长时间服役的进口锅炉T91炉管失效行为研究

针对某进口亚临界锅炉三级过热器T91炉管失效事件,通过对其进行硬度、金相组织和SEM扫描电镜分析找出导致爆管的原因,并根据高温氧化皮厚度对其进行蠕变剩余寿命评估,结果表明该段T91管材爆管类型为典型长期过热爆管,炉管长期处于较高温度运行导致组织老化严重,力学性能下降,引起材料蠕变损伤,导致长期过热爆管,经计算其蠕变剩余寿命已达到寿命极限。本文对该锅炉防止类似事故具有重要作用,并对国内其他同在二十世纪90年代开始服役的T9彳炉管具有重大的参考价值和借鉴意义。     

电站锅炉管件失效泄漏原因分析

火力发电厂管件失效泄漏是频发事故,严重影响机组的安全、经济运行。以某发电厂后墙省煤器和低温再热器管子失效泄漏事故为例,通过对失效泄漏的管件进行宏观形貌分析、金相分析和强度分析,论证了泄漏事故的原因是由于腐蚀和钢管固有缺陷导致低温再热器高温段弯管外侧发生泄漏,泄漏的高速流体冲刷、气蚀导致后隔墙省煤器发生泄漏,进而对低温再热器反冲刷,加剧泄漏事故的恶化。最后提出更换失效管件,加强金属监督,尽量扩大防磨防爆检查范围,对易被气流磨损、冲刷部位进行防磨喷涂或加装防磨罩。     

WNS型锅炉烟管管端热应力裂纹原因分析

热应力破坏是锅炉烟管管端产生裂纹的主要原因.本文通过对一起WNS型锅炉因烟管管端伸出长度过长及受热面结垢导致烟管管端长期处于过热而产生裂纹泄漏的案例进行分析,模拟计算了水垢厚度对金属壁温的影响,并提出相关预防措施.     

On the failure of steam-side oxide scales in high temperature components of boilers during unsteady thermal processes

Failure of steam-side oxide scales in high temperature components of boilers such as superheater and reheater tubes has significant effect on the safety of thermal power plants. Taking into account the influence that temperature has on physical properties of metal substrate and oxide scale, transient heat transfer model as well as multi-layered hollow cylinder stress model is successively developed in this work. Employing the Advanced Oxide Scale Failure Diagram (AOSFD) as failure criterion, a systematic analysis model for the failure behavior of steam-side oxide scales in T92 superheater tubes during unsteady thermal processes is established. Focusing on different steam temperature variation processes, the effects of steam-side oxide scale thickness as well as different steam temperature variation modes and variation durations on oxide scale failure issues have been analyzed. Besides, critical steam temperature drops leading to failure of oxide scales when steam temperature decreases linearly have also been investigated. Based on the analysis results, feasible measures such as selecting reasonable steam temperature variation mode and appropriately lengthening variation duration are subsequently proposed. The analysis results as well as the suggested measures in this work can provide valuable guidance for the solution of steam-side oxide scale failure issues in thermal power plants.     

超临界直流电站锅炉水冷壁开裂原因分析及改进措施

本文介绍了超临界直流电站锅炉检验中发现的水冷壁开裂、变形,调风器鳍片烧损变形,集箱管接头角焊缝裂纹,刚性梁固定耳板处拉裂、变形等问题。对产生这些问题的原因进行了分析和研究,认为各水冷壁管子内水汽温度不均匀是造成拉裂、变形的主要原因。针对产生问题的原因,提出要预防此类问题发生就必须控制水冷壁超温和降低水冷壁各管子间温度差。并详细地论述了控制水冷壁超温和降低水冷壁各管子间温度差的八项具体改进措施。     

Experimental study of flame acceleration and the deflagration-to-detonation transition under conditions of transverse venting

Results of experiments on critical conditions for flame acceleration and the deflagration-to-detonation transition in tubes with transverse venting are presented. Tests were made with hydrogen mixtures in two tubes (inner diameter of 46 and 92 mm) with obstacles. Ratios of vent area to total tube area were 0.2 and 0.4. Venting was shown to influence flame acceleration significantly. The greater the vent ratio, the more reactive the mixture necessary for development of fast flames. Critical conditions for flame acceleration in tubes with venting, expressed through a critical mixture expansion ratio σ_cr, were found to be σ_cr/σ₀1+2, where σ₀ is the critical value for a closed tube. Critical conditions for detonation onset in a vented tube were found to be very close to those in a closed tube with similar configuration of obstacles.     

武钢75t/h锅炉省煤器管泄漏原因分析和对策

通过对省煤器泄漏原因进行分析,得出造成泄漏的主要原因是由于近期锅炉燃料配比改变导致锅炉实际燃烧工况发生了变化,使省煤器沸腾度超过设计值,由此在省煤器蛇形管弯头和汽包布水管内壁产生汽水冲刷,使管壁减薄,最终爆开。采用减少锅炉省煤器管换热面积,降低省煤器沸腾度,并同时对汽包布水管缩径,增加锅炉给水在水平管道流速的方法,彻底消除了焦耐锅炉省煤器频繁泄漏现象,保障了3台锅炉安全连续运行。     

Numerical study on the spontaneous ignition of pressurized hydrogen during its sudden release into the tube with varying lengths and diameters

Fuel cell vehicles (FCV) and other hydrogen systems with pressurized hydrogen has a safety hazard of spontaneous ignition during its sudden release into the tube. Tube parameter is a key factor affecting the spontaneous ignition of pressurized hydrogen. In this paper, a numerical study on the spontaneous ignition of pressurized hydrogen during its sudden release into the tube with varying lengths and diameters is conducted. The models of Large Eddy Simulation (LES), Eddy Dissipation Concept (EDC), Renormalization Group (RNG), 10-step like opening process of burst disk and 18-step detailed hydrogen combustion mechanism are employed. 6 cases are simulated based on the previous experiments. Numerical results show that the possibility of spontaneous ignition of pressurized hydrogen increases inside the longer and thinner tubes, which agrees with the experimental results. The increasing of tube length has little influence on the shock wave formation and propagation inside the tube. However, there exists critical tube lengths for the generation of Mach disk and the normal shock wave: the maximum and minimum distances for the generation of the Mach disk in 10 mm diameter tube are 7.8 and 6.7 mm, respectively. As for the normal shock wave, these critical values are 22.1 and 19.4 mm, respectively. In addition, the formation times and initial positions of Mach disk and normal shock wave are delayed inside the thicker tube. Due to the shock-affected time increases with the increasing of tube length, the temperature could rise to the critical ignition temperature and triggers the spontaneous ignition due to the sufficient tube length even though the less hydrogen/air mixture and the contact surface with lower temperature is produced inside the thicker tube. Finally, a simple time scale analysis is conducted.     

Experimental research into effects of obstacle on methane-coal dust hybrid explosion

An experimental system including pressure transducer, data acquisition card, computer and electric spark ignition device was set up to research methane-coal dust hybrid explosions in closed tubes with different types of obstacles inside. Its dynamic response time was less than a millisecond and the test precision was 0.1%. The experimental results show that the obstacles had great effects on the explosion characteristics in the tube. Hollow obstacles linked with inner wall of the tube induced faster pressure rising than installed center blocked solid obstacles. Obstacles with more sharp corner induce more violent explosions. The most dangerous explosion occurred when spacing between obstacles almost equaled the inner diameter of the tube for the same size obstacle.     

单面受火的方中空夹层钢管混凝土短柱耐火极限

为研究单面受火的方中空夹层钢管混凝土短柱耐火极限,在合理选择材料本构关系和边界条件的基础上,利用ABAQUS软件建立了高温下方中空夹层钢管混凝土短柱温度场和力学场分析模型,通过与试验数据对比验证,结果吻合良好。基于此模型,对不同的混凝土强度、钢管强度、内钢管厚度、空心率、荷载比进行耐火极限参数分析,并定量给出计算此类构件耐火极限的简化公式。研究结果表明:荷载比是构件耐火极限的主要影响参数。荷载比越大,构件的耐火极限越小。     

抽尘热风管内壁尘垢治理探讨

在工业生产中,加热工序中产生的含尘热气由抽尘系统抽走,确保生产场所空气达标.这种含尘气流的温度高于常温,在风管中流动时,在管外常温空气冷却下,水汽会部分凝结成露粘附在管内表面.露水又粘结尘灰,形成一层粘结强度很好的尘垢层,影响抽尘热风流正常流动,也影响风管的使用寿命.分析了抽尘热风管内壁尘垢生成机理并提出了防治措施.     

Physics of failure analysis of power section assembly for positive displacement motor

Power section assembly is the core part of positive displacement motor (PDM), and its mechanical behavior and service life determine the drilling efficiency and cycle. In this paper, fault tree of power section assembly was established, failure reasons were analyzed and improvement measures were put forward. Finite element models of conventional lining and uniform wall thickness lining of 5/6 PDM were established, and the mechanical behaviors were investigated. Working parameters such as drilling fluid pressure, rubber hardness, downhole temperature and pressure difference were discussed. The results show that wear and rust are the main failure modes of the rotor. Failure modes of rubber lining are wear, tear, rupture, peeling off, thermal failure and fatigue failure. Under the action of drilling fluid pressure, the maximum effective stress of rubber lining appears in the bottom of arc, and the minimum stress appears at the top of arc. But deformation distribution is opposite to the effective stress. Deformation of uniform wall thickness lining is more uniform. Effective stress of the lining increases with the increasing of drilling fluid pressure and rubber hardness, but it decreases with the downhole temperature increases. Deformation of the lining increases with the drilling fluid pressure increases, but it decreases with the increasing of rubber hardness and downhole temperature. Effective stress and deformation distribution of rubber lining are more uneven with the pressure difference increases. High stress area lies between the two smallest chambers.     

远场涡流和内窥镜检测技术在换热器管束中的应用

针对某炼油厂目前换热器管束泄漏事故频发的现状,研究了基于远场涡流和内窥镜的无损检测技术在碳钢换热器管束检测中的应用,并提出了通过远场涡流和内窥镜检测技术对换热管柬堵管原则进行完整性评价的方法,实现换热管束堵管的针对性、可靠性和合理性。本文所提出的各项技术的综合应用,可以最大程度地找出在用换热器已经泄漏和尚未泄漏但损伤超过临界尺寸的换热管柬,并根据切实、可靠和有针对性的堵管原则进行堵管处理,可以有效减少运行周期内换热管束的泄漏次数,对石化企业安全生产和经济效益的提高有重要影响。     

电站锅炉水冷壁和过热器爆管分析

采用宏观形貌分析、化学成分分析、金相显微组织分析、材料力学性能测试、SEM微观形貌分析等手段,对某电站锅炉水冷壁管和过热器管破裂进行了分析。结果表明,热（硫）腐蚀导致的过热器管局部穿孔破裂,以及泄漏产生的高温水汽流对水冷壁管的,中刷磨损是爆管的主要原因,过热器管补焊点的再次泄漏是本次事故的直接原因。     

超临界锅炉过（再）热器氧化皮剥落分析

目前,我国新投产的火力发电机组容量大、参数高,超,瞄界和超超,瞄界机组已经成为我国的主力发电机组。随着机组参数的提高,锅炉过（再）热器管蒸汽侧氧化成为影响发电机组安全经济运行的主要因素之一。本文研究了超临界电站锅炉过（再）热器管氧化皮的形成原理和规律,分析了氧化皮的剥落模式及机理,探讨了氧化皮剥落的影响因素,并提出了控制氧化皮形成和剥落的对策,研究结果可对电厂氧化皮剥落问题提供指导作用。     

我国长管拖车安全技术发展综述

长管拖车作为专用气体储运装备实现国产化已有10余年时间,其关键部件——长管拖车气瓶(即大容积无缝钢瓶)由于充装介质多易燃、易爆、且具腐蚀性和毒性,具有较高的安全隐患和潜在危险,因此国家将其纳入特种设备进行全寿命安全监管。中国特种设备检测研究院作为长管拖车定期检验专业机构,累计检验长管拖车气瓶万余只,对其制造使用工况、典型失效模式和缺陷评定方法积累了大量数据。本文综述了我国长管拖车气瓶的制造使用现状、安全检验现状和发展趋势,为长管拖车在我国的安全使用及发展提供依据。     

双层炉排锅炉如何正确操作

根据双层炉排锅炉的特点，从锅炉的安装、点火、燃烧的调节、调风、停炉和调火六个方面阐述了正确操作的方法。     

无起爆药雷管内管装药密度对燃烧转爆轰的影响研究

起爆药雷管生产中产生大量有毒废水,且其运输、贮存存在安全隐患。为克服这些困难,笔者自行制备无起爆药雷管。采用圆筒式金属内管中装填超细PETN(季戊四醇四硝酸酯),作为起爆元件,代替起爆药部分,研究装药密度对内管燃烧转爆轰(DDT)的影响。研究结果表明,在内管壁厚1～2 mm,内径Φ4.0 mm,长25 mm,装压密度为0.8～1.14 g/cm3的范围内,内管能可靠实现燃烧转爆轰。     

Crimped metal ribbon flame arrestors for the protection of gas measurement systems

This paper summarises the results of extensive research to determine the limit of safety against flame transmission for flame arrestors of relatively small size fitted with arrestor elements made of crimped metal ribbon. Depending on the reactivity of the fuel gas/air mixture and the tube geometry the running up to detonation and hence the stressing of a flame arrestor by a detonation is possible in longer tubes with relatively small diameters. Only with reactive gas phases of explosion group I this stressing case for a flame arrestor can be excluded. With detonative gas phases the stressing of the flame arrestor decisively depends on the place of installation with respect to the point of transition from deflagration to detonation in the system considered. Five different stressing cases with a probably very different limiting pressure of safety against flame transmission must be distinguished. The results of the investigations will help to evaluate the results from testing of flame arrestors carried out according to the requirements in national and international standards or regulations.     

Integrating flare gas with cogeneration systems: Operational risk assessment

Flare gas utilization in a cogeneration plant is an attractive proposition considering its environmental and economic incentives. Evaluation of the operational risk of integrating flare gas with cogeneration is complex due to the uncertainty in flare gas quality and process conditions. The current study delves into the change in operational risk after modifying the existing cogeneration process with the addition of fuel from flare gas. Based on the process hazards evaluation, the current study identified two critical loss control events (or top events) - boiler gas temperature exceeding operating design temperature and rich fuel mixture in the boiler firebox. The underlying causes that may contribute and lead to these loss control events were identified using fault trees and were updated to the existing cogeneration scenarios. Similarly, different consequential events that may arise from the loss control events were analysed using event trees with existing system safeguards. A Bayesian network model with its explanatory power mapped all the identified dangerous scenarios from the fault trees and event trees to predict integrated systems reliability and diagnose causal factors. Bayesian Network analysis illustrates the dynamic cause-effect relationship and determines the risk escalation due to the changes in the composition of flare gas that is fed to the boiler. The presence of a higher percentage of hydrogen (above 40 mol%) in the flare gas escalates the risk of lean air to fuel ratio in the boiler firebox and increases boiler radiation zone duty. These conditions are detrimental to the boiler firebox operation and can result in critical scenarios such as flame impingement and tube rupture. Additionally, other consequences-a steam explosion and boiler stack explosion were also investigated. However, their probability of occurrence was relatively insignificant with the given frequency of flare gas utilization in the cogeneration system.