气化炉激冷室内壁堆焊工艺技术

本文介绍大型煤化工设备气化炉的功能、结构及技术特征,通过制造规范要求堆焊工艺评定,确定过程中各项正确、规范的堆焊技术参数,对材料控制、堆焊方法选择、过渡层堆焊、面层堆焊、无损检测等关键工艺过程内容进行详细说明,保证设备堆焊质量,顺利完成设备制造任务。     

RBI技术应用于LNG设备上的改进研究

基于API581的风险评估技术(RBI)是近年来石化行业逐渐采用并得到认可的一种新的评估设备经济可行性和安全性的技术。但是由于LNG的温度一般低至-162℃,使得LNG设备在应用API581时受到了限制。低温脆性断裂是LNG设备需考虑的一项主要的失效模式,API在评估脆断损伤因子时的温度范围是-73~38℃。为了能够评估LNG设备在低温环境下的风险,通过遗传算法将温度扩展至-209℃。扩展得到的脆断损伤因子曲线同夏比冲击试验的冲击功随温度变化曲线的趋势基本一致,因此扩展的损伤因子可以满足低温环境下LNG设备的风险评估。     

浅谈气化炉激冷室内表面堆焊层裂纹形成原因及预防

气化炉是化工造气装置的重要设备,在停车检修时,内表面不锈钢堆焊层总会出现众多裂纹性缺陷,给设备的安全运行埋下隐患,给企业的投产计划带来挑战。笔者结合多年的气化炉定期检验经验,从气化炉内表面堆焊层裂纹形成的原因及预防展开论述。本文针对定期检验发现的问题,采取金相、腐蚀产物分析等方法进行分析,得出内表面堆焊层裂纹形成的原因,为企业在气化炉检修及使用过程中的安全运行提供参考。     

φ1．4m尿素合成塔基体的应力腐蚀裂纹

国内中、小型化肥厂普遍采用水溶液全循环法生产尿素的工艺流程，φ1．4m尿素合成塔是核心设备．其壳体包括上、下封头和筒体．筒体由多层包扎式结构的筒节组焊而成。内层包含上、下封头的尿素级奥氏体不锈钢堆焊层和筒节的尿素级奥氏体不锈钢内简体．基体包含上、下封头的低合金钢基层板和筒节的多层低合金钢的层板．     

基于混凝土循环剥落的隧道火灾损伤数值模型研究

为研究混凝土高温剥落对隧道衬砌火灾损伤的影响,在现有隧道结构非线性瞬态热—力耦合有限元模型基础上,提出1种在火灾高温条件下混凝土发生剥落的循环算法,以模拟火灾下衬砌结构截面面积的损失,并引入混凝土临界剥落温度的概念,得出基于混凝土循环剥落的隧道衬砌火灾损伤数值模型建立流程。利用该模型对某隧道衬砌结构进行火灾损伤模拟,并与试验结果进行对比验证。结果表明:火灾下隧道混凝土衬砌结构内逐渐增大的热应力是导致普通混凝土高温剥落的主要原因;可将衬砌受火面是否达到临界剥落温度作为隧道发生高温剥落的充分条件进行火灾损伤分析;模型求解所得的数值模拟结果与现场火灾试验数据基本吻合,验证了其可行性;混凝土高温剥落与否对衬砌结构等效温度应力有较大影响,在隧道衬砌结构抗火性能分析过程中应尽量考虑混凝土高温剥落造成的影响。     

基于风险的检验(RBI)技术在PX装置中的应用

对PX装置运用基于风险的检验技术,识别装置内的高度危害介质及其危害种类,工艺危害性分析及损伤机理分析表明主要的损伤机理是高温氢损伤、回火脆化和外部腐蚀。定量风险分析结果显示,该PX装置中135台压力容器中高风险设备项6个,占3.09%;中风险153项,占78.87%;低风险35项,占18.4%。根据设备风险制定推荐性检验策略,为装置的风险识别和降低风险提供参考。     

典型加氢反应器衬里开裂原因分析

加氢反应器是加氢装置中最关键的设备,也是众多石油化工企业的核心设备。本文通过对某石化企业5台加氢反应器历年来的检验情况总结,对加氢反应器使用过程中可能发生的应力腐蚀开裂等损伤模式进行了阐述。最后,针对检验过程中发现的反应器堆焊层开裂情况,着重分析了其发生的原因,为该类设备的检验及使用维护提供了非常宝贵的案例。     

大型承压设备不停机电磁无损检测技术及应用

"大型承压设备不停机电磁无损检测技术及应用"针对大型成套装置长周期运行急需的不停机检测技术这一世界性难题。在国家系列科研项目的支持下,在10多家单位、60多名科技人员的共同努力下,历时10多年,研究揭示了大型承压设备常用材料腐蚀和应力损伤在不同电磁激励下的响应规律,开发了具有自主知识产权的三种电磁检测仪器与系统,提出了适用于不同材料腐蚀与应力损伤的四种电磁检测和结果评价方法,研究建立了相应的检测技术标准体系,实现了带油漆层、不拆或局部拆除保温层等的大型承压设备不停机检测,解决了长期困扰政府和企业的瓶颈性技术难题。该成果获得2015年度国家科学技术进步二等奖,本文以该成果的"国家科学技术奖励推荐书"为基础,综述了项目背景、成果及其应用情况。     

灰浆层对钢筋混凝土楼板耐火极限的影响

为保护钢筋混凝土结构不因受到高温影响使结构急剧丧失承载能力而倒塌,常采用增加灰浆层的办法。钢筋在混凝土与灰浆层保护层的包裹之内,可以缓解温度急剧上升。但典型灰浆层对钢筋混凝土的耐火极限的报道还不多。本文针对灰浆层对钢筋混凝土的耐火极限影响进行了试验研究。比较了增加灰浆层与不加抹灰层在耐火极限、烧损面、残余强度等方面的变化,讨论了灰浆层对结构防火的贡献。结果证明：钢筋在混凝土在灰浆层保护层的包裹之内,可以缓解温度急剧上升,保护层使建筑物有一定的耐火作用;增加钢筋混凝土结构构件的保护层厚度能够有效提高构件的耐火极限;混凝土砂浆保护层直接关系到混凝土结构的承载力,直接关系到混凝土结构的耐久性与耐火性。     

考虑设备跌落的天然气计量站失效后果计算方法

天然气计量站阀门多且检定流程中频繁使用桁车,常规天然气站场的失效后果计算方法难以评估由此带来的影响及后果。为此,在API 581标准基础上,考虑阀门截断作用对机械损伤事故的影响,选取管段组储气量为最大天然气泄漏量,并以动量定理为依据,研究了桁车失效所引发的设备跌落事故,建立了潜在影响面积计算模型;将影响面积内损伤的管段及设备、泄漏的天然气、伤亡的人员等折算为经济损失,形成了考虑设备跌落的天然气计量站失效后果计算方法;将该方法应用于某天然气计量站。研究结果表明:设备跌落事故损失金额为机械损伤事故的3倍;当考虑设备跌落事故时,管段风险等级由低级上升为中低级。研究结果可为天然气计量站失效后果评价提供理论支撑。     

Mechanisms of high-pressure hydrogen gas self-ignition in tubes

This paper describes a numerical and experimental investigation of hydrogen self-ignition occurring as a result of the formation of a shock wave. The shock wave is formed in front of high-pressure hydrogen gas propagating in a tube. The ignition of the hydrogen–air mixture occurs at the contact surface of the hydrogen and oxidant mixture and is due to the temperature increase produced as a result of the shock wave. The required condition for self-ignition is to maintain the high temperature in the mixture for a time long enough for inflammation to take place. The experimental technique employed was based on a high-pressure chamber pressurized with hydrogen, to the point of a burst disk operating to discharge pressurized hydrogen into a tube of cylindrical or rectangular cross section containing air. A physicochemical model involving gas-dynamic transport of a viscous gas, detailed kinetics of hydrogen oxidation and heat exchange in the laminar approach was used for calculations of high-pressure hydrogen self-ignition. The reservoir pressure range, when a shock wave is formed in the air that has sufficient intensity to produce self-ignition of the hydrogen–air mixture, is found. An analysis of governing physical phenomena based on the experimental and numerical results of the initial conditions (the hydrogen pressure inside the vessel, and the shape of the tube in which the hydrogen was discharged) and physical mechanisms that lead to combustion is presented.     

Shock-induced ignition of hydrogen gas during accidental or technical opening of high-pressure tanks

This paper is devoted to the numerical and experimental investigation of hydrogen self-ignition as a result of the formation of a primary shock wave in front of a cold expanding hydrogen gas jet. Temperature increase, as a result of this shock wave, leads to the ignition of the hydrogen–air mixture formed on the contact surface. The required condition for hydrogen self-ignition is to maintain the high temperature in the area for a time long enough for hydrogen and air to mix and inflammation to take place.

Calculations of the self-ignition of a hydrogen jet are based on a physicochemical model involving the gas-dynamic transport of a viscous gas, the kinetics of hydrogen oxidation, the multi-component diffusion, and the heat exchange. We found that the reservoir pressure range, when a shock wave formed in the air during depressurization, has sufficient intensity to produce self-ignition of the hydrogen–air mixture formed at the front of a jet of compressed hydrogen. We present an analysis of the initial conditions (the hydrogen pressure inside the vessel, the temperature of the compressed hydrogen and the surrounding air, and the diameter of the hole through which the jet was emitted), which leads to combustion.     

基于802.11n无线传感器网络的巷道人员定位技术研究

针对现阶段矿井人员定位系统定位精度低、成本高、可靠性差等问题,提出了一种基于802.11n无线传感器网络技术的真三维人员定位系统,该系统根据功能特征划分为现场设备管理层、系统运行监控层和地面监控管理层。工作时,定位分站将移动节点通过无线网络传输过来的位置坐标信息通过RS-485总线传输到光纤冗余网中,紧接着将位置坐标信息通过CAN现场总线传输到地面数据服务器内进行解压、分析处理和可视化显示。实验结果表明:当加权因子k取1.1时,该系统在井下巷道测试环境中的平均误差仅为1.15 m,且长期运行无故障,具有较高的定位精度和可靠性,降低了成本。     

圆管状隔爆产品爆炸压力测试实验研究

为了研究隔爆产品内部的爆炸压力,选取了圆管状隔爆产品,设计了隔爆产品爆炸压力测试装置,测试记录了在常温和低温2种环境温度下,乙烯和氢气2种典型可燃性气体在不同内部结构的隔爆产品中的爆炸压力。研究结果表明:相同初始压力条件下,温度越低,气体的爆炸压力越大;在国际标准推荐的试验条件下,低浓度乙烯可以产生与高浓度氢气相同的爆炸压力;隔爆产品结构的变化会导致压力重叠的现象,显著影响爆炸压力的大小。     

某生活垃圾卫生填埋场填埋作业区覆膜抽气除臭试验研究

本文采用三种不同的覆膜抽气模式对填埋场作业面进行除臭试验研究,结果表明:覆膜1.0mm+3台负压车、2条负压管比单层覆膜0.3mm+1台负压抽气车、2条临负压管或覆膜0.3mm+3台负压车对氨气、硫化氢和臭气浓度的去除效果都要更好;但覆膜抽气法对总挥发性有机物(Total Volatile Organic Compounds,TVOC)的去除效果较之前更差,这主要是由于TVOC主要为分子量较大的有机物,扩散较慢,且垃圾堆体在厌氧条件下产生的TVOC浓度更高。     

氢气爆炸特性研究

本文研究、总结了氢气与空气(氢气与氧气)的混合物的爆炸特性.即氢气在空气中,在比较低燃烧界限的情况下,只有向上的传播和非常少的超压可以观测得到.正因为氢气的这种特性,将氢应用于科技将极大地推进社会进步,氢燃料将成为一种主要的能源.然而,氢技术应用的成功与否主要取决于氢使用的安全性.所以,必须掌握实际使用时氢气燃烧的性能.本文在日本过去十年实验数据的基础上,通过实验研究了氢气与空气混合物的燃点.研究了氢气、氧气混合物经氮气稀释后,按化学当量比例将不同浓度的氢气与空气进行混合,并得出了低温下的爆炸压力特性.随后,分别讨论了在初始压力下一致的情况下,试管直径相同的状况下,氢气与空气混合浓度相同的情况下,这三种爆轰传播限制之间的关系.得出了在空气中直接点燃的发生爆轰的最小试管直径,最小的装药量之间的关系,进行了爆轰危险性分级.最后,文章概括比较了氢与其他燃料的燃烧特性,评估了氢气燃烧过程中的危险与安全因素.     

Behavior of buoyancy and momentum controlled hydrogen jets and flames emitted into the quiescent atmosphere

As an effort to improve the prediction of hydrogen dispersion in the atmosphere, effects of buoyancy acting on the hydrogen jets formed by releasing from high pressure vessels are investigated analytically and experimentally. For the analytical study, an integral analysis for buoyant jets and flames is carried out to yield the closed formula describing the jet and flame shapes, including their trajectory and horizontal and vertical lengths corresponding to the critical concentrations. Because the density of hydrogen after releasing from high pressure storage conditions is much close to that of helium than that of hydrogen at room temperature, helium is used as the hydrogen surrogate for the buoyant jet experiments, which were performed by visualizing the jet dispersing in the atmosphere up to the jet Reynolds number Re ～ 2400. The trajectories obtained by the integral analysis and experiments agree relatively well until the transition to turbulence occurs. A further estimate for jets and flames is made by using the integral analysis as a preliminary design to the experiments involving a much greater hydrogen release. Once the comparative investigation of the larger scale experiments with the integral analysis, we anticipate that a more universal hydrogen jet and flame data can be obtained, which perhaps leads to a better safety distance of hydrogen stations.     

CFD modelling of hydrogen and hydrogen-methane explosions – Analysis of varying concentration and reduced oxygen atmospheres

This paper evaluates the predictive capabilities of the advanced consequence model FLACS-CFD for deflagrations involving hydrogen. Two modelling approaches are presented: the extensively validated model system originally developed for hydrocarbons included in FLACS-CFD 22.1 and a Markstein number dependent model implemented in the in-house version FLACS-CFD 22.1 IH. The ability of the models to predict the overpressure and the flame arrival time for scenarios with different concentrations of hydrogen, and thus different Lewis and Markstein numbers, is assessed. Furthermore, the effect of adding methane or nitrogen on overpressure for different regimes of premixed combustion are investigated. The validation dataset includes deflagrations in the open or in congested open areas and vented deflagrations in empty or congested enclosures. The overpressure predictions by FLACS-CFD 22.1 IH are found to be more accurate than those obtained with FLACS-CFD 22.1 for scenarios with varying hydrogen concentrations and/or added nitrogen or methane in the mixture. The predictions by FLACS-CFD 22.1 IH for lean hydrogen mixtures are within a factor of 2 of the values observed in the experiments. Further development of the model is needed for more accurate prediction of deflagrations involving rich hydrogen mixtures as well as scenarios with other fuels and/or conditions where the initial pressure or temperature deviate significantly from ambient conditions.     

Limiting explosible concentration of hydrogen–oxygen–helium mixtures related to the practical operational case

This paper presents data on the limiting (minimum) concentrations of hydrogen in oxygen, in the presence of added helium, at elevated temperature and pressure related to the practical operational case. A 5 L explosion vessel, an ignition sub-system and a transient pressure measurement sub-system were used. Through a series of experiments carried out using this system, the limiting concentrations of hydrogen in oxygen and helium at different initial pressures and temperatures for the practical operational case were studied, and the influence of ignition energy and initial temperature on the limiting concentration of hydrogen in oxygen and helium was analyzed and discussed. The variation of ignition energy within the studied range is found to have a significant effect on the limiting concentration of hydrogen in oxygen and helium at lower initial temperature. However, when the ignition energy is higher than 32 mJ, the limiting hydrogen concentration remains almost changeless as the initial temperature increases from 21 °C to 90 °C. The limiting explosible concentration of hydrogen–oxygen–helium mixture decreases as the ignition energy increases when the initial temperature is lower. When the initial temperature is higher, the ignition energy has little effect on the limiting hydrogen concentration of hydrogen–oxygen–helium mixtures. When the initial temperature reaches 90 °C, the limiting hydrogen concentration remains almost changeless with an increase in ignition energy. The limiting explosible concentration of hydrogen in the mixtures, at the initial temperature of 21 °C and the ignition energy of 0.5 mJ, is 8.5% and that of oxygen is 11.25%.     

Numerical study on the spontaneous ignition of pressurized hydrogen release through a tube into air

Spontaneous ignition of pressurized hydrogen release through a tube into air is investigated using a modified version of the KIVA-3V CFD code. A mixture-averaged multi-component approach is used for accurate calculation of molecular transport. Autoignition and combustion chemistry is accounted for using a 21 step kinetic scheme. Ultra fine meshes are employed along with the Arbitrary Lagrangia–Eulerian (ALE) method to reduce false numerical diffusion. The study has demonstrated a possible mechanism for spontaneous ignition through molecular diffusion.

In the simulated scenario, the tube provided additional time to achieve a combustible mixture at the hydrogen–air contact surface. When the tube was sufficiently long under certain release pressure, autoignition would initiate inside the tube at the contact surface due to mass and energy exchange between low temperature hydrogen and shock-heated air through molecular diffusion. Following further development of the hydrogen jet downstream, the contact surface became distorted. Turbulence plays an important role for hydrogen/air mixing in the immediate vicinity of this distorted contact surface and led the initial laminar flame to transit into a stable turbulent flame.