加氢改质空冷风机故障问题分析及改造

发布时间：2018-01-02 17:19

本文关键词：加氢改质空冷风机故障问题分析及改造　出处：《西南石油大学》2016年硕士论文　论文类型：学位论文

【摘要】：克拉玛依石化公司120万吨/年柴油加氢改质装置自2012年11月投产以来,空冷风机接连出现U型螺栓断裂、叶片轴断裂、叶片断裂、风机轴磨损等诸多故障,严重影响到装置的安全平稳运行。本论文针对以上故障问题开展研究分析,运用相关力学理论对风机的叶片轴强度进行了校核计算,通过有限元软件Abaqus对风机叶片、叶片轴和U型螺栓进行静力学分析,发现其内部均存在高应力集中区,这些高应力区域与工程中的故障失效形式吻合。对风机叶片进行模态分析发现叶片第四阶固有频率与风机旋转激振频率接近,是引起风机叶片共振加速风机故障失效的原因之一；U型螺栓的断裂主要是基于叶片安装时U型螺栓预紧力不足使其长期在松弛状态下运行造成的疲劳断裂,而U型螺栓内部存在较高的应力区域、风机叶片共振等外部因素加速了其断裂进程；风机轴系设计单薄、叶片共振、轴系螺栓尺寸偏小预紧力不足,造成轴承座螺栓松动后叶片撞击风筒壁是叶片及叶片轴断裂的主要原因；风机轴承设计高度不足,轴承座设计单薄,是风机轴承跑内圈、转轴磨损的主要原因。最后通过将直径(?)3658mm风机U型螺栓更换为夹板式固定螺栓、其余型号风机将叶片轴一阶定位改造为二阶双向定位、严格规范叶片安装角度及螺栓预紧力等措施,有效地解决了直径(?) 3658mm风机U型螺栓断裂问题；所有空冷风机将分体式轴承改为整体集装式轴系有效地解决了轴承“跑内圈”、叶片和叶片轴的断裂问题；5台直径(?)3658mm风机增加变频避免共振频率产生,更好地优化了风机的运行状态。综合以上故障分析认为各故障之间存在相互影响的关系,但轴系改造是解决所有故障问题最核心的措施,通过技术改造,有效地解决了空冷风机运行中的重大安全隐患问题,为空冷机组的安全、稳定运行奠定了良好的基础,取得了很好的改造效果。
[Abstract]:Since the 1.2 million ton / year diesel hydrogenation upgrading unit of Karamay Petrochemical Company was put into operation in November 2012, U-type bolts, blade shafts and blades have been broken successively in the air cooler. Fan shaft wear and other failures seriously affect the safe and stable operation of the device. This paper carries out research and analysis on the above faults and uses the relevant mechanics theory to check and calculate the blade shaft strength of the fan. The finite element software Abaqus is used to analyze the fan blade, blade shaft and U-bolt statically, and it is found that there is a high stress concentration zone inside the fan blade. The modal analysis of the fan blade shows that the 4th order natural frequency of the blade is close to that of the rotating excitation frequency of the fan. It is one of the causes of fan blade resonance acceleration fan failure. The fracture of U-bolt is mainly based on the fatigue fracture caused by the insufficient pre-tightening force of U-bolt when the blade is installed, and there is a high stress region inside the U-bolt. The fracture process is accelerated by external factors such as fan blade resonance. The main reason of blade and blade shaft fracture is that the design of fan shaft system is thin, the blade resonance and the size of shaft bolt are not enough, which results in the blade impingement on the wind cylinder wall after the bolt of bearing seat is loosened. Fan bearing design height is insufficient, bearing seat design is thin, is the main cause of fan bearing running inner ring, shaft wear. The U-type bolts of 3658mm fan are replaced by clamped plate fixed bolts, and the other type fans transform the first order positioning of the blade shaft into second order bidirectional positioning, and strictly regulate the installation angle of the blade and the pretightening force of the bolt. Effectively solve the diameter? (3 658 mm fan U bolt fracture; All the air cooling machines change the split bearing into the integral assembly shaft system effectively solve the problem of "running inner ring", blade and blade shaft fracture of the bearing; 5 sets of diameters? By increasing the frequency conversion to avoid resonance frequency, the operating state of the fan is better optimized. Based on the above fault analysis, it is concluded that there is a mutual influence relationship between the faults. But shafting transformation is the most important measure to solve all the trouble problems. Through technical transformation, it effectively solves the major hidden safety problem in the operation of air-cooled air turbine, which is the safety of air-cooled units. Stable operation laid a good foundation, and achieved a very good transformation effect.
【学位授予单位】：西南石油大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TE96

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