In-depth application and detailed case analysis of vertical multistage submerged long-shaft deep-well turbine pumps in industrial and mining fields

In-depth application and detailed case analysis of vertical multistage submerged long-shaft deep-well turbine pumps in industrial and mining fields

The vertical multi-stage submerged long-shaft deep-well turbine pump is a core equipment for high-reliability fluid conveyance in the industrial and mining fields. With its unique structure, where the motor is arranged above the well and the pump body is submerged, it perfectly meets the stringent requirements of long-term continuous operation, complex medium conveyance, and high-load stable water supply in mining and industrial scenarios. Currently, the vertical submerged multi-stage long-shaft deep-well pump has been widely applied in niche areas such as mining and metallurgy, thermal power generation, and petrochemical industry.
· Strong continuous operation capability under extreme conditions: The motor dissipates heat naturally on the ground, eliminating the risk of insulation failure due to immersion in water as seen in submersible motors. It can achieve uninterrupted full-load operation for thousands of hours, fully meeting the water supply needs of industrial and mining enterprises for 24-hour continuous production.
· Wide adaptability to complex and highly corrosive media: The flow-through components can be customized with special materials such as high-chromium alloy, super duplex steel, and rubber lining, allowing for the transportation of special media such as mine drainage containing coal slag and rock debris, mildly corrosive chemical wastewater, and high-temperature industrial circulating water. Its resistance far exceeds that of ordinary submersible pumps.
· Substantially reduced maintenance costs: All core power components are arranged on the ground, eliminating the need to lift the entire pump out of the well or pool for routine inspections, oil changes, and troubleshooting. The modular design allows for direct extraction of the internal core for maintenance, without the need to drain the water from the sump, significantly reducing unplanned downtime.
· High lift and large flow covering all operating conditions: The multi-stage impeller tandem structure can achieve a maximum lift of 350 meters and a single pump flow rate of up to 1600 m³/h, allowing direct water extraction from mines and deep wells hundreds of meters deep, meeting the water demand of large-scale production in industrial and mining enterprises.
· High adaptability to water level fluctuations: The long-axis structure allows for significant rises and falls in the liquid level. Even if the water level drops several meters, the pump's suction inlet remains submerged, preventing frequent dry runs and shutdowns. It perfectly adapts to the special operating conditions of significant fluctuations in mine drainage levels.
1. Mine shaft drainage: Extracting mine inflow water containing coal slag and rock debris from the underground water collection sump is the core equipment of the mine safety production drainage system, directly ensuring that the underground working face is not flooded by water.
2. Water supply for thermal power plant production: Extracting cooling water from deep wells or circulating water pools to provide circulating makeup water for steam turbine units and boilers is a key supporting equipment for the stable operation of the thermal system in power plants.
3. Water supply and drainage in petrochemical parks: Provide industrial fresh water for chemical production plants, while transporting mildly corrosive chemical production wastewater, meeting the high-level explosion-proof and high-reliability safety requirements of chemical parks.
4. Circulating water supply for metallurgical steel plants: Provides cooling circulating water for blast furnaces and steel rolling production lines, capable of withstanding high temperatures and media containing a small amount of iron oxide scale particles, ensuring continuous and stable operation of the metallurgical production lines.
5. Emergency fire water supply for industrial and mining enterprises: Water is directly drawn from deep fire wells or underground fire water pools, with the motor remaining dry throughout the process. Its reliability in starting under fire conditions is significantly higher than that of ordinary submersible pumps, fully meeting the high-level fire protection standards required in industrial and mining sites.
Case 1: Renovation project of the main drainage system of a large coal mine in Shanxi
· Project background: A large-scale underground coal mine in Shanxi with an annual output of 3 million tons. The depth of the underground water collection sump is 120 meters. The mine inflow water contains a large amount of coal slag and rock debris, with a maximum fluctuation range of 15 meters. The original submersible pumps stopped working due to wear and tear on average every three months, seriously affecting the safe production of the coal mine.
· Equipment selection: The Shanghai Jiuhong LY type wear-resistant vertical submerged long-shaft deep-well pump is selected. All flow-passing components are made of high-chromium wear-resistant alloy, and the impeller and guide vane undergo special hardening treatment. The pump adopts a modular extractable core design and is equipped with an automatic water level start-stop electric control system.
· Actual operational effect: After the equipment was put into operation, the average trouble-free operation time increased from 90 hours to 8,000 hours, and the wear rate decreased by 70%. During maintenance, there is no need to drain the water from the sump; the inner core can be directly extracted for maintenance. The single maintenance time was shortened from 8 hours to 1.5 hours, reducing unplanned downtime losses by over 2 million yuan annually. This fully meets the stringent requirements of high-load continuous drainage in coal mines.
Case 2: Circulating Water Make-up Project of a Thermal Power Plant in Hunan Province
· Project background: A 2×660MW thermal power plant in Hunan, which sources its production water replenishment from a 220-meter-deep underground water well within the plant area. It requires a single pump flow rate of 400m³/h, operating continuously for 24 hours. The medium temperature is maintained at 55℃ all year round, placing high demands on equipment operational efficiency, which directly affects the power generation energy consumption of the plant.
· Equipment selection: The Lijia Machinery customized high-efficiency and energy-saving vertical submerged long-shaft deep-well pump is selected. The flow passage components are made of 304 stainless steel, and the hydraulic model has been optimized through CFD design. It is equipped with a national standard high-efficiency and energy-saving motor and connected to the power plant's DCS control system.
· Actual operational performance: After the equipment was put into operation, the actual operational efficiency stabilized at 83%, which is 3 percentage points higher than the national first-level energy efficiency standard. Compared to the original old pump, the single pump saves over 120,000 kWh of electricity annually. It has been operating continuously for 4 years without experiencing shaft wear or motor overheating failures, fully ensuring the stable water replenishment needs of the power plant's generator units.
Case 3: Industrial Water Supply Project for a Large Petrochemical Park in Shandong
· Project background: A provincial-level chemical industrial park in Shandong Province, which houses over 20 chemical production enterprises. The industrial water supply is sourced from a 180-meter-deep groundwater well within the park. The equipment is required to meet the explosion-proof grade Exd II BT4, capable of withstanding groundwater with trace corrosion, with a single pump flow rate of 350m³/h, and operating continuously throughout the year.
· Equipment selection: The Lijia mechanical explosion-proof vertical submerged long-shaft deep-well pump is selected, with flow passage components made of 316L stainless steel, equipped with an explosion-proof motor and an explosion-proof electric control cabinet. The overall equipment has obtained 3CF fire certification and meets the dual requirements of production water supply and fire water supply.
· Actual operational performance: After the entire system was put into operation, it has been running without any malfunction for three consecutive years. Its explosion-proof performance fully complies with the safety regulations of the chemical industrial park, and its water supply reliability has reached 99.99%. This completely avoids the major safety hazards caused by long-term immersion of submersible water supply pumps, such as motor insulation failure and explosion-proof failure, providing a stable water supply guarantee for the safe production of chemical enterprises in the park.
· Prioritized model selection: When conveying media containing solid particles, it is necessary to use high-chromium alloy flow passage components. For conveying corrosive media, 316L or duplex steel materials should be selected. In explosion-proof areas, an Exd-rated explosion-proof motor must be equipped. The head must have a margin of more than 20% to accommodate complex industrial and mining conditions.
· Installation precautions: Install a wear-resistant guide bearing every 2-3 meters along the long drive shaft, ensuring the radial runout of the control shaft is ≤0.05mm/m. When conveying sewage or media containing particles, an external, independent clean lubricating water system must be connected to prevent particle wear on the guide bearing.
Key points of daily operation and maintenance: Conduct vibration and temperature inspections once a week, check the wear condition of the guide bearing every quarter, and during annual overhaul, extract the inner core to inspect the wear amount of the impeller and guide vane. If the wear exceeds 10%, replace them immediately to avoid unexpected failures that lead to unplanned downtime of the production line.