Cause Analysis and Treatment Method of Adjustable Blade Fault of VK160-4 Type Turbine Air Compressor
Fan and compressor technology and application, Magic 604 turbine air compressor deflector adjustable blade failure cause analysis and treatment method Wuhan Iron and Steel Group Oxygen Co., Ltd. Hubei 430083 Cao Shangfeng occurs the inlet deflector adjustable blade can not open the fault , seriously affecting the safe operation of the compressor, restricting the economic performance of the oxygen generator. By exploring the experience of accumulating equipment fault handling, the equipment maintenance and management level was raised and the difficulty was solved.
Treatment method WISCO Oxygen Co., Ltd. introduced from the Linde Company of Germany, the mid-level adjustable blades that often appear in the driving process can not open the fault, seriously affecting the normal production of air separation equipment, posing a threat to the safe production of oxygen. As a last resort, two 3000, 1 oxygen generators were discontinued, and two air compressors were dismantled for maintenance. After the inspection, the situation has improved. However, after the operation year, the adjustable blades of the two air compressors are difficult to open during the driving process. In view of the previous parking treatment experience, successive parking times, respectively, the two air compressor deflectors can be handled separately. Up to now, the two air compressors have been running stably, and the above-mentioned faults have not occurred again. The equipment failure that has been plagued for many years has been solved. The following is a review of the causes of such equipment failures and several parking treatment experiences for reference by peers.
Brief introduction of equipment performance 0001 The air turbine compressor for the oxygen generator is manufactured by German MANNESMANNDEMARG company, model 604, which is grade compression, stage cooling, and 1-shaped arrangement. The structure of the air compressor is simple. 1. The compressor shaft power is 12 490kW, the l2 working wheel speed is 24, the working wheel speed is 6486, the gear speed is 10001, and the processing air volume is 15100 when the standard operating condition is 30 00013 oxygen. 13 rated discharge pressure 5503 pressure. The air compressor load capacity can be adjusted within 700 range, that is, the maximum load capacity of the air compressor can be increased to 166000, 13 processing air volume. At this time, the corresponding oxygen production is 33000, and the minimum load capacity can be reduced to 106000 plus. The amount of air, at this time, the corresponding oxygen output is 21000. The working wheels are equipped with imported adjustable vane deflectors, which are controlled by two servos to smoothly realize the rapid change of air compressor load capacity in the range of 70,0. .
Air compressor adopts step-adjustable blade linkage adjustment control principle and its advantages and disadvantages. Two-stage adjustable blade linkage adjustment mechanism is simple. 2. Because the compressor is in the form of only shape, the same direction, the same direction, respectively, by two The cylinder drives the two linkages to adjust the linkage. The two drive mechanisms are in turn controlled by two regulators. Among them, the 13-stage drive mechanism is controlled by the main regulator, and the 24-stage drive mechanism is controlled by the sub-regulator. The main regulator hull body technology and the application fan and compressor output signals are simultaneously used as the setting values ​​of the sub-regulator automatic adjustment to achieve The purpose of the simultaneous action of the two drive mechanism working wheels.
The main regulator input signal is provided remotely by local operation or by the main control room computer processing air flow controller 02615. Normal production is controlled by the main control room, and it is operated locally when the vehicle is parked. In order to ensure uniform intake and prevent surge between compressor stages, when the deviation of the actual opening signal of the two drive mechanisms is greater than 10, the compressor will automatically stop. Its control box 3.
The use of the stage work wheel with adjustable blade deflector adjustment can evenly distribute the compressed air volume, optimize the compression ratio of each level, strengthen the variable load capacity, and widen the range. In particular, the possibility of pulsation of the unit is reduced under low load conditions. The mechanical efficiency of the compressor is improved and the energy consumption is reduced accordingly. However, since the single-stage adjustable vane deflector structure 4 has been complicated, the adjustment of the linkage mechanism of the two-stage adjustable vane deflector makes the whole transmission mechanism more complicated, and requires not only single-stage adjustable vane transmission flexibility, ipsilateral The linkage mechanism runs freely, and it is also required to be adjusted with the other side linkage mechanism. Only the adjustable blade of the stage working wheel can realize the synchronous adjustment. Otherwise, the deviation is too large and it is easy to cause a parking accident. Secondly, since the same side adopts the link mechanism, it is difficult to accurately determine which stage of the adjustable blade does not move.
Single-stage adjustable vane deflector working principle adjustable vane deflector structure 4.
According to the structure and the actual working condition of the deflector after disintegration, draw the movement of the deflector mechanism, 5.
1. End cap 2. Crank rocker 3. Crank connecting rod 4. Adjusting ring 5. Blade crank connecting rod 6. Blade crank 7. Blade fixing frame 8. Circular arc slide 4. Drive mechanism shaft 8. Blade shaft The working principle of the deflector The crank rocker swings around the end cover fixed shaft 4 in a vertical plane, and the crank ring drives the adjusting ring to transform into a horizontal direction on the arc-shaped slide, thereby pulling or pushing the blade crank connecting rod The operating blade crank 6 drives the blade rotating shaft 8 to rotate in the plane of the vertical end cover. The crank of the link mechanism is connected to the crank of the fixed shaft.
Trouble phenomenon and disintegration checker The air compressor can not be opened when the vehicle is stopped due to external reasons. When the 13th grade is opened with the compressor and the 24th grade cannot be normally opened, it will easily cause surge between the compressor stages. During the surge, the vibration of the stage shaft will increase, and in severe cases, it will cause parking. When the 24th level is opened and the 13th level cannot be opened, it affects the normal intake of the compressor and delays the production time. Therefore, the failure of the adjustable blade can not open the fault and has a great impact on the normal operation of the device. At the beginning of the problem, the on-site control cabinet used the main regulator to quickly switch back and forth to adjust the blade output signal, and the activity will return to normal after several times. It can take a long time, and has to force the connecting rod crank on the spot by external force, and occasionally loosen the stuck connecting rod mechanism. In order to ensure production, the deviation alarm parking signal has to be canceled, so that the compressor load capacity cannot be properly played, and there is often a surge phenomenon that occurs with disease.
In view of the above-mentioned faults, the two air compressors were repaired in the middle, and after disassembling the flow guides at each level, the following questions were found. 1 Each stage of the deflector has adjustable blades and working wheels, covering carbon black, of which the grade is thicker. The bottom surface of the deflector blade rotates and the inner surface of the deflector has more carbon, the contact gap is reduced, and the bottom surface of each blade root is even in contact with the inner surface of the deflector, and the rotational friction resistance of the blade increases. In the first stage deflector of the air compressor, there are three blades. The rotation driving crank and the fixing bolt hinged by the adjusting ring link are cut, and the blades are not controlled by the adjusting ring. The sheared bolt has a spring washer that slides down in the sliding track of the adjusting ring and is caught between the pulley and the slide, so that the entire adjusting ring cannot rotate. The adjustable blade drive mechanism has insufficient output at no load. Among the 12 blades of the deflector, the individual blade shaft sliding bearings are too tightly coupled and the rotation is not flexible. The population of the gas-side outlet stage of the station-level gas cooler is completely deformed by the built-in gas mist trap. Due to the clogging of the mist trap, the stage wheel is difficult to inhale, and the stage exhaust is not smooth. The pressure difference between the mist trap is too large, the mist trap is smashed and deformed, and the filtering function is lost, resulting in a micro-carbon belt with human-level guidance. The flow device and the working wheel make the adjustable blade of the stage inflexible.
The focus of the treatment is on the above situation. The two air compressors are dismantled and repaired with emphasis on the following questions: 1 Thoroughly clean the coke on the working wheel and the adjustable vane, and the carbon deposit on the inner wall of the deflector is also treated. The main deflector of each stage is disassembled, and the ring slide and the blade sliding bearing are adjusted to apply grease. Rinse each stage of the mist trap with high-pressure water, clean the carbon deposits inside and outside, and replace the damaged mist trap. Purge the adjustable vane actuator valve positioner and signal amplifier with dry clean air. The air compressor wheel cleaning system is used by people to reduce carbon deposits in the working wheels and runners.
After the above inspection and maintenance, the two air compressors are in good condition. During this period, the vehicles are parked several times, and there is no longer the symptoms that the deflector can not be opened during the driving process.
2. The first equipment disintegration inspection showed that the two air compressors had a large degree of open blade opening after the operation year. When the air compressor was fully loaded, the adjustable blades were nearly fully open and the energy consumption increased significantly. The direct use of the deflector working wheel flushing device is put into use, and the air compressor deflector can adjust the blade opening degree to reduce the energy consumption of the motor significantly. After running for a while. The two air compressors once again showed the symptoms that the adjustable blade could not be opened during the driving process. The oxygen generator is planned to be repaired annually, the air separation system is heated greatly, the air compressor is replaced with a gas cooler core, and the cylinder of the working wheel is self-injected into the water flushing system. It was found that the F-stage air compressor was difficult to open the 13-level adjustable blade during the driving process. In the year of Taiwan, the key inspections were carried out, and the air compressor-level deflectors were used to repair the F-stage air compressors, and all the demographic-level population deflectors were dismantled.
The disintegration and repair of the EF air compressor population deflector were found respectively. The following questions were asked: 1 each class of deflector shells had metal corrosion, and the corrosion level of the first stage and the first stage demodulator was the most serious. The adjustment ring does not move at all.
The main reason for the analysis is that the seal is not good. There is no sealing gasket on each end of the deflector and the volute end. After the injector uses the deflector working wheel to flush the system, the chamber is not completely atomized during flushing. Because the working temperature of the deflector housing is high, the humid air evaporates inside. Long time, causing corrosion of the metal wall surface, the corrosion material evenly covers each member. The vane shaft has a carbon black in the journal and the frictional resistance increases. The pulley is fixed on the adjusting ring by bolts and pressing gaskets. The thickness of the pulley is smaller than the width of the bolt journal. When the gap between the nut and pulley spacers is covered with corrosives, the pulley cannot rotate around the journal, but only with the pulley. Adjust the ring to drag. The grease applied on the pulley slide is cracked and solidified by temperature cracking, and is mixed with the metal corrosive carbon black to solidify on the slide rail, hindering the sliding of the pulley, causing the adjustment ring to be stuck and losing the adjustment function.
The treatment method is to completely remove each component of the deflector and clean the pounds one by one. The pulley journal slides are hinged with a small amount of temperature-resistant grease. The pulley is polished and polished to remove the covering. Each stage of the deflector and the volute end face is provided with a temperature-resistant rubber gasket having a thickness of 5 and a width of 15,1.
The effect of the use of equipment after the equipment maintenance, the equipment operating conditions have a good change, the first disassembly and maintenance has been a long time, during which two air compressor adjustable blade transmission mechanism has also failed to open, but the failure The incidence is greatly reduced. The main method is to troubleshoot and repair the deflector transmission mechanism and the air compressor. Clean and descale the mechanical transmission deflector components, grease the grease, replace the spare parts; clean the gas cooler and wash it with a high pressure water gun. The carbon deposit on the mist trap between the runner and the gas cooler ensures the safe and stable operation of the large mechanical operating equipment during the operation cycle, and the operating efficiency of the compressor mechanical efficiency oxygen generator is improved. After long-term observation and practice exploration, the consultants canceled the adjustment of the adjustable vane linkage of the two air compressor-level population deflectors, and only adjusted the adjustable vane of the inlet shunt to the full-open state. Fixed dead, its safety and reliability is better, eliminating the interstage surge phenomenon caused by the excessive opening of the blade between the stages, and the click phenomenon has not occurred.
In the past ten years, due to the increase in the number of large-scale oxygen generating units that have been put into operation in China, the sharp question has been asked how to maintain and manage the large compressors. Accumulate fault handling experience to improve the operation and maintenance management level of equipment, to extend the continuous operation cycle of large-scale mechanical equipment, and to ensure the safe and stable operation of oxygen generators. WISCO Oxygen Company has gained experience in this respect and is only for peer reference.
And through a case to give a complete design calculation process. I hope to learn from the design of other similar products.
1 Tang Zhaomin and so on. Mechanical Design. Xi'an Xi'an Jiaotong University Press,
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