JB/T 9105-1999 Technical requirements for large reciprocating piston compressors
Some standard content:
JCS23.140
Machinery Industry Standard of the People's Republic of China
JB/T9105-—1999
Technical reg uirements for
large reciprocating piston compressors
Technical reg uirements for
targe reciprocating cumpressors1999-07-12 Issued
National Machinery Industry Bureau
2000-01-01 Implementation
JB9[05-1999
This standard is a revision of ZBJ72022—88 Technical conditions for large reciprocating piston compressors. Compared with 2BJ72022—88, the main technical changes are as follows: The reference standard has changed, and the original Appendix A has been deleted. Appendix B directly quotes the industry standard. This standard shall replace ZBJ72022-88 from the date of implementation. Appendix A of this standard is a reminder appendix.
This standard is issued and managed by the National Technical Committee for Standardization of Compressors. 4 Standard drafting unit: Shanghai Jianshuailan Compressor Co., Ltd. The main drafters of this standard are Ren Lian, Hu Mengting, Wu Zhen, and Fu Xiaoling. 1 Scope
Machinery Industry Standard of the People's Republic of China
Large Reciprocating Piston Compressors
Technical requirements for
large reciprocating compressorsJB/T9105-1900
720288
This standard specifies the technical requirements, test methods and other requirements for large reciprocating compressors. This standard is applicable to large reciprocating piston compressors with a piston force of 7N or more and a nominal exhaust pressure of 31.5mRa or less, including reciprocating piston compressors with lubrication (hereinafter referred to as reciprocating compressors). For process compressors with a force of less than 7N, this standard shall also be followed. 2 Referenced Standards
The clauses contained in the following standards shall constitute the clauses of this standard through their general use in this standard. When the technical standard is published, the services shown are valid. All standards are considered comprehensive. The parties using this standard should discuss the possibility of using the latest version of the following standards: GR150.1998GR 1511998GDT 228—1987GB.T 2291994CB/T230—1991GB/T 231—1984GB/T699—1988GB/T1031—1995GB/T J184.-1996GR/T1220[992GR/T 1979 — 1980 | | tt | |tt||GB/L11350—1989
GE/T 11351—1989
Steel pressure vessels
Steel shell and tube heat exchangers
Metal tensile test methods
Metal Charpy notched impact test methods
Metal Grignard hardness test methods
Metal Brinell hardness test methods
Technical conditions for high-quality structural steel
Surface roughness values and their values
Shape and position specifications without tolerance values
Stainless steel
Structural steel Macrostructure defect rating chart
Alloy structural steel technical parts
Positive displacement compressor noise level determination engineering method casting dimension small tolerance
Injection molding compressor mechanical vibration measurement and evaluation aluminum food metal missing parts technical pin
Non-metallic inclusions in steel micro-assessment sheet method casting machining residual display
Casting weight metric
Approved by the State Machinery Industry Bureau on July 12, 1999 and implemented on January 1, 2000
GB/T 11352..1989
GB/T132991991
GB/T13306
G8T13819
G50050-1995
JA/T 2231.1—1999
JBT 2231.3—1999
JD/T 6431-1992
B.T6906—1993
JB.T7663.1—1995
JB/T 7663.2I995
JB/T76651995
JB/9104—1599
5148--1993
JB/T9105—1999
General engineering steel parts
Microstructure inspection of steel
Alloy steel parts
Design specification for industrial circulating cooling water treatment plants
Reciprocating compressor parts Part 1: Shaft and pin outer diameter dimensionsReciprocating compressor parts Part 3: BearingsTechnical conditions for grey cast iron for positive displacement compressorsTechnical conditions for plated parts for positive displacement compressors
Technical conditions for packaging of positive displacement presses
Technical conditions for painting compressors
General machinery noise sound power level field measurement sound intensity method Ball suspension cast iron parts for positive displacement compressors: Technical parts metal average cost measurement method
"Safety Technical Supervision Program for Pressure Vessels"
3 Technical requirements
3.1 General requirements
3.1.1 The compressor shall comply with the requirements of this standard and be implemented in accordance with the drawings and technical documents approved by the prescribed procedures. 3.1.2 The compressor, driver and its ancillary equipment shall be able to operate continuously and safely under the prescribed operating conditions. The operating time shall generally be not less than 2 years, and the annual operating rate shall be not less than 97%. The structural design of the compressor shall be convenient for installation, disassembly and maintenance. 3.1.3 The flow rate, suction and exhaust pressure and temperature, specific energy (specific power), speed, cylinder and packing lubrication oil consumption, cooling water inlet pressure, temperature consumption, etc. of the compressor shall comply with the provisions of the relevant technical documents. 3.1.4 The compressor should be operated horizontally, and the measurement and evaluation of the movement of the machine body should comply with the provisions of GB/T 7777. 3.1.5 The maximum allowable sound power level (A) of the compressor unit should comply with the provisions of Table 1. If it exceeds the table, the user should obtain the consent of the user. Table
Maximum allowable sound power level limit value L.
3.1.6 A safety valve should be installed after each stage of the compressor. The safety valve should comply with the relevant provisions of the "Regulations on Safety Technical Supervision of Pressure Vessels".
3.1.? The starting pressure of the safety valve: when the pressure is not more than 10MFa, it should be at least 1.1 times of the rated exhaust pressure; when the pressure is greater than 10MPa, it should be 1.05-1.10 times of the rated exhaust pressure (0.9-0.95 times of the maximum working pressure). The discharge pressure of the safety valve should not exceed 1.1 times of the maximum working pressure. 3.1. The safety valve should be installed in a position that is not disturbed by vibration. The gas discharged from the safety valve should not pollute the environment and endanger personal safety.
.IB/9105-1999
3.1.9 The air, water and exhaust circuits of the machine should be connected in a complete manner and there should be no leakage. 3.1.10 The pressure machine should have an effective turning device
3.1.1 The air cavity of the gas break body, gas valve, gas break, piston and other parts of the gas break should be tested for water. The test is as follows: Amplify the force to 1.3 times of the working force and keep it under pressure for not less than 30m. It should not be full. If there are special requirements for the affected parts, follow the regulations.
3.1, 12 The water cavity and cast iron cylinder liner of the air enclosure, cylinder block and cylinder seat and other parts shall be tested with a pressure of not less than .MPa. The maintenance time shall be not less than min. There should be no turbidity. 3.1.13 The fuselage oil pool shall be tested with kerosene or other highly permeable liquid for 4h. It should not be filtered. 3..14 The design and manufacture of cooling devices, buffer devices, external regulators and other welded pressure devices shall comply with GB150, GB1S1400 square container safety technical regulations, and relevant American standards. 3.1.15 The quality of cooling water shall comply with the provisions of GB5050. 3.1.16 The temperature of lubricating oil shall not be higher than 70, and the precision of the filter shall be 4μm or less. 3.1.1 The compressor should have a safety protection device for alarm or alarm shutdown under the following conditions: a) Exhaust temperature is too high:
) Circulating oil is too low:
c! Exhaust pressure is too high:
) Stage intake pressure is too low
e) Cold start pressure is too low
3.2 Requirements
3.2.1 The fuselage (including crankcase) should have sufficient rigidity under full load and partial load. In addition to the provisions of 3.1.4, the peak value of longitudinal motion should also be measured on the gas cover along the gas axis, and the full amplitude should not exceed 10 grids of the distance from the crankshaft axis to the measuring point. 3.2.2 If necessary, the fuselage can be equipped with a fire safety device according to the agreement. 3.2.3 The shaft and pin, main bearing and connecting head bearing of the compressor should comply with the provisions of B/T2231.1 and B/2231.3 respectively. 3.2.4 The maximum working pressure of the cylinder should be at least 15% greater than the rated discharge pressure or 0.1MPa, whichever is greater. 3.2.5 When the compressed gas may be dissolved into liquid in liquid form, a horizontal cylinder should be used, and the exhaust valve and exhaust connection should be located at the bottom of the gas cylinder to facilitate drainage.
3.1.6 The crosshead should generally have a replaceable and adjustable slide, and ensure that the crosshead pin and slide are sufficiently lubricated. 3.2.7 The shaft and connecting rod should be made of lithium steel or ductile iron of corresponding grade, and ultrasonic flaw detection should be carried out after addition. A large filter screen should be used for connection at the shaft change junction and the pool hole. 3.2.8 The surface of the compressor live rod in contact with the stuffing box should be plasticized, and the surface roughness should be 0.4 μm. The live rod is recommended to be processed by rolling or pre-processing, and the surface roughness ratio should be 32 μm. The piston rod should be ultrasonically inspected after addition, and the finishing shop should be powdered.
3.2. The difference between the inlet and outlet pressure of the cooler should not be greater than ℃, and the maximum outlet temperature should not be greater than 45 ℃. It is recommended that the outlet temperature after cooling should not differ from the cooler inlet temperature by more than 10. 3.2.10 When the seal pressure difference of the stuffing box of a lubricated compressor exceeds 17.5MPa and the seal pressure of the stuffing box of a non-lubricated compressor exceeds 1.75MPa, cooling measures should be taken.
3.2 For compressors that transport special gases (such as corrosive, toxic, flammable, etc.), corresponding measures should also be taken during design. 3
3.3 Technical requirements for castings
JBT9105-1999
3.3.1 The requirements for the connection of cast iron parts shall comply with the provisions of JB/T643E. 3.3.2 The technical requirements for spherical cast iron parts shall comply with the provisions of JB/T91. 3.3.3 The pressure-bearing surface of cast iron parts shall not be repaired by knocking with a chain tip, welding, etc. 3.4 Technical requirements for carbon fiber castings
3.4.1 Carbon fiber castings shall meet the requirements of G/T6416, GB/11350, GB/T113S1, GB11352, etc. 3.4.2 The surface of carbon fiber castings shall not have defects with a depth of more than 3 mm and a diameter of less than 3 mm. Defects on non-machined surfaces may be corrected. For example, when the correction is performed by the force-reinforcement method, the entire piece shall be welded to eliminate the welding stress. When the defects are within the following ranges, they may not be corrected:
a] The surface is not smooth and has no pores, with a depth of less than 3 mm, an equivalent diameter of less than 5 mm, and a diameter of less than 3 mm. 3.4.3 The head and neck of steel castings shall not be short. Ultrasonic inspection shall be carried out after the correction: the entire part shall be inspected by ultrasonic inspection. Individual clean pores are allowed to exist, but their equivalent diameter should not exceed 4mm, the depth should not exceed 1/B of the wall thickness, the spacing should not be less than 100mm, and the total number of pores should not exceed 5.
3.5 Technical requirements for alloy parts
3.5.1 Alloy castings should be in accordance with the provisions of GB9438. 3.5.2 After heat treatment, the aluminum piston should be inspected for micro-hardness in accordance with the provisions of relevant technical conditions: 23 points should be measured on the corresponding ends and the arithmetic mean of the readings should be taken; the hardness difference of the same piston should not exceed 15HB unit iodine value. 3.5.3 The surface of the aluminum piston should be smooth, and there should be no defects such as cracks, shrinkage, etc. that affect the hardness. 3.5.4 The metallographic structure of the cast aluminum piston should be fine and evenly distributed, and there should be no serious segregation and coarse needle-shaped iron compounds and defects.
3.5.5 Saw alloy castings shall comply with the provisions of 0R/T13819. 3.6 Technical requirements for forged steel parts
3.6.1 The general requirements for copper parts shall comply with the provisions of B/T6908. 3.6.2 Important forgings such as compressor crankshafts, high-pressure cylinder blocks, and cylinder heads for boreholes shall also be manufactured and inspected in accordance with the requirements of B/T6908 forgings of Class [1].
3.6.3 Compressor connecting rods, piston rods, connecting rod bolts, connecting rod nuts, piston rod nuts, high-pressure cylinder nuts, head pins and 1-head connections, etc. shall all be manufactured and inspected in accordance with the requirements of B/T6908 forgings of Class [2]. Connecting rod nuts and piston rod bolts may be made of profiles and inspected in accordance with the requirements of Class [3].
3.6.4 The steel and materials used in compressor forging shall be accompanied by the qualified certificate of the smelting unit. The steel composition without certificate shall be: chemical analysis and mechanical property test. If the smelting furnace number can be distinguished, two pieces from the same batch and the same smelting furnace may be sampled. 3.6.5 The chemical composition of the steel forging shall meet the following standards: 1) High-quality carbon steel shall be in accordance with GB/T699. 2) Alloy structural steel shall be in accordance with GB/T3077. 3) Stainless steel and acid-resistant steel shall be in accordance with GB/T1220. 3.6.6 The mechanical property test and sample cutting of steel used in compressor forging shall be in accordance with the following regulations. 3.6.6.1 Mechanical properties test: 1) Tensile test according to the provisions of R/T228: 2) Impact test according to the provisions of R/T229: 3) Hardness test according to the provisions of GB/T230 and BT231. 3.6.6.2 Sample cutting: 1) Sample placement according to the provisions of T69, including: 2) Crankshaft, reverse rod, piston support, oriented from the - end: 3) High-pressure cylinder block, high-pressure cylinder head, high-pressure cylinder cover, etc., samples are taken at the steel chain end. If several high-pressure cylinder heads, high-pressure cylinder heads, etc. are forged in the same steel: then samples are taken at the steel ingot end. (center) If the tangential or transverse test specimen is allowed, its mechanical property value can be lower than the longitudinal test value. The lower value shall be in accordance with the requirements of 1B DIN 6908. 3.6. For crankshafts, connecting rods, piston rods, cylinder blocks, high-pressure cylinder heads with valves, high-pressure cylinder covers, crosshead pins, etc.: micro-metallographic structure inspection shall be carried out. When the diameter or thickness is greater than 80 μm, macro-structure inspection shall also be carried out. The specific requirements are as follows: 36. Except for white spots, cracks, and intergranular corrosion tendency, macro-structure inspection shall not be used as the basis for acceptance. If required, it shall generally meet the following requirements.
3.6.7.1 Requirements for macro-structure:
1) Forgings shall not have white spots and cracks:
b1 Macro-structure defects shall be evaluated in accordance with the provisions of G 1979. The main looseness and central looseness shall not be less than level 3, and the general spot carbon analysis shall not be less than level 3:
c) Low-structure test pieces for ingot forgings should be taken at the bone mouth, and for rolled forgings shall be determined by the manufacturer. For ingot forgings, test pieces shall be taken according to each piece. For rolled forgings, if the smelting furnace number can be distinguished, one piece can be taken from the same smelting furnace. For those whose smelting furnace number cannot be distinguished, additional inspection shall be carried out according to the following:
d) Test method: hot acid immersion. When the system does not allow, cold shoe diameter shall be used. 3.6.7.3 Requirements for metallographic structure:
a) The structure of carbon steel shall be not less than Grade 1 as specified in AB/T13299; b) The grain size of the product shall be evaluated in accordance with YB/T5148: - Forgings with a diameter or thickness less than or equal to 300mm shall not be less than Grade 5; - Forgings with a diameter or thickness greater than 300mm shall not be less than Grade 4. c) Non-metal inclusions shall be evaluated in accordance with GB/T10561, requiring: Class A, Class B, Class C, and Class D inclusions shall not be less than Grade 1 each; the sum of Class A and Class C inclusions shall not be less than Grade 3, and the sum of Class B and Class E deformations shall not be less than Grade 1.
Shan) The metallographic test shall be taken at the end of the tensile specimen or impact specimen. 3.6.7.4 The test requirements for the intergranular corrosion tendency of austenitic and austenitic-fast stainless acid-resistant steel products shall be stipulated in the order contract after negotiation. The intergranular corrosion tendency test shall be carried out in accordance with the provisions of relevant standards. 3.6.8 The crankshaft, connecting rod, piston rod, high-pressure cylinder block, high-pressure cylinder head, high-pressure cylinder cover, half-pin, crosshead connector and other forgings shall be subjected to ultrasonic flaw detection after processing. The specific requirements shall be in accordance with the provisions of JB/T6908. 3.6.9 Parts that need to be subjected to magnetic flaw detection shall be inspected in accordance with the provisions of JB/T6908. 3.7 Technical requirements for machining
The technical requirements for machining can be referred to Appendix A (Appendix A).5
3.8 Technical requirements for assembly
JB/T9105-1999
3.8.1 All parts of the compressor (including purchased parts) shall be qualified products that have been inspected and assembled in accordance with the provisions of the relevant product assembly technical documents.
3.8.2 For compressors that need to be pre-installed before leaving the factory, the position of the main components shall be adjusted according to Table 2. Table 2
Assembly parts
Assembly requirements
The horizontality of the body to be installed on the foundation 1 The coaxiality of the axis of the vertical hole to the axis of the shaft
The parallelism of the axis of the shaft to the crankshaft axis
The axis of the shaft to the crankshaft axis
The axis of the shaft to the crankshaft axis
The crankshaft is installed and rotated for a few revolutions. Check the distance between the horizontal and the required points and the distance between the cylinder axis centerline and the body! The linear axis of the sliding block along the axis centerline is 100-300
300-500
After assembly with the "head", the horizontal yard of the two clear rods, the false inclination is consistent with the false inclination of the "center bone channel"
common value (not more than 1000)
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After inter-position repair
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3.8.3 The following items should be noted in the assembly process, and should comply with the provisions of relevant product technical documents. a) The distance between the inner and outer stop points of each level:
10000) The radial clearance and contact between the head and the slideway: c) The connection between the main bearing back and the bottom hole of the fuselage shaft: d) The radial clearance between the shaft neck and the main bearing: e) The radial distance between the crankpin and the connecting rod big end bearing: ] The radial distance between the connecting rod head and the connecting rod small end bearing: ) The axial distance between the connecting rod support positioning surface.
3, 8.4 After the pre-installation of the straight compressor, after selection and adjustment, the components cannot be interchanged, and the joints should be marked respectively. The marked components are:
a) The bearing seat and bearing cover of the machine body:
h) The same series of machine, middle body, connecting rod, cross head, cylinder, palm: ) The machine body and the corresponding position of the support frame:
4) The level and order of the stuffing box: 6
3.9 Painting requirements
JA/T9105-1999
3.9.1 The requirements for the rolling of the straight compressor should comply with JB/T7663.2 3.2 The non-machined surfaces of the main engine and auxiliary equipment of the compressor shall be painted in accordance with the relevant documents or the regulations of the design. The paint film is required to have certain properties such as high temperature resistance, oil resistance and water corrosion resistance, and the paint surface shall be smooth and intact. 3.3 The two windings of the compressor should be completely disassembled, and the paint film at the connection should be flat, the thickness should be consistent, and the lines should be obvious. 3.4 The non-machined internal surfaces of the main engine and auxiliary equipment of the compressor shall be painted with paint of standard oil and water resistance test (gas control, air valve, air compressor, internal parts of the compressor are not required). 3.9.5 The wheel joints of the flywheel, coupling gear, etc. shall be painted with red oil to draw attention. 3.10 Complete set and supply specifications of compressors
3.10.1 The scope of complete sets of compressors includes the following items: a) Compressor + compressor;
6) Accessories;
c) Driving prime mover, starting equipment and its accessories:
pipe mesh for compressor inlet and outlet (including auxiliary equipment), matching flange and corresponding control instrument:
|) Special tools necessary for disassembling and assembling compressor:
|3.10.2 The scope of application of compressor shall be in accordance with the agreement signed by both parties. 3.10.3 Under the condition that the user complies with the requirements of the product manual, within 18 months from the date of manufacture and delivery, and the compressor operation time does not exceed 100, the compressor shall not be damaged due to poor product quality (excluding wearing parts), and the manufacturer shall promptly repair or replace the damaged parts and components free of charge.
4 Test methods and inspection regulations
4.1 All designs, components and complete compressors and their accessories shall be inspected by the manufacturing quality management department in accordance with the relevant provisions of this standard and in accordance with drawings and technical documents approved by a certain process. 4.2 The first typical prototype of the compressor trial can be subjected to type test as stipulated in the agreement between the manufacturer or the user. The continuous running time of the type test shall not be less than 500 hours. During the running process, in addition to checking the working condition of all mechanisms and screens, the capacity, shaft power, speed, temperature of circulating lubricating oil and cooling water, pressure and temperature of each level of gas, oxygen consumption of cooling water and lubricating oil and special noise of the compressor are also sensed. After running, the wear of components, parts and various friction surfaces are checked. 4.3 The determination of the power level of the wheezing sound of the compressor unit shall be in accordance with the provisions of GB/T4980 or JBFT665. 4.4 The demonstration compressors officially put into production shall be tested by the manufacturer one by one. The methods of factory test are as follows: a) Current installation test: b) No-load running test of the compressor host machine; c) Load running test of the compressor unit.
Which factory test method should be adopted for a certain type of compressor? The manufacturer shall specify it in accordance with the approved technical documents. 4.5 When installing the empty wheel of the compressor, check the correctness of the relative positions of the main parts and components, and whether there are any interference or jamming. 4.6 The no-load running test of the compressor shall be carried out at the rated speed for not less than 2 hours. Check whether the assembled wheel and the relative positions of the parts and components are correct and whether all lubrication pools are unobstructed, and whether the rotating mechanism and the connection parts are in working order. 4,? The compressor unit is operated in load mode, and reversely operates for not less than 3 hours under rated carbon conditions. The quality of the compressor assembly is checked, and the positive relationship between the components, the pressure and temperature of each level, the temperature of the cooling water and lubrication tank, the volume flow rate and the specific energy (specific power), etc. When air is used as the medium instead of the original gas medium test, the highest non-gas pressure is not more than 24.5MP4.8 The test method of the compressor is carried out in accordance with the relevant technical documents approved by the relevant authorities. 4.9 The volume limit deviation of the positive compressor is 0%-6%. When the compressor has a larger coefficient of resistance to special gases (such as ammonia), it shall be in accordance with the relevant provisions.
5 Marking, packaging, transportation and storage
5.1 The compressor shall have an obvious transfer mark. 5.2 The compressor shall have a product label nailed on a conspicuous and flat position. The label size and technical requirements shall comply with the provisions of ISO 13306. The main content below shall be marked:
al) Product name:
6) Product model:
) Flow plate, m/mm;
d) Suction pressure (absolute pressure), MPa:
) Exhaust pressure, MPa
f) Shaft power: kw;
g) Transfer, min;
h) Net weight, kg+
i) Overall dimensions (length × width × height), mm:) Factory number:
k} Date of export;
Manufacturer name [export products should add "People's Republic of China" and other words);! Manufacturer location.
5.3 The packaging of the compressor shall comply with the provisions of the old T7631. 5.4 When packaging the compressor, A will apply anti-corrosion grease to the exposed processing surface. Parts with a surface roughness R value less than or equal to 0.8 μm should be packed with anti-corrugation wax paper (or packed in bags or bundles). The openings of the cases should be sealed tightly. 5.5 The grease and fat of the compressor should ensure that the product will not be damaged within 12 months from the date of shipment. 5.6 The packaging of the compressor should comply with the provisions of the packing list and packing drawings. The markings on the outer skin of the compressor packaging box should comply with the provisions of the sample. The female markings should be clear and neat to ensure that they will not be blurred due to rain or long-term storage during transportation. 5.7 Each compressor should be accompanied by the following documents in the main engine: 1) Product pressure plate qualification certificate,
b) Product instruction manual:
2) Packing list:
3) Spare parts list:
4) Random tool list:
f) Factory documents and group catalogues accompanying the cylinder.
JB/t910s-1999
5.8After packing or before shipping to the user, the product should be stored in a place that is not exposed to sunlight and has a full cover. If the storage time is long, it should be checked regularly. The actual cleaning condition of the sheet should be determined whether it needs to be re-oiled and sealed to ensure that there is no damage and corrosion within the factory warranty period. AF
Surface roughness
[BT9105-1999
Appendix A
(Reminder Appendix)
Machining and connection requirements of the main parts of the compressor The surface roughness of the main wall parts of the compressor should be as specified in Table A1, Al
Required properties
Steering rod screw properties
Crosshead
Prefix shape
Shape and position weight tolerance
J.Selling surface
" prefix slideway support
The crankshaft that matches the movable pump and the crank pin that matches the movable shaft
The oil hole has transitions (edge chamfers)
The shaft has large and small holes, bolt holes
Matching the outer surface, positioning part】 and filter surface
>(K n:m
External circle and positioning support end surface
See the plug ring grid
The outer painting of the upper active chamber rod
The plane of the chamber rod
The matching place with the finger
Surface to surface
E, the surface of the body and the pin hole
Friction source surface
Drawing hole fillet over male wire
The shape and position tolerances of the main parts of the compression heat are in accordance with the provisions of Table A2, o
Surface runniness value,
um(CUT 1G31
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