29 Feb 2024
Sewage treatment plant Water treatment equipment maintenance management
Water treatment equipment maintenance
Overview of equipment maintenance of sewage treatment plants:
1. Operation management personnel and maintenance personnel should be familiar with the maintenance regulations of mechanical and electrical equipment.
2. The structure of the structure and all kinds of gate valves, guardrail, ladder, pipeline, bracket and cover plate should be inspected, repaired and anti-corrosion treatment regularly, and the damaged lighting equipment should be replaced in time.
3. Various equipment connectors should be checked and fastened frequently, and the wearing parts of the coupling should be replaced regularly.
4. All kinds of pipeline gate valves should be regularly tested for opening and closing, and the lead screw should be often filled with lubricating grease.
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5. Check and clean the electrical control cabinet regularly, and test its various technical performance.
6. The limit switch of the electric gate valve and the manual and electric interlocking device should be checked regularly.
7. After each stop of the pump, the sealing condition of the packing or oil seal should be checked and the necessary treatment should be carried out. Add or replace fillers, lubricants and greases as needed.
8. Where there is a wire rope device, the wear of the rope is greater than 10% of the original diameter, or one of the strands has been broken, it must be replaced.
9. All kinds of machinery and equipment should be done in addition to daily maintenance, but also according to the design requirements or the requirements of the manufacturer for large, medium and minor repairs.
10. Connecting pipes and open channels between structures should be cleaned once a year.
11. The maintenance of key components of boilers, pressure vessels and other equipment shall be carried out by maintenance units recognized by the safety labor department.
12. Maintenance of all kinds of mechanical equipment, should be based on the requirements of the equipment, must ensure its coaxiality, static balance or dynamic balance and other technical requirements.
13. The combustible gas alarm should be overhauled once a year.
14. Various process pipelines should be regularly painted with different colors of paint and coatings as required.
15. Lubricating oil, grease and other debris replaced by maintenance equipment shall not be thrown into sewage treatment facilities.
16. When maintaining mechanical equipment, temporary power lines should not be connected at will.
17. The testing, maintenance and cycle of lightning protection and explosion-proof devices of buildings, structures, etc., shall comply with the regulations of the electrical industry and the fire department.
18. Life jackets, fire protection facilities and other protective equipment should be checked and replaced regularly.
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Maintenance of common water treatment equipment:
1. Valves and gates:
(1) The lubrication parts of the valve or gate are mainly screw, gear and worm gear of the deceleration mechanism, and these parts are filled with grease every six months to ensure flexible rotation and prevent rust. Some gate screws are exposed and should be cleaned and coated with new grease at least once a year. Some internal screw gates, the screw long-term contact with sewage, should often be cleaned after the attachment coated with water-resistant grease.
(2) In the use of electric valves or gates, attention should be paid to whether the handwheel is removed and whether the transfer handle is in the electric position. If you do not pay attention to disconnection, when starting the motor, once the protection device fails, the handwheel may rotate at high speed and harm the operator.
(3) When manually opening and closing the valve or gate, it should be noted that the general force is not more than 15kg, if it feels very laborious, it means that the screw, the gate is rusty, stuck or the brake rod is bent, and it should be turned after the fault is removed. When the gate is closed, the gate handle should be reversed one or two turns (excluding idling), which will facilitate the gate to open again.
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(4) The torque limiting mechanism of the electric valve or gate not only plays the role of over-torque protection, but also plays the role of backup parking protection when the stroke control mechanism fails during operation. The operating torque is adjustable and should be adjusted to the torque range specified in the manual at any time. A small number of gate valves rely on torque limiting mechanisms to control the pressure of the valve plate or gate plate, such as some flapper gates, cone valves, etc., if the regulating torque is too small, the closure is not strict; Otherwise, the connecting rod will be damaged, and special attention should be paid to the adjustment of torque.
(5) The needle of the opening indicator of the valve or gate should be adjusted to the correct position, and the valve or gate should be closed first when adjusting, and the pointer should be zeroed and then gradually opened; When the valve or gate is fully open, the pointer should just point to the fully open position. The correct indication is conducive to the operator to grasp the situation, but also help to find the fault, for example, when the pointer does not point to the full open position and the motor stops, it should be determined that the valve may be stuck.
(6) In the northern region, winter should pay attention to the anti-freezing measures of the valve, especially the valve exposed to outdoor and outside the well, and should be wrapped with insulation materials in winter to avoid the valve body being frozen and cracked.
(7) The sewage valve that is closed for a long time sometimes forms a dead zone near the valve, and there will be mud and sand deposits within it, which will form resistance to the opening and closing of the butterfly valve. If the resistance is found to increase when opening the valve, do not open it hard, and the opening and closing action should be repeated to encourage the water to wash away the sediment, and then open the valve after the resistance is reduced. At the same time, if it is found that there is frequent sand accumulation near the valve, the valve should be often opened for a few minutes to facilitate the removal of sand accumulation; Similarly, for valves or gates that are not opened or closed for a long time, they should also be operated once or twice regularly to prevent rust or silt.
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2. Pump:
(1) Daily maintenance of the pump:
A. The lubricating oil or grease in the bearing should be supplemented in time to ensure that the oil level is normal, and the change of oil quality should be regularly detected, and the new oil should be replaced according to the specified period.
B. Pay attention to monitoring the vibration of the water pump. If the water pump exceeds the standard, check whether the fixing bolts and bolts connecting with the pipeline are loose.
C. Pay attention to the vacuum meter, pressure gauge, flow meter, ammeter, voltmeter, thermometer is abnormal, found that the instrument is out of alignment or damage should be reported to replace. It should be checked by the metrological authority once a year, and the pipes and valves should be cleaned.
D. The external parts of the equipment should be effective in corrosion prevention, no rust, no oil leakage, no water leakage, no leakage of electricity, and no leakage of vacuum pipes and suction pipes.
E. Check the valve packing and adjust or replace it if necessary. Do not leak, no oil, no rust.
F. If the screw pump is out of service for a long time, the position of the pump body should be rotated 180° every week. Test run at least once a month.
G. According to the operation condition, the tightness of the packing gland should be adjusted at any time. Packing seal water drops to 30 to 60 drops per minute is good.
H. Replace the packing in time according to the wear condition of the packing. When replacing the filler, each adjacent filler interface should be staggered by more than 90°. The water seal pipe hole should be aligned with the water seal ring water inlet hole, and the packing opening of the outermost ring should be downward.
I. All types of pumps are generally overhauled once a year.
J. When the bending of the pump shaft exceeds 0.05% of the original diameter, it should be corrected. The concentricity between the pump shaft and the shaft sleeve should not exceed 0.05mm, and the shaft sleeve should be replaced when it exceeds. When the pump shaft is rusted or worn more than 2% of the original diameter, a new shaft should be replaced.
K. When the shaft sleeve has regular wear more than 3% of the original diameter and irregular wear more than 2% of the original diameter, it needs to be replaced. At the same time, check the contact surface of the shaft and the sleeve for traces of water seepage, the paper pad between the shaft sleeve and the impeller is complete, and it should be corrected or replaced if it does not meet the requirements. The concentricity between the new shaft sleeve and the pump shaft should not exceed 0.02mm.
L. If the impeller and blade have cracks, damage and corrosion, light can be repaired with epoxy resin, serious to replace the new impeller. If the connection part of the impeller and the shaft is loose and water seepage, the connection key should be corrected or replaced, and the shaking value of the impeller after installing the pump shaft shall not exceed 0.05mm. The repaired or replaced impeller should be checked for static balance and dynamic balance, and should be corrected in time if it exceeds the allowable range.
M. Check the seal ring for cracks and wear, its radial clearance with the impeller should not exceed 1.6mm, if it exceeds the specified value, it must be replaced with a new seal ring.
N. ball bearings and bearing covers should be cleaned, such as bearing corrosion, cracks or excessive clearance, to be replaced in time. The grade of the bearing during replacement shall not be lower than the grade of the original bearing. The scale and debris in the bearing cooling water jacket should be cleaned during each overhaul of the large pump to ensure smooth water flow.
O. The packing box gland should move freely on the shaft or sleeve, the gap between the inner hole of the gland and the shaft or sleeve should be maintained evenly, and the wear should not exceed 3%. The water seal pipe should be kept unobstructed.
P. Clean up the rust in the pump housing, if there is a large pit should be repaired, after cleaning and re-paint anti-rust paint.
Q. The suction bottom valve should be repaired, the action should be flexible, and the seal should be good. The use of vacuum pump water to ensure that the suction pipe valve no leakage phenomenon, vacuum pump to remain intact.
R. Check the working condition of the check valve. Whether the seal ring is sealed, whether the pin is worn too much, whether the buffer and other devices are effective, if there is damage, it should be repaired or replaced in time.
S. The outlet control valve should be checked and replaced in time to prevent water leakage.
T. Check whether the coupling connected to the motor is well connected, whether the key and the keyway are loose, and correct it in time.
U. After the submersible pump is dismantled and repaired, in principle all O-rings and sealing rings should be replaced.
V. In case of catastrophic situations, such as flooding the underground pump room, the water should be removed in time, cleaning and drying the motor and other electrical appliances, and prove that all electrical and mechanical facilities are intact before trial operation.
Overview of equipment maintenance of sewage treatment plants:
1. Operation management personnel and maintenance personnel should be familiar with the maintenance regulations of mechanical and electrical equipment.
2. The structure of the structure and all kinds of gate valves, guardrail, ladder, pipeline, bracket and cover plate should be inspected, repaired and anti-corrosion treatment regularly, and the damaged lighting equipment should be replaced in time.
3. Various equipment connectors should be checked and fastened frequently, and the wearing parts of the coupling should be replaced regularly.
4. All kinds of pipeline gate valves should be regularly tested for opening and closing, and the lead screw should be often filled with lubricating grease.
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5. Check and clean the electrical control cabinet regularly, and test its various technical performance.
6. The limit switch of the electric gate valve and the manual and electric interlocking device should be checked regularly.
7. After each stop of the pump, the sealing condition of the packing or oil seal should be checked and the necessary treatment should be carried out. Add or replace fillers, lubricants and greases as needed.
8. Where there is a wire rope device, the wear of the rope is greater than 10% of the original diameter, or one of the strands has been broken, it must be replaced.
9. All kinds of machinery and equipment should be done in addition to daily maintenance, but also according to the design requirements or the requirements of the manufacturer for large, medium and minor repairs.
10. Connecting pipes and open channels between structures should be cleaned once a year.
11. The maintenance of key components of boilers, pressure vessels and other equipment shall be carried out by maintenance units recognized by the safety labor department.
12. Maintenance of all kinds of mechanical equipment, should be based on the requirements of the equipment, must ensure its coaxiality, static balance or dynamic balance and other technical requirements.
13. The combustible gas alarm should be overhauled once a year.
14. Various process pipelines should be regularly painted with different colors of paint and coatings as required.
15. Lubricating oil, grease and other debris replaced by maintenance equipment shall not be thrown into sewage treatment facilities.
16. When maintaining mechanical equipment, temporary power lines should not be connected at will.
17. The testing, maintenance and cycle of lightning protection and explosion-proof devices of buildings, structures, etc., shall comply with the regulations of the electrical industry and the fire department.
18. Life jackets, fire protection facilities and other protective equipment should be checked and replaced regularly.
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Maintenance of common water treatment equipment:
1. Valves and gates:
(1) The lubrication parts of the valve or gate are mainly screw, gear and worm gear of the deceleration mechanism, and these parts are filled with grease every six months to ensure flexible rotation and prevent rust. Some gate screws are exposed and should be cleaned and coated with new grease at least once a year. Some internal screw gates, the screw long-term contact with sewage, should often be cleaned after the attachment coated with water-resistant grease.
(2) In the use of electric valves or gates, attention should be paid to whether the handwheel is removed and whether the transfer handle is in the electric position. If you do not pay attention to disconnection, when starting the motor, once the protection device fails, the handwheel may rotate at high speed and harm the operator.
(3) When manually opening and closing the valve or gate, it should be noted that the general force is not more than 15kg, if it feels very laborious, it means that the screw, the gate is rusty, stuck or the brake rod is bent, and it should be turned after the fault is removed. When the gate is closed, the gate handle should be reversed one or two turns (excluding idling), which will facilitate the gate to open again.
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(4) The torque limiting mechanism of the electric valve or gate not only plays the role of over-torque protection, but also plays the role of backup parking protection when the stroke control mechanism fails during operation. The operating torque is adjustable and should be adjusted to the torque range specified in the manual at any time. A small number of gate valves rely on torque limiting mechanisms to control the pressure of the valve plate or gate plate, such as some flapper gates, cone valves, etc., if the regulating torque is too small, the closure is not strict; Otherwise, the connecting rod will be damaged, and special attention should be paid to the adjustment of torque.
(5) The needle of the opening indicator of the valve or gate should be adjusted to the correct position, and the valve or gate should be closed first when adjusting, and the pointer should be zeroed and then gradually opened; When the valve or gate is fully open, the pointer should just point to the fully open position. The correct indication is conducive to the operator to grasp the situation, but also help to find the fault, for example, when the pointer does not point to the full open position and the motor stops, it should be determined that the valve may be stuck.
(6) In the northern region, winter should pay attention to the anti-freezing measures of the valve, especially the valve exposed to outdoor and outside the well, and should be wrapped with insulation materials in winter to avoid the valve body being frozen and cracked.
(7) The sewage valve that is closed for a long time sometimes forms a dead zone near the valve, and there will be mud and sand deposits within it, which will form resistance to the opening and closing of the butterfly valve. If the resistance is found to increase when opening the valve, do not open it hard, and the opening and closing action should be repeated to encourage the water to wash away the sediment, and then open the valve after the resistance is reduced. At the same time, if it is found that there is frequent sand accumulation near the valve, the valve should be often opened for a few minutes to facilitate the removal of sand accumulation; Similarly, for valves or gates that are not opened or closed for a long time, they should also be operated once or twice regularly to prevent rust or silt.
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2. Pump:
(1) Daily maintenance of the pump:
A. The lubricating oil or grease in the bearing should be supplemented in time to ensure that the oil level is normal, and the change of oil quality should be regularly detected, and the new oil should be replaced according to the specified period.
B. Pay attention to monitoring the vibration of the water pump. If the water pump exceeds the standard, check whether the fixing bolts and bolts connecting with the pipeline are loose.
C. Pay attention to the vacuum meter, pressure gauge, flow meter, ammeter, voltmeter, thermometer is abnormal, found that the instrument is out of alignment or damage should be reported to replace. It should be checked by the metrological authority once a year, and the pipes and valves should be cleaned.
D. The external parts of the equipment should be effective in corrosion prevention, no rust, no oil leakage, no water leakage, no leakage of electricity, and no leakage of vacuum pipes and suction pipes.
E. Check the valve packing and adjust or replace it if necessary. Do not leak, no oil, no rust.
F. If the screw pump is out of service for a long time, the position of the pump body should be rotated 180° every week. Test run at least once a month.
G. According to the operation condition, the tightness of the packing gland should be adjusted at any time. Packing seal water drops to 30 to 60 drops per minute is good.
H. Replace the packing in time according to the wear condition of the packing. When replacing the filler, each adjacent filler interface should be staggered by more than 90°. The water seal pipe hole should be aligned with the water seal ring water inlet hole, and the packing opening of the outermost ring should be downward.
I. All types of pumps are generally overhauled once a year.
J. When the bending of the pump shaft exceeds 0.05% of the original diameter, it should be corrected. The concentricity between the pump shaft and the shaft sleeve should not exceed 0.05mm, and the shaft sleeve should be replaced when it exceeds. When the pump shaft is rusted or worn more than 2% of the original diameter, a new shaft should be replaced.
K. When the shaft sleeve has regular wear more than 3% of the original diameter and irregular wear more than 2% of the original diameter, it needs to be replaced. At the same time, check the contact surface of the shaft and the sleeve for traces of water seepage, the paper pad between the shaft sleeve and the impeller is complete, and it should be corrected or replaced if it does not meet the requirements. The concentricity between the new shaft sleeve and the pump shaft should not exceed 0.02mm.
L. If the impeller and blade have cracks, damage and corrosion, light can be repaired with epoxy resin, serious to replace the new impeller. If the connection part of the impeller and the shaft is loose and water seepage, the connection key should be corrected or replaced, and the shaking value of the impeller after installing the pump shaft shall not exceed 0.05mm. The repaired or replaced impeller should be checked for static balance and dynamic balance, and should be corrected in time if it exceeds the allowable range.
M. Check the seal ring for cracks and wear, its radial clearance with the impeller should not exceed 1.6mm, if it exceeds the specified value, it must be replaced with a new seal ring.
N. ball bearings and bearing covers should be cleaned, such as bearing corrosion, cracks or excessive clearance, to be replaced in time. The grade of the bearing during replacement shall not be lower than the grade of the original bearing. The scale and debris in the bearing cooling water jacket should be cleaned during each overhaul of the large pump to ensure smooth water flow.
O. The packing box gland should move freely on the shaft or sleeve, the gap between the inner hole of the gland and the shaft or sleeve should be maintained evenly, and the wear should not exceed 3%. The water seal pipe should be kept unobstructed.
P. Clean up the rust in the pump housing, if there is a large pit should be repaired, after cleaning and re-paint anti-rust paint.
Q. The suction bottom valve should be repaired, the action should be flexible, and the seal should be good. The use of vacuum pump water to ensure that the suction pipe valve no leakage phenomenon, vacuum pump to remain intact.
R. Check the working condition of the check valve. Whether the seal ring is sealed, whether the pin is worn too much, whether the buffer and other devices are effective, if there is damage, it should be repaired or replaced in time.
S. The outlet control valve should be checked and replaced in time to prevent water leakage.
T. Check whether the coupling connected to the motor is well connected, whether the key and the keyway are loose, and correct it in time.
U. After the submersible pump is dismantled and repaired, in principle all O-rings and sealing rings should be replaced.
V. In case of catastrophic situations, such as flooding the underground pump room, the water should be removed in time, cleaning and drying the motor and other electrical appliances, and prove that all electrical and mechanical facilities are intact before trial operation.