在焦化工業(yè)生產(chǎn)中，發(fā)電機(jī)組作為核心動(dòng)力設(shè)備，其運(yùn)行穩(wěn)定性直接影響整個(gè)工藝流程。高溫環(huán)境下，發(fā)電機(jī)定子、轉(zhuǎn)子及軸承溫度可能突破安全閾值，導(dǎo)致效率下降甚至停機(jī)。因此，掌握快速冷卻技術(shù)對(duì)保障生產(chǎn)連續(xù)性至關(guān)重要。

　　In coking industry production, as the core power equipment, the stability of the generator set directly affects the entire process flow. In high temperature environments, the temperature of the generator stator, rotor, and bearings may exceed the safety threshold, leading to a decrease in efficiency or even shutdown. Therefore, mastering rapid cooling technology is crucial for ensuring production continuity.

　　一、冷卻系統(tǒng)基礎(chǔ)原理

　　1、 Basic principles of cooling system

　　焦化發(fā)電機(jī)通常采用密閉循環(huán)冷卻系統(tǒng)，通過(guò)冷卻介質(zhì)帶走設(shè)備運(yùn)行產(chǎn)生的熱量。以氫冷發(fā)電機(jī)為例，氫氣在定子膛內(nèi)循環(huán)流動(dòng)，其導(dǎo)熱系數(shù)是空氣的7倍，可顯著提升冷卻效率。某焦化廠的實(shí)際運(yùn)行數(shù)據(jù)顯示，氫壓維持在0.3MPa時(shí)，發(fā)電機(jī)出力可提升15%。對(duì)于空冷機(jī)組，則通過(guò)軸流風(fēng)機(jī)強(qiáng)制空氣對(duì)流，需確保進(jìn)風(fēng)溫度低于40℃，排風(fēng)溫度控制在70℃以?xún)?nèi)。

　　Coking generators usually use a closed cycle cooling system to remove the heat generated by equipment operation through a cooling medium. Taking a hydrogen cooled generator as an example, hydrogen gas circulates in the stator chamber, and its thermal conductivity is 7 times that of air, which can significantly improve cooling efficiency. The actual operating data of a coking plant shows that when the hydrogen pressure is maintained at 0.3 MPa, the generator output can be increased by 15%. For air-cooled units, forced air convection is achieved through axial flow fans, ensuring that the inlet air temperature is below 40 ℃ and the exhaust air temperature is controlled within 70 ℃.

　　二、快速冷卻技術(shù)路徑

　　2、 Rapid cooling technology path

　　優(yōu)化冷卻系統(tǒng)設(shè)計(jì)

　　Optimize cooling system design

　　采用三維流場(chǎng)仿真技術(shù)優(yōu)化冷卻通道布局，減少渦流與死區(qū)。某企業(yè)的改造案例表明，通過(guò)在定子線棒端部增設(shè)導(dǎo)流板，使冷卻氣體流速均勻性提升，局部過(guò)熱點(diǎn)溫度降低。對(duì)于大型機(jī)組，可引入雙循環(huán)冷卻系統(tǒng)，內(nèi)循環(huán)采用除鹽水，外循環(huán)使用閉式冷卻塔，實(shí)現(xiàn)溫差梯度利用。

　　Using 3D flow field simulation technology to optimize the layout of cooling channels and reduce eddy currents and dead zones. The renovation case of a certain enterprise shows that by adding a guide plate at the end of the stator bar, the uniformity of the cooling gas flow rate is improved, and the temperature of local hotspots is reduced. For large units, a dual circulation cooling system can be introduced, with desalinated water used for the internal circulation and a closed cooling tower used for the external circulation to achieve temperature gradient utilization.

　　采用高效冷卻介質(zhì)

　　Using efficient cooling medium

　　在氫冷系統(tǒng)中，通過(guò)補(bǔ)氫裝置維持氫氣純度在98%以上，可降低風(fēng)摩損耗。

　　In a hydrogen cooling system, maintaining a hydrogen purity of over 98% through a hydrogen replenishment device can reduce wind and friction losses. 

　　實(shí)施智能溫控策略

　　Implement intelligent temperature control strategy

　　部署紅外熱成像系統(tǒng)實(shí)時(shí)監(jiān)測(cè)溫升分布，某焦化廠的實(shí)踐表明，該技術(shù)可提前30分鐘預(yù)警局部過(guò)熱。結(jié)合PID控制算法，動(dòng)態(tài)調(diào)節(jié)冷卻風(fēng)機(jī)轉(zhuǎn)速與冷卻水流量，使溫度波動(dòng)范圍控制在±2℃以?xún)?nèi)。在極端工況下，可啟動(dòng)應(yīng)急冷卻模式，通過(guò)旁路管道引入低溫介質(zhì)，實(shí)現(xiàn)快速降溫。

　　Deploying an infrared thermal imaging system to monitor temperature rise distribution in real-time, the practice of a coking plant has shown that this technology can provide a 30 minute early warning of local overheating. Combining PID control algorithm, dynamically adjust the speed of the cooling fan and the flow rate of the cooling water to control the temperature fluctuation range within ± 2 ℃. In extreme working conditions, emergency cooling mode can be activated to introduce low-temperature medium through bypass pipelines for rapid cooling.

　　三、緊急冷卻操作規(guī)程

　　3、 Emergency Cooling Operating Procedures

　　備用冷卻系統(tǒng)啟動(dòng)

　　Backup cooling system startup

　　主冷卻系統(tǒng)故障時(shí)，需在5分鐘內(nèi)切換至備用冷卻水源。某電廠的操作規(guī)范要求，備用泵啟動(dòng)前需進(jìn)行正反轉(zhuǎn)校驗(yàn)，避免造成系統(tǒng)壓力沖擊。同時(shí)，開(kāi)啟事故放油閥，防止?jié)櫥透邷靥蓟?/p>

　　When the main cooling system fails, it is necessary to switch to the backup cooling water source within 5 minutes. The operating standards of a certain power plant require that the standby pump undergo forward and reverse calibration before starting to avoid causing system pressure shock. At the same time, open the accident oil drain valve to prevent high-temperature carbonization of lubricating oil.

　　臨時(shí)冷卻設(shè)備部署

　　Temporary cooling equipment deployment

　　對(duì)于局部過(guò)熱點(diǎn)，可架設(shè)移動(dòng)式軸流風(fēng)機(jī)，風(fēng)量需滿足0.5m3/s·kW的冷卻需求。某檢修案例顯示，采用渦流管制冷技術(shù)，通過(guò)壓縮空氣產(chǎn)生-20℃冷氣流，可在15分鐘內(nèi)將軸承溫度從120℃降至80℃。

　　For local hotspots, a mobile axial flow fan can be installed with an air volume that meets the cooling requirements of 0.5m3/s · kW. A maintenance case shows that using vortex tube refrigeration technology to generate a -20 ℃ cold air flow through compressed air can reduce the bearing temperature from 120 ℃ to 80 ℃ within 15 minutes.

　　負(fù)荷調(diào)節(jié)與停機(jī)保護(hù)

　　Load regulation and shutdown protection

　　當(dāng)冷卻介質(zhì)溫度超過(guò)50℃時(shí)，需在30分鐘內(nèi)將負(fù)荷降至額定值的70%。若溫升速率超過(guò)3℃/min，應(yīng)立即執(zhí)行緊急停機(jī)程序，避免設(shè)備損壞。某企業(yè)的應(yīng)急預(yù)案規(guī)定，停機(jī)后需維持惰走轉(zhuǎn)速，利用殘余動(dòng)能驅(qū)動(dòng)冷卻風(fēng)機(jī)繼續(xù)運(yùn)轉(zhuǎn)。

　　When the temperature of the cooling medium exceeds 50 ℃, the load should be reduced to 70% of the rated value within 30 minutes. If the temperature rise rate exceeds 3 ℃/min, the emergency shutdown procedure should be immediately executed to avoid equipment damage. The emergency plan of a certain enterprise stipulates that the idle speed should be maintained after shutdown, and residual kinetic energy should be used to drive the cooling fan to continue running.

　　焦化發(fā)電機(jī)的快速冷卻技術(shù)需貫穿設(shè)計(jì)、運(yùn)行、維護(hù)全周期。通過(guò)流場(chǎng)優(yōu)化、介質(zhì)升級(jí)、智能控制等手段，可顯著提升冷卻效率。在緊急情況下，需快速啟動(dòng)備用系統(tǒng)，結(jié)合臨時(shí)冷卻設(shè)備與負(fù)荷調(diào)節(jié)，確保設(shè)備安全。日常維護(hù)中，則需重點(diǎn)關(guān)注冷卻通道清潔度與介質(zhì)品質(zhì)，建立傳感器冗余機(jī)制，為發(fā)電機(jī)組構(gòu)建起多層級(jí)保護(hù)體系。

　　The rapid cooling technology of coking generators needs to be integrated throughout the entire design, operation, and maintenance cycle. By optimizing the flow field, upgrading the medium, and implementing intelligent control, the cooling efficiency can be significantly improved. In emergency situations, it is necessary to quickly activate the backup system, combined with temporary cooling equipment and load regulation, to ensure equipment safety. In daily maintenance, it is necessary to focus on the cleanliness of the cooling channel and the quality of the medium, establish a sensor redundancy mechanism, and build a multi-level protection system for the generator set.

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