In the fields of oil and gas exploration and development and geological research, vertical cuttings dryer, as the key equipment, undertakes the important task of rock chip drying and treatment. It can effectively remove the water and oil in the rock chips and realise the reduction and harmless treatment of rock chips, which is of great significance for environmental protection and resource reuse. However, in the actual operation process, the vertical cuttings dryer will inevitably encounter a variety of faults, these faults will not only affect the normal operating efficiency of the equipment, but also may lead to production interruptions, increase the maintenance cost, and even bring about potential safety hazards. Therefore, in-depth understanding of the common faults of vertical cuttings dryer, master effective solutions, and do a good job in the daily maintenance work, to ensure the stable operation of the equipment, prolong the service life of the equipment is crucial.
一.vertical cuttings dryer Common Failures and Solutions
1.Mechanical Failures
Bearing overheating
Bearing as an important transmission part of vertical cuttings dryer, plays the role of supporting and reducing friction in the process of equipment operation. However, overheating of bearing is one of the more common failures. The main reasons for overheating bearings are as follows: firstly, insufficient lubrication is a common factor. If the lubricant is not added in time or the quality of the lubricant is poor, can not form a good lubrication film on the surface of the bearing, it will increase the friction resistance of the bearing, which in turn generates a lot of heat and leads to higher temperatures. Secondly, improper bearing installation can also cause overheating problems. For example, the concentricity of the bearing installation is not enough, will make the bearing in the process of uneven force, local pressure is too large, thus generating overheating phenomenon. In addition, long time high load operation or bearing itself has quality problems, may also lead to bearing overheating. For the problem of overheating of bearings, the solutions are as follows: check the lubrication of the bearings regularly, supplement or replace the lubricant in time according to the requirements of the instruction manual of the equipment, and ensure that the quality of the lubricant meets the standard. When installing the bearings, strictly control the installation precision, use professional installation tools and measuring instruments to ensure that the concentricity and installation position of the bearings are accurate. If the bearings are found to be damaged due to prolonged high load operation or quality problems, they should be replaced with new bearings in time. When replacing the bearings, choose the products with the same model number and reliable quality as the original one, and operate in strict accordance with the installation process.
Vibration abnormality
vertical cuttings dryer vibration abnormality during operation will have a serious impact on the stability and service life of the equipment. The causes of vibration abnormality are complicated, mainly including the following aspects: First, the foundation of the equipment is not solid. If the foundation is not compacted when the equipment is installed, or if the foundation settles or loosens during long-term operation, it will cause the equipment to vibrate during operation. Second, the rotor is not balanced. If the rotor of the rock chip dryer has uneven mass distribution in the manufacturing or installation process, centrifugal force will be generated when rotating at high speed, which will trigger vibration. In addition, wear and tear of transmission parts and loose connection bolts may also lead to abnormal vibration. To solve the problem of vibration abnormality, the first thing to do is to check the foundation of the equipment to ensure that it is firm and reliable. If the foundation is found to have problems, it should be reinforced in time, such as re-pouring the foundation or grouting the foundation for reinforcement. For the case of rotor imbalance, it is necessary to carry out dynamic balancing test and correction of the rotor, and make the mass distribution of the rotor reach a balanced state by increasing or decreasing the counterweight block at the appropriate position of the rotor. At the same time, it is necessary to check the wear and tear of the transmission parts regularly, replace the parts with serious wear and tear in time, and tighten the connection bolts to prevent vibration due to loose connection.
Seal leakage
The function of sealing device is to prevent the leakage of dust, oil and gas produced in the process of rock chip drying, and to ensure the cleanness of the working environment and the normal operation of the equipment. Seal leakage is one of the common failures of vertical cuttings dryer, and its main reasons include aging and wear of seals, uneven sealing surface, improper installation and so on. With the increase of the running time of the equipment, the seals will gradually aging, lose elasticity, which will lead to the decline of sealing performance; in the process of rock chip drying, dust and other particulate matter will produce wear and tear on the seals, so that the sealing effect of the seals will become worse; if the sealing surface in the process of machining or installation of the unevenness, it will also affect the sealing effect, resulting in the occurrence of leakage. The solution to the seal leakage problem is to check the condition of the seals regularly and replace the aged and worn seals in time. In the selection of seals, according to the working environment of the equipment and media characteristics, select the appropriate sealing materials and models. When installing seals, ensure that the sealing surface is clean and flat, and operate in strict accordance with the installation process to ensure that the seals are installed in place. In addition, appropriate sealant can be applied to the sealing part to further enhance the sealing effect.
2.Poor drying effect
Insufficient drying temperature
Drying temperature is one of the key factors affecting the drying effect of vertical cuttings dryer. If the drying temperature is insufficient, the water and oil in the rock chips can not be fully evaporated and separated, resulting in high water content and oil content of the dried rock chips, which can not achieve the expected processing effect. The reasons for insufficient drying temperature may include heating system failure, low heat exchange efficiency and poor heat preservation performance. Heating system failure includes heating element damage, heating control circuit failure, etc.; low heat exchange efficiency may be due to the heat exchanger scale, blockage, or heat exchanger structure design is unreasonable; poor insulation performance will lead to too much heat loss, so that the temperature inside the dryer is difficult to rise. To solve the problem of insufficient drying temperature, first of all, check the heating system, replace the damaged heating elements, repair the heating control circuit failure, and ensure that the heating system works normally. Regularly clean and maintain the heat exchanger, remove the accumulated scale and impurities on the surface of the heat exchanger, and improve the heat exchange efficiency. For the unreasonable design of the heat exchanger structure, technical modification or replacement of a more suitable heat exchanger can be considered. At the same time, it is necessary to strengthen the insulation measures of the dryer, check whether the insulation material is intact, and if broken, repair or replace it in time to reduce heat dissipation.
Drying time is too long
In addition to drying temperature, drying time will also have an important impact on the drying effect. Drying time is too long will not only reduce the productivity of the equipment, but also increase energy consumption and production costs. The reason for too long drying time may be the insufficient processing capacity of the equipment, uneven feeding of rock chips, poor circulation of hot air and so on. If the design processing capacity of the equipment does not match the actual processing capacity, it will lead to the rock chips staying in the dryer for too long; uneven feeding of rock chips will make part of the rock chips drying insufficiently, which will need to prolong the overall drying time; poor circulation of the hot air will affect the transfer and exchange of heat, resulting in low drying efficiency. To solve the problem of long drying time, it is necessary to reasonably adjust the processing capacity of the equipment according to the actual production demand. If the processing capacity of the equipment is insufficient, consider upgrading the equipment or increasing the number of equipment. In the feeding process, it is necessary to ensure that the rock chips are fed uniformly, which can be achieved by installing a feeding metering device and a uniform fabrication device. At the same time, it is necessary to check the hot air circulation system, clean up the debris in the air ducts to ensure that the air ducts are smooth; check the operating status of the fan to ensure that the fan can provide sufficient air volume and air pressure, so that the hot air can circulate well in the dryer.
Excessive residue of rock chips
Excessive residue of rock chips after drying will affect the normal operation of the equipment and the subsequent treatment process. The reasons for the excessive residue of rock chips may be the failure of the discharge system, the internal structure of the dryer is not reasonably designed, and so on. Failure of the discharging system includes damage to the discharging valve and clogging of the discharging pipeline; unreasonable design of the internal structure of the dryer, such as the shape, angle and installation position of the mixing blades are improper, which will result in the rock chips not being able to be adequately stirred and transported inside the dryer, thus resulting in excessive residues. To solve the problem of excessive rock chip residue, it is necessary to check the discharge system regularly, repair or replace the damaged discharge valve in time, and clean the blockage in the discharge pipe to ensure that the discharge system is smooth. For the irrational design of the internal structure of the dryer, the mixing blades and other components can be optimised and improved, and the shape, angle and installation position of the blades can be adjusted, so as to improve the mixing and conveying effect of the rock chips, and to reduce the residue of the rock chips.
vertical cuttings dryer plays an important role in the application of petroleum, geological and other fields, to understand its common failures and solutions to ensure the normal operation of the equipment, improve production efficiency, reduce maintenance costs, ensure safe production is of great significance.
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