大型水泵导轴承润滑与密封研究
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摘要
我国水泵站装机容量7000多万kW,其中,轴流泵及导叶式混流泵占很大比例,特别是正在建设的南水北调东线工程,全部采用大型轴流泵、混流泵或贯流泵。导轴承是大型水泵最为关键的易磨易损部件,故障率高,导轴承故障占泵机组故障的50%以上。研究水泵导轴承的润滑与密封特性,对减小轴承摩擦损耗,降低故障率,提高可靠性,节省泵站维护检修费用有重要意义。本文主要工作:
介绍了大型水泵导轴承的结构形式、工作原理和密封装置类型,针对导轴承应用中存在的问题,从设计、制造、安装等方面分析大型立式水泵导轴承荷载的影响因素,建立了导轴承概率荷载理论。利用流体动力学和摩擦润滑学研究水泵导轴承的润滑和密封特性。计算了油润滑导轴承上油压力和润滑油量,分析了可能发生的润滑故障;计算了清水润滑导轴承所需润滑水量和压力。推导了端面密封、梳齿迷宫密封的泄漏量计算公式和排密封漏水装置的排水量计算公式,计算了典型水泵导轴承的密封漏水量和排漏水量,并对结果进行了分析。最后,从材料、安装、检修、润滑、密封等方面对水泵导轴承进行综合比较,提出了水泵导轴承及其密封装置的选用原则。
研究结果表明:大型立式水泵导轴承荷载与进水流道和机组制造安装质量、结构形式有关。为了保证油润滑导轴承足够的润滑油压以形成循环,主轴必须具有一定的转速。螺旋槽参数、毕托管上油量和轴承间隙是影响油润滑导轴承润滑可靠性的主要因素。
正常情况下,端面密封漏水量比梳齿迷宫密封漏水量小得多,但如果端面密封的弹簧脱落,或顶车后静环座不能回落,或动静环承磨面凹凸不平,密封间隙增大,就会造成大量漏水、排水不及而危及轴承。
油润滑导轴承承载力大,但密封装置易失效。相比而言,水润滑导轴承结构简单,润滑条件容易得到保证,不存在浸水受损问题,但承载力小、耐磨性差。
Water pump station installed capacity in China is over 70,000 MW. The axial-flow pumps and diffuser mixed-flow pumps are in large proportion of them. Especially, large axial-flow pumps, diffuser mixed-flow pumps or tubular pumps are adopted in all pump stations of Eastern Route of South-to-North Water Transfer Project, which is being constructed. The guide bearing is the key part of a large water pump for its grindability. Its failure rate is very high, and its failure is above 50% of pump unit failure. Studying the guide bearing lubrication and seal performance of the large water pump is significant to decreasing bearing friction loss, lowering failure rate, improving the reliability, saving the maintenance and overhaul cost of pump station. Main works in this dissertation are as follows:
Structural styles, operation principles and sealing device types of large pump guide bearings were introduced. Aiming at the open question of guide bearings in application, the influencing factors of guide bearing load of large vertical pumps were analyzed from design, manufacture and installation. The probability load theory of the guide bearing was established. Lubricating and sealing characteristics of the guide bearing were researched by the aid of hydrodynamics and tribology. Lubricating oil pressure and quantity of guide bearings were calculated, probable lubricating malfunctions were analyzed, lubricating water quantity and pressure of clean-water-lubricated guide bearings were calculated. The leakage rate formula of mechanical face seals and comb labyrinth seals, and leakage drainage formula of seal leakage draining device were deduced. The leakage rate and leakage drainage rate of typical guide bearings were calculated. At last, the water pump guide bearings were comprehensively compared from materials, installation, inspection, lubrication, seal, and etc. The selection principles of water pump guide bearings and seal devices were put forward.
The results show that guide bearing load of large vertical water pump has something to do with inlet passage of pump station, pump unit manufacture and installation quality, structure pattern. In order to guarantee enough lubricating oil pressure of oil-lubricated guide bearings to form circulation, shaft must have certain rotational speed. Spiral groove parameter, oil quantity up through pitot tube and bearing clearance are the main factors that influence lubricating reliability of oil-lubricated guide bearings.
In normal conditions,the leakage rate of mechanical face seal is much less than comb labyrinth seal. But if the elastic springs of mechanical face seal pull off, or stationary seat can’t fall back after jacking, or wear faces of rotor and stationary seal ring are irregularity, sealing clearance becomes larger, so the bearings are endangered by large water leakage which can’t be drained in time.
The bearing capacity of oil-lubricated guide bearings is large, but sealing devices are easy to fail. In contrast, the structure of water-lubricated guide bearing is simple, the lubricating conditions are easy guaranteed, without the problem damaged by immersion, but the bearing capacity is small, and resistance to wear is poor.
介绍了大型水泵导轴承的结构形式、工作原理和密封装置类型,针对导轴承应用中存在的问题,从设计、制造、安装等方面分析大型立式水泵导轴承荷载的影响因素,建立了导轴承概率荷载理论。利用流体动力学和摩擦润滑学研究水泵导轴承的润滑和密封特性。计算了油润滑导轴承上油压力和润滑油量,分析了可能发生的润滑故障;计算了清水润滑导轴承所需润滑水量和压力。推导了端面密封、梳齿迷宫密封的泄漏量计算公式和排密封漏水装置的排水量计算公式,计算了典型水泵导轴承的密封漏水量和排漏水量,并对结果进行了分析。最后,从材料、安装、检修、润滑、密封等方面对水泵导轴承进行综合比较,提出了水泵导轴承及其密封装置的选用原则。
研究结果表明:大型立式水泵导轴承荷载与进水流道和机组制造安装质量、结构形式有关。为了保证油润滑导轴承足够的润滑油压以形成循环,主轴必须具有一定的转速。螺旋槽参数、毕托管上油量和轴承间隙是影响油润滑导轴承润滑可靠性的主要因素。
正常情况下,端面密封漏水量比梳齿迷宫密封漏水量小得多,但如果端面密封的弹簧脱落,或顶车后静环座不能回落,或动静环承磨面凹凸不平,密封间隙增大,就会造成大量漏水、排水不及而危及轴承。
油润滑导轴承承载力大,但密封装置易失效。相比而言,水润滑导轴承结构简单,润滑条件容易得到保证,不存在浸水受损问题,但承载力小、耐磨性差。
Water pump station installed capacity in China is over 70,000 MW. The axial-flow pumps and diffuser mixed-flow pumps are in large proportion of them. Especially, large axial-flow pumps, diffuser mixed-flow pumps or tubular pumps are adopted in all pump stations of Eastern Route of South-to-North Water Transfer Project, which is being constructed. The guide bearing is the key part of a large water pump for its grindability. Its failure rate is very high, and its failure is above 50% of pump unit failure. Studying the guide bearing lubrication and seal performance of the large water pump is significant to decreasing bearing friction loss, lowering failure rate, improving the reliability, saving the maintenance and overhaul cost of pump station. Main works in this dissertation are as follows:
Structural styles, operation principles and sealing device types of large pump guide bearings were introduced. Aiming at the open question of guide bearings in application, the influencing factors of guide bearing load of large vertical pumps were analyzed from design, manufacture and installation. The probability load theory of the guide bearing was established. Lubricating and sealing characteristics of the guide bearing were researched by the aid of hydrodynamics and tribology. Lubricating oil pressure and quantity of guide bearings were calculated, probable lubricating malfunctions were analyzed, lubricating water quantity and pressure of clean-water-lubricated guide bearings were calculated. The leakage rate formula of mechanical face seals and comb labyrinth seals, and leakage drainage formula of seal leakage draining device were deduced. The leakage rate and leakage drainage rate of typical guide bearings were calculated. At last, the water pump guide bearings were comprehensively compared from materials, installation, inspection, lubrication, seal, and etc. The selection principles of water pump guide bearings and seal devices were put forward.
The results show that guide bearing load of large vertical water pump has something to do with inlet passage of pump station, pump unit manufacture and installation quality, structure pattern. In order to guarantee enough lubricating oil pressure of oil-lubricated guide bearings to form circulation, shaft must have certain rotational speed. Spiral groove parameter, oil quantity up through pitot tube and bearing clearance are the main factors that influence lubricating reliability of oil-lubricated guide bearings.
In normal conditions,the leakage rate of mechanical face seal is much less than comb labyrinth seal. But if the elastic springs of mechanical face seal pull off, or stationary seat can’t fall back after jacking, or wear faces of rotor and stationary seal ring are irregularity, sealing clearance becomes larger, so the bearings are endangered by large water leakage which can’t be drained in time.
The bearing capacity of oil-lubricated guide bearings is large, but sealing devices are easy to fail. In contrast, the structure of water-lubricated guide bearing is simple, the lubricating conditions are easy guaranteed, without the problem damaged by immersion, but the bearing capacity is small, and resistance to wear is poor.
引文
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