How To Prevent the Damage of High-Pressure Starting Oil Pump 100LY-205 During Low Flow Operation

In thermal power plants, the oil pump is one of the core components to ensure the stable operation of the equipment. In particular, the high-pressure starting oil pump 100LY-205 is often used to drive key systems such as the main oil pump and regulating valve due to its strong pressure output capacity and high reliability. However, in actual operation, if the oil pump is in a low-flow state for a long time, it may cause a series of problems and even cause equipment damage. How to scientifically respond to this challenge has become a skill that power plant operation and maintenance personnel must master.

- The “invisible killer” of the oil pump: the hazards of low-flow operation

The normal operation of the high-pressure oil pump 100LY-205 depends on stable flow and pressure. When the flow rate is lower than the design value, the fluid dynamics inside the oil pump will change significantly. Taking the 100LY-205 oil pump as an example, its design flow rate is usually 205 cubic meters per hour. If the actual operating flow rate is lower than 100 cubic meters per hour for a long time, the following problems may occur:

Mechanical seal overheating failure: Under low flow conditions, the circulation efficiency of the liquid inside the oil pump decreases, causing the temperature of the mechanical seal area to rise sharply. High temperature will accelerate the aging of the sealing material and even cause dry friction on the sealing surface, eventually leading to leakage.
Intensified bearing wear: The lubrication of the high-pressure oil pump bearing depends on the flowing oil. At low flow, the lubrication effect is weakened, and the heat generated by the dry friction of the bearing cannot be taken away in time, which may cause the bearing to get stuck or burn.
Increased pump body vibration and noise: When the flow rate is insufficient, the flow field inside the oil pump is turbulent, and eddy currents and cavitation are prone to occur. This will not only increase vibration and noise, but may also cause fatigue damage to the pump body and pipeline.
Motor overload risk: The power consumption of the high-pressure oil pump is closely related to the flow rate and head. When running at low flow, the motor may overheat due to abnormal load, and even trigger a protective shutdown.

- Practical strategies to prevent low-flow operation

In response to the above risks, power plant operation and maintenance personnel can effectively extend the service life of high-pressure oil pump 100LY-205 and ensure system safety through the following measures:

1. Install a minimum return line

This is the most direct and efficient solution. By setting a bypass line between the outlet and inlet of the oil pump, when the flow rate is lower than the set value, the excess oil automatically flows back to the inlet to maintain the minimum flow demand inside the pump body. For example, installing a flow-limiting orifice plate in the return line of the 100LY-205 high-pressure oil pump can ensure that even under low-load conditions, the pump body can still maintain sufficient fluid circulation inside to avoid overheating of mechanical seals and bearings due to lack of oil.

2. Optimize pipeline design to reduce resistance loss

The flow rate of high-pressure oil pump 100LY-205 is significantly affected by the pipeline system. If the pipeline is too long, there are too many elbows or the pipe diameter is too small, it will lead to increased head loss, forcing the oil pump to operate in a low-efficiency range. To this end, the following improvements can be made:

Shorten the length of the pipeline: Rationally plan the layout of the oil pump and oil-using equipment to reduce unnecessary elbows and valves.
Enlarge the pipe diameter: According to the actual flow demand, select the appropriate pipe diameter to reduce the flow rate and friction loss.
Clean the filter regularly: If the filter at the inlet of the oil pump is clogged, it will significantly limit the flow. Regularly check and clean the filter to ensure that the oil pump is always in the best working condition.

3. Dynamic monitoring and intelligent adjustment

Modern oil pump systems can achieve dynamic monitoring through sensors and automatic control technology. For example, a flow meter and a pressure transmitter are installed at the outlet of the 100LY-205 oil pump to monitor the operating parameters in real time. When the flow rate is detected to be lower than the set threshold, the control system can automatically adjust the valve opening or start the backup pump to maintain the flow balance. In addition, some high-end oil pumps are also equipped with a temperature monitoring function. Once the temperature in the mechanical seal area rises abnormally, an alarm is immediately triggered and the shutdown protection is linked.

4. Regular maintenance and status evaluation

Even if the above measures are taken, the oil pump still needs regular maintenance to ensure long-term reliability. Operation and maintenance personnel should focus on the following aspects:

Check mechanical seals: Disassemble mechanical seal components regularly to observe whether the sealing surface is worn, scratched or has impurities accumulated. If any abnormality is found, replace the seal or grind and repair it in time.
Lubrication system maintenance: The lubricating grease of bearings and gearboxes needs to be replaced periodically to avoid increased friction due to oil deterioration.
Calibrate instruments and valves: The accuracy of flow meters, pressure gauges and regulating valves directly affects the judgment of operating parameters. Regular calibration ensures that the data is true and reliable and avoids misoperation.

High-pressure starting oil pump 100LY-205 plays an irreplaceable role in thermal power plants. However, its performance is inseparable from scientific operation and maintenance strategies. By installing a minimum return line, optimizing pipeline design, dynamically monitoring the operating status and regular maintenance, the risks brought by low-flow operation can be effectively avoided.

When looking for high-quality, reliable oil 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

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