Double oil dry centralized lubrication system installation and debugging
1, the lubrication system
Double oil dry centralized lubrication system is mainly composed of three parts: pumping station valve, pipe, distributor and terminal. Pumping station output high pressure oil regularly, the double pipe to each distributor, double quantitative to fat removal pipe distributor will grease, eventually arrived bearing lubrication points.
Composed of electric pump station is called electric automatic system, often with terminal valve; Composed of manual pump station is called manual system, with no end valves. Double oil dry centralized lubrication system installation and debugging, to bring the book
2, construction flow chart
Install the preparation
Left left
Pump station installed equipment distributor, valve terminal
Left left
Piping preinstallation
left
Line cleaning
left
Piping installation
left
Grease filling system
left
Test run adjustment
3, installation preparation
Good preparation is the key to the smooth construction.
3.1 according to the system diagram, listing, manual know the composition of the lubrication system, equipment functions such as size and quantity, the size of the installation, connection, etc., and check with the actual situation, if have any mistakes or missing parts to remedy in a timely manner.
3.2 determine pump station, distributor, pipe position, try to avoid the temperature too high or too low, avoid pipeline mutual interference with other equipment, also make the pump to the end of the line as short as possible.
3.3 arrange the construction process, to avoid interference with host or other equipment installation, cause slowdown, rework.
3.4 with reasonable allocate personnel, construction equipment and energy. Installation workers must understand the lubrication equipment and various types of pipe, pipe installation, at least one of the whole process of installation experience. Pipe welder should receive special training. To allocate cutting machine, argon arc welding machine, etc.
4, type and installation of pipe joint
4.1 coupling model
Double dry oil lubrication system insert is welded with pipe joint type, welding type, taper, four categories of cutting sleeve type has the seal welding type, there are two main purposes:
(1) used in the pipe to pipe connection, such as direct (union), right Angle, tee, etc.;
(2) of the equipment used for pipe connections, such as: the straight, the right Angle, etc., port of screw to screw into the screw hole of the equipment.
In addition, another part of the connection, high pressure hose connector is used for activities match welded type A, type B card sleeve type.
4.2 the pass-through (rectangular) pipe joint connection with equipment installation
(1) the joint end thread mainly include metric M (such as M18 x 1.5), (such as G3/8), pipe thread G taper pipe threads R (such as R3/8) three;
(2) in metric M, pipe thread G case, must be set into the combination washer screw at the base (or copper washers) after screwing in equipment, until the gasket compression;
(3) in the case of the taper pipe threads R, ptfe head thread shall be wrapped ribbons, from the roots go around about one and a half circle, apex with 1 ~ 2 teeth, direction and threaded fastening rotation in the opposite direction, and then screwing in equipment. For less than the R3/8, with 1/2 width of ribbons. If the ribbons to tie up too much too full, make the ribbons easily shattered and into the line, causing congestion.
4.3 insert welded pipe installation
(1) according to the need, the length of the cut out the pipe with sawing machine or special pipe cutter machine, is absolutely not allowed to use fusing, such as flame cutting or grinding wheel cutting;
(2) to remove the tube inside and outside round burr, metal chip and dirt;
(3) the pipe joint to remove the rust inhibitor and dirt;
(4) insert pipe pipe hole to the end;
(5) the correct position after welding, inspection and related parts meet the requirements, the size of the position with pipe joint welded by argon arc welding tube.
4.4 welded and cone seal welded pipe installation
(1) according to the article 4.3 (1) (2) (3) method in cutting, cutting the welding groove, trash, cleaning, and temporarily removed within the pipe joint type O sealing ring;
(2) the aim the pipe mouth to take over the mouth, correct position after welding, inspection and related parts after the size, location, conform to the requirements of the interface welded with the argon arc welding,
(3) pipeline cleaning after installation, into the type O sealing ring;
(4) after installation, tighten nut slowly, until the pipe can't rotate or shaking, then tighten the nut ~ four thirds two-thirds.
4.5 card sleeve pipe installation
(1) in accordance with the requirements of chapter 9 need pickling pipe should be pickling process;
(2) according to the article 4.3 (1) (2) (3), trash, cleaning method in cutting, but also ensure the pipe roundness;
(3) the nut, card sets of successively set into the pipe, card sets of front end (path) from the pipe on the edge of at least 3 mm, and then insert the pipe joint body cone hole, top so far;
(4) tighten the nut, slowly rotating pipe until not move at the same time, then tighten the nut ~ four thirds two-thirds circle;
(5) open check card set into the pipe, the location is correct. Card sets of axial movement is not permitted, can be a bit rotation.
Turn the nut (6) again after inspection.
4.6 high pressure hose connector installation considerations
(1) the hose in moving or static, cannot excessive bending, also cannot bend in the root, at least to start at 1.5 times the diameter of the bending;
(2) the hose to the extreme position shall not pull too hard, should be more relaxed;
(3) avoid torsional deformation of rubber hose;
(4) the hose as far as possible away from thermal radiation components, necessary fashion insulation board;
(5) should avoid hose external damage, such as used with long-term friction on the surface of the component, etc.;
(6) if the hose gravity cause excessive deformation, should have a rest.
5, pumping station equipment installation
5.1 electric pumping station
Electric pump station is mainly composed of electric lubrication pump, reversing valve, electric pumps, electric cabinet, etc.
(1) to the system output electric lubrication pump high pressure grease, is the core equipment. Is usually the upper storage barrel, the lower is the plunger pump and motor, commonly used models have DRB -l / -s Z Z, DRB - twenty - Z - H L, ZPU twenty G, DRB - M twenty - Z;
(2) the directional valve to change flow direction, make double head road Ⅰ Ⅱ line pressure relief when line pressure, Ⅱ Ⅰ line pressure relief when line pressure, alternate replacement. Mainly include the electromagnetic directional valve, hydraulic directional control valve, electric reversing valve types;
Lubrication pump DRB -l / -s Z Z has electromagnetic directional valve, DRB - twenty - Z - H L have with hydraulic directional valve, but sometimes down original reversing valve, change into several electric reversing valve is composed of complex system.
(3) electric pumps used in the oil storage cylinder added grease lubrication pump. Usually head motor, below is inserted inside the large storage barrel rod pump group. Commonly used models have DJB - F200B, DJB - V70, etc. Sometimes small system using hand pumps (such as SJB - 25);
(4) control of the electric control system according to setting methods of work, usually have automatic and manual two kinds of works, and a variety of monitoring, alarm function.
5.2 manual pump station
Manual pump station is mainly composed of double line of manual lubrication pump and manual pumps.
(1) double manually to the system output, grease lubrication pump has appliance with explorers to the valve, is usually the upper oil cylinder, the lower is the plunger pump, is shaking the handle on the right side. Commonly used models with SRB - -s / -s - SG, SRB - L - Z - -, SGZ - 8, etc.;
(2) manual pumps used to storage tube added grease lubrication pump. Usually the upper to shake the handle, the following is inserted into the oil storage cylinder rod pump components. Commonly used models with SJB - 15, the SJB - 25.
5.3 pumping station equipment installation
(1) electric lubrication pump and are mounting holes at the bottom of the directional control valve, usually has installed on a common base with bolt, only when the installation will be the base of mounting holes with foundation bolt connection, there is also a base of welding on the basis of;
(2) the lower part of manual lubrication pump facade with mounting holes, usually with a screw on the bracket, bracket and foundation structure with bolted or welded, the place should be convenient work * * * a;
(3) the electric pump, manual pump directly placed based it on a plane, without fasteners, fixed position close to the lubrication pump;
Are mounting holes (4) electric cabinet, some advance in a pumping station on the base of the legs, some use Angle in the component such as close to the lubrication pump structure;
6, double distributor installation
6.1 distributor usage and types
Double distributor Ⅰ line, Ⅱ line alternating pressure when the head of road, internal plunger alternating movement, every change to discharge a quantitative lubricant. Usually the upper indicator, can adjust the volume of each action to oil, and observe the discharge of oil plunger movement is normal.
Nominal pressure of 20 mpa series were three DSPQ -l mind (oil), and SSPQ - L - (double oil), etc.;
Nominal pressure of 40 mpa series have mind SSPQ - P -, VSG, VSL, etc, are all double oil.
6.2 distributor oil mouth location, quantity and size
(1) indicator when facing up, four inlet on the left and right side (left and right are interlinked), not series when installation, blocking off one side of the two inlet. Screw hole for taper pipe threads Rc3/8 (nominal pressure 10, 20 mpa series) or pipe thread G3/8 (40 mpa nominal pressure series), individual small specification for R1/4 or G1/4;
(2) - DSPQ - L - just beneath the oil outlet distributor, such as oil mouth 1 ~ 4; Most of the distributor, have the oil outlet, oil mouth 2 ~ 8. Screw hole for taper pipe threads Rc1/4 (nominal pressure 10, 20 mpa series) or pipe thread G1/4 (40 mpa nominal pressure series). Individual small specification for Rc1/8.
6.3 the installation of the distributor
(1) all assigned for screw fixed in advance on the plate, positive outward (i.e., near indicator plate);
(2) to select for inspection, adjustment, repair and not easily collision, but also close to the lubrication points, had better not exceed 5 ~ 6 meters, at the same time to avoid high temperature and wet water, steam, acid and alkali environment;
(3) location is determined to plate welding on the body or stent (what time) on peripheral welding, indicator up as much as possible;
(4) when the lubricating points distribution is relatively close, can be installed in tandem, but should not be more than four;
(5) when don't need one to one of the upper and lower oil mouth, should first unicom upper and lower internal passage between the hatch (take the isolation screw), blocking off the unused to oil mouth,
7, terminal valve installation
7.1 valve terminal
(1) double system terminal pressure control valve valve commonly used YZF - L4 (20 mpa), differential pressure switch YCK - P5 (40 mpa), the pressure switch SA - BAL (40 mpa) three, are used to monitor double pipe end whether meet the pressure or differential pressure, when reach e. after reversing transmission control system;
(2) there are usually two inlet, two oil outlet, but only one inlet pressure switch. Screw hole for taper pipe threads Rc3/8 (YZF - L4) or pipe thread G3/8 (YCK - (P5).
7.2 terminal valve installation location choice
(1) terminal valve to be installed in the pipeline before the end the distributor, i.e. pump to the pipeline is the longest, and terminal valve then put in a distributor;
(2) to facilitate observation, adjustment, repair and not easily collision, at the same time to avoid high temperature and wet water, steam, acid and alkali environment;
7.3 terminal valve installation
(1) with the valve on the terminal screw fixed on the plate in advance;
(2) position will plate after welding on the body or stent, placement for inspection and maintenance;
(3) differential pressure switch to near the inlet pipe with three links in the installation of two pressure gauge. (YZF - L4 itself is with pressure gauge).
8, piping installation
8.1 line profile
(1) double head and manifold: out of the lubricating pump until all the oil inlet distributor, relatively high under pressure. Usually adopt cold drawn seamless steel tube, the material for 10 or 15 steel. Should never be corroded severely pipe;
(2) to the tubing: from the distributor to all lubricating points inlet (bearing oil hole), under pressure is relatively low. Usually adopt drawn copper tube, facilitate to bend the pipe. Also have use cold drawn seamless steel tube or stainless steel tube;
(3) meet parts connection is made of rubber hose connector.
8.2 piping arrangement requirements
(1) line to try to stay away from high temperature radiation and cooling water spray temperature too high or too low, especially the hose joint;
(2) cloth tube shall not influence the host running of equipment, to be safe and reliable, convenient work * * *, observation, maintenance;
(3) cloth tube to horizontal flat vertical, neat and beautiful. Bend bend or less as far as possible little Angle, USES the big circular arc, so as to reduce oil flow resistance;
(4) install collide, tubular to fill and low pressure pipe for high pressure;
(5) the pipeline cannot contact when cross each other, should be separated by a distance;
(6) parallel pipe joint to stagger the installation, lest affect to install and remove;
(7) for ease of disassembly cleaning pipelines, should be appropriate to install union, but with less, to reduce the possibility of a leak.
8.3 the pipe length is determined
(1) according to article 8.2 of the piping path, determine the length of the pipe at the scene, attention should be paid to the influence of the size of the pipe bending radius;
(2) to make all kinds of different coupling access line after taking into account the influence of;
(3) the length of the pipe shall be fixed piecewise, cut off, pre-installed, to facilitate the adjustment according to actual condition, if all of a sudden all cut and accumulated error, piping is difficult;
(4) cut short pipe to make the most of where each need short tube, straight tube joint extension if necessary, but the appropriate section on the joint should not be less more.
8.4 the pipe cutting
(1) cut out the pipe with sawing machine or special pipe cutter machine, is absolutely not allowed to use fusing, such as flame cutting or grinding wheel cutting;
(2) the incision to level off, the section plane degree is not greater than 1 mm, perpendicular to the pipe axis is not more than 1 degree;
(3) using file, scraper such as chip and burr;
(4) with clean compressed air or other method to remove tube attached to the floating rust and debris;
8.5 pipe bending
(1) with pipe bender cold bending, hot bending, large diameter pipe available right Angle joint replacement pipe bending), bending radius to diameter of more than four times;
(2) the ovality of bend (length to diameter change) is less than 10% of the pipe diameter, and cannot appear crease;
(3) if bend the pipe joints, pipe end should be a straight pipe connected to the connector, to avoid affect installation;
8.6 the pipe and the welding joint
(1) using tungsten argon arc welding or tig arc welding welding filling after back. When pressure exceeds 21 mpa, at the same time inside the tube shall be submitted to 5 l/min argon;
(2) the pipe wall thickness > 2 mm, outside the circle should be 35 ° cutting groove, and the counterpart to keep 3 mm gap; Wall thickness of 2 mm or less, not cutting groove, counterpart left 2 mm clearance;
(1) counterpart pipe axis must overlap, wrong side of the amount is less than 15% of wall thickness, partial slope is less than 1 0;
8.7 the installation of pipe clamp
(1) general directly or through the Angle of pipe clamp plate bracket welded on the structure, the concrete floor or wall lateral support with bolts;
(2) pipe clamp when installation should pay attention to leveling, namely the installation surface on the same height;
(3) pipe clamp spacing: pipe diameter phi 10 or less, about 0.5 ~ 1 m; Pipe diameter phi 10 ~ 25, about 1 ~ 1.5 m; Pipe diameter phi 25 ~ 50 is about 1.5 ~ 2 meters, but in the right-angle bend, both sides should be with a pipe clamp.
8.8 pre-installed
(1) pipe and equipment, pipe and tube joint is presented.the connection, until finish all pre-installed;
(2) pipe installation method as shown in the chapter 4;
(3) at the same time the pipe clamp plate welded on the structure or stent, the pipe must not be welded on the pipe clamp or stent;
(4) after completion of installation and inspection, on line printing with mark, a a number of columns into form and set aside. For piping to be removed after cleaning, according to the number.
8.9 matters needing attention
(1) before the installation of all steel pipe can be in accordance with the requirements of chapter 9 first pickling process, in particular, connected to the pipe connector of cutting sleeve type has the steel pipe should be pickling, then tighten card set in advance at the pipe;
(2) all the pipe joint should be received with kerosene is clean, the inside of the type O sealing ring shall be temporarily removed, to be formally put on when installation;
(3) the construction of mouth to keep oil pump, distributor and other equipment, pipe, tube end opening clean, can't keep the water, dust and other foreign matter to enter;
(4) should be in the free state laying pipeline, after the welding line nor excessive radial force forcibly fixed and connected;
(5) and the oil hole of the bearing to check in advance and the internal circuit is open, if oil mouth thread to match with the joint.
9, line cleaning
In order to ensure the purity of lubrication system, bearing and supply of mechanical equipment to clean grease, must be pre-installed piping to be removed after cleaning. Cleaning with kerosene cleaning and pickling two kinds.
9.1 kerosene cleaning object and method
(1) brass, stainless steel tube;
(2) in advance before installation has been pickling process, and now the lining without rust, oxidation of iron sheet steel tube;
(3) with dirty pipe joint;
(4) need to clean the pipe fittings and removed, the pipe with cloth (yarn) or touch kerosene rub tube net, two end fittings and immerse in kerosene wash, and then tube with oil or grease filling with both ends closed well received;
(5) after cleaning can not have visual visible pollutants (such as iron filings, fibrous material, welding slag, etc.), pay special attention to the lining of the welds welding slag must be thoroughly cleaned.
9.2 pickling object
(1) before installation without pickling of steel pipe;
(2) although already after pickling, but now steel tube corroded seriously.
9.3 pickling construction sequence and processing purposes
(1) skim degreasing agent, remove the piping on the adhesion of oil;
(2) the water to wash Clear the dirt on the tubing with water;
(3) cleaning to remove the rusty spot on the wall in the pickling solution, rolling iron filings, etc;
(4) water washing and high pressure water washing Rinse the attachments in the homework, tube internal high pressure water washing;
(5) the neutralization with alkali neutralization tube on the residual acid;
(6) drying In order to effectively dry pipe should be soaked in hot water or steam drying, should make the tubing dry;
(7) rust;
(8) check after pickling pipe inspection, whether clean;
(9) packaging and preservation immediately after pickling with plastic or plastic with a sealed tube opening, in order to avoid foreign bodies, such as moisture intrusion.
9.4 pickling matters needing attention
(1) before pickling pipe welding operation has been completed;
(2) remove, transport, be careful not to touch the wound when pickling line, thread and sealing surface, sealed with adhesive tape or plastic pipe plugging;
(3) the pickling before clean welding slag, spatter and varnish on the pipe, etc;
(4) the thread parts used acid proof material such as plastic belt, rubber belt to protect it, or after degreasing, washing in thread after coated with dry oil again in acid cleaning, to prevent acid erosion;
(5) the pickling note don't make the pipe with the mark disappear or vague.
10, piping installation
After cleaning the pipeline should formally installed and grease filling as soon as possible
(1) all the press printed with the mark line is presented.the connection;
(2) tighten all coupling method in chapter 4, pay attention to in the previous o-rings removed;
(3) all piping should be fixed firmly, not loose;
(4) all give tubing can be fat again after filling with distributor oil outlet and lubrication point connection.
11, system filling grease
Recommended use 0 # or 1 # extreme pressure lithium base grease filling full dry oil lubrication system.
11.1 the electrical wiring
According to the electrical terminal wiring diagram after all good except the valve terminal cable, temporarily replace the function of the valve terminal and travel switch.
11.2 to the oil storage cylinder filling grease lubrication pump
(1) pumps, lubrication pump before the first use, it's best to start a moderate amount of lubricating oil, because of good lubricating oil flow, it will be all parts, when add the lubricating oil pump after long-term storage, is conducive to eliminate internal air;
(2) if some lubricating points can't be used lubricating oil, can be the ministry of oil from the discharge pipe ends after then access all lubricating points;
(3) using pumps to the oil storage cylinder filling grease lubrication pump until high oil level, banned from the top oil cylinder to join grease, make sure all is clean grease.
11.3 to double line supervisor and manifold filling grease
(1) drive lubrication pump, loosen the lubrication pump oil outlet joint, until the oil pump discharge mouth clean grease (continuous appearance, no bubble, no white, clean, no foreign body);
(2) tighten the oil outlet joint, open the double end of the main line, until at the end of a head of pure grease. Make the reversing valve commutation, until at the end of another director also pure grease, then to end seal main line;
(3) to loosen all double pipe with distributor inlet connection, when one pipe discharge clean grease, connected to the pipe connection with distributor, until the side branch pipe is connected, make the reversing valve commutation, in the same way, in turn, connected to the other side of the pipe connection with distributor;
(4) loosen the distributor oil outlet for tubing connection, make the reversing valve reversing repeatedly until the distributor from pure grease.
11.4 to give tubing filling grease
A (1) methods: give the tubing temporarily not access system, using electric lubrication pump or manual pump with custom directly to the individual to the tubing joint filling grease, when the fat pure formal installed to the system. Pay attention to protect the two ports, prevent dirty;
(2) the method 2: give the tubing with distributor connected with lubrication point release, make the reversing valve repeatedly reversing only after the orifice discharge clean grease pipe connected to the lubrication points. When to tubing length is large, there will be a long tube end also did not see fat, and short tube in the bearing grease is too much.
11.5 grease filling matters needing attention
(1) can use grease filling line for washing, to drain oil pure (continuous, no bubble, no dirt) as the principle;
(2) the release of oil in plastic bags, to prevent pollution of the ground;
(3) on the grease filling of each link is to pay attention to cannot be mixed with air in the pipeline, otherwise this line needs recharging, fat;
(4) in the pipeline has been full of fat marking, and check the presence of leakage.
12, test run adjustment
12.1 pressure testing
Driver lubrication pump, will head pressure all the way to system nominal pressure, holding for 10 minutes. Check the piping and components shall be no leakage at this moment, all distributor pointer has action. Try another head all the way with the same method.
12.2 electric automatic system commissioning
(1) of the valve on the terminal cable connected to the electric cabinet, make Ⅰ line head pressure rises, the terminal corresponding electric contact closed valve switch, reversing valve switch to Ⅱ line. When competent Ⅱ line pressure rise, terminal valve closed switch electric contact the other side, reversing valve to Ⅰ line. If not reverse, the terminal can be valve switch electric contact lead swaps;
(2) observe all distributor pointer, each to should all action in time;
(3) work in automatic mode operation, after setting the time interval, the lubrication pump automatically start for the fat, after for the fat automatically stop, after setting the time interval of pump automatically start for fat again... So the cycle, automatic work;
(4) when the oil level down to low, should be able to start a petrol pump grease filling, or send out alarm signal; When the oil level rise to high, should be able to stop the pumps, or send out alarm signal.
12.3 the manual system test run
(1) shake hand lubrication pump handle, with the head pressure slowly rising, splitter pointer action, when the pressure rises quickly, operate the pump at the bottom of the reversing handle reversing. Check all the splitter pointer at this moment, shall all be action once;
(2) to continue shaking lubrication pump handle, when the pressure goes up, soon will recover the reversing handle. Test all the splitter pointer should reverse action again once;
(3) shake hand pump handle, observation of manual lubrication oil pump barrel oil level indication rod should be gradually rise, says it is grease filling smoothly;
(4) when manually lubrication pump cylinder is reduced as a result, the use of grease oil level indication rod should be reduced.
12.4 to fat volume adjustment
(1) to adjust distributor pointer screw position can change of schedule distributor every work for the amount of fat;
(2) adjusting the interval duration of electric automatic systems, can change the system of automatic work per day.
After completion of the above steps, double oil dry centralized lubrication system can put into practice.