電動凝結水回收裝置

電動凝結水回收裝置  ELECTRIC CONDENSATION WATER RECOVERY DEVICE

電動凝結水回收裝置罐體內部設置汽水分離裝置、除污裝置、調壓裝置、汽蝕消除裝置、疏水快排裝置等；下部配置本廠特制的高溫電機泵；同時根據不同工況，并配有水汽引射裝置、泵前加壓裝置、低壓輸送裝置、自動加壓器等，從而達到*密閉回收。

Electric condensate recovery device is arranged inside the tank water separation device, decontamination device, pressure regulating device, cavitation eliminating device, hydrophobic quick exhaust device; the lower part of the allocation of high temperature motor pump factory special; at the same time according to different working conditions, and is equipped with water vapor ejecting device, pump pressure device, low pressure conveying device, automatic pressurizing device etc. thus, completely closed recovery.

1.自動調壓裝置

北疏將設備安全和工藝安全分開，用安全閥保證設備結構安全，用調壓裝置確保生產工藝的系統安全。為確保泵進口處2m以上的正壓頭，在集水容器內增設自動調壓裝置，采用多級水封和“U"型管原理。調壓裝置分兩種：一種是無壓型，PN=0.01-0.09MPa,常用于采暖、溴化鋰制冷的空調等0.1Mpa以下的凝結水回收工程中；一種是壓力型，PN=0.1-1.0MPa,常用于石化、鋼鐵、熱電等工業用熱系統工程中。在保證正常回水的情況下，壓力適當提高，一是有利于二次汽在容器內的二次凝結，是閃蒸回收的重要節能措施；二是二次汽向水面施壓，保證水泵防汽蝕必需的正壓水頭；三是形成閉式系統，保證設備及管道內無氧，不生銹。

1. Automatic voltage regulator

North sparsely separates the equipment safety from the process safety, ensures the safety of the equipment structure with the safety valve, and ensures the safety of the production process by the pressure regulating device. In order to ensure the positive pressure head above 2m at the inlet of the pump, the automatic pressure regulating device is added in the water collector, and the principle of multistage water seal and "U" tube is adopted. The pressure adjusting device is divided into two kinds: one is no pressure, PN=0.01-0.09MPa, condensate recovery project commonly used in heating, refrigerating of central air conditioning in the 0.1Mpa below; a pressure type, PN=0.1-1.0MPa, commonly used in petrochemical, steel, thermal power and other industrial thermal system engineering. To ensure the normal return under the condition of pressure increasing, one is two times to two times the condensation of steam in the container, is an important energy saving measures of flash recovery; two is two times to the surface of the water vapor pressure, to ensure the pump pressure head required anti cavitation; three is the formation of a closed system, and ensure the equipment in the pipeline anaerobic, not rust.

2.除污裝置

因集水容器的體積小于被替代的凝水箱體積，早期試驗時鐵銹等硬塊打壞了水泵葉輪。因此，集水容器內增設除油污和雜質的除污裝置，用于提高水質純凈度。

2. Decontamination device

Condensate tank volume due to the volume of a container is smaller than the alternative catchment, early test of rust lump broken water pump impeller. Therefore, a decontamination device for oil pollution and impurities is added in the container to improve the pure purity of the water.

3.汽蝕消除裝置

多年來的規范認定，將水箱放在水泵上方，讓水泵得到一個靜水頭，用來放置水泵發生汽蝕。研究與實驗表明，靜水頭是在靜態下存在的，水泵汽蝕是在動態下發生的。靜態和動態不能同一時間存在于同一設備上，所以用靜態下的靜水頭解決動態時的水泵汽蝕是不可能的。高位水箱的水從靜止加速至泵前的高速流動過程中（2950轉/分），過流段面急速縮小，高溫水在負壓下瞬間汽化，產生大量汽泡，汽泡入泵受壓破裂，水流質點四周的沖擊頻率達每分鐘2萬次以上，在極微小的面積上壓力常達幾十至幾百個兆帕，極大的機械破壞力猛烈作用于葉輪，很快造成葉輪的損壞。汽蝕產生刺耳的噪音和強烈的振動。

當集中容器內的水位降到底部時，原平靜的水面立即出現降水漏斗（與龍卷風形狀相同），二次汽入泵仍發生“汽蝕"。根據透明玻璃鋼和水摻深顏色觀察的試驗結果，以阿基米德螺線方程為理論依據，用不銹鋼做成的多層導流體，在水位下降時，上部導流結構自動閉鎖，確保了低水位時無“汽蝕"現象發生。該裝置為汽蝕消除裝置。

3. Cavitation elimination device

For many years, the water tank is placed above the pump to make the water pump get a static head to keep the water pump cavitation. The research and experiment show that the hydrostatic head exists in the static state, and the cavitation of the water pump occurs in the dynamic condition. Static and dynamic can not exist on the same equipment at the same time, so it is impossible to use static water head in static water to solve the cavitation of water pump in dynamic condition. The high water tank water to accelerate from a standstill to high speed flow in the pump (2950 RPM), rapidly shrinking flow section, high temperature water instantly under negative pressure evaporation, resulting in a large number of bubbles, the bubble burst into the pump pressure, the flow around the particle impact frequency was more than 20 thousａnd times per minute, in the extreme small area pressure often tens to hundreds of MPA, great mechanical damage to violent impeller, soon caused damage of impeller. The cavitation caused a sharp noise and a strong vibration.

   When the water level in the centralized container descends to the bottom, there will be a precipitation funnel (the same shape as the tornado) on the original calm surface, and the cavitation of the two intake pump will still happen. According to the results of observation of transparent glass steel and water with deep color, with the spiral of Archimedes equation as the theoretical basis, the multilayer made of stainless steel by fluid, decline in water level, the upper guide structure to ensure the automatic locking, the low water level without "cavitation" phenomenon. The device is a cavitation elimination device.

4．汽水分離裝置

由于高溫凝結水為汽液兩相流，如不進行處理就會出現帶汽入泵，增大水泵氣蝕的誘因。可通過內置汽水分離裝置將凝結水中的二次汽和部分一次疏水漏汽分離出來，導流到回收罐體上部，分離出來的二次汽在罐體上部形成汽液動態平衡。再通過吸氣定壓裝置將積存的二次汽和一次汽抽吸，并和泵出口凝結水一并輸送到下一用戶。

通過汽水分離裝置確保凝結水在入泵的瞬間為單相的微過冷水，消除凝結水引起水泵氣蝕的一大誘因。

4. steam water separation unit

Because the high temperature condensate is a two phase flow of steam and liquid, if it is not treated, it will lead to the suction pump and increase the cavitation of the pump. The two steam and part of the condensate water can be separated from the first part of the condensate by the built-in steam water separating device. The steam can be guided to the upper part of the recovered tank, and the two separated steam will form vapor liquid dynamic balance on the top of the tank. Then through the suction constant pressure device, the accumulated two steam and one steam is sucked, and the condensate of the pump outlet is transported to the next user.

Through the steam water separation device to ensure that the condensate is a single phase micro supercooled water at the moment of entering the pump, so as to eliminate the major cause of the cavitation of the water pump caused by the condensate.

5.水泵改型

為滿足集水容器下裝配雙套電機泵的要求，北疏將現有的單級泵改型，一是將水泵進水管由原來的側面改到上面，將泵出水管由原來上面改在側面，形成理想流態；二是將泵體用機械密封，由原耐溫80℃-110℃提高到160℃以上，增強泵體耐溫耐久性能；三是將泵底座改為輕型，直接固定在設備下部的槽鋼上。

從總體結構可以看出，自動調壓裝置保持了集水容器內特定的壓力，凝結水在重力和二次汽壓力下，經汽蝕消除裝置正壓入泵，從根本上消除了高溫凝結水對水泵汽蝕發生的條件。

5. pump modification

In order to meet the requirements of assembling two sets of motor pumps under the water collecting container, Beishu changed the existing single-stage pump. First, the water inlet pipe of the pump was changed from the original side to the top, and the water outlet pipe of the pump was changed from the original top to the side to form an ideal flow state. Second, the pump body was sealed mechanically, from the original temperature resistance of 80 ℃ - 110 ℃ to over 160 ℃, so as to enhance the temperature resistance and durability of the pump body. Third, the pump base was changed It is light weight and fixed directly on the channel steel under the equipment.

From the overall structure, it can be seen that the automatic pressure regulating device maintains the specific pressure in the collecting container. The condensate under the gravity and the two steam pressure, through the positive pressure pump of the cavitation elimination device, basically eliminates the condition of the high temperature condensate water to the pump cavitation.

6. 控制系統

控制系統采用變頻恒液位控制，冷凝水連續輸出。

A、凝結水回收器采有PLC微電腦控制，實現整個裝置全自動運行。

B、液位傳感器設置四個固定液位信號點，從下向上為：超低點、低點、高點、超高點。

C、PLC微電腦根據液位信號控制水泵實現自動間斷運行，即實現高點啟動水泵泵水，低點停止水泵運行，保證凝結水及時泵走。

D、兩臺水泵一用一備，自動定時轉換運行，保證兩臺泵同期運行；每臺水泵都能手動和自動兩種運行方式，可自由轉換。

E、控制柜實現水泵過熱、過載自動保護并報警，當一臺泵出現故障，另一臺泵自動投入運行；實現液位到達超高點自動報警，并啟動另一臺泵，液位低于超低點自動切斷控制電源。

6. Control system

The control system adopts variable frequency constant level control and continuous output of condensate water.

A, The condensate recovery device has PLC microcomputer control to realize the whole automatic operation of the device.

B The liquid level sensor sets four fixed level signal points from down to low, low, high, and super.

C The PLC microcomputer controls the pump automatically and intermittently according to the liquid level signal. That is to realize the high point to start the pump water, the low point to stop the operation of the pump, and to ensure the condensate to pump in time.

D The two pumps are operated automatically and regularly at one time, ensuring two pumps running at the same time. Each pump can operate two modes manually and automatically, and it can be converted freely.

E The control cabinet realizes the automatic protection and alarm for the overheating and overload of the pump. When a pump fails, another pump goes into operation automatically. The liquid level reaches the super high point automatically, and the other pump is started. The liquid level is lower than the ultra-low point, and the power is cut off automatically.

7.吸汽定壓裝置

在閉式回收系統中，由于疏水器一般都有3－5％的疏水漏氣，如果不及時處理，漏汽聚積將導致罐體內壓力升高，從而使用熱設備的背壓升高，嚴重影響用熱設備的效率，實際上很多系統的疏水漏汽會更多，罐內壓力會升的更高；多路回水時匯集到罐體時由于相對高背壓的存在，會形成低壓換熱裝置形成憋壓，進一步造成低壓凝結水疏水不暢。以上這兩點原因都會導致用熱設備不能正常密閉運行。一般的閉式系統在運行一段時間后，不得不排放疏水漏氣和二次汽，由閉式系統變為開式系統，以保證工藝用熱設備的正常運行。從而大大地浪費能源。

為了能夠使閉式系統在有較高疏水漏汽率和多路壓力不等的凝結水回回到一臺回收器的工況下，保證工藝用熱設備及凝結水回收器正常運行，我公司科研人員開發出了*的吸汽定壓裝置，它*解決了上述問題。通過通過該裝置使罐內壓力低于凝結水回收器入口壓力， 降低背壓罐體保證凝結水順利輸出，不影響工藝和前端用熱設備的使用效果。

7. Steam absorption constant pressure device

In a closed recycling system, the traps are generally hydrophobic leak 3 - 5%, if not timely treatment will lead to the accumulation of steam leakage in tank pressure increases, thus the use of heat equipment back pressure, seriously affect the efficiency of heat transfer equipment, in fact many hydrophobic system leakage will be more, the pressure in the tank will rise even higher; multiple backwater together to tank due to the relatively high back pressure exists, will form a low pressure heat exchanger formation pressure, low pressure condensate due to poor drainage. The above two reasons will cause the use of thermal equipment to operate normally. When a closed system is running for a period of time, it has to drain the drain and the two steam, and turn the closed system into the open system, so as to ensure the normal operation of the thermal equipment. It is a great waste of energy.

In order to make the closed system with high leakage rate and hydrophobic multi-channel pressure ranging from condensate return to a recovery condition, ensure that the process of heat equipment and condensate recovery device normal operation, our company researchers developed a unique steam pressure setting device, it thoroughly solves the above the problem. Through the device, the pressure in the tank is lower than the inlet pressure of the condensate recovery unit, and the back pressure tank can be reduced to ensure the condensate output smoothly, without affecting the application effect of the hot equipment in the process and front-end.

 8.低壓輸送裝置

在閉式回收系統中，多路凝結水回到凝結水回收裝置時，由于有相對背壓的存在，壓力較低的高低壓凝結水會形成相互干擾，低壓凝結水管路會形成憋壓，造成疏水不暢，進一步影響前端換熱設備的換熱。當多路共網時一路壓力遠遠低于其他路壓力，而該路凝結水量又較小，另加一臺回收器浪費時；當用壓力低于 0.2MPa ，且用熱點很分散，而且用熱負荷較小，導致凝結水壓力很低，回收困難時，采用低壓輸送裝置。

工作原理：我廠采用*的水水引射裝置通過節流變徑，所產生的相對負壓，將低壓凝結水順利輸送到罐體內。該裝置效率高，穩定性好為了解決低壓管路輸水不暢的問題。

8. low pressure conveyor

In the closed type condensed water recovery system, multi-channel to condensate recovery device, due to the relative pressure of the existence of low pressure high pressure condensate will form a mutual interference, low pressure condensate line formation pressure, causing hydrophobic sluggish, further influence the heat exchanger design front-end preparation. When a road network multi-path pressure is far lower than other road pressure, and the way the condensation of water and small, plus a waste recovery device; when the pressure is lower than 0.2MPa, and the hot spots are scattered, and the heat load is small, resulting in condensation of water pressure is very low, difficult recovery, mining and conveying device low pressure.

Working principle: our factory adopts a unique water water ejection device to transfer the low pressure condensate to the tank through the rheological diameter of the joint and the relative negative pressure produced. The device has high efficiency and good stability in order to solve the problem of poor water transport in low pressure pipeline.

9.泵前增壓裝置

在換熱首站、采暖換熱等系統中所產生的凝結水壓力很低，進行密閉回收，在水泵啟動運行時罐體出水口會出現相對負壓，泵入口的壓力小于水泵的氣蝕余量，水泵會發生氣蝕。利用該裝置可以完該問題，達到*閉式回收。

9. pre pump booster

The condensate pressure produced in the first heat exchange system, heating and heat exchange system is very low, and it is closed recycling. When the pump starts and runs, the outlet of the tank will have relative negative pressure. The pressure of the pump inlet is smaller than the pump's cavitation allowance, and the pump will cavitation. The device can completely solve the problem and achieve complete closed recovery.

 10.多路共網器

用于多路不同壓力凝結水回到同一管網或凝結水回收器，消除各路凝水間相互影響。利用高壓凝水的動能，通過射吸原理來平衡各路凝結水的壓力，保證各種壓力凝結水都能順暢回到管網或凝結水回收器。該設備為非標設備，根據每路凝結水的水量，凝結水的壓力進行系統設計，以便能更好得適應具體工況

安裝簡單，自調節能力強，適用范圍廣。

10. multichannel common network

It is used to return different pressure condensate back to the same pipe network or condensate recovery device to eliminate the mutual influence of all kinds of condensate water. By using the kinetic energy of high-pressure condensate, the pressure of condensate is balanced by the principle of suction, so that all kinds of pressure condensate can smoothly return to the network or condensate recovery unit. The equipment is a non standard equipment. The system is designed according to the water volume of the condensate per road and the pressure of condensate, so that it can be better adapted to the specific working conditions.

Simple installation, strong self-regulation, wide range of application.

11.自力增壓器

蒸汽經過用熱設備產生的凝結水回收流程中，常有回收管道在地下或者向上彎曲，跨越馬路障礙物等需要爬升時，在管道的處安裝自力增壓器。利用自身的特殊結構使冷凝水的余壓和二次汽凝結時的能量得到釋放，提高冷凝水的爬高能力，消除水阻、汽阻和撞管等問題。該配套裝置占地面積小、安裝方便，且不需增加任何動力源。

1）在如下圖所示凝結水回收系統中，有增壓器和沒加增壓器的效果演示圖： 

    沒有安裝自力增壓器水流示意圖                           安裝了自力增壓器后水流示意圖

2）自力增壓器工作原理：
自力增壓器作用在于以下兩點：一是在有水的情況下只走水不走汽；二是防止在拱形管道頂部產生汽阻；三是利用管線泄漏和自身閃蒸的蒸汽產生壓力來推動凝結水爬高。

下圖是自力增壓器的工作原理圖，從圖中可以看出，凝結水在絕大部分管道中是半管水而不是滿管水，也就是說在管道中是汽水共存狀態，汽在上層，水在下層，在通常的管道系統的爬高處，通常管道中的汽是先于水上升到高處，容易在高處形成汽阻，而在管道爬高處安裝一臺自力增壓器，自力增壓器大致結構是頂部出水管延伸到自力增壓器底部，水是從底往上走，當凝結水、汽進入加壓器時，水在增壓器底部，汽則在上部對水面施加一定壓力，推動凝結水爬高，特別是疏水器泄漏的新蒸汽對凝結水的推動力更大，加壓器上部的汽通過做功消耗、自然散熱、管道背壓的作用，也是不斷凝結成水被送走。

由于凝結水在增壓器內存在擴容降壓，所以通過增壓器后的凝結水壓力比進增壓器前的凝結水的壓力要高一些，從這個方面來說也提高了凝結水的爬高能力，重要的是它具有一定的阻汽通水作用，特別是在閉式系統的拱形管道中對汽阻的消除效果十分明顯。這也是閉式系統與開式系統相比必須多考慮的問題之一。

11. self powered turbocharger

After recovering steam from the condensate water generated by the thermal equipment, the recovery pipe often is bent underground or upwards, crossing the road obstacle and so on. When it is necessary to climb, the self pressurizing device is installed at the lowest part of the pipeline. With its special configuration to residual pressure of condensed water and two condensing energy release, improve the ability of the condensed water, eliminate water resistance, steam resistance and impact pipe etc.. The equipment is small in area, convenient to install, and does not need to increase any power source.

1) a demonstration of the effect of a supercharger and no supercharger in the condensate recovery system as shown in the following figure:

No water flow diagram of a self powered supercharger is installed             Flow schematic after installing a self powered supercharger

Self booster role lies in the following two points: one is in the presence of water vapor only water does not go; two is to prevent the generation of steam resistance in the conduit top; three is the utilization of steam pipeline leakage and its flash vaporization pressure to push up condensate.

2) the working principle of self powered turbocharger:

This is independent of turbocharger working principle diagram, it can be seen from the figure, the vast majority of condensed water in the pipeline is half pipe water instead of water filled pipe, that is to say in the pipeline is the soda coexistence of steam in the upper water in the lower layer, in climbing at the pipeline system usually, usually pipeline the steam is before the water rises to the height, easy to form steam resistance on high, but in the pipeline to climb high installation of a self independent turbocharger turbocharger, general structure is the top outlet pipe extends to the bottom of the water is independent of the supercharger, walked up from the bottom, when the condensation of water and steam into the pressurizer, water in the supercharger bottom steam in the upper pressure of water, promote the condensation of water climbing, especially the driver of new steam trap leakage of the condensed water is larger, the upper part of the steam pressurizer through consumption, natural cooling, pipe work The function of the back pressure is also continuously condensed into water to be sent away.

Because the condensed water exists in the turbocharger expansion, so the turbocharger condensate pressure is higher than that in the supercharger before the condensed water pressure, in this respect also improves the condensate climb ability is the most important, it has a certain role in water vapor resistance, especially in the conduit closed system of steam resistance elimination effect is obvious. This is also one of the problems that must be taken into consideration in the closed system compared with the open system.

電動凝結水回收流程圖  Electric condensate recovery flow chart