罗茨鼓风机叶轮损坏事故分析及措施.doc

1、罗茨鼓风机叶轮损坏事故分析及措施摘要：通过对罗茨鼓风机叶轮脆裂损坏、齿轮轮齿变形断裂损坏和联轴器脆裂损坏的事故原因分析，采取了改进的措施，可有效预防此类事故的发生。关键词：罗茨鼓风机;齿轮;叶轮；断裂中图分类号:TH44 文献标志码:BAnalysis and Measures of Roots Blower Impeller Damage AccidentAbstract： Based on analyzing the accident reason of impeller embrittlement damage, gear teeth deformation and fracture d

2、amage and coupling embrittlement damage, the improvement measures are applied for the purpose of preventing similar accidents.Key words: roots blower; gear； impeller; fracture0 引言0 the introduction 罗茨鼓风机因其排气压力在允许范围内调节时具有流量变动小、压力选择范围宽和强制输气的特点而在冶金、化工及环保行业得到广泛应用。我单位安装有4台QT3L64WC型罗茨鼓风机，流量为90m3/min，升压80k

3、Pa，功率160kW，额定转速1 450r/min，使用润滑油为CKC1 50#重负荷工业齿轮油，于2010年12月建成试运行。风机设计用于污水处理站曝气池污水曝气、高效纤维过滤器反洗气源等，设计运行3运1备。自投运以来风机振动大，振动值甚至达到28mm/s，已超过国家规范一倍多1 。噪声达到115dB2 ,现场巡检、检修条件非常恶劣。2011年5月，运行中的一台罗茨风机发生爆裂事故，风机空气滤清器损坏、风机联轴器破裂成多块碎片、部分联轴器螺栓剪切断。风机联轴器防护罩脱落损坏，叶轮转动部分盘不动车。对机组前后油箱进行解体发现:同步齿轮损坏,轮齿脱落13个；齿轮侧有大量油泥；叶轮破碎成多块；所有

4、金属件无色泽发蓝痕迹;润滑油箱油位正常，润滑油色泽暗淡.Roots blower because of the exhaust pressure is within the scope of the permit regulation has a small flow changes, pressure range, width， and forced the characteristics of gas and is widely applied in metallurgy, chemical industry and environmental protection. I have 4 u

5、nits installed QT3L64WC type roots blower, the flow rate of 90 m3 / min, 80 kpa pressure, power 160 kw, rated speed 450 r/min， use the lubricating oil for CKC1 50 heavy load industrial gear oil, in December 2010 completed commissioning. Fan design for sewage treatment station sewage aeration aeratio

6、n, efficient fiber filter backwashing gas source, such as design run 3 1 case. Since put into operation the fan vibration, vibration value even to 28 mm/s， has exceeded national standard double 1。 Up to 115 db noise 2， onsite inspection and maintenance conditions are very bad。 In May 2011, roots blo

7、wer running a burst accidents， damage of fan, air filter， blower coupling broke into many pieces, cut off part of the coupling bolts。 Fan off damage coupling shield， the impeller rotating part plate of car. Disintegration of tank before and after the unit found that synchronous gear is damaged, 13 t

8、eeth fall off; Gear side there is a lot of sludge; Impeller broken into many pieces。 All metal parts have no blue color marks; Lubricating oil tank oil level is normal, oil colour and lustre is dim。 文档为个人收集整理，来源于网络文档为个人收集整理，来源于网络1 原因分析1 analysis of the causes 分析认为由以下原因造成了设备的损坏:Analysts say the equip

9、ment damage caused by the following reasons: 1） 机组在运行过程中，叶轮的同步性能破坏，导致叶轮发生碰撞是事故发生的直接原因。叶轮加工较为粗糙，型线不流畅,间隙不均匀。从解体后的宏观形貌看，有多处碰撞痕迹。罗茨风机运行时，排气温度为100110,据此数据分析，机组在运行过程中存在较大的内泄漏现象,影响了叶轮热膨胀对啮合间隙的影响，当轴承和同步齿轮磨损变形后，加之振动较大，叶轮与叶轮、叶轮与机壳发生碰撞事故。该型风机使用的是一对直齿圆柱同步齿轮，同步齿轮既作传动又起叶轮定位的双重作用，其精度和磨损状况直接影响叶轮的啮合，对同步齿轮的精度、耐磨性及表面

10、工艺处理都有较高的要求.从齿轮断裂的宏观形貌来看，在承受最大弯曲应力的齿根部断裂,轮齿塑形变形、磨损严重。轮齿材质分析结果表明：轮齿的材质为普通碳素钢,材质选择不当，轮齿热处理后的硬度未达到齿轮通用规范的硬度要求3 ，经一段时间的运行，磨损变形加剧后,传动精度降低，传动间隙发生了变化，较小的角位移引起叶轮较大的线位移，叶轮发生摩擦、碰撞,叶轮脆裂损坏,在强大的冲击力作用下，加之齿轮的缺陷，造成了齿轮大面积的轮齿断裂。如图1轮齿断裂变形图和图2风机叶轮脆裂图。材质分析见表1.1) unit in the process of operation, the impeller of the sync

11、hronization performance, cause impeller collision is the direct cause of the accident. Type line impeller machining is relatively rough， not smooth， uneven clearance。 Look from after the collapse of macroscopic morphology， there are more collisions. Roots blower is running, the exhaust temperature i

12、s 100 110 , on the basis of data analysis， unit within a larger operation process of leak phenomenon， influence the effect of thermal expansion of meshing clearance between the impeller， and synchronous gear wear deformation when bearing, combined with vibration is larger, the impeller and the impel

13、ler， the impeller and casing collision accident. The type fan USES a pair of straight tooth cylindrical gear synchronous synchronous gear for transmission and impeller positioning of the dual role, its accuracy directly affect the mesh of the impeller and wear， the synchronous gear's precision,

14、abrasion resistance and surface processing technology have higher requirements。 From gear fracture， macro view, under the maximum bending stress of tooth root fracture and tooth shape deformation， severe wear。 Tooth material analysis results show that the gear is made of ordinary carbon steel， impro

15、per material selection， the hardness after heat treatment of gear tooth did not reach the gear hardness requirements of general specification 3， after running for a period of time, wear and deformation increased， the transmission accuracy is reduced, the transmission gap changed, small linear displa

16、cement， angular displacement cause impeller impeller friction, collision， impeller brittleness damage, under the impact of the strong， combined with the gear of the defects， caused a large area of the gear tooth fracture。 As shown in figure 1 tooth fracture deformation and fan impeller embrittlement

17、 diagram in figure 2. Qualitative analysis are shown in table 1。 本文为互联网收集,请勿用作商业用途本文为互联网收集，请勿用作商业用途2） 联轴器制造质量低劣、加工粗糙是联轴器碎裂的根本原因。现场察看，联轴器内有大量气孔、夹渣，内部组织结构不均匀，键与键槽、联轴器与轴未可靠联接4 ，在叶轮损坏卡死的情况下，在惯性力、强大冲击载荷作用下联轴器脆性破裂飞出。如图3联轴器轴颈图、图4联轴器断裂图。2) the coupling manufacture poor quality, rough machining is coupling t

18、he root cause of the fracture. On-site visit, coupling with a large number of air hole, slag inclusion， internal organization structure is not uniform， no reliable connections between the key and keyway, coupling and 4， in the case of damage of impeller jammed, the inertial force， the strong couplin

19、g brittle fracture under impact loading。 As shown in figure 3 coupling shaft neck fracture figure figure， figure 4 coupling。 3） 传动轴气封、油封不可靠,失效，加剧了轴承、齿轮的磨损.工作腔内的高压气体从端面泄漏后，沿轴向进入轴承和齿轮箱，使齿轮箱、轴承内气体压力处于吸排气压力之间,箱内飞溅产生的润滑油雾和空气产生了循环。现场察看,润滑油污染严重，同步齿轮侧有大量油泥，油色泽发暗。传动轴气封、油封经一段时间的运行,密封效果变差，经过滤后还含有粉尘的空气进入轴承、齿轮侧，

20、造成了油液的污染，加剧了轴承、齿轮的磨损。同时解体发现，润滑油进入了气腔，排气腔的粉尘中含有油分。如图5润滑油色泽图。3) drive shaft seal， oil seal， unreliable, failure， aggravated the wear in the bearings， gears。 After the working cavity of high pressure gas leakage from the end face, along the axial direction into the bearings and gear box, gear box, bear

21、ing inner gas pressure between suction and exhaust pressure, the lubricating oil splash in the fog and air circulation。 On-site visit, lubricating oil pollution is serious， synchronous gear side has a large number of oil sludge， oil。 Shaft seal， oil seal， after a period of time running， sealing effe

22、ct， still contain dust in the air after filtering into the bearings， gears， causing the oil pollution， increase the bearing， gear wear and tear。 Disintegration found at the same time, the lubricating oil into the chamber, the exhaust chamber oil is contained in the dust。 As shown in figure 5 oil col

23、or chart. 文档为个人收集整理，来源于网络个人收集整理,勿做商业用途2 措施及结论2 measure and conclusion 鉴于罗茨风机发生了严重的设备事故，我单位全面更换了四台罗茨鼓风机。选购了转速为730r/min，其他参数与以前一样的风机设备。运行振动值为5mm/s、噪声为80dB，现场巡检、检修条件大大改善,设备安全可靠运行，取得良好效果，为今后罗茨鼓风机的选型改造提供了参考。Roots blower due to serious equipment accident, my unit fully replaced four roots blower。 Choose t

24、he speed of 730 r/min， other fan equipment parameters as before. Run the vibration value of 5 mm/s， the noise of 80 db， on-site inspection and maintenance conditions greatly improved, safe and reliable operation of the equipment, obtaining good results， for the future of roots blower selection trans

25、formation provides reference. 1） 高度重视罗茨风机齿轮的材质和热处理工艺，必须满足齿轮通用规范的要求。罗茨风机的齿轮既作传动又起叶轮定位的双重作用,对同步齿轮的精度、耐磨性及表面处理工艺都有较高的要求。1) attaches great importance to the material and heat treatment process was introduced.we, must meet the requirements of gear general specification. Roots blower gear for transmission

26、 and the impeller of the dual role of positioning precision of synchronous gear， wear resistance, and surface treatment technology have higher requirements. 2） 高度重视罗茨风机润滑油管理5 。罗茨风机齿轮、油与气侧密封的好坏可以通过润滑油的质量反映出来，润滑油质量变差,则加剧齿轮和轴承的磨损，油会进入气侧，影响空气质量。要定期检查润滑油的色泽、杂质、粘度及酸值的变化情况，发现异常需立即检修鼓风机。2) roots blower atta

27、ches great importance to the lubricant management 5. , oil and gas was introduced。we side seal is good or bad can be reflected by the quality of the lubricating oil， lubricating oil quality variation， the gear and bearing wear, and oil in the gas side， affect air quality. To check the colour and lus

28、tre of lubricating oil, acid value, viscosity and impurities， abnormal shall immediately repair blower。 3） 在满足工艺要求的情况下,尽可能选购低转速的罗茨风机,因为其振动和噪声小,运行周期长，更能满足环保站所的安全可靠运行的要求。3) in the case of meet the technological requirements， roots blower as far as possible choose low rotation speed， because of its vibration and noise is small, operation cycle is long， can meet the requirements of like is