Technical Regulations for Reciprocating Pump Engineering

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\"Technical Specifications for Reciprocating Pump Engineering\" 1. Scope These technical specifications establish the minimum requirements for reciprocating pumps used in industrial installations, as well as their drives and auxiliary equipment. These technical specifications address the performance, structural design, materials, drive units, testing and marking, packaging, and procurement of reciprocating pumps. 2. Standards, specifications and regulations 2.1 In addition to the technical specifications for this project, the standards indicated on the pump data sheet (latest version) must also be complied with, such as GB9234 Technical Requirements for Motorized Reciprocating Pumps ； JB1053 Test Methods for Steam Pumps ； GB7784 Test methods for reciprocating pumps ； GB9235 Test methods for steam reciprocating pumps ； API674 Reciprocating Pumps (Positive Displacement Pumps-Reciprocating). 2.2 In the event of a conflict between these technical specifications and the designated standards, these technical specifications shall prevail. At the same time, the seller shall clarify the discrepancies to the buyer in writing, so as to alert the buyer and facilitate resolution. 　3. General Provisions 3.1 Unless otherwise specified, pumps, drives, and their auxiliary equipment shall be suitable for outdoor starting and continuous operation at the specified minimum and maximum ambient temperatures. The continuous operation cycle should be no less than 8,000 hours. 3.2 Untested prototypes cannot be accepted; only pumps that have been verified through actual production can be accepted. Production verification refers to the pump having at least two years of experience in safe operation under similar operating conditions. 3.3 Unless otherwise specified, the seller shall supply the entire pump unit, including the pump, coupling, drive machine, and all auxiliary equipment, and guarantee the quality of the entire pump unit. 3.4 Unless otherwise specified, pumps, drives, couplings and guards, as well as auxiliary equipment, shall be installed on the same base. 3.5 The rated flow rate of the reciprocating pump shall be at least 110% of the maximum (operational) flow rate specified by the user. 3.6 The rated power of the motor should be at least K times the maximum shaft power of the reciprocating pump (including power losses in the gearbox and coupling). Maximum shaft power Pa (kW): K Pa ≤ 19125% → 1955; 110% → 3.7. The effective net positive suction head available NPSHa and the required net positive suction head NPSHr should use the same reference level. When the difference between NPSHa and NPSHr is less than or equal to 0.6 m, a cavitation margin test should be conducted. 　4. Structural Design 4.1 Pressure-bearing Parts 4.1.1 The maximum allowable outlet pressure of the pump shall be at least 110% of the pump’s rated outlet pressure. 4.1.2 All pressure-bearing parts (including areas affected by inlet pressure) shall be designed for the maximum allowable outlet pressure at the pumping temperature. The allowable stress value of the material used shall, for domestic pumps, not exceed the maximum allowable stress value specified in HG20531-93 (cast iron and cast steel vessels) ； For imported pumps, it should not exceed the maximum allowable stress value specified in ASME Section VIII. 4.2 Interfaces 4.2.1 Unless specified in the data sheet, all interfaces are flanged. 4.2.2 Unless otherwise specified, the inlet and outlet connection flanges of domestically produced pumps shall comply with the requirements of GB9112, while those of imported pumps shall comply with the requirements of ANSI B16.1 and 16.5. Flanges with a diameter or thickness greater than the above standards can also be used. 4.2.3 Unless otherwise specified, import and export flanges shall be of the same pressure class. 4.3 Hydraulic End Components 4.3.1 Cylinder Block The cylinder block must be equipped with cylinder liners. 4.3.2 Piston or plunger 4.3.2.1 The piston rod or plunger section in contact with the packing shall be ground and hardened. 4.3.2.2 Unless otherwise specified, hollow pistons or plungers shall not be used. 4.4 Packing Box 4.4.1 The packing box shall be equipped with a packing ring to allow for the flushing or lubrication of the packing. 4.4.2 When the temperature of the transport medium exceeds 80°C or the vaporization pressure exceeds 0.098 MPaG, a water-cooled jacket should be provided for the stuffing box. 4.5 Unless otherwise specified, flexible couplings shall be used for couplings. 4.6 The bearings shall be of standard type; custom-made bearings developed by the manufacturer are not permitted. 4.7 Buffers: If specified in the data sheet, the inlet and outlet buffers shall be provided by the seller, and their type shall be determined through consultation between the buyer and the seller. 4.8 Safety Valves 4.8.1 If specified in the data sheet, the safety valves shall be provided by the seller. 4.8.2 Unless otherwise specified, the inlet and outlet of safety valves shall be flanged. 4.8.3 The set pressure of the safety valve shall not be lower than the greater of 110% of the rated pressure and 0.049 MPaG. 4.9 Lubrication System 4.9.1 Light oil lubrication shall be used. 4.9.2 Pumps with pressure-free lubrication shall be equipped with a fixed oil level gauge. 4.9.3 For pumps equipped with a pressure oil system, such system shall be installed on the pump base and include the following: a. an oil tank with a level indicator ； b. Main oil pump and auxiliary oil pump ； c. 2 oil filters operating in parallel ； d. 2 oil coolers operating in parallel ； e. Fuel pressure gauge and thermometer ； f. Bearing or return oil thermometer ； g. Pressure joint h. Low oil pressure alarm and activation of the auxiliary oil pump i. Tripping due to low oil pressure 4.10 Auxiliary pipelines 4.10.1 If pipeline systems for lubrication, cooling, and seal flushing are required, the seller shall provide them and install them on the pump and/or base. 4.10.2 The pipes, fittings, etc., of all piping systems shall be at least 1/2 inch (13 mm) in diameter, with a wall thickness of not less than 1.6 mm (1/16 inch). 4.10.3 Unless otherwise specified, fittings of 1-1/4 (32 mm), 3-1/2 (90 mm), 7 (175 mm), and 9 (225 mm) inches shall not be used. 　5. Materials 5.1 The materials shall be specified by the buyer and filled in on the pump data sheet. If the seller believes that other materials are more suitable, they may submit a written report, but their adoption must be confirmed by the buyer. 5.2 Unless otherwise specified, the corrosion allowance for carbon steel and low-alloy steel is 3 mm, while for high-alloy steel it is 0 mm. 5.3 The use of materials containing asbestos fibers is strictly prohibited. 5.4 Rubber materials are strictly prohibited when transporting organic solvents. 5.5 Cast iron materials shall not be used for pressure parts that transport flammable, explosive, or toxic media. 5.6 Except for austenitic stainless steels, when the medium or ambient temperature is ≤ -20°C, the seller shall conduct V-notch impact tests on the base metal and welded joints. 　6. Workshop Tests 6.1 The items for workshop tests are listed in the pump data sheet. 6.2 The hydrostatic test pressure shall be 1.5 times the maximum allowable working pressure, but not less than 0.14 MPaG. 6.3 The performance tolerances for the tests carried out in the workshop are specified in the table below: Performance indicators – Reciprocating pump, Steam reciprocating pump: Rated flow rate: +3%–0%; +3%–0%. Rated power: +4%/NPSHr: +0%–0%. 6.4 For those inspection or test items that the buyer requires to be witnessed in person, the seller shall notify the buyer at least twenty days in advance after determining the date of the tests, so that the buyer can attend in a timely manner. 6.5 The results of non-observation tests shall be recorded and submitted for the buyer’s approval. 　7. Painting, Marking, Packaging
7.1 Painting
7.1.1 Before painting, all dust, rust, oil stains, and other contaminants must be removed. 7.1.2 The equipment topcoat shall meet the buyer’s requirements. 7.2 Marking 7.2.1 The pump’s nameplate shall be made of 18-8 stainless steel and firmly fixed in a prominent position on the pump. 7.2.2 The nameplate shall include: a. Tag number ； b. Device name/apparatus name ； c. Name and trademark of the seller (manufacturer) ； d. Pump model and name ； e. The main parameters of the pump, including rated flow rate (m3/h or l/h), maximum allowable outlet pressure (MPaG), safety valve setting pressure (MPaG), shaft power (kW), and pump weight (kg), etc ； f. The pump’s factory serial number and date. 7.3 Metal closure plates shall be installed at the inlet and outlet of the pump, along with rubber gaskets and at least four bolts. 7.4 The packaging of the pump and its auxiliary piping system (including the driver and auxiliary equipment) must ensure that the products remain undamaged and unlost during transportation. It must also be suitable for outdoor placement and capable of withstanding outdoor storage for a period of no less than six months. 　8. Documents and drawings 8.1 Seller’s quotation documents The seller’s quotation documents shall include the following: a. Buyer’s data sheet, which contains the seller’s data filled in completely by the seller ； b. Preliminary dimensional drawings, piping layout diagram ； c. Requirements for utilities such as water, electricity, and steam ； d. Typical cross-sectional view of the pump ； e. Recommended spare parts list ； f. Specific details on whether these regulations are strictly followed for the pump units. If the pump unit does not strictly comply with this manual, the seller shall provide a detailed list explaining each discrepancy. 8.2 Contract Documents 8.2.1 The seller must deliver the documents in terms of timing, type, and quantity as specified in the purchase order, to the address indicated on the order. 8.2.2 The following information shall be marked on each page of the document: a. Name of the buyer (user) company ； b. Project number ； c. Purchase order number or document number ； d. Pump station number ； e. Any other notation specified on the purchase order. 8.2.3 The seller shall provide at least the following documents: a. List of document catalog ； b. Pump data sheet (for manufacturing) ； c. External dimensions and layout diagram (including basic data, the location, dimensions, and pressure ratings of the main inlet and outlet connections, the location of the motor junction box, as well as the allowable external forces and torques on the inlet and outlet pipes) ； d. Auxiliary piping layout diagram and connection list (can also be shown on the external dimensions diagram) ； e. Pump cross-section diagram and a table of components listing the material names of related parts ； f. Shaft seal sectional view and parts list including the material names of relevant parts ； g. Spare parts list ； h. List of lubricants and hydraulic fluids ； i. Auxiliary equipment data sheet (if required) ； j. Installation, maintenance, and operation manuals. 8.2.4 If requested by the buyer, the seller shall also provide the buyer with the following reports and records: a. Material test reports ； b. Factory test data recording ； c. Test reports for other required items.