a total of 3,600 GPM. Tese are high efficiency pumps selected specifically to operate with the limited power available at the installation site. Each of the three new pumps was incorporated into an individual module with its own piping and power/ control connections. Each module also included isola- tion valves, making it possible to replace a pump without shutting down the cooling system. Just two of the pumps are needed to supply all of the capacity required for current operations. Te third pump serves as a connected spare that can be switched in quickly if one of the operating pumps were to fail. Tis design proved its worth the first time Chassix’s new cooling system was turned on after installation. “Tere were the normal hiccups with installation,” Roop said, “but they were handled. Tere was no panic, even when one of the new pumps failed at startup. Because we had planned for the cooling system to operate fully on just two of the three pumps, we quickly isolated the defec- tive pump with the valves installed for that purpose and turned on the fully-connected backup pump, keeping the new cooling system in operation. Because we had pur- chased a spare pump that was stored nearby, we were able to replace the defective pump within the hour. It was a good demonstration of how well the system was designed to keep doing its job even with a pump failure.”
Backup and Emergency Cooling Because effective cooling is so critical to the safe opera-
tion of an induction melt shop, it’s vital that a backup or emergency cooling system be in place in case an equip- ment or power failure shuts down the main cooling system. A common backup covering both pump and power
failures is a direct connection to a city water supply that is either automatically or manually turned on to flow through the furnaces and other equipment served by the main cooling system. Tis is a once-through-cooling arrangement with the heated water being routed to a drain or other outflow site. Another common backup system for power failures is a
battery (in very small systems) or generator that switches on to continue running the pumps in the main cooling system. Many metalcasting facilities also maintain backup cool- ing pumps that can be switched in quickly if an operating pump in the main system fails. Chassix is able to turn on a city water supply for backup cooling in the event of a power failure. Its new cooling sys- tem also incorporates an online backup pump that can be switched on quickly if another pump fails. A stored spare pump is ready to replace any failed pump.
Installation at Chassix Ideally, installation of a new induction melt cooling
system should take place in a large, flat area, with ample space to stage cranes and other heavy lifting equipment. Tere should be plenty of power available for the pumps
自己的管道和电源控制的接头。每个模块还配有隔离 阀，从而可以在更换泵时无需停止冷却系统运行。仅 需要2个泵就可以满足系统全部的流量要求。第3个泵 作为备用泵被连接在系统中，如果1个泵在运行中发 生故障，可以实现快速的切换。Chassix公司新冷却 系统安装运行后，这种设计在第一时间证明了它的价 值。
“安装时出现小问题很正常，”Roop说，“但都 处理了，即使当1台新泵启动时发生故障也不恐慌。 因为我们的设计中，3台泵中只需有2台工作就可以满 足冷却系统满负荷运行，我们用隔离阀快速的隔离了 故障泵，并完全打开了备用泵的连接，让新的冷却系 统保持运行。因为我们已经购买了备用泵并存放在附 近，所以我们可以在1小时内更换故障泵。这是非常 好的证明，新系统的设计如此之好，甚至在泵发生故 障时仍可以继续工作。
备用应急冷却
对于感应熔炼车间的作业安全而言，有效的冷却是 非常重要的。因此设备或电源发生故障，主冷却系统 关闭的情况下，备用或应急冷却系统是至关重要的。 通常的应急处理方式是泵和电源故障时，打开连接 到城市供水的开关，让自来水直接流过炉体和其他连 接主冷却系统的设备。这是非循环的冷却方式，加热 的水被排入下水道或其他地方。
另一种常用的应急系统是蓄电池（非常小的系统） 或发电机，当停电时切换接入主泵，让冷却系统继续 运行。
许多铸造厂备用冷却泵，当主系统的工作泵出现故 障时能快速切换。
Chassix公司的应急系统是电源故障的情况下接入 自来水冷却。其全新的冷却系统还装配了备用泵，当 1台泵出现故障时可以在线快速切换。库存的备用泵 可以随时更换故障泵。
Chassix公司的安装
理论上，为感应熔化设备安装新的冷却系统应该 在足够大且平坦的地方，有充足的空间高度让起重机 和其他重型起重设备作业。应该有足够的电力用于泵 和风扇，并且应急系统能直接接入自来水，保持应急 膨胀水箱充满，当设备或电源故障情况下提供紧急用 水。
September 2014
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 67
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