1、浅析游梁式抽油机减速箱漏油问题摘要:游梁式抽油机是石油开采工程中应用最多、最重要的设备之一,减速箱是游梁式抽油机的重要设备,减速器长期在野外运转, 油质变差、内部润滑油道堵塞等原因会造成润滑油的渗漏,文章通过对漏油部位和原因的分析,提出改进措施,以延长减速器的使用寿命。减速器漏油是一个普遍而又后果较严重的问题,因此,文章针对这个问题进行了探讨。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.关键词:减速箱;漏油;原因分析;技术改进Key words: reducer; Oil spills; Root cause analysis; Technical improvementhttp:/ 、ZLH 、JS
4、 等系列减速器,它是抽油机系统中最重要的设备之一。作用是将电动机的高速转动通过三轴两极减速变为输出轴的低速转动,从而带动整个抽油机系统运转。减速器采用油浴润滑, 齿轮从油池浸油润滑,轴承靠飞溅润滑,其特点是承受载荷大,适应长期的野外运转,但由于各种原因影响,会造成各个部分发生漏油,这不仅影响了其本身的正常工作,也增加了日常的管理和维修工作量。Gear reducer is to put the power machine and working machine to connect in the mechanical transmission, through different tooth
5、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 field pumping units have, CJH, ZLH and JS series reducer, it is one of the most impo
6、rtant 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 reducer lubrication oil bath, oil pool leaching oil lubrication, bearing on splash
7、 lubrication, its characteristic is under load, adapt to long-term field operation, but due to various reasons, parts will cause http:/ http:/ oil leakage occurs, it not only affects the normal work of the itself, has increased the daily management and maintenance workload.1、漏油的危害1, the dangers of t
8、he spill机油是保证减速器正常运转不可缺少的,它对减速器齿轮起到清洗、润滑、降温、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 hazards are:1.1 、造成润滑油的浪费。1.1, causing the waste lubricating oil.1.2 、污
9、染机体及周围环境。1.2, the organism and the surrounding environment.1.3 、漏油严重者,会因缺油而加速齿轮的粘合、剥离,会因减速箱内齿轮无法正常润滑而造成齿轮损坏,严重的甚至会造成机械事故。1.3 serious, leakage, and can accelerate gear because of lack of oil adhesion, peel, will because of the reduction gear box cant normal lubrication, gear damage caused serious eve
10、n can cause mechanical accident.http:/ the cause of the spill在封闭的减速机里,每一对齿轮相啮合发出热量, 使减速箱内温度升高,油箱内压力增加。油便从密封不严处渗透出来。In closed reducer, each pair of gears meshing emit heat, decelerate box temperature, the pressure in the fuel tank is increased. Through sealing oil filters through. Dont introduce2.1 、
11、减速器配件松动。加速器在组装时, 合箱口、油封挡板螺栓紧固力矩达不够,螺栓松动造成漏油。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 、减速机结构设计不合理引起漏油, 如设计的减速机没有通风罩,减速机无法实现均压,箱内压力升高造成漏油。2.2, the structure of the speed r
12、educer 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 ,轻保养 ,未按要求及时添加或更换润滑油。多数减速器自运行以来,一直没有更换润滑油,造成油料乳化变质严重。2.3, heavy use, maintenance, not according to requirements
13、in a http:/ http:/ 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 ,造成减速器内部压力升高造成漏油。2.4, respirator, reducer internal pressure rise caused the spill.2.5 、润滑油过多,润滑油飞溅严重造成漏油。2.5 too, lub
14、ricating oil, lubricating oil splash seriously cause oil leakage.2.6 、合箱口密封不严。2.6 and box sealing mouth is lax.2.7 、减速器回油槽堵。2.7 return chute blocking, reducer.2.8 、油封失效或唇口磨损严重。2.8, oil seal failure or lip badly worn.3、渗漏的部位3, leakage parts在调查中,随机选择76台在用游梁式抽油机进行研究, 其中47 台存在减速器漏油现象:其中中缝接合面漏油16台, 轴承( 包
15、括输入轴、输出轴、中间轴)处渗漏20 台,螺栓处漏油5 台, 放油孔、观察孔渗漏4台,其他部位漏油2台。In the survey, 76 sets of randomly selected in beam pumping unit http:/ studied, including 47 units: speed reducer leakage phenomenon of raphe 16 sets of joint surface oil, bearing (including the input shaft and output shaft, intermediate shaft) le
16、akage 20, bolt spill 5 units, 4 units, oil drain hole, observation hole leakage 2 other parts of the leak.4、渗漏原因分析4, analysis of the causes for the leakage4.1 、中缝接合面渗漏的主要原因The main reason for the 4.1, raphe jointing surface leakage4.1.1、由于螺栓紧固程度差或由于振动造成松动,使合箱口产生缝隙,使润滑油外溢。4.4.1, due to poor or degree
17、s bolts loosening due to vibration, make the close box mouth produces aperture, make the oil spill.4.1.2、由于润滑油长期使用得不到及时更换脏或含杂质较多,堵塞了合箱口的回油孔道,回油不畅,使润滑油外溢。4.1.2, due to the lubricating oil use for a long time not change in time or with impurity more dirty, blocked the mouth of the tanks on oil return
18、hole, poor oil, lubricating oil spill.4.1.3、减速器组装时合箱口无垫片,未抹箱口密封胶。4.1.3, reducer assembly when the closed box without gaskets, didnt wipe mouth sealing glue.http:/ http:/ 、轴承处渗漏的主要原因4.2, bearings, the main reason for the leakage4.2.1、由于润滑油脏或杂质多,堵塞了轴承处回油孔道, 使回油不畅。2, due to the lubricating oil dirty, o
19、r impurities, blocked the bearing return oil hole, make the oil return.4.2.2、由于长时间运转,使油封老化,磨损严重,甚至实效。4.2.2, due to the long time operation, make the oil seal aging and wear serious, even the actual effect.4.2.3、轴下沉,由于轴承齿轮使油封的密封效果受到影响。Holdings, shaft sinking, and due to bearing gear oil seal sealing
20、effect is affected.4.3 、放油孔、观察孔处渗漏原因:4.3, set oil hole, observation hole leakage reasons:为防止盗油者从减速器放油丝堵和观察孔中放油,通常将丝堵与减速器本体焊在一起。由于丝堵未紧固好,或在焊接时将密封材料损坏,从而产生了渗漏。To prevent stolen oil is from the reducer oil drain plug and observation hole into the oil, usually will plug with reducer frame welding. Due t
21、o good plug did not tighten, or when welding will be sealing material damage, causing the leakage.http:/ 、螺栓漏油的原因4.4 bolts, the cause of the leak螺栓处渗漏同缝接合面渗漏原因基本相同,只是润滑油由螺栓处渗漏出来,而未从接合面渗漏,或由于以前中缝处做过堵漏的部位,润滑油不能从原部位流出,而改由螺栓处渗漏。Bolt in seam with the faying surface leakage reasons are basically the same,
22、 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 、其他渗漏为减速器本身制造缺陷造成。4.5, other leakage for reducer itself due to a manufacturing defect.通过分析,减速器
23、漏油的主要原因是:润滑油性能变差,加上杂质以及齿轮磨损的铁屑进入油中,使得润滑油变粘, 润滑效果变差。飞溅润滑过程中,齿轮将含有杂质的润滑油带入减速器的润滑油道将油道堵塞,导致油从中缝或螺栓处渗漏;在轴承部位,刮油舌将含杂质的润滑油刮下,使杂质堆积在轴承附近,造成回油不畅,导致轴承部位漏油发生。Through analysis of speed reducer leakage is the main reason: lubricating oil performance becomes poor, together with impurities and gear wear iron into
24、 oil, lubricating oil turned adhesive, lubrication effect becomes poor. Splash lubrication, gear will http:/ http:/ 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 bearing parts, oil scr
25、aper tongue of lubricating oil, the impurity accumulation near the bearing, causing poor oil return, lead to bearing parts of the oil spill occurred.5、止漏技术方法5, check leakage technology method5.1 、O 型圈治理技术 :用橡胶圈替换油封, 一般能封堵10 天至一个月。5.1, o-rings governance techniques: replace oil seal with rubber ring,
26、 generally can block 10 days to a month.5.2 、油封换取技术:是对密封效果变差的油封进行更换,适用于三轴,该措施现场操作难度大。: 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 、胶封技术 :用高性能弹性胶对接合面、机油观察孔、放油孔。5.3, glue sealing technology: usin
27、g high performance elastic rubber, oil of the joint surface observation hole, set oil hole.5.4 、注胶技术 :用高性能弹性胶对对接合面螺栓处进行封堵。http:/ injecting technology: using high performance elastic glue for sealing joint surface of the bolt in.5.5 、疏导技术 :采用疏通管对轴承处的渗漏进行导流。在轴根部加装一个铝制圆盘扁型盒,盒底部倒出一根导油铜管, 在减速箱轴下部钻孔将导油铜管穿
28、近减速箱内,把漏出的油再送回减速箱。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 the
29、 reducer of the leaking oil.5.6 、C 型油封止漏技术。5.6, C type oil seal leakage technology.6、减速器漏油的改进措施6, speed reducer leakage improvement measures6.1 、减速器机油按规定的适用周期定期进行清洗更换。6.1, reducer motor oil in accordance with the provisions of applicable regular cleaning replacement cycle.6.2 、在减速器制造维修时在合箱面处先涂抹密封胶。6
30、.2, the reducer manufacturing maintenance in carton or in your sealant.6.3 、减速器油位过高,润滑油飞溅严重增加漏油机会,而且导致http:/ http:/ reducer oil level is too high, the lubricating oil splash seriously increase the chance of the spill, and lead to the oil temperature rise, make the annual decline in lubricating oil,
31、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 、在视油孔和放油丝堵处加装密封垫, 拧紧螺栓,使用正确的防盗措施。6.4, in the oil hole and the oil drain plug with gasket, t
32、ighten 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 、保证抽油机平衡率,降低抽油机上、下冲程的负荷差异,减小三轴的跳动量,延长油封的使用寿命。6.6, guarantee the balance of pumping unit rate, reduce the pumping unit load difference of upper and lower stroke, reduced tria
33、xial beat quantity, prolong the service life of oil seal.7、经济效益分析http:/ economic benefit analysis7.1 、直接经济效益:7.1, the direct economic benefits:7.1.1、按标准减速箱机油的加注量应为180-200公斤,每公斤机油为11.0元,如果机油漏失需额外加注每年平均大约50公斤左右。27台抽油机减速箱杜绝机油渗漏,每年可节约机油量约1350公斤, 合计人民币约为14850元。7.1.1, according to the standard reducer oil
34、 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, total about 14850 yuan.=11.0*1350=14850元 = 11.0 * 13
35、50 = $13507.1.2、可有效减少减速器的更换费用,每台抽油机减速器每台大修一次2.48万元,车辆、劳务费用 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=3.28万元 = 2.48 + 0.8 = RMB 32800http:/ http:/ 、社会效益 :7.2 and social bene
36、fits:有效实施减速器止漏技术,可遏制抽油机减速箱内机油渗漏现象,延长减速箱的使用寿命,减少职工劳动强度,保持机体及周围环境的清洁,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 a
37、nd the surrounding environment, beneficial to the improvement of the JingZhan management level.8、结论8, conclusion减速器是抽油机的主要工作部位,修理难度大、费用高。按使用规定减速器在正常情况下,不同季节应更换不同型号的润滑油, 但在现场管理中,由于各种因素的影响,这一点难以实现,长期的运行造成润滑油油质变差甚至变质失效。同时由于减速器使用期限较长,漏油现象也比较严重,目前采用的止漏措施很多都不能从根本解决问题, 治标不治本,最多只能保证1-2年不漏。因此有必要逐步开展减速器的检修工作,
38、对达到一定使用年限的减速器进行开箱清洗、更换润滑油等工作,这可以有效的延长减速器的使用寿命,提高机采设备的使用效率。Reducer is an important task of the pumping unit parts, repair is http:/ difficult and high cost. Reducer under normal circumstances, according to provisions of using different season different models of lubricating oil should be changed, but
39、 in site management, due to the influence of various factors, it is difficult to implement, due to long run lubricating oil deteriorated and even deterioration failure. Service life is longer, at the same time as reducer oil leakage phenomenon is more serious, stop leakage measures applied at presen
40、t a lot of cant fundamentally solve the problem, take temporary solution not effect a permanent cure, not only ensure 1-2 years. It is necessary to gradually repair work of gear reducer, gear reducer of reaches a certain age out of the cleaning, oil change, etc, which can effectively extend the service life of reductor, raise the use efficiency of mechanical production equipment.
