Thrust bearing oil cooler: heat dissipation guard of industrial equipment

Tube sheet: the key hub of the cooler

The tube sheet is an important component connecting the tube bundle and the shell. It shoulders the dual mission of fixing the tube bundle and distributing the fluid in the operation of the thrust bearing oil cooler. There are many tube holes evenly distributed on the tube sheet, which are the "cradle" for the precise installation of the heat exchange tube. The position accuracy and aperture size of each tube hole are carefully designed and strictly controlled to ensure that the heat exchange tube can be tightly and firmly connected to it, thereby building the basic framework of heat exchange inside the cooler.

From the perspective of material, the selection of tube sheets is very particular. In general, in order to ensure the reliability of the connection with the heat exchange tube, its material needs to have good strength and welding performance. In ordinary industrial environments, carbon steel tube sheets are more common. They are relatively low in cost and can meet the strength requirements under general working conditions. However, in some special occasions with extremely high requirements for corrosion resistance, such as contact with highly corrosive media in the chemical industry, special alloy materials need to be used to make tube sheets. For example, titanium alloy tube sheets, with their excellent corrosion resistance, can effectively resist the erosion of various strong acids and alkalis, ensuring the long-term stable operation of the cooler in harsh environments. ​
The manufacturing process of tube sheets is also quite complicated. When processing tube holes, advanced CNC machine tools are widely used. Through high-precision tools and precise programming control, the processing error of tube holes can be controlled within a very small range. At the same time, in order to ensure the overall strength and flatness of the tube sheet, after forging or casting the tube sheet blank, it is necessary to go through multiple machining processes, such as milling and grinding, to finely process the surface and edges of the tube sheet so that it can meet the dimensional accuracy and surface roughness required by the design. ​
The overall structure of the cooler​
With the tube sheet as the core and extending outward, the thrust bearing oil cooler is mainly composed of components such as the shell, tube sheet, tube bundle, head, inlet and outlet pipes and supports. ​
As the solid "armor" of the cooler, the shell is usually made of metal materials such as carbon steel or stainless steel. It not only has to withstand the pressure of the internal fluid, but also has to resist the impact of the external environment. When designing the shell, engineers need to comprehensively consider factors such as strength, sealing, and connection methods with other components. For example, under some high-pressure conditions, the wall thickness of the shell will increase accordingly, and a special welding process or sealing structure will be used to ensure that the entire cooler operates stably under complex conditions without safety hazards such as leakage or rupture. ​
The tube bundle is the core area of ​​the cooler to achieve heat exchange, and is composed of a large number of heat exchange tubes. There are various types of heat exchange tubes, the most common of which are light tube type and enhanced heat transfer tube type. The light tube heat exchange tube has a smooth surface, relatively small fluid flow resistance, good pressure bearing performance and long service life. It is suitable for some occasions where the requirements for heat transfer efficiency are not particularly high, but the requirements for equipment stability and reliability are high. The enhanced heat transfer tube heat exchange tube significantly increases the heat exchange area and greatly improves the heat transfer efficiency by adding special structures such as fins and grooves inside or outside the tube. It is especially suitable for application scenarios with limited space but extremely high heat dissipation requirements, such as some special cooling equipment in the aerospace field. ​
The head is installed at both ends of the cooler, and its shape is mostly elliptical or hemispherical. This design can withstand higher pressures and is conducive to the uniform distribution of fluid in the cooler. The head and the shell are connected by welding or flanges to ensure good sealing performance and prevent fluid leakage. The inlet and outlet pipes are responsible for connecting the cooler with the external oil circulation system and cooling medium system. The inlet pipe introduces high-temperature lubricating oil into the cooler, and the outlet pipe transports the lubricating oil back to the equipment after cooling. Cooling media, such as water or other coolants, also enter and exit the cooler through the corresponding inlet and outlet pipes to exchange heat with the lubricating oil. The pipe diameter and connection method of the inlet and outlet pipes need to be precisely designed according to the flow and pressure requirements of the system to ensure that the fluid can enter and exit the cooler smoothly. ​
The support is used to support the entire cooler so that it can be stably installed on the equipment foundation. When designing the support, factors such as the weight of the cooler, vibration during operation, and installation environment should be fully considered to ensure that the cooler will not be displaced or shaken during operation, providing a solid foundation for the stable operation of the equipment.​
Working principle: the exquisite process of heat exchange​
The working principle of thrust bearing oil cooler is based on the law of heat exchange, that is, heat is always transferred from high-temperature objects to low-temperature objects. When industrial equipment is running, the thrust bearing is subjected to huge axial loads, and frictional heat generation is inevitable, causing the lubricating oil temperature to rise sharply. If the lubricating oil temperature is too high, its viscosity will decrease, and the lubrication performance will be greatly reduced, which will in turn aggravate the wear of the bearing and may even cause equipment failure. ​
In order to maintain the normal working temperature of the lubricating oil, the high-temperature lubricating oil is introduced from the thrust bearing of the equipment into the inlet pipe of the cooler. At this time, the lubricating oil carries a lot of heat and is in a high-temperature state. At the same time, a relatively low-temperature cooling medium, such as water, enters the cooler through another inlet pipe of the cooler. Inside the cooler, the lubricating oil and the cooling medium flow in the opposite direction in the tube bundle. Due to the significant temperature difference between the two, heat is transferred from the high-temperature lubricating oil to the low-temperature cooling medium. Specifically, the heat is first transferred from the lubricating oil side to the cooling medium side through the tube wall of the heat exchange tube. In this process, the special structure of the heat transfer tube heat exchanger plays an important role. It increases the path and area of ​​heat transfer and greatly accelerates the speed of heat transfer. After heat exchange, the temperature of the lubricating oil gradually decreases, while the temperature of the cooling medium increases. The cooled lubricating oil flows out from the outlet pipe of the cooler and returns to the thrust bearing to continue to play its role of lubrication and heat dissipation. The heated cooling medium is discharged from another outlet pipe of the cooler and transported to the cooling system for cooling treatment for recycling. ​
Through such a continuous heat exchange process, the thrust bearing oil cooler effectively removes the heat generated by the thrust bearing, keeps the temperature of the lubricating oil within the appropriate working range, and ensures the stable operation of industrial equipment. ​
Wide application fields ​
Thrust bearing oil coolers have been widely used in many industrial fields due to their excellent heat dissipation performance. ​
In the power industry, whether it is thermal power generation, hydropower generation or nuclear power generation, thrust bearing oil coolers play an indispensable role. In thermal power plants, the thrust bearings of steam turbines generate a lot of heat during high-speed rotation, and the lubricating oil needs to be cooled by oil coolers to ensure the normal operation of the steam turbine. Similarly, in hydroelectric power plants, the thrust bearings of turbines cannot do without the heat dissipation support of oil coolers. When the turbine is running, the huge impact force of the water flow will cause the thrust bearing to bear a high axial load and generate a lot of heat. The oil cooler can take away this heat in time to ensure the stable operation of the turbine and improve the power generation efficiency. In the field of nuclear power generation, the thrust bearings of key equipment such as reactor coolant pumps also need oil coolers to maintain the appropriate temperature of the lubricating oil and ensure the safe and reliable operation of the equipment. ​
In the metallurgical industry, various large-scale smelting equipment and rolling equipment will also generate a lot of heat during operation. For example, in the blast furnace ironmaking process, the rotating parts of the furnace top equipment need to be supported by thrust bearings, and these bearings work in a high temperature and high load environment, and the lubricating oil is very easy to heat up. The thrust bearing oil cooler can effectively reduce the temperature of the lubricating oil, ensure the continuous and stable operation of the equipment, improve production efficiency, and reduce the number of equipment maintenance. On the steel rolling production line, the bearings of the working rolls and support rolls of the rolling mill also need oil coolers for heat dissipation to ensure the rolling quality of steel and the normal operation of the equipment. ​
In the chemical industry, the thrust bearings of many large reaction equipment and conveying pumps also rely on oil coolers for heat dissipation. In the chemical production process, the reaction conditions are often harsh. The heat generated when the equipment is running will not only affect the performance of the equipment itself, but may also have an adverse effect on the chemical reaction. By installing a thrust bearing oil cooler, the lubricating oil temperature can be effectively controlled to ensure the stable operation of the equipment in a complex chemical environment and prevent production interruptions and safety accidents caused by equipment failure. ​
In the mining field, large-scale mining machinery and equipment such as crushers, ball mills, hoists, etc., bear huge loads and generate a lot of heat during operation. These equipment usually work in harsh environments with a lot of dust and high humidity. If the lubricating oil temperature is too high, it is easy to cause aggravated bearing wear and even cause equipment failure. The thrust bearing oil cooler can provide reliable heat dissipation guarantee for the thrust bearings of these equipment, extend the service life of the equipment, and improve the safety and economy of mining production.​
In other industries such as light industry and heavy industry, thrust bearing oil coolers can be seen in any occasion involving large rotating equipment and thrust bearings that require good heat dissipation. For example, in the papermaking industry, the thrust bearings of the transmission system of large paper machines require oil coolers to maintain the appropriate temperature of the lubricating oil to ensure the production quality of paper and the stable operation of the equipment; in the field of shipbuilding and shipping, the thrust bearings of the ship's main engine and propulsion system also require oil coolers for heat dissipation to ensure the stability of the ship's power during navigation. ​