Analysis of the cause of the explosion of the compressed air station and its solution ç¥ Jiangsu Jianghuai Power Co., Ltd. Power Plant, Yancheng, Jiangsu 224001, and compared with the design specification of compressed air station, 8500292003. It can be used as a reference for preventing the occurrence of explosion accidents in compressed air systems.
At the beginning of 2005, a compressed air system exploded in a machinery manufacturing enterprise. The entire system started from a compressed air station, and various gas shut-off valves and check valves exploded. The 2m3 gas storage tank in the compressed air station is deformed, the circumference of the maximum deformation is increased by 13,n, and two other 2, the gas storage tank is affected by the explosives to form obvious concave eyes, and it is confirmed to be scrapped. The impact of the explosion caused damage to the 4208 cylinders and cylinder blocks of the two operating compressors, and no personnel injuries, but caused the company to stop production for 5 days and the losses were huge. Cracks were generated before the explosion. To this end, the engine should be idling for a while, the standby temperature drops to the appropriate temperature and then extinguished. When the water temperature drops to 50, the water is released again.
Timely removal of scale in the cooling water channel After long-term use, a thick layer of scale will be formed on the inner wall of the cylinder head water channel. The main component of the scale is insoluble calcium carbonate, which greatly reduces the cooling efficiency of the cooling system and causes cracks in the machine due to uneven local heat dissipation. To this end, the scale should be removed regularly.
Do not allow the engine to operate at high temperatures for a long time. The engine is overloaded for a long time. The heavy load is uphill. The cooling system is poorly cooled. The oil supply time is too late. The fuel supply of the fuel injection pump is too large or the cooling system leaks to make the engine run out of water, and the turbine increases. If the speed of the press is lowered, the engine will be overheated for a long time, and the cylinder head is prone to cracks. Corresponding measures should be taken for the above different situations to make the engine run at normal temperature. In addition, when the diesel engine oil supply time is too early or the oil supply amount of each cylinder is not uniform, it is easy to cause explosion explosion. The test of the lubricating oil in the machine also eliminates the possibility that the lubricating oil has a low flash point and causes explosion.
After a detailed investigation of the accident by the investigation team, it was concluded that the piston oil-lubricated compressor has a higher exhaust temperature, and the oil will oxidize and deposit carbon under high temperature. Between the compressor exhaust port and the air storage tank of the system The aftercooler is not configured, causing high temperature oil and gas to directly enter the gas storage tank and pipeline system, and the oil and gas containing carbon particles form an explosive mixed gas. Explosion caused by the presence of iron shoulders or other solid particles in the system and the high-speed flow to generate static electricity.
Burning or strong vibration of the body will also cause cracks in the cylinder head.
Properly installing the cylinder head cylinder cap will gradually warp and deform after long-term use. If the flatness error exceeds the overhaul standard, it must be ground or milled to restore the plane warpage to within 0.05mm. Otherwise, not only will the cylinder head be damaged by air leakage, but also the gas leakage will make the cylinder The cover is partially overheated and cracks are generated. In addition, the cylinder head bolts should be tightened with the torque wrench in the specified order and torque, and then tightened after the engine is warmed up to ensure the cylinder head is sealed.
In short, the cracking of cylinder heads for mining and heavy-duty engines is a common question. The reasons are manifold, design materials and reasons for use. As a vehicle user, how to avoid the incorrect operation caused the cylinder head to crack is a question worth exploring.
In order to avoid the recurrence of similar accidents, it is necessary to make a detailed analysis of the investigation results of the accident. The accident should be caused by a combination of the following factors.
There are many irregularities in the gas supply system. The compressed air station has undergone an expansion year. Due to the neglect of normativeness in the expansion process, many irregularities have been formed, mainly in the following aspects.
The number of compressors is more than that. The compressed air station is newly built with three sets of 208 piston sleeve lubrication compressors. With the continuous expansion of the company's scale, the compressed air station has been expanded several times. Currently, it is 8 乩208 piston compressors. According to the design specifications of the deflated air station 085002920, hereinafter referred to as the requirements of Article 3.0.1 of the specification, the number of compressors in the station should be 36 units.
Ambient air compressors should be cleaned of clean, dry, low-temperature air, so the compressor should be installed away from vapor fumes and dust. However, the compressed air station is surrounded by the foundry, and the compressor inlet is extremely easy to inhale smoke and dust. Through the analysis of the residue in the gas storage tank, 90 is carbon deposit, 10 is iron oxide and sandstone, indicating that the compressor inhales a large amount of smoke dust, which seriously violates the requirements of the standard.
An aftercooler should be provided between the exhaust port of the compressor and the gas storage tank between the compressor exhaust port and the gas storage tank. The eight compressors of the compressed air station are not equipped with an aftercooler, and because the exhaust gas temperature is close to or reaches 160 ft, it is easy to form carbon deposits in the gas storage tank and the exhaust pipe, thereby burying hidden dangers.
The cooling effect of the compressor cooling system is not good. The cooling system of the 8 compressors is open cooling. After the river water enters the pool, it is simply precipitated. The water is pumped directly into the compressor cooling water channel and discharged directly through the fuselage cooling water channel. cool down. Due to the poor water quality of the river and the absence of treatment facilities, the siltation in the cooling channel is severe, which greatly reduces the water cooling effect, resulting in a higher compressor discharge temperature.
The compressed air line is too thin. The system has 8 compressors with 8 23 gas storage tanks and 45 compressors in normal operation. The inner diameter of the exhaust of the compressor and the exhaust port of the gas storage tank are 25mm, but after being summarized, they are divided into strip branches. The inner diameter of each branch pipeline is only cold 100, the difference is too large, so that the air flow rate is increased, and the air is sucked in. Dust will flow at high speed in the pipeline and will easily generate static electricity. It is easy to cause explosion when it encounters flammable gas.
Reliability and Failure Analysis After analyzing the cause of the explosion accident, to ensure the safe operation of the compressed air station, the following rectification is made.
An aftercooler is installed between the compressor discharge port and the gas storage tank.
After installation, the cooler can remove part of the oil and water, and reduce the temperature of the compressed air, which is beneficial to reduce the scale and oil to form carbon deposits at high temperatures.
The air line after the compressed air station air tank is modified to reduce the air flow rate. Taking into account the actual situation at the site, it is recommended to replace the original 108 steel pipe with a 133mm steel pipe.
Modification of the compressor cooling system. The cooling system is proposed to soften the water circulation and use a cooling tower for cooling to ensure the cooling effect and save the pen water fee.
Strengthen the inspection and maintenance of equipment. The compressor cooler intercooler and aftercooler must be regularly inspected and level maintained. All discharge points must increase the number of blowdowns. If the conditions permit, the oiler is recommended to relocate the compressed air station to ensure the air quality of the suction port. And use a screw compressor as well.
The club will hold a high-level seminar on modern equipment management innovation and TNPM promotion17, which is standardized, is full participation, step by step, through the formulation of norms, implementation of norms, evaluation results, continuous improvement, in line with Chinese enterprises The actual elbow.
In order to help the majority of business leaders and equipment management and maintenance personnel fully understand the new concept of modern equipment management and maintenance, master the essence of the elbow management model. The Machinery and Maintenance Engineering Branch of the China Mechanical Engineering Society will hold a high-level seminar on modern equipment management innovation and 1 elbow promotion in Harbin on August 47, 2005.
The content of the meeting is TNPM comprehensive standardization of production and maintenance, the essence of elbow; from Ding, elbow to Ding Xie elbow; the significance of promoting Ding Xie elbow in the enterprise; Ding's system elements; the state inspection maintenance system solution; TNPM employee growth model TNPM system promotion process; relationship between TNPM standardization system and other standardization systems.
Excerpt from self-service maintenance dynamics
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