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In various processing industries, including food, dairy, beverage, and biopharmaceutical sectors, slurries represent complex compounds blending liquid and solid properties. Choosing the right type and size of slurry pump is crucial due to this unique composition.
A slurry pump, a centrifugal pump variant, is engineered to propel suspended solids like sand and gravel within a liquid medium. Its design enables pressure augmentation, facilitating the transportation of slurries across long distances and vertical lifts. Widely employed in dredging, mining, mineral processing, and wastewater treatment, these pumps are versatile tools.
Slurry pumps are specifically crafted to handle liquids laden with solid particles, with designs adaptable to various slurry types distinguished by solid concentration, particle size, shape, and solution composition. Compared to standard liquid pumps, slurry pumps exhibit enhanced resilience, featuring sacrificial materials and replaceable components to withstand abrasion effectively.
Mr. Huang owns a sand field and aims to produce sand using small stones and gravel due to strict governmental regulations on river sand extraction. The sand generated during the crushing process of stones and gravel contains a high mud content, resulting in the production of significant muddy water during cleaning. To facilitate handling, the mud needs to be solidified into blocks using a filter press. Given the substantial pressure needed for feeding, Mr. Huang procured two multi-purpose DS sand suction pumps from OCEAN Pump for the filter press.
Upon installation on-site, the multi-purpose DS sand suction pump showed promising results. The mud began solidifying within approximately 10 minutes. However, after some usage, on-site personnel reported abnormalities such as unusual bearing noises, reduced inlet pressure, and prolonged discharge times. Responding promptly to this feedback, OCEAN Pump dispatched engineers to the site to address issues with the DS sand suction pump. Subsequent inspection revealed the following problems:
1. The multi-purpose DS sand suction pump was not aligned horizontally with the motor pulley, with the motor end pulley protruding outwards by half the sheave’s width. Additionally, abnormal noises were detected in the pump’s bearing chamber, likely due to prolonged misalignment causing bearing damage.
2. Reduced pressure at the feed port indicated a decrease in the pump’s lift. The motor was a second-hand purchase, and engineers measured its speed, revealing a lower than expected speed of around 1300 rpm instead of the rated 1470 rpm for a 4-pole motor. To rectify this, engineers suggested upgrading the motor pulley to one with a larger outer diameter of 260 mm from the original 240 mm C-type 4-slot pulley.
3. Examination of the DS sand suction pump’s installation pipeline uncovered issues such as the inlet pipe being loosely connected without clips, leading to potential air intake problems. Additionally, aged packing resulted in mud leakage. These factors contributed to air intake issues and inadequate pressure. Subsequently, engineers proceeded to rectify these deficiencies after identifying the root causes.
Regular inspection is the first step to prevent sand pump failure. Inspections should include but are not limited to key components such as pump body, seals, bearings, motors and power cords. For sand pump maintenance, it is recommended to conduct a comprehensive inspection every 500 hours of operation to ensure that all components are in good working condition.
During the operation of the sand pump, sand and other impurities may enter the inside of the pump body. Therefore, regular cleaning of the pump body and lubrication of key components are important parts of maintenance. Use appropriate cleaning agents and tools to remove impurities inside the pump body and lubricate with suitable lubricants as recommended by the manufacturer.
The sealing system is a key part of the sand pump to prevent sand and water from entering the inside of the machine. Check whether the seals are worn or damaged, and replace them in time to prevent leakage and further equipment damage.
Before making any repairs, it is first necessary to accurately diagnose the cause of the fault. This may include problems such as motor overheating, pump vibration, reduced flow or complete cessation of operation. Using professional diagnostic tools and methods, such as vibration analysis and thermal imaging, can help quickly locate the problem.
The motor is the power source of the sand pump, and its failure may cause the entire system to stop working. The repair of motor failure may include replacing damaged coils, bearings or the entire motor. When performing motor repairs, it should be operated by professional technicians to ensure safety and repair quality.
Long-term sand scouring and corrosion may cause pump body wear. For minor wear, it can be repaired by grinding and coating; for severe damage, it may be necessary to replace the pump body parts.
Damage to the seal is one of the common failures of sand pumps. When replacing seals, high-quality seals that are compatible with the original equipment should be selected and installed according to the manufacturer’s instructions to ensure the sealing effect.
The correct operating parameters are essential to improve the performance of sand pumps. This includes adjusting the pump’s operating speed, working pressure and flow rate to suit different working environments and needs.
With the development of technology, regular upgrades and modifications to the sand pump can improve its performance and efficiency. This may include replacing more efficient motors, improving pump body design or introducing more advanced control systems.
The technical level of the operator directly affects the operation of the sand pump. Regular training of operators to improve their understanding of equipment operation and maintenance can effectively reduce the occurrence of failures.
The use of advanced monitoring systems can monitor the operating status of the sand pump in real time, and detect and deal with problems in a timely manner. This includes installing sensors, data acquisition systems and remote monitoring platforms.
Maintenance and repair of multi-purpose DS sand pumps are the key to ensure their long-term stable operation. Regular inspection, cleaning, lubrication and necessary repairs can significantly improve the reliability and service life of the equipment. At the same time, optimizing operating parameters, regular upgrades, training operators and adopting advanced monitoring systems are all effective strategies to improve the performance of sand pumps. Through these measures, it can be ensured that the sand pump can perform at its maximum efficiency in various working environments.
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