Installation method of centrifugal ammonia synthesis gas compressor

Abstract

The present invention provides a method for installing a centrifugal ammonia synthesis gas compressor, including foundation adjustment, equipment base installation and leveling, equipment base grouting, steam turbine installation, high- and low-pressure cylinder installation, initial unit alignment, high- and low-pressure cylinder disassembly, support bearing removal, support bearing clearance inspection, bearing assembly, thrust bearing removal, rotor axial displacement inspection, thrust bearing assembly, rotor, labyrinth seal, and partition removal, rotor and partition descaling and inspection, cylinder body and component reinstallation, oil circulation, unit fine alignment, and single-unit test run. By rationally arranging the installation process steps, the present invention improves the installation efficiency of a high-pressure centrifugal compressor driven by a steam turbine.

Description

Technical Field

[0001] The present invention relates to the field of centrifugal compressor installation in the petrochemical industry, and in particular to an installation method of a centrifugal ammonia synthesis gas compressor. Background Art

[0002] The demand for centrifugal compressors in the modern petrochemical industry continues to increase, and their installation has become a crucial component of the equipment installation process. However, due to their large size, some compressors are often transported in separate sections for transportation considerations, with on-site assembly taking place upon arrival.

[0003] Due to the complexity of the compressor installation procedure, only by continuously improving the installation method of centrifugal compressors can the installation of core compressors be completed quickly and efficiently, while reducing construction costs, shortening construction periods, and bringing greater benefits.

[0004] In view of the above problems, a method for installing a centrifugal ammonia synthesis gas compressor is proposed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a method for installing a centrifugal ammonia synthesis gas compressor, so as to achieve the purpose of effectively improving the installation accuracy and accelerating the installation efficiency during the installation process of the centrifugal ammonia synthesis gas compressor.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0007] A method for installing a centrifugal ammonia synthesis gas compressor, comprising:

[0008] Step 1: Basic adjustment;

[0009] Step 2: Install and level the equipment base;

[0010] After the surface treatment of the unit foundation is completed, the equipment base is hoisted into place using a truck crane, and the base is leveled using the hanging shim installation method;

[0011] Step 3: Grouting the equipment base;

[0012] The anchor bolt holes need to be grouted with high-strength non-shrinkage grouting material to a height of 100mm, then filled with dry sand, and then formwork is supported around the anchor bolt base plate. Epoxy resin grouting material is poured into the formwork along one side of the formwork. After the strength is reached, the formwork is removed to complete the primary grouting. After the primary grouting, epoxy resin grouting material is used for the secondary grouting.

[0013] Step 4: Steam turbine installation;

[0014] The turbine cylinder and bearing seat are installed on a common base, and the levelness of the unit is adjusted by adjusting the top screws of the base;

[0015] Step 5: Install high / low pressure cylinders;

[0016] After the steam turbine is leveled, use the steam turbine as the reference machine and hoist the high-pressure cylinder, low-pressure cylinder and gearbox in sequence;

[0017] Step 6: Initial alignment of the unit;

[0018] The three-meter alignment method is used to align the components of a centrifugal compressor unit. The turbine is used as the reference machine during alignment. The high-pressure cylinder and the turbine are aligned first, followed by the low-pressure cylinder and the turbine, and finally the gearbox and the driver. Axial alignment calibration is first performed on the vertical plane by adjusting the thickness of the gasket under the compressor leg. After the axial alignment is completed, an instrument with three dial indicators is used to perform preliminary alignment of the machine. One dial indicator in the radial position measures the radial deviation of the shaft, and two dial indicators in the axial position measure the axial deviation of the shaft.

[0019] Step 7: Disassemble the high / low pressure cylinder;

[0020] After the initial alignment and acceptance of the unit is completed, the high-pressure cylinder and low-pressure cylinder of the ammonia synthesis gas compressor unit are disassembled, cleaned and the data is retested;

[0021] Step 8: Remove the support bearing;

[0022] First, remove the instrument and wires installed on the bearing housing cover or bearing cap, then remove the pins and screws connecting the two halves of the coupling guard, and remove the upper half; then remove the bearing housing cover, unscrew the screws that secure the bearing cap, lift the bearing cap vertically out, and finally unscrew the screws connecting the two halves of the bearing;

[0023] Step 9: Check the support bearing clearance;

[0024] To check the support bearing clearance, first clean the bearing and journal carefully, install the upper and lower bearings and place a wire on the top of the journal, then install the top half bearing, followed by the bearing cover. Tighten the bearing cover during final assembly, then remove the bearing cover and the upper half bearing, finally remove the wire and use a micrometer to measure two or three places where the wire is flattened, and read the average value; if the average value of the measurement results is greater than the "diameter clearance" required by the equipment, the bearing needs to be replaced.

[0025] Step 10: Assemble the bearing;

[0026] The assembly sequence is the reverse of the disassembly sequence of steps seven and eight;

[0027] Step 11: Disassemble the thrust bearing;

[0028] First, remove the instruments and cables on the bearing box cover or the bearing cover, then remove the upper half of the coupling guard, then remove the thrust bearing and the gland that supports the bearing, lift the bearing gland, and remove the lower thrust pads one by one during the lifting process, then remove the lower thrust ring, rotate the lower thrust ring to reach the removable position, and finally remove the adjusting gasket of the thrust bearing;

[0029] Step 12: Check the rotor axial displacement;

[0030] When disassembling the thrust bearing, first check the axial displacement in both directions to confirm whether it maintains the designed value of the unit. Then, fix the dial indicator on the casing and make the dial indicator contact the end of the rotor. Then, move the rotor axially in both directions until the inner part of the rotor contacts the casing. Finally, compare the value read on the dial indicator to see if it is equal to the two added clearance values ​​given in the compressor assembly drawing.

[0031] Step 13: Assemble the thrust bearing;

[0032] First, split the thrust bearing's adjusting shim into two halves. Install them so the mating surfaces of the two halves are horizontal, while the mating surfaces of the upper and lower thrust ring halves remain vertical. Then, drill holes in certain pads of the thrust bearing to accommodate thermocouples or adjustment plates for power sensors to detect the rotor's axial thrust. Finally, place the bearing cap on the bracket. If it doesn't engage immediately, manually rotate the shaft in both directions, applying force to position the bearing cap along the rotor shaft until it is completely secure on the bracket.

[0033] Step 14: Remove the rotor, labyrinth seal and partition;

[0034] First, remove the two top halves of the thrust bearing and the support bearing. Next, screw four guide rods onto the lower casing to prevent the labyrinth seal from being damaged when the upper casing is lifted. Then, remove the fixing bolts and locating pins on the center split surface of the casing. Lift the upper casing with the jacking screws, then lift the upper casing and place it on four hardwood supports. Bolt the partition upper half and the labyrinth seal to the upper casing and lift it together with the upper casing. Finally, tie two steel wire ropes covered with rubber or plastic or other durable materials to the two shafts between the shaft neck and the seal, lift the rotor from the lower casing, and keep it level.

[0035] Step 15: Descaling and inspection of the rotor and partition;

[0036] Step 16: Reinstall the cylinder block and parts;

[0037] Step 17: Oil circulation;

[0038] Step 18: Precision alignment of the unit;

[0039] After the oil circulation of the unit is completed and accepted, the unit pipeline needs to be reinstalled. After the reinstallation is completed, the unit is finally aligned using the three-meter alignment method;

[0040] Step 19: Single machine test run;

[0041] After the oil system trial run is correct, the unit trial run can be carried out. The compressor unit should first be tested at no load, and then the load test should be carried out after the no-load test is correct.

[0042] Furthermore, in step one, when adjusting the foundation, first check whether the size, position and verticality of the foundation bolt holes meet the standards; then remove the slurry layer 20-25mm above the upper surface of the foundation, and finally accurately place the top screw pad used to adjust the base height.

[0043] Furthermore, in step two, first place the top screw pad on the foundation, push the top screw onto the top screw pad, slowly place the base on the foundation, and use the top screw to level it so that the distance between the base and the foundation reaches the design given size; use the top screw to carefully level the base in the vertical and horizontal directions, and evenly adjust the adjustment bolts so that they can evenly bear their respective loads.

[0044] Furthermore, in step 4, the lateral levelness of the bearing seats at both ends is ensured to be within 0.3 mm / m, and the axial levelness of the exhaust side base or cylinder body is ensured to be within 0.3 mm / m. After the level and centering adjustment of the base is completed, all foundation bolts are tightened.

[0045] Furthermore, in step 6, to find the radial runout reading, first adjust the radial dial indicator on the perpendicular surface to zero. Rotate both shafts in the direction of shaft rotation and record the dial indicator reading every 90°. If the dial indicator contacts are pressed into their proper position, the reading is considered positive; otherwise, it is considered negative. The axial runout of the shaft is measured using two dial indicators spaced 180° apart, initially returning them to zero. To read the axial runout, use two vertically aligned dial indicators, adjusting them to zero.

[0046] Furthermore, in step nine, a lead wire is placed axially, the length of the lead wire should be longer than the bearing, and the lead wire is glued with vaseline oil.

[0047] Furthermore, in step 15, the dirt on the rotor and partition is first treated with thinner, petroleum spirit, and trichloroethylene, and then metal brushes of different sizes that can contact the impeller channel and diffuser and other internal parts are used to remove the dirt and apply oil protection. Then, the labyrinth seal is tapped to check whether it is damaged, and the sealing gap of the seal and the rust in the impeller flow channel are carefully checked.

[0048] Furthermore, in step seventeen, after all mechanisms are reinstalled and inspected, the entire oil system of the unit needs to be flushed. First, the standby lubricating oil pump is tested on a single unit basis; secondly, the lubricating oil does not pass through the unit bearings, only the lubricating oil circulation pipeline is flushed, and the high-level oil tank is cleaned manually; then, the lubricating oil pipeline and the lubricating oil injection points of each bearing of the unit are connected to flush each bearing of the unit and the high-level oil tank; finally, the control oil system pipeline is flushed.

[0049] The present invention provides an installation method for a centrifugal ammonia synthesis gas compressor. By reasonably setting the installation process steps, the installation efficiency of a high-pressure centrifugal compressor driven by a steam turbine is improved, and the problem of long service life and low efficiency of construction tools in the installation process of the compressor unit under similar construction conditions is effectively solved. The method has the advantages of simple construction process, fast construction speed and high work efficiency, greatly improves the efficiency of the installation of the core compressor, and further saves construction costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The drawings herein are used to provide further illustration of the present invention and constitute a part of this application. The illustrative embodiments of the present invention and their description are used to explain the present invention and do not constitute improper limitations on the present invention.

[0051] Figure 1 The construction procedure for the patent of this invention;

[0052] Figure 2 This is a schematic diagram of the installation of the top screw pad of the unit patented by this invention;

[0053] Figure 3 This is the steam turbine leveling measurement diagram of the patented invention;

[0054] Figure 4 This is a schematic diagram of the alignment of the unit of the patented invention;

[0055] Figure 5 This is a schematic diagram of the cylinder head lifting of the patented invention.

[0056] In the figure, 1- pad, 2- equipment base, 3- foundation, 4- top screw, 5- grouting layer, 6- level, DETAILED DESCRIPTION

[0057] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0058] See Figure 1The installation method of the centrifugal ammonia synthesis gas compressor provided by the present invention includes foundation adjustment, equipment base installation and leveling, equipment base grouting, turbine installation, high / low pressure cylinder installation, unit initial alignment, high / low pressure cylinder disassembly, support bearing removal, support bearing clearance inspection, bearing assembly, thrust bearing removal, rotor axial displacement inspection, thrust bearing assembly, rotor, labyrinth seal and partition removal, rotor and partition descaling and inspection, cylinder body and parts reinstallation, oil circulation, unit fine alignment, and single unit trial run.

[0059] Basic Adjustments

[0060] First, check the size, position, and verticality of the foundation bolt holes to ensure they meet the standards. Then, remove the slurry layer 20-25mm above the upper surface of the foundation by trimming. Finally, accurately place the top screw pad used to adjust the base height.

[0061] like Figure 2 As shown, the minimum distance between the top screw pad 1 and the surface of the foundation 3 is guaranteed to be 20 mm. The height of the surface of the top screw pad 1 can be adjusted within the range of ±5 mm, but the accuracy of its surface level in any direction must be maintained within approximately 1 mm / m, so as to ensure that the equipment base 2 is evenly supported by each top screw pad 1.

[0062] Equipment base installation and leveling

[0063] After the surface treatment of unit foundation 3 is complete, use a truck crane to hoist equipment base 2 into place. Then, push jackscrews 4 onto jackscrew pads 1 and slowly place equipment base 2 on foundation 3. Use jackscrews 4 to level the base 2 to the designed distance between them. Then, use jackscrews 4 to carefully level equipment base 2 in both the vertical and horizontal directions, and evenly adjust the adjustment bolts to ensure that they bear the load evenly.

[0064] After the equipment base 2 is leveled, a formwork is set up around the hanging pads and grouting is performed once. After the grouting is completed, the grouting mold is removed and the entire base is grouted for the second time.

[0065] Equipment base grouting

[0066] First, because the unit's anchor bolt holes are for φ89 pre-buried pipe anchor bolts, they need to be grouted to a height of 100mm with high-strength, non-shrinkage grouting material, then filled with dry sand. Formwork is then supported around the anchor bolt base plate, and epoxy resin grouting material is slowly poured into the formwork along one side. Once the strength is reached, the formwork is removed to complete the primary grouting. After the primary grouting, a secondary grouting with epoxy resin grouting material is performed.

[0067] Before using epoxy grouting material for grouting, ensure that the surfaces of the equipment, base, and foundation are clean, dry, and grease-free. The surfaces of the equipment and base for grouting must be coated with a layer of epoxy primer. At the same time, a grouting space of 25mm to 50mm must be reserved. Finally, all molds and baffles must be pre-coated with two layers of wax to facilitate demolding.

[0068] Steam turbine installation

[0069] The turbine cylinder and bearing seat are installed on a common base. The horizontal level of the unit is adjusted by adjusting the top screw of the base. The lateral level of the bearing seats at both ends of the speed regulation side and the exhaust side must be ensured to be within 0.3mm / m, and the axial level of the exhaust side base or cylinder must be ensured to be within 0.3mm / m. After the level and centering adjustment of the base are completed, tighten all the foundation bolts. The bolts should not be tightened too tight, otherwise the adjusted level and centering will be destroyed.

[0070] refer to Figure 3 , the on-site leveling position needs to be placed as follows Figure 3 Otherwise, the accuracy of the measurement results will be affected.

[0071] High / low pressure cylinder installation

[0072] After the steam turbine is leveled, use the steam turbine as the base machine and hoist the high-pressure cylinder, low-pressure cylinder and gearbox in sequence.

[0073] Initial alignment of the unit

[0074] The three-meter alignment method is used to align the components of the centrifugal compressor unit. The turbine is used as the reference machine during alignment. The high-pressure cylinder and the turbine are aligned first, then the low-pressure cylinder and the turbine, and finally the gear box and the driver are aligned.

[0075] First, perform the axial alignment calibration on the vertical plane by changing the thickness of the gasket under the compressor leg. After the axial alignment is completed, use an instrument with three micrometers to perform preliminary alignment on the machine. One micrometer in the radial position measures the radial deviation of the shaft, and two micrometers in the axial position measure the axial deviation of the shaft.

[0076] like Figure 4 As shown, to determine radial runout during alignment, first adjust the radial dial indicator on the perpendicular surface to zero. Rotate both shafts in the direction of shaft rotation and record the dial indicator readings every 90°. If the dial indicator contacts press into their proper position, the reading is considered positive; otherwise, it is considered negative. Measure axial runout using two dial indicators spaced 180° apart, initially returning them to zero. To determine axial runout, use two vertically aligned dial indicators, adjusting them to zero.

[0077] High / low pressure cylinder disassembly

[0078] After the initial alignment and acceptance of the unit is completed, the high-pressure cylinder and low-pressure cylinder of the ammonia synthesis gas compressor unit are disassembled, cleaned and the data is retested.

[0079] To speed up disassembly and reinstallation, ensure unit installation accuracy, and avoid tilting of the cylinder head and internal components during disassembly and reinstallation, which could result in torsional shear stress, a dedicated lifting tool must be used in conjunction with a fall chain to lift the cylinder head and internal components during the actual on-site installation process. Taking the cylinder head hoisting of a unit as an example, first install the fall chains at the lifting ears at both ends of the shoulder pole tool, then hook the hook to the lifting ear in the center of the shoulder pole tool. During the lifting process, observe whether the cylinder head is level. If the cylinder head is tilted, adjust the fall chain to re-level it. The other components are hoisted in the same way as the cylinder head.

[0080] Removing the support bearing

[0081] First, remove the instruments and wires installed on the bearing box cover or bearing cover, then remove the pins and screws connecting the two halves of the coupling cover, remove the upper part, then remove the bearing box cover, unscrew the screws that fix the bearing cover, take the cover out vertically, and finally unscrew the screws connecting the two halves of the bearing to achieve the removal of the support bearing.

[0082] If there is a threaded hole on the upper part of the bearing, screw the lifting screw on it and use a pulley to lift out the upper half of the bearing. If the two halves of the bearing are difficult to separate, use a wooden hammer to hit the joint surface of the two halves in turn in the horizontal direction; since there is grease on the joint surface of the two halves, in order to prevent the upper half of the bearing from slipping and damaging the bearing alloy or the shaft neck when it is lifted, you need to wipe off the grease with a clean cotton cloth first.

[0083] Check support bearing clearance

[0084] First, carefully clean the bearing and journal. Install the upper and lower bearing halves and place a wire through the top of the journal. Carefully install the top half of the bearing, ensuring the wire does not slip. Install the bearing cap and tighten it for final assembly. Remove the cap and upper bearing. Finally, remove the wire and use a micrometer to measure two or three places where the wire is flattened, reading the average. If the average is greater than the "diameter clearance" required for the equipment, the bearing needs to be replaced.

[0085] Regarding the placement of the lead wire, it should be placed axially, longer than the bearing, and glued with vaseline. The lead wire should be selected according to the measured clearance and standard specifications. For example, a lead wire twice or three times the bearing clearance value can be used.

[0086] Assemble bearings

[0087] The assembly sequence is the reverse of the disassembly sequence for the support bearings. During assembly, carefully align the paint numbers of the components and install them in their original positions. If the lower bearing is not in the correct position, the bearing cap cannot be installed.

[0088] Thrust bearing removal

[0089] Before disassembly, follow the instructions for the compressor equipment and instruments. First, remove the bearing box cover or the instruments and cables on the bearing cover. Next, remove the upper half of the coupling guard. Then remove the thrust bearing and the gland that supports the bearing. Slowly lift the bearing gland, keeping it as vertical as possible during the lifting process. Remove the lower thrust pads one by one during the lifting process, then remove the lower thrust ring. Rotate the lower thrust ring until it reaches the removable position, and finally remove the adjustment gasket of the thrust bearing. After all are removed, clean the thrust block with oil. After cleaning, carefully wipe off the grease and inspect the alloy surface to remove any scratches caused by oil contamination.

[0090] Check the rotor axial displacement

[0091] When removing the thrust bearing, first check the axial displacement in both directions to confirm whether it maintains the designed value for the unit. Next, fix the dial indicator to the casing and make the dial indicator contact the end of the rotor. Then, move the rotor axially in both directions until the inner part of the rotor contacts the casing. Finally, compare the value read on the dial indicator to see if it is equal to the two added clearance values ​​given in the compressor assembly drawing.

[0092] Thrust bearing assembly

[0093] First, separate the thrust bearing's adjusting shim into two halves. During installation, ensure the mating surfaces of the two halves are horizontal, while the mating surfaces of the upper and lower thrust ring halves remain vertical. Some pads in the thrust bearing often require drilling to accommodate thermocouples or adjustment plates for electrical sensors to detect the rotor's axial thrust. Finally, gently place the bearing cap onto the bracket. If it doesn't engage immediately, manually rotate the shaft in both directions, applying force to position the bearing cap along the rotor shaft until it is fully secured to the bracket.

[0094] Rotor, labyrinth seal and diaphragm removal

[0095] First, remove the two top halves of the thrust bearing and the support bearing, and then screw four guide rods on the lower half of the casing to avoid damaging the labyrinth seal when lifting the upper half of the casing. Then remove the fixing bolts and locating pins on the center surface of the casing, lift the upper half of the casing a few millimeters with the lifting screws, and then lift the upper half of the casing and place it on four hardwood supports. Use bolts to fix the partition half and the labyrinth seal to the upper half of the casing and lift it together with the upper half of the casing. Finally, use two steel ropes wrapped with rubber, plastic or other new materials to tie them to the two shafts between the shaft neck and the seal, lift the rotor from the lower half of the casing, and keep it level. Be careful not to damage the labyrinth seal and place it carefully.

[0096] Descaling and inspection of rotors and diaphragms

[0097] For dirt on the rotor and partition, first treat them with thinner, petroleum spirit, trichloroethylene, etc., then use metal brushes of different sizes that can contact the impeller channel and diffuser and other internal parts to remove dirt, and brush oil for protection, then tap the labyrinth seal to check whether it is damaged, and carefully check the sealing gap of the seal and the rust in the impeller flow channel.

[0098] Cylinder block and parts reinstallation

[0099] The assembly sequence is the reverse of the disassembly sequence described above.

[0100] To speed up disassembly and reinstallation, ensure unit installation accuracy, and avoid tilting of the cylinder head and internal components during disassembly and reinstallation, which could result in torsional shear stress, a lifting tool must be used in conjunction with a fall chain to lift the cylinder head and internal components during the actual on-site installation process. Taking the cylinder head lifting of a unit as an example, first install the fall chains at the lifting ears at both ends of the shoulder pole-type lifting tool, then hook the hook to the lifting ear at the center of the shoulder pole-type lifting tool. During the lifting process, observe whether the cylinder head is level. If the cylinder head is tilted, adjust the fall chains to re-level it. The lifting method for other components is the same as that for the cylinder head.

[0101] Oil circulation

[0102] After all mechanisms have been reinstalled and inspected, the entire oil system of the unit needs to be flushed. First, the standby lubricating oil pump should be tested on a single unit basis. Secondly, the lubricating oil does not pass through the unit bearings, but only the lubricating oil circulation pipeline is flushed, and the high-level oil tank is cleaned manually. Then, the lubricating oil pipeline is connected to the lubricating oil injection points of each bearing of the unit to flush each bearing of the unit and the high-level oil tank. Finally, the control oil system pipeline is flushed.

[0103] Precision alignment of the unit

[0104] After the oil circulation of the unit is completed and accepted, the unit pipeline needs to be reinstalled. After the reinstallation is completed, the unit is finally aligned using the same method as the initial alignment, using the three-meter alignment method.

[0105] Single machine test run

[0106] After the oil system trial run is correct, the unit trial run can be carried out. The compressor unit should first be tested at no load, and then the load test should be carried out after the no-load test is correct.

Claims

1. A method for installing a centrifugal ammonia synthesis gas compressor, characterized in that: include: Step 1: Basic adjustment; Step 2: Install and level the equipment base; After the surface treatment of the unit foundation is completed, the equipment base is hoisted into place using a truck crane. The leveling of the equipment base is carried out using the hanging pad installation method; Step 3: Grouting the equipment base; The anchor bolt holes need to be grouted with high-strength non-shrinkage grouting material to a height of 100mm, then filled with dry sand, and then formwork is supported around the anchor bolt base plate. Epoxy resin grouting material is poured into the formwork along one side of the formwork. After the strength is reached, the formwork is removed to complete the primary grouting. After the primary grouting, epoxy resin grouting material is used for the secondary grouting. Step 4: Steam turbine installation; The turbine cylinder and bearing seat are installed on the equipment base, and the levelness of the unit is adjusted by adjusting the top screws of the equipment base; Step 5: Install high / low pressure cylinders; After the steam turbine is leveled, use the steam turbine as the reference machine and hoist the high-pressure cylinder, low-pressure cylinder and gearbox in sequence; Step 6: Initial alignment of the unit; The three-meter alignment method is used to align the components of a centrifugal compressor unit. The turbine is used as the reference machine during alignment. The high-pressure cylinder and the turbine are aligned first, followed by the low-pressure cylinder and the turbine, and finally the gearbox and the driver. Axial alignment calibration is first performed on the vertical plane by adjusting the thickness of the gasket under the compressor leg. After the axial alignment is completed, an instrument with three dial indicators is used to perform preliminary alignment of the machine. One dial indicator in the radial position measures the radial deviation of the shaft, and two dial indicators in the axial position measure the axial deviation of the shaft. Step 7: Disassemble the high / low pressure cylinder; After the initial alignment and acceptance of the unit is completed, the high-pressure cylinder and low-pressure cylinder of the ammonia synthesis gas compressor unit are disassembled, cleaned and the data is retested; Step 8: Remove the support bearing; First, remove the instrument and wires installed on the bearing cover, then remove the pins and screws connecting the two halves of the coupling guard, and remove the upper half; then remove the bearing box cover, unscrew the screws that fix the bearing cover, take the bearing cover out vertically, and finally unscrew the screws connecting the two halves of the bearing; Step 9: Check the support bearing clearance; To check the support bearing clearance, first carefully clean the bearing and journal. Install the upper and lower bearings and place a wire through the top of the journal. Then install the upper bearing and the bearing cap. Tighten the bearing cap during final assembly. Remove the bearing cap and upper bearing. Finally, remove the wire and measure with a micrometer at two or three locations where the wire is flattened. Read the average value. If the average value is greater than the "diameter clearance" required by the equipment, the bearing needs to be replaced. Step 10: Assemble the bearing; The assembly sequence is the reverse of the disassembly sequence of steps seven and eight; Step 11: Disassemble the thrust bearing; First, remove the instrument and cable on the bearing cover, then remove the upper half of the coupling guard, then remove the thrust bearing and the gland that supports the bearing, lift the bearing gland, and remove the lower thrust pads one by one during the lifting process, then remove the lower thrust ring, rotate the lower thrust ring to reach the removable position, and finally remove the adjusting gasket of the thrust bearing; Step 12: Check the rotor axial displacement; When disassembling the thrust bearing, first check the axial displacement in both directions to confirm whether it maintains the designed value of the unit. Then, fix the dial indicator on the casing and make the dial indicator contact the end of the rotor. Then, move the rotor axially in both directions until the inner part of the rotor contacts the casing. Finally, compare the value read on the dial indicator to see if it is equal to the two added clearance values ​​given in the compressor assembly drawing. Step 13: Assemble the thrust bearing; First, split the thrust bearing's adjusting shim into two halves. Install them so the mating surfaces of the two halves are horizontal, while the mating surfaces of the upper and lower thrust ring halves remain vertical. Then, drill holes in certain pads of the thrust bearing to accommodate thermocouples or adjustment plates for power sensors to detect the rotor's axial thrust. Finally, place the bearing cap on the bracket. If it doesn't engage immediately, manually rotate the shaft in both directions, applying force to position the bearing cap along the rotor shaft until it is completely secure on the bracket. Step 14: Remove the rotor, labyrinth seal and partition; First, remove the two top halves of the thrust bearing and the support bearing. Next, screw four guide rods onto the lower casing to prevent the labyrinth seal from being damaged when the upper casing is lifted. Then, remove the fixing bolts and locating pins on the center split surface of the casing. Lift the upper casing with the jacking screws, then lift the upper casing and place it on four hardwood supports. Bolt the partition upper half and the labyrinth seal to the upper casing and lift it together with the upper casing. Finally, tie two rubber or plastic-covered steel wire ropes to the two shafts between the shaft neck and the labyrinth seal. Lift the rotor from the lower casing and keep it level. Step 15: Descaling and inspection of the rotor and partition; Step 16: Reinstall the high-pressure cylinder body, low-pressure cylinder body and parts; Step 17: Oil circulation; Step 18: Precision alignment of the unit; After the oil circulation of the unit is completed and accepted, the unit pipeline needs to be reinstalled. After the reinstallation is completed, the unit is finally aligned using the three-meter alignment method; Step 19: Single machine test run; After the oil system trial run is correct, the unit trial run can be carried out. The compressor unit should first be tested at no load, and then the load test should be carried out after the no-load test is correct.

2. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 1, characterized in that: In step 1, when adjusting the foundation, first check whether the size, position and verticality of the foundation bolt holes meet the standards; then remove the slurry layer 20-25mm from the upper surface of the foundation, and finally accurately place the top screw pad used to adjust the height of the equipment base.

3. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 1 or 2, characterized in that: In step 2, first place the top screw pad on the foundation, push the top screw onto the top screw pad, slowly place the equipment base on the foundation, and use the top screw to level it so that the distance between the equipment base and the foundation reaches the design given size; use the top screw to carefully level the equipment base in the vertical and horizontal directions, and evenly adjust the adjustment bolts so that they can evenly bear their respective loads.

4. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 3, characterized in that: In step 4, the lateral levelness of the bearing seats at both ends is guaranteed to be within 0.3mm / m, and the axial levelness of the exhaust side equipment base or turbine cylinder is guaranteed to be within 0.3mm / m. After the level and centering adjustment of the equipment base is completed, tighten all foundation bolts.

5. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 1, 2 or 4, characterized in that: In step six, to find the reading of radial deviation during alignment, first adjust the radial dial indicator of the vertical corresponding surface to 0, rotate the two shafts according to the direction of shaft rotation, and record the reading of the indicator every 90°. If the dial indicator contact is pressed into its appropriate position, the reading is defined as a positive number, otherwise it is defined as a negative number; the axial deviation of the shaft is measured using two dial indicators with a spacing of 180°, and the initial adjustment is returned to zero; the reading of the axial deviation is measured using two vertically arranged dial indicators, and the dial indicators are adjusted to zero.

6. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 5, characterized in that: In step nine, place the lead wire axially. The length of the lead wire should be longer than the bearing, and use vaseline oil to stick the lead wire.

7. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 6, characterized in that: In step 15, for the dirt on the rotor and partition, first use thinner, petroleum spirit and trichloroethylene to treat them, then use metal brushes of different sizes that can contact the impeller channel and diffuser to remove the dirt, and brush oil for protection, then tap the labyrinth seal to check whether it is damaged, and carefully check the sealing gap of the labyrinth seal and the rust in the impeller flow channel.

8. The installation method of a centrifugal ammonia synthesis gas compressor according to claim 7, characterized in that: In step 17, after all mechanisms have been reinstalled and inspected, the entire oil system of the unit needs to be flushed. First, the standby lubricating oil pump should be tested on a single unit basis. Secondly, the lubricating oil does not pass through the unit bearings, and only the lubricating oil circulation pipeline is flushed. The high-level oil tank is cleaned manually. Then, the lubricating oil pipeline is connected to the lubricating oil injection points of each bearing of the unit to flush each bearing of the unit and the high-level oil tank. Finally, the control oil system pipeline is flushed.

Images