Vacuum pumps are essential in various industrial applications, including metallurgy, chemical processing, food production, and electronic coating. A rotary vane vacuum pump is typically used as a stage pump, capable of operating across a wide pressure range with high pumping speed. It is important to note that the pump should not be used to extract gases containing dust or water vapor, as this can cause damage or reduce efficiency. These pumps are widely utilized due to their reliability and performance.
To ensure proper operation and maintenance, the following standards must be met:
1. The pump's body should be clean, intact, and free from damage, with all components complete and functioning properly.
2. Instruments such as the vacuum gauge and ammeter must be accurate, sensitive, and regularly calibrated with valid inspection marks.
3. The foundation should be solid, with all anchor bolts and connecting parts securely fastened and properly aligned.
4. Pipelines and valves should be installed correctly, clearly marked, and meet all technical requirements.
5. All clearances between moving parts must conform to the manufacturer’s specifications.
The operating performance of a piston vacuum pump must meet specific criteria. The equipment should be well-lubricated, with oil quality meeting required standards. The "five fixed" lubrication system must be stable, with no unusual noise or vibration. During load operation, temperature, pressure, and vacuum levels should remain within acceptable limits.
For the vacuum pump to be in good technical condition, the following documentation and records must be complete:
- Equipment files with accurate data
- Maintenance and inspection records
- Operation manuals and procedures
- Equipment diagrams and part lists
- Records of past incidents and operational logs
The environment around the pump must also be maintained. The pump body should be clean and free of dust and grease. The base area should be free from water, waste, or debris. All valves, pipes, and fittings must be leak-free, and packing seals should not exceed allowed leakage levels.
Routine maintenance includes keeping the surrounding area clean, checking cooling water flow, ensuring proper lubrication, and inspecting fastening bolts for tightness. Operators should monitor the vacuum gauge and ammeter readings, listen for abnormal sounds, and report any issues immediately. Strict adherence to operating procedures is crucial.
If the motor experiences overload, possible causes include a small eccentric ring gap, burned connecting rods, or poor exhaust. Solutions involve adjusting the gap, repairing or replacing parts, and clearing the exhaust valve.
Abnormal impacts during operation may result from loose piston rod nuts, worn bushings, excessive bearing gaps, or debris in the cylinder. Adjustments, repairs, or replacements are necessary to resolve these issues.
Emergency shutdown is required in cases of severe vibration, overcurrent, liquid entering the pump, or loss of cooling water.
Minor repairs include tightening bolts, cleaning internal components, replacing seals, and adjusting clearances. Major repairs involve inspecting and replacing critical parts like crossheads, connecting rods, and pistons. Overhauls may require full disassembly, cylinder boring, and replacement of major components.
Cylinder repair standards require measuring roundness and cylindricity, with repairs or replacements based on wear. The inner surface must be free from cracks or defects. Cylinder diameter increases should not exceed 2% of the original size, and wall thinning must not exceed 1/12 of the original thickness.
Crankshaft maintenance involves checking wear, repairing with plating or spraying if needed, and ensuring proper alignment and straightness. Bearings must have good contact, with specified radial clearance and contact areas.
Piston and piston ring overhaul standards require smooth surfaces, proper clearance, sufficient elasticity, and correct positioning in the cylinder. All components must be inspected and replaced if necessary.
Proper maintenance, regular inspections, and timely repairs are essential to ensure the long-term performance and safety of piston vacuum pumps.
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