风机常见故障的监测与诊断
摘要
风机是锅炉的主要辅助设备之一,按照介质在风机内的流动方向可分为离心式风机、轴流式风机和混流式风机。离心式风机是电厂中应用最多的风机,工作时叶轮里充满着流体,当叶轮转动时,流体也随着转动,因此流体就产生了离心力,由于离心力的作用,流体向出口流动,于是入口就形成了真空,在大气压力和入口压力的作用下,流体源源不断的流向叶轮入口,在由叶轮入口靠离心力作用流向出口,实现风机连续不断的输送介质的工作。
电厂除了三大风机之外,还有各种功能的风机,它们运行中岀现的各种问题,造成机组降低负荷,甚至被迫停机的现象时有发生,直接影响电厂的安全生产。风机运行中与其状态有关的特征有振动、温度、噪声、润滑油中的磨粒和形态、扭矩、扭振等,每个量都从各自不同的角度反映运行的状态,但由于现场条件和测试手段所限,有些特征的提取和分析不易实现,有些特征反映的情况不敏感。相对而言,风机的振动信号中含有设备运行工况的丰富信息,这些信息在振动的相位和谱图中有所体现,从而可以推断出振动的原因和故障类型。
本文结合多年的实践经验,对风机的不平衡、不对中、机械松动和轴承等常见故障的振动机理、振动特征及应对措施进行了分析和讨论,并例举了作者亲自监测、诊断与处理的风机故障实例,对降低风机故障、提高风机效率,实现电厂安全、稳定、经济运行发挥了重要作用。
The blower fan is the main facility of boiler, It can be sorted to centrifugal fan, axial flow fan and mixed flow fan according to the flow direction of medium in the fan. The centrifugal fan is the most one applying in power plant. The impeller was filled with medium during the fan works, the medium will rotate with the speller, thus, centrifugal force was produced. The medium will flow to outlet in the acting of centrifugal force, then the vacuum appears in the inlet. Under the action of atmospheric pressure and vacuum, the medium will flow to inlet of speller continuous, then to outlet with the centrifugal force.
Besides three main blower fan, there are many other function fan in the power plant. The power unit will lower the charge if something was wrong with the fans, or even stopping unit will be occurred. The safety in production of power plant was affected. The features of fan relating with it’s working behavior are vibration, temperature, noise, type of particle in the lubrication oil and torque etc, every parameter could reflect the working station from vary point of view, however, the field condition and testing method limited to pick-up and analysis the features. The vibration signal is the best one relatively which include rich information about the fan working condition, the reason of vibration and failure type could be concluded from the vibration phase and spectral graph.
The vibration mechanism, vibration character and solving method of fan’s failure, such as non-balance, mal-alignment and bearing loose etc., have been analyzed and discussed in this paper. Some failure examples which tested, diagnosed and deal with by the writer himself was listed, it is showed that vibration analysis has played important role in lowing the fan failure, rising the efficiency and safety production of the power plant.
电厂除了三大风机之外,还有各种功能的风机,它们运行中岀现的各种问题,造成机组降低负荷,甚至被迫停机的现象时有发生,直接影响电厂的安全生产。风机运行中与其状态有关的特征有振动、温度、噪声、润滑油中的磨粒和形态、扭矩、扭振等,每个量都从各自不同的角度反映运行的状态,但由于现场条件和测试手段所限,有些特征的提取和分析不易实现,有些特征反映的情况不敏感。相对而言,风机的振动信号中含有设备运行工况的丰富信息,这些信息在振动的相位和谱图中有所体现,从而可以推断出振动的原因和故障类型。
本文结合多年的实践经验,对风机的不平衡、不对中、机械松动和轴承等常见故障的振动机理、振动特征及应对措施进行了分析和讨论,并例举了作者亲自监测、诊断与处理的风机故障实例,对降低风机故障、提高风机效率,实现电厂安全、稳定、经济运行发挥了重要作用。
The blower fan is the main facility of boiler, It can be sorted to centrifugal fan, axial flow fan and mixed flow fan according to the flow direction of medium in the fan. The centrifugal fan is the most one applying in power plant. The impeller was filled with medium during the fan works, the medium will rotate with the speller, thus, centrifugal force was produced. The medium will flow to outlet in the acting of centrifugal force, then the vacuum appears in the inlet. Under the action of atmospheric pressure and vacuum, the medium will flow to inlet of speller continuous, then to outlet with the centrifugal force.
Besides three main blower fan, there are many other function fan in the power plant. The power unit will lower the charge if something was wrong with the fans, or even stopping unit will be occurred. The safety in production of power plant was affected. The features of fan relating with it’s working behavior are vibration, temperature, noise, type of particle in the lubrication oil and torque etc, every parameter could reflect the working station from vary point of view, however, the field condition and testing method limited to pick-up and analysis the features. The vibration signal is the best one relatively which include rich information about the fan working condition, the reason of vibration and failure type could be concluded from the vibration phase and spectral graph.
The vibration mechanism, vibration character and solving method of fan’s failure, such as non-balance, mal-alignment and bearing loose etc., have been analyzed and discussed in this paper. Some failure examples which tested, diagnosed and deal with by the writer himself was listed, it is showed that vibration analysis has played important role in lowing the fan failure, rising the efficiency and safety production of the power plant.
引文
[1] 李庆宜.通风机.北京:机械工业出版社,1981:15—17
[2] 续魁昌.风机手册. 北京:机械工业出版社,1995.5:27—32
[3] 张正松,傅尚新,冯冠平,徐玉铮.旋转机械振动监测及故障. 北京:机械工业出版社,1991:6—8
[4] 韩捷.张瑞林.旋转机械故障及诊断技术.北京:机械工业出版社,1997.8:1—3
[5] 夏松波等.旋转机械故障诊断技术的现状与展望.振动与冲击.1997,16(2):18—21
[6] 李方泽,刘馥清,王正.工程振动测试与分析.北京:高等教育出版社,1992.10:11—12
[7] B.Weichbrodt,“Mechanical Signature Analysis,A New Tool for product Assurance and Early Fault Detection”Research & Development Center,General Company,Schenectady,New York:28—32
[8] W.H.Dornfeld,“Design of a Signature Analysis System For Product and Machinery Condition Monitoring”a Thesis Submitted in Fulfillment of Doctor of Philosophy,University of Wisconsin-Madison:40—43
[9] D.R.Houser et al.,“Vibration Signal Analysis Technique”U.S.Army Air Mobility Research Development Laboratory Technical Report:64—68
[10] 贾民平,钟秉林.设备工况监视与故障诊断方式的研究.中国电力.1997.30(5):21—23
[11] 张安华,机械设备状态监测与故障诊断技术,西安:西北工业大学出版社,1997:56—60
[12] 邝朴生,蒋文科等.设备诊断工程.北京:中国农业科技出版社,1997.11:28—30
[13] 崔宁博编译.设备故障诊断技术-振动分析及其应用.天津:南开大学出版社,1988:8—11
[14] 丁玉兰,石来德.机械设备故障诊断技术.上海:上海科学技术文献出版社,1994:21—24
[15] 施维新.汽轮发电机组振动及事故.北京:中国电力出版社,1998.10:100—102
[16] 高金吉.旋转机械振动故障原因及识别特征研究.振动、测试与诊断,1995(3):29—31
[17] 陈长征,罗跃纲.风机现场动平衡研究.风机技术,2001(5)22-23
[18] 何青,杜冬梅,杨昆.风机振动的在线监测与动平衡.风机技术,2001(6):57-60
[19] [美]J.S.Mitchell 著,林明邦,皱桂根,潘京等译.机器故障的分析与监测. 北京:机械工业出版社,1990:150—151
[20] Schenck .Machine Diagnosis, Field Balancing, Shaft Alignment. Seminar C44e,1995,pp.101-120
[21] 扈英超主编.线性振动.北京:高等教育出版社,1981:23—24
[22] 钟一谔等.转子动力学.北京:清华大学出版社,1987:45—46
[23] 井町勇编著.机械振动学.北京:科学出版社,1979:25—27
[24] Thomson W T. Theory of Vibration With Application.Prentice,1972
[25] [西德]哈托·施奈德著.平衡技术理论与实践. 廖日岳译. 北京:机械工业出版社,1981:31—35
[26] 叶能安,余汝生.动平衡原理与动平衡机.华中工学院出版社,1985:45—47
[27] [日]三轮修三,下村玄.旋转机械动平衡.北京:机械工业出版社,1992:87—89
[28] 孙红春.多功能智能型转子故障诊断与平衡系统的研究.东北大学硕士论文,2001
[29] Thomas D.L. Vibration Monitoring Strategy for Large Turbo Generators. Vibration in Rotating Machinery.1984:91—100
[30] 王汉英.转子平衡技术与平衡机.北京:机械工业出版社,1998:28—31
[31] 陆颂元.汽轮发电机组振动.北京:电力工业出版社,2000:138—139
[32] W C Foiles,D E Bently. Balancing with Phase Only(Single-plane and Multiplane).Journal of vibration,Acoustics,Stress,and Reliability in Design,Vol.110,APRIL.1988,pp.151-157
[33] 徐兴科.对转子平衡配重的探讨.中国设备管理.1999(6):36—37
[34] 丛培田,李秀刚.单面现场动平衡解析三点加重法试验研究.风机技术,2001(6):36—37
[35] 胜利发电厂.Q/SSD007-1999,DG670-13.7/8A 锅炉检修规程,胜利石油管理局:巩汉强等,1999.12
[36] Jackson C.Successful shaft hot-aligment. Hydrocarbon Processing,1969,39:110—123
[37] 黄文虎,夏松波,刘瑞岩等.设备故障诊断原理、技术及应用. 北京:科学出版社,1996:210—214
[38] 顾晃.汽轮发电机组的振动与平衡.北京:中国电力出版社,1998.8:257—268
[39] 张游祖.汽轮发电机组的振动与转子找平衡.北京:水利电力出版社,1963:234—240
[40] 韩捷.齿式联接转子系统的对中故障机理与识别.振动、测试与诊断,1997(2):158—160
[41] 张瑞林.透平压缩机组转子不对中的振动频谱机理和识别.化工机械,1984(4):1—8
[42] 张瑞林,杜云天,张立广.不对中、不平衡频谱分析.化工机械,1983(5):1—9
[43] 胜利发电厂.Q/SSD012-1999,灰水部检修规程,胜利石油管理局:李俭等,1999.12
[44] 屈梁生,何正嘉.机械故障诊断学.上海:上海科学技术出扳社,1986.12:242—246
[45] 虞和济等编.振动诊断的工程应用.北京:冶金工业出版社,1992:112—115
[46] 陈克兴,李川奇主编.设备状态监测与故障诊断技术.北京:科学文献出版社,1991:118—124
[47] 臧朝平.旋转机械检测、诊断理论与方法的研究.东南大学,1994:134—140
[48] R Beebe. Machine condition monitoring. MCM Consultants Pty Ltd,1995,pp.237—254
[49] S.G.Brawn et al.,“Signature Analysis Method and Application for Rotating Machines.”ASME publication,77-WA/Aut-5
[50] 雷继尧,丁康.轴承故障诊断.西安:西安交通大学出版社,1991.7:197—201
[51] [日]丰田利夫著. 高克勣，李敏译.设备现场诊断的开机理展方法.北京:机械工业出版社,1985.10:250—261
[52] 万长森.滚动轴承分析方法.北京:机械工业出版社,1985:98—101
[53] 应怀樵编著.波形和频谱分析与随机数据处理.北京:中国铁道出版社,1985:138—142
[54] 沈庆根.化工机器故障振动技术.杭州:浙江大学出版社,1994:93—97
[55] Ming Xu,“Spike Energy and Its Applications”Shock and Vibration Digest,1995;Vol.27(3):11—17
[56] 陈华辉.引风机电动机轴承故障诊断分析.设备管理与维修,2004:8:29—30
[2] 续魁昌.风机手册. 北京:机械工业出版社,1995.5:27—32
[3] 张正松,傅尚新,冯冠平,徐玉铮.旋转机械振动监测及故障. 北京:机械工业出版社,1991:6—8
[4] 韩捷.张瑞林.旋转机械故障及诊断技术.北京:机械工业出版社,1997.8:1—3
[5] 夏松波等.旋转机械故障诊断技术的现状与展望.振动与冲击.1997,16(2):18—21
[6] 李方泽,刘馥清,王正.工程振动测试与分析.北京:高等教育出版社,1992.10:11—12
[7] B.Weichbrodt,“Mechanical Signature Analysis,A New Tool for product Assurance and Early Fault Detection”Research & Development Center,General Company,Schenectady,New York:28—32
[8] W.H.Dornfeld,“Design of a Signature Analysis System For Product and Machinery Condition Monitoring”a Thesis Submitted in Fulfillment of Doctor of Philosophy,University of Wisconsin-Madison:40—43
[9] D.R.Houser et al.,“Vibration Signal Analysis Technique”U.S.Army Air Mobility Research Development Laboratory Technical Report:64—68
[10] 贾民平,钟秉林.设备工况监视与故障诊断方式的研究.中国电力.1997.30(5):21—23
[11] 张安华,机械设备状态监测与故障诊断技术,西安:西北工业大学出版社,1997:56—60
[12] 邝朴生,蒋文科等.设备诊断工程.北京:中国农业科技出版社,1997.11:28—30
[13] 崔宁博编译.设备故障诊断技术-振动分析及其应用.天津:南开大学出版社,1988:8—11
[14] 丁玉兰,石来德.机械设备故障诊断技术.上海:上海科学技术文献出版社,1994:21—24
[15] 施维新.汽轮发电机组振动及事故.北京:中国电力出版社,1998.10:100—102
[16] 高金吉.旋转机械振动故障原因及识别特征研究.振动、测试与诊断,1995(3):29—31
[17] 陈长征,罗跃纲.风机现场动平衡研究.风机技术,2001(5)22-23
[18] 何青,杜冬梅,杨昆.风机振动的在线监测与动平衡.风机技术,2001(6):57-60
[19] [美]J.S.Mitchell 著,林明邦,皱桂根,潘京等译.机器故障的分析与监测. 北京:机械工业出版社,1990:150—151
[20] Schenck .Machine Diagnosis, Field Balancing, Shaft Alignment. Seminar C44e,1995,pp.101-120
[21] 扈英超主编.线性振动.北京:高等教育出版社,1981:23—24
[22] 钟一谔等.转子动力学.北京:清华大学出版社,1987:45—46
[23] 井町勇编著.机械振动学.北京:科学出版社,1979:25—27
[24] Thomson W T. Theory of Vibration With Application.Prentice,1972
[25] [西德]哈托·施奈德著.平衡技术理论与实践. 廖日岳译. 北京:机械工业出版社,1981:31—35
[26] 叶能安,余汝生.动平衡原理与动平衡机.华中工学院出版社,1985:45—47
[27] [日]三轮修三,下村玄.旋转机械动平衡.北京:机械工业出版社,1992:87—89
[28] 孙红春.多功能智能型转子故障诊断与平衡系统的研究.东北大学硕士论文,2001
[29] Thomas D.L. Vibration Monitoring Strategy for Large Turbo Generators. Vibration in Rotating Machinery.1984:91—100
[30] 王汉英.转子平衡技术与平衡机.北京:机械工业出版社,1998:28—31
[31] 陆颂元.汽轮发电机组振动.北京:电力工业出版社,2000:138—139
[32] W C Foiles,D E Bently. Balancing with Phase Only(Single-plane and Multiplane).Journal of vibration,Acoustics,Stress,and Reliability in Design,Vol.110,APRIL.1988,pp.151-157
[33] 徐兴科.对转子平衡配重的探讨.中国设备管理.1999(6):36—37
[34] 丛培田,李秀刚.单面现场动平衡解析三点加重法试验研究.风机技术,2001(6):36—37
[35] 胜利发电厂.Q/SSD007-1999,DG670-13.7/8A 锅炉检修规程,胜利石油管理局:巩汉强等,1999.12
[36] Jackson C.Successful shaft hot-aligment. Hydrocarbon Processing,1969,39:110—123
[37] 黄文虎,夏松波,刘瑞岩等.设备故障诊断原理、技术及应用. 北京:科学出版社,1996:210—214
[38] 顾晃.汽轮发电机组的振动与平衡.北京:中国电力出版社,1998.8:257—268
[39] 张游祖.汽轮发电机组的振动与转子找平衡.北京:水利电力出版社,1963:234—240
[40] 韩捷.齿式联接转子系统的对中故障机理与识别.振动、测试与诊断,1997(2):158—160
[41] 张瑞林.透平压缩机组转子不对中的振动频谱机理和识别.化工机械,1984(4):1—8
[42] 张瑞林,杜云天,张立广.不对中、不平衡频谱分析.化工机械,1983(5):1—9
[43] 胜利发电厂.Q/SSD012-1999,灰水部检修规程,胜利石油管理局:李俭等,1999.12
[44] 屈梁生,何正嘉.机械故障诊断学.上海:上海科学技术出扳社,1986.12:242—246
[45] 虞和济等编.振动诊断的工程应用.北京:冶金工业出版社,1992:112—115
[46] 陈克兴,李川奇主编.设备状态监测与故障诊断技术.北京:科学文献出版社,1991:118—124
[47] 臧朝平.旋转机械检测、诊断理论与方法的研究.东南大学,1994:134—140
[48] R Beebe. Machine condition monitoring. MCM Consultants Pty Ltd,1995,pp.237—254
[49] S.G.Brawn et al.,“Signature Analysis Method and Application for Rotating Machines.”ASME publication,77-WA/Aut-5
[50] 雷继尧,丁康.轴承故障诊断.西安:西安交通大学出版社,1991.7:197—201
[51] [日]丰田利夫著. 高克勣，李敏译.设备现场诊断的开机理展方法.北京:机械工业出版社,1985.10:250—261
[52] 万长森.滚动轴承分析方法.北京:机械工业出版社,1985:98—101
[53] 应怀樵编著.波形和频谱分析与随机数据处理.北京:中国铁道出版社,1985:138—142
[54] 沈庆根.化工机器故障振动技术.杭州:浙江大学出版社,1994:93—97
[55] Ming Xu,“Spike Energy and Its Applications”Shock and Vibration Digest,1995;Vol.27(3):11—17
[56] 陈华辉.引风机电动机轴承故障诊断分析.设备管理与维修,2004:8:29—30