高速泵齿轮损坏故障分析及处理

FAULT ANALYSIS AND TREATMENT OF THE DAMAGE OF HIGH-SPEED PUMP GEAR

文章针对国内某高压渣油加氢装置进口高速注水泵发生的诱导轮断裂及增速箱齿轮断齿问题,结合运行趋势中的振动、位移、流量和电流判断其故障先后顺序.通过频谱分析,排除了轴承及齿轮故障频率,最终确认故障原因为齿轮疲劳.为解决上述问题,决定对该齿轮进行更换.联系国内某机械设备研究所对齿轮进行1∶1测绘,同时签订技术协议,详细规定了齿面磨削精度、表面淬火处理后硬度、动平衡等级等多项重要参数,在加工厂制造完成并进行运转试验,之后再进行现场安装.齿轮更换后,振动、噪音都控制在较好水平.

This paper aims at the breakage of the inducer and gear fracture of the speed-increasing box in the imported high-speed water injection pump of a high-pressure residue hydrogenation unit in China.The sequence of failures was determined based on the vibration,displacement,flow and current in the operation trend.Through spectrum analysis,the fault frequency of bearings and gears was eliminated,and the cause of the fault was finally confirmed to be gear fatigue.In order to solve the above problems,the gear was replaced.A 1∶1 mapping of the gear was conducted by a domestic machinery and equipment research institute after contact.Meanwhile,a technical agreement was signed to specify many important parameters such as gear surface grinding accuracy,surface quenching hardness,dynamic balance grade and so forth. And the manufacturing of the gear was completed and the operation test was carried out in the processing factory.Then on-site installation was completed.After the gear was replaced,the vibration and noise were in normal range during operation.