核主泵用流体动静压型机械密封的性能研究与端面型槽优化设计
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摘要
一座百万千瓦级的压水堆核电站,有各种泵约130种,300台左右,其中反应堆冷却剂泵(Reactor Coolant Pump,简写为RCP,也简称为核主泵)属于核Ⅰ级泵,被称为反应堆安全运行的心脏。轴端机械密封是核主泵的关键部件,主要用于控制反应堆冷却剂沿核主泵泵轴的泄漏,与主泵的安全、可靠运行密切相关。据不完全统计,核电站放射性物质的泄漏原因40%起因于各类阀门密封不严,20%起因于核主泵轴端机械密封或轴承密封故障,其中最典型的事例是1979年美国三厘岛核泄漏事故,其起因就是核主泵轴端机械密封出现故障而引起,这次事故造成的直接经济损失高达7亿美元。目前,我国核主泵密封还完全依赖进口,不仅价格高,而且供货数量上还受限制,国家最高领导层及相关部委对此高度重视。因此,开展核主泵机械密封的设计理论与方法研究,揭示机械密封各结构件之间的协同作用原理与密封机理,准确预测机械密封在高参数状态下的工作模式与规律,研究并开发拥有我国自主知识产权的高参数核主泵机械密封,填补我国核技术领域的空白,从根本上解决目前迫切需要解决的核级密封问题,不仅对我国核电工业的快速与健康发展意义重大,而且对我国国民经济的长期持续发展与社会稳定具有十分重要的实际意义和战略意义。
本文针对目前国内外在役使用核主泵机械密封的结构特点及其在高参数操作条件下易受端面热弹变形影响的工作特点,主要开展密封热-流-固耦合分析,在现有核主泵主型机械密封结构的基础上,发明新型结构并开展相关设计理论与加工制造方法研究。主要研究内容和结论如下：
(1)考虑机械密封端面间密封流体流态的影响及流体粘度随压力与温度的变化,构建了三维稳态传热模型以及端面流体膜压力和密封环温度的控制方程,交叉采用有限元法及有限差分法并基于Matlab(?)件编制相应计算程序求解了有关方程；基于有限元轴对称变形理论计算密封环的热变形和力变形,对密封进行热-流-固耦合分析,研究了热弹变形对密封性能的影响规律；同时研究了端面温度、热弹变形、端面流体膜平衡间隙等参数随端面表面织构产生的变化规律。
(2)提出了核主泵用双锥面流体静压型机械密封新结构,给出了锥面流体静压型机械密封端面几何参数的统一定义,并对其端面几何结构进行了优化设计；对比分析研究了双锥面与单锥面流体静压型机械密封在高操作参数条件下的密封性能,结果证明了双锥面机械密封具有比传统单锥面机械密封较大的液膜刚度和较高的可靠性,其中端面全加工双锥面机械密封比部分加工双锥面机械密封具有更好的稳定性与可靠性。
(3)研究了不同流态下双锥面流体静压型机械密封的密封性能变化规律,揭示了不同流态下双锥面密封的密封环温度场、端面液膜压力分布和端面液膜刚度的变化规律,以及双锥面密封相比较单锥面密封对流态和端面倾角的敏感度；通过不同流态下摩擦副配对材料对双锥面密封性能影响的研究,证实了目前SiC-SiC、WC-WC和A1203-A1203三种常用配对副的合理性。
(4)系统对比研究了端面毫微米跨尺度孔对多孔端面机械密封性能的影响,提出并证实了大孔端面机械密封应用于高操作参数条件下核主泵的优势；基于大孔端面的流体动压效应,综合流体静压型机械密封和流体动压型机械密封的各自优点,提出了新型锥-孔组合端面流体动静压型机械密封,证明其相比于双锥面密封不仅具有高开启特性和液膜刚度,而且具有优良的耐磨性,给出了核主泵操作条件下这种新型机械密封端面几何形貌的优选值。
(5)基于密封环的变形可控原理,提出了核主泵流体静压型机械密封端面锥度的设计与加工方法,成功加工出具有较高精度的单锥面机械密封和双锥面机械密封,在此基础上采用激光蚀刻技术加工端面多孔,样品成功用于实验研究。
(6)自主设计并搭建了核主泵用机械密封缩小型试验装置,通过测量端面温度,液膜厚度,泄漏率对核主泵用单锥度、双锥度流体静压型机械密封,锥面-微孔、锥面-大孔、锥面-超大孔组合端面流体动静压型机械密封进行了对比研究,验证了部分理论预测结果,证明了新型双锥-大孔组合端面流体动静压型机械密封的先进性和可靠性。
A million-kilowatt PWR plant has about130kinds of pumps. The reactor main coolant pump(RCP) is the heart of the reactor. The main pump seal is the key component mainly used for control the leakage along the pump shaft, which is important to the safty and reliability of the reactor main coolant pump. According to incomplete statistics,40%of the radioactive material leakage accident is due to the seal problem of the valve, and20%was caused by the mechanical seal for reactor main coolant pump. The accident at Three Mile Island nuclear power plant in America was caused by the failure of the mechanical seal, and the financial loss is about700million dollars. At present, the mechanical seals for reactor main coolant pump still depend on import completely, which have the high price and the limited supply quantity. The highest leadership and the related ministries and commissions have attached great importance to the problem. So to research the theory and methods of the design of the mechanical seal for reactor main coolant pumps, to explore the seal mechanism and the synergistic effect theory of each part of the seal, to predict the working mode and rule under the high parameter condition, to have the mechanical seal for high parameter condition with our own patents can solve the nuclear seal problem fundamentally and fill the gap in the fields of nuclear technology, which not only have big significance to the development of the nuclear power industry but also have strategic significance to the social stability and the long-term sustainable development of the national economy.
This paper mainly worked on the thermal-fluid-solid coupling analysis and the invention of the new structure and the research of the design theory and the manufacture methods based on the property of the existing structure of the seal and the susceptibility to the thermal elastic deformation under the high parameter condition. The main contents and conclusions are as follows:
(1) An3-D steady state heat transfer model and a thermo-elasto-hydrostatic coupling model were established by considering the variation of dynamic viscosity with fluid pressure and temperature, heat transfer between lubrication film and seal rings and the deformation of end faces. The governing equations for fluid film pressure and temperature were numerically solved by using finite difference method, and the thermal-mechanical deformations were simulated by using finite element method based on the program of Matlab. The thermal-fluid-solid coupled analyses were carried and the changes of the face temperature, thermo-elastic deformation and the equilibrium clearance with the surface texture and the effect to the sealing performance were studied.
(2) A new type of double tapered hydrostatic mechanical seal was proposed, and the unified definition of face geometry parameter of the mechanical seal was given, and the optimization design face geometry structure was conducted. The comparison of performance of the single and double tapered hydrostatic mechanical seal in the high operation parameters was analysed. The results validated that the double tapered hydrostatic seal has much higher film stiffness and reliability compared with the traditional single tapered mechanical seal, from which we know that seal face with full double tapered structure have higher stability and reliability than partial tapered structure.
(3) The performance variation laws of double tapered fluid hydrodynamic mechanical seal in different flow regime has been investigated. The seal temperature distribution field, face liquid film pressure distribution as well as the varying law of face liquid stiffness of double tapered seal in various flow regime were clarified, coupled with double tapered mechanical seal's sensitivity towards the flow regime and the face inclinational angle. In comparison to the single tapered structure. The rationality of the highly recommended selection of three friction pair matches, ie, SiC-SiC, WC-WC, Al2O3-Al2O3is verified through the investigation of the influence of matching materials in friction pair towards the double tapered mechanical seal performance in different flow regime.
(4) The comparision of the influence of the pores with mm scale and urn scale on the seal performance of the laser textured surface mechanical seal was studied. The mechanical seal with big pores was proposed whose advantage was also proved. The new type of mechanical seal with both surface pores and convergent coning was proposed based on the hydrodynamic effect of the big pores and the advantage of hydrostatic and hydrodynamic mechanical seal, which proved that double tapered mechanical seal not only have high opening force and film stiffness but also have excellentg wear resistance. And the best geometrical structure of the new type of mechanical seal for reactor coolant pump.
(5) The method of design and manufacture of the taper of the hydrostatic mechanical seal for reactor coolant pumps. Single tapered and double tapered mechanical seal were manufactured successfully and accurately.the pores manufactured successfully with laser etching technology, based on which sample was successfully used to experimental research.
(6) The narrow type test device of the mechanical seal for main coolant pump was designed and built. By measuring the temperature, film thickness and the leakage rate, the comprison research of the single tapered mechanical seal and double tapered mechanical seal, the mechanical seal with both surface micropores and convergent coning, the mechanical seal with both surface big pores and convergent coning, the mechanical seal with both surface huge pores and convergent coning was studied, which proved the accuracy of the theoretical prediction and the advancement and reliability of the new type of mechanical seal with both big pores and convergent coning.
本文针对目前国内外在役使用核主泵机械密封的结构特点及其在高参数操作条件下易受端面热弹变形影响的工作特点,主要开展密封热-流-固耦合分析,在现有核主泵主型机械密封结构的基础上,发明新型结构并开展相关设计理论与加工制造方法研究。主要研究内容和结论如下：
(1)考虑机械密封端面间密封流体流态的影响及流体粘度随压力与温度的变化,构建了三维稳态传热模型以及端面流体膜压力和密封环温度的控制方程,交叉采用有限元法及有限差分法并基于Matlab(?)件编制相应计算程序求解了有关方程；基于有限元轴对称变形理论计算密封环的热变形和力变形,对密封进行热-流-固耦合分析,研究了热弹变形对密封性能的影响规律；同时研究了端面温度、热弹变形、端面流体膜平衡间隙等参数随端面表面织构产生的变化规律。
(2)提出了核主泵用双锥面流体静压型机械密封新结构,给出了锥面流体静压型机械密封端面几何参数的统一定义,并对其端面几何结构进行了优化设计；对比分析研究了双锥面与单锥面流体静压型机械密封在高操作参数条件下的密封性能,结果证明了双锥面机械密封具有比传统单锥面机械密封较大的液膜刚度和较高的可靠性,其中端面全加工双锥面机械密封比部分加工双锥面机械密封具有更好的稳定性与可靠性。
(3)研究了不同流态下双锥面流体静压型机械密封的密封性能变化规律,揭示了不同流态下双锥面密封的密封环温度场、端面液膜压力分布和端面液膜刚度的变化规律,以及双锥面密封相比较单锥面密封对流态和端面倾角的敏感度；通过不同流态下摩擦副配对材料对双锥面密封性能影响的研究,证实了目前SiC-SiC、WC-WC和A1203-A1203三种常用配对副的合理性。
(4)系统对比研究了端面毫微米跨尺度孔对多孔端面机械密封性能的影响,提出并证实了大孔端面机械密封应用于高操作参数条件下核主泵的优势；基于大孔端面的流体动压效应,综合流体静压型机械密封和流体动压型机械密封的各自优点,提出了新型锥-孔组合端面流体动静压型机械密封,证明其相比于双锥面密封不仅具有高开启特性和液膜刚度,而且具有优良的耐磨性,给出了核主泵操作条件下这种新型机械密封端面几何形貌的优选值。
(5)基于密封环的变形可控原理,提出了核主泵流体静压型机械密封端面锥度的设计与加工方法,成功加工出具有较高精度的单锥面机械密封和双锥面机械密封,在此基础上采用激光蚀刻技术加工端面多孔,样品成功用于实验研究。
(6)自主设计并搭建了核主泵用机械密封缩小型试验装置,通过测量端面温度,液膜厚度,泄漏率对核主泵用单锥度、双锥度流体静压型机械密封,锥面-微孔、锥面-大孔、锥面-超大孔组合端面流体动静压型机械密封进行了对比研究,验证了部分理论预测结果,证明了新型双锥-大孔组合端面流体动静压型机械密封的先进性和可靠性。
A million-kilowatt PWR plant has about130kinds of pumps. The reactor main coolant pump(RCP) is the heart of the reactor. The main pump seal is the key component mainly used for control the leakage along the pump shaft, which is important to the safty and reliability of the reactor main coolant pump. According to incomplete statistics,40%of the radioactive material leakage accident is due to the seal problem of the valve, and20%was caused by the mechanical seal for reactor main coolant pump. The accident at Three Mile Island nuclear power plant in America was caused by the failure of the mechanical seal, and the financial loss is about700million dollars. At present, the mechanical seals for reactor main coolant pump still depend on import completely, which have the high price and the limited supply quantity. The highest leadership and the related ministries and commissions have attached great importance to the problem. So to research the theory and methods of the design of the mechanical seal for reactor main coolant pumps, to explore the seal mechanism and the synergistic effect theory of each part of the seal, to predict the working mode and rule under the high parameter condition, to have the mechanical seal for high parameter condition with our own patents can solve the nuclear seal problem fundamentally and fill the gap in the fields of nuclear technology, which not only have big significance to the development of the nuclear power industry but also have strategic significance to the social stability and the long-term sustainable development of the national economy.
This paper mainly worked on the thermal-fluid-solid coupling analysis and the invention of the new structure and the research of the design theory and the manufacture methods based on the property of the existing structure of the seal and the susceptibility to the thermal elastic deformation under the high parameter condition. The main contents and conclusions are as follows:
(1) An3-D steady state heat transfer model and a thermo-elasto-hydrostatic coupling model were established by considering the variation of dynamic viscosity with fluid pressure and temperature, heat transfer between lubrication film and seal rings and the deformation of end faces. The governing equations for fluid film pressure and temperature were numerically solved by using finite difference method, and the thermal-mechanical deformations were simulated by using finite element method based on the program of Matlab. The thermal-fluid-solid coupled analyses were carried and the changes of the face temperature, thermo-elastic deformation and the equilibrium clearance with the surface texture and the effect to the sealing performance were studied.
(2) A new type of double tapered hydrostatic mechanical seal was proposed, and the unified definition of face geometry parameter of the mechanical seal was given, and the optimization design face geometry structure was conducted. The comparison of performance of the single and double tapered hydrostatic mechanical seal in the high operation parameters was analysed. The results validated that the double tapered hydrostatic seal has much higher film stiffness and reliability compared with the traditional single tapered mechanical seal, from which we know that seal face with full double tapered structure have higher stability and reliability than partial tapered structure.
(3) The performance variation laws of double tapered fluid hydrodynamic mechanical seal in different flow regime has been investigated. The seal temperature distribution field, face liquid film pressure distribution as well as the varying law of face liquid stiffness of double tapered seal in various flow regime were clarified, coupled with double tapered mechanical seal's sensitivity towards the flow regime and the face inclinational angle. In comparison to the single tapered structure. The rationality of the highly recommended selection of three friction pair matches, ie, SiC-SiC, WC-WC, Al2O3-Al2O3is verified through the investigation of the influence of matching materials in friction pair towards the double tapered mechanical seal performance in different flow regime.
(4) The comparision of the influence of the pores with mm scale and urn scale on the seal performance of the laser textured surface mechanical seal was studied. The mechanical seal with big pores was proposed whose advantage was also proved. The new type of mechanical seal with both surface pores and convergent coning was proposed based on the hydrodynamic effect of the big pores and the advantage of hydrostatic and hydrodynamic mechanical seal, which proved that double tapered mechanical seal not only have high opening force and film stiffness but also have excellentg wear resistance. And the best geometrical structure of the new type of mechanical seal for reactor coolant pump.
(5) The method of design and manufacture of the taper of the hydrostatic mechanical seal for reactor coolant pumps. Single tapered and double tapered mechanical seal were manufactured successfully and accurately.the pores manufactured successfully with laser etching technology, based on which sample was successfully used to experimental research.
(6) The narrow type test device of the mechanical seal for main coolant pump was designed and built. By measuring the temperature, film thickness and the leakage rate, the comprison research of the single tapered mechanical seal and double tapered mechanical seal, the mechanical seal with both surface micropores and convergent coning, the mechanical seal with both surface big pores and convergent coning, the mechanical seal with both surface huge pores and convergent coning was studied, which proved the accuracy of the theoretical prediction and the advancement and reliability of the new type of mechanical seal with both big pores and convergent coning.
引文
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