BC Series Industrial Diesel Engine Emergency Pump

The diesel engine driven water pump unit produced by Shanghai Kaiquan Pump Industry Group Co., Ltd. is developed and designed in accordance with relevant domestic and foreign standards.
In important water supply situations such as cooling circulation and boiler water replenishment, when there is a power supply failure, or when the power supply is normal but the electric pump cannot be put into use due to its own failure, this diesel engine pump can be automatically put into operation to ensure normal water supply and ensure the safety of life and property.
The equipment is technologically advanced and highly automated Due to its superior performance, complete protection functions, reasonable structure, easy installation, and high cost-effectiveness. This system is equipped with various automatic control functions to ensure that the unit can stand by normally for a long time and be put into operation at any time.

Scope of work

Diesel emergency pumps are used in large area and space fire water supply systems such as aircraft maintenance depots, petrochemical oil and gas depots, and thermal power plants; Emergency water supply system for high-risk equipment such as smelting furnace circulating cooling and boiler water replenishment.

Conditions of Use

Environmental atmospheric pressure>90kPa

Environmental temperature 5C-40℃

Air relative humidity ≤ 80%

Performance characteristics

Wide range of pump types:

The unit adopts single stage double suction pumps, boiler feedwater pumps and other pump types, with a wide range of flow and pressure.

Automatic operation:

When the water pump unit receives remote control instructions, or signals such as power outage or electric pump failure (start), the unit will automatically start and operate. The equipment has automatic program process control, automatic data acquisition and display, and automatic fault diagnosis and protection.

Process parameter display:

Display the current status and parameters of the equipment based on its actual operating conditions. The status display includes starting, running, accelerating, decelerating, (idling, full speed) stopping, etc. Process parameters include speed, oil pressure, water temperature, oil temperature, battery voltage, cumulative operating time, etc.

Alarm functions:

Start failure alarm, low oil pressure alarm and shutdown, high water temperature alarm, high oil temperature alarm, low battery voltage alarm, low fuel level alarm, overspeed alarm and shutdown.

Multiple starting methods:

On-site manual start stop control, remote start stop control from the control center, and starting operation after power outage.

Status feedback signals:

Operation indication, startup failure, comprehensive alarm, control power supply closure, and other status feedback signal nodes.

Automatic charging:

During normal standby, the control system automatically charges the battery by floating. When the machine is running, the diesel engine’s built-in charging generator will charge the battery.

Adjustable working speed:

When the flow rate and head of the water pump do not match the actual requirements, the rated speed of the diesel engine can be adjusted.

Dual battery starting circuit:

When one set of batteries fails to start, it will automatically switch to another set of batteries (optional).

Maintenance-free batteries: Do not require frequent addition of electrolyte.
Pre heating of water jacket: It is easier to start the unit when the ambient temperature is low.

Equipment Composition

Water pump

Horizontal single-stage open double suction centrifugal pump (KQSN), horizontal multi-stage boiler feedwater pump (DG)

Diesel engine

The diesel engine driven water pump units produced by Shanghai Kaiquan Pump Industry (Group) Co., Ltd. are powered by well-known domestic and foreign brands of diesel engines, with priority given to products with high performance, high reliability, strong load capacity, and low pollution emissions. This series of products usually uses diesel engines from companies such as Wuxi Power, Chongqing Cummins, Dongfeng Cummins, IVECO, and Xichai, with speeds of 990r/min, 1500r/min, and 2900r/min.

The primary cooling method for the emergency pumps of all BC diesel engines in our company is closed water cooling. The secondary cooling methods include fan water tank cooling and heat exchanger cooling. The hot water generated during the operation of the diesel engine flows from the outlet pipe of the diesel engine to the heat exchanger, and the cold water in the cooling pipe of the heat exchanger cools the circulating hot water of the diesel engine. The circulating hot water of the diesel engine is cooled and then returned to the diesel engine, And cool down the diesel engine

The cold water inside the cooling pipe of the heat exchanger rises in temperature after cooling the circulating hot water of the diesel engine, and is pumped to the cooling tower for cooling. After cooling, it is sent to the cooling pipe of the heat exchanger.

Connection device

The diesel engine and water pump of this product are generally directly connected by an elastic sleeve pin coupling, which has the characteristics of easy installation, low cost, small volume, reliability, and safety. For diesel engines that do not match pump speeds or when using a long shaft pump, a reducer or angle gearbox coupling is required. The cooling method of the reducer and gearbox should be considered, and the cooling method should not be a cooling method that requires power supply.

Control cabinet

The KQK900 series control cabinet developed and produced by Kaiquan Company is used for supporting water supply equipment such as fully automatic diesel engine fire protection, production, and daily life. This series of products is fully functional, reliable, easy to use, sturdy, and beautiful,

Battery

The equipment is equipped with maintenance free batteries, 12V/200Ah. Depending on the capacity and starting requirements of the machine’s starting motor, different quantities of batteries can be equipped. To meet the personalized needs of customers, other brands and models of battery products can also be selected according to customer specific specifications.

Fuel tank

According to the requirements of equipment power, fuel consumption, and operating time, various volumes of fuel tanks can be selected. Generally, emergency products are selected for 4-6 hours. Our company provides 50L-2000L fuel tank products of various specifications.

Product selection

Selection instructions

This series of diesel emergency water supply equipment can be equipped with 10kW-1500kW imported and domestic diesel engines of various series. Only some models are listed in the table. Our company can design and produce them separately according to user requirements to achieve flexible combination of flow and head. The company will continuously adopt new technologies and processes to improve product performance and quality. This table is for selection and installation reference only, and will be revised accordingly in case of changes.

Supporting KQSN double suction pump

Comprehensive technical parameter table
Number	XBC Device Model	Traffic	Pressure	Water pump model	Diesel engine parameters				Tank	Storage Battery
Number	XBC Device Model	L/s	MPa	Water pump model	Model	Power	Speed	Manufacturer	Tank	Storage Battery
1	BC5,4/1360-600M17S	1360	0.54	KQSS600-M17/508	WD360TAB110	1100	1500	Wudong	2000L	6-Q(W)-200=4
2	BC8,5/1050-600M123	1050	0.85	KQSS600-M12/580	KTA50-P1645	1227	1500	Chongkang	2000L	6-Q(W)-200=4
3	BC6,4/611-500M12S	611	0.64	KQSS500-M12/485	KT38-P830	584	1500	Chongkang	1000L	6-Q(W)-200=4
4	BC8/570-400M9W	570	0.8	KQSW400-M9/573	KTA38-P980	664	1500	Chongkang	1500L	6-Q(W)-200=4
5	BC5,9/570-400M13W	570	0.59	KOSW400-M13/481	KTA19-P700	470	1800	Chongkang	900L	6-Q(W)-200=2
6	BC5/560-400M13W	560	0.5	KQSW400-M13/470	WD269TAB43L	432	1500	Wudong	900L	6-Q(W)-200=2
7	BC6/558-400M13W	556	0.8	KQSW400-M13/481	WD269TAB48L	482	1500	Wudong	900L	6-Q(W)-200=2
8	BC7,5/500-500M128	500	75	KQSS500-M12/485	YC8TD840L	580	1500	Yuchai	1000L	6-Q(W)-200=2
9	BC7,5/350-350M9	350	75	KOSN350-M9/503	WD269TAB41L	418	1500	Wudong	700L	6-Q(W)-200=2
10	BC18,5/250-300M4	250	1.85	KQSN300-M4/685	KTA38-P1200	895	1800	Chongkang	1500L	6-Q(W)-200=4
11	BC18/204-300M3	204	1.8	KQSN300-M3/738	KTA38-P1300	&B0	1500	Chongkang	1500L	6-Q(W)-200=4

Supporting DG type boiler feedwater pump

Comprehensive technical parameter table(Supporting Dongkang)
Number	XBC Device Model	Traffic	Pressure	Water pump model	Diesel engine parameters				Tank	Storage Battery
Number	XBC Device Model	L/s	MPa	Water pump model	Model	Power	Speed	Manufacturer	Tank	Storage Battery
1	BC15/7-DG25-50X3	7	1.5	DG25-50X3	QSB3.9-P50	36	2900	Dongkang	100L	6-Q(W)-200=2
2	BC40/7-DG25-50XB	7	4	DG25-50XB	OSB3.9-P115	B5	2900	Dongkang	200L	6-Q(W)-200=2
3	BC60/7-DG25-50X12	7	6	DG25-50X12	OSB6.7-P160	120	2900	Dongkang	200L	6-Q(W)-200=2
4	BC21/13-DG46-30X7	13	2.1	DG46-30X7	OSB3.9-P80	60	2900	Dongkang	200L	6-Q(W)-200=2
5	BC30/13-DG46-30X10	13	3	DG46-30X10	QSB3.9-P115	85	2900	Dongkang	200L	6-0(W)-200=2
6	BC45/13-DG46-50X9	13	4.5	DG46-50X9	OSB6.7-P160	120	2900	Dongkang	200L	6-0(W)-200=2
7	BC55/13-DG46-50X11	13	5.5	DG46-50X11	OSB6.7-P200	145	2900	Dongkang	300L	6-0(W)-200=2
8	BC31.5/24-DG85-45X7	24	315	DGB5-45X7	QSB6.7-P200	145	2900	Dongkang	300L	6-0(W)-200=2
9	BC33.5/24-DG85-67X5	24	3.35	DGB5-67X5	OSB6.7-P230	170	2900	Dongkang	300L	6-0(W)-200=2
Comprehensive technical parameter table(Supporting Xichai)
1	BC15/7-DG25-50X3	7	1.5	DG25-50X3	4DW91	33	2900	Xichai	100L	6-0(W)-200=2
2	BC21/13-DG46-30X7	13	2.1	DG46-30X7	4DX21	70.6	2900	Xichai	200L	6-0(W)-200=2
3	BC40/7-DG25-50XB	7	4	DG25-50X8	4DX23	8B	2900	Xichai	200L	6-Q(W)-200=2
4	BC30/13-DG46-30X10	13	3	DG46-30X10	4DX23	BB	2900	Xichai	200L	6-Q(W)-200=2
5	BC60/7-DG25-50X12	7	6	DG25-50X12	CAB110/12	125	2900	Xichai	200L	6-Q(W)-200=2
6	BC45/13-DG46-50X9	13	4.5	DG46-50X9	CAB110/12	125	2900	Xichai	200L	6-Q(W)-200=2

Other components

Supporting control system

The KQK900 series control cabinet is a fully automatic electronic measurement and control system for diesel engine pump units controlled by a programmable controller (PLC) or microcontroller. The control screen, together with the diesel engine pump group, forms a highly automated centralized control system for the pump group. Its reliable operation, high measurement accuracy, and convenient operation can be widely used in various enterprises and institutions as an emergency diesel engine pump group system control (system) for fire protection, production, and daily life.

The KQK900 series control cabinet can be matched with various specifications and models of diesel engines. According to its core controller and other special requirements, it can be divided into three levels: economy type, standard type, and special type.

Economy type: using a dedicated controller developed by a microcontroller to achieve measurement and control, parameter display, and design .

Standard type: PLC is used to achieve measurement and control functions, and a text display is used as the human-machine interface.

Special type: Based on the standard type, switch to human-machine interfaces such as touch screens and computers, as well as other special configurations.

When the water pump unit receives a valid operation command, or the electric pump power supply system loses power, or receives a remote control start signal, the unit can automatically start and run. If one start is unsuccessful, the unit will undergo multiple automatic restarts.

The control cabinet has the following various alarm functions: startup failure alarm; Low oil pressure alarm; High oil temperature alarm; High cooling water temperature alarm; Overspeed alarm; Battery low voltage alarm; Fuel shortage indication alarm, with protection functions such as low oil pressure shutdown, overspeed shutdown, emergency shutdown, etc

The control system provides a remote start stop control interface and passive status feedback contacts such as “operating status”, “start failure”, “comprehensive alarm”, and “control power on”.

4) The gate can be installed by flipping left and right (equipped with hydraulic hoist)
The working gate adopts a flat sliding type, and the pump is installed horizontally on the gate. The pump opens and closes together with the working gate, and the hydraulic hoist performs the left and right flip switching action.

Fuel tank

Usually, BC equipment requires an independent fuel tank, and the volume of the fuel tank is usually calculated based on the fuel consumption of the equipment during 4-6 hours of operation. The calculation formula is as follows:

Fuel tank volume (L)>Fuel consumption rate (g * Kw/h) × Rated power of diesel engine × Required continuous working hours/800

Fuel tank model and specifications
Model	Fuel tank capacity	Oil storage capacity	A	φB	C	D	E	F	G	8
CYX50	50L	52L	530	360	250	200	350	300	100	2
CYX100	100L	103L	665	450	350	250	450	300	100	2
CYX150	150L	155L	750	520	400	300	520	300	100	2
CYX200	200L	205L	850	560	450	350	570	300	120	2
CYX300	300L	308L	950	650	550	400	620	300	120	2
CYX500	500L	544L	1100	800	700	500	800	300	120	2
CYX700	700L	745L	1250	880	800	550	950	350	140	3
CYX900	900L	925L	1250	980	900	650	950	350	140	3
CYX1000	1000L	1036L	1350	1000	900	700	1050	400	140	3
CYX1500	1500L	1527L	1500	1150	1050	800	1100	400	140	3
CYX2000	2000L	2049L	1500	1400	1300	900	1100	400	140	3

Battery

The equipment is equipped with maintenance free batteries, which usually require a cold start performance of 800A. Generally, two 12V, 200AH batteries are used in series for power supply. The series connection of batteries increases the voltage, but the capacity remains unchanged. The parallel connection of batteries increases the capacity, but the voltage remains unchanged. For high-power diesel engines, due to the high power of the configured starting motor, even two starting motors are equipped. In this case, a larger capacity battery pack is needed for power supply. Generally, four batteries are used, two in series and two in parallel. When using a dual battery starting circuit, In addition to doubling the number of batteries, it is also necessary to equip the control cabinet with two mains charging systems and automatic switching of two battery packs.

Scope of Supply

Belonging to the normal supply scope include: pump unit, fuel tank, battery, control cabinet;
Random spare parts for diesel engines;
Exhaust bellows and muffler;
Connection cable bundle between control cabinet and machine side terminal box (length of 10 meters)

Attention: The supply and return oil pipelines between the diesel engine and the fuel tank are not within the scope of supply, and other pipelines, elbows, and variable diameter pipes of the exhaust system, except for corrugated pipes and silencers, are not within the scope of supply.

Equipment installation

- Lifting requirements:
When lifting the diesel engine water pump unit, it must be lifted and moved horizontally as a whole, and tilting or dragging the water pump unit is strictly prohibited.
- Installation requirements:
1.When installing the water pump unit, a thin iron sheet must be added between the metal common chassis of the unit and the foundation plane to level the foundation and the common chassis;
1. When installing the equipment on site, the coaxiality should be adjusted, and the parallelism error should not exceed 0.2mm, and the radial circular runout error should not exceed 0.3mm;
2. For units with open cycle cooling, soft connections such as rubber hoses must be used between the diesel engine and the inlet pipe for transition. It is strictly prohibited to use steel pipes for rigid connections directly with the diesel engine;
3. The control cabinet should be placed nearby, so that the pump group can be seen when operating the control cabinet. The total extension length of the cable bundle connecting it to the machine side terminal box should not exceed 10 meters;
4. It is advisable to install the fuel tank with the outlet slightly higher than the inlet of the diesel engine;
5. Place the battery near the starting motor;
- Usage requirements:
Please carefully read the accompanying documents of the water pump unit and strictly follow the operating and usage specifications specified in the “Diesel Engine Maintenance Manual” and “Diesel Engine Control Cabinet User Manual” to avoid human operation factors that may cause damage to the machine.
Please pay attention to the following points during equipment debugging and daily operation:
1. Selection of diesel, engine oil, and coolant
2. Diesel: 0 or -10 diesel, selected according to ambient temperature.
3. Engine oil: CF-4 grade or above, 15W/40 grade. Mixing different grades of engine oil is not allowed.
4. Cooling fluid: The cooling water used to cool diesel engines should be tap water and clean river water. Well water contains a lot of impurities and is prone to scale formation, making it unsuitable for use. Corresponding antifreeze can also be selected according to the recommendations in the diesel engine maintenance manual.
5. Preparation before starting the diesel engine pump
6. Check whether all parts of the diesel engine are normal and whether the connections of all accessories are reliable;
7. Check if the coolant is fully filled;
8. Check if the oil level is at the specified oil level;
9. Check if the diesel in the fuel tank is sufficient;
10. Check if the connectors of each circuit in the starting system are tight;
11. Check if the battery is fully charged;
g.Fully open the inlet valve of the pump;
1. Completely exhaust the air inside the pump chamber;
2. Precautions for pump unit operation
3. The pump unit should not operate under overload during operation. Pay attention to the inlet and outlet pressure gauges of the water pump. The actual head after subtracting the inlet pressure from the outlet pressure must be greater than or equal to the rated head marked on the pump nameplate. When the actual head is lower than the rated head of the pump, the water pump is in an over flow working state, and the diesel engine is operating at an over power.
4. The ambient temperature for pump unit operation must be appropriate. When the ambient temperature is higher than the design temperature, power reduction should be considered for use.
5. Daily maintenance of diesel engines
6. Check the oil level in the oil pan. The oil level should reach the mark on the oil dipstick, and if it is insufficient, it should be added to the specified amount.
7. Remove oil, water, and air leaks from diesel engines.
8. Check the installation status of various accessories of the diesel engine, including the firmness of each accessory installation, anchor bolts, etc.
9. Check all instruments and observe if the readings are normal. Otherwise, repair or replace them in a timely manner
10. Clean the exterior of the diesel engine and its ancillary equipment, use a dry cloth or a cloth soaked in diesel to wipe off oil, water, and dust on the surface of the body, turbocharger, cylinder head cover, air filter, etc. Wipe or blow clean the dust on the surface of the charging generator, radiator, intercooler, fan, etc. with compressed air
11. Start and run once a week for about half an hour, or until the water and oil temperatures reach 60C.
- Basic technical requirements:
The foundation of the pump should have sufficient stiffness to support the pump and absorb vibration. The use of a concrete platform above the ground can prevent flooding of the unit and keep the site clean. The unit is fixed with anchor bolts, and the length of the anchor bolts is 15 times the diameter of the bolts. To better locate the unit, the reserved holes for the anchor bolts should be more than 4 times the diameter of the anchor bolts. Secondary grouting should be used, and each side of the foundation table should extend about 300mm beyond the unit base. A sewage pit should be set on the side of the foundation to collect oil and water dripping from the diesel engine.

BC Series Industrial Diesel Engine Emergency Pump

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