A method for online replacement and debugging of constant pressure variable pump

Abstract

The present application relates to a kind of constant pressure variable pump on-line replacement debugging method, belongs to hydraulic equipment maintenance method technical field.The technical scheme of the present application is: in the field hydraulic station, constant pressure variable pump is removed from the bell jar connected with motor, pump end coupling is removed from constant pressure variable pump and installed to new constant pressure variable pump, then new constant pressure variable pump is installed to bell jar together with pump end coupling, and it is normal to run after debugging.The beneficial effects of the present application are: by using puller, pulley, tripod, hand-operated hoist and other tools, constant pressure variable pump is replaced in the field hydraulic station, the efficiency of replacing constant pressure variable pump is improved, the need of on-site production is met, it is practical, and it is strong in adaptability by using on-site conditions and on-site operation.

Description

Technical Field

[0001] The invention relates to an online replacement and debugging method for a constant-pressure variable pump, belonging to the technical field of hydraulic equipment maintenance methods. Background Art

[0002] Hydraulic equipment has been widely used in the steel and metallurgical industry. The constant pressure variable pump commonly used in the hydraulic station works at full load. Once the constant pressure variable pump fails and needs to be replaced, the constant pressure variable pump and motor are usually disassembled as a whole and transported to the maintenance workshop by forklift for replacement. After the replacement, the constant pressure variable pump and motor are transported as a whole to the on-site hydraulic station for installation and commissioning. This repair method has the following disadvantages:

[0003] 1. Long repair cycle: It usually takes 2-3 days for the constant pressure variable pump and motor to be dismantled, transported to the maintenance workshop, and then returned to the hydraulic station after the constant pressure variable pump is replaced, which cannot meet the needs of on-site production.

[0004] 2. It occupies a large number of maintenance personnel, which is prone to work connection problems. Generally, the personnel who remove the constant pressure variable pump and install the constant pressure variable pump are the same group of people, while the personnel who repair and replace the constant pressure variable pump are another group of people, which is prone to work connection problems.

[0005] 3. Many vehicles are involved and the transportation process is complicated.

[0006] These three problems show that the original method of replacing the constant pressure variable pump has great shortcomings, which restricts the needs of on-site production. Summary of the Invention

[0007] The purpose of the present invention is to provide a method for online replacement and debugging of a constant-pressure variable pump. By using tools such as a puller, a pulley, a tripod, and a hand hoist, the constant-pressure variable pump is removed from a bell housing connected to a motor at an on-site hydraulic station, the pump-end coupling is removed from the constant-pressure variable pump and installed on a new constant-pressure variable pump, and then the new constant-pressure variable pump together with the pump-end coupling is installed on the bell housing. After debugging, normal operation is restored, the efficiency of replacing the constant-pressure variable pump is improved, the needs of on-site production are met, the method is highly practical, and on-site operation is performed using on-site conditions. It has strong adaptability and effectively solves the above-mentioned problems existing in the background technology.

[0008] The technical solution of the present invention is: a method for online replacement and debugging of a constant pressure variable pump, comprising the following steps:

[0009] (1) On-site preparation: stop the constant pressure variable pump to be replaced and turn off the power; close the butterfly valve, pump body oil return valve and flushing valve, install the tripod, pulley and hand hoist; remove the fan cover of the motor to expose the fan blades;

[0010] (2) Remove the constant pressure variable pump to be replaced, remove the high-pressure oil output hose, pump body oil return hose and flushing hose; remove the SAE flange connecting the oil suction pipe and the constant pressure variable pump to separate the oil suction pipe and the constant pressure variable pump; remove the four bolts connecting the constant pressure variable pump and the bell cover, and pry the constant pressure variable pump and the bell cover apart; use a hand hoist and pulley to lift the constant pressure variable pump away;

[0011] (3) Assemble a new constant pressure variable pump. Use a puller to pull the pump end coupling from the shaft end of the constant pressure variable pump to be replaced. At the same time, remove the connecting thread heads connected to the high-pressure oil output hose, pump body self-return oil hose and flushing hose on the constant pressure variable pump to be replaced; install the pump end coupling on the shaft end of the new constant pressure variable pump; install the connecting thread heads connected to the high-pressure oil output hose, pump body self-return oil hose and flushing hose on the new constant pressure variable pump;

[0012] (4) Install a new constant pressure variable pump. First, mesh the pump end coupling with the motor end coupling. Install the new constant pressure variable pump with the end of the pump end coupling facing downwards. Install the coupling plum blossom spring washer on the motor end coupling first. Use a wire rope to lift the new constant pressure variable pump to the recess between the square flange and the pump body of the new constant pressure variable pump. Let the pump body boss of the new constant pressure variable pump enter along the bell hole. Push the pump end coupling axially from the back of the new constant pressure variable pump to fully mesh the pump end coupling with the motor end coupling. Install the oil suction pipe. Use the SAE flange to completely install the oil suction pipe on the new constant pressure variable pump. When the tightening is completed, tighten the four bolts of the square flange diagonally.

[0013] (5) Debug the new constant pressure variable pump, turn the impeller of the motor by hand, observe the exhaust and oil discharge from the oil return port of the new constant pressure variable pump, and stop turning the impeller of the motor until clear hydraulic oil without white bubbles is discharged; install the pump body oil return hose to the new constant pressure variable pump, open the pump body oil return valve, and restore the installation of the motor protective cover; loosen the pressure regulating handle of the relief valve and the pressure regulating valve of the new constant pressure variable pump to the bottom, close the switch and supply power; adjust the pressure of the new constant pressure variable pump, and simultaneously turn the relief valve and the new constant pressure variable pump clockwise. Turn the pressure regulating handle of the constant pressure variable pump's pressure regulating valve until the pressure gauge displays a certain value exceeding the rated working pressure, then stop turning it. Turn the relief valve's pressure regulating handle counterclockwise until you can hear the sound of oil leakage from the relief valve. Then turn the relief valve's pressure regulating handle clockwise until the sound of oil leakage disappears, and lock the relief valve's pressure regulating handle with a nut. Turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve counterclockwise until the pressure gauge displays "rated working pressure," and then lock the pressure regulating handle of the variable pump's pressure regulating valve with a nut.

[0014] (6) The new constant pressure variable pump is put into production. After the new constant pressure variable pump is put into operation for one hour, listen to whether the sound of the motor, the new constant pressure variable pump and its coupling is normal, observe whether the pressure is normal, and whether there is oil leakage in the joints of each pipeline. After confirming that everything is correct, it is delivered for production application.

[0015] In the step (1), when the power is turned off, a signboard with the message "under maintenance, do not close the switch" is hung.

[0016] In the step (2), when removing the four bolts connecting the constant pressure variable pump and the bell jar, first remove three of the four bolts connecting the constant pressure variable pump and the bell jar, tie the constant pressure variable pump with a wire rope and pull it with a hand hoist, and remove the last of the four bolts connecting the constant pressure variable pump and the bell jar;

[0017] Pull the hand hoist by hand to make the constant pressure variable pump rise a little, then release the hand hoist to let the constant pressure variable pump drop a little, repeat several times, until the gap between the method flange of the constant pressure variable pump and the bell cover gradually increases, and use a crowbar to pry the constant pressure variable pump and the bell cover apart.

[0018] In the step (3), before using a puller to pull the pump end coupling from the shaft end of the constant pressure variable pump to be replaced, remove the top screw on the pump end coupling, use a micrometer to measure the distance from the end face of the pump end coupling to the shaft end face of the constant pressure variable pump to be replaced, and use this as the data basis for the next step of installing the pump end coupling on the new constant pressure variable pump; use a micrometer to measure the inner hole of the pump end coupling and the shaft end size of the new constant pressure variable pump to confirm the matching of the two, and polish the pump end coupling with fine sandpaper if necessary. The inner hole of the shaft and the shaft end of the new constant pressure variable pump; try to install the pump end coupling twice on the shaft end of the new constant pressure variable pump, until you can tap the pump end coupling with a small hammer. When the pump end coupling moves on the shaft of the new constant pressure variable pump, start to formally install the pump end coupling; when the distance between the pump end coupling installed on the shaft end of the new constant pressure variable pump is close to the distance from the end face of the pump end coupling to the shaft end face of the constant pressure variable pump to be replaced, measure and tap continuously until the measured distance is reached.

[0019] In the step (4), when the pump end coupling and the motor end coupling are engaged, the engagement of the pump end coupling and the motor end coupling is observed through the observation hole of the bell cover. If the engagement is not good, the fan blades of the motor are assisted in rotating to make the two couplings engage well, and the pump end coupling is pushed axially from the rear of the new constant pressure variable pump to make the pump end coupling and the motor end coupling fully engage;

[0020] When installing the oil suction pipe, install four bolts through the four bolt holes of the square flange. Tighten only 3-4 threads of the first bolt. Install the oil suction pipe on the new constant pressure variable pump using the SAE flange. If the bolt holes do not align, properly adjust the axial position of the new constant pressure variable pump. After the oil suction pipe is completely installed on the new constant pressure variable pump using the SAE flange and tightened, tighten the four bolts of the square flange diagonally.

[0021] After installing the oil suction pipe, observe the meshing clearance between the tooth top and tooth bottom of the pump end coupling and the motor end coupling through the observation hole of the bell cover. The appropriate clearance is 2-3mm. If it is too large or too small, remove the new constant pressure variable pump, readjust it, and reinstall it.

[0022] In step (5), the pressure of the new constant pressure variable pump is adjusted, and the pressure adjustment is started after running in for 30 minutes under a pressure-free state;

[0023] When synchronously turning the relief valve and the pressure regulating valve of the new constant pressure variable pump clockwise, when the pressure gauge displays 5MPa, first turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, then turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, repeat several times until the pressure gauge displays the rated working pressure, continue to turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise until the pressure gauge displays "rated working pressure + 3MPa", stop turning the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise.

[0024] The beneficial effects of the present invention are as follows: by using tools such as a puller, a pulley, a tripod, and a hand hoist, the constant-pressure variable pump is removed from the bell housing connected to the motor at an on-site hydraulic station, the pump-end coupling is removed from the constant-pressure variable pump and installed on a new constant-pressure variable pump, and then the new constant-pressure variable pump together with the pump-end coupling is installed on the bell housing. After debugging, normal operation is restored, the efficiency of replacing the constant-pressure variable pump is improved, the needs of on-site production are met, the practicality is strong, on-site operation is performed using on-site conditions, and the adaptability is strong. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a structural diagram of on-site installation of the present invention;

[0026] Figure 2 This is a diagram of the disassembly and replacement process of the constant pressure variable pump of the present invention;

[0027] Figure 3 yes Figure 2 BB view;

[0028] Figure 4 This is a disassembly diagram of the pump end coupling of the present invention;

[0029] Figure 5 yes Figure 4 AA view;

[0030] Figure 6 This is the installation diagram of the pump end coupling of the present invention;

[0031] In the figure: relief valve 1, new constant pressure variable pump 2, bell jar 3, motor 4, pressure regulating valve 5, pump body boss 6, jack screw 7, pump end coupling 8, puller 9, screw rod 10, butterfly valve 11, flexible connection 12, oil suction pipe 13, bell jar hole 14, motor end coupling 15, pulley 16, tripod 17, hand hoist 18, pump body return oil valve 19, flushing valve 20, high-pressure oil output hose 21, pump body return oil hose 22, flushing hose 23, square flange 24. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solutions and advantages of the invention implementation cases clearer, the technical solutions in the invention implementation cases will be clearly and completely described below in conjunction with the drawings in the implementation cases. Obviously, the implementation cases described are only a small part of the implementation cases of the present invention, rather than all the implementation cases. Based on the implementation cases in the present invention, all other implementation cases obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0033] A method for online replacement and debugging of a constant pressure variable pump comprises the following steps:

[0034] (1) On-site preparation: stop the constant pressure variable pump to be replaced and turn off the power; close the butterfly valve, pump body oil return valve and flushing valve, install the tripod, pulley and hand hoist; remove the fan cover of the motor to expose the fan blades;

[0035] (2) Remove the constant pressure variable pump to be replaced, remove the high-pressure oil output hose, pump body oil return hose and flushing hose; remove the SAE flange connecting the oil suction pipe and the constant pressure variable pump to separate the oil suction pipe and the constant pressure variable pump; remove the four bolts connecting the constant pressure variable pump and the bell cover, and pry the constant pressure variable pump and the bell cover apart; use a hand hoist and pulley to lift the constant pressure variable pump away;

[0036] (3) Assemble a new constant pressure variable pump. Use a puller to pull the pump end coupling from the shaft end of the constant pressure variable pump to be replaced. At the same time, remove the connecting thread heads connected to the high-pressure oil output hose, pump body self-return oil hose and flushing hose on the constant pressure variable pump to be replaced; install the pump end coupling on the shaft end of the new constant pressure variable pump; install the connecting thread heads connected to the high-pressure oil output hose, pump body self-return oil hose and flushing hose on the new constant pressure variable pump;

[0037] (4) Install a new constant pressure variable pump. First, mesh the pump end coupling with the motor end coupling. Install the new constant pressure variable pump with the end of the pump end coupling facing downwards. Install the coupling plum blossom spring washer on the motor end coupling first. Use a wire rope to lift the new constant pressure variable pump to the recess between the square flange and the pump body of the new constant pressure variable pump. Let the pump body boss of the new constant pressure variable pump enter along the bell hole. Push the pump end coupling axially from the back of the new constant pressure variable pump to fully mesh the pump end coupling with the motor end coupling. Install the oil suction pipe. Use the SAE flange to completely install the oil suction pipe on the new constant pressure variable pump. When the tightening is completed, tighten the four bolts of the square flange diagonally.

[0038] (5) Debug the new constant pressure variable pump, turn the impeller of the motor by hand, observe the exhaust and oil discharge from the oil return port of the new constant pressure variable pump, and stop turning the impeller of the motor until clear hydraulic oil without white bubbles is discharged; install the pump body oil return hose to the new constant pressure variable pump, open the pump body oil return valve, and restore the installation of the motor protective cover; loosen the pressure regulating handle of the relief valve and the pressure regulating valve of the new constant pressure variable pump to the bottom, close the switch and supply power; adjust the pressure of the new constant pressure variable pump, and simultaneously turn the relief valve and the new constant pressure variable pump clockwise. Turn the pressure regulating handle of the constant pressure variable pump's pressure regulating valve until the pressure gauge displays a certain value exceeding the rated working pressure, then stop turning it. Turn the relief valve's pressure regulating handle counterclockwise until you can hear the sound of oil leakage from the relief valve. Then turn the relief valve's pressure regulating handle clockwise until the sound of oil leakage disappears, and lock the relief valve's pressure regulating handle with a nut. Turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve counterclockwise until the pressure gauge displays "rated working pressure," and then lock the pressure regulating handle of the variable pump's pressure regulating valve with a nut.

[0039] (6) The new constant pressure variable pump is put into production. After the new constant pressure variable pump is put into operation for one hour, listen to whether the sound of the motor, the new constant pressure variable pump and its coupling is normal, observe whether the pressure is normal, and whether there is oil leakage in the joints of each pipeline. After confirming that everything is correct, it is delivered for production application.

[0040] In the step (1), when the power is turned off, a signboard with the message "under maintenance, do not close the switch" is hung.

[0041] In the step (2), when removing the four bolts connecting the constant pressure variable pump and the bell jar, first remove three of the four bolts connecting the constant pressure variable pump and the bell jar, tie the constant pressure variable pump with a wire rope and pull it with a hand hoist, and remove the last of the four bolts connecting the constant pressure variable pump and the bell jar;

[0042] Pull the hand hoist by hand to make the constant pressure variable pump rise a little, then release the hand hoist to let the constant pressure variable pump drop a little, repeat several times, until the gap between the method flange of the constant pressure variable pump and the bell cover gradually increases, and use a crowbar to pry the constant pressure variable pump and the bell cover apart.

[0043] In the step (3), before using a puller to pull the pump end coupling from the shaft end of the constant pressure variable pump to be replaced, remove the top screw on the pump end coupling, use a micrometer to measure the distance from the end face of the pump end coupling to the shaft end face of the constant pressure variable pump to be replaced, and use this as the data basis for the next step of installing the pump end coupling on the new constant pressure variable pump; use a micrometer to measure the inner hole of the pump end coupling and the shaft end size of the new constant pressure variable pump to confirm the matching of the two, and polish the pump end coupling with fine sandpaper if necessary. The inner hole of the shaft and the shaft end of the new constant pressure variable pump; try to install the pump end coupling twice on the shaft end of the new constant pressure variable pump, until you can tap the pump end coupling with a small hammer. When the pump end coupling moves on the shaft of the new constant pressure variable pump, start to formally install the pump end coupling; when the distance between the pump end coupling installed on the shaft end of the new constant pressure variable pump is close to the distance from the end face of the pump end coupling to the shaft end face of the constant pressure variable pump to be replaced, measure and tap continuously until the measured distance is reached.

[0044] In the step (4), when the pump end coupling and the motor end coupling are engaged, the engagement of the pump end coupling and the motor end coupling is observed through the observation hole of the bell cover. If the engagement is not good, the fan blades of the motor are assisted in rotating to make the two couplings engage well, and the pump end coupling is pushed axially from the rear of the new constant pressure variable pump to make the pump end coupling and the motor end coupling fully engage;

[0045] When installing the oil suction pipe, install four bolts through the four bolt holes of the square flange. Tighten only 3-4 threads of the first bolt. Install the oil suction pipe on the new constant pressure variable pump using the SAE flange. If the bolt holes do not align, properly adjust the axial position of the new constant pressure variable pump. After the oil suction pipe is completely installed on the new constant pressure variable pump using the SAE flange and tightened, tighten the four bolts of the square flange diagonally.

[0046] After installing the oil suction pipe, observe the meshing clearance between the tooth top and tooth bottom of the pump end coupling and the motor end coupling through the observation hole of the bell cover. The appropriate clearance is 2-3mm. If it is too large or too small, remove the new constant pressure variable pump, readjust it, and reinstall it.

[0047] In step (5), the pressure of the new constant pressure variable pump is adjusted, and the pressure adjustment is started after running in for 30 minutes under a pressure-free state;

[0048] When synchronously turning the relief valve and the pressure regulating valve of the new constant pressure variable pump clockwise, when the pressure gauge displays 5MPa, first turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, then turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, repeat several times until the pressure gauge displays the rated working pressure, continue to turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise until the pressure gauge displays "rated working pressure + 3MPa", stop turning the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise.

[0049] In actual application, the present invention uses tools such as a puller 9, a pulley 16, a tripod 17 and a hand hoist 18 to remove the constant pressure variable pump to be replaced from the bell 3 connected to the motor 4 at the on-site hydraulic station, remove the pump end coupling 8 from the constant pressure variable pump to be replaced and install it on the new constant pressure variable pump 2, and then install the new constant pressure variable pump 2 together with the pump end coupling 8 on the bell 3, and restore normal operation after debugging.

[0050] The specific steps are as follows:

[0051] Preparatory steps

[0052] (1) Please ask the operator to stop the operation of the constant pressure variable pump to be replaced. At the same time, ask the electrician to turn off the switch in the control room and hang a sign saying "Under maintenance, do not close the switch".

[0053] (2) Close the butterfly valve 11, the pump body oil return valve 19 and the flushing valve 20. Install the tripod 17, the pulley 16 and the hand hoist 18.

[0054] (3) Remove the fan cover of motor 4 to expose the fan blades.

[0055] Steps to remove the constant pressure variable pump

[0056] (1) Remove the high-pressure oil output hose 21, the pump body oil return hose 22, and the flushing hose 23. Remove the SAE flange connecting the oil suction pipe 13 and the constant pressure variable pump to be replaced, so as to separate the oil suction pipe 13 and the constant pressure variable pump to be replaced. Remove three of the four bolts connecting the constant pressure variable pump to be replaced and the bell housing, tie the constant pressure variable pump to be replaced with a wire rope and pull it with a hand hoist, and remove the last of the four bolts connecting the constant pressure variable pump to be replaced and the bell housing.

[0057] (2) Pull the hand chain hoist 18 by hand to make the constant pressure variable pump to be replaced rise a little, then release the hand chain hoist 18 to let the constant pressure variable pump to be replaced fall a little, repeat several times until the gap between the method flange 24 of the constant pressure variable pump to be replaced and the bell jar 3 gradually increases, and use a crowbar to pry apart the constant pressure variable pump to be replaced and the bell jar 3.

[0058] (3) Use the hand hoist 18 and the pulley 16 to lift the constant pressure variable pump to be replaced.

[0059] Assembly steps for new constant pressure variable pump

[0060] (1) Place the dismantled constant pressure variable pump to be replaced in a safe and clean place, remove the top screw 7 on the pump end coupling 8, and use a micrometer to measure the distance from the end face of the pump end coupling 8 to the end face of the shaft of the constant pressure variable pump to be replaced. This will serve as the data basis for the next step of installing the pump end coupling 8 on the new constant pressure variable pump 2. Use a puller 9 to pull the pump end coupling 8 off the shaft end of the constant pressure variable pump to be replaced, and at the same time remove the connecting thread heads connected to the high-pressure oil output hose 21, the pump body self-return oil hose 22, and the flushing hose 23 on the constant pressure variable pump to be replaced.

[0061] (2) Use a micrometer to measure the inner hole of the pump end coupling 8 and the shaft end size of the new constant pressure variable pump 2 to confirm the looseness and tightness of the fit between the two. If necessary, use fine sandpaper to polish the inner hole of the pump end coupling 8 and the shaft end of the new constant pressure variable pump 2.

[0062] (3) Try to install the pump end coupling 8 twice on the shaft end of the new constant pressure variable pump 2 until the pump end coupling 8 can be tapped lightly with a small hammer. When the pump end coupling 8 moves on the shaft of the new constant pressure variable pump 2, start to formally install the pump end coupling 8. When the distance between the pump end coupling 8 installed on the shaft end of the new constant pressure variable pump 2 is close to the distance measured when the pump end coupling 8 is removed from the shaft end of the constant pressure variable pump to be replaced, continue measuring and tapping until the measured distance is reached.

[0063] (4) Install the connecting thread heads connected to the high-pressure oil output hose 21, the pump body self-return oil hose 22 and the flushing hose 23 onto the new constant pressure variable pump 2.

[0064] Steps for installing a new constant pressure variable pump

[0065] (1) Use a wire rope to tie the new constant pressure variable pump 2, adjust the position of the wire rope so that the end of the new constant pressure variable pump 2 installed on the pump end coupling 8 is facing downward, use the hand hoist 18 and the pulley 16 to hang the new constant pressure variable pump 2 near the bell hole 14 of the bell jar 3, and first install the coupling plum blossom spring washer on the motor end coupling 15.

[0066] (2) Adjust the position of the pulley 16 so that the center of gravity of the new constant pressure variable pump 2 is biased toward one side of the bell hole 14.

[0067] (3) Use a wire rope to tie up the new constant pressure variable pump 2 to the recess between the square flange 24 and the pump body of the new constant pressure variable pump 2, and let the pump body boss 6 of the new constant pressure variable pump 2 enter along the bell hole 14. Observe the engagement of the pump end coupling 8 and the motor end coupling 15 through the observation hole of the bell 3. If they are not well engaged, assist in rotating the fan blades of the motor 4 to make the two couplings engage well. Push the pump end coupling 8 axially from the back of the new constant pressure variable pump 2 to make the pump end coupling 8 and the motor end coupling 15 fully engaged. Install four bolts through the four bolt holes of the square flange 24. Tighten only 3-4 threads of the first bolt. Use the SAE flange to install the oil suction pipe 13 on the new constant pressure variable pump 2. If the bolt holes do not match, adjust the axial position of the new constant pressure variable pump 2 appropriately. When the oil suction pipe 13 is completely installed on the new constant pressure variable pump 2 with the SAE flange and tightened, tighten the four bolts of the square flange 24 diagonally. Observe the tooth top and tooth bottom meshing clearance of the pump-end coupling 8 and the motor-end coupling 15 through the observation hole of the bell jar 3. The clearance should be 2-3mm. If it is too large or too small, remove the new constant pressure variable pump 2, readjust it, and reinstall it.

[0068] (4) Install the high-pressure oil output hose 21 and the flushing hose 23 to the new constant pressure variable pump 2 and the corresponding joints, and open the butterfly valve 11 and the flushing valve 20.

[0069] 2 steps to debug a new constant pressure variable pump

[0070] (1) Manually rotate the impeller of the motor 4 and observe the exhaust and oil discharge from the oil return port of the new constant pressure variable pump 2. First, gas is discharged from the inside, then the gas-liquid mixture is discharged, and finally clear hydraulic oil without white bubbles is discharged. Stop rotating the impeller of the motor 4, install the pump oil return hose 22 to the new constant pressure variable pump 2, and open the pump oil return valve 19. And restore the protective cover of the motor 4.

[0071] (2) Loosen the pressure regulating handles of the relief valve 1 and the pressure regulating valve 5 of the new constant pressure variable pump 2 to the bottom.

[0072] (3) Inform the electrician in the control room to remove the sign that says "Under maintenance, do not close the switch" and close the switch to supply power.

[0073] (4) Operate the start button of the new constant pressure variable pump 2, let the motor 4 rotate to drive the new constant pressure variable pump 2 to run in under no pressure for 30 minutes, then start to adjust the pressure. First, turn the pressure regulating handles of the relief valve 1 and the pressure regulating valve 5 of the new constant pressure variable pump 2 clockwise synchronously. When the pressure gauge shows 5MPa, first turn the pressure regulating handle of the relief valve 1 by 1 / 2 turn, then turn the pressure regulating handle of the pressure regulating valve 5 of the new constant pressure variable pump 2 by 3 / 8 turn, then turn the pressure regulating handle of the relief valve 1 by 1 / 2 turn, and then turn the pressure regulating handle of the pressure regulating valve 5 of the new constant pressure variable pump 2 by 3 / 8 turn. Turn the pressure regulating handle of the pressure regulating valve 5 repeatedly several times until the pressure gauge displays the rated working pressure. Continue to turn the pressure regulating handle of the pressure regulating valve 5 of the new constant pressure variable pump 2 clockwise until the pressure gauge displays "rated working pressure + 3MPa". Stop turning the pressure regulating handle of the pressure regulating valve 5 of the new constant pressure variable pump 2 clockwise. At this time, turn the pressure regulating handle of the relief valve 1 counterclockwise until you can hear the sound of "hissing, hi" oil leakage from the relief valve 1. At this time, turn the pressure regulating handle of the relief valve 1 clockwise until the oil leakage sound disappears. Then lock the pressure regulating handle of the relief valve 1 with a nut, and then turn the pressure regulating handle of the pressure regulating valve 5 of the new constant pressure variable pump 2 counterclockwise until the pressure gauge displays "rated working pressure", and then lock the pressure regulating handle of the pressure regulating valve 5 of the variable pump 2 with a nut.

[0074] Steps for putting new constant pressure variable pump into production

[0075] Put the new constant pressure variable pump 2 into operation for one hour. Listen to see if the sounds of the motor 4, the new constant pressure variable pump 2 and its coupling are normal. Observe whether the pressure is normal and whether there is oil leakage in the joints of each pipeline. After confirming that everything is correct, deliver it for production use.

Claims

1. A method for online replacement and debugging of a constant pressure variable pump, characterized in that The following steps are involved: (1) On-site preparation: stop the constant pressure variable pump to be replaced and turn off the power; close the butterfly valve, pump body oil return valve and flushing valve, install the tripod, pulley and hand hoist; remove the fan cover of the motor to expose the fan blades; (2) Remove the constant pressure variable pump to be replaced, remove the high-pressure oil output hose, pump body oil return hose and flushing hose; remove the SAE flange connecting the oil suction pipe and the constant pressure variable pump to separate the oil suction pipe and the constant pressure variable pump; remove the four bolts connecting the constant pressure variable pump and the bell cover, and pry the constant pressure variable pump and the bell cover apart; use a hand hoist and pulley to lift the constant pressure variable pump away; (3) Assemble a new constant pressure variable pump. Use a puller to pull the pump end coupling from the shaft end of the constant pressure variable pump to be replaced. At the same time, remove the connecting thread heads connected to the high-pressure oil output hose, pump body return oil hose and flushing hose on the constant pressure variable pump to be replaced; install the pump end coupling on the shaft end of the new constant pressure variable pump; install the connecting thread heads connected to the high-pressure oil output hose, pump body return oil hose and flushing hose on the new constant pressure variable pump; (4) Install a new constant pressure variable pump. First, mesh the pump end coupling and the motor end coupling. Install the end of the new constant pressure variable pump with the pump end coupling facing downward. Install the coupling plum blossom spring washer on the motor end coupling first. Use a wire rope to tie up the new constant pressure variable pump in the recess between the square flange and the pump body of the new constant pressure variable pump. Let the pump body boss of the new constant pressure variable pump enter along the bell hole. Push the pump end coupling axially from the back of the new constant pressure variable pump to fully mesh the pump end coupling and the motor end coupling. Install the oil suction pipe. Use the SAE flange to completely install the oil suction pipe on the new constant pressure variable pump and tighten it. Then tighten the four bolts of the square flange diagonally. (5) Debug the new constant pressure variable pump, turn the impeller of the motor by hand, observe the exhaust and oil discharge from the oil return port of the new constant pressure variable pump, and stop turning the impeller of the motor until clear hydraulic oil without white bubbles is discharged; install the pump body oil return hose to the new constant pressure variable pump, open the pump body oil return valve, and restore the installation of the motor protective cover; loosen the pressure regulating handle of the relief valve and the pressure regulating valve of the new constant pressure variable pump to the bottom, close the switch and supply power; adjust the pressure of the new constant pressure variable pump, and simultaneously turn the relief valve and the new constant pressure variable pump clockwise. Turn the pressure regulating handle of the variable pump's pressure regulating valve until the pressure gauge shows a certain value exceeding the rated working pressure, then stop turning it; turn the relief valve pressure regulating handle counterclockwise until you can hear the sound of oil leakage from the relief valve, then turn the relief valve pressure regulating handle clockwise until the sound of oil leakage disappears, and lock the relief valve pressure regulating handle with a nut; turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve counterclockwise until the pressure gauge shows "rated working pressure", and then lock the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve with a nut; (6) The new constant pressure variable pump is put into production. After the new constant pressure variable pump is put into operation for one hour, listen to whether the sound of the motor, the new constant pressure variable pump and its coupling is normal. Observe whether the pressure is normal and whether there is oil leakage in the joints of each pipeline. After confirming that everything is correct, it is delivered for production application.

2. The method for online replacement and debugging of a constant pressure variable pump according to claim 1, characterized in that: In the step (1), when the power is turned off, a signboard with the message "Under maintenance, do not close the switch" is hung.

3. The method for online replacement and debugging of a constant pressure variable pump according to claim 1, characterized in that: In step (2), when removing the four bolts connecting the constant pressure variable pump and the bell jar, first remove three of the four bolts connecting the constant pressure variable pump and the bell jar, tie the constant pressure variable pump with a wire rope and pull it with a hand hoist, and remove the last of the four bolts connecting the constant pressure variable pump and the bell jar; Pull the hand hoist by hand to make the constant pressure variable pump rise a little, then release the hand hoist to let the constant pressure variable pump drop a little, repeat several times until the gap between the method flange of the constant pressure variable pump and the bell cover becomes larger, and use a crowbar to pry the constant pressure variable pump and the bell cover apart.

4. The method for online replacement and debugging of a constant pressure variable pump according to claim 1, characterized in that: In the step (3), before using a puller to pull the pump-end coupling from the shaft end of the constant-pressure variable pump to be replaced, remove the top screw on the pump-end coupling, use a micrometer to measure the distance from the end face of the pump-end coupling to the shaft end face of the constant-pressure variable pump to be replaced, and use this as the data basis for the next step of installing the pump-end coupling on the new constant-pressure variable pump; use a micrometer to measure the inner hole of the pump-end coupling and the shaft end size of the new constant-pressure variable pump to confirm the matching of the two, and use fine sandpaper to polish the inner hole of the pump-end coupling and the shaft end of the new constant-pressure variable pump; try to install the pump-end coupling on the shaft end of the new constant-pressure variable pump twice until the pump-end coupling can be tapped lightly with a small hammer. When the pump-end coupling moves on the shaft of the new constant-pressure variable pump, start to formally install the pump-end coupling; when the distance between the pump-end coupling installed on the shaft end of the new constant-pressure variable pump is close to the distance between the end face of the pump-end coupling and the shaft end face of the constant-pressure variable pump to be replaced, measure and tap at the same time until the measured distance is reached.

5. The method for online replacement and debugging of a constant pressure variable pump according to claim 1, characterized in that: In the step (4), when the pump-end coupling and the motor-end coupling are engaged, the engagement of the pump-end coupling and the motor-end coupling is observed through the observation hole of the bell cover. If the engagement is not good, the fan blades of the motor are rotated to assist in engaging the two couplings. The pump-end coupling is pushed axially from the rear of the new constant pressure variable pump to fully engage the pump-end coupling and the motor-end coupling. When installing the oil suction pipe, insert the four bolts through the four bolt holes of the square flange and install them. Tighten only 3-4 threads of the first bolt. Install the oil suction pipe on the new constant pressure variable pump using the SAE flange. If the bolt holes do not align, adjust the axial position of the new constant pressure variable pump appropriately. After the oil suction pipe is completely installed on the new constant pressure variable pump using the SAE flange and tightened, tighten the four bolts of the square flange diagonally. After installing the oil suction pipe, observe the meshing clearance between the tooth top and tooth bottom of the pump end coupling and the motor end coupling through the observation hole of the bell cover. The appropriate clearance is 2-3mm. If it is too large or too small, remove the new constant pressure variable pump, readjust it, and reinstall it.

6. The method for online replacement and debugging of a constant pressure variable pump according to claim 1, characterized in that: In step (5), the pressure of the new constant pressure variable pump is adjusted, and the pressure adjustment is started after running in for 30 minutes under a pressure-free state; When synchronously turning the relief valve and the pressure regulating valve of the new constant pressure variable pump clockwise, when the pressure gauge displays 5MPa, first turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, then turn the pressure regulating handle of the relief valve 1 / 2 turn, then turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve 3 / 8 turn, repeat several times until the pressure gauge displays the rated working pressure, continue to turn the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise until the pressure gauge displays "rated working pressure + 3MPa", stop turning the pressure regulating handle of the new constant pressure variable pump's pressure regulating valve clockwise.

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