Full-Process Response Guide of DFB-II-125-80-250 Cooling Water Pump Leakage

In thermal power plants or industrial cooling systems, the stator cooling water pump DFB-II-125-80-250 is a key component to ensure the safe operation of the equipment. It cools the generator or other high-temperature equipment by circulating cooling water to prevent performance degradation or equipment damage caused by overheating. However, the cooling water pump may leak during long-term operation due to seal aging, mechanical wear or improper operation. The severity of the leakage directly affects the stability and safety of the system. Therefore, mastering the graded disposal method of cooling water pump leakage is a core skill that operation and maintenance personnel must master.

I. Leakage classification: from “small problems” to “big hidden dangers”

The leakage of cooling water pumps is usually divided into three levels: slight leakage, medium leakage and severe leakage. The disposal method for each level is different, and it is necessary to quickly judge and take corresponding measures according to the actual situation.

1. Slight leakage: the “signal light” of daily maintenance

Slight leakage is manifested as occasional dripping of the cooling water pump body or seal, and the flow rate has not decreased significantly. This leakage may be caused by aging of the seal, loose packing or changes in the installation gap. At this time, the operation and maintenance personnel need to immediately check the sealing structure of the pump body (such as the dynamic ring and static ring of the mechanical seal) to confirm whether there is wear or deviation. If slight scratches are found on the sealing surface, it can be repaired by grinding or the packing can be replaced; if the packing gland is not tightened, the bolt tightness needs to be readjusted.

It is worth noting that the sealing design of the stator cooling water pump DFB-II-125-80-250 usually adopts a multi-layer structure. Minor leakage may only affect the local sealing effect, but if it is not handled in time, it may evolve into a bigger problem. For example, air mixed in the cooling water will cause the pump efficiency to decrease and even cause cavitation. Therefore, in daily inspections, it is necessary to focus on the sealing status of the pump body, valve joints and bearing box to ensure that early problems are discovered in time.

2. Medium leakage: “Alarm” of system operation

When the leakage volume increases to several milliliters per minute, accompanied by fluctuations in cooling water pressure or increased vibration of the pump body, it is a medium leakage. This stage may be caused by the failure of the mechanical seal of the cooling water pump DFB-II-125-80-250, cracks in the pump casing, or corrosion on the valve sealing surface. At this time, the pump needs to be stopped immediately and the following operations need to be performed:

Isolate the system: close the inlet and outlet valves of the pump, cut off the cooling water supply, and prevent the leakage from expanding.

Investigate the root cause: disassemble the pump casing and check the wear of the mechanical seal. If grooves or cracks appear on the surface of the dynamic ring or static ring, new parts need to be replaced; if there are small cracks in the pump casing, epoxy resin glue can be used to repair them, and monitoring should be strengthened during subsequent operation.

Temporary plugging: If the parts cannot be replaced immediately, metal hoses or tapes can be used to temporarily plug the leak point, and the operating parameters of the pump (such as reducing the speed or flow) can be adjusted to reduce the risk of leakage.

The treatment of medium leaks needs to take into account both timeliness and safety. For example, a power plant once failed to deal with the medium leak of the cooling water pump in time, causing cooling water to penetrate into the generator winding and cause insulation failure. Therefore, the operation and maintenance team needs to act decisively at the beginning of the leak to avoid escalation of the problem.

3. Severe leakage: the “red line” of emergency shutdown

When the leakage of the cooling water pump reaches more than tens of milliliters per minute, accompanied by a large amount of cooling water spraying out, abnormal increase in pump body temperature or motor overload, it is a serious leakage. This situation is usually caused by complete failure of the sealing system, rupture of the pump casing or external impact. At this time, the following steps must be performed immediately:

Emergency shutdown: cut off the power supply and close the inlet and outlet valves of the cooling water pump DFB-II-125-80-250 to prevent further loss of cooling water or further damage to the equipment.

Personnel evacuation and protection: If the leaking medium is corrosive or high temperature, it is necessary to evacuate the surrounding personnel and wear protective equipment (such as chemical protective clothing, goggles) for subsequent treatment.

System isolation and maintenance: completely isolate the cooling water pump, disassemble the pump body after draining the cooling water, and check the internal structure (such as impeller, shaft neck, seal chamber). If the pump casing is broken, a new pump needs to be replaced; if the mechanical seal assembly is damaged, it needs to be reassembled and the sealing performance tested.

The treatment of severe leakage must give priority to personnel safety and equipment integrity. For example, a chemical plant once caused a steam explosion due to a serious leakage of a cooling water pump, resulting in equipment damage and casualties. Therefore, the emergency plan must clearly define the shutdown process, isolation measures and maintenance standards to ensure that similar incidents do not occur again.

II. Prevention and long-term management of cooling water pump leakage

The hierarchical treatment of cooling water pump DFB-II-125-80-250 leakage is important, but preventive maintenance is the root of risk reduction. The following suggestions can help the operation and maintenance team achieve long-term stable operation of cooling water pumps:

1. Regular inspections and status monitoring

Establish an inspection system for cooling water pumps DFB-II-125-80-250, focusing on the integrity of seals, bearing boxes and pump casings. For example, check the wear of mechanical seals every month, and detect pump body vibration and temperature changes every quarter. Using infrared thermal imagers or ultrasonic thickness gauges, potential leakage risks can be discovered in advance.

2. Optimize sealing materials and design

For the working environment of the cooling water pump DFB-II-125-80-250 (such as high temperature, high pressure or corrosive media), choose wear-resistant and anti-aging sealing materials (such as fluororubber or graphite seals). At the same time, optimize the packing installation process to ensure that the joint angle (30°~45°) and the clamping force meet the specifications to avoid leakage due to improper installation.

3. Operation training and emergency drills

Train the operation specifications of the cooling water pump DFB-II-125-80-250 for operation and maintenance personnel, emphasizing the start-stop process, pressure regulation and leakage identification points. Organize emergency drills regularly to simulate leakage scenarios of different levels to ensure that the team can respond quickly in real accidents.

4. Data recording and trend analysis

Archive the handling process, cause analysis and maintenance records of each leakage incident, and use data analysis tools to identify high-frequency fault points.

As a core component of the power plant generator cooling system, the leakage of the cooling water pump DFB-II-125-80-250 not only affects the efficiency of the equipment, but also may cause cascading failures. Through a graded disposal strategy – from daily maintenance for minor leaks, to emergency shutdowns for serious leaks, to long-term preventive management, the operation and maintenance team can minimize risks and extend the life of the equipment.

When looking for high-quality, reliable centrifugal pumps, Yoyik is undoubtedly a choice worth considering. The company specializes in providing a variety of power equipment including steam turbine accessories, and has won wide acclaim for its high-quality products and services. For more information or inquiries, please contact the customer service below:
E-mail: sales@yoyik.com
Tel: +86-838-2226655
Whatsapp: +86-13618105229

Yoyik offers various types of power plants spare parts for steam turbines, generators, boilers as below:
Boiler Feed Water Pump Mechanical Seal Zu 44-45
Throttle Valve L41H-25
Set Glove Valve Along With Electric Actuator. 100J941Y40
Electric Stop Valve J961Y-P55200V
Reheater Inlet Water Pressure Test Plug Valve Sd61H-P36.562 Wcb
Vavle Spindle Gland 174-141744-7-2
Check Valve H44H-64
Stop Valve J61Y-P5440V
Stop Valve J61Y-P54.5160V
Reheater Inlet Plugging Valve Sd61H-P4064 Sa-105
Check Valve H61Y-420V
Pneumatic Control Valve T667H-600Lb
Solenoid Valve Scg553A017Ms
Electric Butterfly Valve D943H-10C
Stop Valve J61Y-250V
Throttle Valve L61Y-P55.5190V 12Cr1Mov
Reheat System Electric Drain Valve Wj20N-40P
Bellows Valves Wj41W-40P
Solenoid Valve Q5100-41
Stop Valve J65Y-320 25
Reheater Outlet Plug Valve Sd61H-P58.564V Sa-182 F91
Pressure Hose S100-Ac-Ac-0150
Vacuum Pump Working P-1916
Electromagnetic Directional Valve 4We6C-L6X/Ofew220-50Nz4/V
Servo Valve D633-199
Servo Valve Flushing Plate Parts G771K202A
Electric Butterfly Valve D943W-1C
Gate Z61Y-600Lb
Turbine Butterfly Valve D371J-10
Relief Valve Y25-20