2BW4-OEL4安装使用说明书—湖北同方高科泵业有限公司

2BW4-OBL4（OEL4）成套装置

2BW4-OBL4（OEL4）V ACUUM PUMP UNIT

安装使用说明书INSTALLATION AND MAINTENANCE

MANUAL

HUBEI TONGFANG2BW4-OBL4 (OEL4) Vacuum Pump Unit Manual

目录

TABLE OF CONTENTS

一、概述Summary (1)

二、2BW4-OBL4（OEL4）机组结构及原理 (3)

2BW4-OBL4 (OEL4) Unit Structure and Working Principle (3)

2.1 机械部分Mechanical Part (3)

2.2电气部分Electric Part (7)

三、机组安装Unit Installation (11)

四、运行Operation (13)

五、维护Maintenance (16)

六、成套机组性能曲线图Ⅰ、Ⅱ、Ⅲ (23)

Unit Performance CurveⅠ, Ⅱ, and Ⅲ (23)

七、图Ⅴ: 2BW4-OBL4（OEL4）真空泵成套安装图 (28)

八、图Ⅵ: 2BW4-OBL4（OEL4）流程图Unit Flow Chart (29)

九、图Ⅶ: 2BW4-OBL4（OEL4）电气控制原理图Electric Control Diagram (30)

十、图Ⅷ: 2BW4-OBL4（OEL4）电气控制原理图（DCS逻辑控制） (31)

Electric Control Diagram (DCS Logical Control) (31)

十一、图Ⅸ: 2BW4-OBL4（OEL4）机组电器布置图 (32)

Electrical Equipment Arrangement Drawing (32)

十二、图Ⅹ: 2BW4-OBL4（OEL4）机组电气控制箱接线图 (33)

Electric Control Box Connection Drawing (33)

十三、图Ⅺ：2BW4-OBL4（OEL4）电气控制箱外形图 (34)

Electric Control Box Outline Drawing (34)

一、概述Summary

湖北同方高科泵业有限公司是生产水环真空泵的专业厂家，2BW4型水环真空泵成套装置（机组）是在原引进德国西门子公司技术的基础上，进行了大量的结构改进和完善工作，使产品更先进、更合理、更完善、更节能，大大地提高了机组的运行效率和完善了机组的成套功能。

Hubei Tongfang Hi-tech Pump Co., Ltd. is a professional water-ring pump manufacturer. Our key product 2BW4 Water-ring Vacuum Pump Unit is optimized on the basis of Siemens technology from Germany. After persistent structural improvement, the Unit is more advanced, stable, sophisticated, and energy-saving, which has greatly improved operation efficiency of the whole Unit.

2BW4成套共有五种规格十种型式，即2BW4 203－0B(E)L

K

4、2BW4 253－

0B(E)L

K 42BW4 303－0B(E)L

K

4、2BW4 353－0B(E)L

K

4、2BW4 403－0B(E)L

K

4 。2BW4

成套装置配置有：自动进排气系统、自动进排水系统、冷却循环供水系统（闭式循环）、自动及手动控制系统，有带大气喷射器的，有不带大气喷射器的。广泛用于25MW、50MW、100MW、135 MW、200MW、300MW、600MW和1000MW 火力发电机组中抽吸凝汽器真空之用。机组制造及管路连接法兰采用德国DIN标准。

2BW4 Unit covers 5 specifications and 10 types: 2BW4 203－0B(E)L K4、2BW4 253－0B(E)L K42BW4 303－0B(E)L K4、2BW4 353－0B(E)L K4、2BW4 403－0B(E)L K4. 2BW4 Unit includes the following systems: automatic suction and exhaust system, automatic water inlet and drainage system, recycling cooling water system (closed cycle), and automatic and manual control system, with or without air ejector. The Unit is widely applied to evacuate the condenser for thermal power plants of 25MW, 50MW, 100MW, 135MW, 200MW, 300MW, 600MW and 1000MW. The German DIN standard is adopted in the unit production and pipe-connection flanges.

型号表示方法举例：

The type illustration is as follows:

泵转速(r/min）

Rotation Speed (r/min)

泵轴封为填料内供水方式

Padding water supply for pump shaft seal

K：不带大器喷射；L：带大

B：普材；E：不锈钢）

真空泵型号

Type of Vacuum Pump

成套装置代号

Unit Code

二、2BW4-OBL4（OEL4）机组结构及原理

2BW4-OBL4 (OEL4) Unit Structure and Working Principle

2.1 机械部分Mechanical Part

（1）结构Structure

（a）2BW4-OBL(OEL4)机组结构见图Ⅵ，采用闭式循环，主要由以下几个部分组成:

Please refer to ChartⅥfor the 2BW4-OBL(OEL4) unit structure which is

（b）2BW4型成套接口及尺寸表2BW4 Unit Connection and Specification

接口说明Connection Instruction

1. 气体吸入口接汽轮机凝汽器背压出口处。

Air inlet connects with back pressure exit of the turbine condenser.

2. 进水口所进水源为凝结水,最低限度须将自来水软化，防止泵内结垢严重。

Water source to the water inlet should be condensed water, or at least softened tap-water, to avoid pump being seriously scaled.

3. 排水口接排水沟槽。

Water outlet connects with the water drainage trench.

（c）结构说明Structure Instruction

2BW4成套设备常用驱动方式为电机直联传动。

The driving motor of 2BW4 Unit is usually direct coupled.

水环泵的轴封可采用填料或机械密封方式。

The shaft seal of water-ring pump can use packing or mechanical sealing.

真空泵进口设置止回阀，是防止泵在系统突然停机或故障时大气压空气会通过泵倒流入凝汽器降低真空。在高真空下运行的机组还装有汽蚀保护装置，该装置连接在排气管和水环泵的两分配器上。

Check valve is set at the vacuum pump inlet to prevent the air from back flowing to the condenser and decrease vacuum degree once the pump system is suddenly stopped or breakdown. The unit working under high level vacuum is equipped with cavitation-erosion-proof device, which is connected to the exhaust pipe and two distributors of the water-ring pump.

系统控制阀16a由入口压力开关47b控制，功能说明详见电气部分中电气控制说明，压力开关47功能说明详见电气控制说明。

System control valve 16a is controlled by the inlet pressure switch 47b. Please refer to the Electric Control Instruction in electric part for function details of system control valve 16a and pressure switch 47b.

热交换器的功能主要是将泵的工作液冷却，冷却液压力一般为0.2-0.6MPa，流量如下表：

The function of heat exchanger is to cool the operating liquid; the pressure of cooling liquid is normally 0.2-0.6Mpa, with flow volume as follows:

热交换器冷却液流量表Cooling liquid flow volume chart (Heat exchanger)

汽水分离器中的水位由补水电磁阀和磁翻板液位计上的开关控制，通常设置C1，C2开关，水位需控制在C1，C2之间。

The water level of steam & water separator is controlled by switches on the water-feeding solenoid valve and flap magnetic level gauge. C1, C2 switch shall be set and water level should be controlled between C1 and C2.

大气喷射器19应用于高真空状态，水环泵在高真空度下，受到汽蚀的限制，此外，由于泵体内部工作液的蒸发而出现气量减少，为扩大适用范围，在一定状

态下（我厂定位60mbar以下），先启动大气喷射器，与大气喷射器相关的16b、19a两阀由47b控制，动作详见电气说明。

Air ejector 19 is applied under high vacuum where water ring vacuum pump would be affected by caviation. Besides, the mass flow would be reduced due to operating liquid evaporation within the pump. Start up the air ejector at first under certain status (we set it below 60mbar) to expand the application, 16b and 19a valves are controlled by 47b. Please refer to the Electric Instruction for details.

（2）机组工艺流程Unit Process

工艺流程见工艺流程图（图Ⅵ），整个流程分为两个部分：

Please see Process Chart (ChartⅥ), the whole process includes two parts:

a.气体流程;

b.液体（水）流程

a. Air Process;

b. Liquid (water) Process.

a.气体流程：系统接通电源后，泵开始运行，当抽至系统控制阀16a两端真空度达到150hPa时，47b动作，使16a打开，气体经过进气管16进入真空泵中，压缩后从排气管17排至汽水分离器中，经汽水分离器分离后从止回阀18c排出，完成气体抽吸过程。

a. Air Process: Start the pump with power supply. When the vacuum of both ends of system control valve 16a reach 150hPa, 47b begins to work and opens 16a. Air enters the vacuum pump through inlet pipe 16 and is exhausted to the stream & water separator from pipe 17 after being compressed, then the separated air will be discharged from check valve 18c, thus the suction process is completed.

当系统真空度达到60mbar时，压力开关47a开始动作，环形断流阀16b关闭，19a打开，汽水分离器内部分汽体从大气喷射器19流进泵进口，从而使泵进口压力增大，平稳地从系统中抽出气体，从排出管17排向汽水分离器中，多余汽体从止回阀18c中排除。

When the system vacuum reaches 60mbar, pressure switch 47a starts and

ring-shape shut-off valve 16b closes, then 19a opens. Part of the stream in the separator flows into pump inlet from air ejector 19 to increase the pump inlet pressure; and the air would be exhausted from outlet pipe 17 to the separator; the spare air will be discharged from check valve 18c.

b.液体流程：工作液从N3.3入口流经补水电磁阀22a或旁通管路经24b流入汽水分离器中后，经工作液管道到热交换器中冷却，冷却后的水送到水环泵内，部分水经喷射支管28a送到气体入口进入泵中，泵在运转过程中随气体进出带走部分工作液，从排气管17排至汽水分离器中，再经冷却送入泵内，如此形成一个封闭的循环系统；如果汽水分离器中的水位在循环过程中超过△max或低于△min时，则由22a和磁翻板液位计上所配开关量C1，C2自动控制。

b. Liquid Flow: operating liquid goes to the separator through inlet N3.3 and via solenoid valve 22a or bypass pipe 24b, then through operating liquid pipe to the

heat-exchanger where the liquid is cooled. The cooled water is then delivered to the pump and part of the water is carried to the pump by branch ejection pipe 28a. The pump brings out some operating liquid with air in/out during running. The liquid is exhausted to the separator through pipe 17 and then sent to the pump after cooling. The whole process is thus done forming a closed circuit system. If water level in the separator goes higher than △max or lower than △min, C1,C2 switch on flap magnetic level gauge and 22a will take automatic control.

热交换器中的冷却液从N5.0口进入后从N6.0口排出。

Cooling liquid of heat-exchanger enters from N5.0 and exhausts from N6.0.

2.2电气部分Electric Part

（1）2BW4-OBL4（OEL4）水环真空泵装置电气说明Electric Instruction: 本电控制箱采用220V 50Hz单相交流电源，设有S1选择开关可手动、自动、遥控选择和B1、B3压力开关，B2压差开关。

The electric control panel uses 220V 50Hz single phase AC power, and is equipped with S1 switch of manual, automatic and remote control options; B1 and B3 pressure switches; and B2 differential pressure switch.

本机组16a采用220V 50Hz电动蝶阀或气动蝶阀，若采用气动蝶阀，用户需配备6-11bar气源，用以推动气动蝶阀的开启。

The unit 16a adopts 220V 50Hz electric or pneumatic butterfly valve. When using pneumatic butterfly valve, 6-11bar air source should be equipped to drive the valve.

当手动按下开始按钮S3时，辅助接触器K3、K4得电并且保持，机组开始

运行。当真空度达到150hPa左右时，B2[47b]的触点接通并自保，电磁阀Y3得电，使环形断流阀[16a]打开，此时从闭路抽空设备中抽出空气（该阀只有在本装置断开时才可能重新关闭）机组继续运行，当系统真空度达至60mbar（绝对值）时，压力开关B3[47a]动作，即16b关闭19a打开，大气喷射器进入工作状态，按下S2停止钮时，机组便停止运行。

Manually press start button S3, auxiliary contact device K3 and K4 are electrified and the unit starts to operate. When the vacuum gets to around 150hPa, the contact of B2 [47b] connects and maintains, solenoid valve Y3 works and opens shut-off valve. At this time, the air is extracted from the closed circuit unit (the valve can only be

re-closed when the unit is off). The unit resumes operation and when vacuum reaches 60mbar (absolute value), pressure switch B3 [47a] works, namely 16b off and 19a on, the air ejector begins to work. Shut down the unit by pressing stop button S2.

应当指出：环形断流阀16b在抽空开始时是一直打开，工作空气阀19a是处于关闭位置的。在起始阶段空气是以直接方式流入真空泵的，只有达到喷射器工作所规定的压力时，环形断流阀16b才关闭，工作空气阀19a才打开。

Please note shut-off valve 16b keeps open at the beginning of evacuation while air valve 19a is off. The air enters into the pump directly at the beginning; only when the pressure reaches the set value of air ejector, shut-off valve 16b will be closed and operating air valve 19a be opened.

请注意：压差开关B2[47b]、压力开关B3[47a]在出厂时已整定好。

Please note: Differential pressure switch B2 [47b] and pressure switch B3 [47a] are adjusted properly when leaving the factory.

压力开关B1[47]是为自动启动备用泵而设置的，其值请用户自行整定。

Pressure switch B1 [47] is set to start the backup pump automatically, so users can adjust by themselves.

限位开关SQ是由系统控制阀控制的，其触点可作为[16a]的开关位置指示信号，SQ1为开阀信号，SQ2为闭阀信号。

Limit switch SQ is controlled by system control valve, its contact point can be used as indication signal for switch position of [16 a]; SQ1 is “open valve”signal and SQ2 is “close valve”signal.

电气控制原理图中点划线之上外供部分用户自备，不属本公司成套之列。

The bought-in parts indicated in the Electric Control Diagram are not included in the supply unit, so users shall prepare by themselves.

电气控制原理图中K1、K2、K3组成主电机控制电路图，是为了解系统原理的参考电路，用户可根据各自的具体情况另行设计。11号与19号线间是用户供给本控制箱的主电机继电保护触点。

K1, K2, and K3 make up the main motor control circuit diagram, which is only for reference. Users can design according to the actual application. The point between No.11 and No.19 lines is the main motor relay protection contact supplied by user.

电气控制箱底部（B-B）面的3个直径28毫米的孔为橡胶封口孔，给用户引出线用。

Three 28mm-diameter rubber sealed holes on the bottom surface of the electric control box (B-B) are for the users to find lines out.

S4是应用户要求提供的紧急按钮，由用户自行安排。

S4 is emergency button provided on request of users and users can arrange it by themselves.

LD为本控制箱的电源指示灯。

LD is power indicator of the control box.

(2) 电气控制原理图: 见图Ⅶ

Electric Control Diagram: See ChartⅦ

(3) 电气控制原理图（DCS逻辑控制）: 见图Ⅷ

Electric Control Diagram (DCS logical control): See ChartⅧ

(4) 机组电器布置图: 见图Ⅸ

Electrical Equipment Arrangement Drawing: See ChartⅨ

(5) 机组电气控制箱接线图: 见图Ⅹ

Electric Control Box Connection Drawing: See ChartⅩ

(6) 电气控制箱外形图: 见图Ⅺ

Electric Control Box Outline Drawing: See ChartⅪ

(7) 原器件明细表: 见下表

Component List: Sees the following table

原器件明细表Component List:

也可根据用户要求，采用DCS逻辑控制。

DCS logical control is available upon request of the user.

三、机组安装Unit Installation

机组按所提供的基础安装尺寸进行安装(随机组附相应总装图)，吊装时必须使用焊接在底座侧面的四个吊装孔进行吊装，在机组起吊和放下过程中应避免快速移动，机组重量很大(见表4)，安装基础必须牢固，基础表面应十分平坦, 允许差土lmm ，地脚螺栓的固定采用二次灌浆，因此在安装基础上要预留适当的凹槽和孔眼，二次灌浆前可用垫铁调整机组的水平，其水平用水准仪检查底座六点，允差2/1000mm。

The unit shall be installed according to the basic installation dimensions (general assembly drawing is provided with the unit). During erection, 4 erection holes on the pedestal sides must be used. Fast movement should be avoided during hoisting and loading down. The unit is heavy (see table 4), so the base must be fixed and base surface horizontal and smooth, 土1mm difference is allowed. Second grouting is used to fasten the ground bolt, so proper grooves and holes should be prepared. Iron pad can be used to adjust the horizontal level of the unit before second grouting. Level gauge should be used to check 6 points of the pedestal and 2/1000mm error can be allowed.

机组在运输安装过程中可能会造成螺栓松动和相对位移，当机组落位固定后,要重新进行校正，联轴器之间应同心，任何方位偏差≤0.1mm ，调整完毕后，再将泵和电机的地脚螺栓拧紧并检查所有联接螺栓是否有松动现象，所有管路不允许有泄漏现象。

During the transportation and installation of the unit, the bolt may loosen and move, readjustment must be conducted after the unit is put on the ground. The coupling must be concentric with it. Deviation towards any direction must ≤0.1mm. After adjustment, fasten the ground bolts of pump and motor and check all the connection bolts if there is any loosen one. All pipes must have no leakage.

各种管道与机组联接时应将管道支撑或悬挂起来，机组上不允许承受任何附加力，在机组进行安装和焊接作业时，应在敞口处加盖，以防止杂物进入泵内，造成泵内零件损伤。

All pipes should be hung or braced when connected to the unit, and no additional force can be added to the unit. During assembly and welding, exposure must be covered in order to prevent sundries entering and damage the inner pump components.

系统各处接管及尺寸见表1

Please see Table 1 for system connection pipes and their dimensions. 表4机组重量表

四、运行Operation

1、准备工作Preparation

为了保证管道和安装工作完全符合要求，开车前应按流程图和安装图进行全面检查，在确认安装无误后，用手或适当的工具把泵轴转动几次，观察有无碰撞与磨擦等异常现象，防止运行中异物进入泵内，在试运行前最好在泵的入口处加装空气过滤装置。松开填料压盖，打开分离器上的排气管(N2.2)，此时进气管上环形断流阀16a应全关或微开，热交换器上冷却水管打开，检查各阀门仪表及电器是否正常，检查泵的轴承位是否有足够的润滑油量，检查减速机（若有）冷却水管是否接好。

In order to make sure pipes and assembly completely meet the requirements, before starting the pump, overall check must be conducted and follow the flow chart and assembly diagram. After assembly is confirmed, rotate the pump shaft several times by hand or tool, and watch if there is abnormal phenomenon like collision or friction. It shall be better to install air filter at pump inlet to prevent sundries from entering the pump during operation. Open the packing cover and exhaust pipes (N2.2) of the separator, while keep shut-off valve 16a totally closed or opened a little. Open cooling water pipe of the heat-exchanger and check the valve meters and electrics, check if lubricant at the pump bearing is enough, and then check whether the cooling water pipe of the speed reducer (if have) is well connected.

拆掉联轴器上的柱销，点动电机，观察电机转向与泵规定的转向是否一致，确认一致后，重新装上柱销，安装精度见机组安装图。

Take down the pin of coupling and start the motor, watch whether the rotary direction of the motor is in line with the regulated rotary direction of the pump. If it is, then mount the pin again. Please see the Unit Assembly Diagram for the accuracy of installation.

2、机组注水Unit Water Injection

机组注水前，先打开泵排水管道，用水冲洗直到防锈液冲洗清洁后，恢复原状再进行机组注水。

Open the pump drainage pipe and flush the unit until the antirust is cleaned and recover to its original status, thus, begin water injection.

打开补水电磁阀前的阀门，汽水分离器开始注水，水通过连接管道使真空泵的水位不断增加，为加快注水速度，可同时打开旁通阀24b，当水位上升到水泵侧盖上自动排水阀自动排水时，关闭旁通阀，稳定5分钟，检查液面有无变化，检查管路是否畅通,有无漏水现象，如一切正常，即说明注水己达启动要求。

Open the solenoid valve and water begins to inject into the separator, water level in the vacuum pump increases. To increase the injection speed, open by-pass valve 24b. When the automatic drainage valve on the side cover of the pump begins to work, close the by-pass valve and keep the status for 5 minutes. Check whether there is any change on the liquid surface, whether the pipes are unblocked and whether there’s any leakage, if everything is normal, then, the water injection is complete for starting.

3、启动Starting

按动电器控制箱上的启动按钮，机组即投入运行，机组启动后打开环形断流阀16a(或自动)真空装置即为系统工作，机组运行中应检查真空泵填料压盖的松紧情况,填料函允许有少量液体泄漏以不形成流线为标准。

Press start button on the control box and the unit starts to operate. Open shut-off valve 16a (or automatically opened) and the vacuum unit begins to work. During operation, the status of the vacuum pump packing cover should be checked. The packing box allows a small amount of liquid leakage without forming flow line.

注意观察轴承体位的温度，最高温升不得超过50℃，实测温度不超过75℃。

Pay attention to the bearing temperature, the max. temperature rise should be no more than 50℃while the measured temperature no more than 75℃.

注意观察电动机电流是否正常，仪表数据是否正常，分离器水位是否稳定，机组振动是否过大。

Pay attention to electric current of the motor, data of the meter, water level of the separator, and vibration of the unit.

4、停机Shut-off

按动电器控制箱上停机按钮，水环泵停止转动，关闭吸入管上的环形断流阀16a(或自动)，关掉补水电磁阀前的补充水阀门，热交换器冷却水阀门，停机后系统内多余的水由自动排水阀排掉，如果泵停机较长时间(三个月或三个月以上)则打开真空泵、汽水分离器、热交换器等部件底部的放水螺塞，放掉其中多余的水，

必要时作防锈处理。

Press stop button on the electric control box and the unit stops. Close shut-off valve 16a (or automatically closed) of the input pipe, close the water-feeding valve in front of the solenoid valve and the cooling-water valve of the heat-exchanger. The surplus water of the system will be discharged by auto drainage valve after the system stops. If the pump does not work for a long time (3 months or longer), open the water drainage bolts at the bottom of the pump, stream-air separator and heat-exchanger to discharge surplus water, and conduct antirust treatment if necessary.

五、维护Maintenance

1．如果泵内液体中有杂物，可暂时打开排水管道，使之随液体排出，如果运行在有严重积灰的环境下，那么就要在停车后用水冲洗泵。

If there’re sundries in the liquid, please open the drainage pipe for a while to discharge the liquid. If too much dust is found in the operation environment, the pump should be flushed after stopping.

2．定期打开侧盖上的观察孔，检查泵内部情况。

Open the observation hole on the side cover periodically and check the inner part of the pump.

3．运转期间要随时观察填料的松紧程度。

Check the status of the packing during the operation.

（1）使用新填料时，由于会遇水膨胀，安装时应稍放松填料压盖，对于由泵外供给冷却密封水的填料函，则应通过调节密封水压力来控制温升或泄漏量。

New packing would swell when meeting water, so loosen the packing cover a little during assembly. The pressure of sealing water should be adjusted to control temperature rise or leakage flow to the packing box where cooled sealing water is from outside of the pump.

（2）当填料压盖是松的，而水温仍上升时，应暂时增加密封水压力或停机，直到填料函能正常冷却为止。

If the temperature still rises when the packing cover is loose, please increase sealing water pressure or shut down the unit until the packing box is cooled normally.

（3）如果填料长期运行后不能进行调整则应完全更换，在更换新填料之前要清洗填料腔，装填料时使切口互相成90°

If the packing couldn’t be adjusted after longtime operation, please change new packing. Clean the packing chamber before replacing. Keep the notches 90°when adding new packing.

4．轴承润滑Lubrication of shaft.

泵组由供货到试车，如果在有利条件下（干燥，无灰尘，无振动的房间里）保管超过一年，或在不利条件下，不超过半年时，轴承必须重新润滑。

The pump shaft should be lubricated again after one year (from supplying to trial

run) if the pump is kept in the room that’s dry, dust-free and without vibration, or it should be lubricated within less than six months.

轴承的润滑必须严格遵守如下规定：

Lubrication of shaft must accord with the following rules:

不同牌号的润滑油（剂）不能混合使用，否则会降低干油质量。

Lubricants of different types cannot be used together.

第一次加油应在运行1000小时后进行，以后每隔4000运转小时后进行。加油时要清洗两个加油咀，每个轴承的加油量如下表：

The first lubrication should be taken after operation of 1000 hours, then do it again after operation of every 4000 hours. Clean two zerks before lubricating. Please