QYJB 型油净化装置

Type QYJB Oil Purifier

使用说明书
Operation Manual

四川自贡真空过滤设备公司

自贡真空过滤设备有限责任公司
Zigong Vacuum Filtration Equipment Co., Ltd.

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 1、用 途
1. Application
QYJB 型油净化装置主要用于净化或澄清汽轮机、燃气汽轮机以及水电站润滑油的
矿物油。汽轮机中的润滑油对汽轮机起到润滑、冷却、表面保护、密封等作用。润滑
油这些功能中的任何一种故障，都会使发电成本增加或效率降低，甚至会导致汽
轮机停机。因此，必须保证运行中润滑油的质量。
Type QYJB oil purifier is mainly used in purifying or clarifying the mineral oil of
lubricating oil for turbine, gas turbine and hydro power station. The lubricating oil in
steam turbine functions as lubrication, cooling, surface protection and sealing. If any of
these functions of the lubricating oil is fault, it may cause increase of generating cost or
reduction of efficiency, and even brings stem turbine to shut down. Therefore, the
quality of lubricating oil in operation should be guaranteed.
影响润滑油质量的主要因素是汽轮机运行过程中产生的污物。汽轮机的润滑油系统
是一个闭式循环系统，润滑油中的污染物主要来源于系统本身。由于温度的变化，
润滑油系统或油箱中冷凝水，通过轴承进入系统的水蒸汽，轴承或油冷却器的泄
漏等造成了水对润滑油的污染，这是最主要的污染因素。系统运行中的金属磨损或
锈蚀产生的微小颗粒等形成了固体杂质污染物。当然，系统外部的杂质，象空气中
的灰尘、污物也会通过轴承进入系统。造成对润滑油的污染。在润滑油系统中还存
在洗涤液或乳化液，它们对系统的润滑油影响是：使油乳化、加速锈蚀、降低油的
稳定性、消耗添加剂、降低润滑值。
The main factor that impacts the quality of the lubricating oil is the contaminant
produced in the operation of the steam turbine. The lubrication system of the steam
turbine is a closed circulation system, the contaminant in the lubricating oil mainly
derived from the system itself. The contaminations as condensate water in the
lubrication system or oil tank due to variation of temperature, the steam entering the
system from the bearings and the leakage of bearings or oil cooler are main factors of
pollution. The fine grain particles generated from the metal wear or rusting during the
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operation of the system form the solid impurities contaminants. Of course, the impurities
outside the system as dust and contaminants may also enter the system through the
bearings, causing pollution of the lubricating oil. Detergents or emulsified liquid may be
contained in the lubricating oil system, whose impact on the system is to cause oil to be
emulsified, accelerate resting, reduce the stability of the oil, consume the additives and
lower the lubricating value.

固体杂质污染物对润滑油系统的影响：降低油的稳定性。
The impact of solid impurities contaminant on the system is to reduce the stability of the
oil.

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 2.主要部件及其功能
2. Main components and their functions
QYJB 型油净化装置主要由进油阀、粗滤器、聚结分离器、进油泵、排油泵、加热器、
真空分离罐、冷凝器、真空泵、供液泵、精滤器、取样阀、出油阀、回油阀、水箱、单向
阀、电磁阀就地测量控制设备及自动控制箱等组成。主要部件功能如下：
Type QYJB oil purifier is mainly composed of oil inlet valve, coarse strainer, coalescing
separator, oil feed pump, oil drain pump, heater, vacuum separating tank, condenser,
vacuum pump, solution feed pump, secondary filter, sampling valve, delivery valve, oil
return valve, water tank, check valve, solenoid valve, on-site measurement control
device and automatic control box. Functions of main components are as follows:
粗滤器：可保护油泵不被大的颗粒杂质损坏，有效降低装置的故障率；
Coarse strainer: Protecting the oil pump from being damaged by large particles so as to
effectively minimize the failure rate of the machine.
聚结分离器：聚结分离器内的聚结滤芯是由经过特殊处理的玻璃纤维及其复合材
料进行适当组合而成，具有良好的亲水性。有滤除机械杂质，聚结水分的双重作用。
最内层的高精度滤材首先滤除油液中的机械杂质，外面的破乳聚结层将油液中的
微小水珠聚结成大水珠。尺寸较大的水珠会依靠自身的重量沉降到集水槽。尺寸较
小的水珠来不及沉降就会被油液夹带着流向分离滤芯。
Coalescing separator: The coalescing filter element in the coalescing separator is made
by proper combination of the specially treated glass fiber and its composite materials,
and has good hydrophilic. It has double functions as removing mechanical impurities
and coalescing the moisture. The utmost inner high precision filer material removes the
mechanical impurities in the oil first, the outside demulsification coalescence layer will
coalesce the tiny water drops into big drops of water. The drops of water with much
bigger size will settle to the water collecting groove depending upon their own weight.
The drops of water with much smaller size will be entrained in the oil and flow to the
separating filter element without having enough time to settle.
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分离滤芯由特殊处理的复合材料制成，具有良好的憎水性。当油液从外面向内流经
分离滤芯时，小水珠被有效拦截在滤芯外面，只让油液通过，不让水通过，从而
进一步分离水分。
The separating filter element is made of specially treated composite materials, and has
good hydrophobicity. When the oil is passing the separating filter elements while
flowing in from outside, the small drops of water will be effectively captured outside of
the element. In this way, it only allows the oil to pass not the water, enabling further
separation of the water.
加热器：当设备处于真空分离方式时，如果油液温度低于 00C，启动加热器，通
过自动恒温控制器，控制油的温度不高于 600C。用于降低油的粘度，便于水分的
分离。
Heater: When the machine is in vacuum separating mode, if the oil temperature is lower
than 00C, the heater will be turned on, the oil temperature is controlled to be bellow 60 0C
by automatic thermostat controller. It is used to lower the viscosity of oil so as to make it
easy to separate the water.
进油泵、排油泵：用于输送油液。
Oil feed pump and oil drain pump: To be used to deliver oil.
压力表：显示精滤器上压力，当压力表上压力过大（≥0.5MPa）时，表示堵塞严
重，需要清洗滤芯。此时，关闭排油泵，排空加热器、精滤器、预过滤器的油液，
再取出内部的滤芯清洗后重新装上。
Pressure gauge: Shows the pressure on the secondary filter, when the reading of the
pressure gage is too big (≥0.5 MPa), indicates the blockage is very serious and element
is required to clean. In this case, turn off oil drain pump, empty the oil in heater,
secondary filter, pre-filter, then take out the element and refit it as it is before after
cleaning.
压差控制器：显示聚结分离器内滤芯所承受的压力差，当其达到 0.1MPa 时，报警
并停机。此时，取出聚结滤芯（白色的为聚结滤芯），重新装上新的。取出分离滤
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芯（墨绿色的），用干净的柔软的布料轻擦其外表面，擦干净并重新装上。
Differential pressure controller: Indicates the pressure difference of the elements in the
coalescing separator, when it reaches 0.1 MPa, an alarm will be given and the machine
stops. At this time, take out the coalescing element (the white one), and replace it with a
new one. Take out the separating filter element (deep green), wipe its external surface by
using a clean and soft cloth, refit it after cleaning.
电接点压力表：当压力超过 0.3MPa 时，表示精滤器滤芯堵塞太严重 ，取出清洗
或更换。
Pressure gauge with electric contact: When the pressure exceeds 0.3 MPa, it indicates
that the element is seriously blocked and need to take it out for cleaning or replace it
when necessary.
3、使用说明
3. Instructions for use
使用前的准备工作：
Preparation before use:
1、打开电器柜，检查内部各处保险是否齐全，电气接头有无松动，电气元件是否
潮湿和损坏，清除电气各处杂物。
1. Open the electrical cabinet and inspect whether the internal fuses are complete or not,
whether there is any loosening with the electrical joints or not, whether the electrical
element is affected by moisture and damaged or not, remove various unnecessary objects
in the cabinet.
2、检查各处连接部位的螺栓，螺母有无松动，如有松动，须拧紧后再用。
2. Check whether the bolts and nuts at various connection locations become loosen or
not, tighten them if necessary.
3、按真空泵使用说明书的要求，往水箱内注满水。检查真空泵进出水管是否连接
好。
3. Replenish water to the water tank in accordance with the requirements in the
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operation manual of the vacuum pump. Check whether both inlet and outlet water pipes
have been well connected or not.
4、接上总电源和接地保护。
4. Connect main power lines and protective ground line.
5、将本机与待净化的储油容器用软管连接好，连接的管道内部必须清洁，储油容
器的液面不低于本机入口管 500mm 以下。
5. Connect this machine with the tank with oil to be purified by a hose, the inside of the
connected pipe should be clean, the level of oil storage vessel should not be lower than
500 mm from the inlet pipe of this machine.
QYJB 型油净化装置分为真空分离方式和聚结分离方式两种，汽轮机油在不同的
状态时，采用的分离方式不同，下面分别介绍真空分离方式和聚结分离方式：
Type QYJB oil purifier is classified into vacuum separation mode and coalescence-
separation mode. The separation mode for steam turbine oil will vary with different
states, the vacuum separation mode and coalescence-separation mode will be described
respectively bellow:

（一）、真空分离方式
(1) Vacuum separation mode
当汽轮机需要补充新油或汽轮机组检修后重新投入使用时采用真空分离方式（见
工作原理图）。此时，进油阀、粗滤器、加热器、电磁阀、真空分离罐、冷凝器、真空
泵、排油泵、单向阀、精滤器、出油阀工作。
The vacuum separation mode will be used when it becomes necessary to replenish new
oil or when the turbine set is put into service after maintenance (see the operating
principle diagram). In this case, the oil inlet valve, coarse strainer, heater, solenoid valve,
vacuum separating tank, condenser, oil drain pump, check valve, secondary filter and
delivery valve will operate.

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 （二）、聚结分离方式
(2) Coalescence-separation mode
经过真空分离方式运行一段时间后，从取样阀处取样化验油样，当油样的化验结
果能满足汽轮机的运行要求时，停止真空分离方式运行。进行聚结分离方式运行。
此时进油阀、粗滤器、电磁阀、进油泵、聚结分离器、放水阀、单向阀、精滤器、出油
阀工作。
After operation for a period of time in vacuum separation mode, take sample from the
sampling valve for laboratory test, if the test result of the oil sample can meet the
operation requirements of the steam turbine, stop the operation in vacuum separation
mode. Then, carry out operation in coalescence-separation mode. In this case, the oil
inlet valve, coarse strainer, solenoid valve, oil feed pump, coalescing separator, water
drain valve, check valve, secondary filter and delivery valve will operate.

当设备需要在线运行时，请一定用聚结分离方式。
When it becomes necessary for the machine to operate online, the coalescence-
separation mode should be used.

4、油净化装置电气操作说明
4. Description of electrical operation for oil purifier

本控制系统分三部分：
The control system is divided into three parts:
（一）、聚结分离系统
(1) Coalescence-separation system
工作人员打开总进油阀和出油阀。进油泵和进油电磁阀由 PLC 控制。只要将控制柜
面板上油分开关打开，，并同时启动进油泵工作，进入油分工作过程，启动停止
开关即可停该系统继续工作。
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The operator should open the main oil inlet valve and delivery valve. Both the oil feed
pump and oil inlet solenoid valve are controlled by PLC. If the oil separation switch on
the control panel is turned on, start the operation of the oil pump, and enter the oil
separation process; if the stop switch is rotated, the system will stop the operation
immediately.
（二）、真空分离系统
(2) Vacuum separation system
该系统主要由真空泵，真空进油电磁阀，排油泵及真空系统组成。由控制柜面板上
真空开关及停止开关经 PLC 进行自动控制。工作人员打开总进油阀和出油阀。启动
真空开关，首先系统打开真空泵，抽真空（同时进、出油电磁阀打开）经延时 20
秒左右，真空度逐渐上升至 0.08MPa 左右，真空进油电磁阀才打开进油，经加热
器内进入真空罐，油位达到下视孔中部位置时（约 1 分钟），自动启动排油泵进
行排油。系统进入正常真空滤油状态，若旋转面板上的停止开关，可停止真空系统
工作。
The system is mainly composed of vacuum pump, vacuum oil inlet solenoid valve and
vacuum system. The automatic control can be carried out by using the vacuum switch
and stop switch controlled by PLC. The operator should open the main oil inlet valve
and delivery valve. When rotating the vacuum switch, the system will turn on the
vacuum pump first, the vacuum pumping (the oil inlet and outlet solenoid valves will be
opened simultaneously) will last for a time delay of approximate 20 seconds, the
vacuum oil inlet solenoid valve will open the inlet oil after the vacuum degree gradually
rises up to about 0.08 MPa, the oil will flow into the vacuum tank through the heater, the
oil drain pump will be turned on automatically to deliver oil when the oil level reaches
the center of the lower sight hole (about 1 minute). The system enters normal state of
vacuum oil filtering, in case the stop switch on the control panel is rotated, the operation
of vacuum system can be stopped.
注意：当真空系统工作时，是启动不了油分系统的。同时在油分系统工作时是启动
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不了真空系统和手动回油系统的。（真空系统和油分系统是相互自锁的）。
Note: The oil separation system can not be turned on when the vacuum system is
operating. The vacuum system and manual oil return system can not be turned while the
oil separation system is operating. (The vacuum system and oil separation system are
interlocked.)
（三）、回油系统
(3) Oil return system
该系统实质上与真空系统设计的区别主要是，当油分系统或真空系统出现故障需
检修时，要将设备内的油全部排空，就可启动回油系统操作。出油阀打开，将面板
上手动回油开关打开，回油系统自动工作，打开真空泵，延时约 1 分钟启动排油
泵，并且回油电磁阀同时打开，值得注意的是，油分电磁阀和真空进油电磁阀不
打开。若在真空罐内的油还排不尽，还可手动启动排油泵排油。
The difference between this system and vacuum system design mainly is that when the
oil separation system or vacuum system becomes necessary to service after failure, the
operation of oil return system can be started after the oil in the machine should be
emptied completely. The oil outlet valve opens, turn on the manual oil return switch on
the control panel, the oil return system will start operating automatically, the vacuum
pump is turned on, the oil drain pump will turn on after a delay of about 1 minute. The
oil return solenoid valve will open at the same time. It is worth noting that oil separation
solenoid valve and vacuum oil inlet solenoid valve can not be opened. If the oil in the
vacuum tank can not be completely drained, the oil drain pump can be turned on
manually to drain oil out.
（四）、粗、精滤器堵塞差压报警
(4) Differential pressure alarming due to coarse and secondary filter blocking
该报警后能自动停止聚结分离和真空分离系统工作。打开粗、精滤器，取出滤芯，
在煤油中清洗后重新装上。
After this alarm, the coalescence-separation and vacuum separation systems can
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automatically stop. Open coarse strainer and secondary filter, take out the elements and
refit them after cleaning in kerosene.
（五）、油净化完成后，停机，放出聚结分离器下部的存水。
(5) After completion of oil purification, stop the machine and drain the accumulated
water in the lower part of the coalescing separator.

五、故障与排除方法
5.malfunction and solution
故 障 产
生 原 因 排 除 方 法
Malfunction reason solution
1. 管路接头或其它密封不良，
A、 产生漏气； 1. 检修；
真空度下降 2. 真空泵内真空泵油太脏； 2. 更换新油；
达不到额定 3. 真空泵叶片或其它机械损 3. 更换；
数值 坏； 4. 放掉冷凝器内的存水存
4. 大量水份混入被处理的油 油。
中，可凝性气体较多。
1. 排油泵的损坏；
1. 检修；
2. 前后过滤器压力大内部滤渣
2. 更换清洗内部各滤芯或
太多；
滤网
B、 3. 系统中有堵塞物；
3. 排除；
滤油量减少 4. 粗滤器网滤渣太多；
4. 清洗；
5. 排油泵的密封损坏；
5. 更换；
6. 吸油管道太长或进口吸头过
6. 缩短。
高。
1. 泵或传动电机的紧固螺钉松
C、 1. 紧固；
动；
排油泵有不 2. 更换；
2. 内部零部件损坏；
正常的响声 3. 补加或滤完为止。
3. 进油不足。
1. 泵或传动电机的紧固螺钉松
D、真空泵有 动； 1. 紧固；
不正常响声 2. 叶轮或排气阀片及内部零件 2. 更换。
损环。
F、排油泵及 1. 轴承缺油或损坏； 1. 加油或拆修更换；
电 机 温 度 太 2. 内部零件损坏或机械密封损 2. 拆修、更换。

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高 坏。
1. 待净化油含气、含水太多； 1. 作滤前处理；
G、真空罐内
2. 罐内真空度太高； 2. 略开真空放气阀；
泡沫太多
3. 液位阀失灵使液面太高。 3. 检修。
H、加热器开 1. 更换温度计；
1. 温度计失灵；
启后油温不 2. 检修导线或更换管状加
2. 内部管状加热器烧坏或电线
升高或升高 热器
断接。
极小 3. 检修。
1. 取样方法不正确或取样瓶不
1. 用干净瓶取样，按标准
干净；
取样法重新取样；
2. 前后过滤器有滤芯破坏；
2. 更换；
I、取样性能 3. 待净化油中水份、气体或杂
3. 作前级处理；
达不到要求 质太多；
4. 按 G 处理；
4. 真空罐内泡沫太多；
5. 按 A 处理；
5. 真空度太低；
6. 更换。
6. 过滤器失效或损坏。

Malfunction Reason Solution

1. Pipeline joint or other 1..Overhaul
seals leak gas. 2.Change new oil

A 、 vacuum degree 2.vacuum pump oil is too 3.change

descends,it can not dirty. 4. Discharge oil and
reach rated value
3.vacuum pump blade or water in condenser
other parts damage
4. A lot of water mix in
oil
B．Oil filtration amount 1.oil drain pump is 1.overhaul
is reduced damaged 2.change and clean
2.pressure of front filter inner filter elements or
and back filter is too
filter screens
big, a lot of filtration
3.remove

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 dregs in it 4.clean
3.blocks in system 5.change
4 、 a lot of filtration 6.shorten
dregs in coarse filter
screen
5、oil drain pump seal is
damaged
6、The oil suction pipe
is too long or inlet
section head is too
high.
1 、 Fastening bolts of 1. Tightening;

the pump or motor 2. Replace it;

become loosen; 3. Replenish.

C ． Abnormal sound
2 、 Damage of internal
with oil drain pump
parts;
3 、 Oil taking is not
sufficient.
1. Fastening bolts of the
pump or motor
D. Abnormal sound with become loosen;
1. Tightening;
vacuum pump 2. Damage with impeller
2. Replace it.
or discharge valve
plate and internal
parts.
1.bearing leak oil or
E.temperature of oil damage 1.feed oil or
drain pump and motor is 2. Internal parts or repair,change
too high 1.mechanical seal 2.repair,change
are damaged
F．Too much foams in 1. Too much air and 1.pre-filtration treatment;

vacuum tank water in the oil to be 2. Open vacuum release

purified; valve little
2. vacuum degree in the 3.overhaul
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 tank is too high.
3.liquid level meter is
damaged
1. The thermometer 1. Replace the
does not function; thermometer with new
G．Oil temperature 2. Internal tubular heater one;
does not rise up or rise is burnt or the wire is 2. Inspect and repair the
up too small after broken. wire or replace with new
turning on the heater 3. Temperature of the tubular heater;
temperature controller is 3. Adjust the set
not set properly. temperature.
1.take sample method 1.Use clean sampling
is not correct or bottle to take sample,
sampling bottle is not take sample again by
clean using standard
2.Filter element in front sampling method
or back filter is 2.change
H．The performance damaged 3.pre-filtration
of oil sample does not 3.Too much air, water 4.do as G
meet the requirement or impurities in the oil to 5.do as A
be purified; 6.change
4 、 Too much foams in
vacuum tank
5 、 The degree of
vacuum is too low
6.filter is damaged

六、特别注意事项！！

6. Special attentions!!

当设备运行前，一定打开出油阀。

The delivery valve must be opened before operation of the machine.

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该装置为全自动控制式，用户只需按电气操作说明上操作即可。

This purifier is automatic control mode, it just need the user to operate in accordance to the description about the

electrical operation.

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