How centrifugal pumps are used in the solid control system

Centrifugal pump working principle and characteristics in solid control system adaptability

Centrifugal pump is a mechanical device that generates centrifugal force to transport liquid through the rotation of the impeller. Its core components include impeller, pump casing, shaft and sealing device. When the impeller rotates at a high speed driven by the motor, the liquid at the centre of the impeller is thrown out quickly, forming a low-pressure area, which enables the liquid outside to be sucked into the centre of the impeller under the effect of atmospheric pressure. Then, the thrown out liquid is guided by the pump casing to flow along a specific channel to the outlet, realising the continuous conveying of liquid.

In solid control systems, due to the complex nature of the materials handled, the performance of centrifugal pumps puts forward special requirements. Firstly, solid control systems often need to deal with liquids containing a large number of solid particles, which requires the impeller and pump casing of the centrifugal pump to have good wear resistance and be able to withstand the impact and abrasion of solid particles. Secondly, in order to effectively transport these liquids containing solid particles, centrifugal pumps need to have a strong pumping capacity and high pressure to overcome pipeline resistance and resistance caused by solid particles. Furthermore, as the liquids handled are of various compositions and may be corrosive, the centrifugal pump components are required to be resistant to chemical corrosion to ensure long-term stable operation. In addition, the working environment of the solid control system is usually more severe, temperature and pressure changes, centrifugal pumps need to maintain good performance and sealing effect under such conditions.

Centrifugal pumps in the solid control system selection and configuration

Correct selection and reasonable configuration of centrifugal pumps is to ensure efficient and stable operation of the solid control system is a key link. In the selection process, the need for comprehensive consideration of many factors. The nature of the material to be processed is one of the primary considerations. Including the density of the material, solid particle content and size distribution, viscosity and corrosivity. For high solid content and large particles of materials, you need to choose centrifugal pumps with high power and high head to ensure that they can be effectively transported. At the same time, it is important to consider the corrosiveness of the material and select the right materials for the pump components. Flow demand is another important consideration. According to the treatment scale of the solid control system, the process flow and the demand of the subsequent equipment, the required liquid flow rate is calculated accurately. Selection should ensure that the centrifugal pump can provide a flow rate that meets the requirements within the normal operating range and has the ability to regulate the flow rate to a certain extent to adapt to different working conditions. The head requirement is also a factor that should not be ignored. The head determines the height at which the liquid can be lifted, taking into account the resistance loss of the liquid in the pipeline, the vertical lifting height and the pressure requirements of the system. Working temperature and pressure will also affect the selection of centrifugal pumps. High temperature and high pressure environment of the pump material strength, sealing performance and thermal stability of components put forward higher requirements. In terms of configuration, multiple centrifugal pumps are often used in parallel or series to increase system flexibility and reliability. Parallel operation allows multiple pumps to be started at the same time when the total flow demand is high, thus increasing the delivery capacity of the system. This way is suitable for the need for large flow but relatively low head requirements of the working conditions. Tandem operation is to connect multiple pumps in sequence, so that the head of each pump is superimposed, thereby increasing the total head output. Applicable to the need for high head but the flow demand is relatively small. In addition, there is a need to reasonably configure the pipeline diameter, valves and filters and other ancillary equipment to optimise the hydraulic performance of the system to reduce energy losses and pressure fluctuations.

Centrifugal pump in the solid control system installation and commissioning

When installing centrifugal pumps, you need to strictly follow the relevant installation specifications and standards to ensure the quality of installation. First of all, the foundation of the pump must be firm and reliable, able to withstand the weight of the pump and the vibration generated during operation. The level of the foundation should be accurately measured and adjusted to ensure that the installation position of the pump is horizontal, to avoid wear and tear of components and unstable operation caused by tilting. Secondly, the connection with the pipeline should be tight and without leakage. The diameter and material of the pipeline should be matched with the pump’s inlet and outlet size and pressure requirements, and the connection should be made with suitable sealing materials and connection methods, such as flange connection, threaded connection or welding. In the installation process, it is also necessary to equip the centrifugal pump with a suitable motor and transmission device. The power of the motor should be matched with the demand of the pump, and the transmission device (such as couplings, pulleys, etc.) should be installed to ensure the accuracy of alignment and reduce energy loss and vibration in the transmission process. Commissioning is an important step to ensure the normal operation of centrifugal pumps in the solid control system. Before commissioning, carefully check whether the steering of the motor is correct. If the steering is wrong, not only can it not convey the liquid properly, but it may also lead to motor overload and pump damage. Then, gradually increase the speed of the pump and observe whether the flow, head, pressure and other parameters meet the design requirements. At the same time, pay close attention to the pump’s running sound, vibration conditions and temperature changes. During normal operation, the sound should be even and smooth, the vibration should be within the allowable range, and the temperature should not be too high. For the test of flow and head, you can use professional measuring instruments, such as flow meters and manometers, to compare the measurement results with the design values, and if there is any deviation, you need to analyse the reasons and make adjustments. In addition, the sealing performance should be checked to ensure that there is no leakage. If leakage is found, the sealing device should be adjusted or replaced in time.

Centrifugal pump in the solid control system operation and maintenance and troubleshooting

In order to ensure the long-term stable operation of the centrifugal pump in the solid control system, regular operation and maintenance is essential. Routine maintenance work includes regular inspection of the impeller, shaft, bearings, seals and other key components of the wear and tear. The impeller is one of the core components of the centrifugal pump, and if it is found to be badly worn or cracked, it should be replaced in time. Wear of the shaft and bearings will lead to increased vibration and unstable operation, which requires regular filling of lubricant or replacement of bearings. The performance of seals directly affects the sealing effect of the pump, the wear and aging of seals should be checked frequently and replaced in time to prevent leakage. Regular cleaning of the pump of dirt and debris is also an important part of maintenance. Materials in the solid control system may be deposited in the pump, blocking the flow path and affecting the performance of the pump. Therefore, the pump body needs to be disassembled periodically for cleaning. At the same time, the motor should be inspected and maintained regularly, including the insulation of the motor and whether the wiring is loose. During operation, centrifugal pumps may have various failures. Common failures include insufficient flow, reduced head, excessive vibration, abnormal noise, seal leakage and motor overload. Insufficient flow may be caused by impeller wear, pipe clogging, inlet screen clogging, poor sealing or insufficient speed. It is necessary to check one by one and take corresponding measures, such as replacing the impeller, cleaning the pipeline and strainer, adjusting the seal or increasing the rotational speed. Lower head may be due to impeller damage, leakage inside the pump, lower speed or excessive outlet resistance. It is necessary to check the impeller and seal condition, adjust the speed or optimise the piping layout. Excessive vibration is usually caused by bent shafts, unbalanced impellers, damaged bearings, weak foundations or poor alignment. It is necessary to align the shaft, balance the impeller, replace the bearings, reinforce the foundation or re-centre. Noise abnormality may be caused by loose parts, increased friction, cavitation or foreign matter entering. It is necessary to tighten the parts, check the lubrication, eliminate cavitation or remove foreign objects. Seal leakage may be due to worn seals, improper installation, or excessive pressure. Seals need to be replaced, reinstalled properly, or system pressure adjusted. Motor overload may be due to excessive flow, high head, motor failure or transmission problems. Need to adjust operating parameters, check the motor and transmission.

Energy-saving optimisation of centrifugal pumps in solid-state control systems

In the context of rising energy costs, the centrifugal pump in the solid control system of energy saving optimisation is particularly important. First of all, you can choose energy efficient centrifugal pump models. Newer centrifugal pumps often have advanced hydraulic designs and optimised structures, which can consume less energy under the same operating conditions while providing the same or even higher performance. Optimising piping layout is also one of the important means of energy saving. Reasonable design of the diameter, length and direction of the pipeline, reduce the number of elbows and valves, can reduce pipeline resistance, reduce energy loss. Accurate control of pump operating parameters is also the key to energy saving. Through the use of frequency conversion speed control technology, the speed of the pump can be adjusted in real time according to the actual flow rate and pressure demand, avoiding the pump to run in the low-efficiency region, thus realising energy saving. In addition, regular energy efficiency assessment of the system to identify and solve potential energy waste problems is also an important part of energy saving and optimisation.

In summary, centrifugal pumps play an indispensable role in solid control systems. Through an in-depth understanding of their working principles and characteristics, scientific and reasonable selection, careful installation and commissioning, meticulous operation and maintenance, and continuous energy-saving optimisation, the efficient, stable and energy-saving operation of the solid control system can be ensured, and the smooth operation of related operations can be provided with strong support and guarantee.