Submersible pump in China from 2011 to 2016, according to the depth of the market analysis report for the construction of the south-to-north water diversion project will become one of the main constitution that water pump in the future market, forecasts water pump industry in China during the period of twelfth five-year development will reach a small peak, the average annual growth rate, or more than 20%. Domestic research has shown that fluid machinery professional institutions, the world within the scope of the pump power consumption of the total industrial equipment to about 25% of total consumption, the centrifugal pump accounts for about 50% of all water pump power consumption. In this regard, the development of the centrifugal pump if we can from the viewpoint of energy conservation and efficient planning and guidance, the serious lack of processing manufacturing industry and the rapid development of electric power of China, is a great social economic benefit. Therefore, analyzing the problems existing in the centrifugal pump, and put forward the energy saving technology methods is an important topic of the industry development.
Centrifugal pump energy saving technology
Centrifugal pump energy saving technology (network pictures)
First, the current main problems of centrifugal pump energy saving ways
(a) the design level and the concept of limit
At present domestic design of centrifugal pump is mainly follow the traditional model conversion method and the velocity coefficient method, the two design methods are mainly based on experience, there is no breakthrough in the past design level, also not big on efficiency increases, coupled with the centrifugal pump manufacturers too much for the present economic benefits, energy-saving work of centrifugal pump is neglected and even been put on hold.
In addition, in the process of the development of centrifugal pump, shaved was a "total head wind. Design units in order to solve the outlet valve on the whole scene when using super power, bearing heating problems that frequently occur, when the design tends to be the "total head" concept, namely in on the whole performance curve of centrifugal pump, the head is not work, but the actual point is not used in the design of high efficient area, causing large waste of resources.
(2) energy saving understanding is not comprehensive
The concept of centrifugal pump energy saving of the past is more on improving the efficiency of various indicators, in fact this is a misunderstanding of centrifugal pump energy saving energy saving is not simply an efficiency index, but is contained in a centrifugal pump reliability, maintainability, supportability, safety, the improvement of environmental adaptability, and the stability of the centrifugal pump performance and life, to improve the material utilization ratio. Specific to the use of the centrifugal pump environment again, also need to be targeted for energy saving design, such as hydraulic performance and sealing performance of a centrifugal pump, centrifugal pump of wear-resisting, high temperature resistant, corrosion resistant, resistant to cavitation performance and so on, these are for different environment, and don't have to use to carry on the design.
So energy-saving research of centrifugal pump is very complex, not one-sided understanding of the concept of energy saving, but to have a comprehensive understanding of whole.
(3) ***ion is not reasonable
When purchasing a centrifugal pump units used, the allowance are more tend to flow and head is very big, to maximize meet the requirements of their own use, this kind of ***ion is obviously unreasonable, directly caused by the centrifugal pump in use process, the actual operation efficiency is far lower than the design of the highest efficiency, even rated conditions points are not in high efficient area, is not fully effective use of energy, such as motor or diesel engine power (that is, to do a lot of busywork).
(4) use undeserved
In use process, because of improper use of unit operation and maintenance, maintenance, etc., not in time to make a centrifugal pump failure often occurs during use. Cleanliness is poor, such as using the medium containing aquatic plants such as entanglement or other foreign material into the impeller of the centrifugal pump; Again like have not clean, to import the pipe welding slag, iron intake flow, caused by the centrifugal pump suddenly stuck, such as bearing heating, sealing burn out fault. And some use units, in order to adapt to the venue, pipe set unreasonable, horizontal distance and vertical distance is greater than design, corner joints, pipe hydraulic loss serious, far does not conform to the set of pipework curve when the initial design requirements. The above is easy to cause a lot of energy waste. Above all, to solve centrifugal pump existing problems such as design, manufacture, ***ion, use, will make centrifugal pump energy saving technology in our country get rapid development become inevitable.
The design of the centrifugal pump energy saving
The design of the centrifugal pump unit verified try to choose the industry advanced software to design the hydraulic model, design ideas, and don't obsess over the unilateral total head in the flow field analysis and so on, we should use the advanced hydraulic design methods, design the reasonable product. Such as to localization of the imported Russian products design, surveying and mapping, Russia more than a decade ago in the production of centrifugal pump, the hydraulic design has reached a very advanced level, on the design concept to be proactive. In the process of design and development, to carrying out reliability test of centrifugal pump, the product of the material choice test, if used for wet mildew to change environment, but also for resistance to salt fog mould test, so as to improve the efficiency of centrifugal pump products, achieve energy saving purpose.
According to different environment, the design unit should choose different material. Such as the south China sea water has strong corrosive, within the scope of the use of ships with centrifugal pump flow components must choose the corrosion resistance of the material such as nickel aluminum bronze, and the east China sea water containing high sediment content, must choose the material such as high abrasion resistance of high manganese bronze.
In recent years, the application of all kinds of new materials, new technology is an important aspect to promote the development of centrifugal pump technology. Centrifugal pump parts and equipment accessories have adopted a variety of new materials, new technology, extend the service life and reliability of the pump in the corrosive medium, extends the using range of centrifugal pump. At the same time, to improve the flow characteristics of centrifugal pump, corrosion resistance and wear resistance, coating technology and the application of the material surface treatment technology played a very important role, to improve the environmental adaptability of the centrifugal pump.
Different USES, choose different characteristics of the mechanical seal are exquisite. Bilge pump such as ships are particularly high temperature in summer, choose the seals should have high temperature resistant anti-aging properties; Nuclear submarines with large depth centrifugal pump, under high back pressure, ***ion of rubber parts of high pressure performance is required.
In addition, due to the mechanical seal is wearing parts, maintenance frequency is much higher than other parts, often be removed all the centrifugal pump when repair, sometimes limited space in the field may also need to destroy the cabin structure, huge effort. As a result, ensure reliable mechanical seal, and extend the service life of mechanical seal is very important.
During the design process, it is recommended that the preferable utility model patent product CMZ with container ships pump type mechanical seal, of course, if particularly high reliability and safety requirements, also can choose more advanced cooling sealing device, can greatly reduce the failure rate.
The design of centrifugal pump in addition to the hydraulic performance and ***ion of materials, mechanical seal, special attention should be paid to the vibration and noise problem. In recent years, vibration noise reduction has become the national defense, especially is of vital importance to the navy assembly equipment orders, because the size of the pump in the operation of the vibration and noise index warship has a close relationship with the distance of the signal was detected by the enemy in the battle and probability, so in this field at present, vibration noise index is not to say that meet the national or trade standards.
Noise and vibration value with centrifugal pump structure and material ***ion are very close relationship, try to design into the flexible coupling structure, choose good performance of sound absorption material.
Standardization is an important trend in the development of centrifugal pump technology. The centrifugal pump with centrifugal pump industry especially ships, mostly in a state of sheet small batch production. Investigate its reason, on the one hand, is the aim of the customer is supreme, the as long as it is the user request, whether reasonable or not, even if can adjust the ***ion model of existing products, companies are still designed according to the requirements of customers; On the other hand, in order to improve the market competitiveness of enterprises 1, leading enterprises in domestic centrifugal pump deliberately set technical barriers, the capsule, pump body and guide vane design into a special structure. As a result, not only greatly increase the design and manufacturing cost, also after-sales maintenance services increased the unnecessary trouble, often appear chaos spare parts, maintenance costs have risen sharply.
Therefore, the implementation of the standardization of centrifugal pump parts have an eyebrow nimble. After the implementation of standardized centrifugal pump, only need a few special parts and general parts can make up the whole series of centrifugal pump, which can reduce production cost, shorten the time of delivery, reduce the inventory of spare parts and spare parts, to achieve energy saving purpose. This, from Japan and Italy didn't see the name of the parts for the fixed number of centrifugal pump can be confirmed.
Centrifugal pump manufacturing energy-saving
Manufacturing enterprises is higher than the national or trade standards of enterprise standards, improve the casting process, to find ways to reduce the hydraulic losses. Strict control of each process in the manufacturing process, the use of advanced 3 d rapid prototyping wax models of software to generate the precise model, improve the accuracy of the flow line of the flow components and smooth lumen flatness, carefully deal with parting surface and side seam, to improve the hydraulic performance of a centrifugal pump, centrifugal pump energy saving.
Notice centrifugal pump design and manufacturing units used on-site technical training, basic structure, working principle of centrifugal pump, common failure fully to preach, the reasons and treatment methods for the technical service throughout the entire process, put forward problems after the compensation services to clients to assist the user in the correct ***ion, invite users to participate in the design, enterprises and users, achieve win-win situation on both sides.
Centrifugal pump system energy saving
A centrifugal pump with connection accessories
System mainly include centrifugal pump and motor or diesel engine design and related accessories, network connections and cooperation, etc. Such as pipe joint mesh Settings, should follow the principle of short, straight, less, try not to set the throttle device. Motor or diesel engine want to choose the products, low vibration, low noise, and according to the rated power and efficiency of pump configuration optimal driving power, to avoid the "big horse-drawn cart" or "small mara carts" pumps adopt flexible coupling vibration isolation system as far as possible. The dashboard USES the stainless steel connection. For installation of self-priming device to achieve self-priming function of common vertical sea water pump, install the import and export pressure gauge with high quality copper tube, as far as possible when piezometric tube road to reduce resonance phenomenon in operation of the system, every part of the pump system can play their biggest role, so as to improve the overall efficiency of the centrifugal pump system and service life.
Mechanical and electrical integration development
Whether general pump, such as Marine pump of small and medium-sized or large pump used in industry, military products, in particular, are to the integration of units, electronic control, meter to monitor the direction of development. Developed for open sea battle ship such as external fire system, how to make fire water cannon, for water pump set, alarm system, monitoring instrument organically together as a part of a function as a whole? This requires a practical and effective to manipulate the control of electronic control system. Such integration function, make the centrifugal pump products more efficient, energy saving, more convenient in operation and maintenance, improve the reliability of the products, prolong the service life and bring greater benefits for the user.
The use of the centrifugal pump energy saving
Centrifugal pump pipe reasonable layout of the road
Centrifugal pump unit using the use of the environment, from the perspective of technical and economic comprehensive consideration. Piping layout should decorate straight pipe, as far as possible to minimize the accessories and components in the pipeline, narrow pipeline length as much as possible, must bend, bend radius is advisable to take 3 to 5 times the diameter of the pipe, Angle is greater than 90 °, best can maximum limit reducing line loss.
Good maintenance
Using unit should formulate corresponding policies and procedures, earnestly to centrifugal pump system maintenance and regular maintenance. Good maintenance can make the centrifugal pump system is the best running state, and through the daily maintenance and repair timely find problems and timely maintenance of maintenance, prolong the service life of the centrifugal pump system. Cost savings, but also a good way of energy saving.