Water supply companies face numerous challenges, with pump station failures being among the most common and impactful. These incidents directly affect water delivery, especially at pressurized pump stations, where a failure can result in a complete loss of water supply. Such disruptions not only harm operational efficiency but also cause significant economic losses and social unrest. For this reason, pressurized pump houses are often referred to as the "heart" of water supply systems.
Ensuring the smooth operation of all components within a pump station is a critical concern for water utilities. To address this, many companies and professionals have been actively seeking effective solutions to minimize breakdowns and improve reliability.
According to partial statistics, over 90% of pump station accidents occur in the water pump and its outlet piping, while the remaining 10% are related to electrical or other system issues. Of these, 90% of the incidents are associated with the pump's outlet configuration, typically involving problems such as improperly closed valves, pipe bursts, or severe water hammer events.
The traditional configuration of pump systems has several limitations. First, when starting the pump, it is necessary to go through a light-load process to avoid backpressure from the pipeline acting on the impeller. This requires careful control, usually via an electric valve and a delayed start sequence. However, manual operations are often inaccurate, leading to motor burnout or mechanical damage. Additionally, during pump shutdown, preventing water hammer is essential. If the power fails, an electric valve may not close in time, and manual intervention is too slow, increasing the risk of reverse flow or damage.
Another issue is that check valves at the pump outlet are prone to failure due to water hammer, which can lead to valve plate damage. Relying solely on water hammer eliminators is not sufficient, so there is a clear need for a more reliable solution.
Tianjin Guowei Drainage Equipment Manufacturing Co., Ltd. has developed a booster pump control valve designed to address these issues. This device operates automatically without electricity or human intervention, offering a new energy-efficient solution. It was used in the reconstruction of Datong Water Works Second Pump Station, although the original design did not incorporate this technology, instead opting for traditional methods.
The booster pump automatic control valve consists of three main parts: the main valve, the diaphragm control chamber, and a bypass pipe. When the motor starts, pressure gradually builds up at the inlet. The pressure pushes the large valve plate upward, but the diaphragm in the upper chamber initially prevents full opening. As water flows into the lower chamber, the pressure difference causes the diaphragm to move, allowing the valve to open gradually, thus achieving a soft start.
In the event of a sudden power outage or emergency stop, the valve closes quickly (within 3–5 seconds) to prevent backflow. The system also includes a pressure relief mechanism, allowing for controlled closure over a longer period (up to 150 seconds), ensuring no leakage and reducing noise. This combination of rapid closure, linear pressure relief, and a pressure chamber helps eliminate water hammer effectively.
Key features of the new hydraulic valve include:
1. Fully automatic operation, requiring no manual input or power.
2. Combines the functions of a control valve, check valve, and water hammer eliminator.
3. A wide-body design minimizes head loss and pressure drop, improving efficiency.
Compared to alternative products, this valve offers superior performance in eliminating water hammer. Its use in pressurized pump stations significantly reduces the accident rate, saves space, and lowers operational costs. After more than a year of use, Datong Water Supply Company has reported excellent results, making it a promising solution for widespread adoption in the water supply industry.
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