凝液泵透平蜗轮失效原因分析及改进措施_磁力泵_新浪博客

译文:
乙烯装置压缩系统E-GT501透平是凝液泵(位号:E-GA501A)的驱动机,它负责将丙烯制冷压缩机透平(位号:E-GBT501)的凝结水及时排出,以保证机组的正常运行,1998年6月E-GT501透平蜗轮失效,虽经多次维修效果很不理想,新蜗轮的使用寿命很短,最长不超过20小时,导致透平不能正常工作,使另一台电机驱动的凝液泵(位号:E-GA501B)一直在没有备用泵的条件下单台运行,如果E-GA501B泵突然发生故障,必然会造成丙烯压缩机组停车,对整个乙烯装置的稳定生产造成极大的威胁。我们分析并找到了透平蜗轮失效的根本原因,通过改变了蜗轮材质,成功地解决了问题。 原因分析 蜗轮首次失效原因分析 1998年6月蜗轮{dy}次失效后,我们在对透平的检查中发现:透平润滑油箱中含有较多的游离水。由于蜗轮蜗杆的传动靠齿面的啮合来实现,其摩擦表面必须建立极压润滑膜,它是润滑油中的极压剂与金属表面反应生成的润滑膜,它具有较高的强度,能承受蜗轮蜗杆啮合产生的载荷。润滑油带水会造成极压剂失活,使啮合表面无法形成润滑膜,导致蜗轮蜗杆表面直接接触,造成表面磨损。由于蜗轮材质为锡青铜(代号ZQSn10-1),其许用接触应力为220MN/m2,而蜗杆材质为合金钢(钢号:35CrMo),其许用接触应力为850MN/m2,蜗轮相对蜗杆较软,所以失效的形式表现为蜗轮轮齿磨损。 我们对润滑油系统进行了全面分析,{zh1}确认:油系统的水来自透平汽封泄漏蒸汽形成的凝结水。由于透平的保温被密闭性非常好,漏出的部分蒸汽将不可避免地通过轴承油封进入润滑油系统。 针对由于润滑油带水导致蜗轮失效的问题,我们按照透平的随机操作手册要求,每月取样分析润滑油的含水量,定期从油箱底部排水,并制定了相关的管理制度。 经过以上的改进措施,E-GT501透平从2000年10月投用,正常运转已达2年以上,至今仍无损坏迹象,为装置的稳定运行提供了有力的保证,该透平每年能平衡中压蒸汽8000余吨,每年可节电15Kw×8000h=120000度,每度按0.6元计算,年可节约7.2万元电费,经济效益非常明显。 由于凝液泵透平蜗轮原设计轮齿接触强度无余量,导致其频繁失效,通过改变蜗轮材质,并按照要求制定了相关的管理制度,解决了问题。随着我国引进国外设备的增加,根据国情差别对原设计条件进行校核,在备件国产化过程中应该得到重视。凝液泵透平蜗轮失效问题的解决过程对此有一定的借鉴意义。

“ Condensate pump turbine worm Failure Analysis and Improvement ”是由提供的国际水泵新闻,译文仅供参考。另外,中国隔膜泵网还提供相关产品搜索:、、、、等。


 

原文:
Ethylene plant turbine compression system E-GT501 is a condensate pump (Bit No.: E-GA501A) of the driving machine, which is responsible for the propylene refrigeration compressor turbine (Bit No.: E-GBT501) the condensation of water discharged in time to ensure that unit's normal operation, in June 1998 E-GT501 turbine worm failure, despite repeated repair results far from ideal, the new worm's life is very short, the longest no more than 20 hours, leading to turbine does not work, so that another motor-driven condensate pump (Bit No.: E-GA501B) have been operating in standby pump under the conditions of a single operation, if the E-GA501B pump breaks down, will definitely lead to propylene compressor stop, the whole ethylene plant The stable production caused a great threat. We analyze and find the root causes of failure of turbine worm gear, worm gear by changing the material, successfully solved the problem. Analysis Worm the first time, Failure Analysis Worm in June 1998 after the first failure, we found that the inspection of the turbine: turbine lubricating oil tank contains more free water. As the worm transmission by meshing tooth surface to achieve, its friction surface must create extreme pressure lubricating film, which is the lubricant of the extreme pressure agent reacts with the metal surface of the lubricating film, which has a high strength, can withstand load generated by worm gear. Lubricating oil with water will cause extreme pressure agent inactivation, so that the surface can not form a lubricating film gear, resulting in direct contact with worm gear surfaces, causing surface wear. As the worm wheel made of tin bronze (code ZQSn10-1), the allowable contact stress for 220MN/m2, while the worm made of alloy steel (Steel No.: 35CrMo), the allowable contact stress for the 850MN/m2, worm worm is relatively higher than soft, so failure in the form of worm gear tooth wear. We have conducted a comprehensive analysis of lubricating oil system, the final confirmation: oil system, steam turbine seal leakage of water from the condensation of water vapor to form. As the turbine was airtight insulation is very good, some of the steam leakage through the bearing oil seal will inevitably enter the lubricating oil system. With water as lubricant for worm gear failure caused the problem, we follow a random turbine operating manual requirements, the monthly sampling and analysis of lubricants water content on a regular basis from the tank at the bottom of the drainage, and the development of the relevant management systems. After the above improvement measures, E-GT501 turbo from the October 2000 vote in use, the normal operation has reached more than 2 years so far still no signs of damage, and stable operation of the device to provide a strong guarantee that the turbine per year to balance the medium-pressure steam more than 8,000 tons, the annual saving 15Kw × 8000h = 120000 degrees, according to 0.6 yuan per unit basis, the annual electricity savings of 72,000 yuan economic benefit is obvious. As the condensate pump turbine worm gear tooth contact with the original design strength without margin, leading to frequent failure of materials by changing the worm gear and in accordance with the relevant requirements management system developed to solve the problem. With the introduction of foreign equipment, the increase in China, according to different national conditions, checking the conditions of the original design, made in the process of spare parts should be taken seriously. Condensate pump turbine worm gear failure problem-solving process has some referential significance.


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