I. Overview
Our 3DSY-S40 series electric pressure test pumps, an expanded design based on our high-pressure, large-flow test pumps, feature a compact structure, reliability, high flow rate, high efficiency, and a wide pressure coverage range. Moreover, they are versatile, highly compatible, easy to operate, and convenient for mobility. These pumps can be powered by electric motors or diesel engines, making them suitable for operation both indoors and outdoors, or in areas without power supply. The performance and quality of this product are in accordance with JB/T9089-1999 "Pressure Test Pumps" or JB/T6909-93 "High-Pressure Pumps."
Usage
This machine is suitable for various pressure vessels, boilers, pipelines, valves, and other applications requiring pressure burst and strength tests, used for爆破 and pressure testing purposes; it can also be used at oil field wellheads for water injection. Test pressures can be increased from atmospheric pressure up to the rated discharge pressure. Equipped with a microcomputer control system, it can achieve full automation and remote operation. The medium used in this machine is typically normal temperature fresh water, but it can also use emulsion, rust-proof water, and neutral oil products with a viscosity similar to water.
Section 3: Technical Specifications
IV. Main Components and Working Principle
This product is composed of a high-pressure reciprocating pump, check valve, valve, water tank, motor, etc.
The principle of operation is that the motor drives the high-pressure reciprocating pump through a coupling, with normal temperature clean water entering the pump via the inlet pipe. It passes through the inlet and outlet valves, and check valves to form high-pressure water through high-pressure hoses, which is then supplied to the device under test.
1. High-pressure reciprocating pump: This pump is a horizontal three-plunger pump, driven by an electric motor, and is divided into the power end and hydraulic end.
(1) Power End: Composed of belt pulleys, crankshafts, connecting rods, etc. The motor transmits power through belt pulleys and reduces speed, driving the crankshaft to rotate. The crankshaft and connecting rod mechanism converts the rotational motion into reciprocating linear motion, propelling the plunger to move back and forth.
(2) Hydraulic End: Composed of piston rods, cylinder block, pump head, in/out water valves, and valves. The connecting rod drives the piston to reciprocate, causing the cylinder volume to change cyclically. When the piston is in the suction stroke, the outflow valve is closed, and the working medium is pushed into the cylinder by atmospheric pressure through the inflow valve; during the exhaust stroke, the inflow valve is closed, and the piston expels the working medium through the outflow valve and out of the pump head. This process repeats cyclically, thereby completing the function of the pump to吸入 and expel the working medium.
2. Check valve is used for automatic pressure holding and relief system pressure.
After the pressure retention test, turn the pressure relief valve handle to relieve the system pressure. During the pressurization process, if an incorrect operation causes the system pressure to exceed the set value, gently turn the pressure relief valve handle to release some pressure and then re-pressurize.
3. Water Tank: Container for holding water. Securely connect the water source to the inlet connector on the upper left side of the tank. During operation, the water flow should not be less than the pump's rated flow. Monitor the water level in the tank during operation; if it's low, users should promptly replenish the water source (increase the water source flow or clear the clog in the tank's filter). To ensure water quality, do not open the tank cover arbitrarily.
Note:
The pump head is equipped with a pressure gauge, which displays the pressure in the test pipeline during both the pressure increase and pressure maintenance processes.
2. The pump head is equipped with a valve, which is used for system overpressure protection. The trip pressure of the valve is pre-set at the factory and should not be adjusted arbitrarily by the user. It should not be used as an overflow valve.
5. Installation and Usage Instructions
1. Installation
Install the motor starter and power lines; install the non-return pressure relief valve (this part is removed from the main unit and packaged separately at the factory). Use purple copper washers for sealing at the connection points.
Install the pressure gauge.
Connect the pressure test pipeline to the check valve using a high-pressure flexible hose, and seal the connection with a purple copper washer.
Ensure the water tank inlet is properly connected to the inlet pipeline.
2. Usage Instructions
Preparation Before Use
a. Ensure the shell is adequately lubricated, with the oil level reaching the indicated line. Use N46 mechanical oil (or 40# mechanical oil).
b. Inspect all threaded connections for looseness.
c. Inspect the motor and starter's insulation to ensure compliance with electrical regulations. For electrical use, the entire unit must be reliably grounded.
d. Add an adequate amount of water to the tank.
Operation Process
Open the pressure relief valve handwheel.
b. Start the motor and run it under normal pressure for 5 minutes, checking for normal operation of the pump. If there are no abnormal sounds and the discharge medium of the pump shows no significant fluctuations, proceed with the pressure increase operation.
c. Shut down the equipment, close the pressure relief valve handwheel, energize the motor to reach the test pressure, and then stop the machine. At this point, the pressure testing pipeline is in an automatic pressure maintenance state.
d. After pressure testing is completed, open the pressure relief valve handle to release the pressure from the test piping and pump.
Cautionary Notes for Use
If the test piece has a large volume, initially run the pressure continuously, then start the pressure incrementally as it approaches the test pressure. Pay close attention to the system pressure during the operation to avoid accidental overpressure.
b. In case of an accidental overpressure, you can turn the pressure relief valve to release some pressure, then reapply pressure.
c. Test pressure must not exceed the pump's rated working pressure.
Six, **Cautionary Notes**
1. The valve of this unit is pre-adjusted upon factory shipment, and users are not permitted to make any arbitrary adjustments.
2. During operation under load, the instantaneous high pressure must not exceed the pump's rated working pressure.
3. High-pressure pumps and pipelines must be equipped with protective gear. Special attention should be given to the potential injury from pipe end joints during operation. Unauthorized personnel are strictly prohibited from entering the pressure testing area.
4. Absolutely prohibited to install or dismantle the main unit, accessories, and pipelines under high pressure. Fault handling and maintenance should be conducted after shutdown.
Section 7: Common Faults and Solutions
Section 8: Maintenance and Care
1. The lubricant for the crankshaft and the pressure testing medium should remain clean to prevent contamination by impurities.
2. The lubricating oil for a new machine should be changed after 40 hours of first use, with subsequent changes at 80-hour intervals, and thereafter approximately every 200 hours. Additionally, the oil sump should be cleaned.
3. During use, always check that all fasteners at the connections are tight. If loose, tighten them immediately.
4. For use in freezing regions during winter, make sure to empty the pump and internal reservoir of any remaining water after use.
5. When the machine is not in use for an extended period, rust prevention should be applied. First, drain any remaining water, then inject rust preventive oil or water once more. For parts that are not painted, apply machine oil to prevent rust.
6. After 500-600 hours of pump operation, inspect major components such as rods, pistons, seals, valve assemblies, plungers, etc., and replace with new parts if necessary.
