Air compressor installation air compressor transformation technology application
Application of Air Separator Air Compressor Reconstruction Technology Lu Wanli Chu Mingzhe (Henan Coal Chemical Industry Group Zhongyuan Dahua Company, Henan Fuyang 457000) has made the air compressor basically achieve the design effect, ensuring economic benefits, unit stability and post-system The demand for gas supply.
02 Air compressor unit is a power equipment for providing air pressure to the air separation unit. It also provides instrument air and factory air for the entire coal chemical plant. It is a multi-stage centrifugal compressor. Model DMCL1204+2MCL1203+3BCL527 is manufactured by Shen drum. Mainly stator (case, partition, seal, balance disc seal, shaft end seal), rotor (shaft, impeller, spacer, balance disc, bushing, semi-coupling, etc.) and support bearings, thrust bearings, etc. composition. This compressor unit consists of an air compressor and a supercharger that is dragged by the turbine. The steam turbine is a double-out shaft, one end directly drives the air compressor, and the other end speeds up through the speed increasing box and then drags the booster. The air compressor is divided into low and medium pressure cylinders, the casing is horizontally split, the supercharger casing is vertically split, and the transmission is manufactured by DVIDBROWN. The drive machine is a condensing steam turbine, model HNKS50/80, manufactured by Hangzhou Steam Turbine Works.
The air compressor interstage seal and the ring seal are labyrinth seals, and the shaft end pulls the seal and the oil seal to be ZL104; the supercharger interstage seal and the ring seal are the labyrinth seal between the honeycomb seal and the shaft end. The material such as the seal is LD10, the oil seal material ZL102. The gear shape of the gear is involute double helical gear, and the high speed shaft bearing is five tilting tile bearings.
The entire unit has an oil system that is supplied with lubricating oil and control oil.
2. Problems with the device and the content of the modification 2.1 Problems with the device The following problems exist in the production operation: the outlet flow and the outlet pressure of the supercharger are insufficient; when the air compressor unit is in operation, the compressor outlet is sealed due to the impeller ring seal. Insufficient air volume and pressure can not meet the needs of high-load production of air separation units, which seriously restricts the high-load production of coal chemical plants; the high-speed shaft vibration of the unit gearbox is large; and the vibration value of the unit is greatly increased when the unit is loaded, which affects the unit load. Improvement, in the past production, the gearbox was overhauled many times, after replacing the new bearing, the unit was running less than one month, and the high-speed shaft vibration of the gearbox fluctuated near the jump value, which affected the normal production and wasted high maintenance cost. (High-speed shaft bearing bushes are more than 160,000 yuan each, and two sets of 320,000 yuan are replaced at a time); the sealing surfaces of the bearing housings of the unit are leaking oil; when the unit is running, the sealing surfaces of the cylinder bearing housings and couplings are seriously leaked. And with the extension of the unit's running time, the leakage will gradually deteriorate, (the maximum statistical calculation, the force is greater.
In view of the above problems, we intend to carry out technical transformation on the 02 air compressor unit from the internal component structure, oil system operation and environment to eliminate the problems in the operation of the unit and meet the needs of high load, safety and economic production of coal chemical plants.
After many discussions, combined with the daily operation of the equipment and the minor repairs of the unit, I read a lot of technical information about the compressor. For the production problems of the unit, the unit was modified from the following aspects: using a new material, The thermal expansion of the material is used to reduce the gap between the orifices of each stage during normal production of the unit, thereby achieving the purpose of increasing the outlet pressure.
Through the inspection of the gear box, starting from the bearing oil, oil film working and the rotor itself, to ensure the formation of the bearing oil film during high-speed operation of the unit, reducing the impact of the rotor itself on the vibration.
Take measures to reduce the accumulation of soot in the oil system, so that the bearing housings of each cylinder are in a state of micro-negative pressure, and the oil return is smoother.
1) Replace the port ring seal of the supercharger with a PEEK seal made of a new material. The expansion of the new material at a high temperature is used to reduce the gap between the ring seals and increase the outlet pressure.
This kind of scheme can ensure the convenience of installing the mouth ring seal when the unit is cold, and can ensure the increase of the outlet pressure during operation.
2) Overhaul the gear box, scrape the various blocks of the high-speed shaft, increase the bearing surface of the bearing bush, expand the oil inlet hole of the bearing bush, enhance the oil supply of the bearing, and ensure the stability of the oil film during high-speed operation; The high-speed shaft of the box is dynamically balanced, and the residual unbalance of the high-speed shaft is minimized as much as possible, and the influence of the imbalance factor of the rotor on the vibration is weakened.
3) Add another oil-discharge fan of the same power to the original oil-fume fan on the fuel tank of the unit to ensure that the bearing housings of the unit are in a state of micro-negative pressure, improve the oil return environment of the lubricating oil system of the unit, and completely eliminate the oil leakage of the unit oil system.
2.2 Comparison of unit operation before and after the transformation 2.2.1 Comparison of the final outlet pressure PI02161 of the supercharger before and after the transformation and the turbine consumption of the air compressor (under the same speed of the unit) See the Jiangxi Chemical Table: Recording time before the transformation of the project 2010 9 On the 9th of June, 2010, the unit speed booster outlet pressure PI02161 turbine steam consumption before the transformation of the unit operation map (September 9, 2010 22:56) The following picture: pyridine i1 I w wide before the renovation Turbine steam consumption operation map (22:00, September 9, 2010). Below: The air compressor design technology of the air separation unit after the transformation of the unit operation map (June 13, 2012, 17:20) Turbine steam consumption operation map before transformation (17:00, June 13, 2012) Below: Jiangxi chemical speed setting fa 2.2.2 Gearbox high-speed shaft vibration before and after the transformation V0215A/B trend August 31, 010 V0215A/B vibration value trend on September 10. Below: V0215A/B vibration value trend from September 25th to October 12th, 2012. The following figure: Application of air compressor reforming technology of air separation unit 2.2.3 Oil leakage situation of unit before and after transformation Before the transformation, the cylinder joints of the unit are placed at the sealing point to place the oil tank, and the oil is about 200L per day. After the transformation of the oil leakage on the east side of the gear box before the transformation, the oil leakage points of the unit were eliminated.
In September 2012, after the completion of all the transformation, the 02 air compressor unit realized the high-load production of the air separation unit, the vibration of the gear box was effectively controlled, the oil leakage of the unit oil system was completely eliminated, and the unit on-site hygiene was refreshed and weakened. Environmental safety and pressure.
3. Benefit analysis (benefit calculation and explanation) The equipment cost (one fan) is 2000 yuan, the material fee (PEEK seal set 35000 yuan, non-embroidered steel pipe 4000 yuan) 39,000 yuan; the input inspection fee is 6000 yuan; 3.2 .1 After replacing the PEEK seals at all levels of the supercharger, the compressor outlet pressure is increased, the unit saves steam 10T/H, runs for 300 days throughout the year, steam 180 yuan / T. 1.5 million / year 3.2.3 per year Before the modification of the spare parts maintenance cost, due to the vibration of the gearbox of the unit, the gearbox of the unit should be overhauled once a month. The spare parts cost is 320,000, the labor cost is 3,000 yuan, and the cost is about 323,000 yuan. 5 calculations, saving maintenance costs of 1.615 million yuan a year.
In summary, one year can save direct costs of 16.075 million yuan.
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