition.

8.3 Daily servicing programmer

8.3.1. The whole device shall be kept clean and dry.

8.3.2. The oil level shall be suitable for the transmission part of the chemical dosing pump.

8.4Precautionary servicing programmer

8.4.1. It is advice that the gear oil and the liquid pressure oil should be replaced every

half-year.

8.4.2. It is advice that the Diaphragm and the Discharge Check Valve of the mRoy pumps

every year.

8.4.3. The filter shall be cleaned periodically to prevent block.

8.4.4. The bearing of the mixer shall be oiled periodically, the louver shall be checked

regularly to avoid being loose.

8.4.5 The instrument, valve shall be checked periodically and be regulated, repaired or replaced

under abnormal conditions.

8.5Maintenance of machines

The maintenance of the device is need periodically. A part maintenance is need every

months. A complete maintenance is need every year. Get rid of the breakdown immediately.

8.5.1Item of a part maintenance.

8.5.1.1 Remove the dust and dirt.

8.5.1.2 Keep the bolts of facilities firmly.

8.5.1.3 Check up the motors wiring terminal and clear them.

8.5.1.4 Measure the motors insulation resistance.

8.5.1.5 Inspect the sound of bear during working. Check up the lubrication oil.

8.5.2 Item of a complete maintenance

8.5.2.1 Total item of a part maintenance.

8.5.2.2 Check up and clear the internal pumps.

8.5.2.3 Check up and clear the internal motors.

8.5.2.4 Periocal clean the dust deposited in the cubicle, keep the cleanness of the electrical

device and it’s nearby.

8.5.2.5. Check the contactor condition of the air circuit breaker, the AC contactor, the relay and

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the level gauge probel.

8.5.2.5 Check the instrument such as the pressure gauge, level gauge.

8.6 Frequent failure and troubleshooting

Fault phenomenon Causes Processing method Broken of the pump intake pipe

Replace with the new intake pipe to ensure the tightness of the pipe

Block of the pipe Clean the pipe or replace with the new one, check the filter and dismount the filter net to clean

Unfreely operation of the pump valve

Check, clean or replace

Solid crystal appearance or the solid impurities

Increase the output flow or restrain the concentration or clean

The safety valve not reaching the setting pressure to unload.

Check, adjust, clean or replace the safety valve

Leakage of the connection of the outlet pipe

Check to ensure the tightness

Jamming of the check valve Slightly knock the check valve to make the valve core loose

Low output frequency of the frequency converter

Increase the output frequency of the frequency converter

Inadequate liquid pressure oil Increase the liquid pressure oil Broken of the diaphragm of the metering pump

Replace the diaphragm of the metering pump

Inadequate or no output flow

Leakage of the relief valve of the metering pump

As per the instruction of the metering pump, regulate the relief valve of the metering pump

Fault of the control loop Check the wiring and fuse, if the fuse is broken, replace with the same spec. fuse.

Inner fault of the motor Dismantle and repair the motor

Much lower level of the tank Add some chemical solution to be higher than the low low level

Unable to startup of the motor

Action of the frequency converter

Disconnect the air circuit breaker to re-energize

The pump body exceeding the max. allowed pressure results in overload

Reduce the output pressure

Low oil level Fill the oil to the required level Overheat of the pump body (the motor) Long term operation in the low

frequency condition

Manual adjust to reduce the stroke of the metering pump or to reduce the concentration of the chemical solution to improve the operation frequency

Unsuitable pre-charge pressure or the gas leakage

Check the charge pressure and charge to the required value

Broken of the accumulator peltry

Replace the accumulator Over whirling of the indicator of the pressure gauge under normal working pressure The chemical solution

entering the accumulator

Dismount the valve of the accumulator and pour out its inner solution

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No outside control signal

Measure 4~20mA DC power between the terminals of the signal blocks. If not detected, check whether the control system has the output signal and whether the power source wiring is correct Unable to adjust the

dosing amount

The frequency converter not receive the outside signal

Refer to the operation instruction of the frequency converter, set the relevant parameter of the frequency converter to enable it to receive the outside signal

Not energizing of the power source

Check the alarm power works well, including the switch of the power , the wiring and the fuse Not alarm in the low

level Fault of the liquid level sensor

Replace after confirm, if the float column of the level gauge has no magnet, replace the level gauge

The level of the chemical not reduce to the low low level probe location

Not processing

Damage of the liquid gauge Check the probe of the level gauge, the magnetic floater etc.

Not stop operation of the pump in low-low level

Control loop Check the operation loop of the pump motor inside the control cubicle

Incorrect rotation of the motor Adjust the power phase sequenceBig vibration after the startup of the mixer Distortion of the mixer shaft Align or replace the mixer shaft

Fault code occurs in the frequency converter

Check the fault as per the operation instruction of the frequency converter

Check the existence of the fault, re-enegenize the frequency converter after disconnect it

Under long time low frequency operation of the frequency converter

Long stroke or more concentration of the chemical solution

Reduce the stroke or reduce the concentration of the solution

Under the full frequency operation of the frequency converter

Short stroke or lower concentration

Increase the stroke or the concentration of the solution

The frequency of the converter not vary with the change of the current signal

Incorrect wiring or incorrect parameter setting of the frequency converter

Check the wiring, set the parameter as per the operation instruction of the frequency converter

9 Hlorine Feeding System of Circulating Water

9.1 Technical specification of equipment

Name Specification and model Unit Quantity CHLORINE TON CONTAINER

LPT800-00 Ø800×2020mm PN=20kg/cm2

SET 30

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PRESSURE RELEASE VESSEL

DN25 V=13L PN=16kg/cm2 SET 台 3

EAPORATOR 171-200 200kg/h N=18kw SET

2

CHLORINE FILTER

524-205 200kg/h PN=16kg/cm2 SET 2

PRESSURE REDUCING VAVLE

544-220 200kg/h PN=16kg/cm2 SET 2

REGULATOR VACUUM

148-200 200kg/h PN=16kg/cm2 SET 2

CHLORINATOR 145-200 200kg/h DN40 SET

2

WATER INJECTOR

Q=150kg/h DN80 SET 2

FILTER CBR-150 90 m3/h PN=10kg/cm2 SET

2

BOOSTER PUMP CZ50-200 Q=60 m3/h H=50m SET

3

DIFFUSER SCS-2P 1200X800mm 0-2000kg SET

2

LEAKAGE CHLORINE ABSORBER

AGWT-1000 3200X3200X4800mm 1000kg/h

SET 1

RESIDUAL CHLORINE ANALYZER

314-331 0-10ppm SET 1

CHLORINE LEAKAGE DETECTOR

A14/11 0-5ppm SET 2

ELEVTRONIC BALANCE

SCS-2P 1200X800mm 0-2000kg SET 2

PRESSURE RELEASE SYSTEM

AGWT-KZ 1200X600X2100mm SET 1

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9.2 Safety Maintenance of Equipment

9.2.1. Chlorine is a pale green gas, and is choking and poisonous, usually under pressure for

the liquefied gas. It has a disagreeable, suffocating odor that is detectable in low concentrations.

Coughing and vomiting may occur at 30 ppm and lung damage at 60 ppm. About 1000 ppm can

be fatal after a few deep breaths of the gas. Breathing lower concentrations can aggravate the

respiratory system, and exposure to the gas can irritate the eyes. At room temperature and

anhydrous circumstances, relatively non-corrosive, with the water, is highly corrosive. At 32 ℉

and atmospheric pressure, specific gravity of Chlorine is 2.48 share of the air. specific gravity of

liquid chlorine of the air at 32 and under the pressure of 53.5 psia is 1.47. At 32 a℉ ℉ nd

atmospheric pressure, for the liquid into a gas volume ratio of 1:456.5.

9.2.2. Chlorine gas is toxic and harmful. During equipment maintenance, for reducing the harm

of chlorine to the human respiratory system, must to pumping all chlorine out of the being

repaired pipelines and equipment. Using nitrogen to purge will be better.

9.2.3. Only the qualified professional personnel could operate to opening the system,

commissioning and making maintenance of security. At the scene of checking of operation must

have two more officers to make sure each other in the safe condition. Each staff enter the scene

must take necessary communications tools to ensure communication good, and must carry

qualified gas masks in case of leakage of chlorine. If chlorine leakage, the staff must wear gas

masks before entering.

9.2.4. Inspector or maintenance staff before entering should to be allowed by the control room

operators, and fill applications. After maintenance, fill the maintenance record.

9.2.5. The maintenance staff before entering the scene must to carry maintenance tool. The

tools at the scene are standby, used for an emergency situation. The necessary tools are

following: a 200 mm monkey wrench; a 300 mm monkey wrench; a chlorine cylinders angle

valve wrench; two 19 mm opened wrenches; a 14 mm opened wrench; a 17 mm opened

wrench; a 5 mm hexagonal wrench; a 300 mm box spanner; a 400 mm box spanner; a 150 mm

cross point screwdriver; a 150 mm slotted screwdriver; a 250 ml carboy of strong Ammonia

Water; two boxes of Teflon seal tape; DN 25 – DN 100 coupling each have two ones; DN 15 –

DN 25 specified lead pad each have ten ones; two cap lamps; two pairs of insulated rubber

gloves; two pairs of Industrial Safety Optics.

10.2.6. While carrying cylinders of chlorine, can use the safety cover of steel cylinder to handle

with care. Not to be thrown down, turn over or other working methods which be liable to impact.

The cylinders should be properly fixed on the car, and have sunscreen measures.

9.3 Dismantling and Maintenance of Equipment

Dismantling equipment should be in accordance with equipment monomer statement.

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Before dismantling equipment have to prepare spare parts. After the operation of equipment has

ceased completely, to the enterprise equipments, dismantling premise is that must guarantee

there have no potential safety problems.

9.4 Regularly Maintenance of Equipment

9.4.1. The chlorination system room should maintain clean, keep dry and maintain good indoor

ventilation; the ground will not have water and obstructions. The indoor temperature keep at 40

under control and avoid chlorine cylinders and processing chlorine equipment exposure to ℃

direct sunlight.

9.4.2. Maintain equipment clean. Regularly check the coating paint of equipments and pipeline

remain intact or not; if there are, repair with anti-corrosion paint in time to prevent leakage of

chlorine of the pipeline and corrosion of the equipments.

9.4.3. Every day regularly inspect the room that placed chlorination equipment. When smelling

a smell of the leakage chlorine, must be promptly test the pipelines and equipments. Open the

carboy of strong Ammonia Water to detect the leakage place; if there have white smoke, leave a

sign on here. Then find out all leakage points of all the equipments and pipelines in the room

with the same way. During maintenance open standby chlorination system or arrange

time-stopping, and must pumping all chlorine out of the being repaired pipelines and equipment.

9.4.4. Every replacement should to check the new cylinders and angle valve of it with strong

Ammonia Water. If the replaced cylinder leaked, screw angle valve covers its mouth closed and

marked the cylinder leakage exists, and then inform the liquid chlorine factory to maintain. If the

angle valve of new cylinder leaked, immediately leakage of chlorine cylinders connect it to the

busbar, which at this time not to connect other chlorine cylinders. As soon as possible add all

the liquid chlorine into the water circulation system, then mark this cylinder leakage exists and

inform the liquid chlorine factory.

9.4.5. Check the level of lubricating oil of the inflater daily, and keep it within the limits under

BEIJING ANGUO WATER TREATMENT AUTOMATION ENGINEERING TECHNOLOGY CO.，

LTD CHLORINE MANUAL 4 control. Change the lubricating oil at least once a month. In course

of running, pay attention to the change of pressure gauge for ensure that the pressure in the

design of pumps working conditions allowed, avoiding pump flow ultra-load. During the running

time, every one hour inspect the vibration of pump, test the temperature of pump bearings and

motor bearing, and check the sealing reliability of water. Have a small amount of lubricated

cooling water drippage. The pumps with question must to stop running. Open the standby

pumps, and repair the trouble one timely.

9.4.6. Run the hand-barring of the long-term standby pump at least twice a week to prevent

binding and ensure that equipment in good condition.

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9.4.7. Regularly use ammonia detects the chlorine valve for dealing with leakage problems in

time.

9.4.8. Replace the connecting chlorine cylinders flexible pipe once a year. The heat transfer oil

of evaporator should be replaced for every two years, each one for the amount of 110 liters.

9.4.9. Run the leaking chlorine absorber vessel every two months one time (every time is about

10 minutes), and check the alkali density of it (at about 20 percent), keep the alkali level within

scope of the window.

9.4.10. Inspect each chemical probe from chlorine leak alarm. Under the micro-probe, use little

of potassium permanganate and hydrochloric acid to make reaction of chlorine, for whether the

alarm works well. If warning that means no problem. Otherwise, the alarm failed to work, there

need to replace the probe.

9.4.11. In course of running, should always pay attention to pressure changes of the

chlorination system. That is forbidden opening evaporator in the absence of opened chlorination

system, the evaporator could be turned on until ensure that all the valves on the BEIJING

ANGUO WATER TREATMENT AUTOMATION ENGINEERING TECHNOLOGY CO.，LTD

CHLORINE MANUAL 5 pipeline from the evaporator to chlorine cylinders have be opened.

When evaporator heating, the pressure be increased by it can make the liquid chlorine which in

the coil back to chlorine cylinders to ensure that the pressure to maintain normal pipeline

pressure.

9.4.12. Notice: Do not make liquid chlorine through the cooling evaporator. In course of the

equipment in operation or liquid chlorine is still in the evaporator, the equipment can not be

closed. While the liquid chlorine in the evaporator, all the valves that between chlorine cylinders

and evaporator must be opened.

9.4.13. When the equipment needs maintenance, only after the injector of chlorination system

worked normally the angle valves of chlorine cylinders could be closed. Until all chlorine which

in the chlorination equipment and pipelines has been pumped out, all the pressure of gauge

system is 0, the chlorination system can be closed. After that, the pipelines and equipment

which need to be repaired connect to discharge pipe will better. Put the outlet of discharge pipe

to somewhere no one will come cross. Use nitrogen to sweep, keep its pressure not too much

(almost below 0.5 MPa) and velocity of flow not too high (at about five meters per second). The

clean-up time should continue more than three minutes, at least.

9.4.14. Vacuum valve means all the pipelines between the vacuum regulator and injector. The

checking method for vacuum valve: Close angle valves of the chlorine cylinders; Close

proportional valve of the chlorinator; Open butterfly valve of the outlet of injector; Open drive

water valve of the injector; Start the inflater; Open proportional valve of the chlorinator. The

orifice plate flowmeter displays there have no gas-flow. Vacuum means equal to or less than -9

m.wc, therefore the vacuum valve is intact. Otherwise, the vacuum valve has leakage.

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9.5 Common faults and trouble shooting of Gas Dosing Systems

Fault Reason Correction

Spring in differential pressure regulator is soiled Clean the spring Despite constant operating

conditions the vacuum varies Spring in differential pressure

regulator is damaged Replace the spring

Diaphragm in differential pressure regulator is soiled Clean the diaphragm Despite constant operating

conditions the dosing flow varies

Diaphragm in differential pressure regulator is damaged

Replace the diaphragm

Leakage at the rate valve

Bar gasket in the rate valve damaged

Replace the bar gasket

Floater of the measuring tube is caught Measuring tube is soiled Clean the measuring tube

Insufficient injector vacuum Check injector, observe the manual of the injector

Servomotor (option) does not reach the 100 %-position

Adjust the potentiometer of the servomotor resp. check the settings of the electronics

Leakage in vacuum line between differential pressure regulator and injector

Eliminate leakage (see Checking the tightness") "

Vacuum line between differential pressure regulator and injector too long

Observe table Suggested line lengths and diameters" "

Admission pressure at the vacuum regulator too low

If necessary, open gas supply or clean filter (observe manual of the vacuum regulator)

Desired dosing flow is not reached

Regulating channel of the adjusting plunger soiled Clean the adjusting plunger

Despite correctly displayed gas flow the desired gas solution concentration cannot be reached

Leakage in vacuum line between vacuum regulator and gas dosing system

Eliminate leakage (see Checking the tightness") "

Servomotor does not run Servomotor is switched to manual operation

Switch servomotor to automatic operation

Servomotor does not reach the whole range desired

Servomotor resp. electronics adjusted wrongly

Adjust servomotor resp. check settings of the electronics

Servomotor runs in wrong direction

Servomotor resp. electronics adjusted wrongly

Adjust servomotor resp. check settings of the electronics

10 Waste Water Treatment System

10.1 Technical specification for equipment:

No Name Qty Technical specification

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1

Sludge scraper of mechanical accelerated clarifier

1 set

Type DFJN-6 Agitator Motor power 3KW Impeller diameter Ø2000mm Impeller height: 170mm Sludge scraper Motor power: 0.75kw Dia.of scrapping arm: 6000mm

2

Sludge scraper of sludge concentrating tank

1 set Type DFWJ-8.5 Motor power 1.5KW Impeller diameter: Ø8500mm

3 Agitator of coagulation tank

1 set

1.5KW Ø1500mm Motor power: 1.5KW Impeller diameter: Ø1500mm

4 Agitator of neutralization tank

1 set


5 Agitator of PH adjusting tank

1 set


6 Backwash water pump Type Capacity

m3/h Head Rotation rpm

Power KW

Voltage

2 sets

200WFB-AD 250 30 1450 55 400

7

Infrequent wastewater discharge pump

Type Capacity m3/h

m Head

Rotation rpm

Power KW

V Voltage

2 sets

100WFB-A 100 20 1450 15 400

8 Wastewater pump Type Capacity

m3/h m Head

Rotation rpm

Power KW

V Voltage

2 sets

100WFB-B 100 30 1450 22 400

9

Wastewater transporting pump

Type Capacity m3/h

m Head

Rotation rpm

Power KW

V Voltage

2 sets

100WFB-A 100 20 1450 15 400

10.2 Installation sequence of agitator and sludge scraper of mechanical accelerating

clarifier

10.2.1 Face the output center of the driving worm wheel reduction box at the center of the sludge collection pit and turn the adjusting nut at the upper part of the main shaft to put the main shaft at the lowest position and fixing it;

10.2.2 Install φ159 agitating main shaft and impeller; then assemble the pull rod clamp at the middle part of the main shaft and the pull rod is to be tightened and balance calibrated by turnbuckle, then assemble the impeller at the partition board between the No.1 reaction

SEC




chamber and No.2 reaction chamber; if the impeller is lower than the upper plane of the No.2 reaction chamber, then put the seat cushion of the worm wheel box in the No.2 reaction chamber; lift the main shaft by 250mm and the impeller by 110mm;

10.2.3 Then assemble φ102 sludge scraping shaft (long); dismount the coupler and put in the upper coupler from below the impeller, then connect the drive shaft of the upper worm wheel box, finally connect the lower φ102 sludge scrapping shaft (short), then connect the underwater small shaft φ76 facing the sludge collection pit, then fix the bearing seat (nylon); turn φ102 sludge scrapping shaft when fixing. After positioning manually, weld the nylon seat, then fix the underwater scrapping board; turn the sludge scrapping shaft to check whether it is in contact with the sludge collection pit;

10.2.4 Then assemble the scrapping arm seat below the sludge scrapping shaft (short), then use bolts to connect the balancing arm of the scrapping arm; fix φ102 clamps at the upper part of the sludge scrapping shaft, after that, connect the scrapping arm and balancing arm with the clamp by pull rod, and use the turnbuckle on the pull rod to adjust the scrapping arm and balancing arm; then connect the sludge scrapping board to ensure the lower edge of the sludge scrapping board is parallel with the tank bottom with certain distance;

10.2.5 Then assemble the blades under the impeller; 10.2.6 Then connect the cycloid pin-wheel chain; switch the power to start the machine and

check whether the impellers are in balancing state and make adjustment by turnbuckle. The

edges of the impeller shall not contact both reaction cement tanks, finally fix the base seat of

the driving worm wheel box.

10.3 Maintenance of integrated equipment

10.3.1 All metering pumps, valves and instruments are subject to periodical maintenance in

accordance with the operation instruction of the manufacturer;

10.3.2 The agitators and metering pumps shall always maintained in operation free of noise

and vibration and shall be immediately stopped in case of any abnormal case;

10.3.3 Check the outlet pipes of the pump to ensure no vibration and no leakage and check

to ensure no leakage from the pump body and the proper pressure at the pump outlet;

10.3.4 The valves shall be opened or closed to the required level with flexible running;

10.3.5 Stable and normal temperature rise of motor;

10.3.6 The chemical outlet capacity shall be ensured of meeting design requirement when the

equipment is in operation; stop the machine for immediate checkup in case of sub-standard

case and find the causes with proper solution; the future proper running of the equipment

shall be ensured;

10.3.7 The set data shall be timely adjusted based on the actual operation conditions to

ensure the treatment efficiency of the equipments;

10.3.8 In case the equipment shall be shut down for temporary maintenance, close the

equipment according to the operation condition and ensure safe running;

10.4 Cautions for operation of integrated equipment

The equipment shall be subject to regular and irregular inspections after being put into operation to always maintain the optimized operation of the equipment; 10.4.1 Pay regular check of the operation conditions of all electrics of the control system and

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perform timely troubleshooting for any found troubles;

10.4.2 Pay irregular check of the operation conditions of the agitators, metering pumps and

electric motors etc; in case of any abnormal noise or insufficient chemical outlet capacity

etc, please stop the machines in time for maintenance and timely replacement of

easily-worn parts;

10.4.3 All the valves, metering pumps and electric motors are subject to periodical

maintenance as per requirement;

10.4.4 Check the operation conditions of the equipment and observe the flow rate and quality

of the treated water; in case of significant changes of the water quality, it is necessary to

adjust the dosing rate in time to ensure the qualified outlet water and find the best way for

the management of the equipment during the operation.

Chemical Maintenance Manual Qn1 Sec g 04 Tp 011(104)

Documents

15 dn15dn20dn25

sludge collection

adequate safety

card yin phenomenon

2matters needing

electric spark

bypass cycle

sludge scrapping