虹(泵)吸式排泥机

I. Uses
The虹(pump)-type sludge suction and discharge machine is primarily used for sludge removal in municipal water treatment plants, wastewater treatment plants, and rectangular sedimentation tanks.
II. Structure and Operating Principle This equipment adopts a traveling bridge configuration, and the sludge suction method is available in two types: siphon-type and pump-type. Generally, siphon-type sludge suction units are selected for above-ground sedimentation tanks, while pump-type units are used for semi-underground sedimentation tanks.
The sludge suction machine mainly consists of the following components:
1. Traveling drive and transmission mechanism: The large-span sludge suction machine is driven directly by two sets of variable-speed motors and cycloidal gear reducers, with couplings ensuring synchronous operation of the traveling wheels at both ends. The small-span sludge scraper is driven by a single set of variable-speed motor and reducer; through bevel gear reversing, the central shaft drives the traveling wheels at both ends, with speed and direction being adjusted via the variable-speed gear and reversing switch, respectively. The variable-speed motor and reducer, via bevel gear reversing, drive the traveling wheels at both ends through the central shaft.
The wheels are shifted and reversed using a gearshift lever and a reversing switch, respectively.
3. Another type of speed variation is achieved by changing the travel mode and track configuration; the motor is a standard motor, with all other components remaining the same as before. The frame structure is as follows: 4. The main girder is either a box girder (for large spans) or a plate girder (for small spans), with cantilevers and sludge suction ports; the support for the sludge suction pipes is provided by a steel truss. Sludge suction ports and siphon pipe assemblies
5. The flat-mouth sludge suction nozzle is installed between the diamond-shaped sludge collection plates and discharges the sludge out of the tank via a separate siphon assembly. The siphon action of the assembly is generated by an external vacuum system; during winter shutdown, the vacuum break pipe on the siphon assembly is activated to disrupt the siphon and release the sludge.

III. Model Description

IV. Main Technical Parameters

Materials
Sludge suction machine truss: stainless steel or Q235A steel with anti-corrosion coating; walkway deck: stainless steel or hot-dip galvanized steel grating; sludge scraper: 304 stainless steel with rubber; rails: 15 kg/m and 22 kg/m (Q235-A); sludge suction pipe: 304 stainless steel; local control cabinet and electrical control box: 304 stainless steel.
V. Supply, Installation, and Commissioning
The siphon sludge suction machine comprises a gantry steel girder, traveling crane rails, a drive unit, a siphon system, power distribution and travel control equipment, a local control cabinet, an electrical control cabinet, and electric slip-rail conductors. Installation
1. The clearance between the scraper and the pool bottom shall not exceed 50 mm, and the clearance between the sludge suction nozzle and the pool bottom shall not exceed 100 mm.
2. When installing the wheels, ensure that all four wheels are simultaneously in contact with the track.
3. The non-parallelism between the two rails shall be 10 mm, and the elevation tolerance shall be 0.5 mm.

VI. Operation
The design specifies continuous operation for 24 hours under high turbidity conditions, with sludge discharge time and frequency adjustable during operation based on the sludge volume. All components of the sludge suction unit are configured to meet the requirements for continuous operation, and the drive system is capable of operating at full load under ambient temperatures up to 45°C. The sludge suction unit operates by moving while simultaneously sucking sludge; for pump-suction systems, submersible sewage pumps equipped with cutting devices are used to continuously convey bottom-settled sludge from the sedimentation tank into an external sludge discharge trough. One such submersible pump is mounted on a gantry crane.
The design operating conditions for the sludge suction machine stipulate that it must operate normally even under empty-tank conditions. When running at rated load, the machine shall accumulate no fewer than 8,000 hours of fault-free operation, with a service life of at least 10 years. The travel speed of the sludge suction machine is approximately 1–2 m/min, and it is propelled by steel rails and steel wheels.
The sludge suction unit operates smoothly and reliably under all operating conditions, including empty-tank conditions, with no impact, vibration, or abnormal noise. The noise level of the drive unit shall not exceed 80 dB(A), and the temperature rise of the drive unit and all bearings shall not exceed 45°C.
The sludge suction machine is equipped with a synchronous motor fitted with a protective cover; the motor power is specified by the manufacturer, and the motor is a two-speed type. The reduction gear shall be sourced from Guo’an or an equivalent or superior brand; the submersible pump shall be a well-known domestic brand.
The local control cabinet is mounted on the sludge-discharge gantry and houses the electronic equipment for the control and monitoring systems. The power supply for the local control cabinet is 380/220 V, three-phase, 50 Hz AC. The control panel is equipped with a manual/automatic transfer switch, start, stop, and emergency-stop pushbuttons, as well as indicator lights for operation and fault conditions. The cabinet shall contain all electrical components required to supply power to all electrical equipment within this system (including cable trays, cable supports, terminal blocks, etc.), with component selection limited to Schneider, Siemens, or ABB. The local control cabinet shall be capable of outputting a 4–20 mA signal. Its protection rating shall be no lower than IP65. The cabinet shall be provided with one 10 A, 220 V power feed and one 16 A, 380 V backup power feed. The sludge suction unit shall be operable in both manual and automatic modes. The operating modes of the sludge suction unit include local manual control, local timed control, and automatic control.
Local manual control
Switch the “Manual/Automatic” selector on the control panel to the “Manual Control” position, then press the “Start” button to initiate manual control operation. Local timed control.
Manually set the timing in the local control box of the sludge suction unit, and the unit will automatically start and operate for one cycle on a timed basis.

Automatic Control
Automatic operation can be achieved by switching the “Manual/Automatic” selector on the control panel to the “Automatic Control” position. The sludge scraper operates according to a pre-set timing sequence. Upon receipt of the start signal, the sludge suction unit initiates a complete operating cycle.
Perform a manual trial run of 1–2 cycles to check for scraping against the pool walls and bottom, as well as for any obstructions or debris. Then start the motor to operate the sludge suction unit, while simultaneously inspecting the motor for abnormal conditions, the reducer for overheating, the entire unit for unusual noise, the reversing mechanism for responsiveness, and the operating speed for appropriateness. Next, activate the vacuum system to verify the effectiveness of siphon formation and the tightness of the gate valves.
VII. Maintenance and Inspection
1. Regularly inspect and top up the lubricating oil in the reducer to the specified oil level.
2. Ensure 1–2 trips are operated each day.
3. The lubricating oil in the reducer shall be replaced every five months.
4. Conduct a comprehensive, annual equipment inspection and promptly replace any severely worn components.
5.1 Conduct a comprehensive overhaul of the entire equipment once every 2 years, including repainting to prevent paint peeling and subsequent corrosion.

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Keywords: trash-rack equipment, sedimentation equipment, flap-valve filter bed