换热器膨胀节裂纹分析及处理措施
|
摘要
对某化工厂换热器膨胀节裂纹进行了重点分析,找出膨胀节产生裂纹的主要原因是设计膨胀节位移量不足以消除换热器温差应力。为此,设计了一种新型膨胀节,快速有效地解决了膨胀节裂纹泄漏易燃易爆气体带来的安全隐患。经过连续12年的正常运行,证明这种新型膨胀节的经济实用性和安全可靠性。另外,新型膨胀节的伸缩量远大于同规格的标准膨胀节,适用于替代失效的单波膨胀节,也可用于补偿量不太大的结构。
This investigation focused on the analysis of the cracks in the expansion joints for a chemical plant. It was found that the cracks formed because the allowable displacement was insufficient to relieve the thermal stress originating from the heat exchanger.In this regard,a new-type expansion joint was designed providing a fast and effective approach to solve the problems concerning the leaking of flammable and explosive gas. Based on the successful operation within 12 years,this expansion joint of new type was verified to be secure,economical and practical. Furthermore,with an expansion range exceeding that of the standard ones with the same specification,it can be used to replace the expansion joint with single wave,and applied in structures where the compensation is moderate.
This investigation focused on the analysis of the cracks in the expansion joints for a chemical plant. It was found that the cracks formed because the allowable displacement was insufficient to relieve the thermal stress originating from the heat exchanger.In this regard,a new-type expansion joint was designed providing a fast and effective approach to solve the problems concerning the leaking of flammable and explosive gas. Based on the successful operation within 12 years,this expansion joint of new type was verified to be secure,economical and practical. Furthermore,with an expansion range exceeding that of the standard ones with the same specification,it can be used to replace the expansion joint with single wave,and applied in structures where the compensation is moderate.
引文
[1]厉建文,吴东山.半再生重整装置二段混氢换热器膨胀节失效分析及改造[J].石油化工设备,2017,36(6):96-98.Li J W,Wu D S.Invalidation analysis and reconstruct of expansion joint for second stage exchange of mixture hydrogen in semi-regenerative reformer[J].Petro-Chemical Equipment,2017,36(6):96-98.
[2]左贤斌.波纹膨胀节的选用[J].鸡西大学学报,2004,4(2):67-69.Zuo X B. The selection of metallic bellows expansion joints[J].Journal of Jixi University,2004,4(2):67-69.
[3]赵英,王日忱,王玉仁.膨胀节在中温换热器上的应用及失效分析[J].压力容器,1997,14(3):74-76,82.Zhao Y,Wang R C,Wang Y R.The application of expansion joint to moderate-temperature heat exchanger and its failure analysis[J].Pressure Vessel Technology,1997,14(3):74-76,82.
[4]马玺坤,武春青,柏慧.浅谈管壳式换热器的泄漏与预防措施[J].中国特种设备安全,2017,33(12):63-65.Ma X K,Wu C Q,Bai H.Analysis and precautionary measures of shell-and-tube heat exchanger leakage[J].China Special Equipment Safety,2017,33(12):63-65.
[5]张明乐,郭奇,陈庆.1Cr18Ni9Ti波纹管膨胀节失效分析及改进[J].化工设备设计,1999,36(3):30-31.Zhang M L,Guo Q,Chen Q. Failure analysis and improvement of expansion joints made by 1Cr18Ni9Ti[J]. Process Equipment Design,1999,36(3):30-31.
[6]师顺勇.波纹管膨胀节应力腐蚀裂纹倾向控制[J].管道技术与设备,2012,(3):40-41,44.Shi S Y. Control of stress corrosion cracking tendency of bellows expansion joint[J]. Pipeline Technique and Equipment,2012(3):40-41,44.
[7]孙维明,蔡善祥.高温烟气膨胀节爆裂原因分析与对策[J].管道技术与设备,2010,(3):30-33.Sun W M,Cai S X.Cause analysis and preventive measure of burst failures of bellows expansion joints in high-temperature flue gas[J].Pipe Line Technique and Equipment,2010,(3):30-33.
[8]胡建一.波纹管膨胀节发生破坏的原因和防止措施[J].齐鲁石油化工,1995(2):141-144.Hu J Y.Causes and prevention measures for damage of bellows expansion joints[J].Qilu Petrochemical Technology,1995(2):141-144.
[9]初宜军,葛小平.波纹管膨胀节的改进[J].齐鲁石油化工,1998,26(3):226-227.Chu Y J,Ge X P.Improvement of bellows expansion joint[J].Qilu Petrochemical Technology,1998,26(3):226-227.
[10]陈红军.高温高压染色机换热器膨胀节裂纹的原因分析[J].科技创新与应用,2012(29):92.Chen H J.Cause analysis of crack in expansion joint of heat exchanger of high temperature and pressure dyeing machine[J].Technology Innovation and Application,2012(29):92.
[11]郭志军,周建军,丁晓鹏.催化裂化膨胀节失效分析与防护对策[J].材料保护,1998,31(9):9-10.Guo Z J,Zhou J J,Ding X P. Failure analysis and protective countermeasures of FCC expansion joint[J]. Materials Protection,1998,31(9):9-10.
[12]汪凌云.膨胀节波纹管失效分析[J].石油化工设备技术,2001,30(2):52-53.Wang L Y.Failure analysis of expansion joint bellows[J].Petro-Chemical Equipment Technology,2001,30(2):52-53.
[13]徐赤坤,贾新民.波纹管膨胀节实际应用中的腐蚀分析与防护对策[J].材料开发与应用,2001,16(2):17-20.Xu C K,Jia X M. Corrosion analysis and protection measures of bellows expansion joints in practical application[J].Development and Application of Materials,2001,16(2):17-20.
[14]梁红野,贾少磊,陈彦泽.催化裂化装置管道膨胀节失效分析及防护[J].石油化工腐蚀与防护,2004,21(2):27-29.Liang H Y,Jia S L,Chen Y Z.Analysis of pipe expansion joint failure in FCCU and protection[J].Corrosion&Protection in Petrochemical Industry,2004,21(2):27-29.
[15]项忠维,张伟奎,李峰,等.催化裂化装置膨胀节失效原因与措施[J].腐蚀科学与防护技术,2005,17(2):128-130.Xiang Z W,Zhang W K,Li F,et al.Failure analysis of expansion joint in FCC and remedial measure[J].Corrosion Science and Protection Technology,2005,17(2):128-130.
[16]张卫义,安永明.多乙二醇塔再沸器膨胀节失效分析及修复[J].压力容器,2007,24(4):51-55,71.Zhang W Y,An Y M. Failure analysis and repairs plan to the expansion joint of polyglycol column reboiler[J]. Pressure Vessel Technology,2007,24(4):51-55,71.
[17]胡丽莉.壳体膨胀节失效的固定管板换热器的修复[J].压力容器,2003,20(7):48-50.Hu L L. Overhaul of fixed-tube sheet type heat exchanger for disabled expansion joint on shell[J]. Pressure Vessel Technology,2003,20(7):48-50.
[18]刘成勇.固定管板换热器膨胀节的修复[J].聚酯工业,2004,17(4):56-57.Liu C Y.Overhaul of fixed tube plate heat exchanger expansion joint[J].Polyester Industry,20014,17(4):56-57.
[19]张玉明.金属波纹膨胀节开裂失效原因分析[J].化工设备与管道,2009,46(1):66-68.Zhang Y M.Failure analysis for cracking occurred in metal bellow expansion joint[J].Process Equipment&Piping,2009,46(1):66-68.
[20]张荣克.膨胀节的选材、腐蚀和失效分析[C]//第十三届全国膨胀节学术会议论文集—膨胀节技术进展.合肥:合肥工业出版社,2014:287-296.
[21]喻健良,马路,刘润杰,等.催化裂化装置膨胀节失效原因分析与改造方案[J].现代化工,2004,24(6):48-50.Yu J L,Ma L,Liu R J.Failure analysis of expansion joint in catalytic cracking units and improving measures[J].Modern Chemical Industry,2004,24(6):48-50
[22]原欣.催化装置烟气环境中膨胀节失效分析[J].石油和化工设备,2004,7(3):50.Yuan X.Failure analysis of expansion joints of catalytic devices in flue gas environment[J].Petro&Chemical Equipment,2004,7(3):50.
[23]周强,李永生.不同材料波形膨胀节抗应力腐蚀性能研究[J].化工机械,2011,38(5):543-545.Zhou Q,Li Y S.Study on stress corrosion resistance of bellows expansion joints made of different materials[J].Chemical Engineering&Machinery,2011,38(5):543-545.
[24]李小东,郝习云,陈进,等.外压型不锈钢波纹管膨胀节开裂分析[J].理化检验:物理分册,2011,47(3):187-188,191.Li X D,Hao X Y,Chen J,et al.Cracking analysis of external pressure stainless steel bellows expansion-joint[J].Physical Testing and Chemical Analysis(Part A:Physical Testing),2011,47(3):187-188,191.
[25]陈金梅,王茂廷.换热器疲劳寿命的可靠性分析[J].辽宁石油化工大学学报,2006,26(1):55-57.Chen J M,Wang M T.Reliability analysis of heat exchanger's fatigue life[J].Journal of Liaoning University of Petroleum&Chemical Technology,2006,26(1):55-57.
[26]国家技术监察局.压力容器波形膨胀节:GB16749—1997[S].北京:中国标准出版社,1997.
[27]中华人民共和国国家质量监督检验检疫总局,中国国家标准化管理委员会.压力容器:GB150.1~150.4—2011[S].北京:中国标准出版社,2012.
[2]左贤斌.波纹膨胀节的选用[J].鸡西大学学报,2004,4(2):67-69.Zuo X B. The selection of metallic bellows expansion joints[J].Journal of Jixi University,2004,4(2):67-69.
[3]赵英,王日忱,王玉仁.膨胀节在中温换热器上的应用及失效分析[J].压力容器,1997,14(3):74-76,82.Zhao Y,Wang R C,Wang Y R.The application of expansion joint to moderate-temperature heat exchanger and its failure analysis[J].Pressure Vessel Technology,1997,14(3):74-76,82.
[4]马玺坤,武春青,柏慧.浅谈管壳式换热器的泄漏与预防措施[J].中国特种设备安全,2017,33(12):63-65.Ma X K,Wu C Q,Bai H.Analysis and precautionary measures of shell-and-tube heat exchanger leakage[J].China Special Equipment Safety,2017,33(12):63-65.
[5]张明乐,郭奇,陈庆.1Cr18Ni9Ti波纹管膨胀节失效分析及改进[J].化工设备设计,1999,36(3):30-31.Zhang M L,Guo Q,Chen Q. Failure analysis and improvement of expansion joints made by 1Cr18Ni9Ti[J]. Process Equipment Design,1999,36(3):30-31.
[6]师顺勇.波纹管膨胀节应力腐蚀裂纹倾向控制[J].管道技术与设备,2012,(3):40-41,44.Shi S Y. Control of stress corrosion cracking tendency of bellows expansion joint[J]. Pipeline Technique and Equipment,2012(3):40-41,44.
[7]孙维明,蔡善祥.高温烟气膨胀节爆裂原因分析与对策[J].管道技术与设备,2010,(3):30-33.Sun W M,Cai S X.Cause analysis and preventive measure of burst failures of bellows expansion joints in high-temperature flue gas[J].Pipe Line Technique and Equipment,2010,(3):30-33.
[8]胡建一.波纹管膨胀节发生破坏的原因和防止措施[J].齐鲁石油化工,1995(2):141-144.Hu J Y.Causes and prevention measures for damage of bellows expansion joints[J].Qilu Petrochemical Technology,1995(2):141-144.
[9]初宜军,葛小平.波纹管膨胀节的改进[J].齐鲁石油化工,1998,26(3):226-227.Chu Y J,Ge X P.Improvement of bellows expansion joint[J].Qilu Petrochemical Technology,1998,26(3):226-227.
[10]陈红军.高温高压染色机换热器膨胀节裂纹的原因分析[J].科技创新与应用,2012(29):92.Chen H J.Cause analysis of crack in expansion joint of heat exchanger of high temperature and pressure dyeing machine[J].Technology Innovation and Application,2012(29):92.
[11]郭志军,周建军,丁晓鹏.催化裂化膨胀节失效分析与防护对策[J].材料保护,1998,31(9):9-10.Guo Z J,Zhou J J,Ding X P. Failure analysis and protective countermeasures of FCC expansion joint[J]. Materials Protection,1998,31(9):9-10.
[12]汪凌云.膨胀节波纹管失效分析[J].石油化工设备技术,2001,30(2):52-53.Wang L Y.Failure analysis of expansion joint bellows[J].Petro-Chemical Equipment Technology,2001,30(2):52-53.
[13]徐赤坤,贾新民.波纹管膨胀节实际应用中的腐蚀分析与防护对策[J].材料开发与应用,2001,16(2):17-20.Xu C K,Jia X M. Corrosion analysis and protection measures of bellows expansion joints in practical application[J].Development and Application of Materials,2001,16(2):17-20.
[14]梁红野,贾少磊,陈彦泽.催化裂化装置管道膨胀节失效分析及防护[J].石油化工腐蚀与防护,2004,21(2):27-29.Liang H Y,Jia S L,Chen Y Z.Analysis of pipe expansion joint failure in FCCU and protection[J].Corrosion&Protection in Petrochemical Industry,2004,21(2):27-29.
[15]项忠维,张伟奎,李峰,等.催化裂化装置膨胀节失效原因与措施[J].腐蚀科学与防护技术,2005,17(2):128-130.Xiang Z W,Zhang W K,Li F,et al.Failure analysis of expansion joint in FCC and remedial measure[J].Corrosion Science and Protection Technology,2005,17(2):128-130.
[16]张卫义,安永明.多乙二醇塔再沸器膨胀节失效分析及修复[J].压力容器,2007,24(4):51-55,71.Zhang W Y,An Y M. Failure analysis and repairs plan to the expansion joint of polyglycol column reboiler[J]. Pressure Vessel Technology,2007,24(4):51-55,71.
[17]胡丽莉.壳体膨胀节失效的固定管板换热器的修复[J].压力容器,2003,20(7):48-50.Hu L L. Overhaul of fixed-tube sheet type heat exchanger for disabled expansion joint on shell[J]. Pressure Vessel Technology,2003,20(7):48-50.
[18]刘成勇.固定管板换热器膨胀节的修复[J].聚酯工业,2004,17(4):56-57.Liu C Y.Overhaul of fixed tube plate heat exchanger expansion joint[J].Polyester Industry,20014,17(4):56-57.
[19]张玉明.金属波纹膨胀节开裂失效原因分析[J].化工设备与管道,2009,46(1):66-68.Zhang Y M.Failure analysis for cracking occurred in metal bellow expansion joint[J].Process Equipment&Piping,2009,46(1):66-68.
[20]张荣克.膨胀节的选材、腐蚀和失效分析[C]//第十三届全国膨胀节学术会议论文集—膨胀节技术进展.合肥:合肥工业出版社,2014:287-296.
[21]喻健良,马路,刘润杰,等.催化裂化装置膨胀节失效原因分析与改造方案[J].现代化工,2004,24(6):48-50.Yu J L,Ma L,Liu R J.Failure analysis of expansion joint in catalytic cracking units and improving measures[J].Modern Chemical Industry,2004,24(6):48-50
[22]原欣.催化装置烟气环境中膨胀节失效分析[J].石油和化工设备,2004,7(3):50.Yuan X.Failure analysis of expansion joints of catalytic devices in flue gas environment[J].Petro&Chemical Equipment,2004,7(3):50.
[23]周强,李永生.不同材料波形膨胀节抗应力腐蚀性能研究[J].化工机械,2011,38(5):543-545.Zhou Q,Li Y S.Study on stress corrosion resistance of bellows expansion joints made of different materials[J].Chemical Engineering&Machinery,2011,38(5):543-545.
[24]李小东,郝习云,陈进,等.外压型不锈钢波纹管膨胀节开裂分析[J].理化检验:物理分册,2011,47(3):187-188,191.Li X D,Hao X Y,Chen J,et al.Cracking analysis of external pressure stainless steel bellows expansion-joint[J].Physical Testing and Chemical Analysis(Part A:Physical Testing),2011,47(3):187-188,191.
[25]陈金梅,王茂廷.换热器疲劳寿命的可靠性分析[J].辽宁石油化工大学学报,2006,26(1):55-57.Chen J M,Wang M T.Reliability analysis of heat exchanger's fatigue life[J].Journal of Liaoning University of Petroleum&Chemical Technology,2006,26(1):55-57.
[26]国家技术监察局.压力容器波形膨胀节:GB16749—1997[S].北京:中国标准出版社,1997.
[27]中华人民共和国国家质量监督检验检疫总局,中国国家标准化管理委员会.压力容器:GB150.1~150.4—2011[S].北京:中国标准出版社,2012.