大型列管式固定床反应器管板与反应管焊接技术研究
摘要
大型列管式固定床反应器和大型列管式换热器在工业中广泛应用。该类设备在结构上的一个共同点是,管板上的管孔密集,且管板与列管常采用焊接形式连接。采用焊接连接形式,优点是制造方便,连接强度高,缺点是会造成焊接缺陷、产生残余应力、引起管板变形。可见,管板与列管的焊接连接质量是该类设备的一个重要的质量控制点,如果管板与列管焊接质量不理想,将会导致反应物的泄漏和反应物的串流,从而严重影响设备的正常操作,甚至会造成重大的安全事故。因此,确保列管与管板的接头焊接质量对此类设备的安全运行至关重要。
本文以管壳式反应器和换热器的管板与列管焊接技术为研究对象,采用有限元理论和方法,重点对管板与列管间的焊接温度场、焊接残余应力、焊接变形、焊接影响范围和焊接顺序等问题进行分析、研究。采用结构分析软件ANSYS,对一顺酐工业生产中的典型设备-固定床列管式反应器的管板与列管焊接问题进行了数值计算,分析和研究了影响该设备管板与列管焊接质量的问题,给出了确保该设备管板与列管间焊接应力最小的焊接工艺,保证了该设备的制造质量。
It is widely applied that large fixed tube type tubular reactor and large tube type heat exchanger are in industry. There is a common characteristic of this equipment structure:the pipe hole on tube plate is dense and it is welded that the tube plates connect to the tube. With welding connection, there are convenient manufacturing and connect high strength, but there are welding defects, the residual stress and tube plate deformation. Therefore, the quality of welding connection of tube plate and tube is a key which we should control, if this quality is not enough good, there will be reactant leaking and streaming. Thus those seriously affect the normal operation of the equipment, and may even cause serious accidents. So it is vital importance for safe operation of the equipment that the quality of welding connection of tube plate and tube is ensured.
Welding technology of tube plate and tube of the tubular reactor and heat exchanger are regarded the research object in this article. With finite element theory and method, Welding temperature field, welding residual stress, welding deformations, welding affecting scope, and welding sequence are highlighted analyzed and researched. On this basis, the welding connection numerical calculation of tube plate and tube of the typical equipment in the malefic anhydride industry is largely done with ANSYS software, and the fact that welding quality of tube plate and tub is affected by is analyzed and researched. The welding process which ensure the minimum welding stress of tube plate and tube is provided and it also ensure the manufacturing quality.
本文以管壳式反应器和换热器的管板与列管焊接技术为研究对象,采用有限元理论和方法,重点对管板与列管间的焊接温度场、焊接残余应力、焊接变形、焊接影响范围和焊接顺序等问题进行分析、研究。采用结构分析软件ANSYS,对一顺酐工业生产中的典型设备-固定床列管式反应器的管板与列管焊接问题进行了数值计算,分析和研究了影响该设备管板与列管焊接质量的问题,给出了确保该设备管板与列管间焊接应力最小的焊接工艺,保证了该设备的制造质量。
It is widely applied that large fixed tube type tubular reactor and large tube type heat exchanger are in industry. There is a common characteristic of this equipment structure:the pipe hole on tube plate is dense and it is welded that the tube plates connect to the tube. With welding connection, there are convenient manufacturing and connect high strength, but there are welding defects, the residual stress and tube plate deformation. Therefore, the quality of welding connection of tube plate and tube is a key which we should control, if this quality is not enough good, there will be reactant leaking and streaming. Thus those seriously affect the normal operation of the equipment, and may even cause serious accidents. So it is vital importance for safe operation of the equipment that the quality of welding connection of tube plate and tube is ensured.
Welding technology of tube plate and tube of the tubular reactor and heat exchanger are regarded the research object in this article. With finite element theory and method, Welding temperature field, welding residual stress, welding deformations, welding affecting scope, and welding sequence are highlighted analyzed and researched. On this basis, the welding connection numerical calculation of tube plate and tube of the typical equipment in the malefic anhydride industry is largely done with ANSYS software, and the fact that welding quality of tube plate and tub is affected by is analyzed and researched. The welding process which ensure the minimum welding stress of tube plate and tube is provided and it also ensure the manufacturing quality.
引文
[1]FIXED BED MULTITUBULAR REACTOR AND ITS USAGE.Publicationnumber:JP2002306953.Publication date:2002-10-22 Inventor:TANIMOTO MICHIO; HASHIBA HIDETO
[2]Hoebink.Fixed bed reactor design for gas phase chain reactions catalysed by solids:the oxidative coupling of methane. Chemical Engineering Science, v 49, n 24B, Dec,1994, Chemical Reaction Engineering:Science & Technology, p 5453-5463
[3]Fixed bed multitube reactor.Publication number:US2007049769 Publication date: 2007-03-01 Inventor:SUGIYAMA MIEZI (JP); ANDO YOSHIMASA (CN); TANIGUCHI YOSHIYUKI (JP)
[4]FIXED BED MULTITUBULAR REACTOR.Publication number:JP2006142299 Publication date:2006-06-08 Inventor:MORI YASUHIKO; ABE TADASHI
[5]FIXED BED MULTITUBULAR REACTOR.Publication number:JP2006142288 Publication date:2006-06-08 Inventor:MORI YASUHIKO
[6]胡克宁,赵金芝,陈福贵.顺酐反应器管接头焊接工艺[J].石油工程建设.2006,32(6)：59-60.
[7]周彦伟,许庆和,奚敏.铁素体不锈钢管子管板焊接工艺研究[J].电站辅机.2005,95(4)： 13-15.
[8]姜春光,李军.管壳式换热器管子与管板的连接[J].一重技术.2007,115(1)：41-42.
[9]徐大吉吉,湛波,徐岩.新、乏蒸换热器管子与管板的连接[J].锅炉制造.2003,186(1)：36-37+70.
[10]朱日良.管壳式换热器管板与换热管焊接常见质量问题的防止[J].化工设备与管道.2005,42(1)：62-63.
[11]胡大永.管壳式换热器管子-管板接头连接型式改进及其质量控制[J].湖南有色金属.2007,23(6)：61-63.
[12]潘杰军.换热器管-管板角焊缝焊接质量的控制[J].无损检测.2006,28(1)：53-54.
[13]赵增慧；列管式固定床反应器壳程结构的设计.石油化工设备技术,2002年03期
[14]陈尚伟.列管式固定床反应器设计的限制条件.石油化工.2004
[15]吴亚峰.大型列管式固定床反应器结构与制造.化工设计.1992,2(1).-27-32
[16]Ramachandran. DESIGNING A MULTITUBULAR REACTOR. Chemical Engineering World, v 19, n 10, Oct,1984, p 61-66
[17]Filho, R. Maciel. Influence of configuration on controller design of multitubular reactors. Computers & Chemical Engineering, v 17, n 5-6, May-Jun,1993, p 569-583
[18]Multi-tube fixed-bed reactor, especially for catalytic gas phase reactions Publication number:US7226567, Publication date:2007-06-05 Inventor:OLBERT GERHARD (DE); CORR FRANZ (DE); REUTER PETER (DE); WAMBACH LUDWIG (DE);HAMMON ULRICH (DE)
[19]McGreavy, C.; Dunbobbin, B. R. SOME ASPECTS OF THE DESIGN OF MULTITUBULAR FIXED BED REACTORS FOR HIGHLY EXOTHERMIC REACTIONS. Proceedings of the Ontario Industrial Waste Conference, v 1,1976, p 96-106
[20]Hataya, F.; Ito, Y.; Kawara, M.; Matsumoto, T.; Morisawa, J.; Shibato, E.(Hitachi,Japan). Development of a new tube-to-tubesheet welding type for FBR's heat exchangers. DVS Ber.,52(Schweissen Kerntech.),159-63
[21]Baptista, Cristina M.S.G. (Universidade de Coimbra); e Castro, Jose A.A.M.Safe design of industrial multitubular fixed bed reactors based on parametric sensitivity studies. Computers & Chemical Engineering, v 19, n Suppl,1995, p S125-S130
[22]周桂芬,芦伟.超低碳不锈钢管-管板的焊接工艺试验与应用[J].贵州化工.2006,31(2)：54-56.
[23]Stankiewicz. Advances in modelling and design of multitubular fixed-bed reactors Chemical Engineering & Technology, v 12, n 2, Apr,1989, p 113-130
[24]Stankiewicz.Dynamic modelling of multitubular catalytic reactors. Chemical Engineering & Technology, v 14, n 6, Dec,1991, p 414-420
[25]Lengsfeld, Manfred (Fluor Daniel, Inc); Bardia, Kanhaiya L.; LaBounty, Donald G. Fixed tubesheet thickness design with finite element analysis.American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 385,1999, p 159-164
[26]毛国东,徐庆寨.管壳式换热器碳钢管板、换热管(16Mn锻件／20)焊接常见的质量问题与对策[J].化工设备与管道.2005,42(5)：44-47.
[27]史建涛.换热器管子和管板焊接接头浅见[J].广州化工.2009,37(6)：168-170.
[28]曾爱国.Bfe30-1-1/16MnR管壳式换热器换热管与管板接头的焊接工艺[J].化学工程与装备.2008,(3)：71-74+77.
[29]阮鑫,任丽静,张志勋等.钛制换热器薄壁管与管板焊接优化工艺[J].钛工业进展.2005,22(4)：27-29.
[30]李培学,黄桂东,周长会.浅谈换热器管板与换热管胀焊并用连接的制造工艺[J].氮肥技术.2007,28(2)：16-18.
[31]王新红,王淑芬.FWEC管式空气预热器管子管板胀接工艺[J].锅炉制造.2004,193(3)：27-29.
[32]胡迎春,周桂芳.换热器管板接头的焊接工艺改进[J].焊工之友.2007,53(5)：46.
[33]田锡唐.焊接结构[M].北京；机械工业出版社,1982
[34]增援兴一.焊接结构分析[M].北京：机械工业出版社,1983,158-161
[35]潘际奎.展望21世纪焊接科研.中国机械工程[J],2000,11(1-2),21-25
[36]C.L. Tsai and Z.L.Feng. A Computational Analysis of Thermal and Mechanical Conditions For Weld Metal Solidification Cracking. Welding Research Abroad[J], 1996,42(1):34-41
[37]Martin Becker. Nonlinear Transient Heat Conduction with Application to Welding[J]. ASME 32nd National Heat Transfer Conf. Vol.9 Manufacturing and Materials Processing,1997
[38]马庆芳.实用热物理性质手册[M].北京：中国农业机械出版社,1986,1
[39]鹿安理.焊接过程仿真领域的若干关键技术问题及其初步研究.北京：中国机械工程.2000,11(2)：201-205
[40]丛勉.铸造手册第二卷铸钢[M].北京：机械工业出版社,1991,12
[41]万嘉礼机电工程金属材料手册[M].上海：上海科学技术出版社,1990,12
[42]刘敏等.水冷法对管道对接接头残余应力分布的影响.压力容器,1997,(6)：6-10
[43]鹿安理,史清宇,赵海燕等.厚板焊接过程温度场、应力场的三维有限元数值模拟.中国机械工程,2001,12(2)：183—186
[44]汪建华.三维瞬态温度场的有限元模拟.上海交通大学学报,1996,30(3)：120-125
[45][日]佐藤邦彦等.焊接接头的张度与设计[M].机械工业出版社,北京：1983
[46]R.LKarlsson,B.L.Josefson,Three Dimensional Finite Element Analysis of Temperatures and Stresses in a Single-Pass Butt-Welded Pipe [J]. ASME Journal of Pressure Vessel Technology,1990,112,76-84
[47]拉达伊著,熊第京等译.焊接热效应温度场、残余应力、变形[M].北京：机械工业出版社,1997
[48]中国机械工程学会焊接学会编.焊接手册,第二卷焊接结构[M].北京：机械工业出版社,1995
[49]张宏,陈鹏.基于ANSYS平台的不同焊接工艺参数对管线钢焊接温度场的模拟研究[J].焊管,2007,3(30)：33—36
[50]陈仲波.球罐焊缝缺陷与焊接残余应力的数值模拟[硕士论文].福州大学,2006,6
[2]Hoebink.Fixed bed reactor design for gas phase chain reactions catalysed by solids:the oxidative coupling of methane. Chemical Engineering Science, v 49, n 24B, Dec,1994, Chemical Reaction Engineering:Science & Technology, p 5453-5463
[3]Fixed bed multitube reactor.Publication number:US2007049769 Publication date: 2007-03-01 Inventor:SUGIYAMA MIEZI (JP); ANDO YOSHIMASA (CN); TANIGUCHI YOSHIYUKI (JP)
[4]FIXED BED MULTITUBULAR REACTOR.Publication number:JP2006142299 Publication date:2006-06-08 Inventor:MORI YASUHIKO; ABE TADASHI
[5]FIXED BED MULTITUBULAR REACTOR.Publication number:JP2006142288 Publication date:2006-06-08 Inventor:MORI YASUHIKO
[6]胡克宁,赵金芝,陈福贵.顺酐反应器管接头焊接工艺[J].石油工程建设.2006,32(6)：59-60.
[7]周彦伟,许庆和,奚敏.铁素体不锈钢管子管板焊接工艺研究[J].电站辅机.2005,95(4)： 13-15.
[8]姜春光,李军.管壳式换热器管子与管板的连接[J].一重技术.2007,115(1)：41-42.
[9]徐大吉吉,湛波,徐岩.新、乏蒸换热器管子与管板的连接[J].锅炉制造.2003,186(1)：36-37+70.
[10]朱日良.管壳式换热器管板与换热管焊接常见质量问题的防止[J].化工设备与管道.2005,42(1)：62-63.
[11]胡大永.管壳式换热器管子-管板接头连接型式改进及其质量控制[J].湖南有色金属.2007,23(6)：61-63.
[12]潘杰军.换热器管-管板角焊缝焊接质量的控制[J].无损检测.2006,28(1)：53-54.
[13]赵增慧；列管式固定床反应器壳程结构的设计.石油化工设备技术,2002年03期
[14]陈尚伟.列管式固定床反应器设计的限制条件.石油化工.2004
[15]吴亚峰.大型列管式固定床反应器结构与制造.化工设计.1992,2(1).-27-32
[16]Ramachandran. DESIGNING A MULTITUBULAR REACTOR. Chemical Engineering World, v 19, n 10, Oct,1984, p 61-66
[17]Filho, R. Maciel. Influence of configuration on controller design of multitubular reactors. Computers & Chemical Engineering, v 17, n 5-6, May-Jun,1993, p 569-583
[18]Multi-tube fixed-bed reactor, especially for catalytic gas phase reactions Publication number:US7226567, Publication date:2007-06-05 Inventor:OLBERT GERHARD (DE); CORR FRANZ (DE); REUTER PETER (DE); WAMBACH LUDWIG (DE);HAMMON ULRICH (DE)
[19]McGreavy, C.; Dunbobbin, B. R. SOME ASPECTS OF THE DESIGN OF MULTITUBULAR FIXED BED REACTORS FOR HIGHLY EXOTHERMIC REACTIONS. Proceedings of the Ontario Industrial Waste Conference, v 1,1976, p 96-106
[20]Hataya, F.; Ito, Y.; Kawara, M.; Matsumoto, T.; Morisawa, J.; Shibato, E.(Hitachi,Japan). Development of a new tube-to-tubesheet welding type for FBR's heat exchangers. DVS Ber.,52(Schweissen Kerntech.),159-63
[21]Baptista, Cristina M.S.G. (Universidade de Coimbra); e Castro, Jose A.A.M.Safe design of industrial multitubular fixed bed reactors based on parametric sensitivity studies. Computers & Chemical Engineering, v 19, n Suppl,1995, p S125-S130
[22]周桂芬,芦伟.超低碳不锈钢管-管板的焊接工艺试验与应用[J].贵州化工.2006,31(2)：54-56.
[23]Stankiewicz. Advances in modelling and design of multitubular fixed-bed reactors Chemical Engineering & Technology, v 12, n 2, Apr,1989, p 113-130
[24]Stankiewicz.Dynamic modelling of multitubular catalytic reactors. Chemical Engineering & Technology, v 14, n 6, Dec,1991, p 414-420
[25]Lengsfeld, Manfred (Fluor Daniel, Inc); Bardia, Kanhaiya L.; LaBounty, Donald G. Fixed tubesheet thickness design with finite element analysis.American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, v 385,1999, p 159-164
[26]毛国东,徐庆寨.管壳式换热器碳钢管板、换热管(16Mn锻件／20)焊接常见的质量问题与对策[J].化工设备与管道.2005,42(5)：44-47.
[27]史建涛.换热器管子和管板焊接接头浅见[J].广州化工.2009,37(6)：168-170.
[28]曾爱国.Bfe30-1-1/16MnR管壳式换热器换热管与管板接头的焊接工艺[J].化学工程与装备.2008,(3)：71-74+77.
[29]阮鑫,任丽静,张志勋等.钛制换热器薄壁管与管板焊接优化工艺[J].钛工业进展.2005,22(4)：27-29.
[30]李培学,黄桂东,周长会.浅谈换热器管板与换热管胀焊并用连接的制造工艺[J].氮肥技术.2007,28(2)：16-18.
[31]王新红,王淑芬.FWEC管式空气预热器管子管板胀接工艺[J].锅炉制造.2004,193(3)：27-29.
[32]胡迎春,周桂芳.换热器管板接头的焊接工艺改进[J].焊工之友.2007,53(5)：46.
[33]田锡唐.焊接结构[M].北京；机械工业出版社,1982
[34]增援兴一.焊接结构分析[M].北京：机械工业出版社,1983,158-161
[35]潘际奎.展望21世纪焊接科研.中国机械工程[J],2000,11(1-2),21-25
[36]C.L. Tsai and Z.L.Feng. A Computational Analysis of Thermal and Mechanical Conditions For Weld Metal Solidification Cracking. Welding Research Abroad[J], 1996,42(1):34-41
[37]Martin Becker. Nonlinear Transient Heat Conduction with Application to Welding[J]. ASME 32nd National Heat Transfer Conf. Vol.9 Manufacturing and Materials Processing,1997
[38]马庆芳.实用热物理性质手册[M].北京：中国农业机械出版社,1986,1
[39]鹿安理.焊接过程仿真领域的若干关键技术问题及其初步研究.北京：中国机械工程.2000,11(2)：201-205
[40]丛勉.铸造手册第二卷铸钢[M].北京：机械工业出版社,1991,12
[41]万嘉礼机电工程金属材料手册[M].上海：上海科学技术出版社,1990,12
[42]刘敏等.水冷法对管道对接接头残余应力分布的影响.压力容器,1997,(6)：6-10
[43]鹿安理,史清宇,赵海燕等.厚板焊接过程温度场、应力场的三维有限元数值模拟.中国机械工程,2001,12(2)：183—186
[44]汪建华.三维瞬态温度场的有限元模拟.上海交通大学学报,1996,30(3)：120-125
[45][日]佐藤邦彦等.焊接接头的张度与设计[M].机械工业出版社,北京：1983
[46]R.LKarlsson,B.L.Josefson,Three Dimensional Finite Element Analysis of Temperatures and Stresses in a Single-Pass Butt-Welded Pipe [J]. ASME Journal of Pressure Vessel Technology,1990,112,76-84
[47]拉达伊著,熊第京等译.焊接热效应温度场、残余应力、变形[M].北京：机械工业出版社,1997
[48]中国机械工程学会焊接学会编.焊接手册,第二卷焊接结构[M].北京：机械工业出版社,1995
[49]张宏,陈鹏.基于ANSYS平台的不同焊接工艺参数对管线钢焊接温度场的模拟研究[J].焊管,2007,3(30)：33—36
[50]陈仲波.球罐焊缝缺陷与焊接残余应力的数值模拟[硕士论文].福州大学,2006,6