淺析游梁式抽油機(jī)減速箱漏油問題

1、 淺析游梁式抽油機(jī)減速箱漏油問題摘要:游梁式抽油機(jī)是石油開采工程中應(yīng)用最多、最重要的設(shè)備之一,減速箱是游梁式抽油機(jī)的重要設(shè)備,減速器長期在野外運(yùn)轉(zhuǎn),油質(zhì)變差、內(nèi)部潤滑油道堵塞等原因會(huì)造成潤滑油的滲漏,文章通過對(duì)漏油部位和原因的分析,提出改進(jìn)措施,以延長減速器的使用壽命。減速器漏油是一個(gè)普遍而又后果較嚴(yán)重的問題,因此,文章針對(duì)這個(gè)問題進(jìn)行了探討。The beam pumping unit is most used in oil drilling engineering, one of the most important equipment, reducer is an important de

2、vice of beam pumping unit, the speed reducer running in the field for a long time, the oil quality is poor, internal lubricating oil road congestion and other reasons can cause oil leakage, the article through the analysis of the leak position and reasons, put forward the improvement measures, in or

3、der to prolong the service life of gear reducer. Speed reducer leakage is a common and serious consequences of the problem, therefore, in this paper, the problems are discussed in this paper.關(guān)鍵詞:減速箱;漏油;原因分析;技術(shù)改進(jìn)Key words: reducer; Oil spills; Root cause analysis; Technical improvement齒輪減速器是把機(jī)械傳動(dòng)中的動(dòng)力

4、機(jī)與工作機(jī)聯(lián)接起來,通過不同齒形和齒數(shù)的齒輪以不同級(jí)數(shù)傳動(dòng),實(shí)現(xiàn)定傳動(dòng)比減速(或增速)的機(jī)械傳動(dòng)裝置,減速時(shí)稱減速器。目前油田抽油機(jī)普遍采用JLH、CJH、ZLH、JS等系列減速器,它是抽油機(jī)系統(tǒng)中最重要的設(shè)備之一。作用是將電動(dòng)機(jī)的高速轉(zhuǎn)動(dòng)通過三軸兩極減速變?yōu)檩敵鲚S的低速轉(zhuǎn)動(dòng),從而帶動(dòng)整個(gè)抽油機(jī)系統(tǒng)運(yùn)轉(zhuǎn)。減速器采用油浴潤滑,齒輪從油池浸油潤滑,軸承靠飛濺潤滑,其特點(diǎn)是承受載荷大,適應(yīng)長期的野外運(yùn)轉(zhuǎn),但由于各種原因影響,會(huì)造成各個(gè)部分發(fā)生漏油,這不僅影響了其本身的正常工作,也增加了日常的管理和維修工作量。Gear reducer is to put the power machine and w

5、orking machine to connect in the mechanical transmission, through different tooth form and tooth number of gear transmission in different series, realize the fixed velocity ratio reduction (or rate) of mechanical transmission device, the deceleration reducer referred to. Currently widely used oil fi

6、eld pumping units have, CJH, ZLH and JS series reducer, it is one of the most important equipment in pumping unit system. Role is to the high-speed rotation of the motor through the triaxial poles slowdown into output shaft rotation at low speed, thus promote the pumping unit system operation. Gear

7、reducer lubrication oil bath, oil pool leaching oil lubrication, bearing on splash lubrication, its characteristic is under load, adapt to long-term field operation, but due to various reasons, parts will cause the oil leakage occurs, it not only affects the normal work of the itself, has increased

8、the daily management and maintenance workload.1、漏油的危害1, the dangers of the spill機(jī)油是保證減速器正常運(yùn)轉(zhuǎn)不可缺少的,它對(duì)減速器齒輪起到清洗、潤滑、降溫、防腐等作用。漏油的主要危害有:Oil is to ensure the normal operation indispensable gear reducer, reducer gear in it of cooling, lubrication, cleaning, anticorrosive, and so on. Oil leakage of the main

9、 hazards are:1.1、造成潤滑油的浪費(fèi)。1.1, causing the waste lubricating oil.1.2、污染機(jī)體及周圍環(huán)境。1.2, the organism and the surrounding environment.1.3、漏油嚴(yán)重者,會(huì)因缺油而加速齒輪的粘合、剝離,會(huì)因減速箱內(nèi)齒輪無法正常潤滑而造成齒輪損壞,嚴(yán)重的甚至?xí)斐蓹C(jī)械事故。1.3 serious, leakage, and can accelerate gear because of lack of oil adhesion, peel, will because of the reduc

10、tion gear box cant normal lubrication, gear damage caused serious even can cause mechanical accident.2、造成漏油的原因2, the cause of the spill在封閉的減速機(jī)里,每一對(duì)齒輪相嚙合發(fā)出熱量,使減速箱內(nèi)溫度升高,油箱內(nèi)壓力增加。油便從密封不嚴(yán)處滲透出來。In closed reducer, each pair of gears meshing emit heat, decelerate box temperature, the pressure in the fuel ta

11、nk is increased. Through sealing oil filters through. Dont introduce2.1、減速器配件松動(dòng)。加速器在組裝時(shí),合箱口、油封擋板螺栓緊固力矩達(dá)不夠,螺栓松動(dòng)造成漏油。2.1, reducer fittings is loose. Accelerator in the assembly, the close box mouth, oil seal baffle bolt tightening torque is not enough, bolt looseness caused the spill.2.2、減速機(jī)結(jié)構(gòu)設(shè)計(jì)不合理引起漏

12、油,如設(shè)計(jì)的減速機(jī)沒有通風(fēng)罩,減速機(jī)無法實(shí)現(xiàn)均壓,箱內(nèi)壓力升高造成漏油。2.2, the structure of the speed reducer design is not reasonable cause oil leakage, such as the design of the reducer without ventilation hood, pressure reducer can not be achieved, and pressure in the oil spill.2.3、重使用,輕保養(yǎng),未按要求及時(shí)添加或更換潤滑油。多數(shù)減速器自運(yùn)行以來,一直沒有更換潤滑油,造成油料

13、乳化變質(zhì)嚴(yán)重。2.3, heavy use, maintenance, not according to requirements in a timely manner to add or replace lubricating oil. Since most of the gear reducer running, there has been no oil change, caused by oil emulsification metamorphism.2.4、呼吸器堵,造成減速器內(nèi)部壓力升高造成漏油。2.4, respirator, reducer internal pressure

14、rise caused the spill.2.5、潤滑油過多,潤滑油飛濺嚴(yán)重造成漏油。2.5 too, lubricating oil, lubricating oil splash seriously cause oil leakage.2.6、合箱口密封不嚴(yán)。2.6 and box sealing mouth is lax.2.7、減速器回油槽堵。2.7 return chute blocking, reducer.2.8、油封失效或唇口磨損嚴(yán)重。2.8, oil seal failure or lip badly worn.3、滲漏的部位3, leakage parts在調(diào)查中,隨機(jī)選

15、擇76臺(tái)在用游梁式抽油機(jī)進(jìn)行研究,其中47臺(tái)存在減速器漏油現(xiàn)象:其中中縫接合面漏油16臺(tái),軸承(包括輸入軸、輸出軸、中間軸)處滲漏20臺(tái),螺栓處漏油5臺(tái),放油孔、觀察孔滲漏4臺(tái),其他部位漏油2臺(tái)。In the survey, 76 sets of randomly selected in beam pumping unit is studied, including 47 units: speed reducer leakage phenomenon of raphe 16 sets of joint surface oil, bearing (including the input shaf

16、t and output shaft, intermediate shaft) leakage 20, bolt spill 5 units, 4 units, oil drain hole, observation hole leakage 2 other parts of the leak.4、滲漏原因分析4, analysis of the causes for the leakage4.1、中縫接合面滲漏的主要原因The main reason for the 4.1, raphe jointing surface leakage4.1.1、由于螺栓緊固程度差或由于振動(dòng)造成松動(dòng),使合箱

17、口產(chǎn)生縫隙,使?jié)櫥屯庖纭?.4.1, due to poor or degrees bolts loosening due to vibration, make the close box mouth produces aperture, make the oil spill.4.1.2、由于潤滑油長期使用得不到及時(shí)更換臟或含雜質(zhì)較多,堵塞了合箱口的回油孔道,回油不暢,使?jié)櫥屯庖纭?.1.2, due to the lubricating oil use for a long time not change in time or with impurity more dirty, bloc

18、ked the mouth of the tanks on oil return hole, poor oil, lubricating oil spill.4.1.3、減速器組裝時(shí)合箱口無墊片,未抹箱口密封膠。4.1.3, reducer assembly when the closed box without gaskets, didnt wipe mouth sealing glue.4.2、軸承處滲漏的主要原因4.2, bearings, the main reason for the leakage4.2.1、由于潤滑油臟或雜質(zhì)多,堵塞了軸承處回油孔道,使回油不暢。2, due to

19、 the lubricating oil dirty, or impurities, blocked the bearing return oil hole, make the oil return.4.2.2、由于長時(shí)間運(yùn)轉(zhuǎn),使油封老化,磨損嚴(yán)重,甚至實(shí)效。4.2.2, due to the long time operation, make the oil seal aging and wear serious, even the actual effect.4.2.3、軸下沉,由于軸承齒輪使油封的密封效果受到影響。Holdings, shaft sinking, and due to b

20、earing gear oil seal sealing effect is affected.4.3、放油孔、觀察孔處滲漏原因:4.3, set oil hole, observation hole leakage reasons:為防止盜油者從減速器放油絲堵和觀察孔中放油,通常將絲堵與減速器本體焊在一起。由于絲堵未緊固好,或在焊接時(shí)將密封材料損壞,從而產(chǎn)生了滲漏。To prevent stolen oil is from the reducer oil drain plug and observation hole into the oil, usually will plug with

21、reducer frame welding. Due to good plug did not tighten, or when welding will be sealing material damage, causing the leakage.4.4、螺栓漏油的原因4.4 bolts, the cause of the leak螺栓處滲漏同縫接合面滲漏原因基本相同,只是潤滑油由螺栓處滲漏出來,而未從接合面滲漏,或由于以前中縫處做過堵漏的部位,潤滑油不能從原部位流出,而改由螺栓處滲漏。Bolt in seam with the faying surface leakage reasons

22、 are basically the same, just leakage of lubricating oil from the bolt, but not from the faying surface leakage, or due to the parts of raphe place do before plugging, oil cannot flow from the original parts, leakage by bolts.4.5、其他滲漏為減速器本身制造缺陷造成。4.5, other leakage for reducer itself due to a manufa

23、cturing defect.通過分析,減速器漏油的主要原因是:潤滑油性能變差,加上雜質(zhì)以及齒輪磨損的鐵屑進(jìn)入油中,使得潤滑油變粘,潤滑效果變差。飛濺潤滑過程中,齒輪將含有雜質(zhì)的潤滑油帶入減速器的潤滑油道將油道堵塞,導(dǎo)致油從中縫或螺栓處滲漏;在軸承部位,刮油舌將含雜質(zhì)的潤滑油刮下,使雜質(zhì)堆積在軸承附近,造成回油不暢,導(dǎo)致軸承部位漏油發(fā)生。Through analysis of speed reducer leakage is the main reason: lubricating oil performance becomes poor, together with impurities a

24、nd gear wear iron into oil, lubricating oil turned adhesive, lubrication effect becomes poor. Splash lubrication, gear will contain impurities lubricating oil into the gear reducer lubricating oil will oil road congestion, lead to oil leakage from the raphe or bolt; Will contain impurities in bearin

25、g parts, oil scraper tongue of lubricating oil, the impurity accumulation near the bearing, causing poor oil return, lead to bearing parts of the oil spill occurred.5、止漏技術(shù)方法5, check leakage technology method5.1、O型圈治理技術(shù):用橡膠圈替換油封,一般能封堵10天至一個(gè)月。5.1, o-rings governance techniques: replace oil seal with r

26、ubber ring, generally can block 10 days to a month.5.2、油封換取技術(shù):是對(duì)密封效果變差的油封進(jìn)行更換,適用于三軸,該措施現(xiàn)場操作難度大。: 5.2, oil seal for technology is oil seal for replacement of sealing effect becomes poor, apply to the three axis, the site operation is difficult.5.3、膠封技術(shù):用高性能彈性膠對(duì)接合面、機(jī)油觀察孔、放油孔。5.3, glue sealing technolo

27、gy: using high performance elastic rubber, oil of the joint surface observation hole, set oil hole.5.4、注膠技術(shù):用高性能彈性膠對(duì)對(duì)接合面螺栓處進(jìn)行封堵。5.4, injecting technology: using high performance elastic glue for sealing joint surface of the bolt in.5.5、疏導(dǎo)技術(shù):采用疏通管對(duì)軸承處的滲漏進(jìn)行導(dǎo)流。在軸根部加裝一個(gè)鋁制圓盤扁型盒,盒底部倒出一根導(dǎo)油銅管,在減速箱軸下部鉆孔將導(dǎo)油銅管

28、穿近減速箱內(nèi),把漏出的油再送回減速箱。5.5 guidance technology: adopting the dredge pipe leakage of bearing in the diversion. In axial root with an aluminium disc flat box, with oil poured out a guide tubes, at the bottom of the reducer shaft oil drilling will lead brass wearing nearly deceleration box, then back to th

29、e reducer of the leaking oil.5.6、C型油封止漏技術(shù)。5.6, C type oil seal leakage technology.6、減速器漏油的改進(jìn)措施6, speed reducer leakage improvement measures6.1、減速器機(jī)油按規(guī)定的適用周期定期進(jìn)行清洗更換。6.1, reducer motor oil in accordance with the provisions of applicable regular cleaning replacement cycle.6.2、在減速器制造維修時(shí)在合箱面處先涂抹密封膠。6.2,

30、 the reducer manufacturing maintenance in carton or in your sealant.6.3、減速器油位過高,潤滑油飛濺嚴(yán)重增加漏油機(jī)會(huì),而且導(dǎo)致油溫不斷升高,使?jié)櫥湍甓认陆?降低潤滑性能,增加油的流動(dòng)性和漏失量,直接影響齒輪和軸承的潤滑,降低使用壽命。為此,在使用時(shí)必須保持正常的油位高度。6.3, reducer oil level is too high, the lubricating oil splash seriously increase the chance of the spill, and lead to the oil t

31、emperature rise, make the annual decline in lubricating oil, reduce the lubrication performance, increase liquidity and oil loss, directly affect the lubrication of gear and bearing, reduce the service life. Therefore, when use must maintain normal oil level height.6.4、在視油孔和放油絲堵處加裝密封墊,擰緊螺栓,使用正確的防盜措施

32、。6.4, in the oil hole and the oil drain plug with gasket, tighten the bolt, using the right security measures.6.5、加大回油孔道,防止漏油。6.5, increasing oil return hole, to prevent oil spills.6.6、保證抽油機(jī)平衡率,降低抽油機(jī)上、下沖程的負(fù)荷差異,減小三軸的跳動(dòng)量,延長油封的使用壽命。6.6, guarantee the balance of pumping unit rate, reduce the pumping uni

33、t load difference of upper and lower stroke, reduced triaxial beat quantity, prolong the service life of oil seal.7、經(jīng)濟(jì)效益分析7, economic benefit analysis7.1、直接經(jīng)濟(jì)效益:7.1, the direct economic benefits:7.1.1、按標(biāo)準(zhǔn)減速箱機(jī)油的加注量應(yīng)為180-200公斤,每公斤機(jī)油為11.0元,如果機(jī)油漏失需額外加注每年平均大約50公斤左右。27臺(tái)抽油機(jī)減速箱杜絕機(jī)油滲漏,每年可節(jié)約機(jī)油量約1350公斤,合計(jì)人民幣約為

34、14850元。7.1.1, according to the standard reducer oil filling quantity should be 180-200 kg, oil is 11.0 yuan per kg, if the oil leakage should be additional filling a year on average about 50 kilograms. 27 pumping unit reducer to eliminate oil leakage, a year can save oil quantity is about 1350 kg, t

35、otal about 14850 yuan.=11.0*1350=14850元 = 11.0 * 1350 = $13507.1.2、可有效減少減速器的更換費(fèi)用,每臺(tái)抽油機(jī)減速器每臺(tái)大修一次2.48萬元,車輛、勞務(wù)費(fèi)用 8000余元。7.1.2, can effectively reduce the reducer of the replacement cost, each pumping unit reducer overhaul a 24800 yuan each, vehicles, labor costs 8000 yuan.=2.48+0.8=3.28萬元 = 2.48 + 0.8

36、= RMB 328007.2、社會(huì)效益:7.2 and social benefits:有效實(shí)施減速器止漏技術(shù),可遏制抽油機(jī)減速箱內(nèi)機(jī)油滲漏現(xiàn)象,延長減速箱的使用壽命,減少職工勞動(dòng)強(qiáng)度,保持機(jī)體及周圍環(huán)境的清潔,有利于井站管理水平的提高。Effectively reducer seepage technology, which can contain an oil pumping unit reducer box leakage phenomenon, prolong the service life of reducer, reducing the worker labor intensity, maintain the cleanness of the body and the surrounding environment, beneficial to the improvement of th