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This standard is developed in accordance with the rules given in GB/T 1.1-2009.
This standard replaces GB/T 9234-2008 Power reciprocating pump.
In addition to editorial changes, the following main technical changes have been made with respect to GB/T 9234-2008:
——the application scope of the standard is extended, the "coal-to-liquids" medium is added, and the flow is increased to 650 m3/L (see Clause 1, Clause 1 of Edition 2008);
——the performance requirements for the pump are improved, and the efficiency and volume coefficients of the pump are increased (see Table 1, Table 1 of Edition 2008);
——the noise requirements for the pump are improved, and the maximum noise values are dropped by 1 dB to 3 dB (sound pressure level) (see Table 2, Table 2 of Edition 2008);
——the reliability requirements for the pump are improved, and the service life of the first overhaul is increased from 12,000 h to 20,000 h (see Sub-clause 5.4.2, Sub-clause 5.4.2 of Edition 2008);
——the service life requirements for vulnerable parts of the pump are improved, with the service life index requirements for valve groups being specified respectively according to different medium (see Table 3, Table 3 of Edition 2008);
——the requirements for non-destructive testing of shafts and crankshafts are modified and the methods for non-destructive testing are not be limited (see Sub-clause 5.5.1.1, Sub-clause 5.5.1.1 of Edition 2008);
——the requirements for variable speed prime mover and frequency converter governor are added (see Sub-clauses 5.12.2.3 and 5.12.2.4);
——the content “outlet pressure shall not exceed 1.25 times the rated discharge pressure of the pump after the safety pressure relief device with full discharge function is operated” id added (see Sub-clause 5.12.6.3);
——the "pulsation stabilizing device” is changed to "pulsation suppressing device" and the recommended technical requirements for pulsation suppressing device are added (see Sub-clause 5.12.7, Annex C, Sub-clause 5.12.7 of Edition 2008).
This standard was proposed by China Machinery Industry Federation.
This standard is under the jurisdiction of the National Technical Committee on Pumps of Standardization Administration of China (SAC/TC 211).
The previous editions of this standard are as follows:
—— GB/T 9234-1988, GB/T 9234-1997 and GB/T 9234-2008.
Power reciprocating pump
1 Scope
This standard specifies the information confirmation, requirements, test and inspection, delivery preparation, marking, packaging and storage of power reciprocating pump (hereinafter referred to as "pump").
This standard is applicable to the pumps with the transmission medium of clear water without particles, oily sewage, emulsion, crude oil and its petroleum products, coal-to-liquids products and chemical liquids, with rated discharge pressure up to 100 MPa; flow up to 630 m3/h; the temperature of 5℃~160℃ and kinematic viscosity not exceeding 850 mm2/s.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 196 General purpose metric screw threads - Basic dimensions
GB/T 1095 Square and rectangular keyways
GB/T 3098.1 Mechanical properties of fasteners - Blots, screws and studs
GB 3836.1-2010 Explosive atmospheres - Part 1: Equipment - General requirements
GB/T 7784 Test methods for power reciprocating pump
GB/T 7785 Classification and vocabulary for reciprocating pump
GB/T 13306 Plates
GB/T 13384 General specifications for packing of mechanical and electrical product
JB/T 6912 Non-destructive testing for pump parts - Magnetic particle testing
JB/T 9090 Hydrostatic and leakage tests for positive displacement pump components
JB/T 12582 Non-destructive testing methods for pump parts - Penetrant testing
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 7785 and the following apply.
3.1
power reciprocating pump
reciprocating pump driven by independent rotary prime mover (including electric motor, internal combustion engine, steam turbine, etc.). Independent transmission devices (e.g. reduction gearbox, pulley, etc.) that are part of the pump shall be included in the pump range
3.2
ancillaries
independent parts and components (e.g. pulsation suppressing devices) installed on or near the pump, excluding the spare parts that do not need to be installed when the pump is first used
3.3
spare parts
used for replacing the parts and components that may be damaged (e.g. plungers) when the pump is in service
3.4
continuous operation
continuous operation for 8~24 h per day under rated conditions
4 Information confirmation
4.1 Information of the Buyer
When purchasing pumps from the Seller, the Buyer shall provide the Seller with necessary information, referring to the data sheet provided in Annex A. The Seller shall require the Buyer to provide all relevant information shall be considered, including use requirements, environmental requirements, operation requirements, etc.
4.2 Alternative items
The Buyer may put forward special requirements beyond the scope specified in this standard. The specific contents provided by the Buyer can be based on the agreement or purchase order, or Annex A.
4.3 Information of the Seller
The Seller shall provide at least the following information:
——overall dimension;
——assembly dimension;
——axis dimension;
——inlet connection dimension;
——outlet connection dimension;
——public work information.
The Seller may also provide data sheets including flow, pressure, pump speed and other parameters, as well as the requirements of the Buyer.
5 Requirements
5.1 Environmental adaptability
5.1.1 When the Buyer puts forward the requirements for environment, operating conditions and other parameters according to Sub-clause 4.1, the design of pump and pump parts shall meet the characteristics of transmission medium and flow.
5.1.2 The pump shall be able to work normally under the following conditions:
——the minimum air temperature is 2℃;
——the maximum air temperature is 40℃;
——the maximum relative humidity is 80%.
5.1.3 If the environment and operating conditions have the following special requirements, the pump shall also be able to meet these conditions agreed upon by both parties through negotiation:
——the ambient temperature and humidity are not included above scope;
——direct sunlight;
——air pollution including suspended particles;
——biochemical reactions;
——water splashing equipment;
——external shock and vibration caused by machinery or earthquake;
——poor ventilation;
——longer shutdown or inventory;
——work under the horizontal plane;
——marine environment;
——explosion-proof, protection, plateau requirements, etc.
5.2 Basic design criteria
5.2.1 The pump shall meet the requirements of this standard and shall be manufactured according to the drawing and technical documents approved through established procedure. See Annex B for the basic parameters of the pump.
5.2.2 The pump shall meet the requirements put forward by the Buyer according to Sub-clause 4.1 and can achieve continuous/intermittent operation under the specified parameters.
5.2.3 The installation, maintenance, inspection, handling of equipment and the replacement of vulnerable parts shall be considered during the design of pump structure and parts, the necessary facilities such as lid bolts, installation locating pins, eyebolts, etc. shall be provided. In case of oil filling, gasket and valve replacement, it is not necessary to disassemble the main components as much as possible.
5.2.4 The pump shall be able to operate safely under the opening pressure and rated speed of the safety valve.
5.2.5 The design of pump parts shall meet the operating requirements and environmental requirements proposed by the Buyer. The abrasion and fatigue damage shall be controllable during the predetermined service life and working under the specified parameters.
5.2.6 The friction parts of exposed moving parts of the pump shall be made of corrosion-resistant materials for the working environment or protected by other measures.
5.3 Performance requirements
5.3.1 The basic performance index of pump under rated conditions shall meet those specified in Table 1. Among them, the efficiency index of pump is not applicable to pumps that use hydraulic torque converters and continuously variable transmissions for stepless speed regulation, nor to chemical process pumps for transmitting chemical liquids and low-speed pumps with speed not greater than 100 min-1.
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Table 1 Basic performance index of pump
Item Rated discharge pressure/MPa
≤20 >20~31.5 >31.5~35 >35~50 >50~100
Flow/(m3/h) 95%Qr~110%Qr
Efficiency of pump ≥87 ≥86 ≥83 ≥78 ≥77
Required net positive suction head/m Not greater than rated value
Volume coefficient of pump/% ≥93 ≥92 ≥88 ≥84 ≥80
Note: Qr refers to the rated flow of the pump.
5.3.2 When the pump is operated under the rated conditions, the noise shall not be greater than those specified in Table 2. Noise indexes not specified in the table may meet the requirements in Sub-clause 4.2.
Table 2 Noise index of pumps under rated conditions
Rated input power/kW Rated discharge pressure/MPa
≤20 >20~31.5 2>31.5~35 >35~50 >50~100
Noise level (Sound pressure level) /dB(A)
≤11 82 84 85 86 87
>11~37 84 86 87 92 93
>37~75 88 90 91 92 94
2>75~160 90 92 93 94 96
>160~315 93 94 95 96 97
2>315~700 95 96 97 97 98
>700~1 250 96 97 97 98
Note: The noise index in the table excludes the noise of the prime mover.
5.4 Service life and reliability
5.4.1 The operation of pump shall meet the following requirements:
——when the rated flow of the pump is not less than 10 m3/h, the leakage of the packing box shall not exceed 0.01% of the rated flow of the pump; otherwise, the leakage of the packing box shall not exceed 1 L/h;
——all static sealing surfaces shall be free from leakage;
——the lubricant pressure and level are within the specified range, and the oil temperature in the oil pool shall not exceed 75℃;
——the temperature of bearings and crosshead guide holes shall not exceed 85℃;
——there shall be no abnormal sound and vibration (such as abnormal impact sound, irregular and uneven sound and vibration, etc.);
——the prime mover shall not be overloaded when the pump is operated under rated conditions.
5.4.2 Under the condition of operating rules, the cumulative service life from the pump put into operation to the first overhaul (vulnerable parts can be replaced) shall not be less than 20,000 h.
5.4.3 The designed service life of the main bearing of the machine body shall not be less than 25,000 h under rated conditions.
5.4.4 The replacement time of the main vulnerable parts of the pump shall not be less than those specified in Table 3. When the transmission medium is crude oil, the sand content is less than 0.03% and the water is less than 2% (mass fraction); when the medium is sewage, the sand content is less than 0.03%, the mechanical impurities are not greater than 20 mg/L, and the mineralization is not greater than 10 g/L. The service life of vulnerable parts not specified in the table can be conducted according to the requirements of Sub-clause 4.2.
Table 3 Replacement time of main vulnerable parts of pump
Name of vulnerable parts Transmission medium Rated discharge pressure/MPa
≤20 >20~31.5 >31.5~35 >35~50 >50~100
Replacement time/h
Plunger Clear water, emulsion 4,000 3,500 2,000 1,200 1,000
Crude oil 5 000 4,000 3 000 2,000
Sewage 1,500 1,200 1,000 700
Chemical liquid 3,000 2,500 1,500 1,000
Filling Clear water, emulsion 3,000 1,500 1,000 700 600
Crude oil 3 500 2,000 1,500 1,000
Sewage 1,500 1,000 800 600
Chemical liquid 2,000 1,500 1,000 700
Valve group Clear water, emulsion, crude oil, chemical liquid
(Failure-free operation time) 1,200 800
Sewage
(Failure-free operation time) 800 600
Clear water, emulsion, crude oil, chemical liquid
(Repair allowed) 3,000 —
5.5 Main parts
5.5.1 Shaft and crankshaft
5.5.1.1 Non-destructive testing for shafts and crankshafts can be carried out according to JB/T 12582, JB/T 6912 or by other non-destructive testing methods.
5.5.1.2 Rectangular or square keys on the axis shall meet the requirements of GB/T 1095.
5.5.1.3 The shaft end shall be provided with a central hole with screw holes for alignment to facilitate coupling installation.
5.5.2 Machine body
5.5.2.1 Under rated load, the machine body shall have sufficient rigidity to ensure that the power end of the pump works normally under the maximum rated thrust and prevent the deformation of the machine body, abnormal vibration of the pump, etc.
5.5.2.2 All openings of the machine body shall be sealed to prevent leakage of lubricant at the power end and entry of dust at the outer end. All glands shall be padded and fully compressed with bolts.
5.5.2.3 The machine body shall be tested for leakage of parts according to JB/T 9090.
5.5.3 Hydraulic cylinder, packing box and outlet liquid trap
5.5.3.1 Pressure-bearing parts such as hydraulic cylinder shall have sufficient rigidity and cannot be distorted or deformed due to the temperature, pressure, external force and torque of the transmission medium, which leads to the leakage of transmission medium.
5.5.3.2 The hydraulic cylinder, packing box, outlet liquid trap and other hydraulic parts shall be subjected to hydraulic test at ambient temperature and before painting. The test method and technical requirements shall meet the requirements of JB/T 9090.
5.5.3.3 When the liquid cylinder, packing box and outlet liquid trap and other pressure-bearing parts are easy to corrode, their wall thickness shall have appropriate corrosion allowance.
5.5.4 Connecting rod and connecting rod bolt
5.5.4.1 Non-destructive testing for connecting rod can be carried out according to JB/T 12582, JB/T 6912 or by other non-destructive testing methods.
5.5.4.2 The connecting rod bolt and nut, pump body high-pressure bolt and nut and other important threaded connections shall specify the assembly torque.
5.5.4.3 The inlet and outlet valves shall be tested for leakage of parts according to JB/T 9090.
5.6 Sealing and sealing system
5.6.1 The following parts shall be equipped with appropriate seals (including but not limited to):
——the part of the rotating shaft extending out of the crankcase;
——the joint between reciprocating crosshead extension rod (also called centre rod or intermediate rod) and crankcase;
——the joint of reciprocating plunger and packing box;
——the joint of reciprocating piston rod and packing box;
——the joint of piston and hydraulic cylinder;
——the manholes of engine base.
5.6.2 The selection of seals shall be based on the manufacturer's recommendation and the specific needs.
5.6.3 The leakage liquid (or flushing liquid) of the packing box shall be concentrated and led out of the pump by pipelines. When transporting irritant chemical medium, the leaking liquid pipeline shall be directly connected with the packing box. When the transmission medium is toxic or flammable liquid, the leaking liquid pipeline shall be directly connected with the packing box with seamless pipe. The threaded connection of the pipeline shall be sealed and welded, but the connection between the pipeline and the equipment and the connection that shall be disassembled during overhaul shall not be welded. The pump shall also be properly isolated to ensure that leaked liquid or its volatile gas does not leak into the pump workplace.
5.7 Lubrication and lubrication system
5.7.1 If grease is used to lubricate bearings and it is required during the service life of the pump, the appropriate greasing measures shall be taken and shall be explained in the maintenance instructions.
5.7.2 Lubrication of sliding bearings shall be guaranteed, and visual oil level indication shall be provided if necessary. Detailed requirements shall be explained in the maintenance instructions.
5.7.3 When the pressure lubrication system is used, which shall be equipped with a full flow oil filter, an oil pressure gauge (indicating the oil pressure in the pump) and a low oil pressure alarm device. The filtering accuracy of the oil filter shall not be less than 0.10 mm.
5.7.4 When the splash lubrication is used, the minimum crankshaft speed for splash lubrication shall be specified to ensure sufficient lubrication everywhere and visual oil level indication shall be provided.
5.8 Reduction mechanism
5.8.1 Under meeting the requirements, the following reduction types are allowed to be used but not limited to:
——reduction gear;
——pulley;
——built-in gear;
——built-in worm and gear.
5.8.2 For occasions with explosion-proof requirements, pulley deceleration or antistatic pulley deceleration mechanism shall be avoided.
5.9 Inlet and outlet pipeline connection
5.9.1 The inlet and outlet pipelines shall be connected by flange or thread, and their dimensions shall be provided in detail when supplying.
5.9.2 The service pressure of the inlet and outlet connectors shall be higher than the design pressure or equal to the discharge pressure of the safety pressure relief device.
5.9.3 The allowable force and torque of the metal pipeline interface are shown in Table 4. The threaded joint shall not bear the torque used to tighten or loosen the pipeline in the pump body.
Foreword i
1 Scope
2 Normative references
3 Terms and definitions
4 Information confirmation
4.1 Information of the Buyer
4.2 Alternative items
4.3 Information of the Seller
5 Requirements
5.1 Environmental adaptability
5.2 Basic design criteria
5.3 Performance requirements
5.4 Service life and reliability
5.5 Main parts
5.6 Sealing and sealing system
5.7 Lubrication and lubrication system
5.8 Reduction mechanism
5.9 Inlet and outlet pipeline connection
5.10 Drainage and exhaust
5.11 Threaded fasteners
5.12 Ancillaries
5.13 Installation and maintenance
5.14 Material, manufacturing and repair
5.15 Surface protection
5.16 Completeness
6 Test and verification
6.1 Test methods
6.2 Test items
6.3 Inspection rules
6.4 Type inspection
6.5 Sampling inspection
6.6 End-of-manufacturing inspection
7 Preparation of delivery
7.1 Anti-rust
7.2 Opening
7.3 Pipe fittings, ancillaries and spare parts
7.4 Installation and operation instruction
8 Marking, packaging and storage
8.1 Marking
8.2 Packaging
8.3 Storage
Annex A (Informative) Data sheet of power reciprocating pump
Annex B (Informative) Basic parameters of power reciprocating pump
Annex C (Informative) Allowable maximum pressure pulsation margin
