CN114909274A - Installation method of ethylene glycol project tail gas recovery PSA reciprocating compressor - Google Patents
Installation method of ethylene glycol project tail gas recovery PSA reciprocating compressor Download PDFInfo
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- CN114909274A CN114909274A CN202210615071.7A CN202210615071A CN114909274A CN 114909274 A CN114909274 A CN 114909274A CN 202210615071 A CN202210615071 A CN 202210615071A CN 114909274 A CN114909274 A CN 114909274A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/14—Provisions for readily assembling or disassembling
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/32—Foundations for special purposes
- E02D27/44—Foundations for machines, engines or ordnance
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D2250/00—Production methods
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses a method for installing a PSA reciprocating compressor for recovering tail gas of an ethylene glycol project, which comprises the steps of in-place preliminary alignment of a body in a machine body, primary grouting, fine alignment of the body in the machine body, secondary grouting, crankshaft installation, connecting rods, crosshead installation, cylinders, fillers, an oil scraper installation, piston assembly installation, cylinder cover installation, unit cleaning and sealing, in-place alignment grouting for installation of a motor and accessory equipment, process tubing, pressure test, purging, electricity, instruments, installation and debugging, empty load test, an air charging valve and load test.
Description
Technical Field
The invention belongs to the field of equipment installation, and particularly relates to a method for installing a PSA reciprocating compressor for recovering tail gas of an ethylene glycol project.
Background
The piston type compressor is often used in some large-scale chemical enterprises, and because the piston type compressor is large in size and difficult to integrally transport, when a machine tool leaves a factory, a machine body and a middle body are disassembled and respectively packaged, and then assembled on site; however, the field installation and debugging program is complex, the technical requirement is high, the field adjustment is needed in many places, the adjustment cannot reach the standard, the progress of the whole installation work is influenced, the running quality of the compressor is directly influenced by the installation quality of the machine, and equipment or personal accidents can be seriously caused.
Disclosure of Invention
In order to solve the problems, the invention discloses a method for installing a PSA reciprocating compressor for recovering ethylene glycol project tail gas, which optimizes the installation technology, thereby achieving the purposes of reducing labor intensity, improving the installation quality of the compressor and shortening the construction period, providing continuous and stable pressure for process reaction and reducing the gas conveying cost.
In order to achieve the purpose, the technical scheme of the invention is as follows:
the installation method of the PSA reciprocating compressor for recovering the tail gas of the ethylene glycol project comprises the following steps:
(1) base treatment
Shoveling the surface of the foundation to form a pitted surface, wherein each square decimeter of pitted surface is 3-5, and the depth is not less than 10 mm; the oil stain and the loose layer on the surface are uniformly distributed, and the oil stain and the loose layer are uniformly removed;
and (3) shoveling the sizing block seat slurry pit, locally erecting templates around the sizing block seat slurry pit, re-marking a longitudinal and transverse central line, and marking an elevation on the side surface of the foundation.
And placing a temporary sizing block, marking the elevation with a level gauge, and waiting for the machine body and the middle body to be in place.
(2) Fuselage-in-body mounting
Firstly, assembling a machine body and a middle body together, hoisting in place:
when the equipment leaves a factory, the machine body and the middle body are disassembled and respectively packaged, and when the machine body middle body is installed on site, the machine body and the middle body are assembled firstly and then lifted to a foundation to be in place;
aligning and grouting the middle body of the machine body at one time:
the assembled machine body and the middle body are put in place on a sizing block with the found elevation, the levelness is measured by a frame type level meter, the initial levelness is temporarily 0.1mm/m in a natural state, the axial levelness is based on a bearing hole, the column-direction levelness is based on a middle body slideway and is measured at the front, middle and rear three-point positions of the slideway. Measuring the deviation of the central line, and performing primary grouting by using high-strength non-shrinkage grouting material after the deviation of the central line does not exceed the standard;
thirdly, primary grouting maintenance: and covering with cotton felt after grouting, spraying water and maintaining, and keeping the surface of the mortar in a wet state all the time.
Precisely finding the machine body and the middle body and performing secondary grouting:
after the primary grouting reaches the specified strength, the secondary alignment is carried out on the machine body and the middle body: uniformly and gradually screwing the foundation nuts of the machine body and the middle body according to the sequence, checking the levelness of the machine body and the middle body, adjusting the sizing block and calibrating the sizing block if the levelness of the machine body and the middle body is changed until some nuts are screwed, and the levelness of the machine body and the middle body accords with a specified value;
(3) crankshaft mounting
Placing a lower half bush of a main bearing in a main bearing hole of a machine body, hoisting a crankshaft into the machine body to be in place, placing an upper main bearing bush and a main bearing cover, screwing the bearing cover, pressing a nut, screwing a torque according to a regulation, completing in three times, and then rechecking once;
(4) connecting rod and crosshead mounting
And (3) placing the crosshead into the middle body slideway, connecting the small end of the connecting rod with the crosshead, and connecting the large end of the connecting rod with the crank pin. A connecting rod big head tile and a crank pin;
(5) installation of cylinder, filler and oil wiper
Firstly, filling the filler into the filler hole of the filler box, uniformly screwing the fixing bolt to tightly press the filler box, arranging the oil wiper on the middle body,
the mounting steps of each row of cylinders are as follows: the cylinder base is arranged in the cylinder body and then arranged on the middle body together, and the coaxiality is checked;
(6) mounting a piston assembly, connecting a piston rod with a crosshead, and mounting a piston ring;
(7) cylinder cover installation and cylinder dead point clearance adjustment
Installing a cylinder cover, measuring the dead point gap of the cylinder by a lead pressing method, and adjusting the dead point gap of the piston and the cylinder by configuring the thickness of a cylinder adjusting pad;
(8) the turning motor is installed and aligned, and the turning motor is aligned with the turning coupling;
(9) installing a main motor: the motor and the compressor coupler are connected by a keyless expansion sleeve;
(10) installing auxiliary equipment: the auxiliary equipment such as buffers, coolers, separators, pipelines, water stations and thin oil stations at all levels are installed according to the standard, and the electric and instrument installation and debugging are carried out;
(11) compressor oil circulation: the installation of compressor host computer finishes and overall inspection is qualified, and the chain debugging of all electric instruments is accomplished, just needs to begin oil circulation work: injecting specified lubricating oil, temporarily detaching oil pipelines without a bearing bush, a machine body and a slide way, connecting the oil pipelines to a machine body crankcase and a middle body by using transparent steel wire rubber pipes, resetting all the oil pipes, sequentially adding 80-200 meshes of filter screens at the joint of an oil inlet main pipe and a flange of equipment, restarting an oil pump to continuously carry out system flushing, checking each oil supply point, adjusting the oil supply amount, checking a thin oil station filter, debugging a lubricating system interlocking device after the filter differential pressure value is not more than 0.02MPa after operation is qualified, starting a jigger, checking the oil supply amount of each part, removing all the lubricating oil in the oil tank after the oil system is qualified in test operation, cleaning the oil tank and replacing new qualified lubricating oil;
(12) the cooling water system is tested and operated: connecting clean cooling water provided by a public project, checking whether the pressure of a cooling water system is normal, timely eliminating the leakage condition of the system, and checking whether a loop is smooth;
(13) and (3) testing the empty load: the suction and exhaust valves of each stage are not installed, and the suction and exhaust port pipe sections of each stage of cylinder are not communicated; connecting a lubricating pipeline and a cooling water pipeline to enable the lubricating pipeline and the cooling water pipeline to reach respective lubricating points and cooling parts, turning for data transmission, then starting a main motor by inching to check whether the rotating direction of the main motor is correct, starting the main motor to enable a compressor to reach a rated rotating speed, operating for 2 hours, and checking the operating conditions of each part, a contact surface, a lubricating point and a pipeline;
(14) and (3) air valve installation: assembling the cleaned parts according to an assembly diagram, wherein the free heights of the springs of the same valve plate are consistent for the valve springs; then screwing the assembled air valve on a pressure valve cover and installing the air valve into a cylinder valve cavity;
(15) and (3) purging the system: the suction valve and the exhaust valve of each stage of cylinder are installed, the exhaust port of each stage of cylinder is communicated with the accessory equipment and the pipeline system, the air suction port of each stage of cylinder is separately swept with the air inlet pipeline, the air inlet pipeline of the first stage is swept by using the loop pipeline,
(16) air load test run: after the work of idle load operation, inspection and the like is finished, the load of the compressor is gradually increased until the preset load is finally reached, the pressure is gradually increased, the air is used as a medium, the pressure increase and the operation time are controlled, the pressure increase is slowly carried out, the low-pressure-stage loop valve is firstly closed, and then the high-pressure-stage valve is gradually closed.
As an improvement of the invention, when the middle body is assembled on the machine body in the step (2), the lower edge of the flange of the middle body is closely contacted with the corresponding part of the machine body, and each bolt achieves the required pretightening force.
As an improvement of the invention, the primary grouting in the step (2) is carried out, water is fully used for wetting the hole wall 12 hours before grouting, accumulated water in the hole is cleaned before formal grouting, the grouting process cannot be vibrated, a self-flowing mode is completely adopted, dry materials are scattered to absorb water when a bleeding phenomenon occurs, formal sizing blocks are placed after bleeding does not occur on the surface of the primary grouting layer or water stains disappear, and the allowable deviation of the elevation of the upper surface of the sizing block is +/-0.5 mm.
As an improvement of the invention, the expansion sleeve screw in the step (9) is screwed by a torque wrench three times according to a symmetrical and crossed sequence.
As a modification of the invention, after the main motor is installed in the step (9), the motor shaft and the compressor crankshaft are coaxial, the radial displacement of the motor shaft and the compressor crankshaft is not more than 0.03mm, and the axial inclination is not more than 0.05/1000.
As an improvement of the invention, when the lubricating oil is injected in the step (11), a 80-mesh filter screen is bound at the pipe orifice of the transparent steel wire rubber pipe.
As an improvement of the invention, after the lubricating oil is injected in the step (11), a metal filter screen of 80-200 meshes is sequentially replaced at an oil return port of a thin oil station for oil flushing and filtering, and the filter screen is replaced once every 3 hours until no hard particles are visually observed on the screen, and no more than 3 points of soft dirt in the range of every square centimeter are qualified.
As an improvement of the invention, in the step (14), when the air valve is installed, the bolt extending out of the air valve is screwed on by using the air valve handle, then the air valve is taken up by using the air valve handle to be in place, and then the valve cylinder and the valve cover are sequentially installed.
The invention has the beneficial effects that:
according to the installation method of the PSA reciprocating compressor for recovering the tail gas of the ethylene glycol project, disclosed by the invention, the installation quality meets the standard by optimizing the installation technology, the labor intensity is reduced, the construction period is shortened, continuous and stable pressure can be provided for process reaction after equipment is installed, and the gas conveying cost is reduced.
Drawings
Fig. 1 is an installation flow chart of the present invention.
Detailed Description
The present invention will be further illustrated with reference to the accompanying drawings and specific embodiments, which are to be understood as merely illustrative of the invention and not as limiting the scope of the invention.
Taking 100 ten thousand tons/year synthesis gas to ethylene glycol project of Xinjiang XX group Limited company as an example, 60 ten thousand tons/year synthesis gas to ethylene glycol recycle gas, six piston compressors need to be installed in the project tail gas recovery device, and the working principle is as follows: from a PSA-H2 resolved gas (0.02 MPa) → recovered gas reciprocating compressor primary inlet total gas-water separator, the separated gas enters a primary buffer, the gas enters two primary compression cylinders from the primary buffer in two ways respectively, the gas is converged into a first-stage exhaust buffer after primary compression and pressurization, the gas is cooled by a primary tube type heat exchanger, and the gas enters a primary oil-water separator for oil-water separation → two parts: the driving air quantity of the separator is controlled by a regulating valve before one part of the separator is removed from the first-stage inlet; the other part enters a second-level gas buffer for separation, enters a second-level cylinder and a third-level cylinder for pressurization, cooling and separation, one part enters a first-level separator and a second-level separator, the gas flow of the system is controlled and regulated by a regulating valve, the system is started and stopped, and the other part enters a conversion process. The basic task of the project is to provide continuous and stable pressure for the process reaction, reduce the gas conveying cost and be a power source for the gas to flow in the process.
The device has six piston compressors, and the model number is MW-140/0.2-15.
The specific compressor mounting process comprises
1 preparation in the early stage
Firstly, the surface of a foundation needing secondary grouting is spaded with pitted surfaces, the number of pitted points is 3-5 per square decimeter, the depth is not less than 10mm, the pitted surfaces are uniformly distributed, and oil stains and loose layers on the surface are uniformly removed.
And secondly, shoveling the sizing block seat slurry pit, locally erecting templates around the sizing block seat slurry pit, re-marking a longitudinal and transverse center line, and marking an elevation on the side surface of the foundation.
Thirdly, placing a temporary sizing block, marking the elevation with a level gauge, and waiting for the machine body and the middle body to be in place.
2 fuselage mid-body installation
The machine body and the middle body are assembled together and hoisted in place. When the machine leaves a factory, the machine body and the middle body are disassembled and respectively packaged, and when the machine body middle body is installed on site, the machine body and the middle body can be assembled firstly and then hoisted to the foundation to be in place, or can be respectively hoisted to the foundation and then assembled. When the middle body is assembled on the machine body, attention should be paid to the fact that the lower edge of the middle body flange is in close contact with the corresponding part of the machine body along the platform surface, and as the connecting bolts between the middle body and the machine body are screwed down from the inner side of the machine body, the bolts are screwed down symmetrically, alternately and repeatedly during assembly, and finally the bolts are checked one by one to ensure that each bolt reaches the required pretightening force. After the assembly of the machine body and the middle body is finished, the machine body and the middle body are hoisted in place by a 32t/5t traveling crane in the factory building.
Aligning and grouting the middle body of the machine body at one time. The assembled machine body and the middle body are put in place on a sizing block with the found elevation, the levelness is measured by a frame type level meter, the initial levelness is temporarily set to be about 0.1mm/m in a natural state, the axial levelness is based on a bearing hole, the column-direction levelness is measured on the front, middle and rear three-point positions of the slideway based on the middle body slideway. And then measuring that the deviation of the central line does not exceed the standard, and performing primary grouting by using high-strength non-shrinkage grouting material. And (3) fully wetting the hole wall by using water 12 hours before grouting, cleaning accumulated water in the hole before formal grouting, avoiding vibrating in the grouting process, completely adopting a self-flowing mode, scattering dry materials to absorb water when bleeding occurs, and flexibly controlling the surface height of the primary grouting layer by professional fitters according to the thickness of the sizing block. When the surface of the primary grouting layer does not bleed or water stains disappear, a formal sizing block is placed, the allowable deviation of the elevation of the upper surface of the sizing block is +/-0.5 mm, and the sizing block surface (the wood board can be padded under the iron hammer) is pressed by hands or knocked by a wood hammer to enable the sizing block to descend stably, and meanwhile, the levelness of the sizing block is guaranteed to the greatest extent.
Thirdly, primary grouting maintenance: and covering with cotton felt after grouting, spraying water and maintaining, and keeping the surface of the mortar in a wet state all the time.
And fourthly, precisely aligning the machine body and the middle body and performing secondary grouting, wherein the machine body and the middle body are aligned secondarily after the primary grouting reaches the specified strength. According to a certain order, uniformly and gradually screwing the foundation nuts of the machine body and the middle body, simultaneously checking the levelness of the machine body and the middle body, if the levelness changes, adjusting the sizing block to calibrate until some nuts are screwed, and the levelness of the machine body and the middle body accords with a specified value, after checking and acceptance, adjusting the sizing block by spot welding to prevent loosening, and then performing secondary grouting to ensure that the bottom surfaces of the machine body and the middle body are tightly attached and tangent with mortar, so that gaps and clearances are not allowed. And curing after grouting.
Final fastening and level re-examination of machine body and middle body
And after the basic secondary grouting layer completely reaches the strength, performing final fastening according to a torque value specified by a manufacturer specification, and rechecking the levelness.
3 crankshaft mounting
Checking whether the oil circuit of the main shaft bushing is smooth and clean, checking whether the surface of the bushing is smooth and flat, placing the lower half bushing of the main bearing in a main bearing hole of the machine body, hoisting the crankshaft into the machine body to be in place, placing the upper bushing and the main bearing cover of the main bearing, screwing the bearing cover and the gland nut, completing screwing torque according to the specification of a manufacturer in three times, and then rechecking once. During the installation process, the bearing cover and the bearing bush are matched and are not exchanged. The position precision and the assembly clearance of the installed crankshaft respectively accord with the specification of a manufacturer. The main bearing is a thin-wall tile, the precision is not suitable to be adjusted by a scraping method during installation, and when the main bearing is in poor contact with a shaft neck, manufacturers and construction units can be asked to conduct micro scraping.
4 connecting rod and crosshead installation
And (3) placing the crosshead into the middle body slideway, connecting the small end of the connecting rod with the crosshead, and connecting the large end of the connecting rod with the crank pin. The radial clearances between the connecting rod big-head tile and the crank pin and between the small-head bushing and the ten-head pin are in accordance with the specification of a manufacturer. The large-head tile is a thin-wall tile, the gap cannot be adjusted by a scraping method, when a connecting rod bolt is screwed down, enough pretightening force is needed, the elongation is 0.33-0.38 mm, when the elongation is measured, steel balls are put into thimble holes at two ends of the connecting rod bolt, and then a micrometer is used for measuring the elongation (when the connecting rod bolt and the nut leave a factory, the connecting rod bolt and the nut are both provided with marks, and when the connecting rod bolt is screwed down, the marks are aligned).
Mounting accuracy mm of main parts
Assembly gap mm of main part
5 installation of cylinder, filler and oil wiper
The stuffing is firstly filled into the stuffing holes of the stuffing box, the fixing bolts are uniformly screwed to tightly press the stuffing box, the orientation of the air leakage recovery hole or the water inlet and outlet is required to be noticed when the stuffing is assembled, the oil scraper is arranged on the middle body, and the direction of the oil leakage hole is required to be downward. Three six-piece sealing rings, split baffle rings, oil scraper rings and the like in the filler are all processed according to pairs in a combined mode, the pairs have no interchangeability, and the pieces in the same pair are assembled according to marks and cannot be mixed.
The mounting steps of each row of cylinders are as follows: the cylinder base is arranged in the cylinder body and then arranged on the middle body together, and the coaxiality is checked to meet the technical requirements of manufacturers. When installing each stage of cylinder body, it should install the cylinder auxiliary support at the same time to avoid its droop.
6, the piston assembly is installed, and the following points are noted during installation:
firstly, before the end of the piston rod passes through the filler, a material protecting sleeve must be filled so as not to damage the friction surface of the piston rod when the piston rod passes through the filler and the oil wiper.
The piston rod and the crosshead are connected by a hydraulic stretching structure, and the pretightening force of each level of stretcher is detailed in the drawing specification of a manufacturer.
And thirdly, after the piston rod is connected with the crosshead, the gap between the crosshead and the middle body slideway cannot be changed, the piston rod is parallel to the axis of the middle body slideway, the inclination direction of the piston rod is consistent with the inclination direction of the middle body slideway, the value of the piston rod is in accordance with the specification of a manufacturer, and the left gap and the right gap of the piston and the air cylinder are symmetrical and uniform.
Fourthly, when the piston ring is assembled, the notches of the adjacent piston rings are staggered by 180 degrees on the circumference.
7 cylinder cover installation and cylinder dead point clearance adjustment
The cylinder cover is assembled, the dead point clearance of the cylinder is measured by a lead pressing method, the thickness of the cylinder adjusting pad is configured to adjust the clearance between the piston and the dead point of the cylinder, the value of the clearance is in accordance with the technical requirements of manufacturer specifications, and the cylinder adjusting pads at all levels cannot be interchanged.
Piston dead point clearance mm at each stage
8 the installation alignment of barring motor (because the barring ware arrives the goods with compressor end cover is whole, no longer recite the barring ware installation problem here, only need the barring motor with the centering of barring shaft coupling can).
9, comprehensively cleaning and sealing the unit: all parts were carefully wiped with dust-free cotton cloth and then the remaining dust was thoroughly cleaned with the dough. And after comprehensive cleaning, preparing compressor oil for circulating work.
10 main motor installation: the motor and compressor coupling are connected by using a keyless expansion sleeve, the keyless connection device realizes load transfer by screwing a high-strength bolt to generate enough pressure and friction force between tapered containing surfaces, is safe and reliable and is easy to disassemble and assemble, and expansion sleeve screws are screwed up three times by using a torque wrench according to a symmetrical and crossed sequence. The motor shaft and the compressor crankshaft are coaxial, the radial displacement of the motor shaft and the compressor crankshaft is not more than 0.03mm, and the axial inclination is not more than 0.05/1000.
11, installation of accessory equipment and pipelines: the installation of auxiliary equipment such as buffers, coolers, separators, water stations, thin oil stations and the like at all levels is carried out according to equipment layout drawings, relevant national standards (GB 50231-2009, GB50461-2008 and the like) and industrial specifications (SHT 3542-2007 and the like), pipelines are constructed according to relevant specifications and process construction drawings such as GB50235-2010, GB50236-2011 and the like, in order to prevent pipeline vibration, a space pipeline is reasonably supported, and containers and equipment cannot be used as pipeline support. The valves should be collectively mounted on the valve frame for operation.
Electric and instrument installation and debugging
12 compressor oil circulation: the main engine of the compressor is completely installed and is comprehensively checked to be qualified, and the oil circulation work needs to be started after all the electric instruments are debugged in a linkage manner. And injecting specified lubricating oil, temporarily detaching an oil pipeline without a bearing bush, a machine body and a slideway, connecting the oil pipeline with a transparent steel wire rubber tube (a filter screen with 80 meshes bound at a pipe orifice) to a crankcase and a middle body of the machine body, preventing oil stains from entering a movement mechanism, sequentially replacing an oil return port of a thin oil station with a metal filter screen with 80-200 meshes for oil flushing and filtering, replacing the filter screen once every 3 hours until hard particles cannot be observed on the screen by visual observation, and determining that no more than 3 points of soft dirt are qualified in the range of every square centimeter. Resetting all oil pipes after the oil pipes are qualified, sequentially adding 80-200 meshes of filter screens at the joint of an oil inlet main pipe and a flange of equipment, restarting an oil pump to continuously carry out system flushing, checking each oil supply point, adjusting the oil supply amount, checking a filter of a thin oil station, and after the operation for a certain time, judging that the differential pressure value of the filter is not more than 0.02MPa, wherein the filter is qualified. After the flushing is qualified, a lubricating system interlocking device is debugged, the action is accurate and reliable, a turning device is started, the oil supply quantity of each part is checked, and after the oil system is qualified in test operation, all lubricating oil in the oil tank is removed, the oil tank is cleaned, and new qualified lubricating oil is replaced.
13, test operation of a cooling water system: connecting the clean cooling water provided by the public works, checking whether the pressure of the cooling water system is normal, timely eliminating the leakage condition of the checking system, and checking whether the loop is smooth
14, testing at empty load: the suction and exhaust valves of each stage are not installed, and the suction and exhaust port pipe sections of each stage of cylinder are not communicated. Connecting a lubricating pipeline and a cooling water pipeline to enable the lubricating pipeline and the cooling water pipeline to reach respective lubricating points and cooling parts, turning a gear to transmit data, then starting a main motor to check whether the rotating direction of the main motor is correct, starting the main motor to enable a compressor to reach a rated rotating speed, and operating for 2 hours, wherein the following items of check are completed during the period:
checking the quality of assembly and the correctness of the mutual relation of the parts;
checking whether the motion mechanism and the friction part work normally;
checking the condition of a lubricating point, and stabilizing the lubricating oil pressure at 0.35-0.4 MPa (gauge pressure);
checking whether the cooling water pipeline is smooth or not, whether water leakage exists or not and whether the water pressure meets the requirement or not;
checking the fastening condition of each connecting part;
abnormal sounds and vibrations are checked and eliminated;
checking whether the friction surfaces are contacted uniformly, wherein the temperature of the friction parts accords with the following regulation:
15, air valve installation: and (4) assembling the cleaned parts according to an assembly diagram, wherein the valve springs must be screened, and the free heights of the springs of the same valve plate are consistent. After the valve is assembled, the valve plate is required to be opened flexibly without blocking, the valve plate lift of each assembly is required to meet the requirements of a drawing, leakage is tested by using kerosene, only drop-shaped leakage is allowed, and then the assembled air valve is screwed on a pressure valve cover and is installed in a cylinder valve cavity. During installation, the air valves of all stages are not required to be installed in a wrong mode, the air suction valve and the air exhaust valve are required to be cleaned, the gasket is required to be placed correctly, and the positioning is required to be accurate. Then the valve cover which is screwed with the jackscrew in advance is covered, the fastening nut on the valve cover is uniformly screwed, and then the jackscrew is screwed.
Leakage drop number allowed by air valve in air tightness test
The air valve installation needs to be made with a special tool (air valve handle) on site. During installation, bolts extending out of the air valve are screwed on by the air valve handle, then the air valve is taken up by the air valve handle to be in place, and then the valve cylinder and the valve cover are sequentially installed.
16, system purging: the air suction and exhaust valves of the cylinders at all levels are installed, the air exhaust ports of the cylinders at all levels are communicated with accessory equipment and a pipeline system, the air suction ports of the cylinders at all levels are separately swept with an air inlet pipeline, a first-level air inlet pipeline is swept by using a loop pipeline, the time for sweeping the pipeline is not specified, and the following points need to be paid attention to in the sweeping process:
firstly, the pipeline is required to be continuously knocked in the purging process so as to shake off welding slag, oxides and the like on the pipeline, and the pipeline is favorably blown away by airflow.
Secondly, all instruments, safety valves, check valves and the like in the system must be dismantled and replaced by blind plates, plugs and temporary short pipes, the valves inconvenient to dismantle are opened fully, dead corners which hinder purging are cleaned manually if necessary, all the valves are reset after purging is qualified, and then air suction ports of all stages of cylinders are communicated with pipelines.
Before purging the pipeline and the accessory equipment, a purging scheme is compiled by combining field conditions, and the pipeline and the accessory equipment are implemented after approval of a main department is reported.
17 air load test run: after the work such as the empty load operation, the inspection and the like is finished, the load is gradually increased to the compressor until the preset load is finally reached, the pressure is gradually increased, the air is taken as a medium, and the pressure increase (based on the exhaust pressure of the final stage) and the operation time are carried out according to the following table. The pressure rise should be performed slowly, closing the low pressure stage loop valve first, and then closing the high pressure stage valve slowly in sequence.
Step-by-step pressure step meter (gauge pressure)
According to the installation method of the ethylene glycol project tail gas recovery PSA reciprocating compressor, the installation quality meets the standard by optimizing the installation technology, the labor intensity is reduced, the construction period is shortened, and the method is worthy of popularization.
It should be noted that the above-mentioned contents only illustrate the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and it is obvious to those skilled in the art that several modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations fall within the protection scope of the claims of the present invention.
Claims (8)
1. The installation method of the PSA reciprocating compressor for recovering the tail gas of the ethylene glycol project is characterized in that: the method comprises the following steps:
(1) base treatment
Shoveling the surface of the foundation to form a pitted surface, wherein each square decimeter of pitted surface is 3-5, and the depth is not less than 10 mm; the oil stain and the loose layer on the surface are uniformly distributed, and the oil stain and the loose layer are uniformly removed;
shoveling a sizing pit of the sizing block, locally erecting templates around the sizing pit, re-marking a longitudinal and transverse center line, and marking an elevation on the side surface of the foundation;
placing a temporary sizing block, marking the elevation with a level gauge, and waiting for the machine body and the middle body to be in place;
(2) fuselage-in-body mounting
Firstly, assembling a machine body and a middle body together, hoisting in place:
when the equipment leaves a factory, the machine body and the middle body are disassembled and respectively packaged, and when the machine body middle body is installed on site, the machine body and the middle body are assembled firstly and then lifted to a foundation to be in place;
aligning and grouting the middle body of the machine body at one time:
positioning the assembled machine body and the middle body on a sizing block with the found elevation, measuring the levelness by using a frame type level meter, temporarily setting the initial levelness at 0.1mm/m in a natural state, taking the axial levelness as the reference by using a bearing hole, taking the middle body slide way as the reference in the column direction, and measuring the levelness at the front, middle and rear three points of the slide way; measuring the deviation of the central line, and performing primary grouting by using high-strength non-shrinkage grouting material after the deviation of the central line does not exceed the standard;
thirdly, primary grouting maintenance: covering with cotton felt after grouting, spraying water for curing, and keeping the surface of the fiber in a wet state;
precisely finding the machine body and the middle body and performing secondary grouting:
after the primary grouting reaches the specified strength, the secondary alignment is carried out on the machine body and the middle body: uniformly and gradually screwing the foundation nuts of the machine body and the middle body according to the sequence, checking the levelness of the machine body and the middle body, adjusting the sizing block and calibrating the sizing block if the levelness of the machine body and the middle body is changed until some nuts are screwed, and the levelness of the machine body and the middle body accords with a specified value;
(3) crankshaft mounting
Placing a lower half bearing of a main bearing in a main bearing hole of a machine body, hoisting a crankshaft into the machine body to be in place, placing an upper bearing shoe and a main bearing cover of the main bearing, screwing the bearing cover, pressing a nut, screwing a torque according to a specification, completing the screwing in three times, and then re-checking once;
(4) connecting rod and crosshead mounting
Placing the crosshead into the middle body slideway, connecting the small end of the connecting rod with the crosshead, and connecting the large end of the connecting rod with the crank pin;
a connecting rod big head tile and a crank pin;
(5) installation of cylinder, filler and oil wiper
Firstly, filling the filler into the filler hole of the filler box, uniformly screwing the fixing bolt to tightly press the filler box, arranging the oil wiper on the middle body,
the mounting steps of each row of cylinders are as follows: the cylinder base is arranged in the cylinder body and then arranged on the middle body together, and the coaxiality is checked;
(6) mounting a piston assembly, connecting a piston rod with a crosshead, and mounting a piston ring;
(7) cylinder cover installation and cylinder dead point gap adjustment
Installing a cylinder cover, measuring the dead point gap of the cylinder by a lead pressing method, and adjusting the dead point gap of the piston and the cylinder by configuring the thickness of a cylinder adjusting pad;
(8) the turning motor is installed and aligned, and the turning motor and the turning coupler are aligned;
(9) installing a main motor: the motor and the compressor coupler are connected by a keyless expansion sleeve;
(10) installing auxiliary equipment: the auxiliary equipment such as buffers, coolers, separators, pipelines, water stations and thin oil stations at all levels are installed according to the standard, and the electric and instrument installation and debugging are carried out;
(11) compressor oil circulation: the installation of compressor host computer finishes and overall inspection is qualified, and the chain debugging of all electric instruments is accomplished, just needs to begin oil circulation work: injecting specified lubricating oil, temporarily detaching oil pipelines without a bearing bush, a machine body and a slide way, connecting the oil pipelines to a machine body crankcase and a middle body by using transparent steel wire rubber pipes, resetting all the oil pipes, sequentially adding 80-200 meshes of filter screens at the joint of an oil inlet main pipe and a flange of equipment, restarting an oil pump to continuously carry out system flushing, checking each oil supply point, adjusting the oil supply amount, checking a thin oil station filter, debugging a lubricating system interlocking device after the filter differential pressure value is not more than 0.02MPa after operation is qualified, starting a jigger, checking the oil supply amount of each part, removing all the lubricating oil in the oil tank after the oil system is qualified in test operation, cleaning the oil tank and replacing new qualified lubricating oil;
(12) the cooling water system is tested and operated: connecting clean cooling water provided by a public project, checking whether the pressure of a cooling water system is normal, timely eliminating the leakage condition of the system, and checking whether a loop is smooth;
(13) and (3) testing the empty load: the suction and exhaust valves of each stage are not installed, and the suction and exhaust port pipe sections of each stage of cylinder are not communicated; connecting a lubricating pipeline and a cooling water pipeline to enable the lubricating pipeline and the cooling water pipeline to reach respective lubricating points and cooling parts, turning for data transmission, then starting a main motor by inching to check whether the rotating direction of the main motor is correct, starting the main motor to enable a compressor to reach a rated rotating speed, operating for 2 hours, and checking the operating conditions of each part, a contact surface, a lubricating point and a pipeline;
(14) and (3) air valve installation: assembling the cleaned parts according to an assembly drawing, wherein for the valve spring, the free heights of the springs of the same valve plate are consistent; then screwing the assembled air valve on a pressure valve cover, and filling the air valve into a cylinder valve cavity;
(15) and (3) purging the system: installing the exhaust valves of the cylinders, connecting the exhaust port of each cylinder with the auxiliary equipment and pipeline system, purging the air intake port of each cylinder with the air intake pipeline separately, purging the air intake pipeline at one stage by using the loop pipeline,
(16) air load test run: after the work of idle load operation, inspection and the like is finished, the load of the compressor is gradually increased until the preset load is finally reached, the pressure is gradually increased, the air is used as a medium, the pressure increase and the operation time are controlled, the pressure increase is slowly carried out, the low-pressure-stage loop valve is firstly closed, and then the high-pressure-stage valve is gradually closed.
2. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: when the middle body is assembled on the machine body in the step (2), attention should be paid to the fact that the lower edge of the flange of the middle body is in close contact with the corresponding part of the machine body, and each bolt achieves the required pretightening force.
3. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: and (2) performing primary grouting, wherein the wall of the hole is fully wetted by water 12 hours before grouting, accumulated water in the hole is cleaned before formal grouting, the grouting process cannot be vibrated, a self-flowing mode is completely adopted, dry materials are scattered to absorb water when a bleeding phenomenon occurs, formal sizing blocks are placed after the bleeding phenomenon or water marks disappear on the surface of the primary grouting layer, and the allowable deviation of the elevation of the upper surface of each sizing block is +/-0.5 mm.
4. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: and (9) screwing the expansion sleeve screw three times by using a torque wrench according to the symmetrical and crossed sequence.
5. The method for installing the ethylene glycol project tail gas recovery PSA reciprocating compressor according to claim 1, wherein: after the main motor in the step (9) is installed, a motor shaft and a compressor crankshaft are coaxial, the radial displacement of the motor shaft and the compressor crankshaft is not more than 0.03mm, and the axial inclination of the motor shaft and the compressor crankshaft is not more than 0.05/1000.
6. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: and (11) binding a 80-mesh filter screen at the pipe orifice of the transparent steel wire rubber pipe when the lubricating oil is injected.
7. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: and (11) after lubricating oil is injected, sequentially replacing a metal filter screen of 80-200 meshes at an oil return port of the thin oil station for oil flushing and filtering, and replacing the filter screen once every 3 hours until no hard particles are visually observed on the screen, and no more than 3 points of soft dirt in the range of every square centimeter are qualified.
8. The ethylene glycol project tail gas recovery PSA reciprocating compressor installation method of claim 1, wherein: and (14) screwing bolts extending out of the air valve by using an air valve handle during installation of the air valve, then taking the air valve in place by using the air valve handle, and then sequentially installing the valve cylinder and the valve cover.
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