如何延长高粘度齿轮泵的服役时间

如何延长高粘度齿轮泵的服役时间

2010-06-09 09:42:13 阅读13 评论0 字号:

原文:
输送介质的选择 输送介质不仅是能量传递的中介,而且也是润滑、密封及传热介质。输送高粘度液体的齿轮泵应做到在较低的功耗、较少的泄漏、较大的压力下输出最多的流量。液体的粘度反映了介质流动的难易程度,粘度过高会增加内摩擦阻力,降低输出功率,浪费能量,并产生过高的系统温度。在确定所要输送的介质时,应该严格遵循产品说明书上的规定,尽量使用厂家推荐的流体介质,并注意考虑系统的工作温度范围。当希望在某一较宽的温度范围内使用时,输送介质的粘度指数应该高些。 当输送液体的粘度较高,或当系统在寒冷环境工作时,必须确保输送介质能够顺畅地流动。许多油液中含有蜡性成分,它们在低温时很易结晶,输送介质的凝点应该低于预期的{zd1}作业温度。另外,所要输送的介质必须与系统中的密封、垫圈、软管等橡胶材料具有相容性,如果两者不相容,那么就得重新确定输送介质。 噪声问题 在流体输送系统中,液流速度、流量和压力的快速变化,气泡的破裂及交变的负载都是噪声的常见原因,输送高粘度液体的齿轮泵是诱发系统噪声的主要来源。 合理确定齿轮泵的工作转速,使齿轮与轴的转动避开啮合共振频率,可以防止噪声加剧。因为当啮合频率接近于齿轮系的固有频率时容易发生共振。采用适当的隔振技术可以阻止振动传递到临近的结构中去。为此,齿轮泵与驱动电机应通过柔性联轴器连接,并安装在同一底板上,以保证同轴度,该底板装于弹性支承上,可进一步提高隔振效果。在齿轮泵的出口管道上设置一个膨胀形容腔或蓄能器,来吸收泵的压力脉动或缓冲管路内的压力突变,是控制高粘度齿轮泵噪声的有效手段。 一般来说,1台露天工作的高粘度齿轮泵的{zd0}允许噪声应该低于90分贝,否则 就应对噪声源进行主动或被动遏制,同时减少工人直接暴露于噪声环境下的作业时间。如果实在无法控制噪声,也要采取听力保护措施。高粘度齿轮泵在运转过程中一旦出现异常噪声,就应该马上停机检查。 工作压力的选定 泵的额定压力是指泵连续工作时的{zg}许用压力,而其工作压力则决定于外部负载,泵的寿命与其工作压力直接相关。对于不频繁工作的齿轮泵,其工作压力可取为泵的额定压力,考虑到产品质量不同,{zh0}将额定压力降低 20%~30%使用。对于经常工作于较高压力下的齿轮泵,其工作压力应比泵的额定压力低1~2个压力级。石油化工设备常常是24小时连续运转,这时泵的工作压力应该取得比额定压力低得多,且工作转速也应该低于额定转速。如果高粘度齿轮泵的工作压力调整过高,则会使齿轮泵在超负荷下运行。 安装与试运转 高粘度齿轮泵的支座或法兰与其驱动电机应采用共同的安装基础,基础、法兰或支座均需具有足够的刚度,以减小齿轮泵运转时产生的振动和噪声。电动机与齿轮泵须用弹性联轴器连接,同轴度小于0.1毫米,倾斜角不得大于1度。安装联轴器时不得用锤敲打,以免伤害齿轮泵的齿轮等零件。若用带轮、链轮等驱动时应设托架支承,以防主动齿轮轴承受径向力。紧固齿轮泵、电动机的地脚螺钉时,螺钉受力应均匀,连接可靠。用手转动联轴器时,应感觉到齿轮泵能够轻松地转动,没有卡紧等异常现象出现,然后才可以配管。高粘度齿轮泵的吸油管道内径应足够大,并避免狭窄通道或急剧拐弯、减少弯头, 去除不必要的阀门、附件,尽可能地降低泵的安装高度,缩短吸油管道的长度,以减少压力损失。管接头等元件的密封要良好,以防止空气侵入,从而控制气穴与气蚀的发生。 在开始运转前,往齿轮泵的壳体内灌满待输送的液体,便于安全启动。若环境温度低于冰点,应预先向泵内通入热蒸汽,进行预热处理,然后才可启动齿轮泵。齿轮泵的旋转方向要与进、出油口相符。齿轮泵若是{dy}次运行,或长期闲置后再使用,{zh0}在空载或小负荷情况下先跑合一小时左右。如果在跑合阶段预先觉察出异常温升、泄漏、振动和噪声时,应停机检查。 止回阀与安全阀在齿轮泵的输出管路上{zh0}安装一个止回阀。这样在检修泵及输出管道时,系统中的液体不会发生倒流。齿轮泵带负荷停车时,亦可防止泵倒转而在其输出管道内产生局部真空。应当注意,出口止回阀不能装反或出现卡死现象。高粘度齿轮泵的出口管路上还应当设置安全阀等保护装置,这样一旦泵的出口通道发生堵塞,就可以打开安全阀卸压。安全阀可以与泵体或泵盖铸成一体,也可以单独装配。对于需要正反转的高粘度齿轮泵,其进出口管路上均需设置安全阀。


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译文:
The choice of transmission medium Transport medium is not only the energy transfer medium, but also lubrication, sealing and heat transfer medium. Transmission gear pump high viscosity liquids should be in the low power consumption, less leakage, the larger the output up under the pressure of the flow. Viscosity of the liquid medium flow reflects the degree of difficulty, the viscosity is too high will increase the friction within the lower output power, a waste of energy, and produce high system temperature. In determining the medium to be delivered, should strictly follow the instructions on the product requirements, to make use of manufacturer recommended fluid medium, and pay attention to consider the system's operating temperature range. When the hope in a wide temperature range, the transmission medium viscosity index should be higher. When the high viscosity of the liquid delivery, or when the system work in a cold environment, the need to ensure smooth flow of transport medium can. Many of the oil composition containing wax, which is very easy to crystallize at low temperature, freezing point transmission medium should be lower than the expected minimum operating temperature. In addition, the transmission medium must be the system of seals, gaskets, hoses and other rubber material is compatible, if the two are incompatible, so have to re-determine the transmission medium. Noise problems In the fluid transfer system, the liquid velocity, rapid changes in flow and pressure, the bubble burst and the alternating load Dushi noise of the common Yuan Yin, transport of high viscosity liquid pump is induced by the system of Chi Lun Zhu Yao source of noise. Reasonable to determine the working speed gear pump, which makes gear meshing with the axis of rotation to avoid the resonance frequency can be increased to prevent the noise. Because when the gear mesh frequency is close to the natural resonance frequency is high. The use of appropriate isolation techniques can prevent vibration transmission to the adjacent structure to. To this end, the gear pump and the driving motor should be connected through a flexible coupling, and installed on the same floor, to ensure concentricity of the floor mounted on elastic supports, can further improve the isolation effect. Export pipeline in the gear pump set on an expansion chamber or accumulator described, to absorb the pressure of the pump pulse or the pressure within the pipe buffer mutations, high viscosity gear pump to control the effective means of noise. Generally speaking, an open work station with high viscosity gear pump the maximum allowable noise should be below 90 dB, otherwise the noise source should contain active or passive, while reducing the noise of workers directly exposed to the operating environment of the time. If you really can not control the noise, hearing protection should be taken. High viscosity gear pump during operation when abnormal noise, they should immediately stop check. Working pressure of the selected Pump pump rated pressure is the maximum continuous working pressure allowable, and its working pressure is determined by the external load, the pressure pump directly related to their work life. Does not work for frequent gear pump, the working pressure desirable for the pump rated pressure, taking into account the different product quality, the best rated pressure will be reduced by 20% to 30% used. For regular work in the high pressure gear pump, the working pressure should be lower than the pump's rated pressure of the pressure level 1 to 2. Petrochemical equipment is often 24-hour continuous operation, when the pump working pressure should be made much lower than the rated pressure and working speed should be lower than the rated speed. If the high-viscosity gear pump to adjust the working pressure is too high, then the gear pump will run under the overload. Installation and commissioning High viscosity gear pump drive motor bearings or flanges should be used with a common install base, base, flange, or bearings are required to have sufficient rigidity, to reduce the gear pump operation the vibration and noise. Motor and gear pump to be connected with flexible couplings, coaxial is less than 0.1 mm, tilt angle of not more than 1 degree. Install the coupling is not allowed to use a hammer, so as not to damage gear pump gear spare parts. If the use of pulleys, sprockets and other drive supporting bracket should be set to prevent the gear bearings subject to radial forces. Fastening gear pumps, the motor ground screw, the screw force should be uniform, reliable connections. Rotate the coupling should feel the gear pump can easily rotate, there is no abnormal phenomenon such as clamping, and then can piping. High viscosity gear pump suction piping should be large enough to avoid a narrow channel or a sharp bend, reducing elbow, to remove unnecessary valves, accessories, as much as possible to reduce the pump mounting height, reduced suction pipe length to reduce the pressure loss. Fittings and other components of the seal to be good, to prevent air intrusion, so as to control cavitation and cavitation occurred. Begin operation before the gear pump housing to be delivered within the liquid filled, easy to Safe Boot. If the ambient temperature below freezing, should advance into the heat pump through steam for preheating, and then only start the gear pump. Direction of rotation of gear pump with the progress, the oil export line. Gear pump if the first run, or long-term idle before use, preferably in the no-load or low load situations Xianpao-one hours. If the running-in stage to realize the abnormal temperature rise, leakage, vibration and noise should be down to check. Check valves and safety valves in the gear pump output tube the best way to install a check valve. This output in the maintenance of pumps and piping, the system does not occur in the liquid back. Gear pump with a load stop, may also prevent the pump upside down and in its output channels to generate a partial vacuum. It should be noted, anti-export, or there can not be installed check valve stuck phenomenon. The export of high-viscosity gear pump pipeline safety valve, etc. should also be set to protect the device, so once the pump discharge channel clogging, you can open the safety valve relief. Safety valve can be cast with one pump or pump cover can also be a separate assembly. For the high viscosity needed Reversible gear pump, is required to set its import and export pipeline safety valve


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